Adapted Systems for Zinc and Magnesium

Transcription

1 Frech Gating System in Application 65,39 30 Zn Zink 7,14 24,31 12 Mg 1,74 Magnesium Adapted Systems for Zinc and Magnesium 1

2 FGS-Systems For Magnesium Reduction of high remelting costs for magnesium! Shortest flow paths of the melt for least temperature loss and premature freezing of melt! 2

3 Comparison of Processes Extended Cold Chamber Hot Chamber Hot Chamber FGS Gating system* 100% 70% 40% Machine at same size of component DAK 350 DAW 200 DAW 200 FGS Cycle times 100% 80% 75% * depending on part/die design 3

4 First Prototype Die Construction of a Mg Prototype die in summer 2011 First casting operation in autumn 2011 The aim was to avoid almost every gating for a very thin-walled, long profile part. With the use of a FGS system in the die the shot weight is only approx. 1/3 larger than the parts weight. With the classical gating technique of a hot chamber die, the ration would have been 2 : 1 and consequently the part would not have been cast on a 200 t machine. 4

5 FGS Test Die for Magnesium Profile Moveable side Fixed side with two FGS outlets for one separated gate The integration of these components into the die needs an appropriate die design. An essential point here is an accurate die design with regard to the heat balance. Beside this, the process of the die casting method is adapted for the FGS procedure. The machine assures by means of a suitable process that the casting system and the FGS system always is filled with melt during the whole casting cycle. 5

6 Magnesium Profile: Standard and FGS Any distance between the gating points would be possible. Handling and operation complex! 6

7 First Prototype Die FGS system was designed for large machines and is costly in handling. Development of a simple FGS module especially for the most popular DAM machines with 200 and 315 tons locking force (DAM 500 in the pipeline). 7

8 Mg-FGS Profile Technical Data: Casting area: Part: 480 cm² Sprue: 89 cm² Shot weight: Parts weight: Wall-thickness: Flow length: (gate to end of part) 427 g 320 g 1.6 mm 289 mm Direction change: 4 x ~ 90 (2 x 87, 2 x 93 ) Alloy: AM 60 Cycle time: 28 s Magnesium test die for FGS executed with a distributor in one piece FGS process operates stable 8

9 Operation and Setting FGS Layout heating circuits (max. 12); here Mg-FGS Settings of FGS system Control of FGS totally included in machine control Shots are only released when all temperatures lie within the preset limits Heating of every cavity/zone is swiched separately FGS distributor optimized 9

10 Process Control Electric Nozzle and Gooseneck Heating 10

11 Layout of FGS Dies If a gating is retained, this enables the use of proven calculation and layout methods Pin-point gating is not possible due to the required gate cross-section Reduction of gating enables increasing of cavities Short flow ways and liquid melt up to the parting line enables longer filling times Layout of die supported by simulation 11

12 FGS in the Die Temperature levels in the die at a magnesium application Compact system Modular system Verschlussfreie Verbindung Balanced heating household With standard die temperatures red: heated, molten melt orange: remaining gate blue: casting 12

13 FGS Matrix of Advantages Productivity + Cooling time dependent on parts, only + Cycle shorter (quicker cooling, no 1st phase) + More cavities Part quality + Less air in system + Exactly heated melt at gate + Thin-walled casting possible + Filling with low velocities (better ventilation; less porosity) + Less die wear Process efficiency + Less wear at casting set (gooseneck, piston, nozzle) + Relation of part to gate is independent of number of cavities Energy balance + Reduction of cycling material + Reduction of melting loss + Reduction of melting energy + Reduction of casting force - Heating of FGS unit 13

14 Thank you for your Attention! 14