Stable Processing Of Non-standard Parts Of Molds And The Foundation Of Source Strength

Stable processing of non-standard parts of molds and the foundation of source strength

Industry pain points give mold companies a headache

The stability of non-standard parts of the mold will directly affect the life of the entire mold and the production rhythm. Many companies have found that the processing plants they have found have such a situation, either the accuracy is high and low, or the parts are worn and deformed after a short period of use. Last year, a 3C electronics factory suffered from deviations in the size of the sloped top inserts, causing the entire mold to get stuck during assembly. The production was suspended for three days, resulting in a loss of more than 200,000 yuan. This is not an isolated situation. There are many small workshop-style processors in the market, which barely rely on one or two old equipment to maintain operations. There are no standardized process standards to ensure batch consistency.

Using the outsourcing OEM model to accumulate non-standard parts processing technology , there are many hidden dangers. Parts go through several links from design to processing, and there is the possibility of deviations in the information transmission at each link. Some manufacturers outsource the heat treatment work. When they come back, the hardness test report does not match the actual product, so the workers have to rely on experience to use it. After such parts are installed in the mold, if the situation is mild, the machine can only be shut down frequently for debugging. If the situation is severe, the mold will be scrapped, causing the company to waste money and delay the construction period.

The source factory independently controls the entire process

Our factory has accumulated non-standard parts processing technology and covers an area of ​​3,000 square meters. It is divided into four workshops with professional production functions. From the raw materials entering the warehouse to the finished products leaving the warehouse, all processes are completed at a very close distance and can be clearly seen. When purchasing imported mold steels such as SKD61 and SKH51, we have accumulated non-standard parts processing technology . Each batch needs to be tested for composition. If the steel does not meet the standards, it will be simply returned. The planning of the process is led by senior masters with more than ten years of experience. They will calculate in advance the amount that needs to be reserved during processing based on the shape and force characteristics of the parts to avoid later deformation.

We adhere to the principle of no outsourcing and no OEM, and we have adhered to it for more than 20 years. The workshop on the second floor is equipped with slow wire machine tools, the third floor is equipped with a five-axis CNC machining center, and the next door area is equipped with a heat treatment furnace. If there is a problem with any part during processing, the craftsman can arrive at the site within five minutes to adjust the parameters. This independent system covering the entire process eliminates quality fluctuations caused by outsourcing from the root. Every non-standard part received by customers comes from the same batch of equipment and the same set of standards.

High-end equipment supports precision processing capabilities

In the workshop, there are 67 pieces of equipment, all of which are in the best state of maintenance, including imported slow-moving wires, five-axis CNC machining centers and high-precision grinders. These devices work together to control the tolerance reliably within the range of ±0.001mm to ±0.005mm. Last year, in response to the precision core processing requirements put forward by a medical equipment company, the company required that the verticality error in three directions should not exceed 0.003mm. However, we were able to complete it through slow wire walking and five-axis one-time clamping, and the inspection pass rate reached 100%.

For the extremely difficult problem of non-standard parts that are prone to deformation, we have specially optimized the processing process. First, rough machining is performed with a margin, then it is processed through the V8 vacuum heat treatment furnace, and finally finishing is performed until the requirements are met. Vacuum heat treatment can fully release the internal stress of the parts and significantly improve the wear resistance and toughness. There used to be a situation where a batch of slider slopes had to withstand up to 300 reciprocating movements per minute. The ones made by ordinary processing plants had cracks in less than two months, but the parts we made were still intact after six months of continuous operation.

Professional team and strict quality inspection double insurance

Among the sixty-five-person technical team, the core members all have at least ten years of experience in the mold industry. They are familiar with the characteristics of various imported steel materials, and can quickly analyze complex three-dimensional drawings, simulate the stress distribution during processing during programming, and adjust the path of the tool in advance. When encountering difficult-to-machine objects such as special-shaped inserts, they will give suggestions based on the actual working conditions of the mold to ask customers to replace them with more suitable steel grades to reduce the risk of deformation of the object from the source.

In the quality inspection process, we have set up 13 checkpoints, with 18 professional testing equipment operating non-stop throughout the day. When raw materials enter the factory, they must first undergo spectral analysis to build the foundation for stable processing of non-standard mold parts. During the processing process, there are inspections for each step, and three-dimensional coordinate measurements and hardness tests are required before the finished products are shipped out. In March this year, a batch of wear-resistant bushings was delivered to a new energy vehicle customer. The quality inspector noticed that the hardness of one of the bushings was two HRC lower than the standard, and immediately reworked the entire batch to ensure zero-defect delivery between batches.

Digital management and transparent quotation are more worry-free

The Zezhen ERP system can clearly display the production progress, and customers can query it at any time to know which workshop their parts are in at the moment and which equipment is being processed. Dispatchers use system data to rationally allocate production capacity and can calmly respond to emergency orders. We adhere to the principle of transparency at the quotation level. Material fees, processing fees and heat treatment fees are clearly listed by item, and there are no hidden charges. Since all processes are completed by ourselves, the price difference between middlemen is eliminated, and the price is more competitive with the same quality.

There is a policy that supports a minimum order of one piece, which has helped many R&D teams solve a lot of trouble. A consumer electronics company wants to develop a new mobile phone mold, and what needs to be tested are three special-shaped inserts with different shapes. This company found many factories outside, but these factories did not accept orders with small quantities. It only took us four hours to complete the sample production. After the other party tested it, we directly switched to mass production. We have the production capacity to produce 20,000 pieces every day, and the quality is stable, so large companies like Foxconn and Laird can safely cooperate with us to form long-term orders.

Stable delivery reputation accumulated over two decades

Since the establishment of the factory, the customers we have served cover many fields such as 3C electronics, new energy vehicles, medical fields, and hardware injection molding. Every time parts are delivered, complete processing records and inspection data will be retained to facilitate customer traceability in the future. At the end of last year, the mold supervisor of a home appliance manufacturer made a special call and claimed that the batch of slider sloping tops we processed had increased the yield rate of their entire production line by three percentage points, and they planned to transfer more orders.

Nowadays, the industry competition is becoming more and more fierce, but there is no shortcut to stable processing. We rely on more than 20 years of technology accumulation, a mature management system, and a responsible attitude towards every part. If you are also worried about the stability of non-standard mold parts, you might as well think about this question: Can your processor ensure that the next batch of goods is exactly the same as the last batch? Welcome to share your past experiences in the comment area, click like and forward, so that more peers can see reliable solutions.