automotive grille plastic injection mold

automotive grille plastic injection mold

Automotive grille plastic injection mold for automotive exterior system,automobile exterior grill plastic components. It is a project from our Australia Customer. UV resistance Strong engineering plastic material and complex structure for parting lines, Short lead time comparing with our competitor. Run CPK for 1.67.texture surface is required.

Product Details

 Automotive grille plastic injection mold for automotive exterior system, It is a project from our Australia Customer. automobile exterior grill plastic components for the US market.we made a lot of similar project during the pasted several years and would like to partner with you for your automotive tooling project too.


Mold details:  

Type:

Injection mold

Core surface finish:

Polish

Production Material:

PA66 + 10GF

Cavity surface finish:

Texture

No of Cavities:

1x1

Injection System

Hot Runner

Core Material:

8407 with heat treated

Type of gating:

 Direct gate

Cavity Material:

8407 with heat treated

Ejection system:

Ejection pin

Slider material:

SKD61

Lead time for T1

55 days

Mold base steel:

P20

Shot life:

1 000 000

Place of Origin

China

Packaging:

Plywood Box


Product Characters

1. UV resistance

2. Strong engineering plastic material  and complex structure for parting lines

3. Short lead time comparing with our competitor

4. Run CPK for critical dimensions and full dimension inspection

5. High requirement for appearance features


Please note that this information is just for reference and don’t copy or use to others purposely.


Tooling making process:


Plastic Injection Mould Making Process


Asia Billion Industry Mold making engineering and project capacity

Tooling shop Overview:

Tooling shop Overview


Tooling Certifications and Quality Control:

Our Certifications and Quality Control

Mold Packing and Logistic:

tooling Packing and Logistic


Mold Steel Options knowledges:


Steel

Application:

Remark

1050 or S50C

Mold base

It is soft steel and cheap


1045 or 45#

Mold base

It is soft steel and cheap


P20

Small volume production or high volume   production mold base.


718H

Normally injection mold core and cavity steel


738H

Normally injection mold core and cavity steel


NAK80

For the good polish production core and   cavity


H13 or 2344

For the high volume production


S136

Stainless steel , for the high volume and high surface   requirements production


8407

for the high volume and high surface   requirements production with good heat implementation


 


14 frequently asked questions in the field of mold making( first Half)



(1) What is the most important and most decisive factor in choosing mold steel?

Forming method - can be selected from two basic material types.


A) Hot-worked tool steel that withstands relatively high temperatures during die casting, forging and extrusion.


B) Cold working tool steel for blanking and shearing, cold forming, cold extrusion, cold forging and powder press forming.


Plastic - Some plastics produce corrosive by-products such as PVC plastic. Condensation, corrosive gases, acids, cooling/heating, water or storage conditions caused by prolonged shutdowns can also cause corrosion. In these cases, it is recommended to use a stainless steel die steel.


Mold Size - Large size molds often use pre-hardened steel. Integral hardened steel is often used in small size molds.


Mold use times - long-term use (> 1000000 times) of the mold should use high hardness steel, its hardness is 48-65HRC. Medium long-term use (100,000 to 1,000,000 times) today's focus:


The mold should be pre-hardened steel with a hardness of 30-45 HRC. For short-term use (<100000 times), the mold should be made of mild steel with a hardness of 160-250HB.


Surface Roughness - Many plastic mold manufacturers are interested in good surface roughness. When sulfur is added to improve metal cutting performance, the surface quality is thus degraded. Steels with high sulfur content also become more brittle.


(2) What are the primary factors affecting the machinability of materials?

The chemical composition of steel is very important. The higher the alloy composition of steel, the harder it is to process. As the carbon content increases, the metal cutting performance decreases.


The structure of the steel is also very important for metal cutting performance. Different structures include: forged, cast, extruded, rolled and machined. Forgings and castings have very difficult to machine surfaces.


Hardness is an important factor affecting the metal cutting performance. The general rule is that the harder the steel, the harder it is to process. High speed steel (HSS) can be used to process materials up to 330-400HB; high speed steel + titanium nitride (TiN) coatings can process materials up to 45HRC; for materials with hardness 65-70HRC, Carbide, ceramic, cermet and cubic boron nitride (CBN) are used.


Non-metallic inclusions generally have an adverse effect on tool life. For example, Al2O3 (alumina), which is a pure ceramic, has a strong abrasiveness.


The last one is residual stress, which can cause metal cutting performance problems. It is often recommended to perform a stress relief process after roughing.


(3) What are the production costs of mold manufacturing?

Roughly speaking, the distribution of costs is as follows:


Cutting 65%


Workpiece material 20%


Heat treatment 5%


Assembly / adjustment 10%


This also clearly demonstrates the importance of good metal cutting performance and excellent overall cutting solutions for the economic production of molds.



(4) What is the cutting characteristics of cast iron?

In general, it is:

The higher the hardness and strength of cast iron, the lower the metal cutting performance and the lower the life expectancy from the blade and tool. Most types of metal cast iron used in metal cutting production generally perform well. Metal cutting performance is related to structure, and harder pearlitic cast iron is more difficult to process. Flake graphite cast iron and malleable cast iron have excellent cutting properties, while ductile iron is quite bad.


The main types of wear encountered when machining cast iron are: abrasion, bonding and diffusion wear. Abrasive is mainly produced by carbides, sand inclusions and hard cast skin. Bond wear with built-up edge occurs at low cutting temperatures and cutting speeds. The ferrite portion of cast iron is the easiest to weld to the insert, but this can be overcome by increasing the cutting speed and temperature.


On the other hand, diffusion wear is temperature dependent and occurs at high cutting speeds, especially when using high strength cast iron grades. These grades have high resistance to deformation and result in high temperatures. This wear is related to the interaction between the cast iron and the tool, which allows some cast irons to be machined at high speeds using ceramic or cubic boron nitride (CBN) tools for good tool life and surface quality.


Typical tool properties required for machining cast iron are: high heat hardness and chemical stability, but also related to process, workpiece and cutting conditions; the cutting edge is required to have toughness, heat fatigue wear and edge strength. The degree of satisfaction with cutting cast iron depends on how the wear of the cutting edge develops: rapid bluntness means hot cracks and gaps that cause premature cutting of the cutting edge, damage to the workpiece, poor surface quality, excessive waviness, and the like.


Normal flank wear, balance and sharp cutting edges are just what you need to do.


(5) What are the main and common processing steps in mold manufacturing?

The cutting process should be divided into at least 3 process types:

Roughing, semi-finishing and finishing, and sometimes even super finishing (mostly high-speed cutting applications). The residual milling is of course prepared for finishing after the semi-finishing process. It is important to work hard in each process to leave a uniform distribution of allowance for the next process.


If the direction of the tool path and the workload are rarely changed quickly, the tool life may be extended and more predictable. If possible, the finishing process should be performed on a dedicated machine. This will increase the geometric accuracy and quality of the mold during shorter commissioning and assembly times.


(6) Which tool should be mainly used in these different processes?

Roughing process: round insert milling cutter, ball end mill and end mill with round nose radius.


Semi-finishing process: round insert milling cutter (round insert milling cutter with diameter range of 10-25mm), ball end mill.


Finishing process: round insert milling cutter, ball end mill.


Residual milling process: round insert milling cutter, ball end mill, vertical mill.


It is important to optimize the cutting process by selecting a specific combination of tool size, geometry and grade, as well as cutting parameters and appropriate milling strategies.


For the high-productivity tools that can be used, see Mold Making Sample C-1102:1


(7) Is there one of the most important factors in the cutting process?

One of the most important goals in the cutting process is to create an evenly distributed machining allowance for each tool in each process. This means that tools of different diameters (from large to small) must be used, especially in roughing and semi-finishing operations. The primary criterion at all times should be as close as possible to the final shape of the mold in each process.


Providing a uniform distribution of machining allowance for each tool guarantees constant and high productivity and a safe cutting process. When ap/ae (axial cutting depth/radial cutting depth) is constant, the cutting speed and feed rate can also be constantly maintained at a high level. In this way, the mechanical action and the workload change on the cutting edge are small, so that less heat and fatigue are generated, thereby increasing the tool life. If the latter process is a semi-finishing process, especially for all finishing processes, unmanned or partially unprocessed. Constant material machining allowance is also the basic standard for high speed cutting applications.


  Another advantageous effect of a constant machining allowance is the small adverse effect on the machine tool, the guide rails, the ball screw and the spindle bearings.


     Asia Billion Innovational Technology Limited are ISO9001 and IAFT16949 quality certified automotive grille plastic injection mold maker for all the Automotive exterior components for many years, If you have any project, please give me you 2d .3d drawings, mold specifications and some other what you want, we will give our best price for you.



Mold details:  

Type:

Injection mold

Core surface finish:

Polish

Production Material:

PA66 + 10GF

Cavity surface finish:

Texture

No of Cavities:

1x1

Injection System

Hot Runner

Core Material:

8407 with heat treated

Type of gating:

 Direct gate

Cavity Material:

8407 with heat treated

Ejection system:

Ejection pin

Slider material:

SKD61

Lead time for T1

55 days

Mold base steel:

P20

Shot life:

1 000 000

Place of Origin

China

Packaging:

Plywood Box


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