What is the new technology of injection mold manufacturing

With the rapid development of the plastic mold design industry and the promotion and application of plastic products in the aviation, aerospace, electronics, machinery, shipbuilding and automobile industries, the requirements for the mold are getting higher and higher, and the traditional plastic mold design method has been unable to meet the requirements of product upgrading and quality improvement.

Computer-aided engineering (CAE) technology has become the most effective way to develop plastic products, mold design and product processing for these weak links.

Moldflow, Inc., a U.S.-listed company specializing in injection molding CAE software and consulting, has dominated the plastic molding CAE software market since 1976, when it released the world's first flow analysis software.

In recent years, it has been widely used in the fields of automobiles, home appliances, electronic communications, chemicals and daily necessities.

The use of CAE technology can be used to analogous analysis of the entire injection molding process on the computer before mold processing, and accurately analyze the filling, pressure holding and cooling of the melt, as well as the stress distribution, molecular and fiber orientation distribution, shrinkage and warpage deformation of the product, etc., so that the designer can find the problem as soon as possible and modify the part and mold design in time, instead of waiting for the mold trial to repair the mold.

This is not only a breakthrough in the design method of traditional plastic molds, but also has great technical and economic significance for reducing or even avoiding mold repair and scrapping, improving product quality and reducing costs.

Plastic mold design requires not only CAD technology, but also CAE technology.

This is the inevitable trend of development.

Injection molding is divided into two stages, namely the development design stage (including product design, mold design and mold manufacturing) and the production stage (including material purchase, mold tryout and molding).

The traditional injection molding method is before formal production, because the designer designs the mold with experience and intuition, after the mold is assembled, it usually takes several mold trials, and after the problem is found, it is not only necessary to re-set the process parameters, but also need to modify the design of plastic mold design products and plastic molds, which is bound to increase production costs and extend the product development cycle.

With the development of the world economy, the design requirements of industrial products pay more and more attention to fashion, environmental protection, and lightweight design, and the IMR process came into being, which has been widely used in all walks of life, from the earliest consumer products such as notebook shells, mobile phone lenses, household appliances and various decorative panels, automotive dashboards, automotive interior parts, medical instrument panels, cosmetic boxes, children's toys and so on.

IMR (in-moulddecoration by roller): Chinese supermodel interior decoration technology, is to print decorative patterns and functional patterns on the foil film through a high-precision printing machine, through a high-precision foil feeding device to send the foil into a special molding mold for precise positioning, through the injection of high temperature and high pressure of plastic raw materials. Transcribing the pattern on the foil film onto the surface of the plastic product is a technology that can realize the integrated molding of decorative patterns and plastics.

How does IMR work?

It is to print the pattern on a layer of foil, and the film is laminated with the plastic mold cavity by sending the film for injection molding, and the ink layer with the pattern is separated from the foil film after injection, and the ink layer is left on the plastic part to obtain a decorative drawing on the surface.

Advantages of the IMR process.

1.Integrated molding, simplified manufacturing process, reduce production inventory costs and man-hours, shorten product manufacturing cycle, and improve the production efficiency of Hengfan;

2.All kinds of reliability tests are of the highest level in the industry to ensure the stability and durability of products;

3.High automated production to ensure stable production with high yield;

4.The use of automatic printing and environmentally friendly ink, in line with environmental protection requirements;

5.It can be used for multi-color laughter and printing, such as wood grain, carbon fiber, metal color, etc. The surface texture and groove of the product can be colored at the same time. For transparent parts, it can be made semi-transparent. It has a three-dimensional texture.

6.The hard coat treatment (up to 3 hours of pencil hardness) is wear-resistant and aesthetically pleasing.

Rotational mold processing

The method of rotational molding process is to add the plastic to the mold first, and then the mold rotates continuously along the two vertical axes and heats it, and the plastic in the mold is gradually and evenly coated and melted and adhered to the entire surface of the mold cavity under the action of gravity and heat energy, and is molded into the required shape, which is prepared by cooling and shaping.

The rotational molding process has the following advantages compared with the traditional blow molding and injection molding processes:

1. Cost advantage: In the rotational molding process, only the strength of the frame is required to be sufficient to support the weight of the material, the mold and the frame itself to prevent the leakage of the mold. And in the whole molding process, the material is almost not affected by any external force except for the action of natural gravity, so as to fully possess the advantages of convenient machining and manufacturing, short cycle and low cost.

2. Quality advantage. The products of the rotational molding process are more stable in terms of product quality and structure due to the absence of internal stress during the whole production process.

3. Flexible and changeable advantages. The machine mold of rotational molding process is convenient to manufacture and inexpensive, so it is especially suitable for multi-variety and small-batch production in new product development.

4. Personalized design advantages. The products in the rotational molding process are easy to change color, and can be hollow (seamless and weldless), and the effect of pattern, wood, stone and metal can be achieved in the surface treatment of the product, so as to meet the personalized needs of consumers in modern society.

The products produced by this process are: fuel tanks, water tanks, mechanical shells, fenders, etc. The main substitution objects are metal parts and FRP products.

It is to pass the plastic through the injection molding machine and inject it into the mold.

Injection mold is a type of plastic mold.

The quality of precision mold manufacturing is high, which not only requires high processing accuracy, but also processes the surface.

Complex shape The working part of the precision mold is generally a two-dimensional or three-dimensional complex surface (especially the cavity mold), rather than a simple geometric surface that is generally machined.

Mold production is a single-piece, multi-variety production Each mold can only produce Moy's specific shape, size and precision. In the manufacturing process, we should try to use general machine tools, general measuring tools and instruments to reduce the number of special tools as much as possible. In the arrangement of manufacturing processes, the process is relatively concentrated to ensure the quality and accuracy of mold processing, simplify management and reduce process turnover time.

High hardness of materials Plastic mold is actually a kind of machining tool, its hardness requirements are high, generally made of quenched alloy tool steel or cemented carbide and other materials, if the traditional machining method is used, it is often more difficult, so the mold processing method is different from the general machining.

Short production cycle Due to the acceleration of product upgrading and the increasingly fierce market competition, the mold production cycle is required to be shorter and shorter. The production management, design and process work of the mold should be adapted to this requirement, and the design, manufacturing and standardization of the mold should be improved to shorten the manufacturing cycle.

When a part needs to be processed by multiple molds, the product manufactured by the previous mold is the blank of the Houyi mold, and the mutual implication of the mold parts is restricted, and only the final parts are qualified, and these molds are qualified. This feature must be fully considered in the production and planning of molds.