Engine Block Process

Casting cell and die blended into a unit.

The new total solutions for die casting inline and V-engine blocks developed by Bühler Druckguss AG in close cooperation with its partner Schaufler Tooling eliminate the drawbacks of conventional manufacturing processes. They give a further boost to the engine block die casting process, which is already highly efficient. The new total solutions offer the following benefits:
  • Smaller dies of lighter weight, which are therefore more cost-effective.
  • Shorter cycle times.
  • Less wear of the cooling water jacket inserts.

Fewer downtimes through

  • Easier die maintenance (e.g. faster water jacket changes).
  • Less back-splashing of core slide guides.
  • Less die leakage.
  • Reduced rupturing of ejector pins, or none at all.
  • Controlled die heating and cooling.

Appreciably lower die costs.
One of the big problems in conventional engine block production are the very massive, large, and therefore expensive dies. Because the die casting machine fulfills certain functions of the conventional die in the new Bühler concept, the new dies will in the future no longer require any ejector boxes and ejector tables. This and other weight-limiting improvements enable the cost of V-engine dies to be reduced by 25% and those of inline engine dies by 10%.

Shorter cycle times.
The optimized BuhlTemp temperature control concept, the newly developed Flextool die spray system from the Acheson company, and synchronized machine motions allowing simultaneous spraying of both die halves cut cycle times by valuable seconds. Depending on the weight of the raw casting, the cycle time can be reduced by 10 to 20%.

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