Pressure Die Casting

HIGH PRESSURE DIE CASTING
I. Working principle of PDC –
1) High-Pressure Die Casting (HPDC) is an extremely efficient

manufacturing method for producing various product forms.
2) The process forces molten metal at high speed, and high pressure into
a closed steel die cavity. The die has a stationary and moving half, both
of which are mounted to the die casting machine’s platens.
3) The die casting machine has an injection end that uses hydraulics and
pressurized gas to move a piston forward, injecting the molten metal
into the closed steel die.
4) The die casting machine also has a clamping end that utilizes hydraulics
and mechanical toggles to absorb the injection pressure and hold the
die shut while the part solidifies.
5) The process is capable of turning molten metal into a solid near-net-
shape part in seconds.
6) The three main metal groups used with this die casting process are
o Aluminum
o Zinc
o Magnesium
II. Components of PDC –
1) Accumulator 12) Safety door

2) Injection unit 13) Toggle side and top cover
3) Tip lubrication system 14) Cooling water supply
4) Hydraulic pump motor 15) Injection sleeve
5) Plunger rod and plunger tip 16) Main breaker
6) C-frame 17) Automatic spray unit
7) Tie bar 18) Auto ladler
8) Fixed and moving die plate 19) Automatic extractor
9) Die locking unit 20) Molten alloy holding furnace
10) Operating panel
11) Control panel
III. Operation of PDC –
 Manual mode checking points-

1) Die closing, die opening condition should be set on the die movement
setup in control panel.
2) Injection condition should be checked and set.
3) Ejection movement should be checked and setup.
4) All core IN and OUT movement should be checked.
5) All core IN and OUT sensors should be properly connected.
6) In auto ladler, the arm advance/retract, pouring, transferring should be
checked by keeping mode in MANUAL.
7) In automatic extractor, the arm forward/retract should be checked.
8) Automatic spray and air blow should be checked.
9) Hydraulic oil level checking.
 Automatic operation –
Start button
Safety door close
Die close, core IN
Shot ready, lamp light is up
Shot command, push button
High speed shot
Cooling timer
Die open core OUT
Ejection
Spray system water air blows and water cleans the cavity
IV. Periodical checkups -
 Automatic spray unit -

1) Check for air pressure
2) Make sure there is no looseness in the safety hook
3) Check if the spray unit is properly placed in the die area.
4) Check if interlocks are working properly and preventing the entry of
extractor arm.
5) Check if auto drain working normally.
6) There should be no oil leakage from cylinders, valves, piping.
7) In the control panel screen 1 and 3 monthly checkup list should be
followed.
8) Check for limit switches function properly.
9) Check for no loose mounting parts.
10) Apply grease to the grease nipple
11) Check for air leakage.
12) Check if pressure gauges working normally.
 Auto ladler –
1) The arm position is factory set. It is necessary to readjust the arm
retract limit as it depends on the furnace position. This setting can be
done in the auto ladle setup screen.
2) Adjust the molten metal surface sensing electrode and the grounding
electrode so that the ladle does not excessively lowered or
excessively lifted while pouring in molten metal.
3) There should always be a spare ladle ready and replace the spare
ladle at 48 hours interval and should be coated with titanium oxide.
4) Apply the titanium oxide coating with a brush, should allow two thin
coats of titanium oxide.
5) Allow the coating to dry gradually.
6) If molten alloy droplets may hang down from electrodes remove it
with a stick as it can cause measurement errors.
7) The driving chain in the arm may become loose after long period,
inspect and adjust the chain tension.
 Automatic extractor -
1) Greasing of the extractor arm should be done periodically.
2) Before starting check whether the interlocks are working properly
or not.
3) Check if the rod is not bend.
4) Check that there are no loose mountings.
5) All the movements of the arm to be tried out.
 Hydraulic pump –
1) Check for oil leakage daily and oil level in the tank.
2) Check for tightness of bolts and should be fastened with specified
torque.
3) Check for abnormal sounds from pump or motor. Stop the motor
immediately and check motor bearing condition by rotating
coupling shaft and check for tightness.
4) If the pump head is loose or leaking should replace the gasket with
new gasket.
5) Check the discharge pressure of hydraulic oil from pump, should be
set at 15 Mpa.
6) Suction filter should be cleaned once a month or may cause
clogging.
7) If pressure not developing remove control valve and inspect.
 Oil cooler –
1) Clean the oil cooler once 6 months.
2) Remove the bonet on the opposite side of the cooling pipe and
clean inside of copper pipe with a soft brush.
3) If not cleaned may reduce capacity and prevent hydraulic oil from
being cooled.
 Accumulator -
1) Only nitrogen gas to be used for filling accumulator.
2) Remove dust cap from oil port.
3) Open drain so that hydraulic pressure is reduced to atmospheric pr.
4) Charge gas gradually and slowly. Charging gas at high pressure can
damage bladder or core.
5) Close the pressure reducing valve by turning its valve counter
clockwise.
6) Open the cork of nitrogen gas cylinder and make sure primary
pressure of the pressure reducing valve is equal to the atmospheric
pr.
7) Fully close the charging valve by turning the handle clockwise the pr
becomes 0.5 MpaG.
8) Turn the top handle of the charging valve clockwise until you feel
resistance, at this moment pr in the charging valve starts reducing
because nitrogen has started flowing inside accumulator.
9) Remove the charging valve by turning handle clockwise to make it
stop.
10) Loose the union nut and remove charging valve from accumulator.
11) Check for any gas leakage.
12) Torque used to tight is 13.2Nm to 16.2Nm.
13) Nitrogen charging pressure is 7.8Mpa.
 Shot Blasting -
1) Check the dust filter cartridge and replace if dirty.
2) Check for abrasion of the blower plate, inner parts and back plate
and replace all worn parts.
3) Bolts will get loosen on daily basis, should check for tightness.
4) Check for proper closing of shot blasting door or gate.
5) Motor belt should be checked, if worn to be replaced.
6) Clean dust on electrical components and control block.

Pressure Die Casting

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HIGH PRESSURE DIE CASTING

I. Working principle of PDC –

1) High-Pressure Die Casting (HPDC) is an extremely efficient

II. Components of PDC –

1) Accumulator 12) Safety door

 Manual mode checking points-

Safety door close

Die close, core IN

Shot ready, lamp light is up

Shot command, push button

High speed shot

Die open core OUT

 Automatic spray unit -

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