In the manufacture and use of moulds, frequent maintenance is a problem for many enterprises. The failure of the mould not only affects production efficiency, but also leads to high maintenance costs and delays in delivery. Many enterprises, faced with frequent maintenance of moulds, tend to be trapped in a circle of blind repair, resulting in recurring problems and considerable waste of time and money. So, is it a technical problem or is the material wrong? This paper will be analysed in depth from a variety of technical, material, management and other perspectives to help you find real problems and avoid blind maintenance。
I. Frequent maintenance of moulds and effects
Modelling, as a key tool in manufacturing, has a direct bearing on product quality and productivity. However, in reality, many of the moulds are frequently broken, deformed and worn, leading to a significant increase in the number of repairs. Frequent maintenance not only increases the maintenance costs of the moulds, but also severely affects production plans and even delays in customer orders, which damage the credibility of enterprises。
Technical issues: “invisible killers” of design and manufacturing processes
Design defects lead to the unsound design of the concentrated emulsion. This is an important reason for frequent maintenance. When the stress distribution is ignored in the design, resulting in a concentration of stress in certain parts, the moulds are vulnerable to cracks and deformations during their use. For example, sharp corner design, uneven wall thickness, etc. Would become stress points, reducing the life of the mold. The manufacturing of non-compliant moulds involves precision processing and thermal processing. Insufficient processing precision, uneven thermal treatment or poor hardness can lead to low or uneven strength of the molds, which can lead to early wear and tear. In particular, thermal processes are not well controlled and can generate residual stress and crack when used. The presence of large gaps or small fault lines and poor guidance when assembly is not calibrated in accordance with the requirements of the process results in uneven stress, abnormal wear and deformation and increased frequency of maintenance。
The material was wrong? Material performance is closely linked to the life of the mold
Materials that do not match the hardness and resilience of the material must be balanced with hardness and resilience. It's hard to get through, it's hard to wear, it's not resilient, it's hard to break. When selecting materials that focus only on hardness and ignore resilience, the moulds are vulnerable to fragmentation in high load, high impact environments. Part of the anti-corrosive performance mold is exposed to corrosive media, such as certain plastic aids, lubricants, etc., during the plastered or flushing process. If the material is not corrosive enough, the surface is prone to corrosive pits, which in turn induce cracks and damage. Unstable batches of materials, impurities or differences in composition when the quality of the materials is unstable, can also affect the performance of the moulds, leading to unstable lifespans and frequent maintenance。
Iv. Inadequate management and maintenance is also a risk
The damage to the mould is accelerated if the impregnation operator fails to comply strictly with the specifications, such as excessive pressure, uneven cooling, and late demodeling. The lack of maintenance will require regular cleaning, lubrication and testing to remain in good condition. The lack of a scientific maintenance plan, the increased wear and tear of the surface area of the mold, has led to frequent malfunctions. The problem of molds is repeated and a vicious circle is formed when the maintenance method is wrongly repaired with only surface repair, without solving the underlying problem or with irregular maintenance processes。
V. How to avoid frequent maintenance of moulds? Four strategies to help you break through
Optimizing the design, eliminating the concentration of stress in the design of the cae simulation model, optimizing the structure, avoiding sharp angles and wall thickness, rational distribution of stress, and increasing the overall strength and lifetime of the mould. (b) strict control of manufacturing processes to ensure the stability of quality in the selection of powerful mould manufacturing plants, strict enforcement of standards for processing and thermal processing processes, and ensuring that the rigidity and precision of the moulds meet design requirements. Selective materials that match the selection of suitable materials using the environment based on the work environment of the mold, balancing hardness, resilience and corrosive properties, quality testing during procurement and avoiding material problems. Improved management, scientific maintenance, development of detailed template protocols and maintenance plans, training of operators, periodic inspection and maintenance of moulds, timely detection and resolution of hazards。
Concluding remarks
The frequency of maintenance of moulds is not a single factor and is often a combination of design, manufacture, materials and management issues. Blind maintenance only cures symptoms, wastes time and costs. Only an in-depth analysis of the underlying causes, starting with the two core elements of technology and materials, combined with the management and maintenance of science, can effectively extend the life of the moulds, reduce the frequency of maintenance and increase productivity. Let's hope this is a valuable reference for our friends in the mold industry, so don't go blind, grab the key and solve the problem
