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แม่พิมพ์ฉีดขึ้นรูปการออกแบบผลิตและเคล็ดลับกระบวนการ

2020-03-30 hqt

กลไกของผู้ผลิตแม่พิมพ์ฉีดขึ้นรูป

อุตสาหกรรมทั่วโลกมีส่วนร่วมในการผลิตแม่พิมพ์ฉีดขึ้นรูปสำหรับกระบวนการผลิตจำนวนมาก ท้ายที่สุดแล้วการฉีดขึ้นรูปเป็นกระบวนการผลิตที่เชื่อถือได้และมีประสิทธิภาพ เหมาะอย่างยิ่งสำหรับการผลิตชิ้นส่วนจากพลาสติกเทอร์โมเซตติงและวัสดุเทอร์โมพลาสติก

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.

Once the design finishes, next come the formation of molds. Mold maker is responsible for making accurate molds. They can use either aluminum or steel to develop molds. They also use precision machines to ensure the exact shape of the moulds.

After completing the molds, it is time to place the material into the molds. The machine places the material into a heated barrel. It then mixes the material thoroughly. Later, it forces the heated material into a mold cavity.

The material stays in the cavity for as long as it takes to cool it down. Once the material hardens to the designed configuration, it is removed from the mold cavity. Injection molding offers diversity in terms of manufacturing. It is possible to manufacture small parts as well as the entire body of a car.

Injection Moulding Die Manufacturer

 

History

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.

เครื่องจักรกล

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.

They were able to create complex moulds in less time. Despite being created in minimal time, these moulds offered accuracy.

Electrical Discharge Machine (EDM)

Today, the moulding industry has become a fan of the electrical discharge machining process. People often refer to EDM as the Spark Erosion Process. It is perfect for designing complex moulds. In addition, it offers a pre-hardened moulds. Thus, there is no need for heat treatments.

To soften the mould, the manufacturer would need annealing. In order to make changes to the solidified molds, traditional drilling will come into action.

Cost

There are several factors that contribute to the cost of moulds. Some of these factors include part size, cavities, and expected tool longevity. In addition, the injection moulding die manufacturer needs to focus on piece complexity and surface finishes.

แม้ว่าต้นทุนเริ่มต้นจะสูง แต่ต้นทุนลดลงเนื่องจากการผลิตจำนวนมาก

ข้อดีของผู้ผลิตแม่พิมพ์ฉีดขึ้นรูป

  • เป็นไปได้ที่จะทำการผลิตชิ้นส่วนจำนวนมากโดยมีพื้นผิวที่ดี
  • ผู้ผลิตสามารถใช้โลหะร่วมกับแม่พิมพ์ที่ไม่ใช่โลหะเพื่อสร้างชิ้นส่วน
  • กระบวนการนี้ประหยัดในการผลิตชิ้นส่วนขนาดเล็กและรูปทรงที่ซับซ้อน
  • การฉีดขึ้นรูปมีความสามารถในการรักษาความทนทานต่อมิติที่ใกล้เคียง
  • เป็นไปได้ที่จะใช้และจัดวางป่วงขั้นต่ำประตูและทางวิ่ง
  • มีต้นทุนแรงงานต่อหน่วยต่ำ

 ข้อ จำกัด ของกระบวนการฉีดขึ้นรูป

  • ต้องใช้พลังงานสูงในการทำงาน
  • ค่าบำรุงรักษาสูง
  • เครื่องปั้นมีราคาแพง
  • ต้นทุนเครื่องมือสูง

Injection Moulding Die Manufacturers and suppliers

Takeaway

ผู้ผลิตแม่พิมพ์ฉีดให้ความสะดวกและง่ายดาย สามารถออกแบบและพัฒนาชิ้นส่วนที่ซับซ้อนได้ในเวลาอันสั้นและงบประมาณที่ จำกัด กระบวนการขึ้นรูปที่ทันสมัยทำให้มั่นใจได้ถึงความน่าเชื่อถือและประสิทธิภาพ

ผู้ผลิตที่ทันสมัยและมีความเชี่ยวชาญเช่นKatio Mold  มีบริการปั้นที่โดดเด่น พวกเขาใช้เทคโนโลยีล้ำสมัยและเทคนิคสมัยใหม่ในการผลิตชิ้นส่วนคุณภาพสูง ดังนั้นคุณควรติดต่อกับพวกเขา คุณสามารถติดต่อเจ้าหน้าที่ดูแลลูกค้าที่เรียนรู้ได้อย่างง่ายดายที่0086-768-82821468 พวกเขาจะแก้ไขปัญหาและข้อสงสัยทั้งหมดของคุณ



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