France Plastic injection molders in China, French invested mold maker with Chinese joint venture manufacture for electronics, electrical, home appliance, LED lighting, automotive , medical device and so on . well known for Hasco and Meusburge standards.
Project details as below :
France Plastic injection moulders
Core surface finish:
Cavity surface finish:
VDI 3400 Texture
No of Cavities:
5 drops moldmaster hot runner
8407 with heat treatment to 48 to 52 HRC
Type of gating:
Pin point gate
8407 with heat treatment to 48 to 52 HRC
Lead time for T1:
Mold base steel:
1 500 000
Total Mold Price:
1） High temperature PC +10& glass fiber engineering material from Solvay engineering plastis
2) VDI 3400 - 32 texture
3) CPK control for the critical dimension up to 1.67
4) large part up to 250 x 500 mm for 2 cavities mold
5) multi-points for pin injection point up to 10 of each part
6) 15 million cycle time for the mold life
Asia Billion is one stop supplier for your injection moulder needed with European quality standard and engineering capacity as well as European local support. we can help you realize your ideals from concept to mass production with engineering production design and manufacturing feasibility improvement capacity. We have a lot of high quality plastic injection moulder fabrication experience. If you have any plastic injection tooling, plastic injection molding items or similar with this, please contact us freely.
Asia Billion Mold making process:
Asia Billion Injection Molder Quality Control
Our Logistic Solution
In-depth talk about the warping deformation of injection molded products
It means that the shape of the injection molded article deviates from the shape of the mold cavity, and it is one of the common defects of plastic products. There are many reasons for warpage deformation, and it is often impossible to solve the problem by relying on process parameters alone. Asia Billion Mould combines relevant information and practical work experience. The following is a brief analysis of the factors affecting the warpage of injection molded products.
2）the influence of the structure of the mold on the warpage of the injection molded product.
In terms of molds, the main factors affecting the deformation of plastic parts are the pouring system, the cooling system and the ejection system.
The position, form and number of gates of the injection mold will affect the filling state of the plastic in the mold cavity, resulting in deformation of the plastic part.
The longer the flow distance, the greater the internal stress caused by the flow and the filling between the frozen layer and the central flow layer; conversely, the shorter the flow distance, the shorter the flow time from the gate to the flow end of the workpiece, and the freezing during filling The thickness of the layer is reduced, the internal stress is lowered, and the warpage deformation is also greatly reduced. Some flat plastic parts, if only one center gate is used, because the shrinkage rate in the diameter direction is greater than the shrinkage ratio in the circumferential direction, the molded plastic parts will be distorted; if multiple point gates or film types are used instead The gate can effectively prevent warping deformation.
When using a dot gate for forming, also due to the anisotropy of plastic shrinkage, the position and number of gates have a great influence on the degree of deformation of the plastic part.
In addition, the use of multiple gates can also shorten the flow ratio (L/t) of the plastic, thereby making the melt density in the cavity more uniform and shrinking more uniform. At the same time, the entire plastic part can be filled with a small injection pressure. The smaller injection pressure can reduce the molecular orientation tendency of the plastic and reduce the internal stress, thereby reducing the deformation of the plastic part.
2.2） Cooling system
During the injection process, the unevenness of the cooling rate of the plastic part will also form the unevenness of the shrinkage of the plastic part, and the difference in the shrinkage causes the bending moment to be generated to cause the plastic part to warp.
If the temperature of the mold cavity and the core used in the injection molding of the flat plastic part (such as the mobile phone battery case) is too large, the melt close to the surface of the cold mold is quickly cooled down, and close to the surface of the hot mold cavity. The layer will continue to shrink and the unevenness of the shrink will warp the part. Therefore, the cooling of the injection mold should pay attention to the temperature of the cavity and the core tend to balance, and the temperature difference between the two should not be too large (two mold temperature machines can be considered at this time).
In addition to considering the temperature inside and outside the plastic parts tend to balance, it should also consider the temperature of each side of the plastic parts is consistent, that is, the mold should be kept as constant as possible during the cooling of the mold, the temperature of the core is uniform, so that the cooling rate of the plastic parts Equilibrium, so that the shrinkage everywhere is more uniform, effectively preventing the occurrence of deformation. Therefore, the arrangement of the cooling water holes on the mold is critical. After the distance from the pipe wall to the cavity surface is determined, the distance between the cooling water holes should be as small as possible to ensure uniform temperature of the cavity wall.
At the same time, since the temperature of the cooling medium rises as the length of the cooling water channel increases, a temperature difference is generated between the cavity and the core of the mold along the water channel. Therefore, the length of the water channel of each cooling circuit is required to be less than 2 meters. Several cooling circuits should be provided in a large mold, and the inlet of one circuit is located near the exit of the other circuit. For long strips, straight through channels should be used. (And our molds mostly use S-type loops - not only bad for the cycle, but also extend the cycle.)
2.3） Ejection system
The design of the ejection system also directly affects the deformation of the plastic part. If the ejector system is unbalanced, it will cause an imbalance in the ejection force to deform the plastic part. Therefore, it is necessary to balance the mold release resistance when designing the ejector system. In addition, the cross-sectional area of the ejector rod should not be too small to prevent the plastic part from being deformed by excessive force per unit area (especially when the mold release temperature is too high).
The ejector should be placed as close as possible to the part with large draft resistance. Under the premise of not affecting the quality of the plastic parts (including the use requirements, dimensional accuracy and appearance, etc.), as many ejector pins as possible should be provided to reduce the overall deformation of the plastic parts (this is the reason why the topping block is the top block).
When soft plastics (such as TPU) are used to produce deep-walled thin-walled plastic parts, the mold release resistance is large and the material is soft. If a single mechanical ejection method is used, the plastic parts will be deformed and even Topping or folding causes the plastic parts to be scrapped. For example, the combination of multi-component combination or gas (liquid) pressure and mechanical ejection is better (will be used later).
3）the impact of plasticization stage on warpage deformation of products
The plasticization stage is the process of converting the glassy material into a viscous fluid melt (the three-state change of raw material plasticization is mentioned in the training). In this process, the temperature difference between the polymer in the axial direction and the radial direction (relative to the screw) will cause stress on the plastic; in addition, the injection pressure, rate and other parameters of the injection machine will greatly affect the degree of orientation of the molecules during filling. In turn, warpage is caused.
4） the impact of filling and cooling stages on the warpage of products
The molten plastic is filled into the mold cavity under the action of the injection pressure and cooled and solidified in the cavity. This process is a key part of injection molding. In this process, the combination of temperature, pressure and speed has a great influence on the quality and production efficiency of the plastic parts. Higher pressures and flow rates produce high shear rates, causing differences in molecular orientation parallel to the flow direction and perpendicular to the flow direction, while creating a "freezing effect." The "freezing effect" will create a freezing stress that will create the internal stress of the plastic part.
The effect of temperature on warpage deformation is reflected in the following aspects:
(4.1) The temperature difference between the upper and lower surfaces of the plastic parts may cause thermal stress and thermal deformation;
(4.2) Temperature differences between different areas of the plastic part will cause uneven shrinkage between different areas;
(4.3) Different temperature conditions affect the shrinkage of plastic parts.
5） Effect of demoulding stage on warpage deformation of products
The plastic part is mostly a glassy polymer during the process of leaving the cavity and cooling to room temperature. Imbalance of the release force, uneven movement of the ejection mechanism, or improper ejection of the ejection area can easily deform the product (as already mentioned). At the same time, the stress that "freezes" in the plastic part during the filling and cooling stages will be released in the form of "deformation" due to the loss of external constraints, resulting in warpage.
6）the impact of shrinkage of injection molded products on warpage deformation
The direct cause of warpage of injection molded articles is the uneven shrinkage of the plastic parts. If the effect of shrinkage during the filling process is not taken into account during the mold design phase, the geometry of the article will differ greatly from the design requirements, and severe deformation can cause the article to be scrapped (ie, the problem of shrinkage).
In addition to the deformation caused by the filling stage, the temperature difference between the upper and lower walls of the mold will also cause the difference in the shrinkage of the upper and lower surfaces of the plastic part, resulting in warping deformation. For warpage analysis, shrinkage itself is not important, what is important is the difference in shrinkage.
In the injection molding process, the molten plastic in the injection filling stage due to the arrangement of the polymer molecules in the flow direction causes the shrinkage ratio of the plastic in the flow direction to be larger than the vertical direction, and the injection molded parts are warped (ie, each To the opposite sex).
Generally, uniform shrinkage only causes changes in the volume of the plastic part, and only uneven shrinkage causes warpage. The difference in shrinkage between the flow direction and the vertical direction of the crystalline plastic is larger than that of the amorphous plastic, and the shrinkage rate is larger than that of the amorphous plastic. The large shrinkage of the crystalline plastic and the anisotropy of the shrinkage result in the influence. The tendency of warp deformation of crystalline plastic parts is much greater than that of amorphous plastics.
7）. Effect of residual thermal stress on warpage deformation of products
In the injection molding process, residual thermal stress is an important factor causing warpage deformation, and has a great influence on the quality of injection molded articles. Since the influence of residual thermal stress on the warpage of the product is very complicated, it will not be described here.
8） the effect of metal inserts on the warpage of products
For injection molded products with inserts, since the shrinkage of plastic is much larger than that of metal, it is easy to cause distortion (some even cracking); to reduce this, the metal parts can be preheated (generally not less than 100). °C), and then put into production.
There are many factors affecting the warpage of injection molded products. The structure of the mold, the thermo physical properties of the plastic material, and the conditions and parameters of the molding process all have different effects on the warpage of the product. Therefore, the treatment of the warpage of the injection molded article must take into account the above factors.
Our company have one French investor who has 35 years mold making and business development expereince, so we can say Asia Billion is a France Plastic Injection Molders in china. Asia Billion will be a excellent option for France market , around 20% of our projects come from France and we know well for French people's concern and prodution quality standard with think ways.
Contact us at: Asia Billion Innovational Tecnology Ltd
Address:Building 9, Wantou Industrial Park, Hongxing Village, SongGang Town, Shenzhen City, China
Tel: 0086-134 8063 8827 E-mail: firstname.lastname@example.org
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