Only after injection molding tool has been accepted for these steps can mold be shipped

Time:2019-08-16 09:32:10 / Popularity: / Source:

First, appearance, size, and fit of molded products

1. Defects are not allowed on the surface of product: lack of material, charring, whitening, white line, peaking, foaming, whitening (or cracking, breaking), baking, wrinkles.
2. Welding marks: Generally, length of circular perforated weld line is not more than 5 mm, length of shaped perforated weld line is less than 15 mm, and weld line strength can be tested by functional safety.
3. Shrinkage: shrinkage is not allowed in apparent surface, inconspicuous areas allow for slight shrinkage (not feeling dents).
4. Generally, flatness of small molded products is less than 0.3mm, and assembly requirements are guaranteed if there are assembly requirements.
5. There should be no air grain or material flower in obvious area, and molded products generally cannot have air bubbles.
6. Geometric shape and dimensional accuracy of molded products shall conform to requirements of a formal and effective mold opening drawing (or 3D file). Tolerance of product shall be in accordance with tolerance principle, tolerance of shaft type shall be a negative tolerance, and tolerance of dimensional dimension of hole shall be a positive tolerance. According to requirements if there are customers’ requirements .
7. Product wall thickness: Product wall thickness generally requires average wall thickness, non-average wall thickness should meet requirements of drawings, and tolerance should be -0.1mm according to mold characteristics.
8. Product cooperation: bottom shell and surface shell is matched, surface misalignment is less than 0.1mm, there is no shaving phenomenon, and holes, shafts and surfaces with matching requirements should be guaranteed to meet spacing and use requirements.

Second, appearance of injection molding tool

1. Mold nameplate is complete in content, clear in characters and neatly arranged.
2. Nameplate should be attached to mold foot near template and reference angle. Nameplate is fixed and not easy to peel off.
3. Cooling nozzle should be a plastic block nozzle, as required by customer.
4. Cooling nozzle should not protrude from surface of mold base
5. Cooling nozzle needs to be machined with countersinks. Diameter of counterbore is 25mm, 30mm and 35mm. Chamfering of orifice should be consistent. .
6. Cooling nozzle should have an ingress and exit mark.
7. Marked English characters and numbers should be greater than 5/6, position should be 10mm directly below water nozzle. Writing should be clear, beautiful, neat and evenly spaced.
8. Mold parts should not affect lifting and storage of mold. When installing, there are exposed cylinders, faucets, pre-reset mechanisms, etc., which should have support leg protection.
9. Support legs should be mounted on formwork with screws through support legs. Over-length support legs can be fastened to formwork by machined externally threaded columns.
10. Size of die ejector hole should meet requirements of specified injection molding machine. Except for small injection molding tool, it cannot be ejected with only one center.
11. Positioning ring should be fixed and reliable. Diameter of ring is 100mm and 250mm. Positioning ring is 10~20mm above bottom plate. Except as requested by customer.
12. Dimensions of mould shall be in accordance with requirements of specified injection molding machine.
13. Install injection molding tool with direction requirements. Installation direction should be indicated by arrow on front or rear template. There should have “UP” next to arrow. Arrow and text are yellow with a height of 50 mm.
14. There should be no pits, rust, excess rings, water vapor, oil holes, etc. on the surface of formwork and defects that affect appearance.
15. Injection molding tool should be easy to hoist and transport. Mold parts must not be disassembled during lifting. Lifting ring must not interfere with water nozzle, oil cylinder and pre-reset rod.

Third, mold material and hardness

1. Mold formwork should be a standard formwork that conforms to standard.
2. Mold parts and casting systems (cores, moving mold inserts, movable inserts, split cones, push rods, sprue sleeves) are made of materials with properties higher than 40Cr.
3. When molding plastics that are corrosive to mold, mold parts should be made of corrosion-resistant materials, or molding surfaces should be protected against corrosion.
4. Hardness of mold parts of mold should be no less than 50HRC, or hardness of surface hardening treatment should be higher than 600HV.

Fourth, ejector, reset, thrust ferrule, take-up

1. It should be smooth, no stuck, and no abnormal sound when it is ejected.
2. Sloping top surface should be polished and sloping top surface is lower than core surface.
3. Sliding part should be filled with oil groove, surface should be nitrided, and surface hardness after treatment is HV700 or above.
4. All rams should have a non-rotation position and each ram should be numbered.
5. Ejection distance is limited by application limit block
6. Return spring should be made of standard parts, and ends of spring should not be ground or cut.
7. Slider and core should have travel limit. Small slider is limited by spring. When spring is inconvenient, wave screw can be used. Cylinder core must have a travel switch.
8. Slider core is generally inclined column, angle of inclined guide column should be 2°~3° smaller than angle of slider locking surface. If stroke of slider is too long, cylinder should be drawn.
9. When end face of cylinder core forming part is covered, cylinder should be self-locking mechanism.
10. There should be wear plates under large slider with width of slider exceeding 150 mm. Material of wear plate should be T8A. After heat treatment, hardness is HRC50~55, and wear plate is 0.05~0.1 mm higher than large surface, and oil groove is opened.
11. Ejector pins should not be strung up and down.
12. Add barbs to ejector pin. Direction of barbs should be same. Barbs are easy to remove from molded products.
13. Matching clearance between jack hole and ejector pin, length of sealing section, and surface roughness of ejector hole shall be in accordance with relevant enterprise standards.
14. Molded products should be suitable for operator to remove.
15. When molded products is ejected, it is easy to follow inclined top. Ejector pin should be grooved or etched.
16. Top block fixed on ram should be firm and reliable. Non-formed part should be machined to a slope of 3°~5°, and lower part should be chamfered.
17. There should be no iron filings in oil passage holes on formwork.
18. End of return rod is flat and there is no spot welding. There is no gasket, spot welding at the bottom of embryo.
19. Three-plate mold gate plate slides smoothly, and gate plate is easy to pull open.
20. Three-plate mold limit rod should be placed on both sides of mold installation direction, or pull plate should be added outside mold frame to prevent limit rod from interfering with operator.
21. Oil passage should be smooth and hydraulic ejector reset should be in place.
22. Exhaust port should be opened at the bottom of guide sleeve.
23. There must be no clearance for locating pin installation.
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Five, cooling, heating system

1. Cooling or heating system should be fully ventilated.
2. Seal should be reliable. System should not leak under pressure of 0.5MPa, and it is easy to overhaul.
3. Size and shape of sealing groove on formwork shall comply with relevant standards.
4. When sealing ring is placed, it should be spread with butter and placed higher than mold surface.
5. Water and oil passage spacers should be made of materials that are not susceptible to corrosion.
6. Front and rear molds should adopt centralized water supply.

Sixth, pouring system

1. Gate setting should not affect appearance of product and meet product assembly.
2. Cross-section and length of runner should be designed reasonably. Process should be shortened as much as possible to ensure forming quality, cross-sectional area should be reduced to shorten filling and cooling time. At the same time, plastics lost in casting system should be least.
3. Partial section of three-plate mold runner on the back of front template shall be trapezoidal or semi-circular.
4. Three-plate mold has a material break on gate plate. Diameter of runner entrance should be less than 3 mm. Ball head has a 3 mm deep stepped recessed gate plate.
5. Ball pull rod should be securely fixed and can be pressed under positioning ring. It can be fixed with headless screws or pressed with a pressure plate.
6. Gates and runners should be machined according to size requirements of drawings, and manual grinders are not allowed to be processed.
7. Gate gate should be in accordance with specifications.
8. Front end of runner should have an extension as a cold pocket.
9. Z-shaped inverted buckle of pull rod should have a smooth transition.
10. Splitter on parting surface should be round, front and rear modes should not be misaligned.
11. Latent gate on ejector pin should have no surface shrinkage.
12. Diameter and depth of cold hole of transparent product should meet design standards.
13. Material is easy to remove, appearance of product has no gate marks, and there is no residual material in the assembly of product.
14. Bent hooking gate, two parts of block should be nitrided, surface hardness reaches HV700.

Seven, hot runner system

1. Layout of hot runner wiring should be reasonable and easy to overhaul. Wiring numbers should correspond one-to-one.
2. Hot runner should be tested for safety and the insulation resistance to ground is greater than 2MW.
3. Temperature control cabinet and hot nozzle, hot runner should use standard parts.
4. Main flow sleeve is connected with hot runner by thread, and bottom surface is in contact with seal.
5. Hot runner is in good contact with heating plate or heating rod. Heating plate is fixed by screws or studs and surface is well fitted.
6. A type J thermocouple should be used and matched to temperature control meter.
7. Each set of heating elements should have thermocouple control and thermocouple position should be properly arranged.
8. Nozzle should meet design requirements.
9. Hot runner should be reliably positioned, with at least two locating pins or screws.
10. There should be a thermal insulation pad between hot runner and template.
11. Temperature difference between temperature setting table and actual display temperature should be less than ±5℃, and temperature control is sensitive.
12. Cavity and nozzle mounting holes should be punched through.
13. Hot runner wiring should be bundled and covered with a pressure plate.
14. There are two sockets of same size and should be clearly marked.
15. Control line should be jacketed and undamaged.
16. Temperature control cabinet has a reliable structure and screws are not loose.
17. Socket is mounted on a bakelite and cannot exceed maximum size of template.
18. Wires should not be exposed outside mold.
19. All hot runners or stencils should have rounded corners where they come into contact with wires.
20. There is no open circuit short circuit on all lines before template is assembled.
21. All wiring should be properly connected and insulation performance is good.
22. After clamping template, all lines are checked again with a multimeter.

Eight, molding part, parting surface, exhaust groove

1. There should be no defects such as unevenness, pits, rust and other appearances on front and rear mold surfaces.
2. Insert is matched with mold frame, and rounded corners should have a gap of less than 1 mm.
3. Parting surface is kept clean and tidy, and there is no portable grinding wheel to avoid air, and sealing part has no depression.
4. Depth of venting groove should be less than overflow value of plastic.
5. Insert research and development should be in place, and placement is smooth and positioning is reliable.
6. Inserts should be securely positioned and fixed, round pieces are stopped, copper and iron pieces are not placed under inserts.
7. End of ejector pin is consistent with core.
8. There are no defects such as undercut and chamfer in front and rear mold parts.
9. Ribs should be released smoothly.
10. Multi-cavity molded products, left and right parts are symmetrical, should be marked with L or R. If customer has requirements on position and size, it should meet customer's requirements, generally added in the place that does not affect appearance and assembly, font size is 1/8. .
11. Mold frame locking surface should be in place, more than 75% of area will be encountered.
12. Ram should be placed close to side wall, beside ribs and bosses, and use a larger ram.
13. For same piece, numbers 1, 2, 3 should be noted.
14. Each touch surface, insert surface, and parting surface should be in place.
15. Parting surface sealant part should meet design standards. Medium-sized mold is 10~20mm, Large mold is 30~50mm, the rest is machined to avoid blank.
16. Skin and sandblasting should meet customer requirements evenly.
17. For products with required appearance, screws on product shall be protected against shrinkage.
18. Top tube should be used for screw columns with a depth of more than 20 mm.
19. Wall thickness of product should be uniform and deviation should be controlled below ±0.15 mm.
20. Width of rib should be less than 60% of wall thickness of exterior surface.
21. Sloping roof and insert on slider should be securely fixed.
22. Front mold is inserted into front mold or rear mold is inserted into front mold. Surrounding mold should be locked with a bevel and machined to avoid blank.

Nine, injection moulding process

1. Mold should have stability of injection moulding process and repeatability of process parameter adjustment within range of normal injection moulding process conditions.
2. Injection pressure during injection moulding process should generally be less than 85% of maximum injection pressure of injection molding machine.
3. Injection speed of mold injection moulding process, injection speed of three quarters of stroke is not less than 10% of rated maximum injection speed or more than 90% of rated maximum injection speed.
4. Holding pressure during injection moulding process should generally be less than 85% of actual maximum injection pressure.
5. Clamping force during injection moulding process should be less than 90% of rated clamping force of applicable model.
6. During injection moulding process, removal of product and nozzle material should be easy and safe ( time is generally less than 2 seconds).
7. Molds with inserts are easy to install and secure for inserts during production.

Ten. Packaging and transportation

1. Mold cavity should be cleaned and sprayed with anti-rust oil.
2. Sliding parts should be lubricated.
3. Apply grease to sprue feed inlet.
4. Mold should be fitted with a locking die, specifications meet design requirements.
5. Spare parts for spare parts should be complete with a list and supplier name.
6. Water, liquid, gas and electricity inlet and outlet of mold shall be sealed to prevent foreign matter from entering;
7. Outer surface of mold is sprayed with paint, and customized if there has requirements.
8. Mold should be moisture-proof, waterproof, and prevent bumper packaging, as required by customer.
9. Mold product drawings, structural drawings, cooling and heating system drawings, hot runner drawings, spare parts and mold material supplier details, instructions for use, test mode report, factory inspection certificate, electronic documents should be complete.
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