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.