What is insert molded parts?

Insert molded parts are often common to shape products, and are common in a variety of industrial mechanical industries. Mold products such as household appliances, wheels, plastic bottles, electronic equipment, medical equipment, etc.

With the application of CNC technology in the mold processing, they not only have high accuracy. It also meets the specific needs of each product. Besides, the mold manufacturing process is also simpler thanks to the automatic control system of CNC machines.

Thereby helping to save production costs and increase the production efficiency of enterprises.

Insert molded parts is a metal tool common to create products

An Insert molded parts is a metal tool common to create products according to the shaping method. Also, the structure and size of the mold designed and manufactured depend on the shape and quality of the product to be produced. Thereby, it is possible to ensure its features, use and not lose its effectiveness.

2. Types of popular Insert molded parts today

There are 9 types of popular molds today:

2.1. Sand casting mold

Sand casting molds are special tools common to mold liquid objects into shapes. Using technology to make products by pouring materials in liquid form into molds. Also, this is a very popular method that is now widely applied in all fields such as machine building, vehicle manufacturing, etc.

Products of sand- Insert molded parts are usually engine body, distributor, exhaust manifold, wheel, figurines, etc. From metal materials such as steel, aluminum, copper, etc.

Sand casting mold

2.2. Pressure die to Insert molded parts casting

Pressure casting is a method of making products by filling a mold with liquid metal and solidifying under the action of high pressure.

Molds are commonly common and are mainly common to manufacture complex parts such as brass trumpets, air valves, engine parts, precision products, etc. mainly lead, zinc, aluminum, copper, etc.

2.3. Forging Insert molded parts

Products are formed by stamping materials in a stamping die. For example, crankshaft, arm, or coupling, etc.

2.4. Forming stamping mold

A type of Insert molded parts that create a product by stamping a metal sheet into the mold cavity.

Forming dies are widely common in the industry. Moreover, Products from stamping die include metal parts in:

• Automobiles:
• Airplanes
• Home Appliances
• Electrical Appliances
• Electronics
• Consumer Goods
• Military Equipment
• Medical Products
• Frames, Doors, Steel Rims, Aluminum Trays, Shifters, Cups.

2.5. Plastic injection mold

Insert molded parts are common to mold plastic products by heating plastic materials.

Also, Molds are common for various methods of injection molding, injection molding, and extrusion.

Plastic mold products such as electrical appliances, car interiors, or general plastic products such as plastic bottles, etc.

2.6. Plastic Insert molded parts extrusion “Extrusion”

The continuous extruder is formed by placing the material with a screw outside the outlet port of the device. Also, the material will have the same shape as the outlet section of the device. Plastic extrusion products are tubular, or long tube products.

2.7. Blow mold

The product is to Insert molded parts by placing the tubular material in the mold and blowing air in. Make it expand until it has the same shape as the mold for casting.

Widely common for many bottle products.

2.8. Vacuum forming Insert molded parts

Heating the sheet material and close to the mold cavity by vacuum suction to shape the part. Hence, we use both concave and convex.

Large product sizes can be molded at a relatively low cost. Also, this method is not castoff for parts with complex shapes.

Generally, these are common to produce product packaging, fruit boxes, food containers, etc.

Rubber injection Insert molded parts

Soften the castings in the firing chamber and push them into the mold cavity by pressure. 

Rubber injection Insert molded parts are widely common for the molding of thermoset plastics.

This form of casting was developed for casting parts that are difficult to obtain with pressure casting but are of no use for certain types of parts.

3. Insert molded parts processing process

The mold processing process consists of 5 basic steps including: 

• Design
• Program
• Machining
• Heat treatment (depending on required Insert molded parts hardness)
• Measurements
• Assemble
• Polishing (depending on product surface requirements)

Companies can undertake one or more processes, or the entire process to manufacture from the first product to the finished product.

Some large companies may operate in a closed cycle from design to test and assembly. Even directly use molds to produce and trade end products.

4. Applying CNC technology to mold manufacturing and processing

The mold market in Vietnam as well as in the world is growing at a high speed. Also, the mold industry is also developing in the direction of focusing on investment and technology development. Therefore, it is necessary to shorten the production time while the product increasingly requires complexity. 

4.1. Applying CAD to manufacturing plastic molds

This software allows designers to create product models in the form of 2D or 3D drawings. The image of this simulation drawing has a perfect degree of realism that is close to the real product after completion. Helps to complete the prototype quickly and accurately.

4.2. Applying CAM to plastic mold making

CAM is not used to create designs, but it has the function of receiving data analysis, calculating parameters given from full CAD drawings, and then controlling CNC machines to operate.

4.3. CNC application in plastic mold making

The process of machining plastic Insert molded parts usually come on CNC milling machines. The machine is easy to control programmed on the computer and brings a lot of benefits. 

• Automation of the machining process.
• Also, High processing speed, promoting products to market. 
• Moreover, it can produce products from small to large, from simple to complex with high precision. 
• In addition, Mass production of products in a short time.

New technology in plastic mold making is CAD/CAM/CNC – the most modern and advanced software and machines. And form a unified, complete system and operating process according to a strict process.

Conclusion

The application of CNC technology makes mold processing easier. Meet the requirements from simple to complex. Not only helps to increase Insert molded parts quality, but also helps the mechanical engineering industry to develop more and more. Moreover, factories and workshops can bring more diverse and sophisticated products thanks to molds.

Cooling mass production injection molding is about waiting, but with the right part, mold and process design, the time important for cooling is easy to reduce.

If you’ve attended any of the training events, the figure of 80% was probably on your mind. This number refers to how much of the cycle time is needed for cooling the plastic part. It is for temperature that makes it rigid enough to withstand the ejection forces.

What are the areas that affect the cooling stage?

Through the following exercise, the following four areas that impact the cooling stage is good to review:

• Mass production design
• Moreover, selection of material
• Mold design

Mass production injection molding design

The basis for the cycle time lies in the decisions by the mass production injection molding design engineer. 

The thicker the mass production to meet usability conditions, the longer the cycle time in mass production will be. By having a squared variable, this factor becomes the one with the greatest influence on the cooling time.

How material is selected?

Plastic is an insulator par excellence. In a melted or molten state, plastic transfers heat slightly better. By releasing heat, its insulation properties increase. Moreover, the properties of the material that were common in the equation are:

• Melting temperature : Temperature at which there is the transition of the material from solid to liquid
• Mold temperature: The temperature range to replicate the surface finish that machines in a cavity on the plastic mass production
• Thermal Deflection / Distortion Temperature (HDT): Temperature at which the material deflects under load.

Typically, the ejection temperature of mass production injection molding in the equation uses the HDT or a temperature very close to below the HDT. The ASTM test for HDT very accurately represents which zone is hard. Similarly, it comes during ejection by the action of an ejector pin on only one side, while the opposite side is has no support.

What are the variables in the thermal diffusivity equation?

The variables in the thermal diffusivity equation include:

• Thermal diffusivity: Rate at which a thermal disturbance (in an increase in temperature) is going to transmit through the substance.
• Density: Moreover, the amount of substance per unit of volume (g/cm3 for plastics).
• Specific heat: Calorie heat requires raising the temperature of a gram of a substance by one degree Celsius.

For this test, Toyolac 100 resin was common with a melt temperature in the range between 230 and 250 ° C, mass production injection molding temperature of 40 to 80 ° C, and HDT of 83 ° C. Density can usually in the technical sheet of the material, but for thermal conductivity or specific heat.

Moreover, it is better to contact the supplier directly or use the information from the data bank of simulation software. Based on the geometry of the mass production and the selection of the material, the estimated cooling time was 18.00 seconds, from the mass production injection simulation.

Is it possible to remove all the heat?

Given the energy important to melt the material, it is not practical to remove all the heat while the part is still in the mold. Only 40% of the energy must remove to achieve the necessary rigidity and thus expel mass production.

Generally, it is not important to choose a cooling timer for mass production injection molding that only meets the HDT, rather it is good to choose a maximum value as a safety factor.

Moreover, a rule of thumb is to add 20% to the cool-down timer to account for incoming material variation and to lighten machine performance changes. For mass productions with close tolerances, the factor of safety should increase.

Which mold design is suggested?

An eight cavity mold is common for this mass production, with an H feed channel pattern and overlapping edge mass production ion injection points. 

Further, the cooling lines are located in the cavity, core and block of the feed channel following the established guidelines for diameter/depth/pitch. Using proven refrigeration line design methods, warpage and cycle time will be less.

Method of mass production injection molding prosecution

So where does the 80% figure come from? Let’s look at the data that comes for mass production injection molding. The stages of the process were taken as:

• Filling
• Packing / post-pressure
• Cooling
• Mold opening / ejection / closing

What is a robust decoupled II process?

For this experiment, a robust Decoupled II process was developed, resulting in the following mass production injection molding process parameters:

• Actual melt temperature:235 ° C.
• Actual mold temperature: 4 ° C with a 3.0 GPM flow rate for the cooling loop.
• Filling time: 26 seconds with a transfer pressure of 576 bar
• Packing / post-pressure:0 seconds at 286 bar
• Cooldown time: 0 seconds

If the process times add together and divide by the total cycle time, we reach a value of 0.85. This means that the proportion of the cycle that comes cooling the part is 85% to withstand the ejection forces.

Moreover, this graph also indicates that, at some point, leaving the part in the mold does not represent an added value. Based on the concepts of geometry, material, mold and processing, leaving the mass production injection molding closed for 24.73 seconds the mass production does not cool much more than what is important.

Conclusion mass production injection molding

The cooling of the part is always a function of the wall thickness and the material that the design engineer chooses. It is up to the mold designer engineer to locate the cooling channels in the proper zone to allow minimal cooling time. As a process engineer, the old adage to “fill as fast and consistently as possible with quality” still holds true.

For this geometry and material, much of the heat is removed during the filling and packing stages. However, to remove the last 3.2 ° C and reach a lower temperature than HDT, it takes more time than to fill and post-pressure the plastic mass production. Cooling is a waiting game, but with better engineering, the time important to cool the material can be less.

This article explores standards and recommends procedures to ensure neutrality in color measurement to avoid plastic mold for lawn mower parts ion trauma.

The acceptance or rejection of variations in the tone of plastic mold for lawn mowers can generate traumatisms in the plastic mold for lawn mower ion.  This article explores standards and best practices to ensure neutrality in color measurement.  

For this reason, it is established that color is a subjective interpretation, which occurs in our visual process and is generated by a physical phenomenon.

How color represents the Plastic mold for the lawn mower position?

In companies where color is controlled, it is very recurrent that the people who inspect color have different concepts. Also, the interpretation of color can be influenced by your position within the company.

For example, the one for plastic mold for lawn mower parts ion purposes will have a wider tolerance for variations in tonality. Similarly, the one that controls the quality of the molded article will have a more rigorous tolerance. We rely on the history of this plastic mold for lawn mower where your customer.

In the same way, the perception of color represents age, eyestrain, drug use, and other physiological problems. Even so, without these influences, each person perceives color differently. This subjectivity can lead to confusion and frustration among customers, suppliers, quality plastic mold for lawn mower ion teams, and managers.

What is the language of color?

It is very important to know some basic aspects of color and colorimeters, in order to establish better tools in visual perception and make better decisions for plastic mold for lawn mower parts in color tolerance.

Moreover, the color starts from the illumination of an object and the perception by an observer. For this reason, these three aspects, the illuminant, the object, and the observer, are keys in the standardization and tolerance of color.

The CIE “International Lighting Commission” was in charge of quantifying these three aspects. It is in order to give more objectivity to the measurement of the color. For this, a standard observer was established, and the object and illuminants were important.

What is a visible spectrum in Plastic mold for a lawn mower?

Of the entire electromagnetic spectrum, only the fraction from 400 nm to 700 nm takes as the wavelength. Being the fraction where we can perceive color. This fraction is the visible spectrum.

Further, when we talk about the interaction of light with the plastic mold, it refers to the fact. It is the light that falls on the object that will have different reactions.

D65 is the most popular illuminant as artificial light for color inspection of plastic articles. In the graph, the wavelength range for the visible spectrum comes on the X-axis. Similarly, the relative spectral power comes on the Y-axis. Moreover, this will give a spectral distribution in the visible spectrum for the illuminant.

How to show wavelength and spectral power in Plastic mold for a lawn mower?

Moreover, now the standard observer graph is the way to quantify the observer about plastic mold for lawn mower parts. The visual spectrum comes on the X-axis. Three curves plot on the graph each represented for the CIE color matching or color matching functions.

The three functions indicate the amount of each primary function. These are necessary to match the color of one watt of the radiant power of the indicated wavelength.

Speaking the same language

When someone asks us to describe the comparison of color, we can even use words such as darker, redder, and dirtier. Therefore, it is necessary to standardize this language. This is how color models such as those shown in figure 5 are established.

Recommendations for measuring color

If you have a history of lots shipped and lots rated by the company’s color expert staff, you can better determine.  Plastic mold for lawn mower parts being evaluated can be accepted. The first thing that I must structure is a color inspection. For this you need:

Standardization of light and place of visual inspection:

It is necessary to establish under which light we must control the color specification. It is advisable to do it in a light booth using the D65 light.

Object standardization:

Pieces of the same geometry must be compared. The incidence of light must be the same in both pieces, so it is necessary to choose an angle. It is advisable to have the pieces at an angle of 45 °.

Some pigments have a greater change in tone and effect when the angle of observation changes; For example, effects for plastic mold for lawn mowers such as pearls and metallic ones can, due to this phenomenon, carry different information to the brain due to the incidence of light at different angles, which can lead to a bad decision.

Use the same background to carry out the visual inspection:

A phenomenon known as lateral inhibition occurs in our visual process, where we can perceive differences in color in the same items when they are observed in different backgrounds.

We can get the best results if we follow certain instructions from reliable plastic mold manufacturers.

Standardization of the observer:

The decision criteria of the observers must be unified. For this, they must have experience in the history of the plastic mold for lawn mower parts and the client, have on hand a color pattern with maximum, minimum, and standard, built based on the experience of variation of the tone, by formula, machine, and process conditions, among others.

Furthermore, it is recommended to put in this color pattern the most critical variables that affect the tone of the article. Observers’ judgment can be standardized by evaluating the approval tolerance of the customer and the personnel inspecting the color. It is necessary to carry out a color perception test and use a spectrophotometer to build a “cloud” of tolerance between companies and people.