Long life – Ring life is 20000 shots and Ring holder life is 40000 shots.
Less casting Rejection – For efficient vacuum casting completely enclosed space is necessary. An H13 plunger tip has the same coefficient of thermal expansion as shot sleeve. Plunger tip is more exposed to heat and so it expands more than shot sleeve. To prevent seizing of plunger tip with the shot sleeve, gap needs to be maintained between the shot sleeve and plunger tip. During vacuuming air is sucked in the shot sleeve through the gap.
In Ring type Plunger tip a Spring Bush is use. Which made of Soft Steel which adjust its size during thermal expansion of shot sleeve.Adjustment of Spring bush close the gap between shot sleeve and plunger tip results to High Vacuum and lower Porosity.
More Productivity – Wearout ring can replace by plier without disassemble of plunger tip. It reduce downtime and increase productivity.
More Shot sleeve Life – Lower life plunger tip wear out more frequently. Before replacement of wearout plunger tip it start making scratch mark or aluminum deposition on shot sleeve . which reduce shot sleeve life
Erosion of Shot sleeve – Hot aluminium is poured at about 700 °C and H13 tempering temp is 585 °C. So if Shot sleeve is designed with insufficient cooling it will lose hardness and erosion will happen easily.
In thermoregulated shot sleeve temp keeps lower the tempering temp of shot sleeve.
Soldering inside shot sleeve – Soldering is defined as hot Aluminium deposits on Shot sleeve surface to form a compound that becomes part of the shot sleeve surface. Soldering tendency is accelerated as shot sleeve temperature increases.
In thermoregulated shot sleeve, Shot sleeve temperature not increase continuously.
Distortion in Shot sleeve – There are two types of distortion in shot sleeve 1. Longitudinal (Bendness) 2. Radial (Ovality). The aluminium is always partially filled in the lower portion of the sleeve.
Filling ratio is nearly equal to 50%. So the top portion of shot sleeve doesn’t have thermal load as compared to the lower portion of shot sleeve.This unbalanced thermal load Bend shot sleeve.
During injection, clearance between shot sleeve and plunger tip becomes variable along the length of the shot sleeve. As injection starts, the shot sleeve is hot as compared to plunger tip. As the plunger moves further, the plunger tip becomes hot and the shot sleeve transfers heat to platen. So different locations have different expansion in shot sleeve and plunger tip. If design clearance between the shot sleeve and plunger tip is tight then it can seize plunger tip and result in Oval the shot sleeve.
In thermoregulated shot sleeve thermal load balanced which result to minimum distortion.
Long life – Insert life is longer than stander shot sleeve.
Less Cost per shot – Integral insert is simply mounted into the sleeve body and designed for replace when its working surface is worn out. So with complete insert type shot sleeve no need to change full shot sleeve only insert need to change.
More Productivity – Integral insert is designed for replacement directly on the casting machine when its working surface is worn out. It reduce downtime and increase productivity.
Raga is serving to die casting industry with their injection parts from 25 years.Raga’s jointly study with customer and give best design to enhance life of injection parts.
Raga is using premium quality raw material,Vacuum Hardening with 3 tempering cycle & Gas nitriding.
Raga have 25 years injection parts manufacturing process.
TRaga is using ERP, Job Card system, Production Management System, Time Management System.
Raga delivers injection parts in 4 to 6 weeks.
Low cost of injection parts
Expensive Injection parts increase casting cost.
Raga prices are lower than competitors prices.
Expensive Injection parts increase casting cost.
Raga prices are lower than competitors prices.
Major Cause Of Injection Parts Lower Life Is: 67 % Die Caster Don’t Evaluate Injection System Parts Holistically
It’s Time To Avoid These Mistakes With Raga
A structural parts manufacturing company in India want to reduce plunger cost per shot in one of their 1650 ton Die casting machine
Raga studied and observed they are using solid copper plunger tip which average life 4836 shots
Average down time to change plunger tip 18 minutes
Included down time plunger tip cost per shot is 2.36 INR
Raga presented them with a Ring-type Plunger tip.
Ring life 25000 shots and Plunger body life 40000 shots
Average down time to change ring is 11 minutes
They ordered and tried Raga’s full injection system including the shot sleeve, plunger tip, and connector.
After some trials and it reported now their per plunger tip per shot cost is 1.09 INR per casting.
Die caster gave the order for 3 other die casting injection parts
An Die caster in India had reported shot sleeve life is 20000 shots. Die caster was not happy with this short life.
Raga studied it and observed
1.Erosion of material beneath the pouring hole.
2.There is no cooling line in the shot sleeve.
Raga incorporates cooling lines in shot sleeve design and supplied them 2 shot sleeves with a new design.
After the use of it, the die caster achieves 63482 shots life without erosion.
A die caster of India reported Plunger tip was seizing in shot sleeve after 5000 shots.
Raga studies and observes radial distortion (ovality) in the internal diameter of the shot sleeve. Old shot sleeve design had partial cooling.
Raga modified the shot sleeve design and supplied Thermoregulated shot sleeves.
Die caster reported after use it, Plunger tip was not seizing up to 46486 shots.
One of the biggest car making company in India, using Vacuum system but still facing Gas porosity near the Gate area.
Raga studied flow simulation reports and observed some air entrapment near the gate area.Die caster using only mold vacuuming.
Raga suggested to us Shot sleeve vacuuming and supplied them vacuum shot sleeves after trial no rejection due to Gas porosity near Gate area.
