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Key points to know about mold machining
Release date:
2021-09-13
What are the design standards for injection molding laminated molds? 1. Unlike traditional molds, laminated injection molds feature cavities distributed across two or more layers, arranged in an overlapping configuration—essentially stacking multiple molds on top of one another. A common two-layer mold typically consists of two single-layer molds mounted back-to-back, with the parting surfaces synchronized via a gear-rack mechanism during opening.
As various industries continue to evolve, the mold industry is keeping pace. So, what are the injection molding standards in the mold-making sector, and how should molds be properly maintained? Let me now provide you with a detailed explanation.
What are the design standards for injection molding laminating molds?
1. Unlike traditional molds, stack injection molds feature cavities distributed across two or more layers arranged in an overlapping configuration—essentially resembling multiple molds stacked on top of one another. Commonly, a two-layer mold is typically constructed by mounting two single-layer molds back-to-back, with the parting surface usually synchronized via a gear-and-rack mechanism during opening.
2. Typically, when injection molding machines are used with conventional molds, their injection volume and mold-opening stroke are utilized at only 20% to 40% of their rated capacity, failing to fully leverage the machine's performance. In contrast to processing with standard molds, double-layer molds achieve nearly 100% higher production efficiency, while requiring only about 10% more clamping pressure than standard molds. This significantly boosts equipment utilization and productivity, ultimately reducing injection molding costs.
3. Stacked injection molds are ideal for molding large, flat parts, shallow-cavity shell components, small multi-cavity thin-walled parts, and components requiring high-volume production.
The dual-layer laminated mold processing technique also allows for the production of two distinct products—for instance, one product can be manufactured in the first-layer mold, while the other is produced in the second-layer mold. These products can combine identical or different materials, as well as identical or varying colors. For example, the first-layer mold could be used to inject container lids, while the second-layer mold handles the injection of the container bodies.
So, how should molds be maintained after machining?
1. Processing companies should first equip each pair of molds with a historical card to record and track their usage, maintenance (including lubrication, cleaning, and rust prevention), as well as any damage incurred. This allows companies to identify which components are damaged and determine the extent of wear, providing valuable insights for troubleshooting and problem-solving. Additionally, the card should document the molding process parameters and materials used during mold processing, helping to reduce mold trial run times and ultimately boosting production efficiency.
2. Processing companies should test the mold's performance under normal operation of the injection molding machine and mold, while also measuring the dimensions of the molded plastic parts. This information allows them to assess the current condition of the mold, identifying any damage to cavities, cores, cooling systems, or parting surfaces. Based on the data from the molded parts, they can determine the extent of the mold’s deterioration and decide on appropriate repair measures.
3. Monitor and test several critical components of the mold. The ejection guide plays a vital role in ensuring smooth mold opening/closing and proper ejection of the plastic part. If any component becomes stuck due to damage, it could lead to production downtime. Therefore, regularly lubricate the mold ejector pins and guide posts—using an appropriate lubricant—and periodically inspect them for deformation or surface damage. If any issues are detected, replace the affected parts promptly.
After completing a production cycle for mold machining, apply professional anti-rust oil to the mold’s working surfaces, moving parts, and guiding components. Pay special attention to bearing parts with gears and racks, as well as ensuring the elastic strength of spring-loaded molds remains intact to keep them fully operational at all times. As production continues over time, water-based deposits such as scale, rust, sediment, and even algae tend to accumulate inside the cooling channels, gradually reducing their cross-sectional area and narrowing the passages. This significantly diminishes the efficiency of heat exchange between the coolant and the mold, ultimately driving up production costs for the company. Therefore, regular cleaning of the cooling channels is essential. For hot runner molds, maintaining the heating and control systems is critical in preventing production failures—and thus becomes especially important.
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