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Mold lifespan is affected by many factors, of which wear and tear on plastic injection mold components is one of the main challenges. The continuously moving parts such as guide bushings, ejector pins, slides, and nozzles typically experience the highest level of wear. Minimizing this wear can help companies save costs by not having to replace worn-out components frequently. This article will explore the solutions in more detail to help mitigate the wear and tear on plastic injection mold components.
1. Causes of Wear and Tear on Plastic Injection Mold Components
- Abrasive Wear: A major cause of wear and tear on plastic injection mold components is the difference in hardness between the sliding parts. This can be easily observed in components like slides, which often become loose after a period of use, or in the widening of the ejector pin holes after repeated operation. Such wear affects the quality of the molded products, leading to issues like size variations or the appearance of defects like flow marks and voids in the plastic parts.
- Adhesive Wear Due to Dust Buildup: Airborne dust particles can adhere to the sliding parts after prolonged use, creating significant friction and accelerating the wear rate.
- Fatigue and Flaking: The continuous sliding contact between components over an extended period can lead to the hardening and subsequent flaking of the contact surfaces. This can result in changes to the dimensions of the components.
- Wear Due to Melt Flow: During the injection molding process, the flowing plastic crystals create friction against the contact surfaces of the mold components, leading to gradual wear, especially in areas like the gate, runner, and other surfaces in direct contact with the melt flow. The consequence is that the gate may become wider than the original design, requiring adjustments to the injection molding machine parameters. Worn mold components can also cause deformation and dimensional inaccuracies in the molded products. Therefore, the high-speed and high-pressure melt flow is another significant factor contributing to the wear and tear on plastic injection mold components.
2. Methods to Reduce Wear and Tear on Injection Mold Components
To reduce wear and tear on plastic injection mold components, the following measures can be applied:
- Homogenize the hardness of the mold components, especially the sliding components, to limit wear and tear. Manufacture the components with high precision according to the technical assembly tolerances.
- Manufacture the mold components with high accuracy to ensure proper technical assembly according to the design. This will limit gaps and prevent excessive friction.
- Regularly clean and maintain the mold during and after use to prevent dust buildup, which can cause wear and tear from contaminants.
- Inspect and replace worn components periodically or based on the actual condition of the mold.
- Select appropriate mold materials that not only optimize costs but also reduce the impact of wear and tear from the plastic flow during the injection process.
