사출 성형 금형 제조업체의 역학

대량 생산 공정을 위해 사출 성형 금형 제조업체와 협력하는 전 세계 산업. 결국 사출 성형은 신뢰할 수 있고 효율적인 제조 공정입니다. 열경화성 플라스틱 및 열가소성 소재의 부품 생산에 탁월합니다.

There has been an increase of 0.9% in the injection moulding industry since 2014. It seems that numbers are on the increase. The reason being, this manufacturing process can produce hundreds even millions of parts without slight variation.

A consumer can enjoy reliability and consistency even in mass production. Injection moulding has become an imperative part of the manufacturing process. Therefore, we are going to provide you with the basics of the injection moulding process.

What is the Injection Moulding Process?

A manufacturing process uses a special technique to produce the part from both thermosetting plastic and thermoplastic materials.  The process starts with the design of the product or parts. Industry engineers or designers are responsible for product designing.

디자인이 완료되면 다음으로 금형이 형성됩니다. 금형 제작자는 정확한 금형 제작을 담당합니다. 그들은 금형을 개발하기 위해 알루미늄 또는 강철을 사용할 수 있습니다. 또한 정밀 기계를 사용하여 금형의 정확한 모양을 보장합니다.

금형을 완성한 후 재료를 금형에 넣을 시간입니다. 기계는 재료를 가열 된 배럴에 넣습니다. 그런 다음 재료를 철저히 혼합합니다. 나중에 가열 된 재료를 몰드 캐비티로 밀어 넣습니다.

재료는 냉각하는 데 걸리는 동안 캐비티에 남아 있습니다. 재료가 설계된 구성으로 경화되면 금형 캐비티에서 제거됩니다. 사출 성형은 . 자동차의 전체 차체는 물론 작은 부품도 제작이 가능합니다.

역사

Alexander Parkers was the mastermind behind inventing first fabricated plastic. In 1862, during an International Exhibition in London, Alexander demonstrated its material. The named the material “Parkesine”.

Parkesine mainly compromised of cellulose was able to take on any shape. After heating and melting the material, it was possible to mould it in any desired shape.  However, it did have some side effects. The material was highly flammable, expensive and prone to crack.

Later in 1872, Alexander and his brother Isaiah came up with an injection moulding machine. The machine was not as sophisticated as we see today.

It had a huge hypodermic need and to inject the plastic it used a plunger. The material first passed through heated cylinders before they reach the mold cavity. It did take some time for the industry to progress. Initially, it produced online hair combs, buttons and collar stays.

However, in the 1940s, the industry rapidly expanded. World War II led to the demand for mass production of products at an extremely low price. Six years later, James Watson Hendry, an American inventor, introduced the screw injection machine.

The machine was an advancement of what Alexander had designed. It was able to better control the speed of injection. The product was also finer. In addition, the machine permitted the mixing of materials. Thus, allowing adding colors to the material.

The mixing made it possible to add the recycled plastic to the virgin material. Today, most injection moulding die manufacturer use screw injection machines. However, these machines are way advance than their ancestors.

The plastic injection industry has made tremendous progress over the years. Thus, we now can enjoy sophisticated machines. From those simple machines, we know have a wide variety of sophisticated injection moulding machines. These machines can produce almost anything.

Different Types of Injection Moulding Process

The basics of the injection moulding process remain the same in every type. They heat the plastic granules until they melt. The melted material is inserted into the mould using high pressure and nozzles. Finally, you wait for the material to cool down and harden in the required shape. Then remove them from the mould.

Below, are some common types of injections moulding process:

• Injection Blow Moulding
• Gas injection Moulding
• Reaction Injection Moulding
• Multi-station Injection Moulding
• Multi-component Injection Moulding
• Twin Injection Moulding
• Triple Injection Moulding among others

Characteristics of the Process

Below, we have highlighted the main characteristics of the process.

1. To insert the melted material (any type of plastic) into the mold cavity, it uses a screw-type plunger or a ram.
2. The result t is an open-ended and solid shape. The shape is according to the contour of the mold.
3. The process can use either thermoset materials or thermoplastic materials.
4. It is responsible for creating gate marks, sprue, and a parting line.
5. You will come across ejector pin marks, as they are commonly present.

Applications

Today, the injection-moulding machine can create a wide variety of things. For instance, they are used for producing automotive dashboards, bottle caps, packaging, and spools. They can also produce pocket combs, buttons, and several other plastic products.

Today, automobile manufacturers are a fan of injection moulding manufacturing. It is perhaps one of the most common methods to create car spare parts. In addition, industries around the world use this technique to create different types of parts.

The injection moulding process is excellent for mass production with zero tolerance to error. They can replicate the same product for thousand times without a slight error. It is also possible to use a wide range of materials.

The process is cost-efficient. It has minimal scrap losses and low labor costs. Usually, the finished products require none to minimal finishing after moulding. Nonetheless, the upfront cost of injection moulding die manufacture process is high. The machine is expensive and setting it up requires additional cost.

가공

There are two main methods of creating a mould. Frist is the Standard Machine technique and the second is EDM. Both of these techniques offer great results. However, there are some differences in terms of functionality and usage.

Standard Machining

It is the historical method of creating the injection molds. Nonetheless, technological developments resulted in sophisticated technologies such as CNC machines. The CNC machining was highly efficient. They become an integral part of the injection moulding industry.

그들은 더 짧은 시간에 복잡한 금형을 만들 수있었습니다. 이 금형은 최소한의 시간에 만들어졌지만 정확성을 제공했습니다.

방전 가공기 (EDM)

오늘날 성형 산업은 방전 가공 공정의 팬이되었습니다. 사람들은 종종 EDM을 Spark Erosion Process라고합니다. 복잡한 금형 설계에 적합합니다. 또한 사전 경화 된 몰드를 제공합니다. 따라서 열처리가 필요하지 않습니다.

금형을 부드럽게하려면 제조업체는 어닐링이 필요합니다. 응고 된 금형을 변경하기 위해 전통적인 드릴링이 실행됩니다.

비용

금형 비용에 기여하는 몇 가지 요인이 있습니다. 이러한 요인 중 일부에는 부품 크기, 캐비티 및 예상 공구 수명이 포함됩니다. 또한 사출 성형 금형 제조업체는 부품 복잡성과 표면 마감에 중점을 두어야합니다.

Although, the initial cost is high, however, the cost decreases due to mass production.

Advantages of Injection Moulding Die Manufacturer

• It is possible to do mass production of parts with good surface finish.
• Manufacturers can use metallic along with non-metallic moulds to create parts.
• The process is economical to produce small parts and intricate shapes.
• Injection moulding has the ability to uphold close dimensional tolerance.
• It is possible to use and reground minimum sprue, gate and runner.
• It has a low labor cost per unit.

 Limitation of Injection Moulding Process

• It requires high power to operate
• The maintenance cost is high.
• Moulding Machines are expensive.
• High tool cost.

Takeaway

Injection Moulding die manufacturer offers the convenience and ease. It is possible to design and develop complicated parts in minimal time and limited budget. The modern moulding processes ensure reliability and efficiency.

Modern and skilled manufacturers such as the Katio Mould offer outstanding moulding services. They use state of the art technology and modern technique to produce high-quality parts.  Therefore, you should reach out to them. You can effortlessly reach out to their learned customer care staff at 0086-768-82821468. They will resolve all your troubles and queries.