Web003 Operator Training Class 3 - Die Casting Machine & Cell Area Equipment

Operator Training Class 3:
Die Casting Machine & Cell

Area Equipment
NADCA Training
April 15, 2014
Presented by Jeff Brennan, NADCA Technology Manager
1
DC Machine & Cell Area Equipment
1. What are the names of the three platens on a typical die casting machine?
2. Which platen has the hole in it for the shot sleeve?
3. What are the round bars called going through the four corners of the platens?
4. What connects the rear and moving platen to each other?
5. How many hydraulic pumps does a typical die casting machine have?
6. What type of cylinder opens and closes a die casting machine?
7. If too much metal is ladled into the shot sleeve, what can happen?
8. What are two things that spraying the die does?
9. Why is quenching or cooling the die casting rapidly important before
processing it further?
10. What is the order of the machine cycle elements below:
– Die closing
– Die spray/die inspection
– Ejection
– Ladling (cold chamber)
– Dwell/casting inspection
– Injection
– Casting removal/inspection
– Die opening
2
The Die Casting Cell can have over 10
Pieces of Complex Equipment
7-3
3
The Heart of the Cell Area is the
Die Cast Machine
“C” Frame Cold Tie
Accumulator Chamber Bars
Shot
Cylinder
Base
4
The Three Platens Carry the DCM Loads
Stationary
Moving Rear
5
Quick Quiz
What is the name of the platen pictured below?
How can you be sure?
1) Stationary
2) Moving
3) Plate
4) Rear
6
Four Tie Bars Hold the DCM Together
7
The Toggle Mechanism Connects the Rear
and Moving Platens
8
Quick Quiz
What is another name for the Toggle
Mechanism?
1) Chain
2) Lever
3) Linkage
4) Rammy
9
Electric Motors Power the Hydraulic Pumps
10
DCM Typically has Two Hydraulic Pumps
11
Solenoids Shift the valves that control the

volume and direction of hydraulic oil flow
12
Operators Must Check Filter Pressure Gages
Routinely
13
Quick Quiz
What is an indicator that the heat

exchanger is not working properly?
1) Bad Smell
2) Low Hydraulic oil temperature
3) Pressure build-up
4) Rising hydraulic oil temperatures
14
Heat Exchanger Leakage Can be

Troublesome
15
DCM Hydraulics Operate Many Different
Cylinders
• Open and close
the DCM
• Inject the metal
into the die
• Operate the
ejection system
• Move slides on
the die
• Actuate a safety
ratchet and
open and close
a safety door at
the die parting
line
16
Accumulators are used when large

volumes of oil are required
17
The intensifier increases the hydraulic fluid
pressure at the end of the injection stroke
18
Following Safe
Practices is the Most
Important Part of
Your Job
19
Limit switches must never be defeated or
tied back!
20
Questions?
• Before we move on to other parts of

the die casting cell, are there any
question?
21
Did You Know?
• There are all electric DCM.
• There were (are) hydro powered DCM.
• There are two platen machines.
22
Combustion & Temperature Control is

Essential for Holding Metal Properly
23
The Ladling Process can Adversely Affect the

Casting Quality
7-24
24
Quick Quiz
Why do we spray the die?
1) To apply a protective coating for easier

casting release.
2) To Cool the Die.
3) To help with the casting surface finish.
4) To apply a protective coating for easier
casting release & To Cool the Die.
5) All of the Above.
25
Die Spray can be Applied in Many Ways
26
The plunger lubricator lubricates the tip
without contaminating the metal
27
Casting Removal
• Manual removal
• Mechanized
removal
• Drop-through
28
Quenching Achieves rapid

cooling/dimensional stability
29
Conveyors Move the Castings to their Next
Operation
30
Die Temperature Control Can be

Accomplished with Heaters
Hand-held
Hot Oil
Gas Heater
Die
Heater
31
Trim Presses Remove Gates and Runners
from the Shot
Usable
Casting
32
Quick Quiz
What can happen to a casting if it is
improperly located in the trim press?
1) Certain casting dimensions could be go out of

specification.
2) The trim die could be damaged.
3) The extractor could break.
4) Certain casting dimensions could be go out of
specification & The trim die could be
damaged.
5) All of the Above.
33
The machine cycle consists of eight sequential

cycle elements:
1. Die spray/die inspection
2. Die closing
3. Ladling (cold chamber)
4. Injection
5. Dwell/casting inspection
6. Die opening
7. Ejection
8. Casting removal/inspection
34
Step 1: Inspection
35
Step 2: Die Spray
36
Step 3: Machine Closing
37
Step 4: Ladling/Injection
38
Step 5: Machine Dwell/Hold
39
Step 6: Machine Opening
40
Step 7: Ejection
41
Step 8: Casting Removal
42
43
Tomorrow:
How it Works: The Shot End
Questions?
Name: Jeff Brennan
Phone: 847-808-3164
Email: [email protected]
44

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Web003 Operator Training Class 3 - Die Casting Machine & Cell Area Equipment

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Operator Training Class 3:

Die Casting Machine & Cell

Electric Motors Power the Hydraulic Pumps

DCM Typically has Two Hydraulic Pumps

Solenoids Shift the valves that control the

What is an indicator that the heat

Heat Exchanger Leakage Can be

Accumulators are used when large

• Before we move on to other parts of

Combustion & Temperature Control is

The Ladling Process can Adversely Affect the

Why do we spray the die?

1) To apply a protective coating for easier

Quenching Achieves rapid

Die Temperature Control Can be

1) Certain casting dimensions could be go out of

The machine cycle consists of eight sequential

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