TFs scraps reducing

4 ways the TFs is built to battle scrap

Parts differ. Productivity goals TFs don’t. Whether you’re focussed on casting parts for e-mobility, large structural components for industry, or high-spec elements for 5G communication technologies – minimizing scrap is essential. 

Read on to learn how our Toggle Free Smart series (TFs) High Pressure Die Casting machine is designed to battle scraps.

1) Perfect platens that cut casting distortions

Platen hardness is an essential ingredient for scrap reduction. Or more specifically, for reducing the risk of distortions that can lead to scrap. 

Building on the excellent stability already delivered by its hydraulic closing mechanism, the TFs has platens optimised for local, high-stress areas – creating a strong and even distribution of force on the die to help minimize scrap-causing distortions.

2) Closing that locks out risk in an imperfect world

While rigidity is vital, hydraulic locking in any HPDC machine should allow for automatic compensation for geometrical imperfection of the die and its thermal expansion, adapting to different working conditions. 

The TFs does exactly this, helping you to reduce scrap that might be linked to such imperfections.

3) Tie-bars that tackle scrap independently

Tie bars in the TFs work independently, exerting the correct amount of pressure to reach the required closing force (from 1400t to 11000t) and maintain parallelism, before being locked in position on the mobile platen. 

Why is this so important? Because high closing forces and and well-equalized tie bar loads keep the die halves together as they are subjected to high pressure loads from the incoming molten metal – minimizing distortion and parting plane separation that may result in scrap.

4) Separate injection circuits for casting consistency

Sometimes two is better than one. The TFs injection unit is the perfect example.

It employs two separate circuits to manage a phased injection process. One to fill the die at high speed, and a second to push the metal that has already filled the cavity at maximum pressure to minimize the gas porosity included in the casting, thereby avoiding potential defects that could result in scrap. Coupled with our shot control software which continuously monitors melt flow into the die in order to adjust piston speed accordingly, the result is uniform casting quality as standard.