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The detail processing in mold processing is a key factor determining the quality, lifespan, and product accuracy of the mold, and even directly affects production efficiency and cost. The following are the importance and specific manifestations of detail processing:
1. Affects the core performance of the mold
Accuracy and coordination
Inappropriate details such as the fitting clearance of the parting surface (usually required to be ≤ 0.02mm), the tolerance of the top pin hole position, and the grinding accuracy of the slider guide rail can lead to burrs, burrs, or mold jamming.
Case: If the parting surface of the car lampshade mold is not polished enough (Ra<0.1 μ m), visible mold lines will be produced during injection molding, affecting the appearance quality.
Lifespan and Wear Resistance
Details such as hardness gradient control during steel heat treatment (such as H13 core HRC48-52) and uniformity of surface coatings (TD treatment, DLC coating) directly affect the wear resistance of the mold.
Data: The lifespan of mold cores without nitriding treatment may be shortened by 30% -50% in the injection molding of fiberglass reinforced materials.
2. Determine the quality of product molding
Surface treatment
The detail treatment of mirror polishing (sandpaper above # 12000) or etching (VDI 3400 standard) affects the demolding and appearance of the product. For example, if there is color difference or uneven texture in the sun dried pattern of the mobile phone shell mold, it will lead to batch differences.
Cooling system
The aperture deviation (± 0.1mm) and layout rationality (balanced distance from the mold surface) of the conformal cooling water channel directly affect the injection molding cycle and product shrinkage marks.
Tested: The optimized cooling system can shorten cycle time by 15% -20%.
3. Hidden risk point control
Clearing corners and avoiding empty spaces
The R-angle treatment of deep cavity molds (such as insufficient root cleaning during electrical machining) may cause stress concentration, leading to cracking of the mold core.
Exhaust design
Insufficient depth (usually 0.01-0.03mm), position, and cross-sectional area of the exhaust groove can lead to defects such as burning and incomplete filling.
4. Leverage effect of cost and efficiency
Correction cost comparison
Stage correction cost multiplier
Design phase 1x
Processing stage 5-10x
50-100x after trial molding
Case: A certain household appliance mold broke during trial molding due to the failure to guide and chamfer the top pin hole, resulting in a 2-week delay in delivery and a loss of over 100000 yuan.
Key detail processing stage
Design phase
Demoulding slope (usually 0.5 ° -3 °), steel shrinkage compensation (such as ABS with 0.5% -0.7%).
Processing stage
Compensation for electrical losses (0.03-0.05mm margin should be reserved for precision machining electrodes), optimization of tool paths (to avoid tool marks).
Assembly stage
Pre press fit of guide column and guide sleeve (interference fit 0.005-0.01mm), water circuit sealing test (air pressure leak detection).
Debugging phase
Start the process parameter recording for a trial mold (such as segmented control of injection speed) and verify the mold flow analysis.
Industry high standard cases
Medical mold: The cavity of the insulin pen core mold must be below Ra0.05 μ m to avoid bacterial residue.
Optical lens module: The curvature error of the non spherical surface should be ≤ 0.1 μ m, requiring ultra precision turning and ion beam correction.
Summary
Mold processing is an industry where "details are the cost", and a precision difference of 1 μ m may lead to a 20% difference in lifespan. Suggestion:
Establish a detailed checklist (such as 100+verification points in the DFM report);
Invest in high-precision detection equipment (such as white light interferometers to measure roughness);
Train craftsman level technicians (such as the "R&D expert" from a Japanese mold factory who requires 10 years of experience).
A mold factory that ignores details, even if it is large in scale, may still result in bulk returns from customers due to a small chamfer not being processed.
