Aluminum is a much popular metal used by die casters and it melts at a temperature of about 1,200 degrees Fahrenheit or 650 degrees Celsius. Carbon steel is another die casting metal that melts at about 2,700 degrees Fahrenheit (1,500 degrees Celsius). These are high temperatures and that makes die cast foundries very unpleasant places for human workers. However, robots can be an ideal option for these places.
Many die casting companies now make use of robots in their foundries to tend the die cast machinery, ladle the molten metal, spray mold release, and to trim the excess metal away. Consistent process timing is a must to have quality castings and deploying robotic technology in the foundry can help ensure the same.
Die casting is a challenging environment and it is beneficial to use robotic technology for tasks like unloading the casting machinery, and pouring and removing the material. Some of the main benefits of using robotics in foundries are discussed below.
Material Handling
Pouring the molten metal is a risky job and will need a steady hand. A robotic hand can ensure much stability and can be a good alternative to human workers to pour the molten metal. They can be optimized to pour the same quantity of molten metal each time.
A robotic hand can skim dross and ladle the molten metal much faster than human, eliminating turbulence and chances of spills. This also applies to loading the inserts and extraction of the solidified castings.
Material Removal
The unnecessary runners, flashes, and risers are inevitable in casting, and these should be removed before the die cast pieces move to the downstream operations.
A robotic hand will be able to use a grinding wheel or some other cutter to trim away the unnecessary metal or can be used to load the cast shapes into ma trimming or de-gating press. In high volume cells, multiple robots can be used to accomplish various tasks efficiently.
Spraying
Dies will need a lubricant film spray over the surface while open, and spraying the die consistently can be a difficult process for human, as access can be poor and mist can obscure the view, leading to quick fatigues. This may lead to application of excess or little lubricant at some areas of the dies, resulting in uneven die cooling and issues in casting.
Using robots can be beneficial in such cases, as it always follow a programmed path. In fact, many experienced die casting companies have already accepted and adopted such advanced technologies.