In high-pressure die casting machines and forging lines, engineers often encounter a frustrating situation:

On paper, both pressure and flow meet the design requirements, yet during operation the system gradually feels “weak”.
Filling slows down, clamping loses rigidity, and pressure drops appear during critical stages of the stroke.

Problem Background: When Design Parameters Do Not Match Real Performance

A common first reaction is to increase motor power.
However, deeper analysis often shows that the issue originates from the hydraulic pump rather than the drive motor.

Typical causes include:

Pump efficiency degradation under continuous high-pressure operation

Inability to maintain stable volumetric efficiency near 31.5 MPa working pressure

Increased internal leakage and flow fluctuation over time

These factors reduce effective output even when nominal parameters appear sufficient.

Core Requirement: Sustained High Pressure with Stable Flow Output

Die casting and forging applications require:

Stable pressure during filling, clamping, and holding stages

Consistent flow during high-speed filling and return

Reliable performance under continuous heavy-duty operation

This demands a pump designed for sustained high-pressure conditions rather than peak performance under ideal loads.

Solution Platform: FG1 / FG2 High-Pressure Internal Gear Pumps

To address these requirements, many machine builders are selecting FG1 and FG2 internal gear pumps as the main hydraulic power source.

Typical Selection Range

FG1 (40–50 mL/r) is commonly used for systems with medium-to-high force requirements and moderate flow demand

FG2 (64.7–125 mL/r) is selected for high-flow applications such as rapid filling and fast return

Key Technical Parameters

Rated pressure: 31.5 MPa
Maximum pressure: up to 35 MPa
Speed range: 200–3000 r/min

This allows high-speed operation at the upper range and stable pressure control at mid-to-low speeds.

Performance Improvements in Practical Operation

After adopting FG1 / FG2 pumps, engineers typically observe:

More consistent pressure near the end of the filling phase in die casting

Flatter pressure curves during forging, especially when the ram pauses or holds position

Reduced current fluctuation on the main motor, indicating more stable hydraulic load

Smoother acoustic behavior, with less harsh noise under heavy load conditions

These improvements indicate better energy transfer and system stability.

Engineering Value: Strengthening the Hydraulic Source

Instead of increasing motor power to compensate for inefficiencies, upgrading the hydraulic pump addresses the root cause.

FG1 / FG2 pumps provide:

Stable volumetric efficiency under continuous high-pressure operation

Reduced internal leakage and flow fluctuation

Reliable performance across varying load conditions

This ensures that system performance aligns with design expectations over time.

Summary

In high-pressure die casting and forging applications, perceived “weakness” is often a result of pump limitations rather than insufficient motor power.

By using FG1 / FG2 internal gear pumps as the main hydraulic source, manufacturers can achieve:

Stable pressure and flow under continuous heavy load

Improved consistency in filling, clamping, and forging processes

Reduced system fluctuation and better overall efficiency

Selecting a pump designed for high-pressure duty ensures that the hydraulic system performs reliably from initial operation through long-term use.