What is die casting?
Die casting is a specific manufacturing process that produces sharply defined, accurately dimensioned, textured or smooth-surfaced metal parts. It relies on metal casting; a technique that forces molten metal under extremely high pressures into reusable mold cavities (also called metal dies). Mould cavities are made using two toughened steel dies which are machined into a particular shape. They operate similarly to an injection mould. A majority of die casting are manufactured from various non-ferrous metals such as copper, zinc, aluminum, lead, tin-based alloys and pewter. The type of metal that is casted will determine whether a cold or hot chamber machine is used.
The process of die casting is sometimes explained as the nonstop route between a raw material and a finished product. “Die casting” may also describe a finished part.
What role do flow meters play in die casting?
In die casting, a flow meter may be used in two situations: die cooling and or die lubrication.
Since high temperatures are utilized during die casting, die cooling is extremely important. It guarantees controlled solidification and increased productivity by reducing the cycle times. Cooling water lines are relied upon to provide this temperature control. However, these may get chocked up because of their thin and complex design. The cooling impact of liquid is tied to die temperatures. Flow meters provide control of this vital function. They work to maintain ideal temperatures.
Die lubricants are release agents. They are vital in improving efficiency. Die lubricants optimize spreading and wetting times, promote the flow of metal, maintain die temperatures and quickly cool the die surfaces; all these procedures prolong die life and provide fast cycle times. Lubricants also provide protection from temperature peaks which usually occur when the molten metal is dispensed into the molten cavity. Any sort of fluctuation in the lubricant will lead to temperature-related issues; gravely affecting the final product. Providing essential temperature control is a key function that is monitored by a flow meter.
Which types of flow meters are ideal for die casting?
Since the die casting industry faces numerous thermal challenges, a number of Proteus flow meters may be used to monitor temperature and flow: at the outlet and inlet of the die-coolant flow channel. The die caster can then use this information to manage preliminary heat ramp, ensure adequate cooling, compute heat loads, guard against coolant-channel blockage and improve thermal control.
The Proteus V7000 and V7100 series of Vortex flow meters, as well as the 8000 series Liquid flow meters, are well equipped to handle die coolant supervision. The V700 series have an accuracy of 3% or better of the flow range. The V7200, in particular, is microprocessor based which enables higher accuracy since it is capable of connecting directly to a digital field bus.
By integrating Proteus thermal control or vortex flow meters into your current die casting procedure, you will improve start-up scrap reduction, die life and productivity.