Scribd
Upload
119 views2 pages

CTS Plunger Tips ABP 1

The plunger tip is a critical element of die casting that must transmit force to push molten alloy into molds, maintain a seal to prevent flash and air intake, and remain dimensionally stable. The Allper Bush Plunger (ABP) was developed for small to medium machines to meet these needs using materials like Con-Duct steel and beryllium copper that provide strength, conductivity and stability. The ABP features a quick release design and water cooling to maximize heat transfer and reduce cycle times.

Uploaded by

Alson Lee
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
119 views2 pages

CTS Plunger Tips ABP 1

The plunger tip is a critical element of die casting that must transmit force to push molten alloy into molds, maintain a seal to prevent flash and air intake, and remain dimensionally stable. The Allper Bush Plunger (ABP) was developed for small to medium machines to meet these needs using materials like Con-Duct steel and beryllium copper that provide strength, conductivity and stability. The ABP features a quick release design and water cooling to maximize heat transfer and reduce cycle times.

Uploaded by

Alson Lee
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 2

PLUNGER TIPS - ABP

The plunger tip is a critical element of aluminum The ABP Plunger


die casting process. Its’ successful operation
depends on a number of factors. The most The Allper Bush Plunger ABP was developed for small to medium sized machines,
important factor is its’ efficient interaction from 40 mm up to 120 mm diameter. It is composed of a Con-Duct plunger body, a
with a round, straight, thermally and therefore nitrided H-13 (1.2344) replaceable split wear ring, an ultra-high strength Beryllium
dimensionally stable shot sleeve. Copper A-52 spring bush and a stainless steel M303 holder with a quick release
bayonet coupling. Water flow is from the center of the shot rod, through the stainless
Castool’s plunger tips were developed a number holder, and directly to the inside face of the plunger tip where a turbulent flow is
of years ago by Allper of Switzerland. The plunger generated to maximize the heat transfer.
materials have been developed jointly between
Allper and SCHMELZMETALL over the last 30 years Con-Duct has impact toughness of 100J. The thermal conductivity of Con-Duct is
particularly for die-casting. All the copper alloys 42W/mk versus H-13 which is 24W/mk. Con-Duct has better toughness and thermal
are refined from virgin materials, heated and conductivity and reduces thermal and impact stress. It is safer to use and has much
casted in high vacuum to avoid oxides, forged and longer life.
thermally precipitated. The alloy combines high
fatigue, high hardness, high resistance to heat and
high thermal conductivity.

PURPOSE
• Prevent alloy from penetrating between the shot
sleeve and plunger, prolonging tooling life

• Move smoothly and consistently, with a


minimum of lubrication, through the shot sleeve
bore increasing casting properties

• Maintain a secure seal with the shot sleeve wall


necessary for an effective vacuum to be drawn ABP-R 40 to 50 mm dia: ABP-R 50 to 80 mm dia:
reducing porosity This ABP-R incorporates a forged This ABP-R is slightly longer and
Con-Duct steel body and a nitride incorporates a forged Con-Duct steel
• Cool the biscuit quickly to reduce cycle times hot work tool split ring. body, a nitride hot work tool split ring
and a steel coupling.
FUNCTION
The function of the plunger tip is the extension of
the plunger rod, which pushes the molten alloy
into the mold. There are a number of functions
that must be satisfied by an effective plunger tip.
• To repeatedly transmit the force of the plunger
rod, at high temperature, to the alloy.

• To maintain a seal with the shot sleeve wall


during the shot, eliminating flash or blow-by and
preventing air from being drawn into the alloy
when using a vacuum.

• To remain thermally and therefore dimensionally


stable throughout the shot, allowing consistent
and repeatable shot velocities. ABP-R 50 to 120 mm dia: ABP-A (Solid):
This ABP-R incorporates a forged In some cases, because of the die
• Since the tip is dimensionally stable, and the gap Con-Duct steel body, a forged BeCu or shot sleeve configuration, it is
controllable, steel wear rings can be attached to bushing, a nitride hot work tool split difficult to use the split ring. In these
the plunger tip body to provide a guarantee that ring and a steel coupling. cases, it is possible to use the ABP
the seal is maintained. without a split ring.
FUNCTION continued on next page
FUNCTION continued... ABP (Holder)
With the ABP, a stainless steel tip
• Because the ring is flexible, it makes holder is screwed onto the shot rod,
continuous contact with the inside of the shot and the body is securely fastened
sleeve. Flash, which is a major cause of wear, to it with a quick release bayonet
is essentially eliminated. Shot speeds are type connector. The front of the
consistent. steel holder lies in full contact with
the inside face of the plunger tip and
• Since the expanding wear ring ensures a absorbs the total pressure of the shot. The
secure seal between the plunger and the shot face can then be very thin for better heat exchange.
sleeve, a better vacuum can be drawn. The water flow is from the center of the shot rod, through
the stainless holder, and directly to the inside face of the plunger tip
• An additional advantage is that the face of where a turbulent flow is generated to maximize the heat transfer. It then
these is considerably cooler than that of other goes through four channels to the circular external coolant return passage.
plunger tips. This cools the biscuit much faster
and reduces the cycle time significantly. Approximately 10 to 20 l/min. of water flow are necessary to use this system
depending on plunger diameter.

ABP (Ring)
Replaceable wear rings create a superior seal for
BENEFITS of the Allper Plunger Tip vacuum applications and reduces cost. The internal
radius has been increased by 8 times, reducing the
stress concentration factor by 1/3. The overlap length
• Reduce cost per shot
has also been reduced. The total effective stress from
• Increase plunger life the reduced overlap and increased radius reduces the
• Increase shot sleeve life stress to at least 1/5 of the original milled ring.
• Improve vacuum seal
• Reduce flash Two pin hoods are now being machined into most rings.
• Reduce scrap rate The split is kept away from the pour spout and also erosion
prone area of the shot sleeve, under the pour spout. The
• Reduce downtime
ring complies to the ID of the shot sleeve better than with
With the Allper Plunger Tip, Castool again a single hood opposite the split. It is also easier for the
sets a new standard of excellence in the die operator to access the split for removing and installing a
new ring.
cast industry.
Shot Sleeve
Results may vary depending on individual press The sleeve should be straight and round under production temperature. If it is not the
characteristics and setup. case, aluminum will penetrate between the clearance of the plunger tip and sleeve.
The good news is, that in most cases, shot sleeve expansion on small to medium size
shot sleeves is easy to manage.

Lubrication
Lubrication should only be applied
where it is needed. Every effort should
be made to eliminate the possibility of
non-metallic substance getting into
the casting.
For small shot sleeves, a built-in slot
and lubrication channel can be machined
into the shot sleeve that delivers lube
on top of the plunger ring.
For medium shot sleeves the bolt-on
Allper Lube Drop (ALD) system delivers a precisely measured amount of lubricant
directly on top of the plunger or plunger ring.

www.castool.com
HIGH VACUUM COPPER ALLOYS PLUNGER SYSTEMS
August 2019

CASTOOL MAKES DIE CASTING BETTER

You might also like