Search: CWM Equipment — Chicago White Metal Casting, Inc.

CWM Invests in Robotics and Automation

July 25, 2024May 15, 2022 by Dan

Chicago White Metal remains very proactive in researching and implementing advanced technology into the die casting process, added value, and finishing operations. CWM leadership encourages an environment where team members can examine and suggest alternatives to current techniques to improve and enhance quality, efficiency, and measurability. This ultimately leads to overall efficiency for existing and future projects. The team is always excited about taking an original idea and watching it grow into a reality.

One idea that came to life in 2021 is implementing robotics and automation technology in the CNC department. There are currently six active robot implementations: 4 Universal Co-bots and 2 Fanuc Robot Cells. These robots were commissioned quickly in the past 12 months, calling for the promotion of Daniel Lechuga to Automation Specialist to keep up with the equipment maintenance and wiring.

The Fanuc Robot Cells are dedicated to facilitating added value and finishing operation checks, leak testing several parts at a time, and tending to CNC machinery. This allows team members to tend to other machines and focus on performing more critical tasks. The Fanuc robots were the first to be integrated into the CNC department and can be seen on the shop floor with cages around them. They are facilitating parts for an archery riser and an automotive ECU housing.

The Universal Co-bots are collaborative robots that work safely alongside humans. The robots have sensors that detect when someone is near or approaching the robot, triggering the mechanism that slows down and stops the machine. This safety feature reassures the team members about the company’s commitment to their well-being. Chicago White Metal implemented four co-bots, which are currently handling parts for two different models of portable oxygen concentrators, a crossbow riser, an electronic housing, and a medical device handle.

Equipment Highlight: CWM’s new 1000-Ton Die Casting Machine

July 31, 2024November 10, 2021 by Dan

In September 2020, Chicago White Metal’s maintenance team installed a brand-new aluminum 1000-ton die casting machine. Under the leadership of Max Golovin, CWM’s Director of R&D, the installation of a new IDRA-900 Xpress Die Casting Machine was completed in the spring of 2021. CWM produced the first official casting from the new machine on March 24, 2021.

The purchase of the IDRA Xpress 900 Series Die Casting Machine allows CWM to expand its already extensive capabilities. Bill Erbacci, CWM’s Customer Care/Fulfillment Manager, said, “The new IDRA machine gives CWM increased capacity and scheduling flexibility. As a result, CWM can run a broader mix of parts in the new IDRA. This translates into shorter die casting lead times for our customers’ orders.”

Benefits of the IDRA Xpress 900

The IDRA Xpress 900 Series Die Casting Machine features a state-of-the-art design, a 900 Metric (1000 US) ton clamping force capacity, and a larger platen than other CWM machines. In addition, the Xpress Series from IDRA offers a Rigid Toggle System, which gives the machine the closing force necessary to produce larger, thin-walled, complex parts.

The Xpress Series from IDRA was an ideal choice for CWM because it offers excellent efficiency and long-lasting precision – it also provides:

Fast and reliable injection of the molten metal
Longevity, because it’s built to last in heavy-duty conditions
Easy maintenance
Low energy consumption
Full automation

One of the most significant benefits of adding the IDRA Xpress 900 Series Die Casting Cell to CWM’s equipment fleet is that it is a complete Die Casting Cell. It has a melting furnace, two robots, an automatic sprayer, hot-oil heating units, a water-cooling system, a part cooling conveyor, and a trim press. One robot loads ingots into the furnace, while the other extracts the part from the die and places it on the conveyer.

What the Future Holds

CWM has already produced many parts in the new machine, and the results have been excellent. The IDRA Xpress 900 Series Die Casting Machine allows CWM to push the boundaries because we can now produce larger parts while maintaining the highest quality possible.

Contact the CWM Team today if you or your team have a part that might be a good fit for CWM’s high-pressure die casting process. Click here to visit our contact page or fill out a quote request.

Preparing for Installation

After installation:

Equipment Highlight: FANUC Robots

July 31, 2024July 22, 2021 by Dan

Benefits of using Robots

At Chicago White Metal Casting, we strive to have the most advanced technologies available to assist with die casting, CNC machining, and other operations. For example, CWM has two FANUC robots in our CNC department—the M10iA and the M-20iB. The M-10/20 series robots offer increased load capacity and extended reach. These small robots are the perfect automation solution for many applications, especially when it comes to handling, assembly, material removal, and machine tending.

In addition to their increased load capacity and reach, the M-10/20 series robots use considerably less energy than older models. They also boast a cost-efficient modular design. Furthermore, the M-10/20 series robots offer integrated cable routing, making them considerably easier to maintain—ultimately saving time and money.

Robot Use at CWM

At CWM, we use the FANUC M-10/20 series robots to load/unload the CNC machining center for some of CWM’s higher-volume parts. The robots that CWM employs can work with several different part numbers and utilize camera-based vision systems to accomplish the following:

Verify the presence and location of holes
Determine the orientation of the part
Load and unload parts onto a CNC fixture
Install special clamping inserts
Confirm the clamping is correct
Sequence part unloading/loading from conveyor

One of the most significant advantages of utilizing these robots is that several hours’ worth of material can be loaded/unloaded into side-by-side input/output conveyors integrated into the cell and tied into the robot’s logic. This system allows the robot/CNC cell to work continuously, producing a steady flow of parts. In addition, the robot incorporates several camera-based inspection steps using a 2D vision verification system that stimulates the eyes, further assuring that parts will meet CWM’s and the customer’s quality standards.

Why Did CWM Choose FANUC?

The FANUC M-10/20 robots are designed for various light material handling applications. They are considered high-speed robots and can be used in many scenarios, including assembly, CNC machine tending, and even die casting. In addition, this robot simplifies applications and floor plans because it is more compact than other robots while maintaining the highest axis speeds and best repeatability.

Another benefit of using these robots is that they can be mounted at any angle on the floor, wall, or ceiling. They are also very small, so they can fit into tight workspaces. At Chicago White Metal, we currently have six active robots in our CNC department—four universal co-bots and two FANUC Robot Cells. Co-bots, or collaborative robots, are different from robots because they can work with humans to accomplish tasks, while robots work independently and run without human intervention.

To learn more about our equipment at CWM, visit this page if you would like to contact our team at CWM, call (630) 595-4424 or request a quote here.

Equipment Highlight: Investment in Energy-Efficient Furnace Pays Off

July 31, 2024February 10, 2021 by Dan

energySMART Aluminum Furnace

Chicago White Metal always looks for ways to improve the die casting process while decreasing energy usage. In 2014, CWM determined that one of the best ways to accomplish both goals was to replace our old reverberatory furnace from the 1970s with a modern central stack melter aluminum furnace.

CWM worked with energySMART, a Nicor Gas program, to replace our underperforming furnace with a high-efficiency one. After much deliberation, CWM chose the StrikoMelter furnace from StrikoWestofen America because it offered the lowest energy consumption of any furnace in its class.

Energy Efficiency & Improved Performance

When CWM chose the StrikoWestofen energy-efficient aluminum melting furnace, we immediately received energySMART incentives in return for reducing our carbon footprint. With the new furnace, CWM substantially cut the amount of natural gas we used in the melting process. And even though the StikoMelter came with a smaller holding capacity, the melting capacity significantly increased to 4,400 lbs. per hour instead of 1,400 lbs. per hour with the old furnace.

By acquiring the modern furnace, CWM qualified for the Nicor Gas Energy Efficiency Program, an energy-purchase rebate program funded by Nicor Gas Company. The incentives from this program enabled CWM to make the investment, which saw immediate returns.

How it works:

The new furnace came with Striko’s patented ETAmax® system, which efficiently combines preheating, heating, and melting phases in a single melting shaft. While return material and ingots are melted quickly in the lower section, the material preheats in the shaft area above it.

The molten metal is transferred to a holding bath, reducing waste and maintaining a preset holding temperature. This simple but effective recuperative concept resulted in significant fuel consumption savings and a dramatic reduction in metal loss due to oxidation or dross. Other benefits of having a modern, energy-efficient furnace include:

Easy to load: The furnace’s shaft is more expansive and can easily accept up to 2.5m² returns. Extra-large charging bins also mean no need to “cut to fit,” saving precious time, resources, and money.
Less energy wasted: Shortened metal melting, reduced natural gas consumption, and an improved material yield to increase efficiency.
Cleaner metal: The furnace’s design limits the amount of dross and oxide produced, resulting in cleaner metal and less waste.

Looking back almost seven years to the date, we can say that it was well worth the investment in terms of energy savings and improving CWM’s overall product. When asked about the furnace, Jim Reitenbach, CWM’s Production Manager, said, “This was one of the best equipment investments CWM has ever made.”

CWM Adds New Idra Die Casting Machine, Full Implementation Planned for Q4 of 2020

August 1, 2024May 28, 2020 by Dan

Chicago White Metal is extremely proactive in researching advanced technology and innovation and implementing them into the die casting process. The company makes these efforts to improve and enhance quality, efficiency, measurability, and overall cost savings for existing and future projects.

CWM leadership encourages an environment that cultivates innovative ideas regarding process improvement. This allows team members to actively examine and suggest alternatives to modify or drastically change current techniques. The team is excited to implement these innovations into the workflow in traditional and non-traditional ways.

New Idra Die Casting Machine (2019)

A new Idra Die Casting machine was purchased last year. The Chicago White Metal team’s extensive planning was thoughtfully executed, with full implementation planned for the beginning of Q4 in 2020. This new die casting machine has a 900-ton capacity, allowing Chicago White Metal to accommodate substantially larger applications. Although the machine is installed in the magnesium department, it will initially be used to cast aluminum parts.

What’s the Difference Between Hot Chamber and Cold Chamber Die Casting?

July 30, 2024May 27, 2016 by Dan

Die Casting 101: Hot Chamber vs. Cold Chamber

High-pressure die casting (HPDC) is a process where molten metal is injected under very high pressure into premium steel molds (dies) to manufacture high-precision die cast products. The die is designed to cast engineered shapes and complex features with great accuracy and consistent replication.

Chicago White Metal provides two types of HPDC: hot chamber die casting and cold chamber die casting. Although the two types share several similarities, they exist separately for different purposes.

Hot Chamber Die Casting

Hot chamber die casting is a type of die casting that uses alloys with low melting temperatures (i.e., Zinc and Magnesium alloys). Using alloys with high melting temperatures would result in damage to the gooseneck, nozzle, and other components.

In a hot chamber die casting machine, the fixed die half is called a cover die, which is mounted to a stationary platen (large plate to which each die half is mounted) and aligns with the nozzle of the gooseneck. The movable die half is the ejector die and is mounted to a movable platen, which slides along tie bars.

The metal is contained in an open holding pot, placed in the furnace, and melted to the desired temperature. The molten metal flows into the shot chamber when the plunger is in the “up” position. As the plunger moves down, it forces the molten metal through a gooseneck and into the die at injection pressures ranging from 1,000 – 5,000 psi.

The machine pushes the moving platen towards the cover die and holds it closed with tremendous pressure until the molten metal is injected. The plunger remains in the “down” position to hold the pressure while the casting “cools off.” After solidification, the plunger is retracted, and the cast part is either ejected, manually removed from the machine or pushed off the cover die. This ejection system, which includes an ejector die and ejector pins, allows the casting to be pushed out while releasing the die halves.

Watch an animation of a hot chamber die casting machine:

Cold Chamber Die Casting

Cold chamber die casting is a type of die casting that is used for alloys with high melting temperatures (e.g., Aluminum and some Magnesium alloys).

In contrast to hot chamber die casting (pumping molten metal into the machine), molten metal is ladled from the furnace into the shot chamber through a pouring hole. While the general function of the cold chamber machine is similar to that of the hot chamber, the cold chamber works with a horizontal orientation and does not have a gooseneck.

Instead, the plunger forces metal through the shot chamber into the die at pressures ranging from 2,000 to 20,000 psi. The plunger holds the pressure and retracts after solidification. The clamping unit and mounting of dies are set up the same as for a hot chamber; however, the cover die for a cold chamber machine does not have a gooseneck or nozzle and, therefore, aligns directly from the shot chamber.

Watch an animation of a cold chamber die casting machine:

If you want to discuss how CWM can help you with your die casting project, please call 630-595-4424 or contact us at sales@cwmtl.com with your inquiries.

Striko Dynarad & Nicor Gas both feature the newest CWM Aluminum Melting Furnace

July 30, 2024November 21, 2014 by Dan

Striko Westofe n, a global manufacturer of thermal processing technology, is known for providing energy-efficient solutions for various types of casting industries, which include aluminum die casting.

Just recently, Striko featured Chicago White Metal in their latest website article about our latest aluminum furnace addition. This article features the new aluminum melting furnace installation that CWM recently acquired in response to the significant growth in aluminum die castings demand to increase our aluminum melting capacity and to maintain our responsibility to the environment as a part of the CWM culture.

Nicor Gas’s EnergySmart program, in conjunction with Striko Weston, has also featured Chicago White Metal in its latest publication regarding the newest installation of the Striko aluminum furnace. Nicor describes the details of its energy efficiency in day-to-day die casting operations, providing benefits to both CWM and our environment.

CWM Launches New “Green Facilities” Program

July 30, 2024November 25, 2011 by Dan

Building on its ISO 14001 environmental certification commitments, CWM is launching an expanded “Green Facilities Initiatives” program to reduce further its ecological footprint in its offices & production facilities.

Targeting landfill avoidance, waterways improvement, and energy conservation, this program will further enhance CWM activities in recycling production scrap, plastic shrink film, pallets, batteries, packaging containers, corrugated material, office paper, and in reducing chemical & process water usage.

CNC Machining Centers Increased to 27

July 30, 2024October 25, 2011 by Dan

V.P. Brian Andrews announced that Chicago White Metal had increased the number of centers in its CNC Machining Division 27 by adding two new Leadwell CNC machining centers, an MV-40, and an MV-50 unit.

The new Leadwells, in addition to further expanding CWM’s capability for the highest RPM spindle speeds and precision, enable still more significant parts and more efficient multiple operations to be programmed. A more comprehensive range of prototyping, dedicated, and post-casting machining can be performed in-house.

For more on CWM’s CNC capabilities, click here.

Sheffield Pioneer 8.10.6 CMM Unit to QA Dept.

July 30, 2024April 24, 2011 by Dan

CWM’s Quality Assurance Dept. recently installed a Sheffield Pioneer 8.10.6 CMM machine, paving the way to acquiring the latest sophisticated inspection software: PC-DMIS Cad++.

This advanced software integrates directly with 3D CAD modeling, allowing for inspection programming before the die cast product sample is available. Thus, the lead time for providing a first-article inspection report is greatly reduced.

Complex parts can be measured quickly with extreme accuracy, and operator error can be virtually eliminated.

Excellence is Expected