Basic_Die-Casting

PresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006PresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCasting•BasicDieCastingMetallurgyandMelthandlingOctober27,2006-Location:CR-IL93-NewYorkRoom1:30pm–3:30pm•Pressurevs.FlowRate(Q)knownasPQ^2andGatingDesignNovember6,2006-Location:CR-IL93-NewarkRoom9:30pm–11:30pm•DimensionalRepeatabilityandCastingDefectsNovember20,2006-Location:CR-IL93-NewarkRoom9:30pm–11:30pm•DieCoolingSystemandDieCastingLubricantsDecember6,2006-Location:CR-IL93-NewarkRoom2:00pm–4:00pm•DieCoatingsandSurfaceTreatmentDecember15,2006-Location:CR-IL93-NewarkRoom1:00pm–3:00pm•DieDesignConceptsJanuary9,2007-Location:CR-IL93–LV-AssemblyA-9:00pm–11:00pm•ProductDesignForDieCastingJanuary23,2007-Location:CR-IL93–LV-AssemblyA-9:00pm–11:00pmDieCastingFutureSeriesofPresentationsPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieCasting:isaprocessinwhichtheliquidmetalorsemi-liquidmetalisforcedintoareusabledieveryfastwithhighpressureandtemperature.•Threetypesofinjectionmechanism•ColdChamber•HotChamber•Thixomolding•Fourpartsofthebasicprocess•Injection•Solidificationandcooling•Opening•EjectionPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006ColdChamber•Metalsthatmeltathightemperatures•Metalsthatreactwiththeinjectionmechanism•Aluminum,magnesiumandbrassHotChamber•Usedwithmetalsthatmeltatlowertemperatures•Initiallyforzinc,LeadandnowbeingmagnesiumThixo-Molding•Hopper,Mgchips,screwingmechanism•MainlyformagnesiumThreeInjectionsMechanismsPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006Typeofinjectionmechanism:ColdChamberPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006Typeofinjectionmechanism:HotChamberPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006Typeofinjectionmechanism:Thixo-MoldingPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006FourPartsoftheBasicProcess1-Moltenmetalisinjectedintosteeldies.Highpressuresensuremoltenmetalfillstheemptyspacebetweenthediehalves2-Whilemetalisheldinthedie,itsolidifiesandcools3-Whensolidificationandcoolingiscompleted,thedieisopened4-AndthesoliddiecastingisejectedPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieComponentsPartsincludebiscuits,sprues,runners,gates,overflowsandventsThespaceinwhichthecastingisformedusuallycalledthediecavity•DieBlock•Cavity•Injection-relatedcomponents•Ejection-relatedcomponentsPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieCastingMachineSystemComponentsare:Structural,Electrical,HydraulicandSafetyFocus:HydraulicandStructuralHydraulic-Pumps,heatexchanges,cylindersStructural-PlatensandTie-BarsPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieCastingMachineSystem,cont.Hydraulic:InjectionComponentsColdchambercomponentsinclude:Shotcylinder,plungerrodandtip,coupling-andthecoldchamberColdChamberPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieCastingMachineSystem,cont.Hydraulic:InjectionComponentsHotchambercomponentsinclude:Shotcylinder,plungercoupling,plunger,rings,gooseneck,bushingandnozzleHotChamberPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieCastingMachineSystem,cont.Hydraulic:AccumulatorandIntensifierAlargesteeltankpartiallyfilledwithhydraulicoil.Abovetheoilishigh-pressurednitrogengasusedwhenlargevolumeofoilrequiredHydraulicdevicethatincreaseshydraulicfluidpressureatendofinjectionstroke.Thishighpressuredramaticallyincreasesthemetalpressureto:SqueezeadditionalmetalintothediecavityasthemetalshrinksandfurthercompresstrappedgasesPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006ClampMechanismDieCastingMachineSystem,cont.Manytonsofforcearerequiredtoholdthetwodiehalvestogether.Machinesuseatiebar-platen-toggletypemachineconstruction•Achievestherequiredholding(clamping)force•OpensandclosesthedierapidlyPresentationtoAlchemy,28February2002CopyrightMotorola”2002MotorolaConfidential&ProprietaryDieCastingBasicDieCastingOctober23,2006DieCastingMachineSystem,cont.DieLocking/TieBarLoadingMajorprocessvariabletoobservewheneverpossibleistiebarloading,orstrain,whichcanvaryfromcycletocycle.Ifobserva