Analysis of the core characteristics of mold processing

　　Mold processing, as a fundamental process in manufacturing, has significant characteristics that distinguish it from conventional mechanical processing. The following are the six core characteristics of mold processing:
1、 High precision requirements
Dimensional accuracy: usually requires IT6-IT7 level (0.01-0.02mm)
Surface quality:
Ordinary mold Ra0.8-1.6 μ m
Mirror mold Ra ≤ 0.05 μ m (equivalent to # 15000 polishing)
Coordination accuracy:
The clearance between the guide column and guide sleeve is ≤ 0.01mm
Slide mechanism movement clearance 0.02-0.05mm
2、 Complex surface processing
3D surface: The proportion of free-form surfaces in automotive panel molds is greater than 80%
Microstructure:
Texture etching depth 0.01-0.5mm
Quasi dense gear mold tooth profile error ≤ 0.005mm
Deep cavity narrow groove: The depth to diameter ratio can reach 10:1 (such as the threaded cavity of bottle cap molds)
3、 Difficulty in material processing
Material type, hardness (HRC), processing difficulties
Quenched steel (such as SKD11) 58-62 tool wears out quickly
Tungsten steel (such as YG15) 85-90 can only be processed by EDM
Beryllium copper alloy 38-42 has severe knife sticking
Aluminum alloy (such as 7075) 15-20 is prone to deformation
4、 Multi process composite processing
Typical processing chain:
Text
CNC rough machining (removing 90% allowance) → heat treatment (quenching+tempering) → CNC precision machining →
Electric discharge machining (corner cleaning) → slow wire cutting (quasi dense hole position) → laser engraving →
Polishing (mirror treatment) → surface coating (TD/PVD)
5、 Single piece/small batch production mode
Production characteristics:
Long development cycle (15-30 days for ordinary injection molds)
High manufacturing cost (quasi dense molds can reach millions of ji)
Less repeated orders (the lifespan of the same mold is usually 200000 to 1 million times)
Economic Paradox:
Mold cost accounts for 5-15% of the total product cost
But it affects over 80% of production efficiency
6、 Whole life cycle management
Usage stage:
Injection mold temperature cycle: 80-200 ℃
Pressure bearing capacity of die-casting mold: 500-1500bar
Maintenance requirements:
Maintain the guidance system every 50000 times
Surface treatment is required every 100000 times
Failure mode:
Wear and tear (accounting for 65% of failure cases)
Fatigue cracks (25%)
Plastic deformation (10%)
The particularity of mold processing is reflected
Reverse engineering application: repairing old molds through 3D scanning
Compensation processing technology: predicting heat treatment deformation
Simulation First: Moldflow Analysis and Optimization of Pouring System
Knowledge intensive: relying on the experience of experienced craftsmen (such as polishing techniques)
These characteristics determine the requirements for mold processing:
More professional processes (micro electrical discharge machining)
Stricter quality control (full tracking of 3D testing)
A more comprehensive after-sales system (quick response to mold repair needs)
Mastering these characteristics is necessary to effectively improve the quality and efficiency of mold processing.