Die Casting
Castool’s Systems Approach – No single component of the die casting production process should be examined or evaluated individually. Only if the entire process is considered as an integrated system, with all parts working together in common cause, can maximum efficiency be approached.
Controller ensures a measured amount of lubricant is applied when needed
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Lubricant and air are mixed via channels in the rod
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The plunger tip is a critical element of aluminum die casting process. Its’ successful operation depends on a number of factors, most importantly, its’ efficient interaction with a round, straight, thermally and therefore dimensionally stable shot sleeve.
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The lubrication system has been developed to reduce the friction between the sleeve and the plunger; to thus ensure the smooth passage of the plunger through the sleeve. This is necessary for the long shot sleeve or when there is excessive wear under the pour spout.
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The shot sleeve is a critical element of the aluminum die cast process. For maximum productivity – and also maximum operating life for both shot sleeve and plunger tip – the plunger must consistently move smoothly, and at a steady speed through a perfectly round, straight, shot sleeve.
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In order to increase strength to weight ratio of casting, the casting needs to be heat-treated. The heat treatment temperature could go as high as 400ºC and for as long as 24 hours. The air trapped inside could expand and cause blistering during heat treatment, especially for aluminum alloys.
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In order to increase strength to weight ratio of casting, the casting needs to be heat-treated. The heat treatment temperature could go as high as 400ºC and for as long as 24 hours. The air trapped inside could expand and cause blistering during heat treatment, especially for aluminum alloys.
+ Overview
Cycle-Time Matters
Conformal cooling is a technique that improves thermal management in die casting by using cooling channels that follow the tool shape. This can lower the die and plunger tip temperature, speed up the cooling phase and reduce cycle time, and enhance part quality.
Additive manufacturing, and 5/9 axis machines can create complex cooling channels for conformal cooling. Some materials, such as Con-Duct, may also help because they have higher thermal conductivity and toughness than tool steel.
Safe, Reliable, Long-life, Efficient, Economical
Any die caster knows how to produce large, thin, convoluted aluminum castings for the automotive industry. It is already being done quite satisfactorily and profitably in large quantities. There are no secrets. Knowing how to do it and actually doing it, however, are two very different things. When theory is finally replaced by reality, the most fundamental precept of die casting can be found in the old adage: a chain is only as strong as its weakest link.
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