the mold surface roughness is a very important technical parameter in mold making, because the surface finish of the molding area directly affects the surface roughness of the plastic part. A range of polishing tools is used to meet a different surface finish requirement. The society of plastics industry classifies mold surface finishes into 12 grades in 4 categories:
A—mirror image, it is typically polished with diamond paste, it’s surface finish Ra is 0—0.0001mm, applicable for plastic parts whose surface should have high luster. In general, mirror image is further classified into A1, A2, and A3.
B—smooth, it is usually polished with sand paper. It’s surface finish is between 0.0001—0.0002mm, applicable for plastic parts with a typical surface requirement. This category can be further classified into B1, B2, and B3.
C—Semi-smooth.it is polished with whetstone. It’s surface finish is between 0.0002—0.0008mm, applicable for plastic parts without a specific surface finish requirement. This category is also further classified into C1, C2, and C3.
D—General. Sand blasting is commonly used. This category is also further classified into D1, D2, and D3.
the surface roughness of plastic components obtained from disparate processing situations was measured and compared with the surface roughness of inserts. The surface roughness results are in good agreement with the Heat transfer coefficient value and can be used to interpret the cause of variation. The results of this study will be beneficial for understanding the heat transfer process comprehensively, predicting the temperature field, arranging the cooling system, and offering precise Heat transfer coefficient for numerical simulation.
Polishing technology is very critical to determine quality and performance of the final products and occupies up to 30~50% of the whole die manufacturing time. Polishing purpose is to reduce the surface roughness to a desired amount and keep form accuracy. However, polishing is a kind of complex material removal operation, and the surface roughness after polishing is related to many factors such as
machining parameters: polishing pressure, feed rate, tool speed, polishing times, grit of abrasive tool etc.The mould polishing is a complex material removal process under various polishing conditions. The process parameters (polishing pressure, tool speed, feed rate, polishing times, pose angle, etc.) and material parameters (workpiece material, abrasive tool material) have effects on surface roughness.
Mold Surface Roughness technology for injection molding surface finish, Molding Surface Roughness, injection mold finish, and injection molding mold polishing surface finishes.
Mold Surface Roughness technology for injection molding surface finish, Molding Surface Roughness, injection mold finish, and injection molding mold polishing surface finishes. it is very important for mold and molding
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Injection molding is one of the most commonly applied processing methods for plastic components. Heat transfer coefficient (HTC), which describes the heat conducting ability of the interface between a polymer and cavity wall, significantly influences the temperature distribution of a polymer and mold during plastic component injection molding. This study focuses on HTC under diverse processing situations. On the basis of the heat conducting principle, a theoretical model for calculating the average HTC within an injection cycle was presented. Experimental injection studies were also performed to acquire necessary temperature data. The heat quantity and HTC across the interface between a polymer and cavity wall was on the basis of the results of the experimental injection studies. The factors influencing the HTC were analyzed on the basis of the factor weight during injection molding cycle. Finally, the surface roughness of plastic components obtained from disparate processing situations was measured and compared with the surface roughness of inserts. The surface roughness results are in good agreement with the HTC value and can be used to interpret the cause of variation. The results of this study will be beneficial for understanding the heat transfer process comprehensively, predicting the temperature field, arranging the cooling system, and offering precise HTC for numerical simulation.
To check the roughness changes of treated surface, we used a surface profiler, which is a non-touch roughness profiler. The following 4 specimens were measured.
– Treated surface
• solid surface
• micro-cellular foamed plastic surface
– Untreated surface
• solid surface
• micro-cellular foamed plastic surface
As the machine injects material into the mold, it must be able to get into every nook and cranny of the cavity. However, different surface finishes can change how the material flows, potentially preventing it from filling, resulting in insufficient filling pressures or material freezing prematurely.
When surgeons are doing delicate work, they need to be able to hold their tools properly, and the tool should also feel comfortable in their hand. so the surface of product in the mold is different as well
Certain materials will not release with inconsistent or flawed surface finishes. For example, silicone, thermoplastics and metal injection molding commonly require high-quality surface finishes for proper ejection from the mold cavity.
Some molds need to be textured. For example, if operators are making a mold of a medical part—like an endoscope, which a surgeon needs to hold with gloves—they will need to develop a uniform texture for gripping. Medical utensils often need to have a highly tactile capability.
Aesthetics also can play a huge role in surface finish decisions, as the the mold’s surface finish could dramatically change the final part’s application.
For example, silicon requires a mirror finish to work properly, as sometimes the finished piece cannot be touched and residue and oil from machinists’ hands cause issues.
The ratio of flow area of the rougher half with the total flow area of the molded part is used to evaluate the significance of surface roughness effect. The experimental results revealed that mold surface roughness does resist the cavity filling of polymer melt in micro injection molding. For the limited range of injection rate investigated, it is not significant on the surface roughness effects. The increase of mold temperature will decrease surface roughness effects. The change of melt temperature within the range allowed by the process is insignificant for surface roughness effects.
Surface finish is one of the most important considerations when creating a mold. Key factors include mold material and customer-required tolerances.
Delivery of polymer melts into the mold cavity is the most important stage of the injection molding process. I want to say the influence of cavity surface roughness, polymer material (with different flow properties) and technological parameters on the flow length of polymers into mold cavity. Application of the measurement results may have significant influence on the production of shaping parts of the injection molds especially in changing the so far used processes and substituting them by less costly production processes which might increase the competitiveness of the tool producers and shorten the time between product plan and its implementation. Because the finishing operations of machining are very time and money consuming leading to high costs of the tool production.
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I think this definition method is not scientific enough, I am also looking for a better method
The Society of Plastics Industry (SPI) standardized surface finishes on injection molding tools. The process used to achieve the finish determines the following grades:
Grade A – Diamond Buffing: Diamond buffing paste has a very fine grain, so finishes are generally very glossy and product surfaces remain flat. Grade A finishes are considered the highest standard.
Grade B – Sandpaper: This semi-gloss finish is applied using sanding grit and is ideal for hiding visible machining marks. The sandpaper grit number provides surface finish control — 600 for the finest finish, 400 for mid-range, and 320 for the most textured finish.
Grade C – Grit Stone: Grit sanding stones generally follow the grit number and finish textures as sandpaper. However, grit stones cut fairly aggressively, which creates a rougher texture compared to B grades.
Grade D – Pressure Blasting: Pressure blasting plastic surfaces with abrasives — typically sand or glass beads — results in non-directional patterns and dull or flat finishes.
Micro injection molding presents many challenges in the injection-molding community. When the dimensions of the part (and thus the cavity of the mold) are small, micro-scale factors such as mold surface roughness may play an important role in the filling of polymer melt.
Mold polishing usually determines the quality of the surface finish of the injection mold, and this manual process can quickly consume profits. The injection mold may be made very well, and the mold making process may be effective, but if the surface finish is wrong, the part is unqualified.
If unnecessary time is wasted during milling, grinding or EDM to over-polish or compensate for poor surface finish, mold polishing can quickly eliminate profits. In order to avoid this problem, each processing operation must have a surface finish requirement.
Micro-injection faces many challenges in the injection molding industry. When the size of the part (and thus the cavity of the mold) is small, microscopic scale factors such as mold surface roughness may play an important role in polymer melt filling. The effect of mold surface roughness on the cavity filling of polymer melt in micro-injection molding was studied. A disc insert with different surface roughness but the same average line was studied. The significance of the surface roughness effect was evaluated by the ratio of the flow area of the rough half to the total flow area of the molded part. The experimental results show that in the micro-injection molding, the surface roughness of the mold has a certain inhibitory effect on the cavity filling of the polymer melt. The effect on surface roughness is not significant over a limited range of injection rates. An increase in mold temperature reduces the effect of surface roughness. Within the range allowed by the process, changes in melt temperature have little effect on surface roughness.
Now in the mold industry, we have had special equipments or instruments to test the surface roughness of the mold
The surface roughness of the mold is very important, we have special tool to check.
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The surface quality of the mold determines the quality of the injection molding products.
We have some special tools to check the surface roughness of the mold. because it is really important.
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Now CNC machining have been able to achieve high surface roughness
In our mold workshop, I often hear mold workers and engineers talking about it
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please write another blog to tell us how to do, could you?
we will share some experience on this issue with you in the Email we sent to you. if you still have any question, please contact us.
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a lot of factor Influence mold surface roughness during the whole process of mould manufacturing
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