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STEP 1:
“Prevention is always better than cure”, therefore, process control techniques are important.
Understanding the process variables is also the first step to both diagnosis and cure of defects.
Set-up sheets:
Have a set-up sheet available for each job - preferably covered in plastic and attached to the
machine. If defects start to appear don’t try to diagnose at this stage, check the machine settings
against the set-up sheet.
The Design of the set-up sheet is important and should follow the following basic rules:
Gauges:
Ensure that all gauges are present, are working and can be easily read. A 2 inch diameter
pressure gauge with a dirty dial twelve feet up on top of the accumulator cannot be read.
Valves and switch positions should have marked scales so that they can be set without having to
find a tape measure or count turns of valves.
Training:
Don’t assume that because the data is on the set-up sheet the personnel know how to set the
values. Have training sessions between engineering and setters, to ensure:
Measuring Equipment:
Every setter should have a small portable pyrometer with an immersion probe (for metal
temperature, etc.) and a surface contact thermocouple for measuring die temperature. One per
shop is not enough.
Tie bar load gauges should be fitted and working, if the machining has provision for them.
QUIZ SHEET:
Identify each gauge or control and enter details from set-up sheet.
STEP 2:
Proof testing:
Metallurgical Examination:
Metal analysis
Metal temperature
Die face temperature
Lubricant - dilution and quantity
l Step 1
Graph the machine shot-end capability by putting two values
on the graph supplied.
F l o w R a t e Q
F l o w R a t e Q
l Steps 3-6
Put the two together and take readings, then make three
simple calculations.
• Steps 7-6
Fill in readings on the worksheet table and compare values.
This gives fill conditions for a range of gate areas and is PLUNGER DIAMETER = 3.00 IN.
analogous lo carrying out several die trials. HYDRAULIC PRESSURE = 1200 PSI
SHOT SPEED CONTRO L = 100 %
GATE AREA (A) SQ. IN. GATE VELOCITY (V) FPS FILL TIME (T) MS
0.100 121 37.3
0.150 120 25.3
I - - - - - 0.200 ---------------- 117 - - - - - - - - - - - - - - - - - - - - 19.3 ----I
I - - - - - 0.260 ---------------- 114 ------------------- 15.9 ----I
I - - - - - 0.300 ---------------- 111 ------------------ 13.6 ----I
I - - - - - 0.350 ---------------- 107 ----------------- 12.0 ----I
I - - - - - 0.400 ---------------- 104 ---------------- 10.9 ----I
I - - - - - 0.450 ----------------- 100 ---------------- 10.1 ----I
0.500 96 9.4
EASTERN ALLOYS, INC.
The attached graph shows the relationship between minimum die face
temperature and maximum cavity fill time for various wall
thicknesses.
70
60
50
40
30
20
10
0 I I I I I I I I
240 280 320 360 400 440 480 620 660
DIE FACE TEMP DEG F.
EASTERN ALLOYS, INC.
STEP 3:
Examine all the evidence carefully step-by-step, take your time and
be thorough.
k /
Lamination • Dies separating • Check die lock
during filling
• Check tool
support
extraction rate
of tool halves
STEP 4:
The position and type of defect is often more important than the
quantity. Quantitative assessment is difficult and usually
subjective.
Optional extras:
• Crack detecting equipment (eg., dye penetrant spray cans)
• X-ray equipment
• Lathe or milling machine to cut consecutive sections
Method:
• Make surface examination first - use crack detection where
appropriate. Look for external evidence which indicates
internal defects. eg., Sink marks may indicate internal
shrinkage porosity.
• Examine process data for indications of defects likely to be
present, Calculate fill time, gate velocity, etc.
• Examine internal structure by any appropriate means:
X-ray will show most of the internal structure, but
needs a skilled technician to interpret the results.
sections
. Low metal and