Quality. This one word sums up the need for having a defined mold maintenance program. Quality parts come from quality molds. But just like anything that is used as a tool, wear and degradation are part of the process. Having a maintenance program is an investment in quality.
There are a few simple things that can make a significant difference, and are part of any program. The most basic is a maintenance log of your molds. This allows you to document little things that come up, as well having some level of documentation and information should something larger present itself with the mold. The other is to perform periodic maintenance as the tools are run in production.
Keeping track of the materials used for mold maintenance such as what type of degreasers and cleaners are used, what rust preventatives are applied, and what types of greases are being used can also help you identify opportunities for improvement at start up or when preparing the mold for storage.
There are also four factors that can determine the frequency and extent of maintenance required.
Mold Materials:The amount of wear on a mold, and the speed at which the mold wears will be directly related to the softness of the materials used to make it. Softer molds, like those made from aluminum and other conventional mold materials will wear faster than hardened steel.
Environment and Use:There are many factors under this category that can be monitored as part of your program. Monitoring and documenting factors such as clamp pressure and injection pressure can help to avoid subjecting the tool to excessive or extreme conditions. Lubrication of the appropriate and required components can also help with the overall longevity of the mold, and can be a factor in determining the optimal maintenance schedules. Finally, the way the mold is opened and closed can also be a factor in the overall maintenance requirements.
Molding Materials:There are two factors when it comes to what is being shot into the mold that can have a major impact. The first is melt temperature. Higher melt temperature materials will cause a mold to wear faster as it exposes the metals or material of the mold more heat exposure. The second is the type of fill materials used in the molding materials. In most cases, the materials are not liquid, and act as abrasives. Materials such as fiberglass, Mica and even wood are very abrasive.
Mold Complexity:Complex tooling, making complex parts will require a higher level of maintenance than a simple two plate, low precision part mold. Ejectors, slides, lifters, hot runners and small or thin mold components and others add to the maintenance that will be required for a tool.
Mold maintenance can play a significant role in helping to maintain consistent, high quality parts. By following the basic practices of maintaining a mold maintenance log and performing periodic maintenance, as well as taking into account the four factors that impact the frequency and extent of maintenance required, your quest for quality can be realized.
To learn more about how that Nanoplas family of mold maintenance products can be part of your successful program, contact us today!
In this article on ptonline.com, Randy writes about his journey of learning about venting, and uses some real world examples of how they addressed issues in the plant.
Randy is a true “hands-on” injection molding professional, and his insight into may of the challenges and insight regarding tooling and preventative maintenance are amazing.
One of the challenges for injection molders is efficiency. The cycle times for plastic parts can range from 30 seconds to more than a minute. One of the primary contributors to that time and one of the longstanding constraints is cooling time. It is always a trade off of waiting for the parts to properly cool to avoid warping and shrinking, and maximizing productivity.
The concept of additive manufacturing or what used to be considered or associated with laser sintering, is a way to potentially improve the productivity and efficiency of your mold by taking advantage of conformal cooling.
The additive manufacturing process allows the toolmaker to lay down one layer of the mold at a time, creating the ability to get away from straight line drilling of cooling channels that are not as efficient. By utilizing conformal cooling channels that conform or run closer to the shape of the part allows for more efficient cooling process, and has led manufacturers to realize reduced cycle times by as much as 25-40%!
The creation of conformal cooling channels is something that must be considered when designing the tool, and is often considered an optimization task. In many of the mold software tools, are able to simulate the conformal channels, and their impact on the tool.
Making your operation more efficient is not easy. Additive manufacturing concepts for tool creation is one concept that can potentially have a very positive impact.
The Nanoplas line of mold maintenance products, and our mold coatings can also have a significant impact on your productivity levels. Contact us today to learn more about how our products can help you achieve your goals!
Randy Kerkstra wrote a great article at MoldMaking Technology on the topic of venting of mold components.
He addresses the idea that venting of mold components, actions and part details are often not addressed as potential root causes of erosion, part quality issues and gas buildup.
In today’s ever-increasing competitive environment, the ability to produce parts profitably is harder and harder. One of the areas that many molders have looked towards to save time and costs is the concept of Rapid Injection Molding. One area that can make this idea even more feasible is through a progressive mold maintenance program.
Rapid Injection Molding, or RIM, is a way to get parts made faster through the use of molds that are easier and faster to produce. With the molds designed for lower volume production runs, how they are maintained can be the difference between having to produce a new mold, and maximizing the production value of the existing mold. As many of the molds are made from aluminum, it is critical that they be cleaned well after each run.
The cleaning products used in injection molding have gone through major changes of late. Products like Mold Brite and Zap-Ox from Nanoplas are specially formulated to effectively clean molds of various materials, and are very effective for maintaining RIM molds.
Another product that can have a significant impact on mold life is the lubricating grease used. The Nanoplas Cera-Lube Nano Ceramic Grease is a high performance lubricant that works very well and can help prolong your RIM tooling.
Finally, based on the lower volumes, an area that can make RIM tooling even more effective is mold release. There has been a lot of progress in the formulations in this area as well. The challenge with RIM is that downtime to apply mold coatings can be too long. Nanoplas now has a mold release spray called Dri-Kote that is quick drying and with good bonding to metal molds.
Getting the maximum value from your RIM tooling is critical, and the way the mold is maintained and treated can make the difference. Many shops have been using the same maintenance products for a very long time, however there are alternatives that can make a difference in your workflow and tooling.
We invite you to check out the Nanoplas family of products and let us show you how they can make a difference in your shop.
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