The manufacture of Dustbin Mould(FURNITUREMOULD) refers to the processing of forming and blank making tools, in addition to shearing mould and dustbin mould. Usually, the dustbin mould consists of an upper mould and a lower mould. The steel plate is placed between the upper die and the lower die to form the material under the action of the press. When the press is opened, the workpiece determined by the shape of the dustbin die will be obtained or the corresponding waste material will be removed.
(1) High machining accuracy requirements
A pair of moulds is generally composed of female mould, male mould and mould base, and some may be multi-piece modules. Therefore, the combination of upper and lower dies, the combination of insert and cavity, and the combination of modules all require high machining accuracy. The dimensional accuracy of precision dies often reaches μ m.
(2) Complex shape and surface
Some product-shaped surfaces are formed by combining various curved surfaces, so the cavity surface of the mould is very complicated. Some curved surfaces must be treated by mathematical calculation.
(3) Small batch size
Mould production is not mass production, in many cases, only one pair is produced.
(4) Many working procedures
Milling, boring, drilling, reaming, tapping and other processes are always used in the manufacturing of the die.
(5) Repeated production
The use of the mould has a long life. When the service life of a pair of moulds exceeds its service life, a new mould must be replaced, so the production of moulds is often repetitive.
Sometimes there is neither pattern nor data in the mould production, and copying processing must be carried out according to the actual objects. This requires high imitation precision and no deformation.
(7) Excellent mould materials and high hardness
The main materials of the mould are mostly made of high-quality alloy steel, especially high-life moulds, which are often made of Leroi steel such as Crl2 and CrWMn. This kind of steel has strict requirements from blank forging, processing to heat treatment. Therefore, the compilation of processing technology cannot be ignored even more. Heat treatment deformation is also a problem that needs to be taken seriously in processing.
According to the above-mentioned characteristics, the selection of machine tools should meet the processing requirements as much as possible. For example, the numerical control system has stronger functions, higher precision of machine tools, better rigidity, better thermal stability and profiling functions.
If you are interested in our products, you can click Crate Mould to learn more information.
The working conditions of the Air Cooler Mould(FURNITUREMOULD) are different from those of the cold stamping mould. Generally, the air cooler mould must work at 150 C-200 C. Besides being subjected to certain pressure, it must also be subjected to temperature influence. The basic performance requirements of steel for air cooler mould are summarized as follows according to the use conditions and processing methods of air cooler mould:
1. Sufficient surface hardness and wear resistance
The hardness of the plastic mould is usually below 50-60 HRC. The heat-treated air cooler mould should have sufficient surface hardness to ensure sufficient rigidity of the air cooler mould. During the operation of the mould, due to the filling and flowing of plastic, the mould has to bear large compressive stress and friction force, which requires the mould to maintain the stability of shape accuracy and dimensional accuracy and ensure the mould has sufficient service life. The wear resistance of the mould depends on the chemical composition of the steel and the heat treatment hardness, so improving the hardness of the mould is beneficial to improving its wear resistance.
2. Excellent machinability
In addition to EMD processing, most air cooler mould to need certain cutting processing and fitter repair. In order to prolong the service life of cutting tools, improve cutting performance and reduce surface roughness, the hardness of steel used for air cooler mould must be appropriate.
3. Good polishing performance
For high-quality plastic products, the roughness value of the cavity surface is required to be small. For example, the surface roughness value of the injection mould cavity is required to be less than ra 0.1 ~ 0.25, while the optical surface is required to be ra < 0.01 nm. the mould cavity must be polished to reduce the surface roughness value. The steel materials selected for this purpose require fewer impurities, fine and uniform structure, no fibre directionality, and no pitting or orange peel defects during polishing.
4. Good thermal stability
The shape of air cooler mould parts is often complicated and difficult to process after quenching. It should try to choose the ones with good thermal stability. When the air cooler mould is formed and processed after heat treatment, the linear expansion coefficient is small, the heat treatment deformation is small, the dimensional change rate caused by temperature difference is small, the metallographic structure and the mould size are stable, and the processing can be reduced or stopped, thus ensuring the mould size accuracy and surface roughness requirements.
With the development of the plastic industry, the requirements for the complexity and precision of plastic products are getting higher and higher, and higher requirements are also put forward for mould materials. Pre-hardened steel (such as PMS), corrosion-resistant steel (such as PCR) and low-carbon maraging steel (such as 18Ni-250) can be used for manufacturing complex, precise and corrosion-resistant plastic moulds, all of which have better cutting, heat treatment and polishing properties and higher strength.
If you are interested in our products, you can click Crate Mould to learn more information.
(1) The formal drawing of the crate mould after being audited and signed and the brand and transparency of the plastic shall be indicated.
(2) Specifications or technical requirements for plastic parts.
(3) Production output.
(4) Samples of plastic parts.
Usually, the task of designing the Crate Mould(FURNITUREMOULD) is put forward by the craftsman according to the task book of forming plastic parts, and the mould designer designs the mould according to the task book of forming plastic parts and the task book of mould design.
2. Collect, analyze and digest the original data
Collect and sort out the data on the design, moulding process, moulding equipment, mechanical processing and special processing for use in the design of crate mould.
(1) digest the drawing of plastic parts, understand the purpose of the parts, and analyze the technical requirements such as manufacturability and dimensional accuracy of plastic parts. For example, what are the requirements of plastic parts in terms of appearance shape, color transparency and service performance, whether the geometric structure, inclination and insert of the plastic parts are reasonable, the allowable degree of forming defects such as weld marks and shrinkage cavities, and whether there is post-processing such as coating, electroplating, glueing, drilling, etc. Select the dimension with the highest dimensional accuracy of plastic parts for analysis to see if the estimated forming tolerance is lower than that of plastic parts and whether the plastic parts can be formed to meet the requirements. In addition, it is necessary to know the plasticizing and moulding process parameters of plastics.
(2) Digesting process data, analyzing whether the requirements of moulding method, equipment type, material specification, crate mould structure type and the like proposed in the process specification are appropriate and can be implemented.
The moulding materials shall meet the strength requirements of plastic parts and have good fluidity, uniformity, isotropy and thermal stability. According to the application of plastic parts, the moulding materials shall meet the requirements of dyeing and metal plating conditions, decoration performance, necessary elasticity and plasticity, transparency or opposite reflection performance, adhesiveness or weldability, etc.
(3) Determining a moulding method
Is it direct compression, casting or injection?
(4) Selecting moulding equipment
According to the type of moulding equipment to choose the crate mould, so we must be familiar with the performance, specifications and characteristics of various moulding equipment. For example, for injection machines, the following contents should be understood in terms of specifications: injection capacity, mould clamping pressure, injection pressure, mould installation size, ejection device and size, nozzle hole diameter and nozzle spherical radius, gate sleeve positioning ring size, mould maximum thickness and minimum thickness, mould stroke, etc. See relevant parameters for details. The overall dimensions of the mould should be preliminarily estimated to determine whether the mould can be installed and used on the selected injection machine.
(5) Specific structural scheme
The choice of an ideal crate mould structure lies in determining the necessary forming equipment and the ideal number of cavities, which can make the crate mould itself meet the requirements of technological technology and economic production of the plastic parts under absolutely reliable conditions. The technological requirements for plastic parts are to ensure the geometric shape, surface finish and dimensional accuracy of plastic parts. The economic requirements of production are to make the cost of plastic parts low, the production efficiency high, the crate mould can work continuously, the service life is long, and the labour force is saved.
Under the condition that the structure, materials and use conditions of Daily Necessities Mould(FURNITUREMOULD) are unchanged, ensuring the heat treatment quality and adopting the best heat treatment process are the keys to give full play to the potential of mould materials and improve the service life of daily necessities mould. If the heat treatment process is unreasonable or improper operation causes heat treatment defects, it will seriously damage the service performance of the mould and lead to its early failure.
Pre-heat treatment of daily necessities mould working parts blank includes several processes such as annealing, normalizing, quenching and tempering according to different materials and requirements. Correct pre-heat treatment specifications play a great role in improving the structure, eliminating the structural defects of forged blanks, improving the machinability, and improving the bearing capacity and service life of daily necessities mould.
Quenching and tempering of mould materials for daily necessities is the central link to ensure the performance of mould working parts. Whether the quenching and tempering processes are reasonable or not has a direct impact on the bearing capacity and service life of the mould. The heat treatment process specifications should be strictly controlled or advanced heat treatment methods should be adopted.
The purpose of surface strengthening of the working parts of the daily necessities mould is to obtain the effect of external hardness and internal toughness, and to obtain a good combination of hardness, wear resistance, toughness and fatigue strength, thus improving the service life of the daily necessities mould.
If you are interested in our products, you can click Dustbin Mould to learn more information.