Introduction of Automotive Injection Mold

As in all industries, plastic Automotive Injection Mold has its types of defects that can damage or damage the part. It is very important to work with companies that understand and have the quality control and non-compliance skills needed to avoid defects and inaccuracies in production.

Not all defects occur in the same way, so it is important for you, as a client, to understand the reasons for their occurrence. Today we are considering “divorces”, a typical cosmetic defect that may indicate problems with plastic or with the production process.

What is a singularity in plastic injection molding?

Divisions in injection molding are determined by the stripes that occur along the entire surface of the formed part. Most often silver is a reaction due to water entering the plastic during the heating process inside the mold. This is due to the humidity in the places of supply of plastic, which when heated.

In the middle turns into steam. Then it turns into tiny gas bubbles, which penetrate the plastic during its injection, leaving a silver pattern on the surface of the finished part.

 

What are the main causes of divorce?

The main problem with this Automotive Injection Mold defect is moisture, but how exactly does moisture get into the process? Although plastic resins/plastics that melt to form parts are often considered waterproof, it is important to remember that many of these plastics are easy to absorb or covered with moisture at various points in the process.

They may come from the manufacturer already containing moisture or receive this moisture during transportation, storage, or preparation for production. The plastic needs only a little moisture to cause the highlighting effect – ie the appearance of stains.

Elimination of Automotive Injection Mold defects in details

Whether you have already dealt with stains or just want to avoid them in the future, it is important to remember to protect both the material and the equipment from moisture. Here is a list of specific recommendations to avoid this most common problem.

Avoid degradable plastics

If plastics remain heated for too long or at too high a temperature, they can begin to break down and decompose, releasing gas and moisture, causing spills. Avoid too much re-grinding: Too high a re-grinding rate – the use of reusable thermoplastics – sanded after use before.

It can also become contaminated with moisture. Eliminate inaccuracies in the feed rate and the design of the mold: if the plastic melting nozzle is running at too high a speed, or if the Automotive Injection Mold hole is the wrong size, it can also create spray effects – stains.

There are several steps to getting a finished plastic product.

The variety of plastic parts that we encounter every day – is very large, and every day they become more and more. Plastic products are common by more than 90% of the world’s population, in this regard, the processing of plastics is developing very rapidly, there are new technologies for plastic casting. A large niche in this area is occupied by injection molding of plastics with the help of a tool called – a mold.

• Detail design.
• Construction of the mold according to the drawings.
• Making a mold.
• Checking the efficiency of the forming equipment.
• Product casting.
• Product design

To create a 3D Automotive Injection Mold model, such important factors as:

All stages of mold part development are done using software (CAD). The use of CAD reduces the time spent on development, reduces the percentage of design errors in the design of the Automotive Injection Mold. The designer of equipment (molds) makes a mathematical design of 3-d model on the information given to it from the customer.

• product individuality
• material characteristics
• product part optimization

The result will be a model and a drawing of the product. It can be common to evaluate the product and its forming equipment.

Design of Automotive Injection Mold

When the development of the part is completed, the design engineer begins cooking to design the mold. The choice of components for molds is of great importance. The stability of the form, quality of a forming surface of the form, ability to give of processing of working parts, and quality of the future plastic product depends on the material.

Steels with a hardness of 30… 32 HRC are required for the correct operation of the mold, they can be common for the manufacture of Automotive Injection Mold parts of the mold without heat treatment, these factors will significantly reduce the time for the manufacture of equipment.

9 reasons to use Automotive Injection Mold

Nowadays, more and more often molds come from corticosteroids (hot runner systems), and there are reasons for this. The use of corticosteroids has many advantages. Including:

• casting time costs are reduced.
• reduced pressure in the mold.
• improved product quality.
• reducing the cooling time and obtaining the finished product.
• lower cost of the product.
• There are also disadvantages of using corticosteroids
• price
• difficulty in servicing
• there are problems if you work on secondary material.

The Structure of Automotive Injection Mold

The thermostatic structure of the mold must create the correct distribution of the thermal sides of the molding levels of the mold and be separate to reduce the time spent on the manufacture of the part. The final work of the designer to develop an Automotive Injection Mold will be a 3D model of the form, and a set of technical documentation.

The 3-D example of the forming planes come by the designer is common for the writing of programs and processing of surfaces of metal on the ChPU machine. At the end of the creation of products following the design, documentation is assembled, also prepared for testing the mold.

• general information about hot runner systems
• res-forms with a hot-runner system for processing thermoplastics

Conclusion Automotive Injection Mold

After installing the mold on the thermoplastic machine, we test the mold. Our purpose is to collect information for future changes and corrections of surfaces, gutter, and ventilation systems, after these actions the mold comes into operation.

The final stage of manufacturing the part – Automotive Injection Mold. At this stage, it is important to adjust the process of casting plastic parts under pressure.

Introduction of Cavity-Lifter Injection Mold

The production of a perfect part begins with the Cavity-Lifter Injection Mold. Designing a shape is usually time-consuming and requires great precision. The process of its production often requires large funds, so the success of the whole project depends on the correctness of the drawing and the accuracy of the mold.

At the same time, if the goal of the project is to manufacture many parts with a high degree of accuracy, the production process itself becomes even more complex and complex. Plastic manufacturers usually provide information on material shrinkage and melting point and recommendations on melt rate.

Choice of plastic for the mold

The machining and casting process depends on the type of plastic common to make the part. Amorphous plastics are less free-flowing and generally less compressed than crystalline or semi-crystalline plastics, which provide better permeability but greater material shrinkage.

That is why many projects are implemented using technical composites/polymers, which give better melt and less shrinkage. Polymer shrinkage affects the design/drawing and machining of molds. The socket of the Cavity-Lifter Injection Mold must ideally accommodate/shrink the amount of material that will occur when casting the part.

Processing according to Cavity-Lifter Injection Mold standards

Using modern CAD software products, designers usually design Cavity-Lifter Injection Mold. The size of the increased tolerance depends on the characteristics of the polymers/plastics from which the part is poured. Sometimes this shrinkage is easy to correct.

By adjusting the flow of material and maintaining its appropriate level in the mold. It is important to note that any plastics and polymers can compress during cooling, even after the part has been removed from the mold. Deformation of the casting process can occur if there are jumps in temperature, pressure, fluid/material flow rate.

Accurate design work as a guarantee of high quality

Precision parts must accurately meet the standards not only for the parameters of the mold slots but also for the use of components. Similarly, we need to focus on the design of the Cavity-Lifter Injection Mold. Inlets and outlets must be in such a way as to ensure proper passage/flow of material and appropriate pressure.

The size of the inputs/outputs is also an important element. The inputs must be large enough to ensure a proper supply of material without increasing the production time (cycle). If the inlets/inlets are too small, the supply of material may not be enough to fill the mold slot or may provoke other defects in the part. The design of the mold should also provide for appropriate purge/ventilation.

Quality and costing of Cavity-Lifter Injection Mold process

Ventilation openings allow air to be released during the melting of polymers/plastics, get out of the mold. Like the situation with the outlets, the correct location of the vents plays an important role in ensuring the quality of the casting process and the manufacture of parts.

Too large holes can cause material leakage and other problems. Holes that are too small do not allow to release of the mass of air and gas that has accumulated in the Cavity-Lifter Injection Mold. Such gas residues can provoke incorrect filling of the form with material and other defects. The gas may ignite and leave traces of combustion.

The right cooling system is the key

which has accumulated in the mold. Such gas residues can provoke incorrect filling of the form with material and other defects. The gas may ignite and leave traces of combustion. which has accumulated in the mold. Such gas residues can provoke incorrect filling of the form with material and other defects. The gas may ignite and leave traces of combustion.

An efficient cooling system is an important element in ensuring a high-quality mold. The mold must maintain a constant temperature to avoid material shrinkage and deformation of the part while minimizing time cycles and maximizing output. The combination of the described elements is achieved.

Prototyping – improves the quality of the production process

Avoiding inaccuracies in the manufacture of molds and the need to recycle the Cavity-Lifter Injection Mold allows the company to save time and money in the long run. This step is necessary and requires a detailed and accurate drawing of the form, selection of polymers/plastics, and adjustment of appropriate parameters.

Setting the temperature and regulating the flow/supply of material into the form). In the event of problems with the quality of the workmanship, the development team will re-test the samples to achieve strict compliance with the standards, determining the cause-and-effect relationships of defects.

The choice of metal is the basis of high-quality mold production

The more inexperienced a player in the plastic casting market is a company, the more likely it is to use aluminum to make Cavity-Lifter Injection Mold. This material is ideal provided that the form will not be common in the long run. However, if the parts design/plan involves the use of a mold over a long period (several years).

Number of seats/sockets in the Cavity-Lifter Injection Mold

Compared to aluminum, steel withstands higher pressures throughout the production cycle and allows adherence to near-ideal tolerances. In general, most mold manufacturers recommend making a single mold for casting apart, rather than creating a multi-cell mold. Multi-nest forms are made with several places/holes for components. With the help of such forms, as a rule, produce lower quality parts, and the process itself causes more downtime due to maintenance problems. Hardened steel molds last longer to use, but require more money and longer processing. However, when such a Cavity-Lifter Injection Mold is ready, the term of its use for the production/casting of parts is quite long.

Machining of the Cavity-Lifter Injection Mold

All molds must meet the requirements and specifications provided by the customer. Fitting to requirements includes the location of cores, sockets, spouts, cooling systems, and more. Steel, which is common in the manufacture of molds, also affects the cost of the mold itself.

As well as the number of sockets, the complexity of the part itself affects the cost of manufacturing the mold. This includes finishing the surface of the final part as well as the number of required threads. Details that require a clear tolerance also affect the complexity of the mold.

Conclusion

Cavity-Lifter Injection Mold

Some manufacturers of molds also engage in the manufacture of parts. This combination of two tasks: the manufacture of the Cavity-Lifter Injection Mold and the casting of the part allows you to cover the cost of manufacturing the mold. Typically, manufacturers that provide a full range of services include part.

Or all the cost of making a mold in the cost of contact. Such manufacturers will be able to depreciate the cost of the form in such a way as to achieve a margin (make a profit), providing the lowest level of costs for customers.

In this blog, we would like to share some ideas on the plastic molding. It is onto considered when integrating a new mold in your production plant. It is essential that the operator analyze the project to understand the construction of the acquired equipment. And follow some basic guidelines for connecting the mold systems.

Once the mold is in the machine and all the connections and movements have been checked, we proceed to adjust the homogeneous temperatures. In addition, to obtain a process suitable injection, we must adjust different temperatures: Temp the cylinder, Tª of the mold, and Tª of the melt.

Plastic molding temperature-based division

The plastic molding temperature in the plasticizing cylinder is divided into zones. It is where we must be guided by the indications of the polymer manufacturer. The temperatures of the first and last zone cannot differ more than 30 ° C (5-10 ° C between each of the zones). The injection nozzle must be at the same temperature as the front part of the cylinder.

How to correctly define these temperatures, always within the allowed limits? We must know the product: its geometry, thickness, etc. The temperatures that we configure in the mold will be responsible for the quality of the injected product. The cycle time and the dimensional result of the pieces become accurate.

What is the cooling mechanism of plastic molding?

The plastic molding has a cooling system that allows the melt to solidify and control the temperatures from outside the mold. Controlling the result on the piece in injection process optimization is a significant part of injection molding and has its pre-defined.

If work with temperatures lower mold, will obtain cycles shorter, but this leads to work with more powerful machines’ injectors (higher injection pressure and greater closure force). And consider possible defects in the product (greater fragility of the product, hollow parts, dull product surfaces, etc.)

What to do if the work has hot molding?

If work with a hotter mold, we reduce the required clamping force of the plastic molding. It is improving the visual appearance of the product and filling easier. Sounds perfect?! Well, there are drawbacks: the contraction of the material under these conditions is increased, as well as the cycle time.

In addition, due to the greater adherence of the pieces to the surface of the mold, more visible ejector marks can be observed. Moreover, each operator, depending on the product, must adjust the process temperatures to find a compromise between different aspects of the product and the production process.

What is plastic molding?

Plastic molding is a transformation tool common to shape the raw material introduced under pressure and high temperatures for its interior with the use of specific injection machines, guaranteeing its solidification and cooling until the moment of the possibility of ejection of the final piece.

In this way, the mold receives the raw material in its liquid state from the injection machine. Gives it the previously defined shape (in the form of a negative in the cavity and male/punch), rapidly cools the molded part. And carries out the expulsion of the same. Example_mold_3plates

Types of plastic molding

There are 3 basic types of conventional molds:

1. 2-Plate molds
2. 3-Plate molds
3. Hot Runner molds

The fixation of the plastic molding in the injection machine (in its fixed and mobile plates) is carried out by means of mechanical fixation (screws). The clamping plates/clamping flanges move except for some exceptions. The entire mold has centering elements in its design to guarantee the perfect centering of the two main parts of the mold (cavity/punch or fixed / mobile part).

Precautions for plastic molding

During all operations, thus being able to avoid:

1. Dimensional problems in injected parts
2. Risk of damaging internal components, such as inserts and/or molding surfaces
3. Displacement of the two halves of the mold under high pressures of the injection machine

Examples of plastic molding

Some examples of centering elements for plastic molding are:

 →First, guide columns

→ Second, inclined guides

→ Moreover, interlocks / Side centering devices

→In addition, conical centering devices

→ Additionally, bushings

What is an ejection system?

The set of components that guarantee the ejection of the injected and solidified part is called the expulsion system. This system can be mechanical, hydraulic, or pneumatic, depending on the mold and type of product.

Ejectors of plastic molding

Some types of ejectors for plastic molding:

1. Firstly, Cylindrical head ejectors
2. Secondly, tubular Ejectors
3. Moreover, foil ejectors (common for thin gauge parts)
4. Lastly, ejector plate (which can even be part of the molding surface)

One of the important aspects that must be considered when designing a mold is the cooling system and its circuits. It consists of a set of channels in the mold plates for the passage of a cooling liquid. With a good cooling system correctly designed according to the type of product. It allows us to obtain a stable and sufficiently low temperature of the molding elements to cool the injected plastic and solidify it.

Factors of plastic molding

This factor has a direct impact on the quality of plastic parts (aesthetics and mechanics). To guarantee the same plastic molding results at different times / in different production plants, we must always maintain the 2 parameters: compaction and the temperature of the part when demolding/ejection.

As the last point to be discussed in this blog, we are going to talk about the feeding system of a mold. All the molds are divided into 2 large groups: cold runner and hot chamber. Within each group, there are numerous types of solutions, but we will see them in detail in one of the following blogs.

Conventional solution role in plastic molding

A cold runner or conventional solution is the cheapest that exists in the sector, but it presents several limitations. Which are solved with the hot runner solution? Hot runner injection allows the plasticized raw material to be carried to the molding areas.

The main advantages of this system are the significant reduction of material waste by eliminating the casting, the much shorter injection cycles. The product quality is significantly improved, given the large number of solutions provided by the manufacturers of hot runner systems.

Get in touch with us for plastic molding

We hope that this information on plastic molding will serve to improve your production processes and reinforce your improvements on the road to success. Lastly, welcome to contact us; We will accompany you towards the success of your project.