Processing problems of large injection mold (1)

Nowadays, the demand for large injection moulds is growing rapidly. Designers have been promoting the size and complexity of moulds from flat screen televisions to automobile dashboard. However, not every manufacturer can produce large injection mold. This is because there are many barriers to entry and the difficulty of processing.
1. Problems of large injection mold
Handling the size and weight of large injection molds is a huge challenge. This often means extra labor, the need for special tools, a variety of equipment, and potential errors. If we choose the right machining center to produce large injection mold, many problems can be alleviated or avoided. At the same time, it can simplify the equipment and completely change the potential accuracy problems.
The biggest cost of producing large injection mold is mechanical cost. Machines that can produce large injection moulds are very expensive. Therefore, having multi-functional machines is the first condition to enter this market, such as processing blanks and polishing. Once the right machine is selected, even on the same equipment, the blank can be processed and polished with accuracy.
2 machine design of large injection mold
In order to measure the general accuracy and focus on large machines, we must study several necessary design features of a large injection mold machining center.
(1) Iron and steel castings and spindles capable of handling heat
The important design of any machine used to grind large parts is a large steel casting and a mandrel that can handle heat. In terms of machine forming, hardness enhancement and heat reduction, iron and steel castings are still stable materials.
As for the spindle, internal cooling technology must be used to ensure that the spindle will not self ignite or produce errors due to high temperature.
In order to make the surface of large injection mold meet the best quality requirements, a machine and tools are needed to greatly reduce the time of secondary discharge machining and manual polishing. It usually takes several days to process a large injection mold. Because the external conditions will change during processing, these changes must be taken into account in order to achieve the necessary accuracy. A machine that is not used to cut large injection mold will change the temperature of 6 degree machine cylinder at room temperature of 10 degrees Celsius, which will also lead to a change of 0.070mm in the axis angular plane.
(2) Heat stabilization technology
On the other hand, if the thermal stabilization technology is applied, the same environmental change will lead to a temperature change of 3 degree cylinder, or a change of 0.030 mm in the axis angular plane. However, the design of the machine includes the influence of environmental heat to avoid the influence of external air on the processing of parts. If the heat of the machine is constant, it will reduce the problem of mixing ingredients, thus reducing the need for manual polishing.
(3) Speed
The second characteristic to consider is speed. The shaft speed should be at least 20000 rpm and the metal renewal speed should be at least 30 IPM. For example, the cutting rate of a large injection mold machining center should be 787 IPM.
(4) Accuracy
If you want to finish the polishing and blank processing of large injection mold on the same machine, accuracy is very important. The selected machining center must be able to carry out similar precise positioning and small machine repeatability.
Using a large injection mold machining center, the precision positioning is ± 0.000060 inch (± 0.0015 mm), and the repeatability is ± 0.000040 inch (± 0.001 mm). It should also be mentioned that the accuracy of the measurement is also very important and must be within 5 microns.
(5) Feedback
In order to measure the accuracy of machining, we must be aware of the feedback of the machine. Standard feedback of 1 micron is common. When the feedback is 0.050 micron, the polishing is almost perfect. Control and regulation feedback, subdivision screw can improve surface polishing.