Die-casting is a key industrial production process for the manufacture of metal components in many sectors. Within this process, die casting machines play a key role, guaranteeing maximum precision and quality in the production of complex parts.

The two die-casting methods

There are two main methods of die casting:

Choosing the right technology

The choice between hot chamber and cold chamber die casting depends on several factors, including:

Advantages

MethodBenefits
Hot chamber die castingHigh precision, excellent finish, high productivity
Cold chamber die castingStrong process, greater flexibility in alloy selection, lower tooling costs

Applications

Agrati AEE: a reliable partner

Agrati AEE has a long experience in the design and production of die casting machines, offering customised solutions to meet the specific needs of each customer.

Thanks to its high level of know-how and the use of state-of-the-art technology, Agrati AEE is a reliable partner for companies operating in various industrial sectors, guaranteeing them the highest quality and precision in the production of die-cast components.

Die casting machines are a fundamental tool for the production of high quality and precision metal components. The choice between hot chamber and cold chamber die casting depends on a number of project-specific factors. Agrati AEE, with its experience and expertise, supports its customers in selecting the most suitable technology for their needs, guaranteeing them customised, high-performance solutions.

The Internet of Things (IoT) is revolutionising the industrial landscape, offering new opportunities to improve the efficiency, productivity and safety of production processes. In the die casting industry, the IoT represents a significant step towards creating smart, connected foundries that can adapt in real time to changing market needs.

How can the IoT be applied to the die casting industry?

The applications of IoT in this industry are many and varied. Here are some examples:

What are the benefits of IoT for the die casting industry?

The implementation of IoT in the die casting industry can lead to a number of significant benefits, including:

What are the challenges?

The implementation of IoT in the die-casting industry, as in all companies entering Industry 4.0, presents some challenges, including:

The IoT represents an unmissable opportunity for the die-casting industry to improve efficiency, productivity and process safety. The challenges are not insurmountable and, with proper investment and strategic planning, foundries can benefit greatly from this revolutionary technology. The die casting industry is poised to become part of the fifth industrial revolution and IoT is the key to a more efficient, connected and sustainable future.
In addition to the above, the use of IoT in the die casting industry can lead to:

The first step is to have efficient die-casting machines for your sector. If your company’s goal is to be competitive in the market, ask AGRATI AEE’s sales engineers for advice.

Zamak die casting is a production process that combines the versatility of zamak alloy with the efficiency of die casting. This technique offers a number of advantages in terms of quality, durability and sustainability, making zamak a widely used material in a wide range of sectors. Here are its applications and its impact on sustainability.

What is die-casting of zamak?

Zamak die-casting is a production process involving the casting of zamak alloy in a high-pressure mould. Zamak is a metal alloy composed mainly of zinc, with the addition of aluminium, copper and other metals to improve its performance. This alloy is known for its resistance to corrosion and the ease with which it can be cast and machined, making it ideal for die casting.
The process begins with melting the zamak in a ‘special’ hot chamber machine, which keeps the molten alloy at a constant temperature. Once melted, the zamak is injected under pressure into a specially designed mould. The pressure forces the material to completely fill the mould and assume the desired shape. After cooling, the part is removed from the mould and can be further processed if necessary.

Applications of Zamak Die-Casting

Zamak die-casting has applications in a wide range of sectors due to its exceptional mechanical properties and the ease with which it can be moulded into complex shapes. Some of the main fields in which it is used are highlighted below:

  1. Automotive industry: Zamak die-casting is widely used to produce high-quality automotive components, such as engine housings, seat belt hooks, gears and other parts that require precision and strength. The lightness of zamak helps reduce the overall weight of vehicles, improving fuel efficiency.
  2. Electronics: In electronics, die-cast zamak is used to produce housings for electronic devices, connectors, circuit board mounts and other components. The ability to produce intricate parts is fundamental to modern electronics.
  3. Construction Industry: Zamak die-casting is used in the production of locks, door and window handles, hinges and other parts requiring corrosion resistance and durability.
  4. Toy Industry: Many toys contain diecast zamak components such as gears, ball joints, moving parts and decorations for guaranteed safety and longevity.
  5. Furniture and Design: In the furniture industry, zamak is used for the production of handles, knobs and decorative parts for furniture. Lamps, photo frames, clocks and other household items often incorporate die-cast zamak parts for their decorative appearance, elegance and durability.
  6. Plumbing Industry: Valves, taps and plumbing components often contain diecast zamak parts because of their corrosion resistance.
    The versatility of zamak die-casting results in a wide range of applications, helping to improve the quality and durability of products in many sectors.

Sustainability of Zamak Die-Casting

In addition to its versatility, zamak die-casting offers significant advantages in terms of sustainability:

  1. Energy Efficiency: The diecasting process requires less energy than many other production techniques, contributing to a reduction in overall energy consumption.
  2. Recyclability: Zamak is completely recyclable. Zamak parts can be re-melted to create new components, minimising waste and the use of resources.
  3. Durability: Zamak parts are extremely resistant to corrosion and wear, which means that products made from this material tend to last longer, reducing the need for frequent replacement.
  4. Lightweight: Zamak is lighter than many other metals, helping to reduce the weight of finished products, such as vehicles, which can improve fuel efficiency and reduce greenhouse gas emissions.
  5. Replacement of Harmful Materials: In some cases, zamak has been used to replace more environmentally harmful materials, helping to reduce the environmental impact of certain products.
    We can conclude that zamak die-casting is a highly versatile and sustainable production process that finds application in a wide range of sectors. Its ability to create complex components, corrosion resistance and light weight make it a valuable material for many industries. Furthermore, its sustainability contributes to reducing the overall environmental impact of production.

Agrati AEE, which is involved in the development process of die-casting machinery, has integrated all key elements into the design in order to make its machines both energy efficient and sustainable.

EUROGUSS 2024 Exhibition – It is with great pleasure that AGRATI AEE announces its participation in a world-class event that opens up unmissable opportunities.

The manufacturing industry is constantly evolving. It is driven by the relentless pursuit of innovation and the need to remain at the forefront of the highly competitive die casting machinery market. In this context, AGRATI AEE stands as a major player, offering state-of-the-art solutions and maintaining a reputation for excellence in the manufacture of die casting machinery.

Die casting in the manufacturing industry

Die casting, a key production technique in the automotive, aerospace, electronic components, design, fashion and many other industries, requires machinery of the highest precision and reliability. Participation in the EUROGUSS 2024 Exhibition represents a unique opportunity for AGRATI AEE to present the latest innovations and state-of-the-art solutions to an international audience of experts, customers and potential partners.

“The company recognises the importance of this fair not only as a showcase for our products, but also as an opportunity to increase our global presence and consolidate relationships with our existing customers,” – comments Alessandro Betti Export Manager of Agrati AEE. “The event allows us to interact directly with industry professionals, share our knowledge, and learn from the experiences of other market players,” explains AGRATI AEE Operations Manager Simone Viscardi.

At the AGRATI AEE stand NR. 144 in HALL 7A at EUROGUSS 2024, visitors will have the opportunity to discover the latest innovations developed by AGRATI AEE.

What’s new at Agrati AEE for Euroguss 2024?

Among the novelties is the new hot chamber machine. “This product represents a significant step forward in die-casting technology and we are excited to share it with the market” – clarifies Giorgio Colombo General Manager of AGRATI AEE and continues “AGRATI AEE’s hot chamber machine is designed to offer superior performance, higher energy efficiency and greater precision, making it ideal for the most demanding applications.”

Why should you visit the AGRATI AEE stand at EUROGUSS 2024?

  1. Industry experts: AGRATI AEE’s highly qualified and knowledgeable team will be on hand to answer all your questions and discuss your specific needs. We are ready to offer you personalised advice based on our extensive industry experience.
  2. Touch experience: At our stand, you will touch the new AGRATI AEE hot chamber machine.
  3. Networking: The EUROGUSS trade fair is a meeting place for industry leaders and for valuable exchange between professionals.
  4. Sustainable benefits: High quality AGRATI AEE sustainable solutions for companies introducing AGRATI die casting machinery into their production in terms of energy savings and predictive control.

AGRATI AEE’s participation in the EUROGUSS 2024 exhibition reflects our ongoing commitment to innovation and customer satisfaction.

We invite you to join us at our stand and explore the opportunities we offer. You will discover how our state-of-the-art technology can improve your die casting production.

In the ever-changing world of the die casting industry, AGRATI AEE is at EUROGUSS 2024 to lead the way into the future.

YOU CAN FIND US AT HALL 7A- STAND 144

With the transition to Industry 4.0, Agrati’s investments have focused on research and development for the productive improvement of die-casting technologies and machines. The digital transformation of processes has been made possible thanks to the adoption of new tools, and today AGRATI AEE offers all companies interested in seizing the opportunities offered by the new industrial revolution a tangible competitive advantage.

Interconnected Systems and Continuous Monitoring

In the design, construction and optimisation of die casting machines, Agrati Aee takes into account the interaction that takes place with the major software in use for process simulation, and with the accessories/peripherals that constantly dialogue with the press to optimise the process. The press is the central heart of the production cell, both in terms of process and safety information exchange. Agrati AEE die-casting machines can be remotely controlled in case of process faults or process improvements, allowing complete supervision of their functions and procedures via computerised systems. This system makes our production process increasingly automated and reliable, responding quickly to customer needs and reducing downtime and intervention times.

The benefits of the 4.0 model

Today, Agrati Aee’s product range includes state-of-the-art presses that incorporate interconnected systems thanks to the know-how acquired over more than 80 years in the industry. These elements guarantee our customers die casting machines with a number of significant advantages in terms of handling, production capacity and product quality.

One of the main advantages is the greater simplicity and speed achieved through networking. In addition, we offer the possibility to monitor the status of machines and production in real time, and as mentioned before, allowing the rapid identification of faults or interruptions. We also guarantee constant updates and optimisation through remote control of the machines, ensuring that they are always aligned with occupational health and safety standards according to current directives.

Total interconnection between the different components is made possible through the use of advanced digital tools, interactive technologies and centralised databases. In addition, we support the integration and connection of Ethernet and fieldbuses to ensure smooth and continuous communication between all parties involved in the die-casting process.

Quality as a Priority

The priority for Agrati Aee is quality at the heart of every aspect of our production process. By adopting state-of-the-art technology and implementing Industry 4.0 principles, we are able to guarantee high quality standards in all our machinery.

Advanced Automation

Our die-casting machines are equipped with advanced automation features, allowing for continuous production and easy programming. Thanks to the Internet connection and the company network, it is possible to monitor and control these machines in real time, ensuring maximum operational efficiency.

The customer has the possibility of uploading the specific order from the company management system, monitoring the progress of production, and saving all the production data of the order once it has been completed. The press controls the production itself in real time, monitoring certain process parameters. 

Constant Monitoring

Constant monitoring of our presses and their processes allows us to quickly identify any potential problems and take prompt action to resolve them. This level of control allows us to avoid unplanned production stoppages, high intervention costs, and maintain high levels of productivity.

Continuous Updates and Optimisation

The digital nature of our machines allows us to carry out updates and optimisations quickly and without significant interruptions in production. This ensures that our machines are always aligned with the latest technology and safety standards.

Safety at Work

Safety at work is a top priority for Agrati Aee. Our machines are designed and built with the strictest safety regulations in mind. Constant supervision and remote access allow us to verify that the machines are operated safely and in compliance with all applicable regulations.

Energy Efficiency

Energy efficiency is another key aspect of our die casting machines (we were the first to install energy-efficient systems on die casting machines in 2009). Thanks to advanced automation and process optimisation, we are able to reduce energy consumption and minimise environmental impact by up to 77%.

Agrati Aee is committed to offering state-of-the-art die casting solutions for Industry 4.0. Our interconnected machines, continuous monitoring and focus on quality and safety enable us to meet the highest demands of our customers in any field. With our commitment to innovation and excellence, we are ready to meet the challenges of the new industrial era and lead the industry towards a digital and sustainable future.

Die casting is a widely used production process for the manufacture of complex metal components. One of the main objectives of companies using this process is to reduce production time and increase efficiency to improve overall productivity. To achieve this goal, Agrati Aee has optimised the die-casting cycles in its hot chamber and cold chamber machines.

Detailed process analysis

One of the first strategies for optimising production time in die casting is a detailed process analysis. At Agrati AEE, this analysis involves the study of each stage of the die-casting cycle, from the injection of molten metal to the solidification and extraction of the finished part. Identifying any inefficiencies or delays during the process helps identify areas requiring improvement and develop targeted solutions.

Reducing the die-casting cycle

One of the key aspects of optimising production time is the reduction of the die-casting cycle. This can be achieved through a number of measures. One of these is the optimisation of process parameters, such as melt temperature, injection speed and pressure, extraction optimisation, and mould lubrication. Agrati Aee fine-tunes these parameters in its machines, making it possible to reduce cycle times without compromising the quality of the finished part, while also introducing mould control with camera systems.

Automation of the die-casting process

Another strategy to reduce production time is the automation of the die-casting process. The use of robots for the extraction of finished parts enables cycle times to be significantly reduced, as does the use of ingot feeding and electric lubricators. These automated systems are able to perform operations with greater precision, consistency and speed than human intervention, leading to an increase in overall efficiency.

Advanced technologies for process optimisation

The implementation of advanced technologies can help optimise production times in die casting. For example, the use of moulds thermoregulated by external temperature controllers improves the solidification process and reduces cycle times. These moulds are designed to dissipate heat more efficiently, allowing better solidification of the molten metal and consistent temperatures for the extraction of the finished part.

Efficient tooling management

Another important aspect of optimising production time is the efficient management of equipment and materials. A well-organised factory layout, with strategic positioning of the equipment and materials required for the die-casting process, can reduce travel time and improve the smoothness of operations. Furthermore, the adoption of an advanced production management system allows for optimal planning of resource utilisation, minimising waste and downtime.

Monitoring process performance

Optimising production time, in fact, requires constant monitoring of process performance. By using real-time monitoring systems (quality control), any anomalies or inefficiencies can be detected at an early stage and the necessary corrections can be made. In addition, the analysis of historical data can provide valuable information on trends and areas for potential improvement.

A monitoring system applied to the Agrati AEE die-casting machines allows the monitoring of certain essential parameters throughout the day, so that interventions that could compromise production progress and lead to costly downtime can be planned in good time.

In conclusion, the optimisation of production time in die-casting is essential to improve efficiency and increase overall productivity. Through detailed process analysis, optimisation of process parameters, automation, implementation of advanced technologies, efficient management of equipment and materials, and constant monitoring of performance, it is possible to reduce cycle times and achieve better results in terms of productivity and quality.

Thanks to the experience of its consultants and the technology applied to its die-casting machines, Agrati Aee is able to reduce maintenance costs by 70%.

Agrati AEE srl is one of the most prestigious Italian manufacturers of die casting machines in Europe.

AGRATI AEE’s production site is located in Bergamo, a few kilometres from Milan. It draws on almost 90 years of know-how, partnerships with the world’s best technical partners in the fields of electronics and hydraulics, and its own technologies.

In recent years, in collaboration with the world leader in hydraulic technology Parker Hannifin, it has developed the innovative Eco Drive injection technology, a solution for optimising the die-casting process that improves both productivity and product quality.

HOW DOES THE ECO DRIVE SYSTEM WORK?

In order to better understand the EcoDrive System, we drew on the experience of Alessandro Betti, Sales Director of AGRATI AEE, who knows the dynamics and the needs of customers.

“The EcoDrive System works with the 2-way high response valves series TDP in combination with a Compax3F controller, enabling dynamics and accuracies that had not previously been achieved.

This contributes to greater productivity since rejects are reduced to an absolute minimum.

The solution keeps system pressure constant and provides protection from pressure peaks and cavitation thanks to an accumulator on rod side and a check valve. This system also extends the lifetime of all hydraulic components of the die casting machine.

Up to 20 % of energy is saved as a result of energy recovery during injection cycle”

What are the BENEFITS of the ECODRIVE injection system?

We can summarise all the advantages of the ECO DRIVE System, continues Alessandro Betti, by outlining them as follows:

a) Response times of the cylinder movements are greatly reduced;

b) Injection SPEED need is achieved with smaller valve openings;

c) ABSENCE of pressure peaks is guaranteed: the maximum pressure in the circuit is now that of the accumulator (130 bar); previously, with the intervention of the outlet brake, values of 230 bar were also reached;

d) The INCREASE of the mould front surface is guaranteed due to the absence of pressure peaks;

e) TDP lifetime is longer due to the benefits of the smaller opening;

f) Guaranteed better braking and control of the injection cylinder;

g) Reduced accumulator charging time due to oil recovery after first injection phase;

h) In the machine tank, there is now a reduction in emulsions because the injection unit discharges very few and at low pressure;

i) Reduction in the size of the injection unit drainage pipe;

j) Increased pump life due to reduced emulsions in the tank;

k) ENERGY SAVING due to reduced loading times.

Which are the injection cycles?

Here too, we can make use of explicative images, explains Alessandro Betti.

Injection cycle – first phase

All phases of the injection cylinder are performed under accumulator and controlled by the TDP valve. In the first phase, at the exit of the injection cylinder, after the controlled safety cartridge, the oil is no longer discharged into the tank, but returns to the accumulator pressure line.

Injection cycle – second phase

In the second phase, when the TDA valve (TDP in case of closed loop options) is opened, the oil accumulates in a pressure transformer which keeps the pressure on the discharge line constant, thus avoiding pressure peaks and water hammer. A small amount of oil is discharged at low pressure into the tank.

With the additional closed-loop option, 8 speed ranges with corresponding ramps and 5 pressure setting ranges can be defined.