Frech Gating System in Application · Frech Gating System in Application. ... Gating system* 100% 70% 40% Machine at ... gating technique of a hot chamber die,

© Oskar Frech GmbH + Co. KG 16.09.2015FGS-Workshop 1

MgMagnesium

24,31

12

1,74

ZnZink

65,39

30

7,14

Adapted Systems for Zinc and Magnesium

Frech Gating System in Application


For Magnesium

Reduction of high remelting costs for magnesium!

Shortest flow paths of the melt for least temperature loss and premature freezing of melt!

FGS-Systems


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


Construction of a Mg Prototype die in summer 2011

First casting operationin 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 classicalgating technique of a hot chamber die, the ration would have been 2 : 1 and consequently the part wouldnot have been cast on a 200 t machine.

First Prototype Die


FGS Test Die for Magnesium Profile

Moveable side Fixed side with two FGS outlets for oneseparated 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 processthat the casting system and the FGS system always is filled with melt during the whole casting cycle.


Magnesium Profile: Standard and FGS

Any distance between the gating points would be possible. Handling and operation complex!


FGS system was designed for large machines and iscostly in handling.

Development of a simple FGS moduleespecially for themost popular DAM machines with 200 and 315 tons lockingforce (DAM 500 in thepipeline).

First Prototype Die


Mg-FGS Profile

• Magnesium test die for FGS• executed with a distributor in one piece• FGS process operates stable

Technical Data:

Casting area: Part: 480 cm²Sprue: 89 cm²

Shot weight: 427 g

Parts weight: 320 g

Wall-thickness: 1.6 mm

Flow length:(gate to end of part)

289 mm

Direction change: 4 x ~ 90°(2 x 87°, 2 x 93°)

Alloy: AM 60

Cycle time: 28 s


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


Process Control – Electric Nozzle and Gooseneck Heating


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


FGS in the Die

Temperature levels in the die at a magnesium application

� Compact system

� Modular system

� Verschlussfreie Verbindung

� Balanced heatinghousehold

� With standard die temperatures

red: heated, molten melt

orange: remaining gate

blue: casting


FGS Matrix of Advantages

Energy balance

+ Reduction of cycling material

+ Reduction of melting loss

+ Reduction of melting energy

+ Reduction of casting force

- Heating of FGS unit

Part quality

+ Less air in system

+ Exactly heated melt at gate

+ Thin-walled casting possible

+ Filling with low velocities (betterventilation; less porosity)

Productivity

+ Cooling time dependent on parts, only

+ Cycle shorter (quicker cooling, no 1st phase)

+ More cavities

Process efficiency

+ Less die wear

+ Less wear at casting set(gooseneck, piston, nozzle)

+ Relation of part to gate isindependent of number of cavities


Thank you foryour Attention !

Documents

Frech Gating System in Application · Frech Gating System in Application. ... Gating system* 100% 70% 40% Machine at ... gating technique of a hot chamber die,