153 Pushed Ejector Pins

Chapter Twenty-One
PUSHED EJECTOR PINS
153
A. DESCRIPTION AND RECOMMENDED SOLUTIONS
This problem occurs when a the force required for ejection causes a cast-
ing to deform around the ejector pins as they force the casting away from
the die (Fig. 21.1).
Often a lot of force is required to eject the casting because it has con-
tracted against the cores or other features in the die. The the ejector force
is applied when the casting is at a high temperature, typically about 600 F
Fig. 21.1. Example of ejector marks.
154 NADCA DIE CASTING DEFECTS
(315 C), and the casting is still soft. The result is the ejector pins can
sometimes deform the casting.
One problem is that the hold (or dwell) time may not be correct. There
can be problems in setting the correct dwell time because the casting may
crack or seize strongly on the die if it is held too long. This will cause pins
to push into the heavier and hotter sections at ejection. If it is held too
short a time, the casting can be soft and the pins will deform it.
Dwell time is very sensitive to casting and die temperatures. The pro-
cess must be maintained in a very stable condition so as to hold consistent
temperatures and keep the dwell time correct. Adding thermocouples that
will control the dwell time based on die temperature has been done quite
successfully (note: a minimum dwell must be maintained for safety purposes).
Some other factors and corrections to consider for this problem in-
clude the following:
Check for undercuts and drags that might be holding the casting in the
die see also the ejection problems under bending or crack defects
Poor design, with too few ejector pins
Pins in the wrong locations, use ribs or other natural features to spread
the force from ejector pins
Ejector pins too small