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Analysis of Causes for Insufficient Hardness of Furniture Mould

The heat treatment hardness of Furniture Mould(FURNITUREMOULD) https://www.furnituremould.com/
is a very important mechanical property index, and unqualified hardness is a very serious defect. The inadequate or uneven hardness of furniture dies after heat treatment will reduce the wear resistance and fatigue strength of furniture dies, which will lead to Early failure of furniture dies and seriously reduce the service life of furniture dies.

1. Cause

(1) The furniture mould has a large cross-section, and the hardenability of the steel is poor. For example, a large mould has steel with low hardenability.

(2) Carbide segregation or coarse structure in the original structure of furniture mould steel, segregation and aggregation of graphite carbon and carbide in steel.

(3) The forging process of furniture mould is not correct. After the forging, the spheroidizing annealing is not performed well, and the spheroidized structure of the mould steel is poor.

(4) The decarburization layer produced on the surface of the furniture mould is not cleaned or quenched.

(5) The quenching temperature of the furniture mould is too high, and the amount of retained austenite is too much after quenching; or the quenching temperature is too low, the heating and holding time is insufficient, and the phase transformation of the mould steel is incomplete.

(6) The cooling speed of the furniture mould after quenching is too slow, the grading and isothermal temperature are too high or the time is too long, and the quenching cooling medium is improperly selected.

(7) The alkali bath has too little moisture, or the quenching cooling medium contains too many impurities, or the quenching cooling medium is aged.

(8) When the furniture mould is quenched and cooled, the temperature of the quenching cooling medium is too high and the cooling is insufficient.

(9) Insufficient tempering and excessive tempering temperature.

2. Countermeasures

(1) Correct selection of furniture mould steel, large moulds should use high alloy mould steel with high hardenability.

(2) Strengthen the inspection of raw materials to ensure that raw materials meet the standards. Reasonable forging of the raw material steel and spheroidizing annealing to ensure good organization. Carbon tool steels are not easily annealed multiple times to prevent graphitization.

(3) Strictly perform the forging process and the spheroidizing annealing process to ensure a good preliminary heat treatment structure.

(4) Before heat treatment, thoroughly remove the rust and scale on the surface of the furniture mould, and pay attention to the protection during heating. Try to use vacuum heating quenching or protective atmosphere to heat and quench. When the salt bath is heated, it should be well deoxidized.

(5) Correctly formulate the process parameters of the furniture mould quenching heating to ensure sufficient phase change, and rapidly cool at a cooling rate greater than the critical cooling rate to obtain a qualified metallographic structure.

(6) Correctly select the quenching cooling medium and cooling method, and strictly control the classification and isothermal temperature and time.

(7) To strictly control the moisture content of the alkali bath, the quenching and cooling medium used for a long time should be regularly filtered and periodically replaced, and kept clean, and the quenching cooling characteristic curve is periodically checked.

(8) For large-sized furniture mould, properly extend the time of immersion in the quenching cooling medium to prevent the temperature of the quenching cooling medium from being too high.

(9) After the furniture mould is quenched, it should be tempered in time and fully, and the tempering temperature should be prevented from being too high.

(10) Furniture mould with high hardness requirements can be subjected to cryogenic treatment (eg -110 to -196 °C).

(11) Surface strengthening treatment.

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General Principles for Using Table Mould

The maintenance procedures required for each injection moulding location depend on different Table Mould(FURNITUREMOULD) https://www.furnituremould.com/product/chair-table-stool-mould/
cycle times. The following are some general principles that can be used by each table mould user to ensure the effective operation of table mould components such as hot runner, heater, guidepost and thimble to prevent unexpected situations.

1. Check whether there is any early warning rust or damp phenomenon at the blowhole. If you find rust or humidity near the hot runner exhaust hole, it means internal condensation or possible water pipe rupture. Dampness can cause a fatal short circuit to the heater. If the machine is turned off at night or on weekends instead of running all year round, the probability of this condensation phenomenon will increase.

2. Remember to remind the operator not to "clean" the hot nozzle head at the gate. If the operator happens to see a small piece of stainless steel at the table mould nozzle, it may actually be a nozzle assembly. "Clean up" what seems to be an obstacle often destroys the hot tip. In order not to damage the hot nozzle, please confirm the nozzle type of the hot runner system before taking action to ensure that all operators are trained and can identify all different types of nozzles they contact.

3. Slide the stop button. This work should be done once a week for machines that are not running all year round.

4. Check the resistance value of the heater interactively. You should have measured the resistance value of the heater when you first started using it. Now it is time to measure and compare it again. If the resistance value fluctuates by 10%, it should be considered to replace the heater to ensure that it will not fail at the critical moment in the production process. If the initial resistance value has never been measured, measure it once now and use the obtained value as reference data for future inspection of the heater.

5. Check the guide pillar and guide sleeve for signs of wear. Find out whether there are scratches or scratches. This kind of wear is due to lack of lubrication. If the trace is just emerging, you can also extend the service life of the guide pillar and guide sleeve by adding more lubrication. If the wear is serious, it is time to replace the new parts. Otherwise, the cavity and core parts may not fit well, resulting in different thickness of the cavity wall.

6. Check the flow of water-connect a hose at the outlet of the waterway to allow water to remain in the bucket through the hose. If the outflow of water is not clear or has color, rust may occur, and the unsmooth flow of water means a blockage somewhere. If these problems are found, drill through all water pipes again to ensure smooth flow (or clean them by any method you most commonly use). Improving the factory’s water treatment system can prevent future problems caused by rust and blockage.

7. Clean the thimble. After one year, the thimble will become very dirty due to gas accumulation and film-like impurities. It is recommended to use a mould cleaning agent to clean it well every six to twelve months. After cleaning, apply a layer of lubricant on the thimble to prevent scratches or fractures.

8. Check whether there are fractures in the radius area of the hot nozzle. The fracture is caused by the clamping force brought by loose and hardened plastic fragments remaining in the hot mouth of the machine from the injection cylinder assembly during the forward injection. The cause of the problem may also be the misalignment of the centerline.

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What Are The Material Requirements for The Air Cooler Mould

There are many requirements for the materials on the Air Cooler Mould(FURNITUREMOULD) https://www.furnituremould.com/
. Today we have come to understand the requirements of the air cooler mould.

Having sufficient surface hardness and wear resistance: the general hardness of the air cooler mould is usually below 50-60HRC. After heat treatment, the air cooler mould shall have sufficient surface hardness to ensure sufficient rigidity of the air cooler mould. The air cooler mould is subject to large compressive stress and friction due to the filled and flowing plastic during operation, which requires the air cooler mould to maintain the stability of its shape accuracy and dimensional accuracy, so as to ensure sufficient service life of the mould. Wear resistance of air cooler die depends on chemical composition and heat treatment hardness of steel, so the increasing hardness of die is beneficial to improving wear resistance.

Excellent machinability: Most air cooler mould require a certain degree of cutting and fitter repair in addition to EMD processing. In order to prolong the service life of cutting tools, improve cutting performance and reduce surface roughness, the hardness of air cooler dies steel must be appropriate.

Good polishing performance: high-quality plastic products with small surface roughness. For example, the surface roughness value of the injection mould cavity is less than Ra0.1. At the level of 0.25, the optical surface needs Ra <0.01nm, and the cavity must be polished to reduce the surface roughness value. The steel used for this purpose requires fewer material impurities, fine and uniform structure, no fiber direction, and no pitting or orange peel-like defects during polishing.

Good thermal stability: the shape of air cooler mould parts is often complicated and difficult to process after quenching. good thermal stability should be used as far as possible. when the air cooler mould is processed and heat-treated, due to small linear expansion coefficient and small heat treatment deformation, due to small size change rate and stable metallographic structure and mould size, the temperature difference that can be reduced or no longer processed can be reduced, and the requirements of air cooler mould size accuracy and surface roughness can be ensured.

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What Are The Main Performance Requirements of The Table Mould

The main performance of the Table Mould(FURNITUREMOULD) https://www.furnituremould.com/product/chair-table-stool-mould/
requires plastic film processing, the quality of the table mould to ensure the quality of the product is self-evident. Different types of plastic products, different product moulding processes, have different requirements on the material, performance, and shape of the table mould.

1. Heat resistance With the advent of high-speed moulding machinery, the production speed of plastic products is accelerating. Since the moulding temperature is generally between 160 and 350 ° C, some of the flowability is not good, and the forming speed is fast so that the moulding surface temperature of the table mould part exceeds 400 ° C in a very short time. When the working temperature of the table mould is high, the hardness and strength of the table mould are lowered, resulting in early wear or plastic deformation of the mould and failure. In order to ensure the accuracy and deformation of the mould during use, the mould steel should have high heat resistance. In order to reduce the temperature rise, the mould steel should have good thermal conductivity and a low coefficient of thermal expansion.

2. There are sufficient temperatures at the working temperature. The working conditions of the table mould are mostly very bad, and some often bear a large load, resulting in brittle fracture. The extrusion moulding pressure is relatively large, generally, 10~35MPa. Therefore, in order to prevent the table mould parts from suddenly breaking during work, the mould has high strength and toughness.

3. Abrasion resistance With the expansion of the use of plastic products, inorganic materials such as glass fibers are often added to plastics to enhance plasticity. Due to the addition of additives, the fluidity of plastics is greatly reduced, resulting in wear of table mould. Therefore, the mould is required to have good wear resistance.

4. Corrosion resistance Adding anti-burning agent and polyvinyl chloride to ABS resin may cause corrosive gas during the moulding process, and sometimes the table mould is corroded and damaged at the airflow passage, so the mould steel is required to have good corrosion resistance.

5. Good cutting performance With the enlargement and precision of plastic products, it is required that the steel for table mould has good cutting performance and work hardening during cutting. In order to avoid the deformation of the mould and affect the accuracy, it is desirable to control the residual stress to a minimum.

6. The surface of the mirror polishing process cavity is smooth, the moulding surface needs to be polished into a mirror surface, and the surface roughness is lower than Ra 0.4μm to ensure the appearance of the plastic pressed part and facilitate demolding.

7. Dimensional accuracy The mould insert has high precision and high precision, and the cavity size accuracy is generally 3~5. The joint surface of the mosaic cavity is required to be tight to prevent the molten material from entering the gap and causing leakage.

8. Pattern photo-etching performance Many plastic products have been patterned on the surface for beautification. In the leather industry, large-scale embossed sheets are used, which requires mould steel to have good pattern photo-etching properties.

Therefore, the table mould steel should meet the strength, hardness, wear resistance, heat resistance, corrosion resistance, and other performance; at the same time should also have good polishing properties, dimensional stability, easy nitriding and heat treatment deformation and other process performance; good thermal conductivity Physical properties such as sex and small coefficient of linear expansion. Table mould should be selected according to the specific requirements of the parts of the mould steel of different quality and price grade.

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Will Air Cooler Mould Be Affected by Temperature During Processing

Air Cooler Mould(FURNITUREMOULD) https://www.furnituremould.com/
temperature is an important part of injection moulding. If the temperature of the air cooler mould is well controlled, the processed product will be a good product; and if the temperature of the air cooler mould is not well controlled, the processed product may be scrapped.

So, what effect does the temperature of the air cooler mould has on the processed product?

1. The temperature of the air cooler mould will decrease the standard accuracy of the product, which will reduce the yield of the product.

2. The temperature difference between the mould core and the cavity is too large, and the plastic parts are shortened unevenly, which causes the tortuous deformation of the product and affects the appearance of the part.

3. The temperature of the air cooler mould is too high, which will cause the product to deform during the demolding process and after demolding, which will reduce the shape and standard accuracy.

4. With regard to certain crystalline plastics, the use of air cooler mould at high temperatures facilitates the crystallization process and prevents standard seizures during storage or application.

5. With regard to plastic flexible plastics, the use of air cooler moulds can lower the moulding shortening rate, improve the standard accuracy of parts, shorten the moulding cycle, and improve production efficiency.

6. When the air cooler mould is filled at a low temperature, if the melting speed is not high enough, the internal stress of the product increases, which may cause warping deformation or crack, especially for some high viscosity plastics.

7. The temperature of the air cooler mould will cause the fluidity of the plastic melt to drop, making the parts unclear, even filling the mould, or causing obvious cold junction due to excessive melt front temperature drop during the filling process. The seam causes the mechanical properties of the article to decrease. Too low air cooler mould temperature will also make the surface of the product not smooth and cause various surface defects.

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Method for Controlling Cost in Production Workshop of Crate Mould

The layout of the production workshop of the Crate Mould(FURNITUREMOULD) https://www.furnituremould.com/
is focused on two aspects: under the conditions of production demand, the layout is optimized according to the production process, and the requirements for flexible energy consumption under specific production conditions are met.

1. The power supply has an appropriate margin while meeting the power required for stable production, so that the surplus is too large and the non-functional consumption is excessive.

2. Construct an efficient cooling water circulation facility and equip the cooling water system with an effective insulation system.

3. Optimize the overall production layout of the workshop. Many productions have successive processes, and reasonable cooperation can reduce the time and energy consumption required for turnover and improve production efficiency.

4. Consider lighting and other plant equipment as much as possible with effective small units.

5. Regular maintenance of the workshop equipment to avoid damage to the utility facilities, affecting the normal operation of the production, resulting in increased energy consumption.

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How to Distinguish The Quality of The Crate Mould

To distinguish whether the Crate Mould(FURNITUREMOULD) https://www.furnituremould.com/
are good or bad, first of all, see if the size of the injection molded product is qualified. Secondly, look at the appearance of the injection molded parts is neat and tidy. The joint surface of the mold clamping, the slider and the core should have no burrs. If all of the above can be done, then the crate mould is a qualified mold.

First, distinguish from materials and design:

The most important thing about the crate mould is the material. So what kind of material is good? Of course, the hard drive is high, the corrosion resistance is strong, and the polishing performance is good. The long-term use of the crate mould is good. The overall design of the crate mould, including the thimble and the core; the design of the door, the parting surface, the exhaust port, the gate size and position are reasonable, and then see if the crate mould is open and closed, and the product size is qualified.

Then you can look at the process of the crate mould:

To distinguish the quality of crate mould technology, it is first necessary to see if the size of the injection molded product is acceptable. Secondly, the appearance of the injection molded parts should be clean, and the joint surface, the slider and the core should not have burrs. If all of the above can be done, then the crate mould is a qualified mold.

Finally, distinguish from the quality of the crate mould products:

1. Stability and consistency of product size, surface finish and material utilization.

2. Service life: The number of work cycles or the number of parts produced by the crate mould can be completed under the premise of ensuring the quality of the products.

3. Is the use and maintenance of the crate mould the most convenient, whether it is easy to demould, whether the auxiliary production time is as short as possible, continuous maintenance cost, maintenance cycle, etc.

Knowing the following factors, we can find ways to improve the quality of the crate mould. The basic method of crate mould design is the most important step to improve the quality of the crate mould. There are many factors to consider, including crate mould. The choice of materials, availability and safety of the mold structure, mold part processability and crate mould maintenance is convenient, the design should be considered more carefully.

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