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.

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Manifolds and Accessories

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.

AUTOMATION MEANS

• Consistency, process repeatability, efficiency
• Safer environment, more shippable parts
• Better scheduling, more profits

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
• Provide a consistent, quality part
• Reduce labor
• Decrease maintenance costs

Production Improvements - Cycle Time

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. This is a huge waste of time and adds to total cycle time. Many years ago, Advance devised a formula that has worked well in determining proper spraying time. The formula states that 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.

Positioning Accuracy

Digital servo-control gives Advance reciprocators positioning accuracy within .020" This repeatability is important for maintaining control of the process.

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 and Safety Issues

In addition to producing more shippable parts and reducing labor, automatic spraying is safer than hand sprayers. It takes the operator away from the fumes and the opening and closing of the die casting machine versus hand spraying. This can reduce Worker's Compensation premiums and make for a safer plant environment.