inserts en laiton pour moulage par injection plastique

Moulage d'insertion en laiton

What means brass inserts for plastic injection molding

Brass inserts for plastic injection molding are small metal components that are used in injection molding process to create a wide variety of parts and products, this process we call moulage par insertion process. These inserts are typically made from brass, a strong and durable metal that is resistant to corrosion and wear. They are used in a range of industries, including automotive, medical, and consumer products.

Injection molding is a manufacturing process that involves injecting molten material, such as plastic or metal, into a mold to produce parts and products. During the injection molding process, the brass inserts are placed into the mold, and the plastic is injected around them. The mold is then cooled, and the finished part is ejected from the mold.

Advantages of brass inserts for injection molding

inserts en laiton pour moulage par injection plastique

There are a few key benefits to using brass inserts in plastic injection molding:

  • Strength: Brass is a strong and durable metal that is resistant to impact and wear. When used as inserts in plastic injection molding, brass can help to increase the strength and durability of the finished part.
  • Corrosion resistance: Brass is resistant to corrosion, making it a good choice for parts that will be exposed to harsh environments or chemicals. This can help to increase the lifespan of the finished part and reduce the need for maintenance or repairs.
  • Wear resistance: Brass has good wear resistance, making it a good choice for parts that will be subjected to high levels of wear or friction.
  • Customization: Brass inserts can be customized to a wide range of shapes and sizes, making them suitable for a range of applications. They can also be modified with coatings or other treatments to achieve specific properties, such as increased corrosion resistance or improved wear resistance.
  • Ease of use: Brass inserts are easy to install and remove, making them convenient for use in the injection molding process. They can be placed into the mold quickly and easily, and they can be removed from the finished part just as easily.
  • Cost-effectiveness: Brass inserts are generally less expensive than other materials used in injection molding, such as stainless steel or aluminum, making them a cost-effective choice for many manufacturers.

Factors to consider when using brass inserts in plastic injection molding There are a few key factors to consider when using brass inserts in plastic injection molding:

  • Compatibility with the plastic: It’s important to ensure that the brass inserts are compatible with the plastic being used in the injection molding process. Different plastics may have different properties and requirements, and it’s important to choose brass inserts that can be used effectively with the chosen plastic.
  • Compatibility with the injection molding machine: It’s important to ensure that the brass inserts are compatible with the injection molding machine that will be used for the project. Different machines may have different capabilities, and it’s important to choose brass inserts that can be processed effectively by the machine.
  • Required properties of the finished part: The properties of the finished part, such as strength, stiffness, and corrosion resistance, will depend on the specific grade of brass being used. It’s important to choose the right grade of brass for your application to ensure that the finished part has the desired properties.
  • Cost: The cost of the brass inserts is an important factor to consider, as it can have a significant impact on the overall cost of the project.
  • Availability: It’s important to ensure that the brass inserts you need are readily available, as delays in material delivery can impact the timeline of your project.
  • Sustainability: If sustainability is a concern, it may be worth considering brass inserts made from recycled materials.

In conclusion, brass inserts are a popular choice for use in plastic injection molding due to their strength, corrosion resistance, wear resistance, customization, ease of use, and cost-effectiveness. When using brass inserts in plastic injection molding, it’s important to consider factors such as compatibility with the plastic and the injection molding machine, the required properties of the finished part, cost, availability, and sustainability. By carefully considering these factors, you can choose the best brass inserts for your injection molding project and ensure the success of your project.

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moulage par injection de plastique à court terme

moulage par injection de matières plastiques à long terme

When the requirements for polymer parts go beyond 3D printing and machining, it is recommended that product engineers should turn to injection molding. Conventional injection molding entails identifying the right tooling vendor and then buying the tooling, which may take several months. It may take a long time and is very tiresome, but the cost per unit is relatively low, especially when making many pieces of the items. Fortunately, there is an alternative: short run plastic injection molding.

Comprehension Short Run Plastic Injection Molding

When there is a small production of the product, short-run injection molding employs cheaper tools as compared to long-run injection molding (or moulage par injection à haut volume). This process also does away with the conventional high-volume manufacturing system that requires much rigidity, long cycle time and large capital investment. However, in this case, short-run injection molding is more appropriate in the short run than in the long run.

The temporary molds are of aluminum while the ‘hard’ production tools are of cemented tool steel. This metal is characterized by high thermal conductivity and good workability. Aluminum molds are slightly less rigid than steel molds, but they are the most suitable for runs of less than 10,000 pieces. In addition, they are cheaper than steel molds and the final parts are made in weeks, not in months, as is in the case of steel molds.

Short run injection molding is the most appropriate for any organization that needs quality plastic parts at an affordable price and within a short time.

moulage par injection de plastique à court terme

Benefits of Short Run Injection Molding

The benefits of short-run injection molding are as follows:

Aluminium injection moulds are cheaper as compared to reinforced steel moulds that are available in the market today. The degree of savings is dependent on the number of cavities, the geometry of the part and the moulding issues like undercuts or inserts. However, the difference in costs is normally quite large.

But this is not the only advantage that can be derived from this, the cost factor has to be considered. The ability to make changes and the short cycle times can thus be helpful in cutting down the time taken to develop products hence, cutting down the time to market. However, unlike most organizations, our short-run injection molding service does not bind the customers to order in large quantities. They are made from materials of production-grade and have adequate surface finishes that can be used.

Short Run Injection Molded Costs For Parts Production

It is also important to note that the cost of manufacturing the short run injection mold for fabricating small quantity products and setting up is fixed and has to be spread over the number of orders.

Generally, short run injection molding is appropriate for parts ranging from 1 to 10,000. At Sincere Tech, we provide two tooling options: prototype molds, which are normally associated with a warranty of at least 2000 shots and on-demand production molds, which are associated with a mold life warranty. If the aluminum tool is spoilt, then the company will replace it without charging the customer anything. Regarding the quantity of the produced product, both options are fairly inexpensive.

Other special services are first article inspection, capability reports, scientific molding process development reports and PPAP. Some clients have realized that a short-run aluminum mold can be used as the end product mold.

If the volumes are in the millions, then production tooling might be more appropriate. On the other hand, 3D printing can be cheaper in the instance of manufacturing a few numbers of parts. Some of the manufacturers use 3D printing to create the prototypes and then use small run injection molding.

Uses of Short Run Injection Moulding

The best strategy is relative to the needs of the organization and the situation in the organization. For example, a medical device manufacturing firm that has developed a new medical device but is in doubt about the market situation can use a short-run injection instrument. This is in favor of a “pay-as-you-go” approach during the product’s introduction. If, at some later date, they decide to invest in a steel tool, the aluminum mold can be used as an interim tool up to the time the production mold is made.

It is also significant to note that bridge tools are not limited to the ramp-up stage of the product introduction only. They can be a fairly cheap way to have an insurance policy for mature programs. For instance, an appliance manufacturer was in a position to proceed with the production process since he or she utilized a bridge tool to fix the main tool. They now have an extra mold that they can use in the future, for instance, if the demand for the product rises or if the current tool is not effective.

The short-run injection molding is a good middle ground for the designers to get the best mold design and the performance of the final product with relatively low risk as compared to the direct use of steel production tools from the 3D printed models. This is more so in industries such as medical devices where it is important to shorten the time it takes to develop these products while at the same time ensuring that the products meet the set regulatory standards since this is cost-effective.

outillage de moulage par injection plastique

High-volume injection molding

Our digital network is capable of producing larger and more intricate parts in high volume in case short run injection molding is not applicable to your case. Our expandable range of services includes;

  • Projects for molded elements that are large, heavy and elaborate in design
  • Quotes for more than 100,000 components
  • Molding capabilities for parts that are up to 79 inches (2 meters) in size
  • Mold-Tech finishes and a variety of surface finishes (A1-A3, B1-B3, C1-C3, D1-D3).
  • Toolings like Tool Steel P20 and Aluminium & Steel, color matching Tooling as per the requirement of the customer.
  • Would you like to know more about short run injection molding? Upload a file for a free mouldability check and then speak with a member of the Protolabs molding team. Start the fast and effective production of parts with our services.

Is the Cost of Short Run Injection Molding High?

Some of the everyday products that have parts made through injection molding are electric kettles, light controls, and keyboard keys. Usually, such products are produced in large volumes, starting from hundreds of thousands of sets.

This construction method has several benefits, such as cost-effectiveness, versatility of materials, and flexibility.

This technique is the most appropriate for mass production due to its versatility, availability of numerous types of materials, and the fact that it is cheaper per part. This procedure makes the current affordable pricing possible because the cost of elements is in pennies, and cycle times are in seconds. It also applies to the choice of materials, which may be flexible elastomers and polymers that can be used where metals are normally used.

moulage par injection à haut volume

What if you require a fewer number of components?

The cost of tooling forms a significant component when a small number of parts are to be manufactured. The traditional method of manufacturing tooling is expensive and also takes a lot of time. However, there are many modern counterparts that can be pointed out to minimize expenses today.

The main cost factors are setup and recurring.

The tool is located in the molding press, the material/color is dried and provided, the molding conditions are set, and the initial quality control samples are taken during the setup. The tooling has to be protected, the rest of the material has to be stripped off, and the mold has to be opened and stored after the molding cycle. This setup is usually billed on a per-part basis, especially for short runs, and can take anything from one hour to half a day, depending on the size of the tools and the number of material/color changes.

The procedure of shaping

The costs that are incurred in the molding phase include the cost of the material used, the cost of the press, and the manual or automatic operation of the media. The cost of materials also depends on the type of material used and the amount of material that has been bought, there is a big difference between buying a small amount of material and a large amount of the same material. Specialized pigments can also cause an increase in costs since they are used in the process of producing the final product.

The factors that affect the press cost include shot weight which is the amount of plastic injected in a single cycle, and the tonnage, which is the force used to close the mould during injection. Large presses are costly due to high operating costs and depreciation of the equipment. The costs may also be affected by the need for manual operations, for instance, insert loading and discharging or any other post molding operations.

Tools that are fully automated and create volume on a constant basis are differentiated from tools that are created for small lots and require manual transfer and packing.

Alternatives to Prototyping

Prototyping in the intended production material is very advantageous. In the case of prototype and short-run production, there are many choices of tooling, and it is possible to mould as few as two parts. However, the rate of prototyping and part manufacturing can be variable, and some of the occurrences may take days. This depends on the surface, material, and geometry of the structure to be coated. The delay times are normally between two and four weeks.

Tooling expenditures

The cost of tooling depends on the complexity of the element, its size and the time required to make it. Molds are not cheap; they start from £2,000 for the simple ones, but the more complex ones range from £5,000 to £7,000. The price of large or complex items can go up to £30,000. The data of the particular project and the detailed quotation are the basis of accurate cost estimation.

For low-volume injection molding projects, it is advised that you seek advice from professionals to get a broader understanding of the possible costs and the possible feasible solutions. If you are thinking of using short run injection molding for your project and would like to know the cost of the required quantities, feel free to contact us for a quote.

Service de prototypage rapide

Injection Molding Services Offered by Sincere Tech

Sincere Tech is one of to 10 plastic injection molding compnies in China that was founded over a decade ago and has been involved in the design and production of plastic injection-molded parts and goods. Because of our extensive expertise, we are capable of effectively managing all phases of short-run injection molding projects, including With this extensive expertise, we are capable of effectively managing all phases of short-run injection molding projects, including:

Conception du moule : We use the best technologies and mold-making technologies to produce instruments that will satisfy the needs of your product. We create tooling designs based on your original drawings, schematics, or models, or we can create them for you. We have expertise in the use of AutoCAD, SolidWorks, ProE, Cimatron, and CADKey formats of CAD.

Our mold fabrication team uses up-to-date CNC machining technologies to produce high-quality and accurately dimensioned molds in the shortest time possible after the injection mold design has been completed. This is an example of custom tooling. We are able to create prototypes for various thermoplastics, including ABS, HDPE, LDPE, PE, HIPS, TPU, and PET.

Prototyping: We use 3D printing to quickly build each part to make sure that it fits the form and works as it should before the construction of the injection molding tool. We offer FDM printed prototypes in various types of materials such as ABS, PLA, and TPU. We work with other service providers for additional prototyping services, such as urethane casting, SLS, and SLA.

Injection molding: The moulage par injection facility is run by experienced staff and the equipment can produce a clamping force of 28 to 240 tonnes and can also show reproducibility. The material that we process during our molding operations ranges from 0 to 16 ounces per cycle. Sincere Tech is also capable of providing injection molding services for small and large quantities of products.

We guarantee that the custom plastic injection-molded parts that we will provide at Sincere Tech will be of the best quality, will be delivered on time, and at a reasonable price.

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Dépannage du rougissement de la porte

défauts de porte rougissants

Qu'est-ce que le Gate Blush ?

Le voile de porte est un défaut de moulage généralement causé au niveau de la porte d'une pièce moulée par injection. Il se présente sous forme d'anneaux ou d'ondulations dans la cavité du moule entourant la zone de la porte. Ce défaut se produit lorsque la matière plastique s'écoule à travers la cavité du moule au lieu de former un écoulement en fontaine et de geler dans la cavité du moule. Au fur et à mesure que davantage de matière pénètre dans la cavité du moule, elle érode la matière de la surface du moule, provoquant l'apparence de voile de porte, parfois appelé défaut de cisaillement de porte.

défauts de porte rougissants

Cause

La pression et la vitesse d'injection sont trop élevées.

Défauts de rougissement de la porte causés par des pressions et une vitesse élevées traversant une porte de moule au 1St Lors de l'injection par étapes, les plastiques fondus passent trop rapidement à travers la porte, ce qui crée un cisaillement excessif.

Température du moule trop élevée.

La température du moule est trop basse ou trop élevée, ce qui peut entraîner des problèmes de rougissement de la porte. Il peut donc être important de comprendre la température correcte du moule pour différentes matières plastiques. Le rougissement de la porte est un phénomène étrange qui peut être amplifié par la température de l'acier. Des températures d'acier trop basses ou trop élevées peuvent entraîner une mauvaise formation du plastique initial à travers la porte.

Certains matériaux comme l'ABS, le PC, le PA66 augmentent la température du moule et amélioreront la surface du moule, de sorte que le rougissement de la porte sera également amélioré.

La taille de la porte du moule est trop petite

La taille de la porte sera également la principale cause de ce problème de rougissement de la porte, une petite taille nécessitant une pression et une vitesse d'injection élevées.

Solution

Il existe plusieurs solutions pour résoudre le problème du rougissement de la porte. La première consiste à réduire la vitesse d'injection afin que la résine plastique ne s'étende pas autant qu'avec des vitesses plus élevées. Cela permettra de déposer une couche de matériau propre et d'améliorer le problème du rougissement de la porte. Il est également possible de réduire la vitesse d'injection, au début de l'injection pour commencer par une vitesse d'injection lente, puis passer à une vitesse d'injection plus élevée une fois la cavité remplie.

Augmentez la température du moule pour améliorer ce problème de rougissement de la porte, une basse température rendra le matériau difficile à remplir et cela nécessitera également une vitesse et une pression d'injection élevées.

Augmentez la taille de la porte et ajoutez un puits de limace froide, une grande taille de porte réduira la force de cisaillement de la porte, ajoutez un puits de limace froide pour recevoir la première limace de matière plastique de la première étape de la buse et maintenir la même température de matériau avec le trajet d'écoulement du matériau plus chaud derrière. L'absence d'un puits de limace froide peut forcer ce matériau plus froid à pénétrer dans la porte et dans la pièce apparaissant comme un voile de porte. Il est très important d'ajouter un grand puits de limace froide à chaque extrémité du canal.

Si vous cherchez plus d'informations sur la porte, bienvenue sur moulage par injection à point précis page, si vous recherchez une entreprise de moulage par injection de plastique personnalisée pour vous offrir la meilleure qualité de moulage par injection sans aucun défauts de moulage, n'hésitez pas à nous contacter, nous sommes l'un des 10 meilleurs entreprises de moulage par injection de plastique en Chine, propose le moulage par injection personnalisé, le moulage sous pression, la post-fabrication, l'usinage CNC, la finition de surface et bien plus encore.

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Injection molded parts ribs design tips

Moulage par injection de produits électroniques

Why need design ribs on the injection molded parts

Injection molding technology is the most common manufacturing technology for producing high volume of plastics parts in the world. The purpose of these parts can range from a picture frame that is never touched to a gear that is used in a moving assembly every day. Many times, the stiffness of a part must increase due to the load applied to the plastic part design. When designing strength into an injection molded part, considerations must be made to accommodate for the manufacturing process. This is where ribs and supports come into the design.

Ribs are thin wall protrusions that extend perpendicularly from a wall or plane. supports are triangular shaped ribs that support a main wall. Ribs and gussets add strength and rigidity to primary walls without the dangers and high costs caused by excessive wall thickness.

Conception DFM pour la fabrication

Conception DFM pour la fabrication

 

If the mean wall is too thick, sink marks and distortion may occur on the molded part, resulting in a rejected part design. Ribs solve this problem by providing additional support for thin walls, and are in fact, more effective structurally than just a thick wall. Along with being stronger, ribs also require less material than thick mean walls making them the economical choice as well.

 

Ribs increase the durability and quality of your part while reducing material cost, but if used incorrectly, can have negative effects on the aesthetics of your molded part. The area where the rib intersects with the main wall will experience a thicker plastic section. If the rib is too thick it will cause a sink mark in the main wall due to inconsistent cooling rates. To avoid this there are several rules to follow when using ribs in your design:

Please send us your part design, we will review your part design and send you a completely Rapport DFM for your project, this will save you a lots of cost and time.

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Mold Texturing Surface Finish

Mold texturing

Are you looking for different mold texturing surface finishs on a plastic part cavity side? Plastic parts not only benefit from designs that are pleasing to the eye, but they also benefit from the way a product feels when handled. Depending on the application, you may want your plastic mold part to be as smooth as glass or possess a rough feel to indicate strength and durability. One way to injection mold a molded part with a unique look with different grain on the part surface, which we call mold texture surface finish.

Mold texturing

What is Mold Texturing surface finish?

Mold Texturing surface is a process used to apply patterns to the mold cavity surface. This process allows flexibility in creating the final appearance of your parts. Mould Texturing finish is an integral piece in overall product development and should be considered during the design process to achieve the desired results. Mold Texture can be a functional component of design as well.  Some surface issue on molding part can be covered by the right texture. Is the part designed for frequent handling? Texture finish can be used to hide finger prints and improve the grip for the end user. Surface Texture can also be used to reduce part wear from friction.

Some important considerations to keep in mind when you plan to add texture surface finish on your plastic molded part

  • Which surface do you need to add texture finish? normally texture finish will go to the outside surface
  • what plastics will use for your plastic molding part? Thermosets, Ryanite, Glass Filled Nylon, Glass Filled Polypropylene, ABS, Polycarbonate, etc. different plastics material will usually require different draft for same texture finish.
  • What grade /type of texture finish do you need? on the market the most use of surfaces are VDI 3400 texture, leather texture, wood texture, etc., each type of texture has different grade of texture finish as well, for example VDI 3400 texture finished that has grade texture finish from VDI 12 to VDI 45, different grade of VDI texture requires different of draft angle.

In order to facilitate the removal of the finished product, there must be an appropriate draft angle in the ejection direction of the finished product; for finished products that do not bite, it is recommended to have at least 1°, and of course the larger the better.
For finished products with bite marks, depending on the type and depth of the bite marks, the angle should be at least 3~5° if possible.
VDI 3400 is Electric Discharge Pattern (EDM)
For VDI 3400, please refer to the table below: (Generally, it is better to add 1° to the angle)

Below is VDI3400 plastic surface finish chart

VDI3400 Average depth

Ra(μm)

 Maximum depth

μm

 PC(Draft angle) ABS(Draft angle) PC/ABS(Draft angle)
12 0.40 1.50 1.00 0.50 1.00
15 0.56 2.40 1.00 0.50 1.00
18 0.80 3.30 1.00 0.50 1.00
21 1.12 4.70 1.00 0.50 1.00
24 1.60 6.50 1.50 1.00 1.50
27 2.24 10.50 2.00 1.50 2.00
30 3.15 12.50 2.00 2.00 2.00
33 4.50 17.50 3.00 2.50 3.00
36 6.30 24.00 4.00 3.00 4.00
39 9.00 34.00 5.00 4.00 5.00
42 12.50 48.00 6.00 5.00 6.00
45 18.00 69.00 7.00 6.00 7.00

 

by above explaining about plastic molding texture surface finish I assume you may little confused, but no worries, we are professional on all of the moule texture surface finish  jobs, you only need to send us your part design and we will handle all of questions for you.

VDI 3400 surface

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Moulage par injection à faible volume

moulage par injection de plastique sur mesure

Soft Mold Low Volume Plastic injection molding

In line with the history of the branch, since 1999, completely different companies have been providing innovative soft mold low volume quantity injection moulding solutions to numerous high profile organizations throughout a variety of industries throughout all of the continents. Undoubtedly the addition of low volume injection moulding capabilities to the portfolio makes these establishments a complete one-stop store for quick product growth; providing options from next day concept models all through to soft mold low quantity plastic injection moulded components in actual engineering plastics.

In the first place, let’s discuss injection moulding process. Predominantly, in accordance with the floor end in addition to quantity necessities we select essentially the most applicable in addition to cheap material to produce the moule en plastique from, which is mostly aluminium or pre-hardened steel which we call soft mold. Therefore, mould design is created to satisfy the exact benchmarks of your project.

In addition, conventional machining utilizing the newest Excessive Velocity Milling (HSM) and CNC spark erosion techniques. It means that the mould tool is polished in addition to might be textured utilizing acid etching to create the desired surface finish. Moreover, detailed CMM inspections are carried out to guarantee that mouldigs are inside tolerance and of high quality. Last but not least, there’s submit processing of elements; including assembly, printing, portray in addition to chrome plating. All that is full mission managed by the companies.

moulage par injection à faible volume

You ought to perceive that there exist some advantages of low volume y injection molding. For instance, it requires low investment prices; short lead-times (from three weeks); needs as much as 10, 000 parts from a single mould soft steel; and components are available actual engineering plastics. Let us discuss them in more detail.

Perhaps allow us to start with the astonishing determine of as much as 10,000 parts from a single mould tool. Don’t forget that the mold will be designed to lessen costs whereas fulfilling your element’s visual, technical and amount needs. What’s extra, we guarantee that instruments are manufactured as cost effectively as possible, for instance, by designing a manual or automatic device depending on the quantity required.

We proceed to components are made in actual engineering plastics. This means your elements could be moulded in most engineering plastics, which enables the manufacture of parts which are suitable for most production environments.

You know that low funding prices in a mold instrument is a great advantage. By making a soft mold from aluminium, machining time and prices are low and the mold cavity of an aluminum tool may be polished quickly and cost effectively. What you will like concerning the offer is brief lead-times. Your mission can go from CAD & UG design to moulded parts in as little as 3 weeks. And you’ll reveal that there may be moreover environment friendly moulding of small batches. As there may be often no minimum order quantity, your low volume initiatives are all the time produced very cost effectively.

And to prime it, an experienced staff always provide a  custom-fit resolution, including over moulding to produce components containing a couple of material, for example a PC-ABS handle over molded with a TPE. Besides, surmoulage of electrical connections, inserts and steel plates with an engineering plastic can also be attainable.

General, soft mold low volume injection moulding is the ideal answer for low quantity manufacturing, bridging resolution in addition to pre-launch testing, we can offer you the low volume injection mold cost as low as $500, and this will be the best idea for you to open you market. if you have large quality parts, you could go to our moulage par injection à haut volume pour en savoir plus.

Contact us to get a quote.

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Part Thickness Design

moulage par injection paroi épaisse

How to save injection molding cost by Part thickness design reduction

By do the DFM (Design For Manufacturing) report and mold flow analysis to keep part thickness down to the minimum but having the same strength, we have reduced cooling times by as much as 31 seconds!  As you can see by the table below example to show you how much you could save your coût du moulage par injection,  it doesn’t take a big annual volume for the savings to add up.

Attribute Valeur
Volume of Plastic Reduced .06  Lbs.
Cost / Pound of Plastic $ 5.34
Material Savings / part $ .32
Cycle Time Reduction 15 seconds
Machine Cost / Hour $60
Production cost saved / part $.25
Annual Part Volume 10,000
Total Annual Savings $5,700

Theory

It has been shown that cooling time averages about 50% of the molding cycle for a typical plastic molded part. The additional 50% of the time consists of the filling, packing, and part ejection phases, which do not vary significantly from mold to mold. The cooling phase is the only phase that has any degree of variability.  This is because the cooling of a molded part is determined by the rate of mold heat removal.  Heat removal is impacted by many factors. Factors include the melt temperature, canaux de refroidissement design,  part thickness, and the material and mold steel’s thermal capabilities.

Part Thickness design

Out of all the factors, the part wall thickness is the easiest to impact. In short, the thinner the part, the faster the cycle time, the more molded parts per hour get made. Since the relationship of part thickness to cooling time is exponential, a small thickness reduction yields big cooling time reductions and big savings.

As stated on the Pression d'injection page, part thickness reductions increase the injection pressure. The fundamental limit of how thin you can make the part is the machines pressure capability assuming that the part will still meet design intent with a thinner wall.

Without the use of mold flow analysis the part thickness is usually designed so that it errors on the thick “safe” side to avoid fill problems.  However, with analyse du flux des moules, the thickness of the part can be iteratively reduced until the pressure reaches safe level (typically 17,000 psi). The process is usually complimented by performing a stress analysis to verify that the thinner walled part still meets the products design intent.  The FEA process usually adds ribs and gussets  to preserve the strength while using thinner walls.

If We have any plastic project that is ready to start make the moule en plastique and massive production, you are welcome to send us, we will check the conception des pièces issues for you and send you a price for your reference.

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Analyse de la conception des pièces en plastique

Théorie de l'analyse de la conception des pièces en plastique

Le processus de moulage des pièces en plastique est fortement influencé par les facteurs de conception de la pièce en plastique. Si les paramètres critiques de la conception d'une pièce ne sont pas définis correctement, la pièce présentera des problèmes de qualité pendant le processus de moulage. Le plus critique de ces paramètres est le suivant :

  • Épaisseur de paroi des pièces en plastique
  • Longueur d'écoulement partielle
  • Transitions d'épaisseur
  • Matériau de la pièce en plastique
  • Emplacement des portes
  • Nombre de portes
  • Emplacement des évents de moisissure
  • Température du moule
  • Température de fusion

Un rapide, rentable analyse du flux des moules sur une conception de pièce avec le matériau choisi et emplacements des portes peut donner une prédiction précise de la façon dont une pièce sera moulée avant la construction de l'outil. Il est essentiel de vérifier que la conception d'une pièce fonctionnera avec l'ensemble donné de paramètres critiques. Si la pièce présente des problèmes de qualité, notre rapport d'analyse recommandera des moyens d'ajuster les paramètres requis afin d'éliminer le problème.

Conception de pièces en plastique Sans l'utilisation de l'analyse de l'écoulement du moule, le concepteur est contraint d'utiliser des règles empiriques, de deviner ou de ne pas tenir compte de ces paramètres critiques. Il en résulte un risque élevé que la pièce ne soit pas moulée avec des niveaux de qualité acceptables. Parfois, pousser les conditions de traitement à l'extrême peut donner une pièce « acceptable ». 

Cependant, cela entraînera des niveaux élevés de contrainte de moulage, dégradera le matériau, augmentera les taux de rebut et/ou augmentera les temps de refroidissement. Malheureusement, les moules conçus sans l'utilisation de l'analyse de flux de moulage doivent recourir à ces tactiques de « dépannage ».

D’autres données critiques obtenues en exécutant une analyse de conception de pièce comprennent :

  • Localisation de lignes de soudure
  • Exigences de tonnage des pinces
  • Pressions d'injection
  • Localisation des taux de cisaillement élevés
  • Localisation des contraintes de cisaillement élevées
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Défauts de marques d'affaissement

Comment prévenir à l'avance les défauts de marques d'affaissement

Défauts de marques d'enfoncement Les creux sont des creux localisés à la surface des pièces moulées par injection, causés par un rétrécissement non uniforme du plastique pendant le processus de refroidissement. Dans les pièces critiques sur le plan esthétique, ils peuvent constituer un problème sérieux. Les creux dépendent de la géométrie de la pièce et des taux de rétrécissement du matériau. Les creux sont souvent une surprise une fois le moule terminé.

Si le défauts de marques d'enfoncement sont répréhensibles pour le client, le fabricant de moules en plastique Le fabricant de moules est souvent chargé de « les éliminer ». Le moule étant terminé, le fabricant de moules n’a pas le luxe de modifier la géométrie de la pièce. À ce stade, il n’est généralement pas possible de remplacer le matériau par un matériau présentant un facteur de retrait inférieur en raison de problèmes de dimensionnement avec d’autres pièces. À ce stade du processus, la seule option qui reste à l’entreprise de moulage est d’ajuster les conditions de traitement pour tenter d’éliminer le retassure. Cela signifie généralement faire fonctionner la machine de moulage aux extrémités de la fenêtre de processus, ce qui peut allonger les temps de cycle et augmenter la quantité de contraintes moulées.

La plupart du temps, la meilleure solution pour résoudre le problème des marques d'affaissement est de réduire l'épaisseur de la paroi, car le moule est fabriqué par l'entreprise de moulage, il sera donc très coûteux de résoudre ce problème. Pour éviter ce problème de marques d'affaissement à l'avance, l'idée sera de prévenir ce problème. analyse du flux des moules et Rapport DFM (conception pour la fabricabilité) est le rôle le plus important pour éviter cela défauts de marques d'enfoncement.

La partie ci-dessous souffrait défauts de marques d'enfoncement au-delà de ce qui était autorisé par les exigences du concepteur de la pièce. Si l'outil avait été construit selon cette géométrie, ils auraient eu un sérieux problème. En regardant l'échelle graduée, nous pouvons voir un enfoncement maximum de 0,004″. Cela ne semble pas beaucoup, mais 0,005″ est la limite sur l'impression. Pour résoudre le problème, les deux nervures épaisses sur la face inférieure de la pièce ont été réduites en épaisseur.

défauts de marques d'enfoncement

défauts de marques d'enfoncement

 

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Temps de remplissage du moule

Le temps de remplissage du moule est un autre nom pour l'avancement du front de fusion. Nos animations de temps de remplissage permettent de visualiser le remplissage de la cavité de la pièce sous vos yeux ! Comme vous pouvez le voir dans l'animation, des phénomènes tels que le suivi de course, la formation de lignes de soudure et la formation de pièges à air sont faciles à visualiser. Le suivi de course se produit lorsque le flux de plastique remplit la section la plus épaisse des pièces avant de remplir les sections les plus fines. Le suivi de course déplace le plastique de manière non intuitive, ce qui emprisonne l'air dans l'outil à des endroits difficiles à évacuer. L'utilisation de l'outil d'avancement du front de fusion résout ces problèmes avant la construction de l'outil, évitant ainsi les problèmes de qualité dans la pièce.

L'avancement du front de fusion est particulièrement utile dans notre analyse d'optimisation de la porte. Lorsque vous essayez plusieurs emplacements de porte, l'avancement du front de fusion vous aide à visualiser comment les changements de position de porte modifieront la façon dont la cavité se remplit. Cela vous permet de positionner les lignes de soudure de manière à ce qu'elles se trouvent dans des zones à faible contrainte ou à faible visibilité de la pièce. Notez que les lignes de soudure (lignes rouges dans l'image ci-dessous) sont formées du côté boulon des ports où le flux se rencontre lorsqu'il contourne le port. Cela a été fait pour les placer dans un endroit moins visible sur la pièce.

L'avancement du front de fusion est également impératif lors de l'exécution d'une analyse d'équilibrage des canaux. L'exigence critique d'un équilibrage des canaux est que toutes les cavités de différentes tailles se remplissent complètement en même temps. Cela crée une condition dans laquelle toutes les cavités reçoivent la même pression de remplissage. Cela évite un remplissage court dans les cavités plus difficiles à remplir ou un remplissage excessif ou un collage dans les cavités faciles à remplir.

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