Preparation for injection molding production

1、 Material preparation
1. Confirm the material number/type according to the product drawing.
2. Confirm color master number and mixing proportion (if the color master is needed)
3. Check whether the material in the barrel is correct, and there is a material identification plate for engineering mold test on the barrel
4. Confirm the proportion of recycled materials, drying temperature, and drying time (according to material properties and product requirements)
2, mold preparation
1. Confirm the mold number
2. Check whether the mold has special requirements such as insert and core pulling
3. Mold inspection: check whether the appearance of locating ring and hot runner interface is OK
4. Inspection of mold accessories: check the diameter and length of water pipe, pressing plate, pressing plate bolt length, suspension bridge, etc
5. Whether the injection nozzle r of the mold matches the nozzle of the machine
3、 Machine preparation
1. Confirm whether the mold can be installed on the injection molding machine: maximum clamping force, mold size, mold thickness, core pulling function, air blowing device.
2. Is the machine ejector suitable for the mold
3. Check whether the screw has been cleaned
4. Check whether the mold temperature machine, manipulator, automatic mixer, and automatic suction machine can work normally: the manipulator fixture matches the mold
5. Confirm product drawings/samples (if any) and understand important dimensions
6. Prepare relevant tools
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4、 Mold testing steps
1. Before loading the mold, clean the machine for 5 seconds, and check whether the appearance of the positioning ring, thimble hole, core pulling device, and hot runner interface is OK.
2. Install the rings (bending rings are not used). The depth of the rings into the mold must be greater than 1.5 times the ring diameter. If the ring surface is not attached to the mold, gaskets must be used to prevent the rings from bending and breaking. After confirming that there is no problem with the machine, lift the mold
3. Place the mold between the moving and fixed plates and keep a certain height, and connect the water pipe and relevant interface (if any) under the mold
4. Align the positioning hole, adjust the level, and align the die into the positioning hole of the machine. After the horizontal balance is determined, a pressing plate on each side of the fixed die is slightly locked to locate the die
5. Close the operation door, close the mold and start the automatic mold adjustment
6. Adjustment of clamping force
7. After completion, open the operation door and lock the pressing plate of the dynamic and fixed die.
8. Loosen the rope and remove the suspension bridge
9. Connect the water pipes on both sides of the mold and related equipment (if any)
10. Connect the hot runner plug and preheat the mold in advance
11. Close the operation door and set the mold to preheat the mold at a lower temperature.
12. Hold the main part of the ejector rod tightly (the ejector rod must be held tightly when closing the mold, otherwise, the sliding block will not damage the ejector pin when opening the mold)
13. Open the mold and check the parting surface
14. Adjust the position of the thimble to zero, adjust the strength and speed of the thimble, and eject this number.
15. Adjust the mold opening and closing (mold opening and closing speed, position, low-voltage protection position, monitoring time), find out the correct speed - when closing the mold, start fast = = > > slow = = > > slow again, when opening the mold, slow first = = > > fast = = > > slow down. The contact point between the guidepost and the guide sleeve is selected by switching the slow closing position. The lower the protection pressure, the better. The monitoring time is 0.1s longer than the actual closing time
16. Check the operation condition under the idling state and adjust it to be stable and appropriate
17, input process parameter data, (please adjust within a small error range is allowed, generally 5%). It is not necessary to follow exactly the same value of the process card. For the temperature setting range of various materials, please refer to the relevant material temperature setting reference table.)
18. Feeding: verify whether the material number is correct before feeding
19. Return to the shooting table and spray to prevent die sticking
20, top firing platform: Top firing platform, zero firing platform
21. For hot runner mold, hot runner injection should be done before this to ensure smooth flow passage. 1) cardboard must be used to pad between the moving and fixed mold to catch the injected material; 2) Before the injection of the runner, the temperature can be appropriately increased (, and then it can be adjusted back to the normal value after it is confirmed to be normal
22. Semi-automatic production, check whether the injection condition is normal, adjust the injection pressure and injection speed. 1) For smaller parts, the cover should be used to block both sides of the mold to prevent parts from splashing. 2) set the maximum injection pressure according to the actual display injection pressure;
23. Find the switching point of pressure maintaining, make the product 95% ~ 98% full, and then add pressure maintaining
24, adjust the melt backpressure, screw speed, metering time, the best time is 65% ~ 75% of the cooling time, the best is 75%.
25. Turn on the monitor and set the counter
26. Weigh the weight of the product at the conversion point, and record the comparison with the weight of the conversion point on the process card. During PPAP, two molds should be collected, one mold should be put into the mold retention bag, and the process engineer of one mold should keep it for future reference
27. Compare the product with the sample. If the mold core is changed, the product number must be confirmed
28. Send to QA for inspection, send 5 mold products to QA for inspection, and provide 300 mold samples (for reference, different mold requirements can be adjusted for different products)
29. After production, collect the last mold product and put it into the mold sample bag before shutdown
During PPAP, the process engineer needs to record the process parameters, fill in the blank injection process parameter card, and send the set process parameters from the machine to the server host for the next call
31. If the process has been optimized in the formal production, the new process parameters should be sent from the machine to the host for updating.
32. In case of alarm or shutdown during production and the safety door needs to be opened, it should be returned to the battery first to prevent material spraying
33. When the machine is restarted, it needs to shoot. If the hot runner mold needs to do hot runner injection to prevent die sticking
34. Shut down and open the mold for maintenance
35. Close the mold and return to the fort; Turn off the mold temperature machine and hot runner
36. Turn off the electric heating after cleaning the screw
37. When loosening the ejector, it is necessary to loosen the ejector when closing the die, otherwise, the sliding block may damage the ejector
38. Open the operation door, install the suspension bridge, and hang the mold tightly. The suspension rope should not be too tight, and it can be shaken slightly
39. Loosen the pressing plate and remove the die
40. Lift the mold and place the lower mold area
41. Clean up the injection table, and hand over the nozzle materials and scrap products to the production department for recycling.