It seems that you’ve listed several issues that may be related to the injection molding process. Let’s address each of them separately:
- Bending Size of the Mold: If the mold is experiencing bending or distortion, it could be due to improper cooling, high injection pressure, or inadequate support during the molding process. Properly align and support the mold to prevent any bending or distortion. Additionally, ensure that the cooling system is functioning correctly to maintain uniform temperature throughout the mold and prevent thermal stresses.
- No Unloading: If the molded parts are not being unloaded from the mold, it may be due to mechanical issues with the ejection system. Check the ejector pins and ensure they are operating smoothly. Lubricate the ejection system regularly to prevent sticking. If the problem persists, inspect the mold design and ejection mechanism to identify any potential issues.
- Uneven Feeding: Uneven feeding of the material into the mold can result in incomplete or defective parts. This issue may be caused by inadequate material flow, improper runner design, or improper mold venting. Check the gate design and runner system to ensure proper material flow and avoid any material blockages.
- Poor Riveting: If the molded parts require riveting and the process is not yielding satisfactory results, it could be due to poor mold design or material selection. Ensure that the mold design allows for proper alignment of the rivets during the molding process. Additionally, consider using a material that is suitable for riveting applications to achieve strong and reliable connections.
Addressing these issues may require a thorough evaluation of the injection molding process, mold design, and material selection. It is critical to work closely with experienced mold engineers and process technicians to identify and correct specific problems encountered during the injection molding process. Regular maintenance, proper mold design, and correct processing parameters are critical to ensuring consistent and high-quality molded parts.
First, a thorough evaluation of the injection molding process is the first step in solving the problem. This includes a detailed analysis of aspects such as the injection molding machine’s operating procedures, temperature control, pressure control and injection speed. By carefully examining each step, you can determine if there are any potential issues or room for improvement. For example, if you find that an operation at a step is imprecise or inconsistent, you can take steps to improve the accuracy and consistency of the operation.
Secondly, mold design is also an important factor affecting product quality. A good mold design can reduce defects and scrap. Therefore, a comprehensive evaluation of the mold design is required, including the structure and size of the mold, the design of the cooling system, and the location of gates and runners. By optimizing the mold design, the molding quality and production efficiency of the product can be improved.
In addition, material selection also plays a key role in product quality. Different materials have different characteristics and performance, and choosing the right material can ensure that the product has good strength, wear resistance and appearance quality. Therefore, the materials used need to be evaluated and ensure they meet the product’s requirements and standards. At the same time, attention needs to be paid to the storage and use conditions of materials to avoid contamination or damage to the materials.
Finally, regular maintenance is key to ensuring a stable operation of your injection molding process. Regular inspection and maintenance of injection molding machines, molds and other equipment can detect and repair potential problems in time, avoiding production interruptions and quality problems. In addition, regular cleaning and lubrication of equipment can extend its service life and increase productivity.
To sum up, solving problems in the injection molding process requires comprehensive consideration of multiple aspects such as process, mold design, and material selection. Working closely with experienced professionals and performing regular maintenance and optimization ensures the stability of the injection molding process and consistent product quality.
Bending size of the mold, no unloading, uneven feeding, poor riveting
- Bending size
a. The mold is not adjusted in place, resulting in angle error, which causes dimension deviation, poor closing height or poor angle difference
b. Insufficient elasticity leads to poor angle, resulting in dimensional deviation Replace the spring
c. The material does not meet the requirements, resulting in poor angle, which leads to size change or re adjustment of gap deviation
d. Poor angle caused by material thickness deviation determines the material thickness due to size deviation. Replace the material or readjust the gap difference
e. Size deviation caused by improper positioning Adjust the positioning to make the size OK
f. Design or processing errors cause repair welding and grinding between the bending male parts, eliminate the gap between the parts, and lead to small bending size~
g. There is no R angle for forming, and the bending height is too small under the angle and other normal conditions for forming the common R angle
h. The bending size on both sides is too large- Unstable size caused by unilateral bending and drawing, increase spring force, and adjust positioning
j. Unreasonable clearance, resulting in poor angle and dimension deviation
k. The height of the folding knife is not enough. The bending punch is too short to close the folding knife. The height of the folding knife is increased to make the bending punch close to the folding knife position as much as possible, causing more bad angles
l. When bending, the speed is too fast, causing deformation at the bending root. Adjust the speed ratio and select a reasonable speed
m. The structure is unreasonable, the folding knife is not inserted into the fixed template, and the groove is milled again. When the folding knife is inserted into the template for stamping, the gap becomes larger
n. The hardness of the forming male during heat treatment is not enough, resulting in the collapse of the pressing line or the flattening of the reshaping male pressing line- No unloading
a. Improper positioning or feeding Adjust the positioning or feeding device
b. Refuge position is not enough, repair and grind the avoidance position
c. The inner guide pillar is strained, which causes the blocking movement to be impeded. Replace the inner guide pillar
d. The punch is strained or the surface is not smooth Replace the punch
e. Unreasonable layout of ejector pin Relocate the position of ejector pin
f. The ejection force is not enough or the stripping force is not enough. Replace the ejection spring or stripping spring
g. The punch and the splint don’t fit smoothly. Repair the punch and the splint to make the punch fit smoothly
h. The formed slider does not fit smoothly. Trim the slider and the guide groove to make them fit smoothly- The stamping heat treatment is not suitable, and the deformation occurs after stamping for a period of time. Grind the stamping again, and correct the deformation
j. The punch is too long or the length of the ejector pin is not enough. Increase the length of the ejector pin or replace it with a punch with a suitable length
k. Punch break Replace the punch
l. The template is not magnetized, and the workpiece is demagnetized upward to the template- Unsmooth feeding
a. The mold is not upright, resulting in the material belt not in the same line with the feeder and the mold to re frame the mold or adjust the feeder
b. Uneven belt leveling machine or material replacement
c. If the feeding is not smooth due to non unloading, refer to the non unloading solution
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d. Positioning is too tight Adjust positioning
e. The guide pin is too tight or the straight wall position is too long Adjust the guide pin
f. The punch is not fixed well or is too long to interfere with the strip. Replace the punch with a suitable length and fix it again
g. The ejector pin is too short, and the strip interferes with the forming block. Adjust the length of the ejector pin to avoid interference
h. Improper arrangement of floating block position Adjust floating block position- Poor riveting
a. The closing height of the die is improper. The riveting is not in place. Adjust the closing height
b. The workpiece is not put in place, and the positioning deviation is adjusted for positioning
c. Before riveting, confirm whether the riveting hole is chamfered by referring to the countermeasures for solving the defective workpiece. If there is no chamfer, increase the chamfer
d. The riveting punch is not long enough. Replace it with a punch with proper length
e. Confirm that the riveting punch does not meet the requirements and use the riveting punch that meets the requirements
