The special die casting machine „DuoCast“

Electromobility will play an increasingly important role in the German as well as in the international economy in the future. Particularly the die casting industry is affected by this change and faces the challenge of a completely new portfolio of die casting parts. Druckguss Service Germany meets this challenge and answers the question of the process of the future with the product group-specific DuoCast die casting machine. The revolutionary „series connection“ of two die casting moulds in one clamping unit in combination with a vertical casting unit is the ideal condition for high-quality casting of centrally injected high-volume parts, making intensive processes such as 3-platen tools and multiple forming redundant. The patented tie bar arrangement has made it possible to maximize the overall stiffness of the closing unit and to reduce plant dimensions significantly. Looking at the vertically arranged casting unit, the economic and casting advantages are further underlined. The enormous economic benefits are largely driven by the greatly reduced cycle time compared to a horizontal die casting machine with multiple moulds. The cycle time reduction of the DuoCast method results from the counter-piston principle of the vertical casting unit, this allows a dosing of melt at an open die casting mold. For removal of the finished castings the mould can even be opened in a stage when the press residue is not yet completely solidified. In addition, due to the smaller single casting weights, significantly reduced solidification times for the die castings can be achieved, as well as reduced spraying times for die casting molds. The vertical arrangement provides a 100% filling rate of the casting chamber and eliminates the known problems of air pockets during the 1st phase of the mould filling process. Next to this, the closing of the gates during the dosing process provides an optimal chance to evacuate the two moulds. The short casting runs following the mold filling process lead to a reduced volume of circulation material and therefore cause a positive effect on the energy balance sheet of the DuoCast process in addition to the advantages of casting technology. The revolutionary DuoCast process offers the foundry the opportunity to react to the electrification of the powertrain with quality, cost and energy efficiency, this prevailing over the worldwide competition.

Advantages: 

Quality Benefits:

• 100% filling rate
• Optimal vacuum
• Shorter sprues

Time Benefits:

• Reduction of the cycle time 
• Dosing at open mould
• Shifting of solidification period of press residue into te non-productive time period

Investment Benefits:

• Casting oft wo moulds with one chamber filling (double ejection during one cycle)
• Smaller area required in comparison with horizontal machines
• Doubling of the closing force by series connection

Efficiencies Benefits:

• Material
• Energy
• Emission