Die Cast
Aluminium Die Casting
Aluminium die casting
Aluminium is the choice metal for making light weight parts of vehicles, aerospace and transport industries. Casting of liquid aluminium alloys into metal moulds utilizing systems like gravity, low pressure and high pressure die casting is an economical way of making difficult shapes which need minimum machining. Australia’s auto industry supports a large local die casting business, manufacturing parts that include cylinders, pistons and engine sumps etc.
Rising demand in world auto market for aluminium die cast parts is producing great opportunity and challenge for Australian business which wants to emerge as a global player. By setting partnerships between Nissan and Ford, CAST has developed and produced new and latest technology that has been benefiting our partner’s products. In turn these skills have created IP that is poised on the verge of commercialization.
To increase production of high pressure die casting by lessening its time cycle by 30%. The cycle time has been reduced by more than 20% on certain parts at two industry partner plants. The project involves identifying places where cycle time may be reduced, and doing it practically to prove the findings of research. This made it essential to involve shop floor staff to implement the changes needed in systems. These trails are generally in variation with day to day production and due to true co-operation of shop floor staff it become possible to achieve targets.
The third year of project has seen the true spirit of co-operation between researches and industrial partners in which latest research results got through simulated trails have been done practically on shop floor with help and support of Ford and Nissan staff. The changes once tested during trials have been incorporated in production systems giving benefits of reduced costs by reducing time of each part manufactured. An example of reduced time achieved is at Nissan on a gearbox side cover made in twin cavity die has given successful results after many months; from an initial cycle time of 75 seconds down to 60 seconds. While research at Ford on a changer housing casting, has been successfully implemented by lessening cycle time from 90 seconds to 74 seconds.
In future the reduction of time cycle will be tried for other parts as well.
Automatic fault detection in aluminium die casting:
This involves developing a system to detect surface and sub surface defects.
A fully automatic fault detecting machine named CAST vision has been produced and a prototype process is in place for extended in-plant on-line trials. This is the third year of this project and it is giving good results. The result of algorithm which was designed and developed in 2nd year has been put to test now. By prototyping the CAST team had designed and developed a working system CAST vision. This can discriminate between good and defective parts.
The prototype system has capacity to detect blocked holes on any of holes on this complex casting. Offline processes have also been readied which will detect hot tears and cold shuts on Ford’s structural sump casting.
Work at Nissan on their pump cover casting has led to a CAST vision type process for in-line fault detection. The process can take images and find certain types of defects on the surface part. This project has shown that advances in mechanical vision applied for finding faults of aluminium castings can be converted from project stage to a working prototype successfully. The next stage is take concepts from single stage to multistage processes capable to handle more complex shapes and surfaces. This result will become a strong contender for future commercialization.
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Best Pressure Die Casting
Best pressure die casting
This relates to a pressure die casting machine and in particular to an apparatus and method for moving a die of a pressure die casting machine.
Pressure die casting is the injection of melted metal or plastic under high pressure into a mould cavity.
Before injecting the melted metal into the cavity, the mould is “closed” i.e. the two halves of the mould, called dies are brought together, after which dies are held together while the melted metal is forced into the cavity they form. The metal is allowed to solidify in the shape of mould cavity and then the dies are pulled apart so that solidified object may be ejected and the cycle repeated.
To manufacture die castings free of pores and shrink holes it is normal practice to fill the mould at high pressure and to let the metal solidify while under high pressure so as to effect compression of die casted metal. The apparatus which closes the dies and holds them together needs to have capacity to withstand this high pressure and it is required to work for long hours.
To simplify the clamping procedure for holding the dies together the apparatus uses a die casting machine which has one die fixed on the machine base and second die half is removable into and out of apparatus. Thus movement and control apparatus might be given for one half of die. This has an additional advantage that the hot melted metal can be fed into the mould cavity or chamber between the dies through a sprue in the fixed die.
Aluminium and copper alloys that attack and erode machine components with which they are in regular contact are generally produced in what is called cold chamber machine, whereas tin, lead and zinc die castings are processed in a chamber called hot chamber machine. The pressure die casting machine is equally well used in hot and cold chamber pressure die casting.
A die casting machine uses a fixed and moveable die. Four tie bars or guideways are rigidly connected to two plates upstanding from the machine lease; one die is placed on one plate while the other die is slidably mounted on the tie bars. Pressure oil is given to an operating cylinder containing an operating piston which is linked to a displacement yoke linked in turn with guide spars these are externally threaded to receive nuts between which the yoke is clamped.
The dies are closed and melted metal is entered into cavity of dies from the sprue in the fixed die and required pressure is given. After the metal solidifies the pressure on the dies is released and two halves of dies are separated and finished product is taken out and process of pressure die casting is repeated.
The same process of pressure die casting is used in plastic moulded die casting products the only difference being that instead of melted aluminium, melted plastic is poured into the die from a sprue fixed in lower die and required pressure is given. After the plastic cools down and solidifies the pressure is released, and die opened and finished product is taken out and process repeated.
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