Mold Spec Guide

Best Molding
Practices
presented by:
www.traininteractive.com | (tel) 978.957.0700
FREE Information
Please visit: www.IDES.com
Free Material Information

Free Design Guides
Free Articles and Newsletters
Ongoing Informational Webinars
traininteractive.com | 978.957.0700
2 / 53
FREE Information
Please visit: www.traininteractive.com
Free Weekly Focused Training Modules
Free Training Report & Payback Calculator
Ongoing Informational Webinars
3 / 53
Best Molding Practices

Focus on Money Savings:
$ - Machine Considerations
$ - Process Considerations
$ - Tooling Considerations
$ - Quality Considerations
$ - Material Considerations
$ - Facility Considerations
4 / 53

Machine Considerations
$ - Mechanical Functions
$ - Energy Usage
$ - Preventative Maintenance
5 / 53
Machine - Mechanical Functions

Minimize Clamp Movements:
Reduce Opening
Reduce Ejection Travel
Avoid Top Speeds
Minimizes Power Usage
6 / 53
Machine - Mechanical Functions

Reduce Screw RPM:
Should Take 80% Of Cooling Time
Minimizes Power Usage
7 / 53
Machine - Energy Usage

Turn Machine Off:
During Off Shifts
During Breaks
Reduce Warm Up Times
8 / 53

Evaluate Energy Consumption:
Use Amp Probe
Consider Energy Saving Motors
Have Plant Evaluated By Expert
9 / 53

Consider Electric Machines:
Very Fast Payback
Faster With Long Cycle Times
Can Be Less Than 1 Year
10 / 53
Machine - Preventative Maintenance

PM Schedule Reduces:
Equipment Breakdown
Unscheduled Stops
Machine Caused Defects
11 / 53

Develop PM Schedule:
Replace Filters
Hydraulic Fluid
Machine Leveling
Platen Parallelism
Checkring
Calibration
12 / 53
Always Keep A Maintenance Log

To Maintain A Permanent Record
Of Changes And Repairs.
13 / 53

Process Considerations
$ - Melt Temperature
$ - Gate Seal Study
$ - Tact Temperature Optimization
14 / 53
Process - Melt Temperature

Use Lowest Temperature Possible:
Reduces Energy Consumption
Decreases Degradation
15 / 53

Melt Pyrometer:
Accurate To 1C Or 1F
Thin Probe - Preferred
Thin Wire - Avoid
Easily Damaged
Thick Probes - Avoid

Requires Pre-Heating
16 / 53

30/30 Method:
Preheat Temperature Probe
30 Above Barrel Setting
If Thick Probe Is Used
Purge And Insert Probe

Wait 30 Seconds
17 / 53
Process - Gate Seal Study

Always Determine Gate Seal Time:
Reduces Variability
Ensures Energy Is Not Wasted
Allows For Lower Screw RPM
18 / 53

Procedure:
Establish Proper Fill
No 2nd Stage Time
Mold & Record
Part Weight
2nd Stage Time
Increase 2nd Stage Time And Repeat
19 / 53

Plotting:
Plot Data
Draw Trendline
20 / 53

Graph Interpretation:
Gate Seals At Stabilization Point
Optimal 2nd Stage Time Is Next Point
Allows For Variation
21 / 53
Process - Tact Temperature Optimization

Optimal Feed Zone Temperature:
Provides Highest Friction
Between Barrel And Material
Optimizes
Feed Capacity
Melt Capacity
Reduces Energy Usage
22 / 53

To Determine:
1.
2.
3.
4.
Set Rear To Lowest Recommended Temp

Measure Screw Recovery Time
Increase Rear Feed Zone Temp
Repeat Until Peak And Drop Is Found
23 / 53
Set Temperature Within Optimum

Recovery Time Range And Reduce
Screw RPM To Consume 80% Of
Cooling Time.
24 / 53

Tooling Considerations
$ - Cooling & Venting

$ - Material Concerns
$ - Cavitation
$ - Ejection Design
$ - Tooling Specifications
$ - Maintenance Schedules
25 / 53
Tooling - Cooling & Venting

Maximize Cooling:
Use Multiple Thermolators
For Each Mold Half
Verify Flow With Flow Meter

Check Temperature With Pyrometer
26 / 53
Tooling - Cooling & Venting

Maximize Venting:
Improves Filling
Allows For Faster Flow Rate
Increase Vent Cleaning Interval
Additional Vents Do Not Cause Flash
27 / 53
Tooling - Material Concerns

Avoid Wear:
Use Wear Resistant Materials
Brass Inserts
Brass Plated
Graphite Impregnated
Ball Bearing Loaded Bushings
28 / 53
Tooling - Material Concerns

Avoid Galling:
Use Materials With Disimlar Hardness
With Moving Components
With Angled Or Curved Mating Surfaces
29 / 53
Tooling - Cavitation
Avoid Partial Cavitation:
Creates Imbalance
Reduces Productivity
Makes Mold Difficult To Process
30 / 53
Tooling - Ejection Design

Maximize Ejection:
Even Distribution Of Force

Provide Push Points
Use Easily Removed Undercuts
Use Larger, More Durable Actions
31 / 53
Tooling - Ejection Design

Reduce Stresses And Vacuum Forces...
Draft Angles
Draw Polishing
Radii
Fillets
Ribs
32 / 53
Tooling - Tooling Specifications

Standardize When Possible:
Clamping Plate Design
Off-The-Shelf Components
Mold Bases
Slides
Lifters
Bushings
Ejection
33 / 53
Tooling - Tooling Specifications

Document Company Standards:
Create Tooling Specifications
Require All Vendors To Adhere
Consider Retrofit Of Current Tooling
34 / 53
Tooling - Maintenance Schedules

Schedule Preventative Maintenance:
Vent Cleaning
Lubrication
Inspection
Polishing
Descaling
35 / 53

Quality Considerations
$ - Quality Board
$ - Post Metrics
$ - Ongoing Training
36 / 53
Quality - Quality Board

Provide:
Acceptable Parts
Unacceptable Parts
Quality Specifications
Documentation
37 / 53
Quality - Post Metrics

Inform Everyone:
Cost
Cost
Cost
Cost
Of
Of
Of
Of
Scrap
Equipment
Repairs
Production
38 / 53
Quality - Ongoing Training

Provide Training For:
Production Employees
Quality Employees
Maintenance Employees
Technical Employees
Supervisory Employees
Tooling Employees
39 / 53
Quality - Ongoing Training

Use A Blended Learning Model:
Interactive Training
On-The-Job Instruction
Practical Exercises
Get Everyone Involved
40 / 53

Material Considerations
$ - Material Delivery
$ - Incoming Inspection
$ - Flow Of Materials
$ - Service Provision
41 / 53
Material - Material Delivery

Materials Should Be Delivered:
Via Vacuum Line Or Covered Containers
Minimal Contamination
Can Affect An Entire Batch
Can Cause Defects
42 / 53
Material - Incoming Inspection

Incoming Inspection:
Visual Contamination Check
Material Viscosity
43 / 53
Material - Flow Of Materials

Optimize Flow Of Materials:
Shorten Distance Of Travel
Minimize # Of Steps
Use Circular Or Horseshoe Layout
44 / 53
Material - Service Provision

Provide Services:
Under Floor - Preferred

Floor Level - OK
Along Walls - Acceptable
Ceiling - Avoid If Possible
45 / 53

Facility Considerations
$ - Housekeeping
$ - Air Supply
$ - Vacuum Supply
$ - Water Supply
46 / 53
Facility - Housekeeping
Poor Housekeeping:
Introduces Contamination
Increases Complications
Reduces Morale
47 / 53
Facility - Housekeeping
Workplace Complications:
Increases Time To Find Things

Everything Gets Dirtier
Adds To Frustration
Safety Risk
48 / 53
Facility - Air Supply

Inefficiencies Result From:
Excessive Line Pressure
Fixed Speed Pump Motor
Air Leaks
49 / 53
Facility - Vacuum Supply

Excessive Vacuum
Vacuum Leaks
50 / 53
Facility - Water Supply

Water Leaks
Unbalanced Supply
Low Supply Temperatures
Consider Using Localized Chillers
51 / 53
Special Offer 20% discount

Scientific Troubleshooter Package
DECOUPLED MOLDINGSM Series
Intelligent Molder Series
Machine Evaluation
Mold Evaluation
Process Evaluation
52 / 53
Q & A Session
Please Ask Via Chat Feature
presented by:
53 / 53

Mold Spec Guide

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Mold Spec Guide

Încărcat de

Drepturi de autor:

Formate disponibile

Best Molding

www.traininteractive.com | (tel) 978.957.0700

Free Material Information

Best Molding Practices

Best Molding Practices

Machine - Mechanical Functions

Machine - Mechanical Functions

Machine - Energy Usage

Machine - Energy Usage

Machine - Energy Usage

Machine - Preventative Maintenance

Machine - Preventative Maintenance

Machine - Preventative Maintenance

Always Keep A Maintenance Log

Best Molding Practices

Process - Melt Temperature

Process - Melt Temperature

Thick Probes - Avoid

Process - Melt Temperature

Purge And Insert Probe

Process - Gate Seal Study

Process - Gate Seal Study

Increase 2nd Stage Time And Repeat

Process - Gate Seal Study

Process - Gate Seal Study

Process - Tact Temperature Optimization

Reduces Energy Usage

Process - Tact Temperature Optimization

Set Rear To Lowest Recommended Temp

Process - Tact Temperature Optimization

Set Temperature Within Optimum

Best Molding Practices

$ - Cooling & Venting

Tooling - Cooling & Venting

Verify Flow With Flow Meter

Tooling - Cooling & Venting

Tooling - Material Concerns

Tooling - Material Concerns

Tooling - Ejection Design

Even Distribution Of Force

Tooling - Ejection Design

Tooling - Tooling Specifications

Tooling - Tooling Specifications

Tooling - Maintenance Schedules

Best Molding Practices

Quality - Quality Board

Quality - Post Metrics

Quality - Ongoing Training

Quality - Ongoing Training

Best Molding Practices

Material - Material Delivery

Material - Incoming Inspection

Material - Flow Of Materials

Material - Service Provision

Under Floor - Preferred

Best Molding Practices

Increases Time To Find Things

Facility - Air Supply

Facility - Vacuum Supply

Facility - Water Supply

Special Offer 20% discount

Best Molding Practices

S-ar putea să vă placă și