45 Proper lubricant application in metal forging and casting operations can help lower frictional forces and create a smoother flow of metal through the mold. In addition, lubrication can create a thermal barrier between the workpiece and the die, helping to reduce temperature gradients that can affect component integrity. Lubricants also aid in keeping the metal and die surfaces from sticking together and assist in the removal of the workpiece from the die. Process consistency is the first step in achieving total quality. Lubricant spray units with durability, reliability, accuracy, ease of operation and low maintenance costs can help deliver consistent part quality. Specialized Servo-Driven Reciprocating Sprayers quickly and accurately guide the spray manifold into the die area for precise lube application as each nozzle can be programmed at any location in the spray cycle. Manifolds come in all sizes, offer quick disconnect, and are available in a variety of drip-free spray tips and tubes. WHAT TO LOOK FOR IN A RECIPROCATING SPRAYER 1. Alphanumeric program storage for different parts. 2. Heavy-duty construction components. 3. Direct drive for better accuracy and longer life. 4. 100% straight-line travel in the die, quad head, internal and external nozzles. 5. Spray head and manifold choices (ie. bar or picture frame, double opposed outlet head, double outlet for cover or ejector, and bottom outlet.) 6. 100% fully digital servo control with feedback for positioning to .020”. 7. Warranty on the unit, controls and mechanism, spray heads and spray head body. 8. Customer support. RECIPROCATING SPRAYER DESIGN Reciprocating sprayers come in multiple configurations, including Dual Axis, Linear, Robotic and Floor Mounted. DUAL AXIS SPRAY UNITS: Designed for use on 1400 to 2000 ton die casting Machines, dual axis spray units (figure 1) are ideal for die casters that have short-run work. One axis is fully programmable to position the spray manifold into the die area. The second axis has an 8-inch horizontal travel and can be operated from the control panel or a handheld remote to adjust the reciprocator for different cover die thicknesses. A horizontal slide base with a pedestal mount is useful for many applications. For some applications, the pedestal mount can be eliminated. Various risers are also available to avoid obstructions like water lines. A gear reducer is mounted on the top of the slide base. The main drive arm carries the vertical snout with manifold attached to the end into the die. The snout has a 12-inch adjustment to allow different spray manifolds to match the die being sprayed. TECHNICAL TOOLBOX ISSUE TROY TURNBULL President Industrial Innovations ARTICLE TAKEAWAYS: • Changing needs for ladle preheaters • Preheating the refractory lining DIGITAL SERVO RECIPROCATING SPRAY SYSTEMS FOR DIE CASTING MACHINE Continued on next page Proper lubricant application in metal forging and casting operations can help lower frictional forces and create a smoother flow of metal through the mold. In addition, lubrication can create a thermal barrier between the workpiece and the die, helping to reduce temperature gradients that can affect component integrity. Lubricants also aid in keeping the metal and die surfaces from sticking together and assist in the removal of the workpiece from the die. Process consistency is the first step in achieving total quality. Lubricant spray units with durability, reliability, accuracy, ease of operation and low maintenance costs can help deliver consistent part quality. Specialized Servo-Driven Reciprocating Sprayers (FIGURE 1) quickly and accurately guide the spray manifold into the die area for precise lube application as each nozzle can be programmed at any location in the spray cycle. Manifolds come in all sizes, offer quick disconnect, and are available in a variety of drip-free spray tips and tubes. WHAT TO LOOK FOR IN A RECIPROCATING SPRAYER 1. Alphanumeric program storage for different parts. 2. Heavy-duty construction components. 3. Direct drive for better accuracy and longer life. 4. 100% straight-line travel in the die, quad head, internal and external nozzles. 5. Spray head and manifold choices (ie. bar or picture frame, double opposed outlet head, double outlet for cover or ejector, and bottom outlet.) 6. 100% fully digital servo control with feedback for positioning to .020”. 7. Warranty on the unit, controls and mechanism, spray heads and spray head body. 8. Customer support. RECIPROCATING SPRAYER DESIGN Reciprocating sprayers come in multiple configurations, including Dual Axis, Linear, Robotic and Floor Mounted. Dual Axis Spray Units: Designed for use on 1400 to 2000 ton die casting Machines, dual axis spray units (figure 2, shown above) are ideal for die casters that have short-run work. One axis is fully programmable to position the spray manifold into the die area. The second axis has an 8-inch horizontal travel and can be operated from the control panel or a handheld remote to adjust the reciprocator for different cover die thicknesses. A horizontal slide base with a pedestal mount is useful for many applications. For some applications, the pedestal mount can be eliminated. Various risers are also available to avoid obstructions like water lines. A gear reducer is mounted on the top of the slide base. The main drive arm carries the vertical snout with manifold attached to the end into the die. The snout has a 12-inch adjustment to allow different spray manifolds to match the die being sprayed. Linear Spray Units: Designed for 200 to 600 ton die casting machines, linear spray units (figure 3) provides smooth operation with super fast speed of 80 inches per second. Continuous positioning accuracy is TROY TURNBULL President INDUSTRIAL INNOVATIONS ARTICLE TAKEAWAYS: • Lubrication in metal forging & die casting for higher quality parts • All about servo-driven reciprocating sprayers • Importance of manifolds DIGITAL SERVO RECIPROCATING SPRAY SYSTEMS FOR DIE CASTING MACHINE 22 Figure 1.
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