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Advanced Injection Mold & Molding

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Auto Water Tank

About auto air & water tank product mold, the process controlling of design and manufacturing are more difficult than normal type, as this type parts normally molded by the material PA6 (PA66) + GF (30-35%) compound, and this kind of material is easy to get the deformation during the molding process, and corresponding product size are out of tolerance. Therefore, familiar with the deformation regularity of the type of product, to do the pre-deformation design based on experience and CAE analysis software in the early design process has become the key to the success of mold manufacturing.
2、 Analyzing the parts drawings, clarify the key areas of the product and size.To understand important areas of the product and associated key sizes are always the first step when customers' product drawings arrived, then pay more attention on those importance, such as product "End surface" ("End surface" was required most strictly straightness, flatness and form size tolerance requirements, and other parts of the product size will follow their changing),"Tube orifice" area (the dimension of "tube orifice" is also very important, usually the positioning, cylindrical and dimensional tolerances are required)and product "Boss" and "U-shaped" ribs etc., as shown below:
For new mold, do pre-deformation for the product (doing the " material compensation" on the opposite direction of estimated deformation in advance according to experience and CAE analysis, trying to make them correct after the actual deformation acted). After the mold trial, doing some small modification based on the actual deformation of the product molding, to correct the plastic geometry, shape and position and so on. 3、 Drawing the products.  As these products are easy to get deformation, in order to facilitate the future mold optimizing, drawing a new 3D product data by ourselves according to customer's product is necessary (important parameters to be retained). Determining the products deformation value, combined with mold flow analysis and experience to modify the product data, below you can see the experienced deformation trends:
 the product "U" shape plastic bit deformation    "U-shape" plastic also need to do about 2-3 degrees deformation,the middle area of the "U -shape" ribs should do the material cutting by side.
After all the products have been drawn well and then design the "R" radius(also for facilitating the changing, sometimes "R" radius rebuilding will fail or spent too long time), if some geometrys in customer 3D data are not chamfered, we can chamfer them if they are not affect the parts assembly (most customers prefer the chamfer the sharp shape with "R" radius).
 In addition, some prominent geometry on the product main body are big , this type of product deformation should pay more attention on parallelism and perpendicularity .