TECHNICAL TOOLBOX ISSUE 47 Figure 5. Figure 6. Contact: TROY TURNBULL [email protected] Spray heads can be placed in an unlimited number of patterns for even the most complex parts. They can also be fitted with standoffs and on and off plane Ts to give even more location options. Conversion adapters are also typically available to spraying technology on existing systems. WHY PROPER MANIFOLDS & ACCESSORIES ARE IMPORTANT Consistency, Repeatability and Efficiency—three things all die casters want in their spraying systems. To achieve all three requires the proper spraying equipment. After selecting an automatic die spray system, the spraying package is the most important next step. The manifold is the heart of the die casting spray system. Manifold selection, along with the choice of spray heads and nozzles, are significant factors in achieving optimum die spraying. Too often, little consideration is given to manifold design and usage. When you consider that spraying is the most time consuming part of the total casting cycle, it is important to select a manifold that will: • Reduce cycle time • Give you a consistent, quality part • Reduce labor • Be easy to maintain • NOT LEAK NOZZLE DESIGN Proper spraying with the right nozzles can reduce cycle time and labor and give you more consistent, usable parts. The consistency and repeatability of automatic spraying makes it a key contributor to the efficiency of your production and your bottom line. Die casting spray heads feature interchangeable nozzles, and each can be configured for different spray patterns. High density spray heads operate from 40 to 110 psi (5 gpm per each nozzle outlet). Dual Nozzle Design (Single Opposed Nozzle Outlets): With fewer parts, adjustablility is greatly improved with dual nozzle (figure 5) with a full three-turn range. There is also improved atomization consistency over a larger variation of air to lube pressure. Quad Nozzle Design (Dual Opposed and Quad Side-by-Side Nozzle Outlets): Need more lube in a concentrated area? Quad nozzles (figure 6) offer a wide range of spray patterns with interchangeable nozzles from ultra-fine mist to max output. PRODUCTION IMPROVEMENTS – CYCLE TIMES As a rule of thumb, spraying should be less than 20% of total cycle time. Many die casters are spraying for 30-40% of the cycle time, which is a huge waste of time. A formula that works well in determining proper spraying time states you should spray one second for every 100 ton of the size of the die cast machine. Add one second per slide and one second for a second spray zone. For example, for an 800-ton DCM with two zones and two slides, your spray time is: 1 sec. x 8 + 1 (additional zone) + 2 (slides) = 11 seconds QUALITY ISSUES How you spray determines the quality of your part. Proper spraying: • Produces more consistent, shippable parts • Produces more presentable, shiny parts • Reduces scrap • Increases die life • Increases machine up-time It is important to understand that quality drives production schedules, which translates into MONEY. If you have consistent, quality parts, it is easier to calculate the number of shippable parts made per hour. This translates into better prediction of shipping schedules, which, in turn, controls production schedules. ENVIRONMENTAL & SAFETY ISSUES In addition to producing more shippable parts and reducing labor, automatic spraying is safer than hand spraying. Automatic spraying it takes the operator away from the fumes and the opening and closing of the die casting machine. This can reduce workers’ compensation premiums and make for a safer plant environment. SUMMARY Proper automatic spraying with the right manifold, spray heads, and nozzles will reduce cycle time and labor and give you more consistent, usable parts. It is this consistency, repeatability, and efficiency of automatic spraying that make it so vital to your production and your bottom line. WHY PROPER MANIFOLDS AND ACCESSORIES ARE IMPORTANT Consistency, Repeatability and Efficiency… Three things all die casters want in their spraying systems. To achieve all three requires the proper spraying equipment. After selecting an automatic die spray system, the spraying package is the most important next step. The manifold is the heart of the die casting spray system. Manifold selection, along with the choice of spray heads and nozzles, are significant factors in achieving optimum die spraying. Too often, little consideration is given to manifold design and usage. When you consider that spraying is the most time consuming part of the total casting cycle, it is important to select a manifold that will: • Reduce cycle time • Give you a consistent, quality part • Reduce labor • Be easy to maintain • NOT LEAK NOZZLE DESIGN Proper spraying with the right nozzles can reduce cycle time and labor and give you more consistent, usable parts. The consistency and repeatability of automatic spraying makes it a key contributor to the efficiency of your production and your bottom line. • Produces more consistent, shippable parts • Produces more presentable, shiny parts • Reduces scrap • Increases die life • Increases machine up-time It is important to understand that quality drives production schedules, which translates into MONEY. If you have consistent, quality parts, it is easier to calculate the number of shippable parts made per hour. This translates into better prediction of shipping schedules, which, in turn, controls production schedules. ENVIRONMENTAL AND SAFETY ISSUES In addition to producing more shippable parts and reducing labor, automatic spraying is safer than hand spraying. Automatic spraying it takes the operator away from the fumes and the opening and closing of the Figure 6 Figure 7
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