The Importance and Safety of

Hydraulic Accumulators
in
Die Casting Machines
[Enhancing Performance and Ensuring Operator Safety in
Die Casting Operations.]
Bharat Sharma
Keep Learning Till Death

Company name: SDS

Website: www.steadydiecastingsolutions.com
Mobile App: HPDC Pathshala http://on-app.in/app/home?orgCode=dnrro
Mail Id : hpdcpathshala@gmail.com

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Introduction:
Die casting machines are widely used in various industries for their ability to produce
complex metal parts with high precision. One crucial component of these machines is the
hydraulic accumulator. While it may seem like a simple steel tank, the accumulator plays a
vital role in ensuring smooth and efficient operations during the die casting process. In this
article, we will explore the significance of accumulators and emphasize the importance of
their safe handling.

Understanding the Hydraulic Accumulator:

An accumulator is a large steel tank that contains hydraulic fluid and a column of high-
pressure nitrogen gas. It acts as a storage reservoir for hydraulic oil, which is required during
specific stages of the die casting process. For instance, during injection and intensification or
die open/close phases, when a large volume of hydraulic oil is needed, the accumulator
comes into play.

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How Accumulators Facilitate Smooth Operation:
During the fast shot phase of injection, the accumulator's valve opens, allowing the hydraulic
oil to flow into the shot cylinder. This rapid flow of oil cannot be supplied by the hydraulic
pumps alone. The accumulator, with its high-pressure stored oil, ensures that the required
volume of oil is readily available for cavity filling. Once the accumulator is discharged, its
task is complete. At other stages of the casting cycle, the oil is pumped back into the
accumulator, recharging it for future use.

Safety Considerations:
While accumulators provide essential functionality to die casting machines, it is crucial to
recognize the potential hazards associated with them. Accumulators store a large amount of
oil under high pressure, which can pose risks if not handled properly. Therefore, when
performing maintenance activities that require the machine or die to be "locked out," it is
essential to return the accumulator to a "zero energy state" (ZES). This process involves
relieving the pressure in the accumulator to eliminate any possibility of hydraulic cylinder
movement.

Ensuring Safe Practices:

Maintaining a safe working environment is paramount when dealing with hydraulic
accumulators. Here are a few key practices to ensure their safe handling:
 Proper Training: Operators and maintenance personnel should receive comprehensive
training on the safe handling, maintenance, and servicing of accumulators. They
should understand the potential hazards associated with accumulators and know the
appropriate safety protocols.

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  Lockout/Tagout Procedures: Before performing any maintenance or repair work on
the die casting machine, it is crucial to follow lockout/tagout procedures. This
involves isolating the energy sources, including the accumulator, to prevent accidental
activation and ensure the safety of personnel working on the equipment.
 Pressure Relief: Whenever the accumulator needs to be serviced or when the machine
is not in use, it is essential to relieve the pressure in the accumulator. This can be done
by following specific procedures outlined in the machine's operation and maintenance
manual.
 Regular Inspection and Maintenance: Accumulators should undergo regular
inspections to detect any signs of wear, damage, or leakage. Routine maintenance
should be performed as per the manufacturer's recommendations to ensure their
optimal performance and safety.

Calculating the size of a hydraulic accumulator involves considering various factors,

including the required volume of hydraulic fluid, system pressure, and desired accumulator
capacity. Here's a step-by-step explanation of how to calculate accumulator size using an
example:

Example:
Let's consider a die casting machine that requires an accumulator to provide hydraulic oil
during the injection phase. The injection phase requires a certain volume of hydraulic fluid to
fill the cavity effectively. The system operates at a pressure of 150 bar (2,175 psi).

Step 1: Determine the Required Volume:

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First, calculate the required volume of hydraulic fluid needed for the injection phase. This
depends on factors such as the size of the cavity and the desired fill ratio. For instance, let's
assume the required volume for cavity filling is 20 liters (20,000 cc).

Step 2: Determine the Desired Accumulator Capacity:

Next, decide on the desired accumulator capacity, which refers to the volume of hydraulic
fluid that the accumulator can store. This capacity should be sufficient to supply the required
volume of fluid during the injection phase. A general guideline is to select an accumulator
capacity that is at least twice the required volume. In our example, we'll choose a desired
accumulator capacity of 40 liters (40,000 cc).

Step 3: Calculate the Precharge Pressure:

The precharge pressure is the pressure at which the accumulator's nitrogen gas is initially set.
It ensures proper operation and allows for quick response when hydraulic fluid is required. A
typical precharge pressure is around 80% of the system pressure. In our example, the system
pressure is 150 bar (2,175 psi), so the precharge pressure would be 0.8 * 150 = 120 bar
(1,740 psi).

Step 4: Determine the Gas Volume:

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To calculate the gas volume required in the accumulator, use the ideal gas law equation: PV =
nRT, where P is pressure, V is volume, n is the number of moles of gas, R is the gas constant,
and T is the temperature. Assuming the temperature remains constant, we can simplify the
equation to P1V1 = P2V2.

In this case, the initial pressure (P1) is the precharge pressure (120 bar) and the initial volume
(V1) is the gas volume in the accumulator. The final pressure (P2) is the system pressure (150
bar) and the final volume (V2) is the sum of the gas volume and the required accumulator
capacity (40 liters or 40,000 cc).

Using the equation: P1V1 = P2V2

(120 bar) * V1 = (150 bar) * (V1 + 40,000 cc)

Solving for V1:

120V1 = 150V1 + 6,000,000
30V1 = 6,000,000
V1 = 200,000 cc

So, the gas volume required in the accumulator is 200 liters (200,000 cc).

Step 5: Determine the Accumulator Size:

Finally, calculate the total size of the accumulator, which includes both the gas volume and
the desired accumulator capacity. In our example, the accumulator size would be 200 liters
(gas volume) + 40 liters (accumulator capacity) = 240 liters.

Conclusion:
Hydraulic accumulators are integral components of die casting machines, enabling efficient
operation by storing and supplying hydraulic oil when needed. However, their high-pressure
nature requires strict adherence to safety procedures to prevent accidents and injuries. By
implementing proper training, lockout/tagout procedures, pressure relief protocols, and
regular maintenance, operators and maintenance personnel can ensure a safe working
environment and maximize the benefits of hydraulic accumulators in the die casting industry.

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