Die-casting and Precision Machining

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.