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Operator Training Program NADCA's popular operator training manuals feature an increased level of technical content and emphasize safety. They include six lessons covering: die casting machine introduction; die casting machines; die casting dies; materials; the die casting cycle; and controlling the die casting process. These manuals provide sources for information and reference, aid in improving die cast skills and shop floor knowledge, increase productivity and higher quality products, and communication between operators and supervisors.
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TABLE OF CONTENTS
Lesson 1 Introduction Objectives 1-1 Perspective 1-1 Advantages of die casting 1-4 The training program 1-11 Safety 1-14 Math & science Force and pressure 1-24 2 Die Casting Machines Objectives 2-1 Perspective 2-1 Structural components 2-4 Electrical system 2-13 Hydraulic system 2-16 Injection components 2-26 Variations in conventional machines 2-34 Non-conventional machines 2-35 Safety 2-36 Math & science Tie bar stretch 2-53 Glossary 2-54 3 Die Casting Dies Objectives 3-1 Perspective 3-1 Conventional dies 3-1 Major die components 3-4 Mold base 3-4 Stationary half 3-8 Moving half 3-14 Ejector box 3-16 Cavities 3-27 Die / shot terminology -39 Die manufacturing 3-44 Dimensions & tolerance 3-45 Thermal expansion 3-46 Die life factors 3-48 Glossary 3-54 4 Die Casting Materials Objectives 4-1 Perspective 4-1 Die casting alloys 4-1 Freezing behavior 4-2 Heat in the alloy 4-5 Zinc example 4-6 Aluminum exercise 4-9 Magnesium exercise 4-13 Die casting alloys thermal properties 4-16 Shrinkage 4-17 Thermal conductivity 4-20 Alloy chemistry 4-22 Aluminum systems 4-22 Zinc systems 4-30 Magnesium systems 4-37 Die lubricants / release 4-41 Application 4-43 Hydraulic fluids 4-50 5 The Die Casting Process Objectives 5-1 Perspective 5-1 Equipment Holding furnace 5-2 Ladle 5-7 Die spray 5-10 Plunger lubricator 5-14 Casting removal 5-15 Quenching 5-17 Conveyors 5-18 Die heaters 5-18 Trim presses 5-23 Cell environment 5-23 The cold chamber cycle Cycle start / Machine close 5-26 Making the shot 5-29 Machine dwell / hold 5-33 Machine opening 5-34 The hot chamber cycle Cycle start / Machine close 5-36 Making the shot 5-39 Machine dwell / hold 5-41 Machine opening 5-41 Detail description of the Machine Cycle Elements Modes of Operation 5-43 Machine die close 5-43 Injection / making the shot 5-54 Machine dwell / hold 5-68 Machine opening 5-70 Ejection 5-72 Casting removal 5-74 Inspection 5-76 Die spray 5-77
6 Controlling the Die Casting Process Objectives 6-1 Perspective 6-1 Heat in the process 6-2 Mechanisms of heat flow 6-4 Conduction 6-4 Convection 6-9 Radiation 6-13 Heat flow from the die 6-14 Operator control of heat flow 6-15 Defects 6-22 Surface defects 6-22 Metal flow defects 6-22 Other surface defects 6-45 Internal defects 6-49 Inclusions 6-50 Porosity 6-56 Force of Injection 6-64
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