Ultimate Vent Blocks -...

transcript

Ultimate Vent Blocks

www.midlandtechnologies.com

2 midland technologies, inc. B

• Higher casting yields with less dross

• Betterprocesscontrol

• Lowinitialcostswithhighreturnoninvestment

• Technicalassistancefrompre-planningthroughimplementation

advantage of Ultimate Vent BlocksBecaUse knowing if yoUr die has sUfficient Venting shoUld neVer Be a qUestion

conVentional Vents Ultimate Vent Blocks

the adVantage of Ultimate Vent Blocks

comParing conVentional Vents and Vent Blocks

• Only.005in2-.008in2ventarea• Easilyclogged• Excessiveflash• Toothinforeffectiveremelt• Lowerupfrontcost,greaterrisk• Unknownprocessvariable

• .035in2to.140in2ventarea• Ensureproperevacuation•Minimizeventrunnerflash• Thickerventrunnerstoreclaim• Contributestojobprofitability• Knownprocessconstant

*OptionalVariablePatternShown

Theserratedpatternofferslargeventingareawithoutflashing

Knownventingareaprovidescontrolvariableforcastingprocessplanning

Reducerawmaterialcostsasdrossisreducedandcastingyieldsareimproved

Maximizepressusageasscrapcastingsarereducedandjobsarecompletedfaster

AvailableinH-13steel,pre-hardH-13,orberyllium-freecopperforspecificprocessapplication

(763) 428-4229 | midlandtechnologies.com 3B

comparing conventional Vents and Vent BlocksUltimate Vent Blocks allow for more efficient Venting than conVentional Vents. not only is more air eVacUated and risk of flash redUced, BUt the Vent rUnners that tie the Ultimate Vent Block to the die caVity insert also do not oXidiZe dUring remelt as seVerely as conVentional Vents. this allows the caster to reclaim more casting alloy.

Runnertoothinforeffectiveremelt

ConventionalVent1”x0.005”A=0.005in2

MidlandUVS-2500A=0.040in2

0.056in2 total runnerarea

Thickerrunnerscanbereclaimedtoenhance

jobprofitability

cost of Porosity-related scrap

how mUch does it cost to rUn scraP on yoUr casting Press?

when rUnning 8% scraP rate on a 10,000 Part joB with a 60 second cycle yoU will sPend:*

*Calculatedusingsamplepressrateperhourvaluesinchartabove

think aBoUt yoUr cUrrent joBs with scraP rates…what are the costs of scraP?

• Additionalpressruntime• Additionalalloyusage• Extralaborcosts• Fasterpressanddiewear

• Missedquotas• Troubleshootingexpenses• Increasedperipheralcosts(i.e.moreelectricity,hydraulicfluid,dielube)

60sec.cycletime

Extra cost per good casting due to excess pressrun time caused by 8% scrap rate

Extra cost in ¢per good casting

Die casting machine press rate

Press rate$200/hr

Press rate$250/hr

Press rate$300/hr

$0.40$0.45

• Anextra13.3hoursofpressruntimetoproduce10,000goodparts• Anextra$2,660-$3,990inextrapresstimedependingonpressrate• Anextra$0.26-$0.40pergoodpartinextrapresstimedependingonpressrate

• Increasecastingyields

• Reduceporosity-relatedscrap

• Completequotaswithlesspresstime

• Reclaimmorematerial

• Reducewearoncastingpress

• Reducewearondie

• Reduceperipheralcosts

Ultimate Vent Blocks offer a net PositiVe retUrn to die casters

Ultimate Vent Blocks in eVery die sUPPort greater Process PredictaBility, efficiency and ProfitaBility!

Vent Blocks cost Pennies Per shot But help you save Big!

Ultimate Vent Block Size

Cost in ¢per shot

Cost per Ultimate Vent Block sizeammortized over 100,000 cycles

1.5 ¢

1.9 ¢

2.6 ¢ 2.7 ¢ 2.8 ¢

3.0 ¢3.3 ¢

Ultimate Vent Blocksmore Vent area, less waste

Patent#7,134,637

ProdUct oVerViewTheUltimateVentBlockisahighlydurableinsertwithnomovingpartstofailorreplace.Thespecializedserratedpatternprovidesmoreventingareathanconventionalventswhilesignificantlyreducingriskofflash,acriticalfeaturewhenautomatingthediecastingcell.MostexistingdiescanbemodifiedtoacceptUltimateVentBlocks.

oPerationTheUltimateVentBlockisinstalledintoapocketcutdirectlyintothediesetorismountedtotheoutsideofthedieusingoutboardsupportblocks.LocatingpucksareutilizedtoensurecriticalalignmentbetweenthestationaryandmovablesidesoftheUltimateVentBlock.ArunnersystemiscutfromthediecavityinsertandtiedintotheUltimateVentBlocktoprovideahighlyefficientmeansforevacuatingairandgas.

aPPlicationThepatentedUltimateVentBlockisidealfor alldiecastingapplicationsthatcanbenefitfromincreasedairevacuationforreducedpartporosity.

featUres• Largeflowareatoenhanceventingwithoutflash

• Sevenstocksizesavailableorcustomdesign toyourspecifications

• AvailableinpremiumH-13steel,pre-hardH-13steel,orberyllium-freecopper

• Canbewatercooled

• MostexistingdiescanberetrofittedtoacceptUltimateVentBlocks

• Complementaryassistancetocalculatetheneededventingareaforyourcastingapplication

ProdUct oVerViewTheVariablePatternprovidesanoptionforapplicationswhereexcessivestickingorbreakingofthemetalintheValve-LessBlockflowareaisanissue.TheVariablePatterncanberequestedbyadding–VariabletotheendofanyValve-LessBlockcatalognumber.

oPerationRadiiontheteethneartheinputendofthepatternallowforthickermaterialbuild-uptopreventbreakingduringrelease.Flatgeometryonthetopofteethneartheoutputendofthepatternhelptopreventblow-throughofmaterial.Increaseddraftofthesideanglesoftheteethassistswithreleaseofthesolidifiedmetal.

aPPlicationTheVariablePatternisidealforalldiecastingapplicationsthatcanbenefitfromreducedporosityandwherestickingofmetalwithintheflowpatternisofconcern.

featUres• Flowpatterndesignedtofacilitatereleaseofsolidifiedmetal

• InterchangeablewithallStandardValve-LessVacuum,UltimateVentandSuperChillBlocks

Teethontheinputendofthepatternhaveradiiwhileteethontheoutputendhaveaflatprofile

Increaseddraftofsideanglesontheteethassistswithreleaseofmetal

optional Variable Patterntm

Patent#8,424,587B1

midland materialsqUality materials for VarioUs aPPlications

Ultimate Vent and standard VacUUm Blocks (PremiUm h-13 steel)Valve-LessBlocksmadefrompremiumH-13steelareidealfordiesusedinlongproductionrunsofaluminumcastings.Heat-treatedto44-46HRC,premiumH-13steelValve-LessBlockshavehigherresistancetoheat-check,cracking,andwearcausedbythermalshock.

featUres:

• Durableforlongproductionruns• Heat-treatedto44-46HRC• Highresistancetothermalshock

e-series Vent and VacUUm Blocks (Pre-hard h-13 steel)Valve-LessBlocksmadefrompre-hardH-13steelwithMelonitesurfacetreatmentareidealfordiestobeusedinproductionofzincormagnesiumcastings,ormaybeusedforshortproductionrunsofaluminumcastings,typicallyupto50,000shots.ToorderEBlocksadd–EtotheendofaStandardVacuumBlockorUltimateVentBlockpartnumber.(i.e.UVS-2500-E)

featUres:

• Idealforcastingwithzincormagnesium• Canbeutilizedforcastingaluminuminshortproductionruns• Pre-hardH-13steelis35-36HRC• Melonitetreatmentofferssurfacehardnessof60-65HRC

UVc Vent and sUPer chill VacUUm Blocks (BerylliUm-free coPPer)Beryllium-freecopperisidealforrepeatedheatingandcoolingcyclesinsituationswhereveryhighthermalconductivityisrequired.Beryllium-freecopperhasthesamecoolingcharacteristicsasberylliumcopperbutwithoutthetoxicityorenvironmentalconcern.

featUres:

• Noreactivitywithaluminummeanslesssticking• Highthermalconductivity• Notoxicitywhenmachining

MidlandTechnologieswillcalculatetherequiredevacuationareaforacastingandproviderecommendedventblocksizeswhenaBlockSizingFormisreceived.TheBlockSizingFormcanbedownloadedorfilledoutonlineatwww.midlandtechnologies.com.

Considerationofventblockplacementinrelationtothecavityisimportantforachievingthebestresult.Ventblocksaremostoftenplacednearlastareatofillinthecasting.MidlandTechnologiescanassistwithselectionofplacementforventblocksinrelationtothediecavityandprovideasuggestedventblockrunnerlayoutwhena3Dlayoutofthetoolisprovided.

Ultimate Vent Block flow areas

size and Placement of Vent Blocks

flow areas

rUnner information

Ultimate Vent Block dimensionsstationary

Patent#7,134,637

Model No. W L T P P1 P2 P3 S S1 S2 S3 S4 THD NPT B B1 BC

±.001 ±.001⁺.001⁻.000 ±.005 ±.0005 ±.001 ±.005 ±.02 ±.02 ±.02 ±.02 ±.02 ±.02 ±.02

SHCS BoltClearance

UVS-‐Mini 2.250 3.540 1.000 1.250 0.625 1.500 1.246 0.875 0.313 ― ― 2.375 1/4-‐20 1/8 0.438 0.750 ―

UVS-‐2500 2.500 5.940 2.000 2.340 0.750 3.000 1.496 1.000 0.500 2.250 4.000 ― 1/4-‐20 1/4 0.755 0.625 3/8

UVS-‐4000 3.938 5.940 2.000 2.340 0.750 3.000 2.996 1.250 0.375 4.250 ― ― 3/8-‐16 1/4 0.755 1.460 3/8

UVS-‐4500 4.566 5.940 2.000 2.340 0.750 3.000 2.996 1.905 0.500 3.500 ― ― 3/8-‐16 1/4 0.755 1.460 3/8

UVS-‐5500 5.512 5.940 2.000 2.340 0.750 3.000 2.996 2.375 0.500 3.500 ― ― 3/8-‐16 3/8 0.835 1.890 1/2

UVS-‐6500 6.500 5.940 2.000 2.340 0.750 3.000 2.996 2.375 0.500 3.500 ― ― 3/8-‐16 3/8 0.835 1.890 1/2

UVS-‐8000 8.000 6.440 2.000 2.340 0.875 3.000 2.996 2.875 0.625 3.625 ― ― 1/2-‐13 3/8 0.835 1.890 1/2

Ultimate Vent Block dimensionsejector

Patent#7,134,637

Model No. W L T P P1 P2 P3 S S1 S2 S3 S4 THD NPT RD RB RA B B1 BC

±.001 ±.001⁺.001⁻.000 ±.005 ±.0005 ±.001 ±.005 ±.02 ±.02 ±.02 ±.02 ±.02 ±.005 ±.005 ±1° ±.02 ±.02

SHCS BoltClearance

UVS-‐Mini 2.250 3.500 1.000 1.250 0.500 1.500 1.246 0.875 0.313 ― ― 2.375 1/4-‐20 1/8 0.203 0.241 10° 0.438 0.750 ―

UVS-‐2500 2.500 5.900 2.000 2.340 0.625 3.000 1.496 1.000 0.500 2.250 4.000 ― 1/4-‐20 1/4 0.203 0.241 10° 0.755 0.625 3/8

UVS-‐4000 3.938 5.900 2.000 2.340 0.625 3.000 2.996 1.250 0.375 4.250 ― ― 3/8-‐16 1/4 0.277 0.328 10° 0.755 1.460 3/8

UVS-‐4500 4.566 5.900 2.000 2.340 0.625 3.000 2.996 1.905 0.375 3.375 ― ― 3/8-‐16 1/4 0.298 0.352 10° 0.755 1.460 3/8

UVS-‐5500 5.512 5.900 2.000 2.340 0.625 3.000 2.996 2.375 0.375 3.375 ― ― 3/8-‐16 3/8 0.375 0.375 10° 0.835 1.890 1/2

UVS-‐6500 6.500 5.900 2.000 2.340 0.625 3.000 2.996 2.375 0.375 3.375 ― ― 3/8-‐16 3/8 0.369 0.436 10° 0.835 1.890 1/2

UVS-‐8000 8.000 6.400 2.000 2.340 1.000 3.000 2.996 3.000 0.625 3.625 ― ― 1/2-‐13 3/8 0.472 0.537 5° 0.835 1.890 1/2

Vacuum and Vent Block sizing formThefollowinginformationisutilizedtocalculatethenecessaryevacuationareaforthecastingapplicationandtosuggestanappropriatevacuumorventblocksize.Theaccuracyoftheinformationprovidedcanaffectresultsofthecalculation.Wherepossible,providinga3Dpartmodelwillhelptoconfirmneededdata.Pleasenoteyourunitsofmeasure.

installing Ultimate Vent Blockscorrect installation of Ultimate Vent Blocks is critical to ProPer fUnction.

ItisoptimaltoinstallUltimateVentBlocksdirectlyintothemoldbasewheneverpossible.UltimateVentBlocksshouldbeinsertedatleast4.50”fromtheedgeofthemoldbase.TheinletsidesofbothhalvesoftheUltimateVentBlockmustbeflushtothediecavityinsertandmateevenlywitheachotherwhenintheclosedcondition.there should be approximately a .040” mismatch in height between the stationary and ejector halves of the Ultimate Vent Block when installed correctly.ThepartinglineoftheUltimateVentBlockhalvesshouldbepositionedflushto,or.001”-.002”proudtothediecavityinsert.

Keysareprovidedineachblocktoensurealignmentbetweenthestationaryandejectorhalves.Ifpocketsarenotcorrectlymachinedtotolerance,thekeymaynotholdandshiftinblockcouldoccur.Thiscanresultinshutoffofventing.

Waterisprovidedintheblocksusingthehorizontalmountingholes.Ifwaterisused,theverticalholeswillbeusedtoretaintheblocks.

.0005"

Mismatch.040" REF

RecommendedMinimum of 4.500"

(4.750" for 8000 series)

StationaryEjector

Die inserts orRunner inserts

Vent blocks flushto +.002" proud

Screws(Option 2)

Screws(Option 1)

installing Ultimate Vent Blocks Using outboard support

• SquareandgrindflatsonmoldbaseformountingoutboardsupportsandUltimateVentBlocks

• Installlocatingdowelsbetweenthemoldbaseandoutboardsupportblocks

• Useadequateboltstoconnectoutboardsupportstomoldbase

• InstallH-13ventrunnerinsertorcutrunnerpatternintothemoldsettoconnecttheUltimateVentBlockswiththediecavityinsert

• EnsurethattheUltimateVentBlocksarepositionedataminimumofflushto,or.001”-.002”proudtothediecavityinsert

Top View

Back upplate

Side View

Ejector pin

Supportrails

Supportblocks

UltimateVentBlocksallowformoreefficientventingthanconventionalvents.Notonlyismoreairevacuatedandriskofflashreduced,buttheventrunnersthattietheUltimateVentBlocktothediecavityinsertalsodonotoxidizeduringremeltasseverelyasconventionalvents.Thisallowsthecastertoreclaimmorecastingalloycontributingtooveralljobprofitabilitywhileatthesametimereducingporositythroughimprovedventing.

Correctlydesigningventrunnersfromthecavitytotheventblockiscriticaltoproperventing.Ventrunnersshouldbedesignedtocontrolvelocityoftheexitingmetalwhileprovidingsufficientareaforairandgasevacuation.Thisisachievedbydesigningaventrunnersystemwhichcreatesapressuredropandprovidessufficientresistancetoslowthemetal.Properejectionoftherunnersmustalsobetakenintoconsideration.

MidlandTechnologieswillofferasuggestedventblockrunnerlayoutspecifictoadiewhenMidlandUltimateVentBlocksarepurchasedanda3Dlayoutofthetoolisprovided.

considerations for Vent Block runners

need assistance with Vent runners?

custom Vent Blocks

• CustomDimensions• CornerRadii• DoubleFlowAreas• EjectionPins• CustomWaterLines• Steps

alternative formatsPictUre frame BlockThePictureFrameformatisafrontloadingdesignforapplicationswhereitisdesirabletoinstallorremovetheValve-LessVacuumorUltimateVentBlockwithoutremovingthediefromthediecastingmachine.

TheBlockissecuredinitspocketbytworetainerbarsthatareboltedfromthefront.SlotsarecutintotheValve-LessBlocktoprovideforeasyremovalfromthepocket.ThePictureFrameformatalsoprovidesincreasedshutoffareaonthesidesoftheValve-LessBlock.

semi-cUstom BlocksAt timesitmaybedesirabletohavealargershutoffareathanthatofstandardValve-LessBlocks.ItispossibletoordertheflowareafromasmallerstandardValve-LessBlockonthefootprintofalargerValve-LessBlock.

SpecifythecatalognumberoftheValve-LessBlockfromwhichflowareayourequireandwhichlargerValve-LessBlockfootprintyouwouldliketoorder.Asopposedtofullcustomdesigns,thereisnoprogramminganddesignchargeforthesesemi-customrequests.

cUstom ValVe-less Blocks for large castingsMidlandcandesignandmanufactureyourcustomValve-LessVacuumorVentBlocksforlarge castingapplications.

Withfulldesignandprogrammingcapabilities,anddecadesofexperiencecalculatingcorrectevacuationareasforventingorvacuumofhighpressuredies,MidlandcanhelpdelivereffectiveValve-LessBlocksforyourspecificapplication.

Additionally,ourtechnicalexpertscansuggestanoptimalValve-LessVacuumorUltimateVentBlockrunnerlayoutforyourapplication.

FlowArea OverallWidthModel

2.250in.

2.500in.

3.938in.

4.566in.

5.512in.

6.500in.

8.000in.

.035in2

.040in2

.070in2

.080in2

.100in2

.120in2

.140in2

mini250040004500550065008000

EJECTORSIDESTATIONARySIDE

IfyourdieiscurrentlyrunningvacuumvalvesyoumaybeabletoswitchtoUltimateVentBlocksinordertoreducemaintenanceissuesassociatedwithvalves.Midlandwillworkwithyoutodetermineifpassiveventingcanbeusedwiththespecificcastingapplication.ThefirststepistofilloutandsubmitaBlockSizingformfoundatwww.midlandtechnologies.comsothatwecancalculatetheareaneededforsufficientairandgasevacuationofthediecavityinsert.

RetrofittingexistingtoolstoutilizeUltimateVentBlocksrequiresspecialconsiderationofalignmentofeachhalfofthedie.Acheckoftheclearancebetweenleaderpinsandbushingsshouldbeperformed,andifnottooriginaldimensions,newpinsandbushingsarerecommendedtoensureproperclearanceinUltimateVentBlocks.

sPacer Blocks

SpacerblockscanbeutilizedtoinstallUltimateVentBlocksintoapre-existingpocketforvacuumvalves.Ensurethattheoutletrunnerfromthedieinsertismatedtothecorrectblockhalfwhenretrofitting.

cUstom Blocks

MidlandcansupplycustomUltimateVentBlockstofitthepre-existingpocketofyourformervacuumvalve.Provideuswithpocketdimensions,boltlocationsanda3Dmodelofyourtoollayouttobeginutilizingthemostefficientpassivedieventingmethodonthemarket.

oVersiZed Vent Blocks to fit VacUUm ValVe Pocket

Retrofitting Vacuum Valves

MidlandcanmanufactureH-13runnerinsertswithyourcustomventrunnerpatterntoconnectthediecavityinserttoUltimateVentBlocks.H-13runnerinsertscanbeinstalledquicklyandeasily.Runnerinsertsarealsousefulasacommontie-inpointwhenutilizingUltimateVentBlocksinUnitDiesthatwillrunmultipledifferentcavityinserts.

Specifytheouterdimensionsforyourinsertandprovidea3Dmodeloftherequiredrunnerpattern.Midlandcanalsoprovidetechnicalassistancefordesigningventrunnerlayoutsuponrequest.

custom h-13 Vent runner inserts

Provide3DmodelofthepatternorrequestassistancefromMidland

Length

Thickness

Length

Focusonyourmostvalue-addedactivitiesandletMidlandtakecareoftherest!

14800JamesRoad Tel: (763)428-4229 Rogers,MN55374 Fax:(763)428-4720

www.midlandtechnologies.comcorPorate memBer

Made in U.S.A.

06/14v.1

Ultimate Vent Blocks -...

Documents