How to solve the problem of insufficient injection during the production process of injection molds?
The phenomenon of under injection in the production process of injection mold, that is, partial incompleteness at the end of the material flow or partial filling in the multi cavities of the first mock examination, especially in the thin-walled area or the end area of the flow path, will affect the product quality and production efficiency. Here are some solutions to address the phenomenon of under registration:
1. Check the injection molding equipment:
Ensure that the maximum injection volume of the injection molding machine is greater than the weight of the product (including the product, runner, flash, etc.), and the total injection volume should usually be kept below 85% of the maximum injection volume.
Check whether the screw, barrel, nozzle and other components of the injection molding machine are worn or leaking glue, to ensure that the glue can be smoothly delivered to the mold.
2. Improve the fluidity of raw materials:
Add appropriate additives such as plasticizers and lubricants to the raw materials to improve the flowability of the resin.
Check the proportion of recycled materials in the raw materials and reduce the amount of recycled materials appropriately to improve the fluidity of the melt adhesive.
3. Optimize mold design:
Reasonably set the position of the sprue, expand the size of the sprue, runner, and sprue to reduce fluid resistance.
Use larger nozzles to ensure that the adhesive can smoothly enter the mold.
Improve the pouring system of the mold, such as adopting a design scheme with balanced distribution channels, so that each cavity can be filled simultaneously.
Check if the exhaust system of the mold is in good condition, and if necessary, set up exhaust slots or holes in the under injection area.
4. Adjust process parameters:
Raise the material temperature and mold temperature to increase the fluidity of the melt adhesive and prolong the filling time. However, it is important to avoid excessive material temperature that may cause the molten material to decompose.
Appropriately increase the injection pressure and injection speed to improve the filling ability of the melt adhesive. However, it is important to avoid injecting too quickly, which may cause the melt to rupture.
Choose appropriate holding time and pressure to prevent the adhesive from flowing back during the filling process.
5. Cleaning molds and injection molding machines:
Regularly clean the flow channels, gates, and other components of the mold and injection molding machine to prevent blockage of the filling channel by cold glue, impurities, etc.
Check and repair the worn parts of the mold and injection molding machine to ensure the normal operation of the equipment.
6. Optimize product design:
When designing the shape and structure of plastic parts, pay attention to the relationship between the thickness of the plastic part and the ultimate flow length of the melt during mold filling. The thickness of plastic parts is usually between 13mm, and the thickness of large plastic parts can be appropriately increased to 36mm. Avoid excessive thickness of plastic parts that may hinder the flow of molten metal.
For products with complex shapes and large forming areas, multi-point feeding can be used to reduce the resistance of the melt during the flow process.
In summary, solving the problem of under injection in the production process of injection molds requires starting from multiple aspects such as equipment, raw materials, mold design, process parameters, mold and injection molding machine cleaning, and product design. By comprehensively considering and taking corresponding measures, the problem of insufficient injection can be effectively solved, and product quality and production efficiency can be improved.
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