Injection mold manufacturing can be roughly divided into the following steps:
1. Process analysis of plastic products.
Before the mold design, the designer should fully analyze and study whether its plastic products conform to the principle of injection molding processing. It needs to be carefully negotiated with the product designer and a consensus has been reached. This includes the necessary discussion on the geometric shape, dimensional accuracy and appearance requirements of the product, and try to avoid unnecessary complexity in mold manufacturing.
Second, mold structure design.
A set of high-quality molds requires not only good processing equipment and skilled mold manufacturing workers, but also a very important factor is to have good mold design, especially for complex molds, the quality of the mold design accounts for 80% of the quality of the mold. %the above. An excellent mold design is: on the premise of meeting the requirements of customers, the processing cost is low, the processing difficulty is small, and the processing time is short.
To do this, we must not only fully digest the customer's requirements, but also have an understanding of the injection molding machine, mold structure, processing technology and mold factory's own processing capabilities. Therefore, to improve the mold design level, the following points should be achieved:
1. Understand every detail in each mold design and understand the purpose of each part in the mold.
2. When designing, please refer to the previous similar design, and understand the situation in its mold processing and product production, and learn from the experience and lessons.
3. Learn more about the working process of the injection molding machine to deepen the relationship between the mold and the injection molding machine.
4. Under the factory to understand the process of processed products, to understand the characteristics and limitations of each process.
5. Understand the test results and mold changes of the molds designed by yourself and learn from the lessons.
6. In the design, try to use the mold structure that was more successful in the past.
7. Learn more about the impact of mold water on products.
8. Study some special mold structures and understand the latest mold technology.
3. Determine the mold material and select standard parts.
In the selection of mold materials, in addition to considering the accuracy and quality of the product, it is necessary to give the correct choice in combination with the actual processing and heat treatment capabilities of the mold factory. In addition, in order to shorten the manufacturing cycle, the existing standard parts are used as much as possible.
4. Parts processing and mold assembly.
In addition to giving the best structure and reasonable tolerances in the design of the mold precision, parts processing and mold assembly are crucial. Therefore, the choice of processing accuracy and processing method occupies an absolutely dominant position in mold manufacturing.
The dimensional error of molded products is mainly composed of the following parts:
1. The manufacturing error of the mold is about 1/3
2. The error caused by mold wear is about 1/6
3. The error caused by uneven shrinkage of molded parts is about 1/3
4. The error caused by the inconsistency between the predetermined contraction and the actual contraction is about 1/6, the total error = (1) + (2) + (3) + (4)
Therefore, in order to reduce the manufacturing error of the mold, the processing accuracy should be improved first. With the use of CNC machine tools, this problem has been well controlled. In addition, in order to prevent the errors caused by the wear and deformation of the mold, when the mold with high processing accuracy and large product output is required, the key parts such as the cavity and core should be quenched. In medium and large molds, in order to save materials and facilitate processing and heat treatment, the mosaic design should be used as much as possible.
In order to solve the error caused by the uneven shrinkage of the molded parts and the inconsistency between the predetermined shrinkage and the actual shrinkage, 1/3 of the product tolerance is generally selected in the mold manufacturing as the manufacturing tolerance of the mold. Its purpose is to leave a more Large adjustment room to solve the error caused by the molding process.
5. Trial mode.
A set of molds is only 70%~80% of the entire manufacturing process from design to assembly. For the error caused by the inconsistency between the predetermined shrinkage and the actual shrinkage, the smoothness of the demoulding, and the cooling effect, especially the influence of the size, position, and shape of the gate on the accuracy and appearance of the product, must be checked by trial mold. Therefore, the trial mold is an indispensable step to check whether the mold is qualified and to select the best molding process.
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