Die-casting and Precision Machining

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