The trial operation and adjustment of the 90 ton hot chamber die casting machine mainly include the following aspects:
Test run
- Before the test run
- Empty Cycle Step Mold Clamping
- Ejection
- Precautions Keep the environment clean and tidy
- Set the injection pressure
- Adjust the shooting time
- The setting of other process parameters
- Precautions Keep the environment clean and tidy
Before the test run
Check the oil level in the oil tank and make sure it is at the upper limit of the oil sight glass.
Check the hydraulic system for leaks and ensure that the safety devices are intact.
Check whether the inside of the electrical box is dry and tidy to ensure smooth airflow and good heat dissipation conditions.
It is first necessary to carry out an empty cycle to check whether the action of the hot chamber die casting machine is smooth and whether there is no abnormal sound or vibration. The purpose of the trial run is to check the performance and quality of the machine and ensure that the machine can work normally.
Empty Cycle Step Mold Clamping
The mold is closed and ready for the next pour. Injection: Activates the hydraulic system to inject molten metal into the mold. Injection return: After the injection is completed, the hydraulic system returns the injection cylinder to the initial position. Mold opening: Open the mold and take out the casting.
Ejection
Use the ejection mechanism to eject the casting from the mold. Ejection return: After the ejection is completed, the ejection mechanism returns to the initial position.
Precautions Keep the environment clean and tidy
Ensure that the space around the die-casting machine is unobstructed, and the ventilation and ventilation equipment should be in good working condition.
The materials and auxiliary appliances used should be placed reasonably according to the regulations, the floor of the die-casting workshop should be non-slip, and the roof and windows should be in good condition to ensure that the die-casting machine is not exposed to rain.
Set the injection pressure
Switch the die casting machine to the “manual” mode, and turn on the power supply, start the hydraulic pump to make it run normally.
Adjust the total pressure digital DIP
On the operator panel set it to the appropriate shot pressure position. Ensure that the pressure is set correctly by observing the pressure value indicated by the needle of the shot pressure gauge.
Adjust the shooting time
The shooting time is the time from the beginning of the beating to the end of the shooting. The shot time can be optimized by adjusting the injection curve.
When the injection rod starts to act, it moves slowly under the push of the low-speed valve, and when it reaches the specified position, the high-speed valve opens, and the speed will rise rapidly, rising to the maximum value in a very short time.
The setting of other process parameters
The slow injection speed of the injection punch should be as low as possible to reduce the pressure loss caused by the friction and turbulence of the liquid metal during the flow process while maintaining contact between the liquid metal and the wall surface and avoiding air mixing.
According to the requirements of product characteristics, it is also necessary to set and adjust parameters such as running speed and position, pressurization mode, and pressure construction time.
Oil quantity inspection: check whether the connection and fixation of hydraulic pipelines and components are loose, whether there is oil leakage, and solve it in time.
Check the lubrication of each lubrication point and the oil level of the lubricating oil tank.
Lubrication method: Prepare a sufficient amount of grease that meets the standard and add the grease to the grease gun. Grease is injected through a grease gun into each area that needs to be lubricated.
Precautions Keep the environment clean and tidy
Ensure that the space around the die-casting machine is unobstructed, and the ventilation and ventilation equipment should be in good working condition.
The materials and auxiliary appliances used should be placed reasonably according to the regulations, the floor of the die-casting workshop should be non-slip, and the roof and windows should be in good condition to ensure that the die-casting machine is not exposed to rain.
Safe operation: The parts and sheet metal dismantled during maintenance should be installed in time according to the original condition, especially the safety door and Corinth sheath.
Operators are not allowed to step on the sheet metal and Corinth columns with their feet to avoid damage to the sheet metal and Corinth columns or the risk of personal injury.
Hydraulic system maintenance: The hydraulic system is the core part of the die casting machine and needs to be checked and maintained regularly to ensure its proper operation.
Emergency shutdown: If during operation, any limit switch or inductive switch to the computer input point signal is wrong, the machine should be stopped immediately to check the corresponding line of the input point.
Adjustment
Adjust the injection speed, pressure, time and other parameters according to the product requirements. Set the injection pressure, adjust the total pressure digital DIP to the appropriate position on the panel, and start each operation.
Maintenance:
Regularly clean the surface and interior of the hot chamber die casting machine for impurities such as dust, dirt, and metal shavings to ensure that it does not affect the efficiency and safety of the equipment. The column frame part is the core part of the whole die-casting machine, and it is very important to maintain the column frame part to stabilize the working performance of the die-casting machine and prolong its life.
Check the amount of oil in the fuel tank to ensure that the oil volume is more than eighty, the highest shall not be higher than the black upper line of the oil temperature gauge, and the minimum shall not be lower than the red warning line of the oil thermometer. Strengthen the lubrication of each moving pair of the column frame, so that the surface of each moving pair is in a good lubrication state.
Through the above steps, it can ensure that the 90-ton hot chamber die casting machine achieves the best working conditions during trial operation and adjustment, prolongs the service life of the equipment, and ensures the production quality.
Lubrication maintenance:
Lubricate all sliding surfaces and ensure the oil level in the lubricating oil tank is normal.
Clean the electric box every three months to keep the interior dry and tidy.
The common problems and solutions of the 90-ton hot chamber die-casting machine in the trial operation are as follows:
Unable to lock the mold:
Reason: It may be due to the failure of low-pressure clamping caused by foreign matter in the mold or poor closure.
Solution: Check the mold for foreign objects to make sure the mold is well closed.
Abnormal noise and unstable action:
Reason: Because the hot die-casting machine works under high temperature, high pressure, and high speed, the working conditions are relatively harsh, and after continuous and long-term work, it is easy to have abnormal noise and unstable action.
Solution: The operator should pay great attention to it, observe it, judge the location of the fault, and carry out maintenance on time.
The machine stops in a certain position and does not move, and the cycle cannot continue:
Reason: Also due to the working conditions of high temperature, high pressure, and high speed, the machine may be stuck in a certain position and cannot continue to run.
Solution: The operator should carefully observe, judge the location of the fault, and carry out maintenance in time.
Mold heating and expansion:
Reason: After a period of mold molding, the mold will heat up and expand, resulting in an increase in the clamping force.
Solution: Adjust the mold space and clamping force in strict accordance with the mold adjustment steps, and pay attention to adjust the mold capacity in time to make the clamping force return to the original set value.
Mold Clogging:
Cause: The porosity in the mold is not smooth or the material is stuck on the mold, resulting in mold blockage. Solution: Inspect the molds to make sure they are not damaged or worn, and remove foreign objects from the molds.
Hydraulic Oil Problems:
Causes: Insufficient hydraulic oil quantity in the oil tank or oil quality does not meet the regulations, which may lead to hydraulic system failure.
Solution:
Check the amount of hydraulic oil in the tank to ensure that the oil level is higher than the upper limit of the oil window, and use the hydraulic oil that meets the regulations.
Through the above analysis, it can be seen that the common problems in the trial operation of the hot chamber die casting machine are mainly concentrated in the mechanical, electrical, and hydraulic systems.