06 Schlotterbeck M Requirements and Solution Proposals For Optimal Design of The Zinc Diecasting Process1

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Requirements and solution
proposals for optimal design
of the zinc diecasting process
Martin Schlotterbeck
Oskar Frech GmbH + Co. KG
73614 Schorndorf-Weiler /Germany
Author: Martin Schlotterbeck

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We have prepared the following for you:
Short presentation from the Frech company

Introduction and intentions for this
presentation
Facts and suggestions for an optimal layout
of the process
Summary

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Frech Worldwide
Headquarters: Schorndorf-Germany
17 subsidiaries and
numerous international agencies
approx. 700 employees worldwide
Product Lines
Hot chamber diecasting machines

Cold chamber diecasting machines

Dies
3

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Hot
chamber
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Hot chamber diecasting machines

Locking force range from 50 kN 9300 kN
Machine types: hydraulic, fully electric, hybrid
Different technology levels
Application: Pb, Zn, Mg
Automation
Heating and cooling units
Removal technology
Spraying technology
Verification systems
Transport systems
Melting and holding
technology
Die Technology -
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Cold
chamber
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Cold chamber diecasting machines

Locking force range from 1.25 MN 50 MN
Application: Al, Mg
Machine types: hydraulic, Realtime Control and Standard Shotend
Different technology levels and
process techniques: (Standard, VACURAL)
Heating and cooling
units
Removal technology
Spraying technology
Verification systems
Plunger lubrication
Transport systems
Furnace technology
Die Technology
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Service
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Services
Training
Technical consulting
Condition Monitoring
RSD
Worldwide service network
Replacement components
Overhaul expertise
Replacement and Consumable
Parts
Simulation
Test casting (Prototyping)
Engineering
Overhauls
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Introduction and Intentions
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The use of the latest methods such as FGS, optimized machine
processes and new alloys can only be employed efficiently when the
basic design of the process is correct.
The design of a die with regard to flow and heat technology is still not
yet a matter of course. Passive, economical and highly efficient
ventilation systems are not yet common practice.
A fast, repetition-accurate diecasting machine with real-time control,
pre-filling, camera system, etc. can be optimally utilized when good
process design is also taken into consideration as part of the whole.
With this presentation, we would like to demonstrate or at least remind
you of the requirements of the optimized zinc diecasting process
with our specific solution proposals in order to improve upon any
untapped potential in the diecasting process.
Facts
and suggestions durch
for an optimal
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layout
of the process
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1
A modern
Machine
A dynamic
shot end
Useful
peripherals
Melting and
holding
technology
Innovations
for the process
Optimized
Die system
4
5
The
most exciting part of
the success
story of
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Frech
machines is its continuation!
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STOP
From the Schorndorf technology museum
And more than 50 years later
For an optimal casting process, you need a reliable, repetition-accurate and

extremely dynamic machine. The modular design of modern machine technology
has the advantage that it can adapt to infrastructure and requirements
accordingly.
10
The
control system -- the
cockpit
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the casting system!
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Today, the control system is the foundry personnel's cockpit. Gone are hand wheels
and cams for manual adjustment work because manual settings are unfortunately
not always reproducible and hardly proofable. Today everything is visualized via the
control system. A range of adjustment aids are available for optimal configuration.
Setup work is shortened, data is saved and personnel can comfortably set up the
machine. A complex casting profile can only be adjusted and monitored with
integrated measurement technology (casting graphic).
11
Casting
parameters aredurch
the
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parameters
of success!
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STOP
Correct casting parameters are not easy to determine, as the casting process
is very complex. Adjustment profiles help the operator to graphically and
geometrically depict, calculate and monitor the casting process.
12
Casting
parameters aredurch
the
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parameters
of success
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STOP
With older control systems, you can

adjust a machine but cannot monitor
the process.
A complex casting profile can only be adjusted

with integrated measurement technology
(casting graphic).
An experienced caster "hears" whether the casting process sounds good. However,
he cannot hear the gate velocity and pressures, etc. Casting graphics have been the
standard at Frech since the mid 1990's and have been continually upgraded for
ease of adjustment. Parameters such as filling times, plunger velocities and
pressures can only be correctly determined and monitored using these graphics.
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The shot end: The engine of progress!
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Standard shot end

with conventional proportional
technology in the intake.
Real-time control shot end

with servo hydraulics in delivery and
closed position control circuit.
Various shot ends are available according to the requirements of the cast part.
The highest demands are met with the real-time controlled "RC" shot end.
Absolute reproducibility from casting process to casting process is guaranteed.
A freely programmable, process-oriented plunger course makes nearly any shot
profile possible.
14
There
is a patent (no. EP
1284168
A1)
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against
too much air!
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"Standard"
"Pre-filling"
The melt in the casting

system is at the metal
level.
The system is filled with melt

up to shortly before the
nozzle tip.
Air inclusions are the most frequently occurring casting defects. With the
"prefilling" system, the casting system is nearly completely filled with melt.
Through simultaneous execution of the piston and locking movement, the cycle
time is additionally shortened.
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The
die must also be protected!
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"Standard"
"New FRECH Standard"
A die protection system which is

manually adjustable via the
pressure is too slow and imprecise.
Intelligent die protection system with

monitoring of the pressure curve
previously determined in learning mode.
Long service life is above all a question of die design. However, useful
machine features, such as an active, sensitive die protection system of the
machine with "teach function," for example, also protect the die during the
closing process.
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Melt
zinc at a high level!durch Klicken
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"Standard 1-chamber furnace"
"Multichamber furnace"
with unstable melt level and variable

casting profile as a result.
with constant melt level in order to enable

an absolutely uniform melt dosing from
shot to shot.
The quality of a component begins with the melt. The charging side is separated
from the removal side by separate chambers, for a clean melt and a stable,
uniform melt level.
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Melt
zinc and not yourdurch
money!
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The newly developed cover not only saves energy but also reduces oxide formation
and protects the melt from outside contaminants.
Furnace type:
ZC 50/180*
Measurement
over 14 hours
Average
consumption
Savings in comparison,
without cover
Savings
in %
Without cover
73.35 kW/h
5.24 kW/h
New cover with

insulation
56.2 kW/h
4.01 kW/h
1.23 kW/h
23.5 %
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The
correct die temperature
lies
somewhere
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between
hot and cold!
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Preheating with a burner
Temperature control systems for the dies
does make the die hot, but is not a

reproducible parameter and does not
replace a temperature control system.
for heating and cooling with water or oil, for

maintaining the required temperature and for
measuring and monitoring.
High product quality, low production costs and high process reliability usually
cannot be achieved without temperature-controlled dies. The greatest primary
source of error is a less than optimal die temperature. A controlled heat flow in the
melt, precise die filling, directed solidification and long die service life all require a
professional temperature control system, customized to the die.
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We
are spraying with excitement!
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Point spray 15
Flat spray 70
This retrofit set (2 wires, one plate) is

not available from FRECH.
Modular fine spraying technology, adaptable

as desired for all spraying tasks IS available
from FRECH.
The spraying process must already be taken into consideration during the
designing of dies and processes. The spraying systems must be conceptualized,
selected and considered. Spraying devices are continually misused in order to
eliminate insufficient thermal die designs, whereas only a fine separating film
should be applied. A wide selection of spraying devices, tools, spray nozzles and
die lube containers are available. We can provide you with more information.
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Service
lives of dies: the
longerKlicken
the better!
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Zinc Hot chamber

from 600,000 cycles
STOP
to 2,000,000 cycles
Magnesium Hot chamber

from 400,000 cycles
to 1,000,000 cycles
Aluminum Cold chamber

from 150,000 cycles
to
350,000 cycles
The service life of the die depends on: flow speeds

Gate velocities, pressure peaks, cycle times, die lubes, die temperature control,
thermal change stress, mustering (preheating) and the alloy. The manufacturing
method of the die, the geometry of the contour and the die material used are
also decisive.
The die designer must know and master these arguments. If they are
incorporated into his considerations, the expense for an optimally designed die
is relatively minor.
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Massive
problems fromdurch
"unstable
dies"!
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Unstable die structure with many thin

plates, weak frame and supports.
Stable die structure with a few thick

plates, solid frame and strong supports.
A massive and thick die plate has a greater bending resistance than 2 thin
plates, at about the same material costs. The more stable die plate can better
absorb pressure peaks. Its greater thermal capacity serves as a heat reservoir
and can better equalize temperature fluctuations. Flash development occurs
with weak, bendable dies. These causes of defects are frequently mistaken for
locking force being too low. An unstable die cannot be repaired.
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The
nozzle tip: bottleneck!
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One often sees "mini nozzle tips."

They throttle capacity, are prone to
freezing up and are unfavorable with
regard to flow technology.
The correct mathematical design of the die

begins with large nozzle tips matched to the
required casting capacity.
The nozzle tip, a bottleneck? Yes! Unfortunately, this is often too small. The
result is casting problems. The diameter A is decisive for the usable section, for
the velocity of the melt and the quantity of flow! A nozzle tip that is too small is
thermally inefficient and throttles the machine capacity. Large nozzle tips are
available from FRECH.
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Sprue
bushing: save ondurch
cooling,
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costs
cycle time!
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A "rod sprue" without the possibility

for placement of efficient cooling.
Thermally and flow optimized distributor and

sprue bush.
There should never be a shot bushing without cooling. There is usually space to
be found for a small cooling channel. The transition from the nozzle tip into the
shot bushing is critical with regard to thermal efficiency and therefore must be
temperature-controlled. If this area is too hot, the sprue taper sticks. The casting
process is interrupted and the cooling time must be extended. Not the cooling
time of the part, but the cooling time of the cross sections determine more often
the length of the cycle time.
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Don't
take too many stages
at once!
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d
A
B
C
B
Differing sections and a bottleneck on

the distributor are unfavorable with
regard to flow.
72%
81%
D
90%
100%
Correctly staged sprue system.
A general decrease of the sections in the flow direction is required so that the
melt always remains under static pressure and air inclusions are thereby
avoided. After a direction change in the runner, the sections should be reduced
by approx. 10% per deflection.
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Runner:
the flow's the thing!
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Unfavorable
Done correctly
correct
Blind flow:
Flow-optimized runner:
The melt front is continually swirled in.

Contaminated melts cannot be collected, since
this area is flushed out time and again.
Short flow paths and small deflection angles
A flow-optimized runner with sections correctly tailored to the casting

volume can be produced at neutral cost.
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Gate
design: "limitless potential!"
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Standard Tangential sprue:
Flow-optimized variant:
The classic has its limits. The casting stream is

deflected on the outsides. As a result, there is risk
of confluence of the melt opposite the gate.
For round and oval geometries, but also for a wide

variety of other configurations, a casting stream
aligned to the center is the ideal solution.
The design of the gates is the most important fundamental for good parts quality.
Experience and an understanding of the filling process are important for a solid
gate design. The die filling simulation is an important element for predicting the
character of the filling. The very precise statements made by today's die filling
simulations should always be applied for complex parts.
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Small
gate, big damage!durch Klicken
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Cavitation risk due to localized gate

velocity being too high:
A thin, smaller gate section increases the
velocity of the melt.
Variant for high gate section:

The correct gate section must be calculated. The
gate velocity should be approx. 40m/s. 60m/s should
not be exceeded.
Cavitation occurs when localized melt velocity is too high. In subsequent section
expansions, a vacuum occurs which causes the melt to vaporize. Damages
occur due to the condensation of melt vapor. Correctly graduated sections to
the gate and gentle curves in the sprue system as well as gate thicknesses
greater than 0.35mm are required. The filling time in particular (2nd phase)
must be monitored by the machine.
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The
air must go!
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Without ventilation system:
With ventilation system:
Overflow channels are often designated as

ventilation systems. However, there is no
connection to the outside, unfortunately.
Here in the form of a wash-board milled directly

in the die insert. An excellent alternative to the
"chill block."
Air is usually not displaced by the melt flowing in at high velocity, but rather enclosed
and compressed at the specific casting pressure. Good and sufficient ventilation
already begins at low pressure in the 1st phase. The ventilation pathways are
guided to the outside; the melt is aligned toward the center. Connections to the
ventilations are thereby reached only at die filling end. With correctly placed
ventilations which can be securely removed, sufficient ventilation is possible.
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One
can never have enough!
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STOP
Simple temperature controlled channel

system:
Too little exchange surface in the die inserts
is insufficient for efficient thermal transfer.
As a general rule, the more channels the better.

Shielding of the die hollow space area is achieved
through correspondingly placed temperature
channels.
The temperature control should generate surface temperatures which are as

uniform as possible. This requires a sophisticated channel system for optimal
thermal transfer, in accordance with the complexity of the parts. The overheated
regions in the die extend the cycle time and increase spraying agent
consumption. Areas with shrink porosity and low part stability result due to slow
cooling.
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Small
section, high loss!
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STOP
Improvized assembly of pipes and

nipples.
Do not leave it to chance. Correctly

designed connections are the work of the die
designer.
Unfortunately, section bottlenecks are often unknowingly built into different

points in temperature control connections. Deflections, section bottlenecks and
long inlets throttle the volume flow and consequently the energy transfer of the
temperature control unit.
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Feedback
for die designers
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Crack the safe and get the feedback!
The most important casting parameters

can be calculated, monitored and
evaluated directly on the machine.
The calculated values from die design can be entered directly on the machine,
with only a few manual steps. The machine is adjusted using these values.
Feedback on the die design is thus possible. Retrieve this valuable info before
you start a new design.
32
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Everyone
knows the price,
but Klicken
not the value!
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Manufact. costs /part 0.839
0.452
Material costs
Manufact. costs /part 0.819
0.452
Machine costs at
30 s cycle time
0.304
0.083
Material costs
Machine costs at
27 s cycle time
0.274
Die service life
600,000 cycles
Costs 100,000
0.093
Optimized die design
Existing die design
STOP
Die service life

700,000 cycles
Costs 130,000
At 10% cycle time savings and a service life increase of only 16%, 30% greater die costs
can be amortized. Even greater savings are possible by reducing the rejection rate, which
is not even mentioned in this comparison.
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Summary
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My notes have perhaps not been revolutionary innovations for you. But
it is precisely the simple things which are not in our direct focus.
This, my field report from practical experience shows as an example
where the greatest potentials for improvement still lie.
Often, a great deal can be accomplished here with very little.
This presentation can also be used as a kind of checklist.
Go through your foundry next week and take a look at the topics I have
compiled.
Any improvement is better than postponed perfection.
I wish you the best success.
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A great deal more information about diecasting technology as a
whole, from 5 tons hot chamber to 4400 tons cold chamber,
can be found at:
www.frech.com
info@frech.com
Tel.: 0049 (0)7181/702-0

Schorndorfer Strae 32
D-73614 Schorndorf-Weiler
Germany
35

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Thank you for your attention.

Martin Schlotterbeck
36

06 Schlotterbeck M Requirements and Solution Proposals For Optimal Design of The Zinc Diecasting Process1

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Titelmasterformat durch Klicken

Oskar Frech GmbH + Co. KG

Titelmasterformat durch Klicken

Short presentation from the Frech company

Oskar Frech GmbH + Co. KG

Titelmasterformat durch Klicken

Hot chamber diecasting machines

Cold chamber diecasting machines

Titelmasterformat durch Klicken

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

Hot chamber diecasting machines

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

Cold chamber diecasting machines

Oskar Frech GmbH + Co. KG

Oskar Frech GmbH + Co. KG

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

From the Schorndorf technology museum

And more than 50 years later

For an optimal casting process, you need a reliable, repetition-accurate and

Oskar Frech GmbH + Co. KG

Oskar Frech GmbH + Co. KG

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

With older control systems, you can

A complex casting profile can only be adjusted

Oskar Frech GmbH + Co. KG

Standard shot end

Real-time control shot end

Oskar Frech GmbH + Co. KG

The melt in the casting

The system is filled with melt

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

"New FRECH Standard"

A die protection system which is

Intelligent die protection system with

Oskar Frech GmbH + Co. KG

"Standard 1-chamber furnace"

with unstable melt level and variable

with constant melt level in order to enable

Oskar Frech GmbH + Co. KG

New cover with

Author: Martin Schlotterbeck

Oskar Frech GmbH + Co. KG

Preheating with a burner

Temperature control systems for the dies

does make the die hot, but is not a

for heating and cooling with water or oil, for

Oskar Frech GmbH + Co. KG

This retrofit set (2 wires, one plate) is

Modular fine spraying technology, adaptable

Oskar Frech GmbH + Co. KG

Zinc Hot chamber

Magnesium Hot chamber

Aluminum Cold chamber

The service life of the die depends on: flow speeds

Oskar Frech GmbH + Co. KG

Unstable die structure with many thin