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In the process of industrial products to diversify and high-grade development, how to improve the quality of the mold that directly affects product quality is an important task.
In the mold manufacturing process, the smooth processing and mirror polishing stage processing after the shape processing is called parts surface grinding and polishing processing, it is an important process to improve the quality of the mold.
Mastering the reasonable polishing method can improve the quality and service life of the mold, and then improve product quality.
Common polishing methods and working principle
1.1 Mechanical polishing
Mechanical polishing is by cutting or plastic deformation of the material surface to remove the workpiece surface projection to get a smooth surface polishing method, generally using oil stone, wool wheel, sandpaper, etc., mainly by hand, the surface quality requirements of high can be used to the ultra-precision polishing method.
Ultra-precision polishing is the use of special abrasives, in the polishing fluid containing abrasives, pressed on the surface of the workpiece being processed, for high-speed rotary motion.
The use of this technology can achieve Ra0.008 μm surface roughness, which is the best surface roughness of various polishing methods. Optical lens molds often use this method. Mechanical polishing is the main method of injection mold polishing.
1.2 Chemical polishing
Chemical polishing is the material in the chemical medium so that the microscopic convex part of the surface is preferentially dissolved than the concave part, to obtain a smooth surface.
This method can polish workpieces with complex shapes and can polish many workpieces at the same time with high efficiency. The surface roughness obtained by chemical polishing is generally Ra10 μm.
1.3 Electrolytic polishing
The basic principle of electrolytic polishing is the same as chemical polishing, that is, by selectively dissolving the tiny projections on the surface of the material to make the surface smooth. Compared with chemical polishing, it can eliminate the effect of cathodic reaction, the effect is better.
1.4 Ultrasonic polishing
Ultrasonic polishing is a processing method of polishing brittle and hard materials through abrasive suspension by using ultrasonic vibration of the tool section.
The workpiece is put into the abrasive suspension and placed in the ultrasonic field together, and the abrasive is ground and polished on the surface of the workpiece by relying on the oscillating effect of ultrasonic waves.
Ultrasonic processing macro force is small, and will not cause deformation of the workpiece, but the tooling production and installation are more difficult.
1.5 Fluid polishing
Fluid polishing is to rely on the flow of liquid and the abrasive particles it carries to scour the surface of the workpiece to achieve the purpose of polishing.
Fluid power grinding is driven by hydraulic pressure, the medium is mainly used in the lower pressure flow through the good special compounds (polymer-like substances) and mixed with abrasives made, abrasives can be used silicon carbide powder.
1.6 Magnetic grinding and polishing
Magnetic grinding and polishing are to use magnetic abrasives to form abrasive brushes under the action of the magnetic field to grind and process the workpiece.
This method has high processing efficiency, good quality, and easy to control the processing conditions. With suitable abrasives, the machined surface roughness can reach Ra0.1 μm.
1.7 EDM ultrasonic compound polishing
To improve the surface roughness Ra1.6 μm above the polishing speed of the workpiece, the use of ultrasound and special high-frequency narrow pulse peak current pulse power for diamond compound polishing.
By ultrasonic vibration and electric pulse of corrosion at the same time on the surface of the workpiece, quickly reduce its surface roughness, which is obvious and very effective for polishing the rough surface of the injection mold after processing by turning, milling, EDM and wire-cutting processes.
What else can I help you with?
What is involved in 'injection mold tooling'?
Injection mold tooling is done by fusing powder to create mold geometry, then filling with bronze. You can learn more about Injection Mold Tooling at the Dinsmoreinc website.
Where do you buy materials to do plastic injection molds?
There are some company who sell mold base, such as LKM, And there are lots of companies who sell injection mold accessories.
How many parts can an injection mold make?
How many products an injection mold can make is mainly determined by the following factors: a. The material of the plastic product. b. The structure of the plastic product. c. The material of the injection mold. d. The structure of the injection mold. e. The number of holes in the injection mold. f. The type of flow channel of the injection mold. How does the material of a plastic product affect mold life? The material of a plastic product can have a significant effect on the life of the injection mold used to produce the product. a. The additives of some products are corrosive, which will cause a certain degree of corrosion to the mold during the mass production manufacturing process. Which can also lead to decreased mold life. b. Harder materials, such as some products have higher requirements on strength and need glass fiber-filled materials. Such as (PA+GF, PBT+GF, etc.). , can wear down the mold more quickly than softer materials, which may cause the mold to need to be replaced sooner. c. Additionally, some materials may be more prone to sticking to the mold, which can also lead to decreased mold life. The material fluidity of some products is not good, and the injection pressure needs to be increased during production. If the production is continued under high injection pressure, it will also affect the number of injection molded parts. d. Some products are made of high-temperature materials, such as PPS, PPSU, PPO, etc. Which requires a high temperature during production, and the injection mold also needs to maintain a stable high temperature, which will also reduce the number of products made by the injection mold. In general, it is important to carefully consider the material being used for a plastic product and its potential impact on mold life when designing and manufacturing the product.
Who uses injection molds and what can they make?
An injection mold is a closed mold where the material to be molded into that specific design is fed through a fill hole in the mold. This is a common process for plastic goods but is also used for cars' body panels.
What is the Hand injection mold weight?
Maximum 20 Kgs.
What type of equipment is used for injection molding?
One can use a shot utensil for injection molding. Many carpenters and renovators use a mold injection to closely mold two things together. Glue may also be used as well for a better grip.
How much pressure should be used in injection moldingHow many parts can an injection mold make?
The amount of pressure used in injection molding is a critical factor in the success of the molding process. Too little pressure can result in poor-quality parts with defects, such as incomplete filling of the mold cavities or inadequate bonding between the plastic and the mold. Too much nozzle pressure can cause damage to the mold and the injection molding machine, as well as excessive wear and tear on the equipment. The amount of pressure used in injection molding is determined by several factors, including： a. The type and viscosity of the plastic material. b. The size and shape of the part being molded. c. The design and construction of the mold. d. The injection molding machine. e. The complexity of the part being molded. In general, the pressure used in injection molding should be sufficient to fill the mold cavities and create a strong bond between the plastic and the mold.
How does the type of injection mold runner affect mold life?
The type of injection mold runner can affect mold life in several ways. A cold runner mold uses a separate, unheated channel to deliver plastic to the mold cavity.Which can reduce the risk of warping or other damage to the mold caused by exposure to high temperatures. This can help extend the mold’s lifespan. On the other hand, a hot runner mold uses heated channels to deliver molten plastic to the mold cavity.Which can increase the risk of heat-related damage to the mold. This can decrease the mold’s lifespan. Additionally, the design and construction of the runner itself can impact its durability and lifespan. Overall, the type of runner used in an injection mold can have a significant effect on its life.
How does injection molding work?
Injection molding is a process in whih the material normally plastic,is injected into a mold to produce a componenet.
What are the domestic uses of a plastic injection mold?
There are many different domestic products that are made through the use of a plastic injection mold. Common household and domestic items include toothbrushes and Lego block toys.
Which materials are commonly used to injection mold?
Such as P20,718,NAK80, 2344,8407,S136...
What manufacturing technique is used to create the unique foamposite upper?
Injection mold
