By Andy from Baiyear factory
Upated November 5, 2022
Regarding the introduction of the specific production steps of the mold, we have divided it into 2 articles to introduce, this is the first article, the key content: 1: Custom Plastic Injection Mould 2: Factory Mold Making 3: Plastic Injection Mould 4: Precision injection mold 5: plastic mould die maker 6: mold design for injection molding 7: mold making and casting 8: mold makin
1. Opening
According to the mold design requirements, the blanks are first opened according to the material requirements of the materials used in different molds. First, rough machining according to the net size designed in the drawing, and the machining allowance should be controlled at about 5mm on both sides. Use a milling machine to process the inner mold, rows, inserts and copper male blanks into rough blanks with straight six sides and right angles around the periphery. Then it is processed into a fine blank with a smooth surface and a flat surface by a grinder, so that the next process can be made.
(1) When cutting the material, the requirements of the drawings should be clearly seen, and the material should be cut according to the materials used for each part of the mold.
(2) After the blank is processed, there must be enough allowance to prevent errors in the next process and facilitate correction. The specific machining allowance is about 3mm on both sides, and the allowance should be placed as far as possible in the direction of the thickness of the inner mold.
(3) Each piece of mold material must ensure the accuracy of the angle ruler when processing the grinding machine, ensure that the opposite side is parallel, the adjacent side is vertical, and the perpendicularity tolerance is preferably controlled at about 0.02/100mm.
(4) The finished blank should be marked with the mold number and material name.
2. Frame
The frame is processed according to the requirements of the design drawings, and the parts where the inner mold, the row position and the inserts are installed on the mold blank are processed into a working matching position that conforms to the mold structure. The machining process is divided into rough machining (rough frame) with a small amount of machining allowance and finishing (fine frame) machining to the size required by the drawing and process.
(1) Before opening the frame, the model number and part number of the whole set of molds should be marked.
(2) Before opening the frame, you must check the verticality between the head shaft of the milling machine and the working table, and the verticality should be controlled at about 0.02/100mm.
(3) It is best to control the tolerance of the center size of the inner mold frame at about 0.02/100mm.
3. Carving
Engraving is a processing and manufacturing process that is processed into the shape required by the required mold design according to the coordination requirements of the drawings and the shape of the mold parting glue. It must be processed according to the proportion required by the design, which is divided into two steps: roughing and imitation carving.
(1), open thick
Rough machining of inner molds, rows and inserts with large machining allowances during engraving, and machining with milling machines to the minimum allowance.
(2), copy engraving
Install the oversized blank on the engraving machine, set the center according to the parting center, adjust the positioning accuracy and proportion of the mold and the parting glue sample, and carry out copy engraving according to the shape of the parting glue sample, so that the shape of the mold and each processing The runners of the parts and the glue entering the water are exactly the same.
(3), process requirements
a) Before engraving, check the verticality of various blanks sent to ensure that the square surface is correct and there is enough machining allowance.
b) Look at the drawings and make sure that the center of the finished workpiece is exactly the same as the parting glue sample before drawing the line thicker.
c) See the accuracy of each finished product of the mold. If the shape is complex, the material level is deep, and the lines are thin, and the use of engraving cannot ensure the accuracy, single-sided copper males and three-dimensional copper males should be used. Some with coordination or insertion should be used as inserts, especially glass windows and small lamps, so that the fronts appear in the production process after the patterning, and the method of raising the inserts is used to eliminate the fronts when they cannot be welded.
d) If the precision of the finished product is general and it is not necessary to engrave the copper male, the upper or lower mold should be carved, and the other side should leave a margin of 0.1-0.3mm for polishing the mold. and smooth lines.
e) After engraving, each finished product should be inspected. The parting should be the same as the parting glue sample, the material level should be clear, and there should be no uneven knife marks and unclear lines in the carved parts.
f) The lower mold of the glass window of the simulated car should leave a margin for the upper mold when engraving, so as to coordinate with the upper mold. The parting surface of the glass window of the simulated car is generally at the discharge position of the upper mold. No gaps.
(4), Copper bar
Copper bar is an electrode used for EDM machining of inner mold cavity with complex shape, deep material level and thin lines that cannot meet the product accuracy requirements by profiling engraving. As a tool for EDM, It is a product entity that is imitated according to the required shape and size of the product. It must be engraved and produced according to the product design, mold-parting solid glue sample and customer information, and then be carried out by the professional technicians of the copper company according to the solid glue sample, the figure and the product photos. Manual correction.
a) Refer to the figure and the customer’s photo to correct the engraved copper male to the line size is moderate, the line connection of the R part is smooth, the surface is smooth, and the angle of the acute angle part is clear.
b) There should be enough empty space (gap) between all coordinations to ensure the gap between fuel injection and spark discharge.
c) The coordination part must conform to the processing data, so that the transition part of the line is clear and smooth.
d) The three-dimensional copper is coordinated according to the copper of the product. If there are special requirements, the beer must be tested and then coordinated according to the beer. Such as windows, lights, ghost masks, doors, rear mirrors, etc.
4. Framo
(1), fit correction (for mold)
Apply red paint on the parting collision surface of the carved inner mold, fix the inner mold with the opposite inner mold, and open the upper and lower inner molds after collision in place. Check whether the edge of the inner mold that is not painted with red paint is printed with red paint. If it is not completely printed, use a sander, file and shovel to grind, trim, and check repeatedly until all the red paint is printed. When the engraved inner mold is to be molded, the reference plane should be repaired as the reference first, and then the other side should be removed.
(2), model execution (correction)
Use a file and a shovel tool to file, correct the material level (the die-casting position of the workpiece on the mold), the runner (the workpiece material flow path), the water inlet (the position of the material edge where the workpiece material flows into the material level), and smooth the drafting slope (beer). ), to remove the prongs, burrs, protrusions, etc. that affect the smooth ejection of the beer parts. (If the runner and water inlet are not processed by an engraving machine, they must be processed by a milling machine according to the drawing)
5. Row processing slide
The slider is processed on the row position, and the row position slot and pressure strip are opened in the row position frame of the mold base, so that the row position can move on the slideway.
6, the position
After the inner mold is finished, fix the upper and lower molds and the row position in place, use red paint to check the fitting surface of the row position and the inner mold, and use grinding wheels, files and shovel tools to repeatedly grind, repair and check until they fit. The edge of the fabric is completely fitted. Fixed row position:
(1), clamp the row position in place
(2) Take a point on the plane on the row position as the starting point for drilling, and continue to drill blind holes on the mold frame after drilling the row position. (This hole is a process hole, which is used to fix the position of the pin without the beveled edge and the beveled chicken.)
To be continued, the rest of the content will be introduced in the next article. If you are interested in Baiyear’s mold design and production, please feel free to contact us, we will give you a great surprise.
Contact:Andy Yang
What’s app : +86 13968705428
Email: Andy@baidasy.com
Post time: Nov-29-2022