Common Problems and Solutions in Injection Mold Processing for Plastic Injection Parts

Common Problems and Solutions in Injection Mold Processing for Plastic Injection Parts

 

Injection mold processing plays a critical role in modern manufacturing and is widely used in the automotive, electronics, and medical fields. However, various problems often arise during the processing process, affecting mold quality and production efficiency, leading to product defects and increased costs. Therefore, a deep understanding of these common problems and their solutions is crucial for improving mold manufacturing and product quality.

1. Mold Design Problems and Solutions

1.1 Dimensional Accuracy Deviation

 

Causes: Misunderstanding of product dimensions, improper software accuracy settings or usage, and insufficient understanding of mold structure and processing techniques.

 

Influencing Factors: Product material properties, mold structure complexity, and designer experience and skills.

 

Preventative Measures: Accurately calculate and compensate for shrinkage, select and master appropriate software, and strengthen communication and collaboration between design and process personnel.

 

Solution: Adjust processing parameters for minor dimensional deviations; rework or reprocess for major ones.

 

1.2 Irrational Structure

 

Causes: Inadequate analysis of product molding and demolding requirements, lack of innovation, and adherence to traditional designs.

 

Influencing Factors: Product shape and structure, molding process, manufacturing cost, and cycle time.

 

Preventive Measures: Analyze product design optimization, draw on leading practices, and conduct design reviews.

 

Solution: For demolding difficulties, increase the slope or use a release agent. For runner and gate issues, redesign the runners and gates. If the problem is severe, redesign and manufacture the mold.

 

2. Processing Problems and Solutions

2.1 Cutting Errors

 

Causes: Tool wear, improper cutting parameters, insufficient machine tool accuracy and stability, an unreasonable process route, and uneven workpiece material.

 

Influencing Factors: Tool material quality, degree of cutting parameter optimization, machine tool performance and maintenance, and workpiece material characteristics.

 

Preventive Measures: Regularly change tools, select and optimize parameters, maintain the machine tool, and develop a reasonable process route.

 

Solution: Correct tool wear with compensation. For large errors, reprocess or repair. For roughness issues, adjust parameters or perform subsequent processing.

 

2.2 EDM Defects

 

Causes: Improper discharge parameters, improper electrode design and manufacturing, and poor working fluid circulation and filtration.

 

Influencing Factors: Discharge parameters, electrode quality and accuracy, and working fluid circulation system performance.

 

Preventive Measures: Properly set discharge parameters, manufacture electrodes with high precision, and regularly inspect and replace the working fluid.

 

Solution: Polish surface burns. Repair or reprocess the electrodes if discharge marks are deep. Inspect and adjust parameters and the working fluid system if discharge is unstable.

 

3. Material Selection Issues and Solutions

3.1 Material Performance Mismatch

 

Cause: Insufficient understanding of product usage and operating environment, procurement inspection and acceptance not performed according to standards.

 

Influencing Factors: Product operating conditions, mold life requirements, supplier reputation and quality control.

 

Preventive Measures: Consider the operating environment when selecting materials, establish a procurement standard acceptance system, and partner with reliable suppliers.

 

Solution: If alternative materials are not used, surface treatment can be used to improve performance.

 

3.2 Unstable Material Quality

 

Cause: Unstable supplier production process, material transportation and storage issues, and inadequate company inspection methods.

 

Influencing Factors: Supplier management level, transportation and storage conditions, and company inspection capabilities.

 

Preventive Measures: Evaluate and manage suppliers, optimize transportation and storage conditions, and improve inspection equipment processes.

 

Solution: Communicate with suppliers for improvements, return or replace unqualified materials, and strengthen quality control during production.

 

4. Assembly and Commissioning Issues and Solutions

4.1 Poor Part Fit

 

Cause: Part machining accuracy does not meet requirements, assembly process is not rational, and parts are not cleaned and trimmed.

 

Influencing Factors: Part machining accuracy, assembly process rationality, and assembly personnel's skills and operating standards.

 

Preventive Measures: Improve part machining accuracy, develop a rational assembly process and train personnel, and clean and inspect parts before assembly.

 

Solution: Repair and grind parts for poor fit. If the problem is severe, rework or adjust the assembly process. Adjust assembly accuracy based on molding results during commissioning.

 

4.2 Improper Commissioning Parameters

 

Cause: Insufficient understanding of injection molding process parameters, failure to consider the influence of multiple factors, and subjective judgment during commissioning.

 

Influencing Factors: Mold structure and dimensions, product material and shape, injection molding machine performance parameters, and commissioning personnel's experience and skills.

 

Preventive Measures: Commissioning personnel must be familiar with parameter settings and techniques, analyze and determine preliminary parameters before commissioning, and use scientific experiments to optimize parameters.

 

Solution: Adjust injection molding process parameters based on the type of product defect, observe the molding process, and continuously optimize.

 

         Injection mold processing is of great significance in modern manufacturing, but problems can arise at every stage of the process. An in-depth analysis of common issues and corresponding solutions in mold design, processing technology, material selection, assembly and commissioning will help us effectively address them in practice, thereby improving mold quality and production efficiency, ensuring product quality, and promoting the development of the injection mold processing industry.