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Johann Emmenegger, Engineering Director & Instructor
Innovations in Vacuum Die Casting: Vacuum Technology for High Quality Die Casting Parts
ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
COPYRIGHT © 2016 FONDAREX SA 4ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Consulting
Vacuum project recommendation
Vacuum application study Vacuum system
Vacuum valve
Chill-block
Technical support
Spare parts
Training
Forum
Fondarex world
COPYRIGHT © 2016 FONDAREX SA 5ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The pressure die casting vacuum system:
COPYRIGHT © 2016 FONDAREX SA 6ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Movement of air and metal inside the shot sleeve and the runner
COPYRIGHT © 2016 FONDAREX SA 8ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Products
SUPERVACMONOVAC
MONOVAC MINI MACROMEDIO MAXI
CHILL-BLOCKSCCZ 12 SCS 30 SCS 140SCS 60 SCS 100
COPYRIGHT © 2016 FONDAREX SA 9ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
COPYRIGHT © 2016 FONDAREX SA 10ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Determine the evacuation system
Size and adapt the gating system
Size and adapt vacuum channels
Fondarex advices on production parameters.
Vacuum application studies
COPYRIGHT © 2016 FONDAREX SA 11ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Influence:
Evacuation capacity > Metal at the gate
Maintenance frequency > Downtimes
Size of overflows / vacuum channels> Reduce the amount of metal recycling
Projected area > Locking force of the die casting machine
Vacuum application studies
COPYRIGHT © 2016 FONDAREX SA 12ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
To start the vacuum channel lay out:
Fondarex is recommending rather small overflow volume for the following reasons:
− Less alloy passing the die cavity, less die wear - more parts per die, die temperature control !
− Less alloy recycling
− The «switch over» point from velocity to pressure is easier to find
− The dynamics of the DCM work better
− Therefore better micro structure of the die cast part
− The projected area can be kept lower
− Therefore less flash
− Less flash means better vacuum, better productivity, better results, geometricaly preziseparts!
− If a modification is necessary, it is much easier to open a small overflow than to weld a large one
COPYRIGHT © 2016 FONDAREX SA 13ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The vacuum channel basics:
COPYRIGHT © 2016 FONDAREX SA 14ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The vacuum channel basics:
COPYRIGHT © 2016 FONDAREX SA 15ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The vacuum channel basics:
COPYRIGHT © 2016 FONDAREX SA 16ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The vacuum channel basics:
Force during and after solidification
- Use your DC knowledge(think of extraction!)
- Use new machiningtechnologies
- Use both die sides- Do not use too much of
parting line area- Machine nice surfaces- Use radiuses- Use mobile and fixed die
side
COPYRIGHT © 2016 FONDAREX SA 17ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The vacuum channel basics:
COPYRIGHT © 2016 FONDAREX SA 18ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
The vacuum channel basics:
COPYRIGHT © 2016 FONDAREX SA 19ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
COPYRIGHT © 2016 FONDAREX SA 20ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
COPYRIGHT © 2016 FONDAREX SA 21ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
COPYRIGHT © 2016 FONDAREX SA 22ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
COPYRIGHT © 2016 FONDAREX SA 23ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
COPYRIGHT © 2016 FONDAREX SA 24ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
COPYRIGHT © 2016 FONDAREX SA 25ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
Example of a vacuum channel lay out:
Examples of vacuum die casting parts:
Johann Emmenegger, Engineering Director & Instructor
ADCA-AFI Joint Casting Conference – October 9-11, 2016 Deakin Waterfront Campus, Geelong, Victoria, Australia
