Mould Maintenance A Kumar
Mould Maintenance A Kumar
Mould Maintenance A Kumar
By
A. KUMAR
Central Institute Of Plastics Engineering &
Technology (CIPET)
CHENNAI
INTRODUCTION
Injection moulds play a vital role in
production of qualified quality components.
Consistency in the quality of component would
also depend on the quality of mould. Unreliable
mould would need frequent adjustment, repairs
etc. it is therefore necessary that mould should be
reliable in its function and moulding of qualified
components.
UPKEEP AND MAINTENANCE
PURPOSE
SCOPE
RESPONSIBILITY
DEFINITION
FACTORS – MOLD LIFE
Purpose :
To provide a systematic approach to the
maintenance requirements of molds.
Scope :
In order to maintain quality parts, they must be
produced in quality molds. The best quality parts are
produced from precision molds. Molds, quite like cars,
begin to wear with use and maintaining a tool is an
investment in precision.
Proper tool maintenance is a matter of attention to
detail. As things begin to wear, they must be noted and
attended to. This is a simple matter of keeping a molding
log for maintenance as little things come up and
performing periodic maintenance as the tool is run in
production.
Responsibility :
Defining ‘Upkeep’
Defining ‘Maintenance’
History sheets
fumes do come in contact with mould surfaces. Hence a fine layer of ‘rust’
appears on the cores, cavities and other parts of the mould. This happens if
‘Rusting’ can be very much minimised if the moulds are kept covered by PVC
sheet covers.
DEFINING MAINTENANCE
In General terms, maintenance means to keep the moulds
and bring them to production in a worthy condition, some
essential aspects of mould maintenance are covered here.
Preventive maintenance of the moulds would cover examining
the mould for small damages
Increase in the clearance of the moving parts, the adjusting of the
locking wedges
The cleaning of the water channels
Sometimes, any guide pin or cam pin may found shaky in its
holding hole. In that event, as a maintenance action, either a new
pin may be put or the existing one may be copper plated at the
holding surface.
SPECIFICATION SHEETS
Specification may vary from mould to mould.
It gives complete information about the mould,
which can be stored in a computer.
Each sheet may be stored in a computer, allotting
a suitable file number.
Inadequate physical strength of mould parts to withstand the loads encountered and
caused by clamping force injection pressure, ejection forces etc.,
Improper mould makes selection.
Improper allowance for fatique in mould studies in a frequent cause for breakage,
Improper heat treat specifications.
Lack of lubrication of sliding faces.
Incorrect machine setup.
Poor maintenance practices and rough handling of the mould, especially if the
moulder does not adhere to the suggested start up and maintenance procedure.
The use of dirty and contaminated plastics.
Abrasive, erosion or corrosive fillers such as glass and some other additives.
Corrosive plastics, which may attack (corrode) poorly suited mould materials.
High humidity.
Dirty and corrosive cooling water.
Maintenance Frequency
Level 1: Every time the mold is pulled from production or put
back into production, Routine Maintenance.
Level 2: 20,000 cycles or nine production shifts for Inspection
Maintenance.
Level 3: 100,000 cycles or every 10 production runs for General
Maintenance.
Level 4: 250,000 cycles or half the anticipated life time volume,
whichever comes first for Major Maintenance.
Break Down Maintenance
Break down maintenance done unexpectedly when an
accident occurs to the mould is in production.
Using a mild, clean shop safety solvent and soft, clean towels,
gently clean internal mould surfaces to remove residual dirt and
grime.
More the ejector system fully forward and spray both mould
halves with a shop-approved, protective rust preventive before
retracting the ejector and closing the mould.
Drain and blow free all residual water to avoid rust buildup.
No water should be trapped inside the mould and it is critical.
Make sure all bolts plates and clamps are properly placed and
the safety straps are secured and tightened.
Remove mould, check and clean it again, if required.
Bag the last two or four shots to store with the mould (including
parts, sprue and runner) as examples of the expected run quality.
Don’t let water lines stick out when storing moulds on racks.
Wrap the mould with plastics. Ensure that air is dry when
wrapping, or put a desicant air absorption bag inside so that
temperature changes don’t cause condensation inside the wrapping
that could form rusting.
QUALITY PLAN FOR MOULDS
QUALITY PLAN -MOLDS
ORDER RECEIVED ON :
Released by:
Name: Signature:
Name: Signature
POINTS THAT LEAD TO DISPUTES LATER ON
•TOLERANCES
• MATERIAL SHRINKAGE FACTOR
• RADIUS
• MACHINE FITTING
• DRAFT ANGLES
• POLISHING STANDARDS
This is a critical stage of the mould, and any undue haste could well
damage months of planning and craftsmanship. Testing or proving
recommended procedure to be followed: