Construction of the casting tool
The goal in the design of our iron tools, is the construction of a casting tool with maximum performance . Underperformance , we understand not only the dimensional accuracy , surface quality and durability of the casting mold. We also value the optimum design . This is the first step towards a more efficient production to the customer. For a casting tool with these characteristics is the basis for an economic production process and thus responsible for lower component costs than competitors.
The optimal design of a casting tool is aimed in the first place according to the requirements of the customer. Among other things, the required service time must be calculated based on the total order volume. The decisive factor is also whether different castings are required in the same number . If this is the case , so-called family molds could be beneficial. But the lot size of the individual orders should be considered. In addition, component size , component weight , machine specifications and storage capacities . Using these parameters , we determine , for example, the appropriate wells or adapt the materials to the stresses . Due to the customized requirements of the design of the casting tool , we achieve the highest possible savings . Thus, we achieve the maximum cost reduction of the iron tool with consistent performance.
The optimal design of a casting tool is achieved by the precise definition of technical requirements , while complying with economical aspects .
The ejector in a casting mold required primarily for the removal of the cast part. Press the casting from the mold ejector side . However, the number and positioning of ejectors is not only of importance for demolding . Because by the ejector considerable damage to the casting may arise. The number of ejectors should generally be kept as low as possible , because they cause marks on the component. In the advanced age of the casting mold , caused by the ejector may also burrs on the casting . To avoid this , we place special emphasis on placing the ejector in the design of the casting tool possible. The number of ejectors is set according to the principle : as little as possible but as much as necessary .
The positioning device determines the position that the casting is the casting tool . She takes great influence on other factors and characteristics of a cast mold. These include the required number of working parts, the flow length and the filling behavior . But also mold removal , required number of slides and arrangement of the cooling channels are affected by it . Already in component positioning, we create the basis for an economic casting mold design and avoid complexity. Unnecessary complexity makes it difficult , for example, the replacement of worn parts , causing increased repair costs.
When spreading a mass in a casting mold is called a flow front . Spreads the cast material in different ways , so it has more flow fronts. If two order multiple flow fronts in a casting each other , this is a weak point dar. Because the two flow fronts combine to considerably worse . This reduces the capacity and may lead to breaking points and other component failure. Flow fronts can not be avoided completely in many cases. However, we are constantly striving to use in the construction of our casting tools that evolved from experience solutions to prevent flow fronts .
The determination of the flow paths in a casting mold contribute significantly to the filling behavior . That is, the flow paths during the production process are responsible in large part for the error-free filling of the casting tool . Through the proper length of the flow paths to reduce defects and waste can . Apart from the qualitative point of view is achieved by the shortest possible flow paths and shorter cycle times and reduces the waste to remove the casting . Therefore, short flow paths not only minimize the degree of re einzuschmelzenden material , but also the time for the removal of excess material. We pursue another time an established maxim of our company: The reduction of waste and excess !
A filling simulation is an animation of the filling in a casting tool . A specially developed for the analysis of iron tools in the software simulation illustrates the behavior of the casting material during filling of the casting tool . Here, the cast material is injected into the CAD design of the casting tool and under specified conditions . Flow simulation helps us to draw conclusions about possible problems in the casting process . Based on the obtained conclusions , we determine the optimal position of the gate and, if required excesses . The flow simulation is not only used for positioning of the runner . It is also an indicator of the best possible placement of the vents in pressure diecasting .
Cavity or mold cavity is defined as the centerpiece of a casting tool . The actual form in which the liquid molding material is injected and hardens therein. The number of cavities in a casting tool is crucial for the economical production of each casting. With the number of cavities in a casting tool sets you how many castings in Spirtz or cast are manufactured in one machine cycle . The design of a casting tool , we consider many criteria and define the knowledge out of it resulting from an optimal number of cavities.
Wear parts such as slide or ejector can be cast into molds usually not completely avoid . However, they are often sources of repair costs and increase the risk of default of the casting mold. The reduction of wear parts , therefore, is primarily for reliability and longevity of a casting tool . Built with redundant components reduce maintenance-free life of a casting tool . To reduce the repairs to a casting mold to a minimum , we try redundant and highly stressed components to be replaced by alternative design options . We not only reduce the cost of repairs . We also limit the risk of failure and repair cycle of the casting mold.