The Process Of Precision Metal Stamping

Precision metal stamping is the process of making 3-dimensional metal parts, lettering and other embossing. This is a kind of metal stamping used mostly for decorative purposes. It is similar to normal metal stamping, which is the process of molding metal into different shapes and sizes.

The products obtained through metal stamping are used as components for some larger products in other industries. The most common metals and alloys used for precision metal stamping are copper, aluminum, brass, beryllium, nickel, nickel silver, steel, stainless steel, phos bronze and titanium.

Precision metal stamping is applicable to many industries like computers, electronics, electrical, dental, aerospace, instrumentation, military specs, defense, telecom and automotives. There are many methods in precision metal stamping for producing stamped prototypes. Blank creation is one such method. Blank creation involves the creation of a flat state of the component. The flat blank sheet is then used to make the part’s features. In blank creation, there are many processes
like nibbling, chemical etching, water jet cutting, wire EDM, punch and die.

There are also many methods for producing prototypes by precision stamping. The type of method used depends on the size and intricacy of the parts to be produced as well as the number of prototypes. Single part transfer is one such method in which single parts are transferred from one station to the next for blanking and metal forming.

The main advantage with this method is the cost effectiveness. One single, standard system can be maintained for designing, manufacturing and holding tooling inserts. However, this system is slow because it needs individual prototype parts. The other method is the progressive strip prototyping which involves the automatic transfer of the metal from one stage to the next.

Precision metal stamping can be done at very high speeds and even up to 1,200 strokes per minute. Precision metal stamping gives several advantages like the ability to use any metal or alloy and creation of components with very precise dimensions and shapes. Plating can also be very precise which is helpful when working with precious metals like gold and palladium.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

The History of Plastic Molding

The history of rotational molding began somewhere between 1940 and 1950 in the USA when the process was developed for a small number of plastics. By the late 1950s, when the rotational molding process was better understood, applications for other industries were developed including road cones, marine buoys, and car armrests. A process was developed in Europe in the early 1960s that enabled large hollow containers to be created in low density polyethylene (LDPE) by rotating (or rocking) a mold on a chassis, houses open gas jets, through 30 degrees which coated the inside of the mould with the polymer…

The history of plastic injection molding has seen steady industry growth since its beginnings in the late 1800s. The technique has evolved from the production of combs and buttons to major consumer, industrial, medical, and aerospace products. In 1868, John Wesley Hyatt invented a way to make billiard balls by injecting celluloid into a mould.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

What is Plastic Moulding

Plastic moulding is the process of shaping plastic using a rigid frame or mould. The technique allows for the creation of objects of all shapes and sizes with huge design flexibility for both simple and highly complex designs. A popular manufacturing option, plastic moulding techniques are responsible for many car parts, containers, signs and other high volume items.

Plastic Moulding Techniques

The underlying concept of plastic moulding is placing liquid polymer into a hollow mould so that the polymer can take its shape, often with various ranges of pressure and heat required. There are different plastic moulding techniques available to accomplish this including rotational molding, injection molding, blow molding, and compression molding to name just a few. Each technique has its benefits and is best suited for the creation of specific items.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

Your Guide To Plastic Molding

Plastics are synthetically produced non-metallic compounds. It can be molded into various forms and hardened for commercial use. Plastic molding products can be seen everywhere. Examples are jars, protective caps, plastic tubes, grips, toys, bottles, cases, accessories, kitchen utensils and a lot more.

Even the keyboard and the mouse that you use are made through plastic molding. Even the plastic parts of the chair that you are sitting on are created this way.

The basic idea in plastic molding is inserting molten liquid plastic into a ready shaped mold, for example the mold of a bottle. It will be then allowed to cool, then the mold will be removed to reveal the plastic bottle.

Plastic molding can also custom-mold a wide variety of plastic products including: garden pots, cabinets, office trays and boxes, barriers, barricades and traffic signage and displays for product and marketing promotions.

If you are planning to go into plastic molding business, you should first know the different processes. Choose from a plastic molding process that fits your budget, your expertise, and your resources. Here are basic definitions of various methods of plastic molding.

The Plastic Molding Processes:

Injection Molding
In Injection Molding, melted plastic is forced into a mold cavity. Once cooled, the mold can be removed. This plastic molding process is commonly used in mass-production or prototyping of a product. Injection molding machines were made in the 1930’s. These can be used to mass produce toys, kitchen utensils, bottle caps, and cell phone stands to name a few.

Blow Molding
Blow molding is like injection molding except that hot liquid plastic pours out of a barrel vertically in a molten tube. The mold closes on it and forces it outward to conform to the inside shape of the mold. When it is cooled, the hollow part is formed. Examples of blow molding products are bottles, tubes and containers.
Equipments needed in setting-up a blow molding business are relatively higher than injection molding.

Compression Molding
In this type of plastic molding, a slug of hard plastic is pressed between two heated mold halves. Compression molding usually uses vertical presses instead of the horizontal presses used for injection and blow molding. The parts formed are then air-cooled. Prices of equipments used for compression molding are moderate.

Film Insert Molding
This plastic molding technique imbeds an image beneath the surface of a molded part. A material like film or fabric is inserted into a mold. Plastic is then injected.

Gas Assist Molding
Also called gas injection molding is used to create plastic parts with hollow interiors. Partial shot of plastic is then followed by high-pressure gas to fill the mold cavity with plastic.

Rotational Molding
Hollow molds packed with powdered plastic are secured to pipe-like spokes that extend from a central hub. The molds rotate on separate axes at once. The hub swings the whole mold to a closed furnace room causing the powder to melt and stick to the insides of the tools. As the molds turn slowly, the tools move into a cooling room. Here, sprayed water causes the plastic to harden into a hollow part. In this type of plastic molding, tooling costs are low and piece prices are high. Cycle time takes about 40-45 minutes.

Structural Foam Molding
Structural foam molding is a process of plastic molding usually used for parts that require thicker walls than standard injection molding. Inserting a small amount of nitrogen or chemical blow agent into the plastic material makes the walls thicker. Foaming happens as the melted plastic material enters the mold cavity. A thin plastic skin forms and solidifies in the mold wall. This type of plastic molding can be used with any thermoplastic that can be injection molded.
Thermoforming

In this plastic molding process, sheets of pre-extruded rigid plastics are horizontally heated and sucked down into hollow one-piece tools. When the hot plastic solidifies, its shape conforms to that of the mold.

Tooling costs are usually low and piece prices vary on the machinery.

Plastic molding is a very technical process. It needs experts in this type of manufacturing business for it to be competitive in the market. Therefore, a very scientific and systematic study should be first made before going into this endeavor.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

History of CNC Machining

Before CNC machining was invented, all metalworking fabrication processes were completed with NC (Numerical Controlled) machines. The concept of CNC was introduced in 1967 but the first CNC machines were introduced in 1976. Since then the popularity of CNC grew very significant and it was recognized as the industry standard in 1989. Today, almost all metalworking fabrication processes can be completed with CNC machines. Actually, there are many CNC variations for all metalworking equipment, such as grinders, turret punches, routers, milling machines, drills, lathes, EDMs, and high-powered cutting devices.

 The main advantage of CNC machining is to improve safety, productivity, efficiency, and accuracy in metalworking fabrication. With CNC, operators do not have to interact directly in the metalworking processes and it significantly reduces risks at workplace. Recently produced CNC machines can be operated continuously for 24 hours a day and 7 days a week. The machines only need to be turned off for regular maintenance. The reliability of these machines makes most companies to continue operating the machines during weekend, even without any human supervision. The machines are usually equipped with additional system that can contact off-site operator when an error occurs. When an error occurs, the process stops automatically.

Types of CNC machining

Although there are many large companies that specialize in building CNC machines for other companies, small shops or garages are actually able to build small CNC machines. It results to endless types of CNC machines. Even there are many hobbyists who continuously build small machines and promote the machines to small companies. Actually, the creation of CNC machines depends on the creativity of the maker and since there is no limit of creativity, there is no limit of the types of machines that can be built.

Advantages of CNC Machining

The first advantage is that operators can maximize the use of raw materials and minimize waste. A skilled engineer might be able to make same components but when each component is thoroughly analysed, most likely the components are different. In this way, a company can increase profit through the optimal use of raw materials.

The second advantage is that once an engineer correctly programs the machines, they can continuously produce same quality components in shorter time. CNC machines can shorten production processes, so a company can produce more components and receive more orders.

Another advantage is on safety. As mentioned above, CNC automates almost all processes so operators do not have to interact with dangerous equipment. A safer working environment will be beneficial for both company and operator.

CNC also helps a company to reduce the need of skilled engineers. One engineer is able to monitor several CNC machines. By employing fewer skilled engineers, a company can reduce expense on employee salary.

Disadvantages of CNC machining

Although CNC machines have been widely used worldwide; there are several disadvantages that all companies need to notice. The first main disadvantage of implementing CNC at workplace is the initial investment. CNC machines are very expensive compared to manually operated machines. However, these machines are beneficial for long term because it helps to minimize production costs. Another disadvantage is that when a company invests on these machines, it can leads to unemployment because the company needs fewer operators to complete all the metalworking processes.

As a conclusion, with the speed and efficiency of CNC machines to complete various metalworking tasks, investing on CNC machining is highly recommended for companies to stay competitive and profitable.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

What is Injection Molding Process

Injection molding is often ranked as the one of the commonly used processes in the production of plastic items. The popularity of plastic injection molding is often due to the fact that it is a fast process which can be used to produce vast quantities of identical plastic items ranging from disposable consumer goods to high precision engineering components.

Typically Produced Products
The majority of thermoplastics, such as nylon, polystyrene and polycarbonate are produced through the injection molding process, as are the majority of all plastic products ranging from micro parts to large components such as wheelie bins. Also, the fact that this process can produce items that range greatly in shape and size has resulted in the extension of the boundaries of plastic design and enabled significant replacement of traditionally used materials in part due to light weighting and freedom of design.

The Basic Process
The basic process involves the introduction of a material, via a hopper, into the injection molding machine. This molding machine consists of a heated barrel, equipped with a reciprocating screw (which is driven by a hydraulic or electric motor), which itself feeds the molten polymer into a temperature controlled split mold through a channel system of runners and gates.

The reciprocating screw plasticises (melts) the polymer as well as acting as a ram during the injection phase. The shearing action of the screw on the polymer also provides additional heating during this part of the process and the polymer is then injected into a mold which is created according to the required dimensions of the finished product.
The pressure used when injecting the polymer into the mold is very high and (depending on the material being processed) this pressure could even reach one thousand atmospheres.

The tools used in the plastic injection molding process are typically made out of steel (as it can be hardened and plated if required) and alloys of aluminium to allow increased cutting and hand polishing speeds. The costs associated with the production of the tools required in this process mean that injection molding tends to lend itself to high volume production of plastic products and components.

There is a large number of companies which specialise in the production of plastic components and products via injection molding and the supply of molds for the process. The fact that the service provided by these companies is demanded by a wide range of customers (including those in the defence and aerospace industries) shows the importance of this process and the necessity of its products.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

Automotive Plastic Mold

vehicle body stampings broadly divided into panels, beams, parts and general stampings. Able to image features clearly indicated that car is the automotive panel stamping. Classification of automotive plastic mold many ways, in accordance with the method of molding plastic parts can be divided into different categories:

Compression mode: compression mode, also known as mold or adhesive mode suppression. This mold is characterized by the molding process the plastic material directly added to the open mold cavity, then close the mold, the plastic under heat and pressure in the molten state was after the cavity filled with a certain pressure. At this point, the molecular structure of plastics chemical cross-linking reaction, and gradually harden stereotypes. Compression mode used for thermosetting plastics, the molding of plastic parts for the electrical switches are mostly shell and daily necessities.

Extrusion die: also known as extrusion die extrusion die. This section of the mold can be the same shape as the continuous production of plastic, such as plastic pipe, bar, sheet and so on. Extruder heat and pressure of the device and the device the same injection machine. Molten plastic through the nose to form a continuous molded plastic parts, especially high production efficiency.

Injection Mould: injection mold, also known as injection molding. This mold is characterized by the forming process will be placed in the injection machine plastic raw materials, heating the barrel. Heated molten plastic in injection molding machine screw or plunger driven by the nozzle and the casting mold system into the mold cavity, the plastic in the mold cavity by heat, pressure, cooling, curing. As heat and pressure devices can play a role in phases, not only molding injection molding of plastic parts of complex shape and high efficiency, good quality. Therefore, in the plastic injection molding parts account for a large proportion of molding, plastic mold injection mold accounted for more than half. Machine is mainly used for thermoplastic injection molding, in recent years have gradually molding for thermosetting plastics.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

Stripping reasons for the difficulties

Stripping reasons for the difficulties

A mould from the groove
2 stripping slope less than
3 mould finish is not high

II. Related Knowledge

1 As the stripping slope failure caused by lack of very common during the product design, mould must be marked in surface slope, stripping slope is usually in the range 1 to 2 degrees, in this context much good as far as possible, allow for special occasions, more than 0.5 degrees
2 If the injection pressure is too high, products closely aligns with the mould too closely, it becomes difficult to mould
3 in order to successfully make the products from the mould, silicone mould release agents containing generalists, but only when using a thin coating of release agent layer. If the coating is too thick to wipe hard. Well as release agent to the role of the print markings on the products of secondary processing becomes very bad, once the coating on the mould release agent attached to the products on the wipe is quite difficult to think of.

II. Related Knowledge

1 As the stripping slope failure caused by lack of very common during the product design, mould must be marked in surface slope, stripping slope is usually in the range 1 to 2 degrees, in this context much good as far as possible, allow for special occasions, more than 0.5 degrees
2 If the injection pressure is too high, products closely aligns with the mould too closely, it becomes difficult to mould
3 in order to successfully make the products from the mould, silicone mould release agents containing generalists, but only when using a thin coating of release agent layer. If the coating is too thick to wipe hard. Well as release agent to the role of the print markings on the products of secondary processing becomes very bad, once the coating on the mould release agent attached to the products on the wipe is quite difficult to think of.

III. Solution

An instant: decreased injection pressure, shorter dwell time, lower temperatures reduce the ejection speed of the mould, spray release agent
2 Short-term: to improve the finish of the mould cavity
3 Long-term: increase the stripping slope, increase the number of ejection pin

IV. Material Differences

1 is heavy and hard materials, such as GPPS, due to lack of slope hat thing common cause product damage. Of both sticky and soft materials like PE, has the potential to block the root of certain products were cut

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

Introduce about Shell Moulding

In recent years, the financial crisis makes the slump, but the portable electronic products in the day and night to practitioners, but a lot of people are in short supply. Short and thin portable electronic products, pay attention, when shell thin to almost 1 mm, or less than 1 mm, the material suppliers, product and mould designers, mould factory, moulding plant and machine equipment manufacturer and subsidiary is a challenge. In this paper, shell moulding from material selection, product and mould design, CAE analysis, mould forming machine and equipment settings to choose the highlights. Period to initiate a total creative machine.

Fixed electronic products, the shell enable cost reduction, cycle time, thus increasing productivity. For portable electronics, the lighter weight shell allows the size reduction. Demand for portable electronic products grew by 30% per year, growth will be faster the next decade. With this product were also very few – less than 5% in the United States, less than 1% of the world – the market is amazing.
Typical shell thickness ratio of flow length on the range of 100:1 to 150:1 or more. To achieve such a high ratio without increasing the gate, they have high melt temperature, high injection pressure and the high rate of fire.
C-Mould simulation of injection moulding using the Cross-WLF model viscosity is as follows:
This model can be moulded in a wide range of conditions appropriate description of viscosity, one of the benefits is a better deal viscosity on the temperature and pressure sensitivity (viscosity The sensitivity of the pressure increases as temperature decreases). In the Cross-WLF viscosity model, the pressure on the viscosity to D3 show. In the traditional moulding conditions, the pressure had no significant effect on the viscosity, D3 can be set to 0. Under high pressure, the pressure on the viscosity becomes important, D3 must decide to make the simulation results can capture the effects of stress. D3 to obtain a reasonable value, the viscosity of special test procedures and data analysis is necessary.
Without taking into account the impact of pressure on viscosity, when the system pressure increases, the forecast error will be greater and greater pressure. The figure of the flat plate model is a good example of non-zero entry pressure on the viscosity of D3 can improve the filling and post-filling simulation of pressure prediction. Flat plate with polycarbonate (PC) material, the average thickness is 1mm, flow length is 170mm. Pressure on the viscosity of item D3 into the calculation, the predicted pressure was significantly increased, and quite consistent with the measured pressure.
Through the sprue gate, pin point gate, the second hot runner poured directly into the gate so thin, you should use the gate well, in order to reduce gate stress, to help fill, and products in time to the gate damage to a minimum. When the wall thickness less than 1.2mm, the diameter often greater than the thickness of the gate used to help flow, and coagulates in the gate before the completion of the appropriate tamping.
In order to have enough pressure to fill the thin cavity, flow pressure drop preferably not more than the machine can provide 15% of injection pressure. Great use of more traditional flow from 1.25 to 1.4 times the flow. Select more entrants with valve gate hot runner to effectively reduce the pressure to expectations.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold

High thermal conductivity copper alloy mould

High thermal conductivity copper alloy mould manufacturing plant can have higher production efficiency, both to save money, but also improve product quality. Some car bumpers and instrument panels manufacturing companies have used this kind of material the mould and has achieved significant production efficiency.

With the normal industrial / die steel compared to copper-based alloys due to the high cost of production in the mould, therefore, a lot of mould factory has yet to find a better way to make a rational use of high thermal conductivity copper alloy materials, But in fact, the use of high thermal conductivity of copper alloys to save time and efficiency benefits of such areas is very significant.

In this paper to explore the high thermal conductivity copper alloy is a copper-based materials, alloys and manufacturing techniques by the method of combining, it is necessary to keep copper inherent characteristics of the high thermal conductivity, but also it has a certain hardness to be able to let in a production environment for a variety of processing conditions.

The main advantage of copper alloy

In the injection mould in the use of high thermal conductivity of copper alloys include the following special advantages:

A, thermal diffusivity properties

Plastic in the mould of the injection moulding process, the high thermal conductivity copper alloy will absorb a large amount of heat, of course, its initial absorption of heat is a key factor, while the latter will rely mainly on thermal cooling system. In each plastic injection process, heat is absorbed the initial rate of high thermal conductivity copper alloy to play a role in a real place.

2, polished performance

In contact with plastic packaging used in the production process of high thermal conductivity copper alloy moulds, its excellent polishing performance has been proven in practice. In a highly polished high thermal conductivity copper alloy inserts in the future, you can create high-quality transparent plastic packaging, to meet the inspection through the packaging production needs. Practice has proved that this inserts polished steel inserts longer than the time required to finish four times faster, work cycle, but it can reduce 57%.

3, coating

In order to improve the wear resistance, high thermal conductivity copper alloy surface can be easily coated with a layer of non-plated nickel coating, hard chrome coating, PVD coating (physical vapor deposition layer), or CVD coating (chemical vapor deposition layer), so that the hardness of the surface coating to achieve 60 ~ 90 HRC. Non-plated nickel coating can make uniform the thickness of the coating to penetrate into every hole, but its essence is not as galvanizing process, as is also not as hard as chrome plating process. In order to facilitate the plastic mould release, non-plated nickel coating with PTFE (PTFE) or a combination of boron nitride materials. PTFE or boron nitride coated with non-plated nickel coating the surface of the mould parts are very smooth as if coated Feizao Mo in general, it will not make already-formed plastic pieces glued to the mould, the mould release very easily.

Of course, the use of high thermal conductivity copper alloy moulds, there are some limitations, such as eliminating stress or annealing (the only way to maintain the hardness of the material characteristics) should be placed in a long time to avoid mould temperatures above 900 F being.

From Website
Edited by Leafly Mould Provides Injection Mold, Plastic Mold, Injection Molding, Die Casting Mold, Stamping Mold