NBVAB

About the project

The ejector system of the die-casting tool is an important factor influencing the production reliability and component quality and thus the economic efficiency of the casting process. An inadequate design of the ejector system can lead to inadequate component shaping and thus to component defects and production interruptions. In contrast, overdimensioning of the ejector system is associated with increased production and maintenance costs as well as lower technological feasibility. The challenge in the design of ejector systems lies in the lack of systematic knowledge regarding the optimum design of the position and number of ejectors. As a result, tool designers currently rely on their own experience or intuition when designing ejector systems, and the systems are often oversized in order to avoid production problems.

The aim of the project is the development of data and models which can be used to select the optimum position, number and dimension of ejectors in terms of high production reliability for high-quality die-cast components on the basis of knowledge. For this purpose, the factors influencing the ejection forces will be investigated in all work stages using both experimental and simulation-based methods. Therefore, casting tests and simulations are carried out under parameter variation.

To measure the transient ejector forces in the die casting process, a measuring method using piezoelectric force sensors is being developed. This will be validated in subsequent casting tests at the Light Metal Centre Soltau (LMZS) of the ifs as well as in industry. Furthermore, tests and simulations will be carried out on the reduction of ejector pins and the influence of ageing and wear on ejector forces.