Casting mold exhaust system design adopts standardized groove size and layout rules, ensuring complete gas discharge and eliminating gas-induced casting defects.
Exhaust groove depth is strictly graded by process: LPDC 0.15–0.2mm, CPC 0.12–0.18mm, gravity 0.2–0.3mm to balance exhaust and flash control.
Exhaust groove width is uniformly designed at 8–12mm per section, with spacing controlled within 15mm for high-precision mold cavities.
Closed exhaust structure is used for LPDC and CPC molds, while gravity casting molds adopt open full exhaust layout for large gas volume discharge.
Procast CAE gas flow simulation optimizes exhaust groove distribution, ensuring cavity gas discharge rate reaches 99%+ before complete filling.
Reasonable exhaust system reduces gas porosity defects by 40%, solving the most common defect problem in aluminum casting production.
Aluminum wheel mold sets intensive exhaust grooves at rim and spoke connection positions where gas is easy to accumulate.
EV structural part mold adds special exhaust structures at thin-wall dead corners to avoid local gas trapping and incomplete filling.
Exhaust groove chamfer treatment prevents burr residue, reducing mold cleaning and maintenance frequency by 25%.
High-pressure CPC molds adopt layered exhaust design to adapt to high-speed high-pressure filling gas volatilization characteristics.
Casting mold trial-test verifies that standardized exhaust layout improves casting qualification rate by 3.5% compared with irregular design.
Gas trapping is one of the main causes of porosity, bubble and incomplete filling defects in aluminum alloy castings, making the exhaust system a key functional structure of casting molds. Different casting processes have different gas generation and filling characteristics, so exhaust groove size and layout must be designed in a targeted manner. Gravity casting has fast filling speed and large gas volatilization, requiring larger open exhaust grooves; LPDC and CPC high-precision molds adopt smaller closed grooves to prevent flash while ensuring exhaust efficiency. Professional Procast CAE gas flow simulation accurately locates gas accumulation dead corners, guiding intensive exhaust layout optimization. For complex-structured wheel molds and thin-wall EV molds, targeted exhaust reinforcement effectively solves local gas trapping defects. Standard chamfer treatment and graded size design not only ensure full gas discharge, but also control casting flash generation and reduce daily mold maintenance workload. Strict trial-test verification ensures that the exhaust system operates stably in mass production, continuously improving casting yield and reducing defective rate.
FAQs
Q1: What is the exhaust groove depth standard for gravity molds? A1: 0.2–0.3mm open groove for large-volume gas discharge.
Q2: What exhaust depth is used for high-precision CPC molds? A2: 0.12–0.18mm layered closed exhaust groove design.
Q3: What is the gas discharge rate of standardized exhaust system? A3: Achieve 99%+ cavity gas discharge before full filling.
Q4: How much do qualified exhaust structures reduce porosity defects? A4: Effectively cut gas-induced porosity defects by 40%.
Q5: Where to add intensive exhaust for wheel molds? A5: Rim and spoke connection gas accumulation positions.
Q6: How does exhaust optimization improve mold maintenance? A6: Reduce daily mold cleaning frequency by 25%.
Q7: What exhaust improvement is needed for EV thin-wall molds? A7: Special dead-corner exhaust to eliminate local gas trapping.
