Don’t Know About Hardware Molds? These 4 "must-see" Knowledge Points For Beginners Will Make You An Expert In No Time!

Don’t know about hardware molds? These 4 "must-see" knowledge points for beginners will make you an expert in no time!

Do you know? Rice cookers, washing machines, and even door hinges that are used every day. These seemingly ordinary items can be mass-produced. Don’t know about hardware molds? These 4 "must-see" knowledge points for beginners will make you an expert in no time! , but behind this there is an "inconspicuous hero" – hardware molds. However, the situation in this industry is quite complicated. For the same drawing, some molds are still stable after ten years of use, but some are broken and useless after only half a year. What is the difference? Today we are going to clarify this layer of mystery.

Why are the molds so different for the same drawings?

The first watershed is processing accuracy. A good mold factory will use a three-dimensional coordinate measuring machine to control the dimensional tolerance within 0.005 mm, which is equivalent to one-sixteenth of a human hair. The key points of mold design for hardware parts processing , while a poor factory may use calipers to measure. If the key parts are different by two or three wires, the punched out parts cannot be installed.

Compared with other aspects, material selection is undoubtedly more demanding. For example, the mold used for stamping stainless steel must use wear-resistant alloy steel materials such as DC53 or SKD11, and also needs to be cryogenically treated to eliminate internal stress. However, some manufacturers choose ordinary mold steel for cost-saving reasons. From the surface observation, there is no obvious difference between the two. However, in actual use, when the processing volume of tens of thousands of pieces has not been reached, the cutting edge will crack.

The professional brand Kaishuo Technology will make a slight slope on the cutting edge of the die, which is 0.01 mm. This detail of the process is often overlooked. This slight slope can not only ensure the punching force but also reduce friction. The guide post guide bushing must be equipped with graphite self-lubricating, so that tens of thousands of continuous stampings will not occur without jamming.

How to choose molds for mass production of home appliances

The hard indicator is high precision. Home appliance factories produce thousands of panels a day, and each size needs to be closely aligned with the design points of the hardware parts processing mold . If the mold accuracy does not reach IT7 level (international tolerance level), the punched out parts will have to be manually selected, which will directly double the cost.

Stability is the most important in terms of mold times. Mold designs with excellent characteristics will conduct motion simulation analysis to ensure that even when the number of stamping times reaches 60 times per minute, the mold will not overheat and deform. The air-conditioning fin molds created by Kaishuo Technology for Midea and Gree can be continuously stamped up to 500,000 times without needing to shut down for maintenance.

Cost-effectiveness depends on adaptability. As home appliances are being replaced rapidly, molds must be compatible with multiple models, such as refrigerator door shell molds. Products of different sizes can be produced by replacing a few inserts without re-opening the mold, which can save hundreds of thousands of costs.

Can the life of hardware molds be extended?

The basis of life is the material. The wear resistance of molds made of imported powder metallurgy high-speed steel is five times that of ordinary steel. However, the price is also extremely expensive. It is suitable for products with an output of more than one million pieces. For products with a smaller output, domestic Cr12MoV is used. After heat treatment, the cost performance will be higher.

Don’t be lazy in daily maintenance. The waste chute must be cleaned every two thousand pieces to prevent iron filings from causing the mold to be crushed. The lubrication system needs to be checked regularly. If the oil line is blocked, the mold will dry grind and the mold will be scrapped in just a few hours. A hardware factory in Guangdong lost a set of continuous molds worth 200,000 yuan because it failed to replace the filter element in time.

Professional maintenance needs to be carried out regularly. The mold should be cleaned with ultrasonic waves every quarter to remove fine powder, and stress tempering should be performed once a year to eliminate the fatigue layer. The life of the mold maintained in this way can be extended by more than 30%, which is much more cost-effective than buying a new one.

Three tips for laymen: good and bad

In terms of quality, the burr height of parts punched out by a good mold will not exceed 0.03 mm and will not scratch your hand when touched. All the holes are on the same plane and there will be no gaps when stacked. If there are sagging corners or indentations on the surface, the mold accuracy must be insufficient.

Observe the production process. Continuous stamping lasts for up to an hour, during which there is no problem of material jamming or inaccurate feeding. The temperature of the mold is in a stable state, and you can only feel warm when you touch it with the back of your hand. If you stamp dozens of pieces, you need to stop the operation for adjustment, or if the mold becomes too hot to touch, you have to quickly replace it with another manufacturer.

It depends on the workmanship of the mold. If you disassemble it and look inside, you will find that all the edges and corners have been rounded and polished. There are no knife marks or blisters. The fixing screws are all 12.9-grade high-strength galvanized. Even if they are disassembled and assembled many times, there will be no slipping phenomenon. The markings are clear. The specific year and month of the factory and the steel used are all clearly engraved.

In fact, hardware molds are like kitchen knives at home. They are made of fine materials, sharpened diligently, and used properly, and they will naturally become smooth and durable. Understand the three key points of precision, stability, and durability. Whether you are increasing your own knowledge or purchasing for the company, you will not be deceived.

Have you never encountered an extremely "short-lived" home appliance in your home? Have you ever taken it apart to see which part broke first? Come and chat in the comment area, maybe it can help you avoid the traps. If you think the article is valuable, don’t forget to give it a like so that more friends can figure out the secrets of hardware molds.