• Production Objectives
• Typical Production Cell
• MD Series - Metal Dispensing Machines
  

The MD Series - Metal Dispensing Machine

The MD Series metal dispensing machine is CoreTech Systems, patented equipment system used to produce and recover metal alloy cores involved in the process. The system meets the plastic molding industry's need for a variable volume, turnkey system that produces repeatable, quality metal cores.



Its design and construction incorporates CTS's 21 years of production experience in casting metal cores. This experience has created a unique body of knowledge surrounding the working physical properties of metals used within this process.

Alloy Injection Station

The standard MD Series machine accommodates one, two or four injection assemblies, each with multistage, programmable profile capability. For clean, low pressure injection control that is repeatable shot after shot, the profile is driven by a closed-loop air servo system. Injection capacities ranging from 1 to 120 pounds per cycle are available to suit any application.

The MD Series uses low pressure injection to produce void-free, flash-less cores with good surface finish that are free of cold shuts and other defects. Controlled injection, without turbulence, pushes air out of the cavity ahead of the alloy surface. This eliminates porous areas in the core, caused by entrapped air, that would later collapse from the pressure of injection molding.

The MD Series utilizes a hot-runner system with direct cavity injection that permits sprue-less and runner-less core production minimizing energy consumption and handling, and eliminating the need for any post-machining of the core.

Tooling Stations

The orientation of the mold cavity is critical for proper filling during alloy injection. As a result, the line of draw for mold opening may not always be horizontal. To meet a full range of tooling positions, two tooling station options are available.



Machine Table: A horizontal machine bed allows installation of a tool with its own dedicated dieset and clamp mechanism designed to meet any required orientation. The bed is retractable for easy maintenance and access to the nozzle mechanism during setup. Since the nozzle can be raised and lowered in a wide range of positions, the injection point can be adjusted to accommodate a variety of tooling configurations. This version is particularly useful for R&D applications.



Horizontal Clamp: For more conventional tools, CoreTech offers an all-hydraulic clamp tooling station. Either model has large opening strokes for ample robotic access and generous platen sizes that permit the use of large, multi-cavity tooling. To provide accurate, programmable, control of opening and closing, the MD Series uses a closed-loop proportioning valve system.

Valves are manifold-mounted directly on the clamp unit to reduce pressure losses, while two cylinders distribute the clamping force evenly. Induction-hardened tie bars and graphite impregnated bronze bushings are used to ensure long life and low maintenance of the equipment.

Melt-Out / Core Recovery Station

Melt-out of the metal core from the plastic part is achieved by the use of either the efficient power and speed of induction heating or the simplicity of thermal melt-out by straight immersion of the part in heated oil. The fully automated melt-out system recovers nearly all of the alloy core material and returns it to the core casting station for reuse. The melt-out operation is interlocked with the core casting process, and all process variables are monitored and displayed on the operator's control screen.

Machine Control

The core-making and melt-out operations of the MD Series system use high speed microprocessor controls with CoreTech's advanced machine and operator interface software. All machine motions are monitored; warnings and alarms are triggered automatically. Set up time is reduced as part parameters can be stored in memory for reloading when needed, allowing automatic configuration of the MD Series machine for the next tool.



Easy-to-read, menu-driven screens, with dynamic interactive color graphics are provided for control and monitoring, with quick access - protected by password system - to screens such as:

• Machine setup and configuration controls
• Process monitoring information
• Injection control profile
• Historical trend graphs
• Alarm and warning messages
  
  

The control system can be linked to a central computer to support factory management and statistical process control programs. Also, many languages can be used on operating screens including French, German, Spanish and Italian.

Engineering Support And Customer Services

Core tooling, alloy injection, melt-out/core recovery, equipment controls and software are all integral parts of the MD Series system. Each system is supported by CoreTech's engineering staff, which is involved in all phases of an MCT program.

• Systems engineers will assist in design and layout of new production cells for optimum use of floor space and efficient process flow.
• If a turnkey system is planned, CoreTech will take complete responsibility for its design and delivery so that all elements perform as a single unit.
• Technical support is provided for tool design to take advantage of our extensive application experience.
• Comprehensive operation and maintenance training is provided in the classroom and on the plant floor after installation.
  
  

Prototype Testing

The performance and cost of new products can be evaluated at minimum cost by using cores produced at CoreTech's prototype facility. Cores can be over-molded, then melted-out, returning the finished components to the customer for evaluation. This service has proven extremely useful in reducing initial investments, speeding development and reducing unit cost when full production starts.

Production Objectives

A clear definition of the desired and mandatory objectives need to be realized from the implementation of the MCT process is a critical element of any successful program. Establishing these goals early in the program will benefit all involved. Such topics which need to be addressed include:

• Specifications detailing dimensional accuracy; molding integrity, and the like, for the part to be produced
• Expectations from the prototyping program
• Performance capabilities of the molded component
• Production volume requirements; supply logistics, etc.
• Economic parameters for the project

Typical Production Cell


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