"When the plunger moves we cannot do anything anymore", "during quickly shot we are able to accelerate and decelerate the plunger up to five times", "when we have fantastic castings we make a temperature image and measure the plunger speeds. If we get excellent troubles we just go back what we documented to produce good castings again". 3 statements I heard from a die caster, a die casting machine vendor plus a professor. What did I discovered from it? There's a kernel of truth in all statements.
The first situation is what we see one of the most inside the industry. The shot is set and checked with monitoring systems. Casting poor high quality the set up is going to be changed, at times the parameter are stored and used for future production runs.
Parameter altering throughout quick shot is just not used at all. The closes to this carrying out would be the plunger deceleration at end of quickly shot to minimize plunger effect load at end of fill. There are several motives this chance just isn't utilised in additional specifics. Velocity reduction reduces the force behind the melt and fronts wouldn't merge making cold runs. At the same time it increases the fill time resulting in colder melt and cold runs. Variations inside the poured melt volume produce deviations involving switch distances and melt fronts. In other words we've an unstable approach.
So and why could be the third strategy not working? Checking plunger speeds is definitely an quick task and performed in many facilities now. Measuring the temperature is far more difficult. The camera is extremely costly and die caster shy away based around the costs. The camera is huge and therefor can not be directed to capture all regions of interest. Depending around the angle the measured values will alter. To produce photos the production must be stopped and the die cools in the course of capturing the temperature profile. As longer the strategies about the machine and as a lot more complicate the camera position as additional away could be the measured temperature in the true temperature. Adjust the die temperatures with water or oil intakes by way of the channels in the die maybe not probable. Cooling a brand new die is different to cool a die with scaling in the water channels. And on major there's greater than temperature and plunger switches the professor told me. Like clocking of wind vents, altering in clearances between components inside a new and an old die. To not mention to help keep exactly the same plunger stroke but possess a plunger using a different diameter. Or plain the die inserts at their surfaces for spotting goal and lessen the gate area at the very same time. Now the casting high-quality and shot parameter modify even with the exact same plunger strokes and velocities.
As usual there's not a single remedy for the proper approach parameter set for the total life in the die. With deterioration in the die course of action parameter may possibly need to be changed. As extra documentation is carried out and as extra data the die caster has at hand as much easier it will be to seek out the optimized machine setup.
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