Macrocast GmbH relies on accurate and reliable Tool-Temp temperature control units

Partner

Foundry Corporate News

04. July 2023

Tool-Temp spoke with Jens Paul, Technical Manager of Macrocast die casting foundry, about the tempering of their moulds, the challenges in the production process and the development in foundries.

Pressemitteilung | Reading time: min

Macrocast GmbH is a specialized die casting foundry based in Samstagern on the upper side of Lake Zurich in Switzerland and is an affiliated company of Franz Binder GmbH & Co. Elektrische Bauelemente KG in Neckarsulm, Germany. One of the core competences of this successful Swiss company is the production of complex zinc die cast components, mainly with mechanical CNC finishing, and specialises in the production of small components as well as small series. Macrocast is one of the renowned manufacturers for connectors with its vertical range of manufacture and produces most of the zinc die casting series for the Binder Group (65 %).

Tool-Temp AG is proud to count Macrocast among its valued customers for many years. Ten oil temperature control units are in daily use in this die casting foundry and recently a large TT-216'000 cooling unit with a nominal power capacity of 216 kW was put into operation for the entire die casting foundry. We visited Mr. Paul and asked him a few questions.

1. What exactly is being tempered at Macrocast?
Steel moulds weighing 120 - 180 kg are tempered. The temperature range to be covered is 90 °C for large- or thick-walled die castings, and up to 200 °C for very thin-walled die castings that require high and fast flow properties. An average of 4 parts per cycle are produced in the tool sizes used.

Examples of moulds and casting parts at Macrocast GmbH

2. Zinc casting is suitable for countless applications, from simple window fittings to complex electronic components and automotive components to spectacle cases. To which industry do your biggest customers belong? The die cast parts are mainly supplied to the electrical industry and drive technology. Brackets and fittings for doors or windows are also produced for the fastening industry. 60 - 70 % of these die cast parts are exported and approx. 30 % are produced for Swiss customers.

3. How has your industry and applications developed in recent years?

Many die casting foundries are following the trend and investing in Megacasting, the joining of several components into one die cast part. It has the potential to revolutionize the manufacturing process of automobiles. Since Macrocast specializes in small-series parts and produces small parts, Megacasting is not done. There are no such changes coming in the casting process for small parts. The more cavities a mould has, the greater the challenge to ensure that all castings in the same production cycle are cast in perfect and equal quality.

However, there is a clear trend towards connectivity. Connecting the temperature control unit to the machine control system simplifies the production process significantly and is indispensable in terms of quality assurance. The temperature controller ensures that the die cast parts are produced without quality problems.

4. In what way do Tool-Temp units simplify the production process in your die casting foundry?

The greatest risk in the production of die cast parts is material doubling, which can occur due to cold fronts during casting (too low casting speed leads to premature solidification). Especially with thin-walled castings, material doubling is particularly visible and cannot be accepted. The solidification temperature of zinc is 387 °C and therefore, Macrocast relies on Tool-Temp oil tempering units, by controlling at high temperatures.

Our goal is the continuous optimization of cycle times, and this is achieved by using the Tool-Temp oil temperature control units TT-248 (up to max. 200 °C), TT-288 / MP988 (up to max. 250 °C).

5. How many hours are the Tool-Temp units in use every day?

We use the units for 13 hours per day (at the end of the shift the units are switched off), but they can easily be used in 24/7 operation.

6. We are very grateful for our long-standing good business relationship. What brought you to Tool-Temp years ago?

More than 6 years ago, employees came across Tool-Temp through internet research. Since the focus was on independence, individual solutions, quick communication channels and fast availability of equipment and spare parts, it quickly became clear that Tool-Temp would become the business partner.

7. What are your experiences with the Tool-Temp units?

The temperature control units are very reliable, this is proven by their control accuracy. They easily withstand the rough everyday conditions in die casting.

Oil tempering unit type TT-248 in operation at Macrocast

With very small cooling bore cross-sections, there is the difficulty of heat dissipation, and this can be easily compensated for by higher tool temperatures. Macrocast relies on the robust Tool-Temp oil temperature control units. The uncomplicated system design makes the units easy to operate

8. Are you satisfied with the performance of the units and the Tool-Temp service?

We appreciate the very short reaction times and solutions from Tool-Temp-After-Sales and are pleased to confirm that we have not had any production downtimes with the use of Tool-Temp temperature control units.

We are very satisfied with the unit’s performance, consequently, when we wanted to modernize our cooling system a year ago, it was also clear to us that Tool-Temp would offer a solution tailored to our requirements. Since then, the TT-216'000 cooling unit has provided the cooling water supply for the entire die casting system and all temperature control units.