CPT International 04/2014


The leading technical journal for the
global foundry industry – Das führende Fachmagazin für die
weltweite Gießerei-Industrie

In the area of energy consumption

have been created standards that allow

customers to compare the equipment

from different manufacturers. In cooperation

between VDMA and leading

manufacturers in Europe, a standardized

cycle has been defined. In relation

to the specific machine data and performance

of the die casting machine,

the energy consumption is indicated

during that standard cycle.

These are reference numbers, which

provide assistance to customers to be

able to value the efficiency of the cell

using its process requirements. Despite

efforts by machine manufacturers to

optimize energy consumption of the

machine itself, we must be aware, that

process-related energy consumption

occurs in the die casting process, which

are often more dominant as intended.

Therefore, it is important when optimizing,

to look at the complete process.

Cold chamber die casting machine

Modern cold chamber machines are

modularly designed today. This creates

the option to adapt the shot-end

according to the needs of the respective

caster, oriented toward the process and

procedures. With reference to the technology

of the machine, for example, as

normal proportionally controlled die

casting machine or as real-time controlled

die casting machine. If the process

requires a very complex casting

profile, with a progressive speed progression,

for example, and a compression

profile after die filling, this can be

easily achieved with the options of a

real-time controlled shot-end. If these

demands are not required, because the

parts require a simple, standardized

Figure 1: Cold chamber die casting machine DAK 720-71 with Vacural (Photos:

Oskar Frech)

casting profile but must be executed

with high dynamics and still very high

casting power, a standard shot-end already

meets the requirements. This

technology requires less process understanding

and therefore a lower level of

training of personnel.

The cold chamber machines from

Frech (Figure 1) also have in addition

the ability to adapt the shot-end technology

and shot-end power accordingly.

Thus in addition to the standard

injection unit (Figure 2), additional

variants can be employed. E.g. those

with less capacity but higher dynamics

as a result of lower mass inertia in the

system, that are particularly well suited

for the high dynamic requirements

of magnesium die casting in the cold

chamber process. For working in the

SSM process (Semi Solid Metal casting),

high forces and less high speeds are generally

required during die filling. The

respectively higher specified injection

units are used here.

All of these combinations are based

on a machine concept that guarantees

the customer a high availability of components,

because Frech can serve every

customer demand from its product line.

The machines are now largely optimized

in the drive techniques. It is not

always necessary that the machine is

equipped with frequency-controlled

drives. Depending on the process, such

drive systems bring little additional en-

Figure 2: Three schemes with different aggregate sizes

Casting Plant & Technology 4/2014 15

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