- Oct 20, 2017 -
How to improve the quality of mould effectively?
Quality is an old and new topic.
The quality of the mould, whether it is designer and manufacturer of mould, the designers of the parts, or users of mould should be actively concerned about problems, with the constant innovation of technology, new material widely used, and processing technology unceasing change, use and maintenance condition difference, and so on are different degrees of influence the quality of the mould.
Quality of the mould, it will directly affect the product quality, yield, cost, production of new products and old products renewal cycle, product structure adjustment speed and market competitiveness, so the economy puts forward higher and higher requirements about the quality of the mould.
How to improve the quality of molds more rationally is the key to the manufacturing leap.
How to make the mould in high precision, low cost, high efficiency, more time, more die production of qualified products.
This has become increasingly the focus of attention.
How to improve the quality of mould effectively:
Mold quality includes the following aspects:
Length of service: the number of work cycles or the number of parts produced by the molds under the precondition of ensuring the quality of the products;
Quality of products: stability of product size, conformity, finish of product surface, utilization of product materials, etc.
Maintenance costs, maintenance cycles, etc.
The use and maintenance of the moulds: is it the easiest to use, easy to remove, and to produce as short as possible?
The basic way to improve mold quality:
1, the product design is reasonable, choose the best structure scheme, as far as possible product designer should consider the technical requirement and the structure of the product must meet the manufacturability and feasibility of the mould manufacturing.
2, the design of the mould is the most important step to improve the quality of the mould, need to take into account many factors, including the selection of die materials, die structure of the usability and safety, the machinability of mold parts and mould maintenance convenience, these at the beginning of the design should be considered more carefully.
（1）When designing the mould structure, it is necessary to be compact and easy to operate, and to ensure that the mould parts have sufficient strength and stiffness.
When the mold structure is allowed, the corners of the mould parts should be designed as round corners to avoid stress concentration.
For the concave mold, cavity and part of the punch mode, the core can be combined or set to eliminate stress concentration, long, elongated die or core, and appropriate protective measures should be taken in the structure.
For cold die, the device should be configured to prevent the blockage of the assembly or scrap (e.g., bullet pin, compressed air, etc.).
At the same time, it is also important to consider how to reduce the influence of sliding fitting and frequent impact on the quality of mould.
(2) the selection of die materials, both to meet customer requirements for product quality, also need to consider to the cost of materials and in the strength of the set period, also according to the type of mold, using the way of working, processing speed, the main failure form factors such as material selection.
For example, the main failure mode of punching die is the edge wear, and the surface hardness is high and the wear-resistant material is selected.
The stamping die is mainly subjected to periodic load, which can cause the surface fatigue crack, which leads to the peeling of the surface, which is to choose the material with good surface toughness.
The deep die should choose materials with especially low friction coefficient;
Because of the cyclic thermal stress, the pressure casting mould should choose the material with high thermal fatigue.
For injection mold, when the plastic parts for materials such as ABS, PP, PC, mould materials can choose hard quenched and tempered steel, when the plastic parts for high smoothness, transparent material, optional corrosion resistant stainless steel, when the products batch big, can choose quenched tempered steel.
In addition, it is necessary to consider the use of mold materials with small affinity with the making parts, so as to prevent the adhesion from increasing the wear of the die parts, thus affecting the quality of the mould.
In the design, it must reduce the scope of disassembly, especially in the change of the vulnerable parts, to minimize the extent of the disassembly.
3. The manufacturing process of the mould is also an important part to ensure the quality of the mould. The machining methods and machining precision of the mould can also affect the service life of the mould.
Directly affect the precision of parts of the mold the whole assembly, get rid of the influence of accuracy with the device itself, through the improvement of the processing method of parts is needed, improve the level of fitter in the mold in the process of grinding with technology, to improve the processing precision of mould parts;
If the overall assembly effect of the die is not up to the requirement, the chance of making the mold in the die will be increased in the test mode, and the overall quality of the mould will have a great impact.
In order to ensure the mold has good precision of the original - the original mold quality, the first selection of high precision in the process of manufacturing processing methods, such as edm, line cutting, CNC machining, etc., at the same time we should pay attention to the precision of the mould inspection, including mold parts processing, assembly accuracy and precision through the test mould acceptance work, a comprehensive check the precision of the mould during inspection also need to choose high precision measuring instruments, as far as possible for those who are forming on the surface of complex curved surface structure of mold parts, if use ordinary ruler, vernier card will not be able to achieve accurate measurement data, then we have to choose three coordinates measuring instrument such as precision measuring equipment, to ensure the accuracy of the measurement data.
4. Surface strengthening of main forming parts of molds to improve the wear resistance of molds, so as to better improve the quality of molds.
For surface strengthening, different reinforcement methods should be used according to different USES.
For example, the punching die can be used to enhance the wearability and compressive strength of the surface of the mould.
It can be used to improve the wear resistance, heat resistance and abrasion resistance of the die casting die and plastic mould.
The deep die and bending die can be treated with the carburizing to reduce the friction coefficient and improve the abrasion resistance of the material.
Carbonitriding (soft nitriding) can be applied to the surface strengthening of all kinds of molds.
In addition, in recent years developed a kind of known as FCVA vacuum metallizing corundum membrane technology, can form a layer on the surface of parts to combine with matrix remarkably strong and very smooth and dense protective film, this technology is especially suitable for the mold surface protective treatment, is also a kind of effective method to improve the quality of the mould.
Of course, if the product is a trial product or a small batch, it is not necessary to carry out the surface reinforcement of the parts.
5. The correct use and maintenance of molds is also a major factor in improving mold quality.
For example: mould installation way should be appropriate, in the case of a hot runner, the power supply connection to correct, the cooling water to meet the design requirements, the mold in the production of injection molding machine, die-casting machine, the parameters of the press should be consistent with the design requirements, and so on.
In the correct use of die, still need to regular maintenance of the mold, the mold of the guide pin, guide sleeve, and other parts with relative motion would often filling lubricating oil, such as forging die, plastic mould, die-casting mould mold before each mold forming lubricant should be spray or stripping agent on the surface of formed parts.
It can prevent the problems of mould in production and improve the efficiency of maintenance.
In order to improve the quality of the mould, we must first consider the impact on the quality of the mould. Secondly, we must work together through the departments.
The quality of mould is the real embodiment of mold enterprise's own strength.
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