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  • Injection Moulds Often Encounter Problems And PVD Coating Plays A Role
    Dec 24, 2018

    Injection moulds often encounter problems and PVD coating plays a role

     

    TiAlCrN14


    With the widespread use of glass, metal fiber reinforced engineering plastics and refractory resin and the increase in the number of plastic production, the working condition of plastic mold is increasingly bad, the cavity surface often occurs serious wear and corrosion, affect the appearance of the product quality and cause the difficulty of demolding, and greatly shorten the service life of the mold cavity.

     

    Practice has proved that the application of surface strengthening technology to improve the surface hardness, abrasion resistance, friction reduction, corrosion resistance and fatigue resistance of molds and relative moving parts is an effective way to avoid early failure of molds and improve the service life. At the same time, it can make up for the shortage of mold materials to a certain extent, reduce the cost of mold manufacturing and improve productivity.

     

    A set of injection mold is usually composed of several different parts assembly, for different purposes of the mold, its requirements are not the same.If the plastic injection mold should have the following characteristics: first, the pressure caused by the force.Secondly, several metal moving parts without lubrication will be subjected to: 1. Bite abrasion; 2.2, corrosion wear, plastic powder heat brings corrosion and wear products particles.In addition, some mold areas should bear: 1.2. Abrasive wear caused by adding glass fiber to some products;3. Corrosion caused by decomposition of chlorine-containing polymers and abrasion caused by product particles;4. The "internal combustion effect" (diesel effect) of combustible exhaust gas will be generated due to the dual effects of heat and pressure in some sealing areas of parts, sometimes causing flash fire or burning.

     

    In the mold, some parts that are subjected to harsh working conditions include injection nozzle, moving tappet, drawing rod, guide rod or guide rail, etc. Suffered fatigue, wear and corrosion conditions can produce defects on the mould, these defects will reduce the die life, may cause the deterioration of mould: 1, plastic and mold filling speed operating speed and general sliding friction coefficient is inversely proportional to mold parts, mold defects certainly influence on the speed of operation, thus directly impact the cost of the mould operation; In the mold, some parts that are subjected to harsh working conditions include injection nozzle, moving tappet, drawing rod, guide rod or guide rail, etc.Suffered fatigue, wear and corrosion conditions can produce defects on the mould, these defects will reduce the die life, may cause the deterioration of mould: 1, plastic and mold filling speed operating speed and general sliding friction coefficient is inversely proportional to mold parts, mold defects certainly influence on the speed of operation, thus directly impact the cost of the mould operation;2, the physical and chemical interaction between the mold surface and the injection mold material will cause plastic, rubber or aluminum alloy "tumorous" defects, or can be called malignant "adhesion".For example, in an injection molding factory, the original plastic mold is made of 35NCD16(35Ni4CrMo steel), which is cooled by water.Due to myxoma and "internal combustion effect", the mold needs to be cleaned and polished after processing one million pieces. The average operation time of each piece is 17s, which seriously reduces the production efficiency.The mold was later treated with a PVD coating, 3um after a single mask, with high wear resistance, and the mold material was changed to a cu-be alloy (beryllium bronze) with good thermal conductivity, which could Be cooled without water.This treatment of the mold does not have "internal combustion effect", mucinoma phenomenon is greatly reduced, so that the cleaning work can be carried out every 6 million injection molding.In addition, due to the low chemical affinity between mold coating and plastic, the average time of each operation was reduced from 17s to 10s.The second example is the polystyrene key mould, which is made of high alloy steel Z38CDV5(1.2343, equivalent to American H2 steel).The problems are the poor filling property of plastic injection cavity and the phenomenon of mold mucinoma.In order to improve the filling speed, some PVD coating was applied to the mold, with amazing results and a 30% reduction in operating time.Because the friction between plastic and steel is reduced, demolding force is reduced, mold pattern carving does not have to worry too much.The third example is the o-ring mould of synthetic rubber, which was originally electroplated with hard chromium, but is now coated with chrome-based PVD.When hard chromium plating is used, due to severe "nodules", the mold shall be cleaned (brushed and removed in the cleaning solution) every 20,000 operations.In order to reduce maintenance costs and production stoppage costs, the hard chromium layer was changed into a single 4um thick chrome-based PVD coating.The result of this replacement is clear: cleanup can be done after every 100,000 units, with a five-fold reduction in idle hours.2, the physical and chemical interaction between the mold surface and the injection mold material will cause plastic, rubber or aluminum alloy "tumorous" defects, or can be called malignant "adhesion".For example, in an injection molding factory, the original plastic mold is made of 35NCD16(35Ni4CrMo steel), which is cooled by water.Due to myxoma and "internal combustion effect", the mold needs to be cleaned and polished after processing one million pieces. The average operation time of each piece is 17s, which seriously reduces the production efficiency.The mold was later treated with a PVD coating, 3um after a single mask, with high wear resistance, and the mold material was changed to a cu-be alloy (beryllium bronze) with good thermal conductivity, which could Be cooled without water.This treatment of the mold does not have "internal combustion effect", mucinoma phenomenon is greatly reduced, so that the cleaning work can be carried out every 6 million injection molding.In addition, due to the low chemical affinity between mold coating and plastic, the average time of each operation was reduced from 17s to 10s.The second example is the polystyrene key mould, which is made of high alloy steel Z38CDV5(1.2343, equivalent to American H2 steel).The problems are the poor filling property of plastic injection cavity and the phenomenon of mold mucinoma.In order to improve the filling speed, some PVD coating was applied to the mold, with amazing results and a 30% reduction in operating time.Because the friction between plastic and steel is reduced, demolding force is reduced, mold pattern carving does not have to worry too much.The third example is the o-ring mould of synthetic rubber, which was originally electroplated with hard chromium, but is now coated with chrome-based PVD.When hard chromium plating is used, due to severe "nodules", the mold shall be cleaned (brushed and removed in the cleaning solution) every 20,000 operations.In order to reduce maintenance costs and production stoppage costs, the hard chromium layer was changed into a single 4um thick chrome-based PVD coating.The result of this replacement is clear: cleanup can be done after every 100,000 units, with a five-fold reduction in idle hours.