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Metal Casting Technologies : June 2007
29 METAL Casting Technologies June 2007 Make your furnace control automatic with industry leading results PreciMeter Control AB, Sweden phone+46317645520 fax+46317645529 email@example.com www.precimeter.com World leader in molten metal level control A gravity furnace becomes automatic using Precimeter Tap- out actuator TXP-6-E together with the ProH sensor and the actuator control unit. This set up ensures to keep the level down stream at a desired point within 0.3 mm A tilting furnace becomes automatic by using the ProH sensor combined with Precimeter tilt control unit. This set keeps the desired level downstream within 0.5 mm. DESIGN IMPROVEMENTS In addition, the project team implemented a number of die design measures. These increase the uptime of the die and therefore the capacity utilization rate of the die casting cell. For example, the contour core slides can be changed on the machine itself with great ease and within a very short time. A special locking design reduces the deflection of the outer slides by as much as 50 percent. This, in turn, reduces the injection of molten aluminum behind the slides while improving the dimensional accuracy of the engine blocks. A new technique for sealing the cooling bores diminishes their proneness to leakage. Furthermore, a concept which eliminates the need for ejectors in making inline engines additionally prevents downtimes. MACHINE FULFILLS DIE FUNCTIONS One major problem in conventional engine block production is the very massive, large, and therefore expensive dies that must be used. In the new Buhler concept, the die casting machine fulfills certain functions of the conventional die. This eliminates the need for ejector boxes and ejector tables in the new dies. This and additional weightreducing optimizations enable the die costs for making Vengines to be slashed by 25 percent, and inline engines by 10 percent. Last, not least, the new concepts also boost productivity. An optimized temperaturecontrol design, the freshly developed "Flextool" die spray system from the Acheson company, and synchronized machine motions allowing simultaneous spraying of both die halves save valuable seconds. These features cut the cycle time by 10 to 20 percent, depending on the weight of the raw part. TEST PHASE Together with Schaufler Tooling, Buhler presented this novel concept to a number of renowned engine block producers as far back as in early 2006. This has triggered projects that will be implemented in the course of this year. At present, the prototype of a V6engine crankcase is being tested. At the same time, a prototype die is being made for an inline engine crankcase and will be tested this spring in the Die Casting Center Laichingen (DCL). ● Further information: firstname.lastname@example.org