In order to increase the output of large parts and reduce the production cost of single-cavity molds, two alternative methods have been developed: using large injection molding machines to produce superimposed molds and double-cavity molds, both of which are technically Insufficient: No matter the double-cavity mold or the superimposed mold, the injection rate is doubled compared with the single-chamber method. This is critical for large flat plastic parts with small wall thicknesses, such as body panels and bumpers. At the same time, the balance between the two chambers is difficult to achieve when injected with a larger injection volume.
The use of a two-cavity method requires that the tonnage of the injection molding machine be doubled and that the speed is slower than that of a single-cavity injection molding machine. With the superimposed mold, although the same tonnage injection molding machine can be used, the mold opening stroke is doubled, resulting in an increase in the processing cycle.
Double mode machine
The dual mode machine has an intermediate template installed between the conventional fixed template and the active template. Two standard molds are mounted on both sides of the intermediate formwork, and the two molds are alternately opened during operation to remove the workpiece. The injection molded parts are moved to the back of the injection molding machine and each mold is injected alternately. The injection molding process of the two molds is mutually staggered, and the working cycle of the mold A (opening the mold, ejecting, clamping, injecting, and holding) is performed during the cooling of the mold B.
Design features: Two molds can be mounted on one injection molding machine with an intermediate floating template. An offset injection molded part is used to sequentially stop the injection of the two thermal flow gates on the intermediate form. Two separate hot runners on the intermediate form feed the plastic to each mold. A hydraulically operated clamping sleeve is used to ensure that the other mold remains closed when one mold is opened. The shut-off valve on each hot runner distributor is used to control decompression and prevent flashover between injection cycles.
2. Advantages of the two-mode injection molding machine
1) Increase production: A dual-mode injection molding machine can double the production capacity of a traditional injection molding machine. This is to use the workpiece's cooling time to inject more than one workpiece.
2) Machine load balancing: For assembly assemblies with paired use requirements, the dual-mode machine simplifies warehouse management and is especially suitable for JIT production methods (just-in-time production).
3) Accurate color matching: Feeding with the same injection part, the material stays in the injection cylinder for a short period of time, thus ensuring accurate color matching.
4) Molds are interchangeable: existing molds can be easily modified for use in dual-mode machines.
5) Saving land: One dual-mode machine occupies less than two traditional injection molding machines.
6) The injection molding process can be controlled independently: When two different workpieces are produced, most of the two injections can be controlled independently.
7) It can manufacture large workpieces: the double-cavity balance problem that is usually encountered when using large-tonnage large injection parts and large-sized workpieces produced by multi-cavity molds. It is now possible to use two-mode machine and single-cavity mold, only half of the original tonnage. Can be solved. The problem of the injection volume balance of the two molds can now be avoided by separately injecting two separate molds.
8) Saving energy and manpower: Using a dual-mode machine saves energy and reduces labor costs.
9) Saving installation costs: Installation and maintenance costs are significantly reduced for a dual-mode machine compared to two conventional injection molding machines.
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