Die Cast Chill Vents - DME Catalog - na. · PDF filewith Vacuum Machine ... Die Cast Chill...
6
Die Cast Chill Vents Optimizing part quality through efficient exhaustion
Transcript of Die Cast Chill Vents - DME Catalog - na. · PDF filewith Vacuum Machine ... Die Cast Chill...
11
Die Cast Chill Vents
Optimizing part quality through efficient exhaustion
U.S. 800-626-6653 n Canada 800-387-6600 n www.dme.net
D-M-E
Die Cast Chill Vents
Chill Vent Features & Benefits•Chill vents are often used with permanent molds for die casting light
metalssuchasaluminumandmagnesium.Thechillventfunctionsasameansofefficientlyexhaustingresidualairand/orgasfromtheinsidetotheoutsideofadiecastmoldcavity.
•Chillventsminimizethespoutingofmoltenmetalandreduceflashingwhenchargingmoltenmetalintothediecavity.
•Ifresidualairand/orgasremainsinthediecavity,theresultmaybegasholesinthecastingsthatdegradeproductquality.
•Gasexhaustpassagedesignisgenerallyshapedinazigzagmannertoensurethatafterthegashasbeenexhaustedoutsideofthechillvent,themoltenmetalwillbechilledinthezigzagpassagebeforeitisflashedoutside of the permanent mold. However, since molten metal flowsunderhighpressure,itisdifficulttocompletelypreventflashingevenbyincreasingthelengthofthechillvent.
Why Chill Vents?•Tool steels, although high in hardness, have low thermal conductivity, and, therefore, cannot rapidly remove heat from non-
solidifiedmoltenmetalbeforeflashingoccurs.
•Sincebothhighhardnessandsuperiorthermalconductivityarecriticalrequisitesinachievingacceleratedcoolingofmoltenmetalunderhighpressure,ithasbeenconsideredthatcopperalloyswouldprovidesuperiorthermalconductivity.However,fewcopperalloysprovideboththermalconductivityandhardnessincombinationsufficienttowithstandthepressurethatresultsindiecastingmoltenmetal.
•Additionally,copperalloysaregenerallydifficulttouseformoldsbroughtintocontactwithmoltenmetalbecausetheyareeasilydissolvedbylightmetalalloyscomparedtotoolsteel.
•Conventionalchillventmaterialhasbeenpredominantlymadeoftoolsteel,typicallythesameasthepermanentmoldcavity.Itisnecessarythatthechillventbeashardasthepermanentmoldcavityduetothehigh-pressureconditionthatdevelopswhenthemoltenmetalischargedintothechillvent.
Why Beryllium Copper?•Onlyonealloy,berylliumcopper,canprovideboththehardnessand
thermal conductive properties required for use as a chill vent inaluminumand/ormagnesiumdiecasting.
•Beryllium copper also provides the benefit of causing a passive-stateoxidefilmtobeformedonthesurfaceofthechillvent,therebypreventingdissolutionbylightmetalalloys.
•Thesefactorsprovideaneffectivemeansofexhaustingairandgasesoutside themoldwithoutbeingdissolvedwhile chilling themoltenmetalbeforeflashingoccurs.
•As a further consideration, the addition of water cooling pipes inthechillventwillservetoimprovetheoverallcoolingpowerwhichcanresultinashorteningofthelengthofthegasexhaustpassage,leadingtoasmallerchillvent,thusincreasingdiespace.
2
U.S. 800-626-6653 n Canada 800-387-6600 n www.dme.net
3
D-M-E
Die Cast Chill Vents
Reduces Porosity•Large vent gap promotes better venting
(3-8 timesbetterthanconventionalH13)
•Longer effective vacuum time sincethemetalalwaysfreezesinthevent(Avoidsthetimelagcausedbythevacuumvalve)
Cuts Downtime & Maintenance Costs with Vacuum MachineD-M-EChillVentscanbeusedwithavacuummachinein place of the vacuumvalve,reducingmaintenancecost,downtimeandporosity.•Protectsvacuumsystemfrommoltenaluminum
– Vacuum valvecanbereplacedwithaD-M-Echillvent– Highsolidificationratepreventsaluminumfromenteringthevacuumequipment
•Easytouse– Itssimple structure requiresnospecialknowledgeortechnique
Minimizes Sticking•Copper doesn’t promote a chemical reaction withaluminumcomparedwithH13•Thethicker wafflefromthelargeventgapiseasilyremoved,andishigher
qualityscrap•Low surface temperature duetohighconductivityfurtheravoidssticking
Saves Die SpaceThesizeofventareacanbehalfthatneededforH13duetohighersolidificationperformance.Thisreducethetotaldiearea.
Why D-M-E Chill Vents?1) Made of Hard Copper Alloy (Beryllium Copper)
•Noreactionwithaluminum No “Sticking”•*H13reactswithaluminum Causes“Sticking”
2) High Thermal Conductivity
Vacuum System
Overflow
CastingProduct
(Plunger)(Die)
D-M-E Chill-Vent installedin place of vacuum valve
Vacuum Pump
Compatible with Vacuum Machine
Air
H13 0.020”(0.5 mm)
Vent gap
D-M-E0.028”– 0.043” (0.7–1.1 mm)
*BerylliumcopperisseventimesmoreconductivethanH13forfasterchillingandfastersolidificationofthemoltenalloy.
*Allowsalargerventgap(1.4to1.8timeslargerthanH13)forbettergasexhaustibility(3to8timesmorethanH13)toreduceporosity!
D-M-E C/V H13 C/V
Solidify Eruption!
Product Availability
•CopperAlloy(BerylliumCopper)suppliedbyNGKBerylCo./NGKMetalsCorp.
•AllcopperalloyrecommendedforA390,zincandallalloys
•Vacuum/non-vacuumtype
•Customdesignsarewelcome
U.S. 800-626-6653 n Canada 800-387-6600 n www.dme.net
D-M-E
Die Cast Chill Vents
IMPORTANT SAFETY INFORMATION
DANGER
BEFOREUSINGTHISPRODUCT,REFERTOIMPORTANTSAFETYINFORMATIONATMANUFACTURER’SWEBSITE:http://www.ngkmetals.com/index.cfm/m/19
ADDITIONALINFORMATIONMAYBEFOUNDAT:http://www.osha.gov/dts/hib/hib_data/hib19990902.html
READALLINSTRUCTIONSBEFOREHANDLINGTHISPRODUCTINCLUDINGTHEMSDS.THISINSTRUCTIONISTOBEPROVIDEDTOTHEENDUSER.
INSTALLATION INSTRUCTIONSPOCKET DIMENSIONS
ITEM NUMBER
“Xp”+ 0.030 / + 0.010
(+ 0.0012 / + 0.0004”)
“Yp”+ 0.030 / + 0.010
(+ 0.0012 /+ 0.0004”)“Zp”
VSCL7US 135.000 (5.3150”) 80.000 (3.1496”)SEE
POCKET NOTES
VLCL7US 175.000 (6.8998”) 90.000 (3.5433”)
VECL7US 185.000 (7.2835”) 100.000 (3.9370”)
Dimensions shown are in millimeters (inches).
POCkET NOTES:
• PerpendicularityandparallelismofpocketsmustbemachinedsuchthatChillVentinserthalvesmateafterinstallationwithoutgapsbetweeninserthalves.
• CornerradiiofChillVentinsertpocketsaretobemachinedtosuitdimensionsshown.• Allsurfacesofpocket tohaveasurfacefinishnogreater than0.8μm(micrometers).
Checkforburrs.• ForZp,useshimpacktoaccommodateflushness.Flushnesstolerancemustbe+0.05/–0
(+0.002/–0”).ZpmustbegreaterthanZ(appliestobothinserthalvesandpockets).
CHILL VENT DIMENSIONS
ITEM NUMBER
“X“ + 0 / – 0.06
(+ 0 / – 0.003”)
“Y” + 0 / – 0.05
(+ 0 / – 0. 02”)
”Z” + 0.05 / – 0
(+ 0.002 / – 0”)
Ø D1+ 0.02 / – 0
(+ 0.00 / – 0”)”P”
”k” +/– 0.046
(+/– 0.0018”)”B” SCREW
THREAD “L1””F1 “
× THREAD DEPTH
Ø D2 “T”
VSCL7US 135.00 (5.315”)
80.00 (3.150”)
50.00 (1.968”)
10.00 (0.394”)
26.0 (1.02”)
55.00 (2.165”)
40.0 (1.575”)
5/16 – 18 UNC
20.00 (0.787”)
1/2 – 14 × 10.0
NPT (0.39)
18.00 (0.709”)
45.00 (1.772”)
VLCL7US 175.00 (6.890”)
90.00 (3.543”)
50.00 (1.968”)
10.00 (0.394”)
30.0 (0.18”)
65.00 (2.559”)
60.0 (2.36”)
1/2 – 13 UNC
25.00 (0.984”)
3/4 – 14 × 12.0
NPT (0.47)
23.00 (0.906”)
45.00 (1.772”)
VECL7US 185.00 (7.283”)
100.00 (3.937”)
50.00 (1.968”)
10.00 (0.394”)
35.0 (1.38”)
65.00 (2.559”)
60.0 (2.36”)
1/2 – 13 UNC
25.00 (0.984”)
3/4 – 14 × 12.0
NPT (0.47)
23.00 (0.906”)
50.00 (1.968”)
Zp
Yp
(Example pocket forone half of Chill Vent
Insert Assembly)
Yp
Xp
CHILL VENT POCkET DETAIL
4
D-M-E
Die Cast Chill Vents
U.S. 800-626-6653 n Canada 800-387-6600 n www.dme.net
CHILL VENT INSERT – DETAIL
INSTALLATION NOTES:
• 10mmDINEjectorPin tobeusedwith thisproduct
• Key slots provided on product as shown.Customerisresponsibleforkeyingproduct.
• Tap threads are provided in product forretainingscrews.Customertosupplyscrews.
• Customer to supply NPT pipe fittings.High temperature pipe thread sealant isrecommendedtobeusedwiththisproduct.
• Once installed, Chill Vent insert halvesmustalignproperlytoachievegoodseal-offbetween mating surfaces. Use a blue-offcompound to check for proper fit. Adjustshim pack accordingly during installationuntildesiredmatingseal-offisachieved.
NOTICE:D-M-E shall not be liable for misuseor failure to follow the enclosedinstructions and specifications. D-M-Eherebydisclaimsallimpliedwarranties,including merchantability and fitnessfor a particular purpose. In no eventshallD-M-Eberesponsiblefor lossofuse,revenueorprofit,orforincidentalorconsequentialdamages.
20.00 ± 0.08(.787 ± .002)
B
X
L1
1/4 – 18 NPTThread Depth– 8.0 (.32)(2)
PP
Y
Z
F1
Ø D2
K
T SCREWTHREAD
SHARPCORNER
13.6 (2)(.54)
20.0
(.79)
18.6
(.73)
TOP HALF
SHARP CORNER
SCREWTHREAD
X
PP
Y
5.00 REF(.197)
R3.0(.12)
R0.51(. 020) 20.00±0.06
(.787±002) 1/4 –18 NPTThread Depth– 8.0 (.32)(2)
0.5 (Max) × 45 DEG (.12)
15.00 ± 00.06(.591 ± .002)
1.0
x 45
DEG
(. 04
)
Ø D1
20.0
(.79)
5.00
(.197
)
20.0
(.79)
20.0
(.79)
6.00
(.236
)
22.0
(.87)
B
Z
K
T
BOTTOM HALF
NOTE: Dimensionsshownareinmillimeters(inches).
5
World Headquarters D-M-E Company29111StephensonHighwayMadisonHeights,MI48071800-626-6653 toll-free tel248-398-6000 tel888-808-4363 toll-free faxwww.dme.net [email protected] e-mail
D-M-E of Canada, Ltd.6210NorthwestDriveMississauga,OntarioCanadaL4V1J6800-387-6600 toll-free tel905-677-6370 tel800-461-9965 toll-free [email protected] e-mail
D-M-E EuropeD-M-EBelgiumC.V.B.A.IndustrieparkNoordB-2800MechelenBelgium32-15-215011 tel32-15-218235 [email protected] e-mail CV
-8/0
9
D-M-E,anessentialresourcetothecustomersitservesworldwide,offerstheindustry’sbroadestrangeofmarket-leadingproducts,unsurpassedknowledgeandexpertise,agloballogisticsinfrastructurethatensuresspeedandaccuracy,andasupportorganizationunrivaledforitsabilitytoassistcustomerswhenandwheretheyneedit.Acompletelineofunitdies,diecomponents,hotrunnersystems,controlsystems,moldbases,MUDquick-changemoldsystems,moldcomponents,moldmakingandmoldingsupplies,coldrunnersystemsforelastomers,andtechnicalserviceshelpscustomerscompeteeverystepoftheway.
SeethecompletelineofD-M-Ediecastdieassemblies,unitdiesandcomponentsatwww.dme.net/dme/resources/catalog.html
orD-M-EcallCustomerServicetorequestaprintedcatalog.
