Omar Khalid
Plastic injection moulds are complex and precise tools that require careful operation and maintenance. Effective maintenance is essential to ensure long-term accuracy, extend the lifespan of the mould, and improve efficiency. Regular maintenance can also prevent part failures and lower overall costs. This includes routine cleaning, lubrication, and inspections, as well as addressing any issues that may arise, such as corrosion, residue, or dislocation of parts. Preventative measures, such as selecting the right moulding equipment and following proper procedures, are crucial to avoid costly repairs and maintain optimal production standards.
| Characteristics | Values |
|---|---|
| Complexity | Plastic injection molds are more complicated and precise, with higher requirements for operation and maintenance. |
| Regular maintenance | Regular, careful maintenance can prevent part failures and lower overall costs. |
| Preventative maintenance | Preventative maintenance is critical in protecting the asset and ensuring it keeps producing quality parts. |
| Cleaning | Clean regularly to ensure sanitation and remove burrs. Use soft plastic media blasting to clean the mold surface without damaging surface texture and polish. |
| Rust prevention | Spray with anti-rust oil or store in a dry, cool, and dust-free place. |
| Lubrication | Lubricate sliding parts regularly, especially in summer when the temperature is high. |
| Cooling channels | Apply the right cooling channel surface coating to keep water lines flowing. |
| Mold protector | Use a mold protector to prevent damage from plastic residue or dislocation of the slider. |
| Mold size | Select the right-sized molding equipment to meet requirements without wasting resources. |
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What You'll Learn
Regular cleaning and maintenance
Firstly, it is important to select the right moulding equipment and determine reasonable process conditions. If the injection moulding machine is too small, it will not meet requirements; if it is too large, it will waste resources and may damage the mould. When selecting the injection moulding machine, check the maximum injection volume, the effective distance of the tie rod, the mould installation dimensions on the plate, the maximum and minimum mould thickness, the plate stroke, the ejection type, and the ejection stroke.
Before the mould is put into operation, it must first be operated with the empty mould to observe whether the operation of each part is smooth, whether there is any anomaly, whether the ejection and opening strokes are proper, whether the parting surface is tightly matched when the mould is closed, and whether the pressure plate screw is tightly fastened.
During operation, a normal temperature should be maintained to help extend the service life of the mould. Sliding parts on the mould, such as the guide pin, the return pin, the push rod, and the core, should be inspected, cleaned, and lubricated regularly. Especially in summer when the temperature is high, add lubricants at least two times per shift, so as to ensure that these sliding parts are smooth enough to prevent seizures. Each time before closing the mould, check that the mould cavity is clean – no residual products or any other foreign objects are allowed.
If the downtime is expected to exceed 24 hours, the surface of the core and the cavity should be sprayed with anti-rust oil or release agent. Especially in moist areas and rainy seasons, they should be rust-proofed even if the downtime is very short. Before the mould is put into operation again, the oil on the mould should be removed and wiped clean. When cleaning a mould with mirror surface requirements, first use compressed air and then hot air to dry it, or the oil will be oozing out to cause product defects during the moulding process.
It is forbidden to clean hard objects such as wire and steel bars to avoid scratching the surface. If there are rust spots caused by corrosive injection moulding, it is necessary to use a grinder to grind and polish, spray with professional anti-rust oil, and then store the mould in a dry, cool, and dust-free place.
Several important parts of the plastic injection mould should be tracked and tested: ejection and guide parts are used to ensure the opening and closing movement of the mould and ejection of plastic parts. If any injection-moulded part is stuck due to damage, it will lead to a production halt. Therefore, the lubrication of the mould thimble and guide pillar should be kept regularly, and it should be checked whether the thimble and guide post are deformed and damaged on the surface, and replace them in time if damage is found.
Mould maintenance usually includes daily maintenance and off-machine maintenance. Dry ice blasting is great for cleaning the injection mould while installed in the injection machine. While typical sandblasting media would damage a mould surface, soft plastic media blasting cleans the mould surface without damaging the surface texture and polish. Lasers will burn off mould contaminants and reflect off the clean metal surface. However, it is important not to over-clean the mould, as this can damage the mould surface and strip the mould of any protective surface coatings that were applied.
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Preventative measures
Plastic injection moulds are complicated and precise tools with high requirements for operation and maintenance. Regular and meticulous maintenance is essential to keep them in good working order and to prevent inferior parts from being produced.
- Before first use, the injection moulding machine should be operated with the empty mould to check for any anomalies and ensure the smooth operation of each part.
- During use, the mould should be kept at a normal temperature to extend its service life.
- Sliding parts, such as guide pins and push rods, should be regularly inspected, cleaned, and lubricated.
- Before closing the mould, always check that the mould cavity is clean and free of any residual products or foreign objects.
- Ensure the mould cavity is well-designed with the right draft angle, ejector pins, and gates to avoid issues like difficult ejection and poor mould filling.
- Regularly clean the mould to prevent rust and other contaminants from building up and affecting the surface quality. Soft plastic media blasting is a good method for cleaning without damaging the surface.
- Apply the right cooling channel surface coating to keep water lines flowing smoothly and prevent clogs.
- If downtime exceeds 24 hours, spray the surface of the core and cavity with anti-rust oil or a release agent, especially in moist areas or rainy seasons.
- Keep a detailed record of the mould's use, care, and damage to track its condition and maintenance needs.
- Regularly inspect and maintain other parts of the injection moulding machine, such as the injection pressure and melt mixture, to prevent unnecessary strain on the mould.
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Rust-proofing
Rusting and corrosion are serious issues in the plastic injection moulding industry. Rust and corrosion can cause costly downtime, frequent repairs and replacements, and product quality issues. Therefore, it is important to take steps to prevent rusting and maintain the moulds.
One way to prevent rusting is to apply protective coatings to the moulds. These coatings can include chromate conversion coatings for aluminium moulds, which improve their corrosion resistance. Other protective coatings or surface treatments can also be applied to enhance corrosion resistance. For example, MilCorr VpCI Shrink Film is a durable plastic film that contains corrosion inhibitors and UV-resistant additives, protecting metal surfaces from rusting and the film from deteriorating in sunlight. Applying anti-rust oil or a release agent to the surface of the core and cavity can also help prevent rusting, especially in moist areas and during rainy seasons.
In addition to protective coatings, it is important to regularly clean and maintain the moulds. This includes inspecting, cleaning, and lubricating sliding parts such as guide pins, return pins, push rods, and cores. It is also crucial to ensure that the mould cavity is clean before each use, as residual products or foreign objects can cause issues.
Another way to prevent rusting is to choose the right material for the mould. Stainless steel, for example, is more resistant to rust and corrosion but is also more expensive. Additionally, understanding the science behind corrosion can help manufacturers implement targeted prevention strategies. For instance, environmental factors such as acidic or basic conditions, harmful production chemicals, and plastic material residues can accelerate corrosion.
Finally, proper storage and transportation of moulds can help prevent rusting. Moulds should be dried and coated to prevent corrosion during storage. During transportation, products like MilCorr VpCI Shrink Film can be used to protect the moulds.
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Choosing the right equipment
Firstly, select equipment that matches the scale of your operation. If the injection moulding machine is too small, it won't meet production requirements. Conversely, a machine that's too large will waste resources and may damage the mould or mould plate due to improper adjustment of the clamping force. Check specifications such as the maximum injection volume, effective distance of the tie rod, and ejection type to ensure the equipment matches your needs.
Secondly, opt for equipment that is durable and can withstand the stresses of the moulding process. Injection moulds undergo significant stress, leading to residue accumulation, wear, and potential defects. Choose a machine with robust components that are less likely to succumb to these issues.
Thirdly, consider the type of plastic material used in the process. Different materials may cause varying levels of wear and tear on the mould, and some may require more frequent cleaning to prevent buildup and damage. Ensure your equipment is suitable for the specific material you'll be using.
Additionally, prioritise equipment with comprehensive maintenance features. Regular maintenance is crucial for the longevity of injection moulds. Select a machine that facilitates easy access for cleaning, lubrication, and inspection. This will enable you to implement a structured maintenance program effectively.
Furthermore, invest in equipment with advanced features that enhance performance and prolong mould life. For example, surface treatments like nitriding or DLC (diamond-like carbon) coating can improve wear resistance and reduce friction.
Finally, opt for equipment that is widely supported by the manufacturer or supplier. This will ensure you have access to spare parts, maintenance expertise, and potential customisation options in the future.
Remember, choosing the right equipment is a critical step in maintaining plastic injection moulds effectively and ensuring the success of your manufacturing operations.
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Inspection and testing
Plastic injection moulds are complex and precise tools that require meticulous maintenance to ensure normal production and efficiency. Regular and careful maintenance can prevent part failures, lower costs, and extend the lifespan of the mould. Here are some detailed instructions for the inspection and testing of plastic injection moulds:
- Routine Inspections: Regularly inspect the mould for any signs of damage, including residual material, rust, cracks, or other abnormalities. This helps identify potential issues before they become serious problems.
- Testing Properties: During normal operation, test various properties of the mould, such as size, pressure, and temperature. By monitoring these parameters, you can determine the existing status of the mould and identify any damage to critical components like the cavity, core, cooling system, and parting surface.
- Surface Maintenance: Pay close attention to the surface quality of the mould. Apply suitable anti-rust oil to prevent corrosion, especially in moist areas or during rainy seasons. Ensure that the mould is wiped clean and free of any oil or residue before putting it back into operation to avoid product defects.
- Critical Parts Inspection: Track and test critical parts such as ejection and guide parts, which ensure the smooth opening and closing of the mould. Regularly lubricate these parts to prevent seizures and inspect for any deformation or damage, replacing them promptly if necessary.
- Preventative Maintenance: Implement a preventative maintenance schedule to avoid costly repairs and downtime. This includes regular cleanings and inspections after a set number of cycles or a specified time interval. Proper maintenance can extend the lifespan of the mould and ensure consistent production of quality parts.
- Avoid Common Pitfalls: Be mindful of common causes of mould damage, such as missing pull rods, gaskets, or other parts, which can lead to compression damage. Also, protect the mould from excessive pressure due to low-voltage protection and ensure proper ejection pin function to prevent fractures or inadequate restoration.
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Frequently asked questions
Regular cleaning and maintenance are essential to keeping your plastic injection mold in good working order. Clean your mold after a set number of cycles or time to prevent part failures and extend its working life.
There are several cleaning methods to consider, including chemical cleaning, manual scrubbing, and dry ice blasting. It's important not to over-clean your mold, as this can damage the surface. You should also avoid using hard objects like wire or steel bars to clean your mold, as these can cause scratches.
Rust can be prevented by applying anti-rust oil or a release agent to the surface of the core and cavity. It is especially important to do this during periods of high humidity or in moist environments. Store your mold in a dry, cool, and dust-free location to prevent corrosion.
