A chiller in casting purpose is to control the solidification sequence of the casting, accelerate local cooling to improve the casting quality.
The core role of the chiller in die casting is to solve the problems of mold overheating and slow cooling of castings through precise temperature control and efficient heat dissipation, thereby improving product quality, production efficiency and equipment life, while reducing energy consumption and scrap rate.
The purpose of a chiller in casting has the following six main functions:
Control mold temperature,ensure product quality
Mold temperature directly affects the quality of castings
The chiller removes heat from the mold through circulating cooling water to ensure that the mold is in a reasonable operating temperature range (usually adjusted in real time by temperature sensors and flow meters), avoiding defects such as shrinkage holes, hot bubbles, and surface depressions in castings due to excessive temperature.
Uneven mold temperature
Uneven mould temperature can cause problems such as unstable casting dimensions and deformation. The constant temperature control of the chiller can significantly improve the density and surface quality of the product.
Maintains thermal balance
In aluminum alloy and magnesium alloy die casting, the chiller maintains thermal balance to prevent the scrap rate from increasing due to sticking or material expansion.
Surface hardening
A chill in casting, in some cases, condensate can also be used for surface hardening to make the surface of the casting hard and durable, suitable for applications requiring wear resistance.
Controlling thermal stress
Condensate can reduce thermal stress caused by temperature gradients by accelerating cooling in local areas, thereby preventing cracks.
Shorten production cycle and improve efficiency
Condenser is a material with high heat capacity and thermal conductivity. It is often placed at the edge or inside the mold cavity to accelerate the cooling rate in that area. This helps to change the solidification sequence of the casting so that the casting solidifies in the desired order.Accelerate the crystallization and solidification of castings through low-temperature cooling.
Shorten casting solidificate time
The chiller can shorten the solidification time of castings, reduce the die-casting cycle (such as filling, cooling, and spraying time), and improve production efficiency by 20%-30%.
Solidify quickly
Rapidly cool plastic or molten metal to make the product solidify quickly (such as plastic cooling in injection molding machines) to avoid production delays.
Extend equipment life and reduce maintenance costs
Reduce thermal stress damage to equipment
Effectively cool the die-casting machine and mold, reduce thermal fatigue, wear and corrosion, and extend the service life of the mold. For example, stable thermal balance can delay mold cracks and reduce the risk of thermal cracking of steel.
Reduce maintenance costs
Prevent equipment from overheating failure and reduce downtime maintenance caused by high temperature.
Shorten production cycle and improve efficiency
Using condensate can increase the feed distance of the riser and reduce the number of risers required, thereby improving production efficiency.
- Accelerate the crystallization and solidification of castings through low-temperature cooling.
- The chiller can shorten the solidification time of castings, reduce the die-casting cycle (such as filling, cooling, and spraying time), and improve production efficiency by 20%-30%.
- Rapidly cool plastic or molten metal to make the product solidify quickly (such as plastic cooling in injection molding machines) to avoid production delays.
Energy saving, environmental protection and process stability
Enviroment protection
The chiller adopts a closed-loop circulation system (industrial pure water for internal circulation and soft water for external circulation), and dissipates heat efficiently through a heat exchanger:
Optimize colling process
Optimizing the cooling process can reduce energy consumption and water waste (cooling water is recycled and not discharged).
Stable process
The constant temperature, constant flow and constant pressure design ensures process stability and reduces production fluctuations.
Auxiliary functions and special applications
Safety assurance
In magnesium alloy die-casting, the chiller is combined with a gas protection system to prevent the metal from burning when it melts.
Environmental control
Some chillers also have the function of cooling down the factory positions to improve the high-temperature working environment.
System compatibility
Supports time control (timing opening and closing solenoid valve) or temperature control (automatically adjusted according to the mold temperature) to meet different process requirements.
Precaution of chiller in die casting
Water quality requirements: softened water or purified water must be used to prevent scaling and clogging of the cooling pipes.
Selection differences: air-cooled chillers are more affected by the environment, water-cooled chillers are more stable but require a water tower; the model must be selected based on parameters such as cooling load and temperature range.
Above from all, we can know that the purpose of a chiller in casting in the casting is to control the solidification sequence. And quality of the casting by locally accelerating cooling. Thereby improving the overall performance of the casting and production efficiency.
Haichen die casting chiller
Haichen, is one Chinese machine manufacturer produces high pressure die casting machines. It includes cold chamber die casting machines and hot chamber die casting machines.They have high durable and precise features. we have auxiliary machine-cooling chillers for option.
