Our Die Casting Technology Center is the heart of K1 Innovation + Performance. This is where we develop ever better tools and engineering solutions to meet the challenges of our customers.
This is the basis for the K1 product family.
HPDC prototypes in 12 weeks
Sustainability through die casting competence! The development intervals for new drive technologies in the automotive industry have been considerably shortened in recent years. It is therefore becoming increasingly important to produce prototypes within a short period of time that demonstrate the properties of the subsequent series production parts. Until now, sand casting was the only way to manufacture comparable cast parts in a short time. The problem: These castings are only conditionally comparable with series production HPDC parts, meaning that “completely” developed die casting components of a series production HPDC die only achieve the required properties following extensive modifications.
K1 Prototyping revolutionizes component development! At K1 Prototyping, we at Heck + Becker do not act as a classic toolmaker, but instead as your comprehensive engineering partner. With our K1 competence platform, we can analyze and optimize the feasibility of your components in the die casting process at a very early stage of development. K1 Prototyping enables the substitution of sand casting! Already 12 weeks after a preliminary “design-freeze” we supply you with die casting components with the properties of the later series production components, so that you can carry out initial trials at a very early stage with congruent components.
Worldwide unique prototype die casting die
Accelerated production time
We enable the continuous further development of your castings. On the one hand, we offer maximum flexibility and time savings, because changes to the components giving the contour can be implemented within the shortest possible time. On the other hand, you can try out and analyse new casting technologies (vacuum, lost cores, temperature control) with us. In our attached Die Casting Technology Center (DTC) you can already cast your prototype castings in the first series with converging parameters for the subsequent series casting.
State-of-the-art systems technology gives you the opportunity to test and improve new and customer-specific technologies. For this purpose we have developed a unique HPDC die that is able to map all casting parts and geometries. The die manufacturing time is additionally accelerated by appropriate material selection and innovative manufacturing processes. Our K1 competence team is looking forward to meeting you!
K1 HEAT BUSTER
The K1 HEAT BUSTER from HECK + BECKER is a brand new, innovative and user-friendly tool temperature control system with many advantages. The HEAT BUSTER enables efficient and precise temperature control in areas of the mould where conventional cooling is not technically feasible, e.g. in long cores with small diameters. This added value reduces the wear of the tool on the one hand and optimizes the quality of the casting on the other.
When developing the K1 HEAT BUSTER, our focus was not only on its technical performance during the cooling process, but also on the user-friendly installation, operation and use of the system:
- Only two media lines are required for the supply to and return from the tool. This ensures simple installation and thus few sources of error.
- The testing technology with valves and pressure sensors is integrated in the K1 HEAT BUSTER and is therefore not located directly on the tool or on the cooling manifold. This also eliminates further sources of error.
- Pre-calibration of the pressure sensor is unnecessary. This makes the system very easy to maintain.
- The intuitively operable Siemens S7 control system with 7-inch touch screen enables safe operation of the system through logical authorization levels and storage of tool-specific parameters.
- Another process parameter is the water quality. This is ensured by a permanent conductivity measurement and can be guaranteed by an integrated water treatment system. The integrated 100 L V2A water tank as a temperature or buffer storage tank is automatically refilled via a conventional mains water connection.
- The K1 HEAT BUSTER achieves significant cost advantages for the entire process due to its efficient remote maintenance option, its modular system design in a compact and robust V2A housing and its compatibility with all common Jet Cooling systems.
- Implementation of a PROFIBUS or PROFINET interface for data exchange between die casting machine and K1 HEAT BUSTER.
- Integration of an OPC interface for data exchange between die casting machine and K1 HEAT BUSTER.
- Expansion with flow meter of the individual cooling circuits.
- Start of the cycle and filling of the tool with aluminum, subsequent start delay of the cooling procedure – based on the signal of the die casting machine or of the melting furnace.
- Fill cooling circuit of the tool with water (depending upon the casting parameters). The water subsequently circulates in the cooling circuit for a defined cooling period.
- Flush delay for calming of the water flow due to mass inertia.
- Removal of water with compressed air. The duration depends upon the length of the line between the K1 HEAT BUSTER and the manifold on the tool.
- Delay prior to leakage test for calming of the air flow due to mass inertia.
- Closing of the return line valve and start of pressure build-up for the leakage test. Generate a defined air pressure for leakage test of the cooling circuit.
- Calming of the air current prior to leakage test.
- Carry out the leakage test by closure of the supply line valve and the measurement of ∆p and pmin over a definable period of time ∆t.
- Opening of the valves and reduction of air pressure with subsequent filling of the line with water up to the cooling manifold for preparation for the next cycle.
The duration of one cooling cycle depends both upon the effective cooling time and upon other individual casting parameters.
Die venting improves casting quality and process reliability. There are basically two different types of die venting: Pressure venting and evacuating the die. The K1 product family offers the best possible solution for both variants..
K1 Chill Vents
Depending on the application, the K1 Chill Vents are available as pressure or vacuum venting plates. The specially developed geometries and alloys of the K1 Chill Vents achieve an extremely high venting performance until the end of the complete die filling process. Compared to other venting techniques, our K1 Chill Vents do not require an ejector, cooling or spraying.
K1 VACUUM VALVES
Centrepiece of the K1 Vacuum Valves is the sophisticated geometry of the seal pin, which achieves the best possible seal in the vacuum system. It is almost maintenance-free and stands for durability and quality. The cooled hydraulic system was developed by us for use in hot environments. An essential advantage for you is the easy assembly into the die. The K1 Vacuum Valves have a simple interface to the casting machine and can therefore be used quickly.
INNOVATIVE TEMPERATURE CONTROL SYSTEMS
COPPER BOND COOLING
The principle of this cooling is based on the use of solid-state heat conduction in the spatial material composite of steel and copper. In this process, the steel forms the shell of the cavity including the entire outlining surface. This provides a high level of wear protection and mechanical stability. The copper is located inside the mold core and enables high heat dissipation. Copper and steel are connected completely diffusively. Due to the division of labour of the materials, you obtain a very stable contour component with the high thermal conductivity of copper.
3D cooling leads to a homogeneous surface temperature. This reduces mechanical stresses, increases service life and significantly reduces cycle time. The offset close to the cavity enables very intensive cooling, which eliminates the usually high number of cooling holes. For example, the strength of the main bearing area for the crank shaft is increased considerably as a result. The sealing (leakage rate) of other components could be improved.
COPPER CARTRIDGE COOLING
Copper cartridge cooling is a preliminary stage of copper bonded cooling. Here we incorporate the copper cartridges under pressure into the cooling bores so that the entire surface of the copper is in contact with the steel, which ensures improved heat dissipation. The copper cartridge cooling enables you to achieve close contour temperature control with a distance of 20 mm to the mold cavity. If a defect should occur in the steel, the cooling is not affected by the additional copper layer, which means no direct downtime (closed circuit). In addition, the danger of a “water shot” is minimized.