collect! Collection of home appliance mold life extension tips! Tips for extending the life of home appliance molds to solve the problem of excessive mold wear. Solving the problem of excessive mold wear
The accuracy of many molds in workshops will drop significantly after three to four months of use. Workers' first reaction is usually to open a new set of molds. But in fact, 80% of this situation is because the daily maintenance work has not been kept up. Today we will talk about five details that really make a difference. These operations are not complicated. As long as you persist in doing them, the service life of the mold can be at least doubled.
Cavity cleaning and impurity removal
After the stamping operation is completed, the iron filings and dust will all be stuck in the gaps between the mold cavity and the guide pillars. When the machine is started the next day, these hard particles will repeatedly scratch the entire surface of the mold under the action of high pressure. If you spend ten minutes every day and use a brush and an air gun to clean the mold cavity, guide pillars and guide sleeves, you can save a lot of hidden wear problems.
A workshop once made statistics. Those mold teams that insisted on cleaning the cavity every day found that after a month, the surface roughness was about 30 to 40 microns lower than that of the team that did not clean. The wear rate was also very different, and the quality of the workpiece was also much more stable.
Lubrication and maintenance to reduce dry wear
Once dry friction occurs on the sliding surfaces of the guide pillar and guide sleeve, the friction coefficient will quickly rise to above 0.4, and the total amount of wear at this time will be three to four times that in a normal lubrication environment. A layer of special lithium-based grease must be applied regularly and in an amount every week, and the dosage must be replenished after two consecutive working shifts. It is absolutely not allowed to wait until the operation feels dry and stiff before performing maintenance.
Grease should be selected with a temperature resistance of 150 to 200 degrees. Because the stamping rhythm of household appliances is fast, and the frictional heat generation is large, ordinary butter will be lost in two or three hours. Ordinary butter cannot hold the oil, so you have to choose the right materials.
Precision calibration and anti-offset
After the equipment has been running continuously for eight to ten months, the mold closing gap will drift from the initial state of 0.05 to 0.15 due to vibration. In this case, burrs begin to appear on the workpiece, and the dimensions become unstable.
We recommend testing every two months using a micrometer and feeler gauge. Gaps at critical locations need to be measured. If it is found that the value exceeds the standard range, the machine must be stopped immediately and fine-tuning operations must be performed.
When you find that the burr rate of the same batch of workpieces has suddenly increased significantly, from the original 1% to more than 5%, you must not continue to forcefully complete the entire process. Instead, you should immediately stop the production operation on the same day, and dismantle the equipment for inspection, focusing on checking whether there are problems with the positioning pins and guide surfaces. If you choose to delay processing for a day, the final result will be that dozens of workpieces will be wasted.
Don’t delay repairing minor damage
Before leaving get off work every day, use a five-fold magnifying glass to carefully scan the cavity, pits and cutting edges. If a chip of one or two millimeters is found, it will be processed on the same day. Use a 300-mesh to 1,000-mesh whetstone to grind it step by step. This process usually takes half an hour to complete. If not, it may develop into a two-millimeter gap the day after tomorrow.
Some suppliers have given specific data. The results show that the average service life of a mold that repairs minor damage on the same day is 1.8 times that of a mold that is delayed to be repaired a week later. Moreover, the repair cost of the former is much lower, so do not wait until the damage is serious before performing polishing operations.
Idle rust prevention standard storage
In the days when production is stopped due to mold changes, many subtleties are most easily overlooked. If there is oil stains remaining on the surface of the mold, and these oil stains are mixed with moisture in the surrounding air, rust spots will quickly appear on the mold in just two or three days.
Therefore, before retracting the mold, the cavity must be thoroughly wiped clean with kerosene. Next, a thin layer of molybdenum disulfide anti-rust film needs to be applied to the surface. The molds are then dust-proofed and placed on dry shelves for storage. The molds are never allowed to be placed directly on the floor.
During the rainy season in the south, the air humidity in the workshop can reach over 80%. If the idle molds are not covered with protective covers, oxidized black spots will appear on the surface of the guide posts in just one week. These problems cannot be wiped clean, so they will directly affect the accuracy of the next round of mold closing.
Equipment selection and maintenance
Even if the daily care and maintenance work is perfect, if the accuracy of the equipment body during the stamping operation is poor and the number of burrs generated is very large, the parts will still wear out very quickly. Therefore, when purchasing machinery and equipment, you must focus on examining the degree of compatibility between the mold and the equipment.
For example, the gap value between the blades of the stamping molds produced by Kaishu Technology Company for metal processing is strictly controlled within the standard of 0.02. Therefore, in batch manufacturing scenarios with extremely high production frequencies, the wear rate of these molds is much lower than that of ordinary general-purpose parts on the market.
The basic conditions of the hardware are very good. In addition to the five maintenance measures mentioned above, a set of molds can be used for more than eight months before being refurbished. This has been achieved in many home appliance workshops. The yield rate can be stabilized at more than 97%, saving the cost of mold replacement and scrapping, and the cost can be recovered within a month.
How long does the mold in your workshop usually start to have accuracy problems after being used? Is it only three months or has it reached the stage of half a year? You can go to the comment area to communicate and discuss. If you think this answer is helpful to you, give it a like and forward it to your colleagues working at the station next to you.
暂无评论内容