Die-casting and Precision Machining

Floor Space
The amount of floor space required to automate a die casting operation depends largely on part processing
requirements as well as peripheral equipment design and sizes. The most effective way to ensure that appropriate
space is earmarked for the robotic automation
process is by performing a simulation of all the robotic
operations. Al die casting,This will ensure that equipment is placed
in locations that will suit all process requirements and
sequence of operations. A significant benefit of using
robotic simulation is the ability to test multiple product
styles and dies to arrive at a common layout configuration
which reduces changeover time and associated
costs. The simulation done in conjunction with
mechanical design and layout development will act as
a virtual three dimensional integrated cell.
Payload and Robot Selection
Robot selection is driven not only by environmental conditions but also based on payload, reach and part access
within the die. Al die casting,The mass, center of gravity and moments of inertia about the mounting face of the robot determines
the robot model based on payload capacity. The mass data for the payload analysis can be generated from
the mechanical design CAD package as long as the data entered into the system for material properties is accurate.
The mass data that is generated can then be entered into a payload calculation program to determine the
robot model that can withstand the payload requirements. die casting ,Apart from payload, other factors that help drive robot
selection are – die travel (horizontal vs. vertical), gantry vs. floor mounted robots based on equipment size and
access and cycle time requirements.
Cycle Time Validation
The main driver for production rate on a die casting system is the time it takes for one cycle of the press and the
unload time. Once this data is known, process design must focus on ensuring that the press spends a minimum
wait time on other pieces of automation. The time
spent by the robot after unloading the part from the
dies should not exceed the time required by the
press to cycle and generate a new zinc die casting.
Robotic simulation in conjunction with external robot
controller software (RCS) can be used to generate
accurate robot motion cycle time. The use of virtual
controls replicates real-world conditions and allows
for evaluation of both individual processes and
coordinated activities of robots within a system.

Designing a Robotic Cell for Die Casting
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.
Product and Die Design
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.al die casting ,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.
Environmental Factors al die casting
Safety is a major issue in die casting operations due to the extreme heat and emissions that are generated during
the die casting process. Robots are used primarily to avoid humans from being exposed to this dangerous environment.
Most robot OEM’s have a “foundry” series of robots that are designed and manufactured using strong heat
resistant materials which could be used if applicable. End-effector component materials should be selected based
on heat resistance since these parts interact with the high temperature product as it exits the die.zinc die casting
End-effector Design
While the size and shape of the die casting
product is the major factor in the design of the
robotic end-effector, other factors like
temperature, payload, and force requirements
should be taken into account. al die casting
 3D product,fixtures and die models should be used to
design the end-effector to ensure that the
design has appropriate clearances to
surrounding parts within the die. Clamping
surfaces are generally based on quality and
finish requirements and should be carefully
chosen with the customer. End-effector design
should be developed in conjunction with
robotic simulation to ensure that the design is
suitable for all robot tasks and associated
equipment. In cases where removal of gates,
risers and “biscuits” on the product is required,
the end-effector may need to be designed with
the appropriate force compensation or compliance
devices.al die casting

Abstract
This paper identifies key reasons for automating die casting operations, the impact of robots on the automation,
and the advantages of using Product Life Cycle Management (PLM) tools to generate and validate the automation
process.
Introduction
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 for Die casting Automation
In the last 25 years, there has been a steady increase in the role of industrial robots in manufacturing. With over
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 al die casting and zinc die casting operations are:
• Low cost of robots leading to cost effective automation with quick return on investment (ROI).
• Increased requirements for system flexibility to produce multiple parts.
• Ever increasing focus on the human factor/ workcell 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.