Die locking system and methods of using the same

Abstract

An exemplary die casting press includes a moveable platen that can be actuated to move toward and away from a fixed platen along tie bars. A fixed die is mounted on the fixed platen and a moveable die is mounted on the moveable platen. A die locking system has a locking post that is attached to and extends from the fixed die and a locking cam that is attached to the moveable die. An actuator moves the locking cam between a locked position and an unlocked position to engage and disengage from the locking post, respectively.

What is claimed is: 
     
         1 . A method of die casting, the method comprising:
 actuating a main actuator to close a first die half against a second die half to form a mold cavity enclosed by the first die half and the second die half, wherein the main actuator applies a clamping force between the first die half and the second die half;   actuating a locking actuator to lock a die locking system by moving a locking cam from an unlocked position to a locked position, wherein in the locked position the locking cam engages a locking post, wherein the locking post is round and comprises a flange extending around a circumference of the locking post, and wherein the die locking system is attached to the first die half and to the second die half;   actuating the locking actuator when the locking cam is in the locked position to apply a locking force between the locking post and the locking cam of the die locking system; and   injecting molten casting media into the mold cavity.   
     
     
         2 . The method of die casting of  claim 1 , wherein:
 the molten casting media is injected into the mold cavity at a pressure that generates an injection force on the first die half and the second die half; and   the injection force is greater than a maximum clamping force of the main actuator.   
     
     
         3 . The method of die casting of  claim 2 , comprising:
 monitoring an injection force exerted on at least one of the first die half and the second die half by the injection of the molten casting media into the mold cavity at an injection pressure; and   adjusting at least one of the clamping force and the locking force so that a total clamping force is greater than the injection force by a predetermined margin of safety, wherein the total clamping force is equal to the sum of the clamping force and the locking force.   
     
     
         4 . The method of die casting of  claim 1 , wherein:
 a total clamping force is equal to the sum of the clamping force and the locking force;   the molten casting media is injected into the mold cavity at an injection pressure that generates an injection force on the first die half and the second die half; and   the total clamping force is greater than the injection force.   
     
     
         5 . A method of operating a die casting press, the method comprising:
 providing a die comprising a first die half and a second die half, wherein closing the first die half against the second die half encloses a mold cavity;   providing a die locking system, the die locking system comprising a locking post, a locking cam, and a locking actuator;   attaching the locking post to the first die half;   attaching the locking actuator to the second die half;   closing the first die half against the second die half with a main actuator, wherein the main actuator applies a clamping force to the die;   actuating the locking actuator to move the locking cam from an unlocked position to a locked position, wherein in the locked position the locking cam engages the locking post; and   actuating the locking actuator when the locking cam is in the locked position to apply a locking force between the locking post and the locking cam of the die locking system.   
     
     
         6 . The method of  claim 5 , wherein the locking post is attached to the first die half between a side of the first die and a parting line formed at a perimeter of the mold cavity. 
     
     
         7 . The method of  claim 5 , wherein the step of attaching the locking post to the first die half comprises inserting the locking post into a slot extending into the first die from a side of the first die. 
     
     
         8 . The method of  claim 7 , wherein the locking post is round and comprises a flange extending around a circumference of the locking post. 
     
     
         9 . The method of  claim 5 , wherein the second die half comprises a hole for receiving the locking post, wherein the hole is located between a side of the second die half and a parting line formed at a perimeter of the mold cavity. 
     
     
         10 . The method of  claim 9 , wherein:
 the second die half comprises an opening that extends from a side of the second die half to intersect the hole;   the locking cam is arranged inside the opening; and   the locking actuator is mounted on a side of the second die half.   
     
     
         11 . The method of  claim 10 , wherein the opening extends into the second die half beyond the hole. 
     
     
         12 . The method of  claim 10 , wherein the actuator covers the opening when the actuator is mounted on the side of the second die half. 
     
     
         13 . The method of  claim 5 , wherein the first die half and the second die half each extend to an end located outside of a projected area of a first platen and a second platen of the die press. 
     
     
         14 . The method of  claim 5 , further comprising:
 attaching a second locking post to the first die half; and   attaching a second locking actuator to the second die half.   
     
     
         15 . The method of  claim 5 , further comprising:
 attaching a second locking post to the second die half; and   attaching a second locking actuator to the first die half.   
     
     
         16 . A die casting press comprising:
 a first platen and a second platen, wherein the first platen and the second platen are movable relative to each other via a plurality of tie bars;   an actuator for moving at least one of the first platen and the second platen relative to the other of the first platen and the second platen;   a die comprising a first die half mounted on the first platen and a second die half mounted on the second platen;   a die locking system attached to the first die half and the second die half, the die locking system comprising:
 a locking post attached to and extending from the first die half, wherein the locking post is attached to the first die half between a side of the first die half and a parting line formed at a perimeter of a mold cavity enclosed by the first die half and the second die half when the die is in a closed condition; 
 a locking actuator attached to the second die half, the locking actuator comprising an extendable shaft; and 
 a locking cam attached to the extendable shaft of the actuator; 
 wherein the locking actuator extends the extendable shaft to move the locking cam from an unlocked position wherein the locking cam is disengaged from the locking post to a locked position wherein the locking cam engages the locking post; and 
 wherein in the locked position, the locking actuator can be further actuated to provide additional locking for between the first die half and the second die half. 
   
     
     
         17 . The die casting press of  claim 16 , further comprising a slot for receiving the locking post, wherein the slot extends into the first die half from a side of the first die half. 
     
     
         18 . The die casting press of  claim 17 , wherein the locking post is round and comprises a flange that extends outward from the locking post. 
     
     
         19 . The die casting press of  claim 16 , wherein the second die half comprises a hole for receiving the locking post, wherein the hole is located between a side of the second die half and the parting line formed. 
     
     
         20 . The die casting press of  claim 19 , wherein:
 the second die half comprises an opening that extends from a side of the second die half to intersect the hole;   the locking cam is arranged inside the opening; and   the locking actuator is mounted on a side of the second die half.