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Process Parameter in High Pressure Die casting by Ralf Kind





Process Parameter in High Pressure Die casting by
Article Posted: 01/23/2012
Article Views: 99
Articles Written: 21
Word Count: 514
Article Votes: 0
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Process Parameter in High Pressure Die casting


 
Business,Manufacturing
“when the plunger moves we can’t do anything anymore”, “during fast shot we can accelerate and decelerate the plunger up to 5 times”, “when we have good castings we make a temperature image and measure the plunger speeds. If we get quality issues we just go back what we documented to make good castings again”. Three statements I heard from a die caster, a die casting machine vendor and a professor. What did I learned from it? There is a kernel of truth in all statements. The first scenario is what we see the most in the industry. The shot is set and checked with monitoring systems. Casting poor quality the set up will be changed, sometimes the parameter are stored and used for future production runs. Parameter changing during fast shot is not used at all. The closes to this doing is the plunger deceleration at end of fast shot to reduce plunger impact load at end of fill. There are several reasons this opportunity is not used in further details. Velocity reduction reduces the force behind the melt and fronts would not merge creating cold runs. As well it increases the fill time resulting in colder melt and cold runs. Variations in the poured melt volume create deviations between switch distances and melt fronts. In other words we have an instable process. So and why is the third approach not working? Checking plunger speeds is an easy task and done in many facilities today. Measuring the temperature is much more complicated. The camera is very expensive and die caster shy away based on the costs. The camera is big and therefor can’t be directed to capture all areas of interest. Depending on the angle the measured values will change. To make images the production has to be stopped and the die cools during capturing the temperature profile. As longer the ways around the machine and as more complicate the camera position as further away is the measured temperature from the real temperature. Adjust the die temperatures with water or oil intakes through the channels in the die maybe not possible. Cooling a new die is different to cool a die with scaling in the water channels. And on top there is more than temperature and plunger switches the professor told me. Like clocking of wind vents, changing in clearances between components in a new and an old die. Not to mention to keep the same plunger stroke but have a plunger with a different diameter. Or plain the die inserts at their surfaces for spotting purpose and reduce the gate area at the same time. Now the casting quality and shot parameter change even with the same plunger strokes and velocities. As usual there is not a single solution for the right process parameter set for the complete life of the die. With deterioration of the die process parameter may have to be changed. As more documentation is done and as more information the die caster has at hand as easier it will be to find the optimized machine set up.


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