German supplier ABK Pressenbau und Automation, working with Aulbach Trimming Technology, has developed a hydraulic trimming press for ‘mega-cast’ parts. Mega-casting, or giga-casting, is the high-pressure die-casting process now emerging for producing large-dimension, unitary components for automotive structures. Like many die-cast parts, mega/giga-castings must be trimmed after they are released from the mould.

The concept of trimming die-castings with a press and mould is based on an established procedure that can be found in foundries worldwide. The advantages of punch trimming are well-known: short cycle times, defined contour cut with adjustable knives and high-repeat accuracy, trimming removal through the table opening, return of the trimmed material to the melting furnace, as well as a straightening effect.

The four-column ABK Pressenbau mega-press is designed for trimming tools with a base plate of 3 000mm by 3 000mm and weighing approximately 30 metric tons. It is capable of 300 metric tons pressing force

The new generation of ABK hydraulic trimming presses and tools – the SP 30/23-4-300 – has a 3 000mm by 2 300mm column passage, 3 000mm by 3 000mm clamping size, and 300 metric tons of pressing force.

The trimming tools are changed fully automatically.

The machine can be installed together with an immersion cooling basin in sizes up to 3 000mm by 3 000mm, to receive individual mega-castings after trimming.

In terms of size and geometry, the trimming presses have proven to be effective for diecast parts. ABK builds machines of this type in series production, and has logged 17 orders: Seven presses have already been delivered, and several machines are currently under construction. “There is already a high degree of standardisation and many examples of successful implementation,” according to ABK.

In addition to the large machines, the company’s standard program of smaller presses will continue, along with general overhauls and comprehensive service for all machine sizes.