Improvement of aluminum diecasting processes, any ideas?
- From: whrlwnd2@xxxxxxxxx
- Date: Sun, 12 Feb 2006 05:51:31 -0500
Cause and effect variation between furnace / dip well temperature and
flatness of finished parts.
Problem: as flatness increases, dimensional issues arise with fit /
function at machining. We try to keep the flatness of our parts below
0.50mm, and issues arise after 0.65mm. Rework is sometimes an option,
but this depends on the amount of the defect produced.
There are actually 2 factors involved: soldering of core pins and
furnace temperature, and furnace temperature having the most dramatic
impact on flatness variation.
We strive to keep our furnace temperature around 1190 degrees. The
correlation between furnace temperature and flatness was discovered by
accident, one day we were fighting an unusually high flatness of .90mm
to 1.2mm, we were making junk! We were 'assuming' the solder on the core
pins was our only issue, we polished them up, still 0.9mm, then we
discovered the furnace was at 1222 degrees! We tossed some ingots in the
furnace and dip well and got it down to 1190 again, the flatness came
down to 0.6mm with that single adjustent. Still out of spec, but the
parts were useable.
Is there any ideas to help with furnace temp variation? We have all
sorts of variation in our die casting process, biscuit thickness is
another one. High variation in biscuit thickness brings about a whole
new dimension of quality issues, non-fill, intensification problems,
shotspeed variation, flowlines, shink porosity. Any ideas?
Thanks, Quality Control
.
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