Real-time control boosts diecasting accuracy

The realtime control capabilities of a machine are helping a zinc diecaster meet the specifications of a job, for which consistency and dimensional accuracy are critical.

The realtime control capabilities of a machine are helping a zinc diecaster meet the specifications of a job, for which consistency and dimensional accuracy are critical.

The realtime control capabilities of a Frech machine are helping a zinc diecaster meet the specifications of a job for which consistency and dimensional accuracy are more than usually important.

PMS Diecasting of Rotherham, UK, has a DAW 20RC that is used exclusively to produce zinc alloy bodies for the Gripple, an ingenious device for joining wire that sells in the millions all over the world.

Manufacturer Gripple completes the product by loading the bodies supplied by PMS onto a high-speed, continuous production line where other components are added.

"All the dimensions of the body are critical, especially internally, because it takes only one out-of-spec part to bring Gripples whole line to a halt explains PMS engineering director Gordon Panter.

"Thats why the RC facility on the DAW20 is so important to us.

The machine monitors its own injection cycle and adjusts it to pre-set parameters as it happens, so we can be sure that every part that emerges from the die is identical.

"The need for consistency extends to other characteristics - surface appearance, for example, and porosity especially, because every Gripple is load-tested before it is released from the factory.

"Realtime control gives us parts that are almost flash-free and need tumbling only very briefly.

The virtual absence of flash also indicates that the tool is not taking unnecessary punishment, which is good news for die life Currently running on a five-day 12-hour basis, the Frech has also impressed with its cycle time, which is almost 40% faster than predicted.

It incorporates a fastest possible filling time that has improved the density and strength of the parts.

Deliveries are made in response to Gripples kanban system ? and prompt arrival is assured because the two companies are only 15 minutes apart at the intersection of two motorways.

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