Die casting is a process that has been around for several decades. It is a flexible process for producing metal parts by forcing molten metal under pressure into reusable steel molds or dies. The dies can be designed to produce highly accurate and repeatable complex shaped parts.

      Die cast products are the bulk of mass-produced items manufactured by the metalworking industry, with applications in a variety of consumer, commercial and industrial products. Various products ranging from alloy based toys to automotive engine parts are manufactured using this process. Based on the size of the end product and the volume requirements, automation of die casting operations can be critical for a successful manufacturing process.

Business drivers

      In the last 25 years, there has been a steady increase in the role of industrial robots in manufacturing. With more than 15,000 industrial robots sold every year, robots have become a mainstay in the manufacturing industry. Their flexibility, reliability and repeatability, to name a few advantages, have made them a vital component in the automation process for die casting applications.

      Some of the business drivers for automation of die casting operations are:

      •Low cost of robots leading to cost effective automation with quick return on investment.

      •Increased requirements for system flexibility to produce multiple parts.

      •Ever increasing focus on the human factor/ work cell safety.

      •Variety of production rate requirements based on market for cast products.

      •Cycle time requirements by station or operation.

      •Life cycle of manufactured product to ensure acceptable ROI.

      •Product handling requirements.

      •Maintenance requirements.

      •Safety standards related to heat and gas exposure in casting operations.

      If business requirements drive the die casting cell to be automated, there are many factors that need to be considered during the design of the cell.

      The size and shape of the cast product essentially drives the design of the dies used for casting the product. Shape, size and stroke of the die have a strong impact on the automation in terms of robot reach and accessibility. In today’s technologically advanced climate, almost all manufacturers have their product and dies designed in 3D CAD packages. This 3D data is critical for accurate end-effector design as well as design of storage racks or conveyor pallets. Ensure that this data is at the latest revision and the product used for equipment design is displayed in the form and shape that it is expected to be in after exiting the die cast machine....