Mold processing

What is Mold Machining?

The mold, also known as the mold, is the heart of injection molding technology. The mold is machined and shaped based on the desired product shape. Injection molded products are shaped by the structure and shape of the mold cavity (also known as the core of the mold, the hoe, the mold, etc.).

The mold consists of two main parts called the male mold and the female mold. In engineering language and mold manufacturing industry factories. People divide the mold into 2 parts; mold fixed part and mold movable part.

         Khuôn mẫu là gì?

Mold processing process:

1. CAD
Product design:

  • Design products can be brought by customers or designed by themselves, CAD is used to perform the following tasks:
  • Design contours, geometric shapes of products by 3D simulations.
  • Technical analysis of products, details, (conditions of corners, exit angle, thickness...).
  • Publish technical drawings.

Design patterns:

Thiết kế khuôn

  • Work, order figures: Part design, quantity, material
  • product material.
  • Plastic injection machine data: Injection pressure, clamping force, plastic capacity,
  • the size of the plates.
  • Mold type.
  • Shrinkage: Determine material properties, wall thickness.
  • Mold material: Material type of each part, hardness.
  • Mold cavity and convex part (negative - positive mold): Solid or assembled.
  • Layout of mold cavity: Number of mold cavity, layout, position.
  • Cross section of the channel: Round, semicircle, trapezoidal, channel
  • hot plastic.
  • Nozzle system: Membrane, ring, spray line, submarine latch,
  • locating the nozzle…
  • Mold release system: Push pin, push plate, push ring.
  • Guide and plate positioning: Positioning by cone, guide post, ring pin
  • locate.
  • Design and layout of the exhaust system.
  • Export drawings or design files.

2. CAE.

CAE

  • CAE (Computer Aided Engineering) is the use of computer software
  • computer to simulate and test the following technology and product characteristics
  • when designing. CAE brings many benefits to machining and manufacturing
  • after that. CAE allows mold designers and manufacturers to shorten
  • design time as well as cost in mold manufacturing.
  • Purpose of using CAE
  • Flow analysis of liquid plastic (plastic filling process
  • inside the mold).
  • Analyze the process of solidifying and shaping the product in the heart
  • mold.
  • Calculate the state of filling and heat dissipation.
  • Know the defects of the product.
  • Based on the above work, it helps us to determine the appropriate injection port location.
  • Therefore, applying CAE analysis to this process to optimize
  • design by simulation and calculation.
  • After finding the location of the plastic gate (gate location), channel, system
  • cooling is complete, continue to design the exhaust system with parts
  • CAE software.
  • Thanks to the CAE analysis of the above design steps, it is possible to minimize
  • The cost of mold making as well as the probability of damage will be reduced
  • down to the smallest thanks to analysis and simulation
  • Based on the above work, it helps us to determine the appropriate injection port location.
 

3. CAM

CAM

  • CAM is a computer-aided manufacturing technology. Progress
  • manufacturing is managed and controlled by a computer system.
  • CAM does the following tasks:
  • The first step is to set up the process of making a mold from the product.
  • Analysis of costs in the manufacturing process.
  • From there, choose appropriate mold and product materials.
  • Select the type of machine, the necessary parameters for pressing the product.
  •            

4. CNC machining.

  • As a stage using a CNC machining machine, the cutting tool performs the work of cutting metal and forming molds according to the technology established on the CAM.
Gia công CNC
  • Example Mold Machining Cycle.

Ví dụ Chu trình gia công Khuôn.
 

5. Polishing, mold assembly.

Đánh bóng, lắp ráp khuôn

  • Step 1: Clean the inside and outside of the mold. Especially, the polishing part of the mold needs to pay attention to the polishing stage of the mold cavity. If not polished properly, errors will occur during the test run.
  • Step 2: Check and clean the bavia on the components before assembling the mold to avoid scratches on the product.
  • Step 3: Gather all the mold details and detailed drawings
  • Step 4: Proceed to assemble the mold according to the assembly drawing
  • Step 5: Check the quality of the fully assembled mold and test run.
  • Machining the complete mold from the mold to the mold parts is often very time-consuming (machining time depends on the complexity of the mold). As simple as polishing, roughening the surface of details needs to be very attentive, because only when polishing too much, the product will be damaged and become NG goods.
 

6. Test Mold (Extrusion test).

Test Khuôn ( Ép thử)

Final inspection of the product, if the product is satisfactory, delivery, if not, then redesign the product.