Apparatus and method for simultaneous usage of multiple die casting tools

Abstract

The preferred embodiment of the present invention is a die casting apparatus and method evidencing increased apparatus output including the ability of using multiple die tools. The invention includes an indexing assembly removably engaged with at least one die block assembly for transporting between four stations, including an injection station, a cooling station, an ejection station, and a recovery station. The injection station includes a frame, a clamp assembly attached to the frame for clamping and releasing the die block assembly, a shot sleeve assembly engaged with the die block assembly for receiving molten material, such as metal, from a furnace means and injecting the molten material into the die block assembly, and a shot cylinder releasably coupled with the shot sleeve assembly for controlling the injection of molten material. The ejection station includes an ejector lift assembly which engages the die block assembly for ejecting a finished part from the die block assembly, and the recovery station includes an ejector drop assembly which engages the die block assembly for placing a preload on the die block assembly.

1 . A plunger tip assembly for a die casting apparatus having a shot rod and a shot sleeve, comprising:
 a plunger tip secured to an upper end of the shot rod; and   an insulating bushing positioned about an outer surface of the plunger tip and sized to seal against an inner surface of the shot sleeve, wherein the insulating bushing minimizes heat loss through the side of the plunger tip.   
   
   
       2 . The plunger tip assembly of  claim 1 , further comprising:
 cooling water communicated through the shot rod to the plunger tip to remove heat from the plunger tip.   
   
   
       3 . The plunger tip assembly of  claim 1 , wherein the plunger tip comprises copper. 
   
   
       4 . The plunger tip assembly of  claim 1 , wherein the insulating bushing comprises a ceramic material. 
   
   
       5 . The plunger tip assembly of  claim 1 , further comprising:
 a gasket seated against a lower end of the insulating bushing; and   a washer seated between the gasket and the upper end of the shot rod.   
   
   
       6 . The plunger tip assembly of  claim 1 , further comprising:
 waterlines operatively connected between the shot rod and a water source for communicating cooling water.   
   
   
       7 . The plunger tip assembly of  claim 6 , further comprising a diverter operatively connecting the waterlines and a core of the shot rod so that cooling water flows upwards along the interior of the core and downwards along the exterior of the core. 
   
   
       8 . A shot sleeve assembly for a die casting apparatus, comprising:
 a shot sleeve defining a sleeve core, a cover flange at an upper end of the shot sleeve for engaging the die block assembly, and an inlet port that mates with a conduit for communicating molten material to the sleeve core;   a shot rod within the shot sleeve;   a plunger tip secured to an upper end of the shot rod;   an insulating bushing seated against an outer surface of the plunger tip and sized to slidably engage with an inner wall of the shot sleeve for injecting molten materials into the die block assembly; and   waterlines operatively connected between the rod core and a water source for communicating cooling water.   
   
   
       9 . The die casting apparatus of  claim 8 , wherein the shot sleeve assembly further comprises a diverter operatively connecting the waterlines and the sleeve core so that cooling water flows upwards along the interior of the sleeve core and downwards along the exterior of the sleeve core. 
   
   
       10 . The die casting apparatus of  claim 8 , wherein the plunger tip comprises copper. 
   
   
       11 . The die casting apparatus of  claim 8 , wherein the insulating bushing comprises a ceramic material. 
   
   
       12 . The die casting apparatus of  claim 8 , further comprising:
 a gasket seated against a lower end of the insulating bushing; and   a washer seated between the gasket and the upper end of the shot rod.   
   
   
       13 . The die casting apparatus of  claim 8 , wherein the shot sleeve assembly comprises a coupler that couples and uncouples the shot sleeve with a shot cylinder. 
   
   
       14 . The plunger tip assembly of  claim 8 , wherein the plunger tip comprises copper. 
   
   
       15 . The plunger tip assembly of claim  81 , wherein the insulating bushing comprises a ceramic material. 
   
   
       16 . The plunger tip assembly of  claim 8 , further comprising:
 a gasket seated against a lower end of the insulating bushing; and   a washer seated between the gasket and the upper end of the shot rod.   
   
   
       17 . A method of cooling a shot rod for a die casting apparatus, comprising:
 providing a shot sleeve for engagement with a die block assembly, the shot sleeve having an inlet port for communicating molten material;   providing a shot rod within the shot sleeve, the shot rod defining a core;   providing a plunger tip secured to an upper end of the shot rod;   providing an insulating bushing seated against an outer surface of the plunger tip and sized to slidably engage with an inner wall of the shot sleeve for injecting molten materials into the die block assembly; and   providing waterlines operatively connected between the core and a water source;   communicating cooling water through the water lines from the water source to the core; and   transferring heat from the plunger tip to the cooling water.   
   
   
       18 . The method of  claim 17 , further comprising:
 providing a diverter operatively connected between the waterlines and the core; and   communicating cooling water from the diverter upwards along the interior of the core and downwards along the exterior of the core.   
   
   
       19 . The method of  claim 17 , further comprising:
 providing a coupler engaged with a lower end of the shot rod; couples and uncouples the shot sleeve with a shot cylinder;   coupling the shot rod with a shot cylinder with the coupler; and   uncoupling the shot rod from a shot cylinder with the coupler.   
   
   
       20 . The method of  claim 19 , further comprising:
 extending the shot rod with the shot cylinder to inject the molten material into the die block assembly; and   retracting the shot rod to a release position with the shot cylinder.