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Understanding and Understanding and Controlling the Die Controlling the Die Casting ProcessCasting Process
Session I: BackgroundSession I: Background
Training OverviewTraining Overview
What is Die Casting?Making a CastingMonitoring & Measuring
What is Die CastingWhat is Die Casting
The Basics of CastingThe Basics of Casting
What is Die Casting?What is Die Casting?
The Basics of CastingThe Die Casting Machine
The Basics of Die CastingWhat Metals Can be Die Cast?Are There Other Ways of Casting?
The Basics of CastingThe Basics of Casting
The Die Casting MachineThe Die Casting Machine
Clamp EndShot EndBasic Electrical ControlsBasic HydraulicsSprayerExtractorTrim Press
The Clamp EndThe Clamp End
PlatensTie BarsPump / Motors
The Shot EndThe Shot End
Shot CylinderAccumulatorGooseneckShot Tip and Rod
Basic Electical ControlsBasic Electical Controls
VoltageAC or DCCurrentSolenoidsMotorsRelay ControlPLC - Programmable Logic Controller
Basic HydraulicsBasic Hydraulics
PressureFlowCylindersPumpsDirectional ValvesAccumulators
SuperShot Hydraulics DiagramSuperShot Hydraulics Diagram
Other EquipmentOther Equipment
SprayerExtractorTrim PressFurnance
What is Die Casting?What is Die Casting?
Questions & Answers
Making a CastingMaking a Casting
Making a CastingMaking a Casting
Parts of a CastingWhat Can Go Wrong Will Go WrongInjecting the MetalAbout the Die
Parts of a CastingParts of a Casting
SprueRunnersGateCavityOverflowsEjector Pins
What Can Go Wrong Will Go What Can Go Wrong Will Go WrongWrong
PorosityPoor FillBlisterShrinkageWarpingSurface FinishFlash?
Injecting the MetalInjecting the Metal
Covering the Fill HoleSlow ShotFast ShotImpactDwellCooling and Ejecting the Casting
Covering the Fill HoleCovering the Fill Hole
PurposeGuidelinesWorking with Vacuum
Slow ShotSlow Shot
PurposeWhat Speed?Is there a Critical Slow Shot Speed?Tip Drag?
Fast ShotFast Shot
PurposeWhat Speed?When to Change to Fast Shot
ImpactImpact
What is it? Where does it come from?How to reduce it
DwellDwell
Purpose
Cooling and Ejecting the CastingCooling and Ejecting the Casting
CoolingEjecting
About the DieAbout the Die
Cooling the DieCleaning the DieKeeping the Casting from StickingExtending Die LifeControlling the Temperature
Making a CastingMaking a Casting
Questions & Answers
Monitoring & Monitoring & MeasuringMeasuring
Monitoring & MeasuringMonitoring & Measuring
What Can be MeasuredWhere are the Transducers LocatedWhat Measurements are TakenUsing the Tymac Monitoring Equipment
What can be MeasuredWhat can be Measured
PositionVelocityPressureTemperatureStrainFlowTime
Where are the Tranducers Where are the Tranducers Located?Located?
Position & VelocityPressureTemperatureStrainFlow
What Measurements are TakenWhat Measurements are Taken
Slow ShotFast ShotImpactDwell / IntensificationTemperatureTie Bar StrainCycle Time
Measurements taken during Measurements taken during Slow ShotSlow Shot
Plunger VelocityPlunger PositionHead PressureRod PressureOther PressuresTime
Measurements taken during Measurements taken during Fast ShotFast Shot
Plunger VelocityPlunger PositionHead PressureRod PressureOther PressuresTimeFill Time
Measurements taken at Measurements taken at ImpactImpact
Head PressureRod PressureOther PressuresTime
Measurements taken during Measurements taken during Dwell / IntensificationDwell / Intensification
Head PressureRod PressureOther PressuresTimeIntensifier DelayIntensified Length
Measurements taken at Measurements taken at End of the ShotEnd of the Shot
Stroke LengthTemperatureTie Bar StrainFlowsCycle Time
Monitoring and MeasuringMonitoring and Measuring
Questions & Answers
Understanding and Understanding and Controlling the Die Controlling the Die Casting ProcessCasting Process
Session II: EquipmentSession II: Equipment
Training OverviewTraining Overview
Using Tymac Monitoring EquipmentControlling the Die Casting Process
Using Tymac Using Tymac Monitoring EquipmentMonitoring Equipment
Using Tymac Monitoring Using Tymac Monitoring EquipmentEquipment
The EquipmentChecking the Process StatusView the Shot Summary ReportLook at a Shot ProfileSPC / SQCSetting up the ParametersProductivity and Downtime Reporting
Tymac Monitoring EquipmentTymac Monitoring Equipment
RTU-9000LCM-9000MTU-9000
SPC/SQC SoftwareSPC/SQC Software
Using Tymac Monitoring Using Tymac Monitoring EquipmentEquipment
Questions & Answers
Controlling the ProcessControlling the Process
Controlling the Die Casting Controlling the Die Casting ProcessProcess
7 Phase Real Time Velocity ControlTemperature Control
7 Phase Real Time Velocity 7 Phase Real Time Velocity ControlControl
1st Phase/LIFT-OFF2nd Phase/CLOSE FILL HOLE3rd Phase/SLOW APPROACH4th Phase/FAST SHOT5th Phase/LOW IMPACT6th Phase/FINAL FILL7th Phase/FINAL SQUEEZE
7 Phase Velocity Control7 Phase Velocity Control
SuperShot Retrofit ControlsSuperShot Retrofit Controls
SuperShot Shot EndSuperShot Shot End
Benefits of Low ImpactBenefits of Low Impact
Elimination of Flash
Benefits of Low ImpactBenefits of Low Impact
Lower Metal TemperatureIncreased Die LifeMetal Savings
Temperature ControlTemperature Control
Metal TemperatureOil TemperatureDie Temperature
Controlling the Die Casting Controlling the Die Casting ProcessProcess
Questions & Answers
Understanding and Understanding and Controlling the Die Controlling the Die Casting ProcessCasting Process
Session III: Session III: TroubleshootingTroubleshooting
Training OverviewTraining Overview
Trouble Shooting and Repair
SuperShot Hydraulics DiagramSuperShot Hydraulics Diagram
LCM-9000 ComponentsLCM-9000 Components
Troubleshooting & RepairTroubleshooting & Repair
Questions & Answers
