Mold is a key part of injection molding. The quality and applicability of the mold are very important in injection molding. The same is true for the applicability of plastics to product types. Well-made molds contribute a lot to the total cost of injection molding. The mold may cost a lot of money. When you spend so much money on something, it is worth paying attention to how to make it last and work well. Injection mold is one of the main equipment in injection production. Therefore, the method of spot check and maintenance of mold is formulated to effectively maintain the precision of mold and stabilize production operation, ensure the quality of molded products, reduce the occurrence of failures in the production process, ensure the normal production of molds in injection workshop, reduce mold failures and product quality problems, and keep the best performance state and prolong the service life of molds, so as to ensure the normal production.All our injection moulds can be maintained on a daily basis in accordance with the above, for example auto bumper mould and plastic car mirror mold,etc.
The Importance and Significance of Mold Maintenance
A well-maintained mold can shorten the time of mold assembly and debugging, reduce production failures, make production run smoothly, ensure product quality, reduce waste loss, and reduce the operating cost and fixed asset investment of the enterprise. At the beginning of the next production cycle, the enterprise can successfully produce qualified products. Therefore, for injection molding products processing, in the current fierce market competition, well-maintained molds can help enterprises.
As the most important molding equipment for processing injection products, the quality of injection mold is directly related to the quality of products. Moreover, because the mold occupies a large proportion in the production cost of injection molding, its service life directly affects the cost of injection molding products. Therefore, improving the quality of injection mold, maintaining it well and prolonging its service life are important issues for injection product processing enterprises to reduce costs and increase efficiency.
For injection molding products, due to the variety of products and frequent mold replacement, after one production cycle, the molds are generally stored in the warehouse and then taken out for use until the next production cycle comes. If we don’t pay enough attention to the preservation of molds, the molds will be rusted and the surface smoothness will decrease during the preservation period, resulting in the decline of product quality and high rejection rate. Some molds are even difficult to reuse, and a large amount of money needs to be re-invested to set up new molds, resulting in great waste.
What factors will affect the durability of plastic molds?
Factors affecting the durability of plastic molds include environment, materials, maintenance, molding conditions and structural design. Tool life of injection mold refers to the total number of molding cycles that the mold can experience before failure. The failure here means any deformation that will affect the quality of the parts produced.
The surface finish will naturally show signs of wear earlier than most of the mold.
Some factors will affect the speed of this kind of wear, whether at the surface level or in the general design of the mold. The most important factors can be found below.
Higher environmental cleanliness makes the service life of the mold longer. The operating conditions of the plastic mold will not only seriously affect the health of the mold itself, but also the health of the parts produced. The harsh and dirty environment will shorten the life expectancy, because of the extra wear and tear, these conditions apply to the mold. On the other hand, molds used in very clean environments (such as clean rooms) can last for decades.
Stronger materials like steel make the plastic mold more durable, and the plastic materials used in the mold will also wear it. The material of the mold can be different according to the details of the injection molding process related to the required parts. The wear rate of molds made of harder materials (such as steel) is much slower than that of molds of the same design made of softer materials (such as aluminum).
When talking about materials, those materials used in the manufacturing process can also play a role in the degradation of plastic injection molds. If the machine used to manufacture the mold shows some degradation that may change the structure of the mold, small invasive elements (also called impurities) may interfere with the injection mold itself. In addition, the final product (part) may also be affected by any corrosive or abrasive components used in the molding process. In other words, if the impurities in the mold are not detected in advance, the parts may have problems.
Types of injection mold maintenance
Daily preventive maintenance
These are daily, weekly, monthly or annual maintenance. This is to ensure smooth operation. This includes; Mold inspection, cleaning, lubrication of moving parts and other routine maintenance. Less routine maintenance may include more intensive cleaning of the injector unit.
This is not a desirable method. This means that a failure has occurred before maintenance. This is usually done after a failure occurs. Then, the engineer carries out maintenance inspection. This is to see how to solve the problem and then make a diagnosis.
Some skills of mold maintenance
First of all, it is important to ensure that the product is well designed. Poor design may lead to problems such as difficult ejection and poor mold filling. Make sure that the correct draft angle is used, the ejector pin position is correct and the correct gate is used. The failure of other parts of the injection molding machine may eventually enter the mold. At the same time, there can be a good mold operation and maintenance. If other processes in the injection molding machine are not working properly. The resulting problems may be transferred to the mold. For example, if the injection pressure is too high, it will cause unnecessary pressure on the mold. Or, if the melt is not well mixed and melted, and contains particles that may damage the mold surface. It is important that other components should be well operated and maintained. This is the important point of cooperation with reliable mold manufacturers. This is to ensure that these factors are considered first.
Comply with the maintenance plan
There should be a documented maintenance plan. This includes the process of maintenance work.
The process of confirming the maintenance work that has been done and the next maintenance due.
Each mold should be accompanied by an operation and maintenance instruction manual and list. This can guide the operator and reduce the chance of human error.
A feedback system that allows errors to be detected before they occur.
Provide appropriate and continuous training for operators.
Regularly check the wear, blockage and damage of cavities, gates and runners.
Lubricate or surface
Clean and remove debris from cavity and all parts regularly.
Ensure that the detergent is nontoxic, and use the recommended solvent and detergent.
Use anti-corrosion or anti-rust agents and coatings
Avoid moisture problems by properly flushing and draining pipelines.
Check that the board alignment is good.
Ensure that the injection system is unimpeded and operates normally.
And clean and lubricate thimble and parts.
Check and replace all parts that need to be replaced, such as pins, screws, bolts and bushings.
There is a certain level of use after a routine replacement of parts. Even if there is no detectable damage. This promotes the maintenance of culture and minimizes the chance of mold damage.
If so, please follow the mold manufacturer’s operation and maintenance guidelines. The mold manufacturer may make some suggestions on how to best operate and maintain the mold. Take these suggestions seriously.
There is a system to track the number of cycles that the mold runs. Because many molds are graded according to the number of cycles. Depending on your size and ability, this can be a digital or analog system for tracking. Then, the circulating track can be used as an indicator of maintenance. For example, maintenance after 100 cycles may be different from maintenance after 1000 cycles.
Ensure that other components and processes work well.
Check that the cooling pipe is well sealed and free of leakage. This may lead to corrosion or low cooling efficiency.Have a special maintenance budget.
We are a professional manufacturer of injection moulds and we have a wide range of products such as precision mould,etc.If you need to contact the manufacturer.