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
4 midland technologies, inc. B
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
$0.26
$0.33
$0.40$0.45
$0.40
$0.35
$0.30
$0.25
$0.20
$0.15
$0.10
$0.05
• Anextra13.3hoursofpressruntimetoproduce10,000goodparts• Anextra$2,660-$3,990inextrapresstimedependingonpressrate• Anextra$0.26-$0.40pergoodpartinextrapresstimedependingonpressrate
(763) 428-4229 | midlandtechnologies.com 5B
• 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
3.5
3
2.5
2
1.5
1
0.5
0
UVS-
MIN
I
UVS-
2500
UVS-
4000
UVS-
4500
UVS-
5500
UVS-
6500
UVS-
8000
1.5 ¢
1.9 ¢
2.6 ¢ 2.7 ¢ 2.8 ¢
3.0 ¢3.3 ¢
6 midland technologies, inc. B
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
(763) 428-4229 | midlandtechnologies.com 7B
}
}
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
8 midland technologies, inc. B
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
(763) 428-4229 | midlandtechnologies.com 9B
MidlandTechnologieswillcalculatetherequiredevacuationareaforacastingandproviderecommendedventblocksizeswhenaBlockSizingFormisreceived.TheBlockSizingFormcanbedownloadedorfilledoutonlineatwww.midlandtechnologies.com.
Considerationofventblockplacementinrelationtothecavityisimportantforachievingthebestresult.Ventblocksaremostoftenplacednearlastareatofillinthecasting.MidlandTechnologiescanassistwithselectionofplacementforventblocksinrelationtothediecavityandprovideasuggestedventblockrunnerlayoutwhena3Dlayoutofthetoolisprovided.
Ultimate Vent Block flow areas
size and Placement of Vent Blocks
flow areas
rUnner information
10 midland technologies, inc. B
Ultimate Vent Block dimensionsstationary
Patent#7,134,637
B
B1
BC
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
(763) 428-4229 | midlandtechnologies.com 11B
Ultimate Vent Block dimensionsejector
B
B1
BC
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
12 midland technologies, inc. B
Vacuum and Vent Block sizing formThefollowinginformationisutilizedtocalculatethenecessaryevacuationareaforthecastingapplicationandtosuggestanappropriatevacuumorventblocksize.Theaccuracyoftheinformationprovidedcanaffectresultsofthecalculation.Wherepossible,providinga3Dpartmodelwillhelptoconfirmneededdata.Pleasenoteyourunitsofmeasure.
(763) 428-4229 | midlandtechnologies.com 13B
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)
14 midland technologies, inc. B
installing Ultimate Vent Blocks Using outboard support
• SquareandgrindflatsonmoldbaseformountingoutboardsupportsandUltimateVentBlocks
• Installlocatingdowelsbetweenthemoldbaseandoutboardsupportblocks
• Useadequateboltstoconnectoutboardsupportstomoldbase
• InstallH-13ventrunnerinsertorcutrunnerpatternintothemoldsettoconnecttheUltimateVentBlockswiththediecavityinsert
• EnsurethattheUltimateVentBlocksarepositionedataminimumofflushto,or.001”-.002”proudtothediecavityinsert
Top View
Dow
elpi
ns
Back upplate
Back upplate
Sid
em
ount
ing
bolts
Side View
Grin
d b
oth
sides
to m
atch
Ven
tru
nner
inse
rts
Ejector pin
Cav
ityin
sert
Forc
ein
sert
Supportrails
Supportblocks
(763) 428-4229 | midlandtechnologies.com 15B
UltimateVentBlocksallowformoreefficientventingthanconventionalvents.Notonlyismoreairevacuatedandriskofflashreduced,buttheventrunnersthattietheUltimateVentBlocktothediecavityinsertalsodonotoxidizeduringremeltasseverelyasconventionalvents.Thisallowsthecastertoreclaimmorecastingalloycontributingtooveralljobprofitabilitywhileatthesametimereducingporositythroughimprovedventing.
Correctlydesigningventrunnersfromthecavitytotheventblockiscriticaltoproperventing.Ventrunnersshouldbedesignedtocontrolvelocityoftheexitingmetalwhileprovidingsufficientareaforairandgasevacuation.Thisisachievedbydesigningaventrunnersystemwhichcreatesapressuredropandprovidessufficientresistancetoslowthemetal.Properejectionoftherunnersmustalsobetakenintoconsideration.
MidlandTechnologieswillofferasuggestedventblockrunnerlayoutspecifictoadiewhenMidlandUltimateVentBlocksarepurchasedanda3Dlayoutofthetoolisprovided.
considerations for Vent Block runners
need assistance with Vent runners?
16 midland technologies, inc. B
custom Vent Blocks
• CustomDimensions• CornerRadii• DoubleFlowAreas• EjectionPins• CustomWaterLines• Steps
(763) 428-4229 | midlandtechnologies.com 17B
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
18 midland technologies, inc. B
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
(763) 428-4229 | midlandtechnologies.com 19B
MidlandcanmanufactureH-13runnerinsertswithyourcustomventrunnerpatterntoconnectthediecavityinserttoUltimateVentBlocks.H-13runnerinsertscanbeinstalledquicklyandeasily.Runnerinsertsarealsousefulasacommontie-inpointwhenutilizingUltimateVentBlocksinUnitDiesthatwillrunmultipledifferentcavityinserts.
Specifytheouterdimensionsforyourinsertandprovidea3Dmodeloftherequiredrunnerpattern.Midlandcanalsoprovidetechnicalassistancefordesigningventrunnerlayoutsuponrequest.
custom h-13 Vent runner inserts
Provide3DmodelofthepatternorrequestassistancefromMidland
Provide3DmodelofthepatternorrequestassistancefromMidland
Length
Thickness
Thickness
Width
Width
Length
Focusonyourmostvalue-addedactivitiesandletMidlandtakecareoftherest!
14800JamesRoad Tel: (763)428-4229 Rogers,MN55374 Fax:(763)428-4720
www.midlandtechnologies.comcorPorate memBer
Made in U.S.A.
Made in U.S.A.
06/14v.1