Die-Shot Monitor: Ejection Force Measurement
With a Die-Shot system it is very easy to measure and monitor the force required to eject the part from the die. It uses the same sensors that are used to measure Cavity Pressure. Therefore, if you have installed a Cavity Pressure Sensor behind the head of an ejector pin, you can also measure ejection force at no extra cost.
It turns out that Ejection Force is a very useful parameter to measure because it gives you direct insight into the effectivness of your die release agent (or die spray) the robustness of your ejection system, and the condition of the surface of your die.
You can use this information to lower costs and increase productivity.
Ejector Pin Breaking Force
If you enter the diameter and length of an ejector pin, Die-Shot will calculate and display the force that will cause the pin to bend. Knowing this value, you can set a target force that is less than this value, which will set off an alarm if exceeded. You can use this feature to eliminate the cost and lost production due to broken ejector pins.
This is especially useful on dies which have a lot of small ejector pins.
Ejection Force Measurement at Die Trial
When you trial a new die for the first time, with force sensors installed, you immediately obtain a measurement of how much force is required to eject the casting.
If it is very high, then you know that the die will have ongoing problems with ejection. You can immediately take action to address the issue, such as increasing the size of the ejector pins, or adding more, before the die goes into production.
Continuous Monitoring of Ejection Force
It is good practice to use Die-Shot to continuously monitor ejection force during production and compare it to a target value. If there is a change in the production conditions and the alarm is activated, you immediately know about an impending problem.
Release Agent Problems
If the ejection force suddenly increases above the target value, it is often a sign that the die release agent is not doing its job. This enables you to take action before the process starts to produce defective parts.
Detecting Die Damage
If the ejection force increases slowly over time, this is usually a sign that the die surface is deteriorating. It could be due to thermal fatigue, to soldering, or to wear and tear. This is particularly useful for aluminium and brass Die Casting where heat checking of the die surface is a continuing problem.
Using Die-Shot in this way enables you to set a target ejection force value at which die cavity repair or replacement needs to be implemented.
Die-Shot enables you to measure and monitor your Die Casting process to a degree not possible with any other system.