Vacuum Pumps and Accessories www.midlandtechnologies.com
Vacuum-Assist Die Casting Why Vacuum-Assist The two leading causes for rejection of high pressure castings are poor fill and excessive porosity. Vacuum-assist is an effective tool to combat both poor fill and air porosity when casting aluminum, zinc, magnesium or brass parts that are difficult to fill or have low porosity requirements. Difficult to Fill Thin walls or ribs Sharp angles Standing posts Low Porosity Requirements Pressure sensitive components Structural castings Cosmetic parts Vacuum-Assist as a Production Process Incorporating vacuum-assist when first quoting a part can help to maximize job profitability and minimize potential loss by ensuring proper air and gas evacuation from the start. Promote Higher casting yields Faster job completion with less press time More efficient casting processes Avoid High fallout rates due to porosity or poor fill Downtime while troubleshooting Resources spent troubleshooting Vacuum-Assist as a Corrective Process Vacuum-assist can be a highly effective remediation tool when a casting presents unacceptable or undesirable fallout rates due to poor fill or excessive air and gas porosity. Midland Technologies provides the service of reviewing specific casting porosity and fill issues to evaluate applicability of vacuum-assist. Getting started with Vacuum-Assist Step 1: Complete and submit a Vacuum Block Sizing Form (found on our website). If available, please send us a 3D model of the part and shot. If you have an existing casting with porosity or fill issues, please include a picture of the problem where possible. Step 2: Midland will calculate the required evacuation area for the casting and then recommend the correct Valve-Less Vacuum Blocks. If it is an existing casting, Midland will first evaluate the casting issue to determine if vacuum-assist is likely to help. Step 3: Provide a 3D layout of the die with a purchase order for the recommended Valve-Less Vacuum Blocks. Midland will provide you with a recommended vacuum block exit runner layout to help ensure optimal function. C2 Midland Technologies, Inc.
Vacuum-Assist Die Casting Basic Principle of Vacuum-Assist Casting Vacuum-assist operates by means of a pressure differential. A vacuum pump creates a vacuum atmosphere within a receiver tank that will contain less matter than the ambient atmosphere. The volume of air that is present within the cavity and shot sleeve (V C ) will move to fill the lower pressure receiver tank at a theoretical maximum speed (v s ) of 340 m/s. The exit flow rate of air (R v ) from the die is limited by the smallest area of the exit orifice (A) in the mold set. If the volumetric flow rate of air is assumed to be constant, then the time required to evacuate the cavity (t e ) can be approximated as: When utilizing Valve-Less Vacuum Blocks, the pathway between the vacuum receiver tank and the die is governed by a solenoid valve. The solenoid valve is opened using a PLC, limit switch or timer when the pour hole of the shot sleeve is covered by the plunger. Valve-Less Vacuum Blocks allow the pathway to remain open throughout solidification to simplify process planning. Sizing Vacuum Pumps and Receiver Tanks Correctly sizing vacuum pumps and receiver tanks for specific applications is critical to proper function. Vacuum pumps generate the vacuum level within a defined volume that is the receiver tank. Vacuum level is measured in relation to ambient atmospheric pressure and reported in units such as Torr, inches of mercury ( Hg), Pascals (Pa) or millibar (mb). The critical feature of the pump is the speed at which it can evacuate a volume of air down to a particular vacuum level as measured by average cubic feet per minute. If the pump is too small, it will not be able to achieve sufficient vacuum within the shot cycle. If the tank is too small, it will not provide a sufficient reservoir to evacuate air from the cavity. Midland Technologies can calculate the required pump and tank size for your specific casting application. Checklist when Utilizing Vacuum Vacuum pump is properly sized for the casting application Correct size and quantity of vacuum blocks provide sufficient area for evacuation Proper vacuum block runner design from the cavity to manage velocity Vacuum blocks are correctly installed in the die Proper filtration between the press and the vacuum pump Proper maintenance is performed on vacuum blocks, pump, filters and hoses Floor operators understand how to turn the vacuum process on and off (763) 428-4229 midlandtechnologies.com C3
Vacuum-Assist Casting Process with Valve-Less Blocks The advantage of vacuum-assist die casting with Valve-Less Vacuum Blocks is simplicity! Step 1 Pre-Injection Solenoid is closed Vacuum pump evacuates the receiver tank down to vacuum level Die is in the closed position Closed 1.0 or 1.5 dia. hose x 15 Filters Step 2 Evacuation of Cavity/Injection Injection begins Solenoid on vacuum system opens when plunger tip covers pour hole Air evacuates from the sleeve and cavity through the vacuum block Slowing down the slow shot can increase time for air evacuation Open 1.0 or 1.5 dia. hose x 15 Filters Filters Step 3 Solidification Cavity fill and solidification Vacuum can remain on throughout solidification for process simplicity and to ensure maximum evacuation Open 1.0 or 1.5 dia. Hose x 15 Step 4 Casting Ejection/Recovery Solidification complete Solenoid on vacuum system closes Die opens and casting is ejected Vacuum pump recovers vacuum level in receiver tank as necessary Cycle repeats Closed 1.0 or 1.5 dia. Hose x 15 Filters C4 Midland Technologies, Inc.
Vacuum Pump Sizing Form MIDLAND WILL PROVIDE A RECOMMENDED VACUUM SYSTEM WHEN THE INFORMATION BELOW IS SUPPLIED. VISIT WWW.MIDLANDTECHNOLOGIES.COM TO FILL OUT AND SUBMIT THE FORM BELOW ONLINE. Contact Name: Title: Company: Phone: Email: Number of machines that will be connected to the system: Anticipated number of machines that will be connected to the system in the future: Tonnage of all presses to be connected: Pump motor voltage required: SIMPLICITY & RELIABILITY (763) 428-4229 midlandtechnologies.com C5
Portable System Configuration Midland can supply a range of portable vacuum systems in various configurations and sizes for different casting applications. Vacuum Pump Pump Receiver Manual Valve Vacuum Vacuum Gauge Gauge ** Connect Air **Connect Air for for Air Air Assist FL-0016 FL0016 Media Filter Prefilter Vacuum Vacuum Vacuum Vacuum Gauge Gauge Gauge Gauge (Optional) (Optional) FL-0803 Knockdown FL0803 Filter 1 or 1.5 ID Hose 1 ID x Hose Solenoid 15 x 10 Filter Valve 1 or 1.5 ID Hose x 15 1.0" I.D. or 1.5" Dia. Hose x 15' Use 1" NPT Tee if using Use 1 2 NPT or more Tee Vacuum if using 2 Blocks or more vacuum blocks Valve-Less Vacuum Block Valve-Less Vacuum Block C6 Midland Technologies, Inc.
Pump Sizes and Configurations Portable and central vacuum systems are available in the following sizes and configurations. Midland can help you to select the pump size appropriate for your casting applications. CONFIGURATION OPTIONS Horizontal Tank Mounted* - One pump mounted horizontally on receiver tank Vertical Tank Mounted - One pump mounted on a vertical standing receiver tank Tank Mounted Duplex - Two pumps mounted on a horizontal receiver tank *Horizontal tank mounted is the standard configuration for Midland vacuum systems Portable Systems Oil-sealed, rotary vane pumps Central Systems Dry claw vacuum pumps Pumps are available with 208, 230 or 460 volt starters Oil-sealed, rotary vane pumps can be ordered customized to be H 2 O cooled (763) 428-4229 midlandtechnologies.com C7
Troubleshooting Poor Cavity Fill OR CONTINUED POROSITY Poor cavity fill or continued porosity can result from a variety of process and engineering factors. In the case of vacuum-assist die casting, poor cavity fill or continued porosity can result when there exists a blockage or failure to achieve an open flow path between the cavity and the vacuum tank. This can result in a failure to evacuate the cavity. Note that significant die leakage can also introduce enough air to overcome the ability of the vacuum pump to achieve sufficient vacuum levels. When troubleshooting, it is recommended to first ascertain the level of vacuum being achieved in the die cavity for reference. This can be done by placing a rubber mat over the pour hole of the sleeve while the die is in the closed condition. Slit the rubber mat and place a vacuum gauge within the slit. Turn the vacuum pump on, ensure the tank is at vacuum pressure, and activate the system by opening the solenoid. Check the vacuum gauge at the pour hole to determine if an effective vacuum level has been obtained through the cavity. BLOCKAGE IN HOSES AND FILTERS Excessive velocity as alloy exits the cavity and reaches the Valve-Less Vacuum Blocks can result in metal passing through the block and into the vacuum hose. If the quantity of metal is excessive, it may be necessary to install a filter close to the block. This will require regular cleaning of the filter so as to maintain a free outflow of air from the cavity. Alternatively, the hose can be disconnected and cleaned out as necessary. The optimal solution is a review of exit gating and vacuum block runners, and redesign as necessary to manage metal velocity. Midland can offer technical assistance in this area. Failure to Achieve Expected Vacuum Level at Pump If the vacuum pump is not achieving the expected level of vacuum within the receiver tank, check to ensure that all drain valves are closed. If all drain valves are closed, then check the oil level, oil quality and all filters on the pump. Replace the oil and filters as needed. If this does not resolve the issue, please contact us for further assistance. Pumps should be overhauled periodically. Overhaul and filter kits can be purchased directly from Midland Technologies. Please have your pump model number ready when calling. C8 Midland Technologies, Inc.
Midland Filters Product Overview Midland can supply the necessary filters, die cast machine hookup kits, and spare parts to get your vacuum system operational and keep it running. Midland filters include the FL-0016 Media Filter, the FL-0803 Knockdown Filter, and the FL-1250 Large Knockdown Filter. Additionally, Midland can provide spare parts for hooking up multiple vacuum blocks or maintaining vacuum systems. Operation FL-0016 - The FL-0016 Media Filter utilizes wire mesh pads to catch metal particles, dust, and liquids that pass through the vacuum blocks prior to reaching the vacuum tank and pump. FL-0803 - The FL-0803 Knockdown Filter utilizes baffles to prevent material and liquid from passing through the vacuum blocks to the vacuum tank or pump. FL-1250 - The FL-1250 Large Knockdown Filter utilizes baffles to prevent material and liquid from passing through the vacuum blocks to the vacuum tank and pump. Application FL-0016 It is recommended to place the FL-0016 Media Filter behind the FL-0803 Knockdown Filter in the vacuum system in order to catch any liquid droplets or fine materials. FL-0803 It is recommended to place the FL-0803 Knockdown Filter approximately ten feet from the vacuum blocks in the vacuum system in order to catch any large material. FL-1250 - The FL-1250 is a larger version of the FL-0803 Knockdown Filter. This filter is intended for use in central vacuum systems connected to multiple presses and with systems connected to high tonnage presses. FEATURES FL-0016 Anodized Aluminum Body Replaceable Wire Mesh Pads Quick Connect/Disconnect Ends FL-0803 Anodized Aluminum Body Removable Baffles Drain Ball Valve FL-1250 Anodized Aluminum Body Removable Baffles Drain Ball Valve (763) 428-4229 midlandtechnologies.com C9
FL-0016 Filter WM-0392 X 3 Operation The FL-0016 Media Filter utilizes wire mesh pads to catch metal particles, dust and liquids that pass through the vacuum blocks prior to reaching the vacuum tank and pump. It is recommended to place a FL-0016 Media Filter behind the FL-0803 Knockdown Filter in every vacuum system. Separate filters should be utilized for each press when multiple presses are connected to the same vacuum system. Cleaning FL-0016 Media Filters is specific to process and system configuration, and should be conducted on both a regular schedule and as needed. Cleaning can be achieved by replacing the three wire mesh pads and cleaning the wire screen inside the body of the filter. If filters are not properly cleaned, they may clog and prevent proper function of the vacuum-assist tool within the casting process. For convenience, the FL-0016 has quick connectors at each end of the filter allowing for easy exchange of the FL-0016 to minimize press downtime. For safety, the FL-0016 is designed with a pressure relief valve. FL-0016 MAINTENANCE PARTS WM-0392 Mesh Media (sold in packs of 3) MD-3562 Screen Filter MID-154 O-Ring RV-0016 Relief Valve QC-0016 Quick Connect Ends C10 Midland Technologies, Inc.
FL-0803 Filter Operation The FL-0803 Knockdown Filter utilizes baffles to prevent material from passing through the vacuum system to the pump and tank. It is recommended to place the FL-0803 approximately ten feet from the vacuum blocks. The FL-0803 may be drained by means of a valve located at the bottom of the filter. To ensure proper function, drain the FL-0803 regularly. Occasionally, the body of the FL-0803 should be disassembled and the baffles cleaned. FL-0803 MAINTENANCE PARTS MID-154 O-Ring FB-0803 Filter Bracket (763) 428-4229 midlandtechnologies.com C11
FL-1250 Filter Operation The FL-1250 is a larger version of the FL-0803 Knockdown Filter. This filter is intended for use in central vacuum systems connected to multiple presses and in systems connected to high-tonnage presses in order to prevent material that passes through the vacuum blocks from reaching the tank and pump. FL-1250 MAINTENANCE PARTS MID-167 O-Ring C12 Midland Technologies, Inc.
Vacuum System Hookup Kits and Accessories Midland Technologies provides spare parts or complete kits that contain all the necessary components to connect Valve-Less Vacuum Blocks to the vacuum system. Hookup kits come in two sizes that include either a small or large solenoid valve which is responsible for regulation of the open or closed state of the vacuum system. Hookup Kits* DCMH1000 includes 1000 Activating Solenoid Valve, 30 ft. of 1 vacuum hose, brackets and hardware to connect one Midland Valve-Less Vacuum Block DCMH1250 includes 1250 Activating Solenoid Valve, 20 ft. of 1-1/2 vacuum hose, 10 ft. of 1 vacuum hose, brackets and hardware to connect one Midland Valve-Less *Midland can help you choose the correct hookup kit for your application. Please advise if multiple Valve-Less Vacuum Blocks are being utilized. Valves DCMH10AV24V 1000 Activating Solenoid Valve 24V DC DCMH10AV11V 1000 Activating Solenoid Valve 110V DCMH12AV24V 1250 Activating Solenoid Valve 24V DC DCMH12AV11V 1250 Activating Solenoid Valve 110V Gauges 4FLTS Small Vacuum Gauge VG4A Large Vacuum Gauge Vacuum Hose* 12104MB 3/4 Vacuum Hose 16104MB 1 Vacuum Hose 24104MB 1-1/2 Vacuum Hose *Hose is sold per lineal foot Hose Barbs & Clamps 1034HB 1 x 3/4 Hose Barb 3434HB 3/4 x 3/4 Hose Barb 1814HB 1/8 x 1/4 Hose Barb TBC125 3/4 Hose Clamp TBC150 1 Hose Clamp TBC200 1-1/2 Hose Clamp (763) 428-4229 midlandtechnologies.com C13
Maintenance Parts for Vacuum Systems Exhaust Filter Kits Exhaust Filter w/ O-Ring Exhaust Valve Assembly Gasket Kit Oil Filter Vanes Inlet Filter Cartridges Bearing Sleeves Shaft Seals Overhaul Kits Vacuum Pump Oil Please specify pump make and model when requesting maintenance parts. Maintenance Parts for Midland Filters WM-0392 Mesh Media for FL-0016 MD-3562 Screen Filter for FL-0016 MID-154 O-Ring for FL-0016 and FL-0803 MID-167 O-Ring for FL-1250 FB-0803 Vacuum Filter Bracket RV-0016 Relief Valve for FL-0016 QC-0016 Quick Connect Ends for FL-0016 C14 Midland Technologies, Inc.
Monorail Slides Custom to your dimensions! Save time and money sourcing custom slides from Midland Technologies! Simply specify the dimensions that you need or fill out the Easy Custom Diagram at our website to receive a quote. Upon receipt of a purchase order, we will send you a print and design file along with a delivery date for your custom Monorail Slide. Focus on your most value-added activities and let Midland take care of the rest! 14800 James Road Tel: (763) 428-4229 Rogers, MN 55374 Fax: (763) 428-4720 www.midlandtechnologies.com v.1 06/14 Made in U.S.A. CORPORATE MEMBER