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difficulty of making automotive injection molds

by:YESHINE     2020-06-09
Injection molding is a common manufacturing process for plastic parts.
There are too many products made using this method, and their complexity, size and application are different.
Auto parts are some of the products that use this manufacturing process.
Use injection molding machines, molds and plastic raw materials to achieve injection molds.
In this process, the plastic is first melted in the molding machine, then injected into the mold, cooled in the mold and solidified into the desired final part.
Injection molding produces thin-walled plastics for various applications.
The most popular product obtained from this process is the plastic housing needed for car dashboards, power tools and household appliances and even consumer electronics.
In addition to its extensive use in the automotive industry, injection molds are also used in other applications, including the manufacture of medical equipment such as syringes and valves.
In this approach, however, the automotive injection molds still account for a large proportion.
Although it may be perfect, it is also a method and faces many challenges, making it difficult to achieve accurate injection molds for cars.
Here are some of the challenges and flaws that make this process difficult. Flash -
This happens when the molten material penetrates out of the mold cavity and then sets.
This means that after the part pops up, there is a thin layer of material attached along the part parting line, interfering with the final quality of the product.
This is a problem that usually comes from too low clamping force or too high injection pressure. Warping -
When the part goes through permanent bending, some parts shrink much faster than others.
This is due to uneven cooling rates, which is a very common challenge for mold manufacturers. Sink marks -
Another difficulty faced when forming is the appearance of the sink mark.
They are the result of the shrinkage of the molten material, eventually filling the gaps that may exist on the part, and when the material is injected into the mold, the gaps will first solidify.
Typically, a sink mark appears when the injection pressure is too low or the cooling rate is uneven. Bubbles -
Bubbling also affects the possibility of achieving the desired final car part.
The final product affected by this problem has bubbles on the surface, affecting the appearance, feel and even quality of the mold.
This happens when the material used is too hydrated or the injection temperature is too high.
Unfilled part-
This is another problem that the injection mold of the car generally faces.
This simply means that the end product will have parts that are not properly and thoroughly filled due to the material flow rate being too low or insufficient during processing. Ejector marks -
When the top output is too high or the cooling time is too short, it is very possible to have a top-out mark on the injection mold.
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