a casting unit that is extremely powerful and precise is required
Larger and more complex parts are becoming increasingly popular in the automotive industry, which is the root cause of this trend. These larger parts necessitate the development of new manufacturing processes and represent a new challenge for customers. The extensive experience Bühler has gained with large die-casting solutions over the years makes it your ideal partner for the entire manufacturing process for even larger components.
The automobile manufacturers are breaking new ground in terms of their manufacturing techniques. You will be able to put your ideas for even larger parts into action thanks to our Carat series. Bühler die cast parts's Managing Director Cornel Mendler says, "We are committed to assisting our customers in the development of these new processes."Bühler's die-casting portfolio is currently completed by the addition of the Carat 840 and Carat 920, which have clamping forces of up to 92,000 kilonewtons (kN). The Carat platform is the company's solution for die-casting large parts in large quantities."We are seeing a tremendous increase in the demand for ever larger machines," says the author of the article.
Bühler's vision for the future of the Metal Plating industry is zero rejects, 40% shorter cycle times, and availability around the clock. The greater the size of the cast parts, the greater the leverage for lowering production costs through shorter cycle times, fewer rejects, and greater availability of parts. It is also important to note that the design of the Carat 840 and Carat 920 has a positive impact on the overall quality of these complex, thin-walled parts. For their production, a casting unit that is extremely powerful and precise is required, as is the uniform introduction of clamping force.
For uniform application of the clamping force, Carat's two-plate technology features a patented, stiffness-optimized plate design that ensures minimal plate deflection and high dimensional accuracy of the cast parts. The Carat, in conjunction with Bühler's one-of-a-kind real-time controlled casting unit and the DataView control, provides the highest casting dynamics and quality - shot for shot.
Currently, Bühler manufactures custom die casting platforms in three locations: Asia, Europe, and North America. Because of the short transport routes and the reliable supply of spare parts, this results in short delivery times. Customers can rely on a stable global production network to deliver what they need. A network of local service technicians provides assistance to foundries and automobile manufacturers. On-site and remote maintenance services are available immediately, as is detailed training at the customer's location or in one of Bühler's application centers.
Several of the Carat series' largest die casting machines are the size of a small house. Eight meters high and covering an area of approximately 100 square meters, they are an impressive sight. A mold can be filled with more than 200 kilograms of liquid aluminum in just a few milliseconds thanks to the Carat 920. With a force of 92,000 kN, it holds the shape together tightly. According to Michael Cinelli, Product Manager Die Casting at Bühler, "it's as if the entire Eiffel Tower, with its approximate 9,000-ton weight, was pressed into the mold, and that was with every single shot."
The company Bühler was a pioneer in large die-cast parts and has been the world market leader in this segment for more than a decade. Bühler develops and designs complete solutions for its customers, and then puts them into operation. The company, in collaboration with its partners, can provide process solutions ranging from aluminum bars to finished body parts. When compared to smaller parts, the manufacturing and handling of large parts are significantly more complicated. This means that the China die casting manufacturer cell's upstream and downstream production steps must be capable of processing the parts in question. A continuous transport system is formed by robots and transport frames because the components are too large and too heavy to be transported by humans alone. Their responsibility extends from casting to body part handling. "Fortunately, Bühler has solutions for each of these processes.
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