Why Automate and Integrate Your Die Casting Sprayer Solution? Read This.

ELK GROVE VILLAGE, IL, April 7, 2022 -

Would you fry an egg without applying oil to the pan first? Any chef knows the answer to that question is no. However, too much or too little oil can cause less than ideal results. Using just the right amount of oil ensures the egg doesn’t stick to the pan and can be easily released to flip, with the end result being a delicious breakfast.

The same goes for spraying lubricant in the die casting process. Any operator knows that to ensure a high-quality manufactured part, the film formation and wetting on the mold surface from the lubricant is required to act as a release agent and for cooling purposes. But just like applying oil to the pan, you don’t want to over or under-apply the lubricant because in doing so the result could be a poor finish with other quality issues. 

So the question remains, how can your factory become more exacting in lubrication spraying? Not enough lubricant means the casting won’t properly release which causes overheating, defects, or even serious die damage. On the flip side, dies with an excess lubricant are more likely to blister, leave castings with porosity, and over-cool which can cause the metal to pre-maturely freeze off. The answer to improving your spraying process is through automation and direct integration with your die casting machine. In doing so, your sprayer solution can improve the repeatability of clean and defect-free high-quality castings.

Automate and Integrate

Being able to spray evenly across the die area can be easier said than done. Particular parts with irregular shapes and varying wall thickness can be a challenge for spray applications. Shibaura Machine’s spray system provides factories with a highly flexible modular spray system that integrates directly with their TOSCAST controller for improved ease of use.

The spray system brings consistency and repeatability to the factory. The operator is allowed to provide exact direction on where the copper tubing will spray the flow and to what amount. Tubes can be individually turned off, meaning the lubricant only goes where it is needed. The fluid spraying contains release agents so the material doesn’t stick to the tool steel and the volume helps to control the heat. High-pressure air is also used to further clean and prepare the mold surface. Customers can choose to tailor the spray module attached to the spray system based on their needs with various spray nozzles, configurations, and flood tubes. 

The integration between TOSCAST and the spray system allows the operator to work directly on a single controlling system with no additional HMI. Through TOSCAST the operator can set the positions and speeds of the sprayer's motion, along with the rest of your die cast machine. Since the sprayer is integrated with the TOSCAST, all the maintenance and monitoring functions are also controlled on the same single screen as the machine operations. Being able to control the sprayer with ease and accuracy helps improve the consistency and repeatability, key contributors to the efficiency of your production and bottom line.

Learn More

Proper, precise spraying is critical, along with adjustability – to ensure intense spraying in hot areas versus low-temperature areas. Contact the Die Cast Team to learn more about how the spray system controlled with the TOSCAST can start improving your factory productivity.

Contact the Die Casting Team to learn more about how the integration spray system can improve your manufacturing capabilities.

• Phone: (888) 593-1616
• Email: dc-sales@shibaura-machine.com