Classification of Die Casting Machines and Operational Procedure

Publish Time: 04/27 2021 Author: Site Editor Visit: 20053

Die-casting machine is an important basic technical equipment in die-casting production, which has a direct impact on the quality, production efficiency, operating cost, labor intensity, environment, and hygiene of die-casting parts. Therefore, there should be a clearer understanding of the die-casting machine, so that the die-casting machine can be used in a standardized and reasonable manner to ensure the smooth progress of the die-casting production and increase labor productivity.

Classification Of Die Casting Machine

There are many classification methods for die-casting machines. According to the scope of use, they are divided into general die-casting machines and special-purpose die-casting machines; according to the clamping force, they are divided into small machines (≤4 000 kN), medium machines (4 000～10 000 kN) and large machines. Machine (≥10 000 kN); Generally, it is mainly classified according to the machine structure and the position of the injection chamber (hereinafter referred to as the pressure chamber) and its working conditions. The names of various types of die-casting machines are shown in Figure 1.

The Classification Of Die Casting Machine

Fig.1　Classification of die casting machine

The horizontal hot-chamber die-casting machine in Figure 1 is placed horizontally. It was first developed by Harvill Company in the United States in 1981, and it was advertised in 1982. In 1983, it was exhibited at the 12th International Die-casting Conference and Exhibition in the United States. Horizontal hot chamber injection mechanism. Due to various reasons, this kind of machine has not yet been popularized, so I will not introduce it for the time being.

The Composition Of The Die Casting Machine

The mold clamping mechanism drives the die-casting mold to close and open. When the mold is closed, it has enough ability to lock the mold to ensure that the mold parting surface will not expand during the injection filling process. The force of clamping the mold is called the clamping force (also known as the closing force), and the unit is kilonewton (kN), which is the primary parameter that characterizes the size of the die-casting machine.
The injection mechanism pushes the molten metal in the pressure chamber at a specified speed, and has enough energy to make it flow through the runner and inner gate in the mold, and then fill it into the mold cavity, and then maintain a certain pressure to transmit to The molten metal is solidifying until a die casting is formed. After the injection action is all completed, the injection punch returns to reset.
The hydraulic system provides sufficient power and energy for the operation of the die-casting machine.
The electrical control system controls the execution of each mechanism of the die-casting machine to run according to a predetermined program.
All parts and components of the machine base are assembled and assembled to form the whole die-casting machine and are fixed on the machine base.
Other devices The advanced die-casting machine is also equipped with parameter detection, fault alarm, die-casting process monitoring, computer-aided production information storage, calling, printing and management systems.
The auxiliary device is equipped with devices such as pouring, spraying, and picking according to the degree of automation.

How The Die Casting Machine Works

Hot chamber die casting machine

The normal working mode of hot chamber die casting machine is shown in Figure 2. The furnace 10 of the hot chamber die casting machine is placed in the machine.
Pouring into the furnace, the pouring pot 9 with the pressure chamber and the gooseneck channel and the injection punch 8 are all immersed in the molten metal 7. The opening and closing actions of the mold move horizontally. After the mold is opened, the die casting remains in the movable mold. The working steps are as follows:

The machine head plate and mold sprue sleeve are close to the nozzle (some machines do not have this program);
Close the mold;
When the injection punch is at the position shown in the figure, the molten metal enters the various spaces in the pouring pot from the orifices on the side. After flowing in, the gooseneck channel
The liquid level inside is flush with the liquid level in the furnace;
The injection punch moves down at a slower injection speed until the side hole is sealed;
The injection punch pushes the molten metal at high speed, and passes through the gooseneck channel 6, the nozzle 5, the sprue 4 of the mold, the splitter 3, and the inner gate
2 Fill into the mold cavity, and then solidify into a die casting 1;
The injection punch is lifted, and the molten metal in the nozzle and gooseneck channel flows back into the pouring pot;
Open the mold, leave the die-casting part and gate on the movable mold, then eject and take out the die-casting part;
The machine head plate and mold sprue sleeve leave the nozzle (some machines do not have this program); so far, a die-casting cycle is completed.

Hot chamber die casting machine

Figure 2 Working mode of hot chamber die casting machine

1. Die castingparts 　
2. Inner gate 　
3. Splitter 　
4. Sprue 　
5. Nozzle
6. Gooseneck channel 　
7. Metal liquid 　
8. Injection punch 　
9. Pouring pot 　
10. Furnace

Cold Chamber Die Casting Machine

The main engine of the cold chamber die casting machine is separated from the furnace, the furnace is placed on the side, and the molten metal is transferred from the furnace to the press chamber of the main engine. The furnace is usually only guaranteed.Because it is used for warming, it is often called a holding furnace; only when the number of machines is small or small batch production, the holding furnace also serves as a melting point. The cold chamber die casting machine is divided into vertical cold chamber, horizontal cold chamber and full vertical cold chamber.

Working mode of vertical cold chamber die casting machine

The working mode of the vertical cold chamber die casting machine is shown in Figure 3. The pressure chamber 7 is placed vertically, and the upper punch 8 is above the pressure chamber (the position above the figure), and the lower punch 10 is located at the place where the nozzle 5 orifice is blocked, so as to prevent molten metal from pouring into the pressure chamber and flowing into the nozzle hole by itself. The opening and closing of the mold is horizontal.After moving and opening the mold, the die casting remains in the movable mold. The working steps are as follows:

Working mode of vertical cold chamber die casting machine

Figure 3 　 Working mode of vertical cold chamber die casting machine
1. Die casting parts 　
2. Shunt 　
3. Inner gate 　
4. Sprue sleeve 　
5. Nozzle
6. Sprue 　
7. Press room 　
8. Upper punch 　
9. Leftover cake 　
10. Lower punch

Close the mold;
Pour molten metal into the press chamber manually or by other means;
The upper punch moves down at a lower injection speed, enters the pressure chamber and just touches the molten metal surface;
The upper punch is turned to a higher injection speed to press down, while the lower punch and the upper punch maintain a relative distance between the middle section and the molten metal and move down quickly;
When the lower punch moves down to let out the nozzle orifice, it just goes down to the bottom and is supported; therefore, the upper and lower punches squeeze the molten metal at high speed to the nozzle hole (part of sprue 6) Jet;
The molten metal passes through the sprue 6, which is composed of the nozzle, the sprue sleeve 4, the tapered hole of the fixed mold, and the diverter 2, and is filled into the mold cavity from the inner gate 3;
The filling is completed, but the upper punch still maintains a certain pressure until the molten metal in the cavity is completely solidified into a die casting 1; the molten metal in the runner and the pressure chamber solidifies into a straight gate and a remaining cake 9 ;
The upper punch is lifted and reset; at the same time, the lower punch moves upward to cut away the remaining cake that is still connected to the straight gate;
The lower punch continues to rise, lift the remaining material cake out of the top surface of the pressure chamber, and then manually or other means take it away;
Move the lower punch down and reset to block the nozzle orifice;
Open the mold, the die-casting part and the straight gate remain on the movable mold together, and then eject and take out the die-casting part; once the remaining material cake is cut away, the mold opening action can be executed immediately, or it can be slightly slowed down to an appropriate time Execution has nothing to do with the lifting and resetting of the lower punch; at this point, a die-casting cycle is completed.

Working mode of horizontal cold chamber die casting machine

The working mode of the horizontal cold chamber die casting machine is shown in Figure 4. The pressure chamber 7 is placed horizontally, and the injection punch 5 is at the dotted line at the rightmost end of the pressure chamber. The opening and closing movements of the mold move horizontally. After the mold is opened, the die-casting part remains in the movable mold. The working steps are as follows:

Close the mold;
Pour molten metal into the press chamber manually or by other means;
The injection punch pushes the metal liquid at a predetermined speed and a certain pressure, so that it passes through the runner 3 of the mold, and is filled into the mold cavity from the inner gate 2;
After filling, the punch maintains a certain pressure until the molten metal is completely solidified to become a die casting 1; at this time, the runner and the sprue sleeve 6 (the mold without the sprue sleeve is the conjoined pressure chamber here) ) The molten metal inside also solidifies at the same time, becoming the gate and the remaining material cake 4;
Open the mold, the punch moves synchronously with the mold opening action, so that the remaining material cake is pushed along with the die-casting part and the gate to stay in the movable mold and leave the fixed position.
When reaching a certain distance, the punch will return to reset;
After the mold is opened, the die-casting part, gate and remaining material cake remain on the movable mold, eject and take out the die-casting part; at this point, a die-casting cycle is completed

Working mode of horizontal cold chamber die casting machine

Figure 4 　 Working mode of horizontal cold chamber die casting machine
1. Die casting parts 　
2. Inner gate 　
3. Runner 　
4. Leftover cake 　
5. Injection punch
6. Sprue sleeve 　
7. Press room

Working mode of full vertical cold chamber die casting machine

The working mode of the full vertical cold chamber die casting machine is shown in Figure 5. The pressure chamber 5 is placed vertically at the lower part of the machine, and the opening and closing of the mold move up and down, so it is called a full vertical die-casting machine. Usually the movable mold of the mold is fixed on
After the mold is opened, the die-casting part remains in the movable mold. The working steps are as follows:

Pour molten metal into the press chamber manually or by other means;
Close the mold;
The punch 6 moves and pressures the molten metal to pass through the runner 3 diverter 4, and fills it from the inner gate 2 into the mold cavity;
After filling, the punch maintains a certain pressure until the molten metal is completely solidified to become a die casting 1; at this time, the molten metal in the runner and the pressure chamber is also solidified at the same time, and the pressure in the pressure chamber becomes the residual cake 7;
Open the mold, and the punch moves upwards synchronously with the mold opening action, so that the remaining material cake follows the die casting and the gate together with the moving mold and leaves the fixed mold. When reaching a certain distance, the punch moves down. Reset;
After opening the mold, immediately eject and take out the die-casting part; at this point, a die-casting cycle is completed.

Working mode of full vertical cold chamber die casting machine

Figure 5 　 Full vertical cold chamber die casting machine
1. Die casting parts 　
2. Inner gate 　
3. Runner 　
4. Shunt 　
5. Press room
6. Injection punch 　
7. Leftover cake

Relevant standards of Chinese die casting machine

In order to further promote the development of my country's die-casting machine production, the relevant departments of my country's machinery industry promulgated the die-casting machine parameter standards in 1980 and revised it in 1990. In the same year, standards for the accuracy and technical conditions of the die-casting machine were also promulgated, which provided a reference for the design, manufacture, and acceptance of the die-casting machine. Since then, it has been revised several times to make it more complete and more practical. The machinery industry standards for die-casting machines and their serial numbers promulgated after the revision in 2000 are as follows. Die-casting machine parameters (JB/T 8083 -2000) 　The standard defines the parameters of the die-casting machine. The die-casting machine is divided into three types: horizontal cold-chamber die-casting machine, vertical cold-chamber die-casting machine and hot-chamber die-casting machine. The main parameters and basic parameter values of the three types are listed in the appendix.

Accuracy of cold chamber die casting machine (JB/T 8084.1 -2000) 　This standard lists the accuracy and inspection method of cold chamber die casting machine.
Technical conditions of cold chamber die casting machine (JB/T 8084.2 -2000) 　 This standard lists the relevant terms and definitions, technical requirements, test methods, inspection rules, etc. of cold chamber die casting machines.
The accuracy of hot chamber die casting machine (JB/T 6309.2 -2000) 　This standard lists the accuracy and inspection method of hot chamber die casting machine.
Technical conditions of hot chamber die casting machine (JB/T 6309.3 -2000) 　 This standard lists the relevant terms and definitions, technical requirements, inspection methods, inspection rules, etc. of hot chamber die casting machines.
Die-casting machine safety requirements (JB 10145-1999) 　The standard lists the relevant terms and their definitions, important dangerous items, safety requirements and/or measures, and determination of safety requirements and/or measures.
The relevant standards for the full vertical cold chamber die casting machine have not yet been promulgated. With the development of die-casting technology, new requirements are continuously put forward for die-casting machines, the working methods of die-casting machines will be continuously improved, and the types of die-casting machines will gradually evolve.

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