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1、塑模保養維修講義mold maintenance handout,前述preface,重點:判斷力(外觀及組立之公差)Weight bearing point:judgment(outward appearance and tolerance of assembly),方法:維修之方法影響到速度和效果Method:method effects the velocity and result,對策:“快”“準”“精”,以便能力之提升 Countermeasures:“quick”“accurate”“master”,to improve ability,1:使模具保持良好的工作狀態.Keep m
2、old in good working state 2:保証生產產品品質,減少不良.Ensure the quality of products 3:延長模具使用壽命.Lengthen the usage life of mold 4:避免臨時搶修,提高生產效率.Avoid temporary repairing,raise production efficiency 5:達到 的目的.Reach the purpose of“cost down”.,保養目的()/為什么要保養?purpose,Cost down,PURPOSE,適用範圍及責任單位suitable scope and resp
3、onsibility unit,適用範圍:suitable scope:HPQ/內銷成型廠-塑膠模具.HPQ/inside market molding factory-plastic mold2.責任單位:responsibility unit:模修單位 toolmaker 成型加工單位 molding department,保養作業內容maintenance operation contents,塑模保養Mold maintenance,日常保養Daily maintenance,定時日常保養Timely daily maintenance,每班保養Every class maintena
4、nce,公模面 core surface,母模面 cavity surface,滑塊外側復位杆頂針outer surface of sliding block,reset ram,eject pine,模具外表面 outer surface of mold,細部保養Details maintenance,定時細部保養Timely details maintenance,工令結束時End of work order,模仁core模板plate,組立assembly,熱澆道 hot runner,水路清洗 clean water route,清洗排氣系統clean air system,頂針及滑塊
5、 eject pin and sliding block,日常保養時機 daily maintenance opportunity(定時保養和每班保養)(timely maintenance and every class maintenance),1.定時保養模面清潔:Timely maintain mold surface 生產中之模具-每隔1小時一次.mold in production-one time every 1 hour2.每班保養:every class maintenance生產中之模具-每班保養一次.mold in production-one time each cla
6、ss,細 部 保 養 時 機opportunity for details maintenance,1.工令結束 the end of work order2.定時保養:timely maintenance:大型外觀件模具-每隔四萬模次 large-sized mold-every 40 thousands times PVC 模具-每隔二萬模次 PVC mold-every 20 thousands times 其它模具-每隔五萬模次.other mold-every 50 thousands times,細 部 保 養 時 機,常用保養工具maintenance tool in commo
7、n use,扳手spanner 氣槍air guns 油石oilstone 去漬油eliminate spot oil 棉花/棉布cotton/cotton cloth 銅錘/銅棒 copper hammer/copper club,模具保養的一般步驟steps of mold maintenance,Separate mold 拆模 Clear up 清理 Lubricate 潤滑 Assembly 組立Set to former position 歸位,一:日常保養 daily maintenance,日常保養主要內容main contents of daily maintenance,公
8、,母模面及排 氣槽的清洗clean the surface of mold and air vent,1.用氣槍吹乾凈公模面,母模面及排氣槽內的料屑.Clean the material trifles of mold surface and air vent by air gun.2.用沾去漬油的棉布擦拭乾淨公.母模面Clean mold surface with the cotton cloth soaked eliminate spot oil.,3.用氣槍吹乾凈排氣槽內的料屑.Clean the material trifles in air vent by air gun.,one,
9、1.用氣槍吹乾凈導套、頂針、滑塊等部位clean bush、eject pine and sliding block etc.with air gun,導套、頂針、滑塊的清洗Clean bush、eject pine、sliding block,2.用沾去漬油的棉 布擦拭乾淨Clean it with cotton cloth soaked eliminate spot oil.,2nd,3.給公模導柱、复位桿、頂針、滑塊等部位抹上一層潤滑油Add lubricant for guide post、reset ram、eject pine and sliding block of core,4
10、.給母模導柱、導套等部位抹上一層潤滑油Add lubricant for guide post and bush of cavity,5.從頂針固定板 間隙噴頂針潤 滑油Spurt lubricant on eject pine from the space of pines stable plate,3rd,模具外表面的保養maintenance of molds outer surface,用噴槍吹模具表面上的粉塵,使其保乾凈Blow the dust of mold surface by air gun and keep it clean,end,NOTICES,日常保養注意事項matt
11、ers needing attention in daily maintenance,一.保養前要注意確認:Confirm before maintenance:射座退出,料管內無料,液壓馬達關閉.Injection seat falls back,no material in pipe,motor is off.二.保養時注意:Attentions in maintenance:1 鏡面和噴砂紋面不能用棉布擦拭;Dont clean mirror surface and lines surface spurted sands with cotton cloth.2 擦拭過程不能碰傷咬花面和鏡
12、面;Texture and mirror surface cant be damaged in cleaning it.3 禁止在模面直接噴射潤滑油,使模面殘留油漬.Forbid to directly spray lubricant on mold surface.Make sure there is no oil sludge remained on mold surface.保養后注意:Attentions after maintenance:成品外觀有無異常,模面有無損傷等不良,登記結果于記錄表.Confirm there is unusual of outer appearance
13、or not,there is injury and defect etc.on mold surface or not.Fill the data on record list.,二:細部保養Details maintenance,細部保養主要內容Main contents in details maintenance,因各模具的結構不同,保養時應依次對模具的模仁、模板、頂針、滑塊、鑲塊、水路、導柱等作相應保養Do corresponding maintenance for core、plate、eject pine、sliding block、embedded lump、water rou
14、te、guide post in turn because of the difference of molds structure.下面以電鍍件為例,對細部保養作例圖說明(因為電鍍件對油污敏感性要求比一般塑件要高.因此,清理保養更加徹底.)Use electroplated part as example to introduce details maintenance.(The maintenance of electroplated part is more thorough than others because its requests of greasy dirt sensitiv
15、ity is more than others.),contents,從拆模開始.Start from separating mold.,首先,用天車將模具放在整洁的工作台面上,准備好拆模工具.Set mold on the clear working table by workshop traveler firstly and prepare the tools.然后,將公模與母模分開,准備拆公模Then separate the core and cavity,prepare to separate core.,第一步,公模底板上與模框連接的螺栓卸下然后將公模固定板和模腳一起拉出放于一旁S
16、eparate the screws that join cores base plate with mold frame then pull out the stable plate and mold foot together.注意點matters needing attention:對于大模具,直接拉出比較困難,可以先用拔模器拔掉底板上的導柱.拉出時要平穩,防止折彎折斷型芯.所卸螺釘導柱等放在預備好的工作盤中.It is difficult to pull out the big mold.Had better pull out the guide post on the base pl
17、ate firstly.Pull it smoothly to avoid damaging the core.Must set the screw and guide post in the prepared plate.,將,頂出底板上的螺釘卸下拆出頂出底板Separate the screw of eject base plate then separate it.注意點:Matters needing attention:如果復位彈簧是在導柱中內置的,卸螺釘時應該先卸對角,以免頂出板卡死,不易脫出.Separate the screws on the diagonal line fir
18、stly to avoid that eject plate will be jammed if the reset spring is inbuilt in guide post.,再將,頂出板從模板中脫出放于安全的地方防止踫傷頂針和斜梢Pull out the eject plate from mold plate and set it on the safe place to avoid damaging eject pine and slanting pin.注意點:Matters needing attention:有斜梢時要先卸掉斜梢后的滑塊(注意編號).拉出時要平穩,不要踫傷頂針
19、或斜梢.Separate the sliding block on the back of slanting pin(pay attention to the NO.)if there is it.Pull the sliding block smoothly,dont damage eject pin or slanting pin.,此時要將,將模板上的模仁固定螺栓拆下Separate the screw fixed core on the mold plate.用兩個較長的螺釘鎖入模仁對角并交替敲擊兩個螺釘以取出模仁Set two longer screw in the diagonal
20、 of core then hit these two screw by turns to pull out the core.注意點:Matters needing attention:如果模仁生銹太緊,可以先用防銹油浸潤一會.模仁取出后要注意保護好成型面.Soak the core with against rust oil if the core with rust.Pay attention to protect the molding surface after pulling out the core.,然後,將模仁上的入子依次取出,對于配合比較緊不易取出的入子可以用小銅棒輕輕敲出
21、.Take out the core pins at last,tap out it lightly with small copper stick if the core pin assembled tightly.注意點:Matters needing attention要看清入子、鑲塊、模仁對應部位是否已經標示,如果沒有,要用磨棒在非成型面上刻上,以免混淆.Confirm the core pin、embedded lump、core are marked or not.If not,mark it with grind stick.,最後,開始公模部分清洗作業Start the cle
22、an operation of core,第二步,Clean waterproof ring and water route注意點:Matters needing attention要檢查防水圈是否良好,對于已經損坏的要及時更換.防水圈一定要放在工作盤中以免丟失.Inspect the waterproof rings are good or not.Replace the damaged rings timely.Set the waterproof rings in the working plate.,防水圈及水路清理,Clean the rust dirt of core surfac
23、e用油石將模仁外表的銹污清除.Clean the rust dirt of core surface with oilstone.注意點:Matters needing attention:檢查水塞是否密閉良好,對于 損坏的水塞及時更換.Inspect the water stopper is airtight correctly or not,replace the damaged water stopper timely.,模仁外表的銹 污清除.,Clear the hole of embedded lump 用小油石裝有鋼刷的電轉除去鑲塊孔中的銹污.Clean the rust dirt
24、 in the hole of embedded lump with small oilstone and electric drill assembled steel brush.用小油石(320#以上)除去鑲塊表面的銹,并用噴槍清洗,吹乾.Use small oilstone(over 320#)to clean the rust on the surface of embedded lump and clean it with spray gun.,頂針孔或是小型芯孔內的銹污也可用頂針或型芯來清理,只要用相應的頂針或者小型芯在孔內反复抽動几次即可.Can clean the rust d
25、irt in eject pin hole or small hole of the core with eject pin or core pin,just use the corresponding eject pin or small core pin to twitch several times in the hole.,頂針孔及小型芯孔清洗,用去漬油對模仁和模框噴洗乾淨后吹乾,尤其是模仁孔內部一定要清洗乾淨.Spurt cleaning oil on core and mold frame to wash it then dry it,especially clean the ho
26、ld of core.注意點:Matters needing attention:清理的順序一般是先側面,再正面,再反面,最后又正面.In general the clean order is flank firstly,then front,then reverse side and front again at last.,模仁和模框清洗,開始公模部分組裝 Start to assemble the core組裝時注意導柱 入子等清潔,潤滑Pay attention to clean and lubricate guide post and core pin etc.when assemb
27、ling it.,接下來,Assemble embedded lump and core pin用乾淨的手裝上鑲塊及入子.Use clean hands to assemble embedded lump and core pin.注意點:Matters needing attention:注意鑲塊入子的編號要和模仁上保持一致,裝入后要檢查是否裝正确.Confirm the no.of embedded lump and core pin is same as the core,inspect the assembly is correctly or not.,裝上鑲塊及入子.,將模仁裝入裝好
28、防水圈的模框中,并用螺釘緊固好.Assemble core in the mold frame installed waterproof rings and fix it with screws.,裝防水圈及模仁,用乾淨的布條將頂針及導柱擦乾淨,在導柱上塗上少許白油潤滑.再將頂出板裝入公模板,并將所有的頂針依次裝好.Clean guide post and eject pin with clean cloth,smear a lot of white oil on guide post to lubricate it.Then install eject plate in core plate
29、,assemble all eject pin in turns.注意點:Matters needing attention:注意頂針是否裝反,對于有斜梢的模具還要檢查斜梢是否裝正确.Inspect the installing condition of eject pin and slanting pin.,裝頂針及公模板,用乾淨的布條對頂出底板稍作擦拭,再將頂出板和頂出底板合好并用螺釘緊固好.Slightly clean eject base plate with clean cloth then assemble the eject plate with base plate and f
30、ix it with screws.注意點:Matters needing attention:頂出底板裝入時要平穩,否則容易使裝好的頂針震出.鎖螺釘時先鎖對角.鎖好后最好再次檢查頂針等是否裝正确.Install eject base plate smoothly,otherwise the installed pin will be shaken out.Install the screws on diagonal line firstly.At last inspect the install condition of eject pin etc.,頂出板和頂出底板組立,用油石將模腳和底板
31、上的銹除去并用布擦乾淨.再在導柱上塗上白潤滑油.Use oilstone to clean the rust on mold foot and base plate and clean it with cloth.Then smear white lubricant on guide post.,導柱潤滑,將模腳及公模底板推入合好,并用螺釘緊固好.Assemble mold foot and core base plate and fix it with screws correctly.注意點:Matters needing attention:對于有型芯的底板要注意檢查型芯是否轉到位,确認
32、后用小螺釘緊固好.Make sure the location of core pin is correct if the core has core pin,then fix it with small screw after confirming it.,模腳及公模底板組立,用乾淨的布條擦拭模面,除去模面上所粘的塑膠、屑等雜質.Use clean cloth to wipe mold surface,get rid of the plastics、trifles etc.impurities.裝好后,應該將模具放倒,用天車吊起頂出板,以檢查頂出和復位是否順利.Place mold down
33、 after assembling,use workshop traveler hang up the eject plate to inspect it goes forward and falls back smoothly or not.,模面清潔,該模具的公模就保養完成了!Now the maintenance of core is finished!,用同樣的方法保養母模 Use same method to do the maintenance of cavity,至此,接下來,保養作業注意事項matters needing attention in maintenance,1.模
34、修人員應將保養結果及模況記錄在上.Toolmaker should take down maintenance result and mold condition in the.2.模修單位應每月底依據生產計劃制定次月之模具細部保養計劃表,並經主管單位核準並作為模具保養作業之參考.Toolmaker department should work out details maintenance plan for next month at the end of month according to the production plan,which must be approved by sup
35、ervisor then use it as reference for maintenance.3.模修單位應每日稽核生產中模具已生產模數,以落實定時保養制度 Toolmaker department should check the number of the mold used times,so as to carry out timely maintenance plan.4.模修單位應將模具實際執行細部保養之日期記錄在模具細部保養計劃表里,以方便保養作業之追蹤.Toolmaker department should fill the actual date of details ma
36、intenance in the mold details maintenance plan in order to follow it.5.在模具細部保養時,如出現模具異常,需要維修時,參考執行.If there are problems of mold when doing mold details maintenance and mold need repair,do it referring to.,以上是普通二板模具一般保養內容,對三板模具和 PVC 料等特殊模,除以上常規保養以外,還另作要求.Above-mentioned contents are about the genera
37、l maintenance of common 2 plates mold,there must be more requests of the maintenance for 3 plates and PVC mold.,例:For example:,對PVC模For PVC mold除常規作業外,每日需用專用中和劑(SPRAY NO.816)均勻噴洗母模面和排氣槽一次,待3分種酸鹼中和后,用氣槍吹乾凈模面,詳細要求參考:Spurt neutralizer for a special purpose on cavity surface and air vent 1 time,after 3
38、minutes use air gun clean mold surface.Detailed request according to:,例:For example:,對客戶有特殊要求之模具除常規作業外,依 之要求進行保養,其重點在清潔与潤滑作業.Maintain the mold that customer has special request according to except standard operation,the weight-bearing point is cleaning and lubricating.,常用清模作業英語MOLD CLEANING PROCEDUR
39、E ENGLISH,一.准備清模工具:噴槍,氣槍,手電鉆,去漬油,砂紙,碎布,油石,煤油,圓銅刷,棉花.Prepare mold cleaning tools:Engine cleaner,Air gun,electric hand drill,Cleaning oil,broken Cloth Sandpaper,Oil stone,Kerosene,Round copper brush,Cotton.二.用油石將公母模入子的油污清除.(400#油石)Use oilstone and kerosene to polish dirt on the inserts,which is fixed
40、in mold cavity or core.三.用油石清除排氣槽內瓦斯.(400#油石)Use oil stone to polish gas off,which trapped in air-vents.四.用噴槍吸去漬油清洗模仁入子,用棉花擦乾淨.Use spray gun to clean solvent liquid,wash mold inserts,wipe it off with cotton五.拆出水塞將鉆頭裝在手電鉆上,清除公母模仁水孔內污垢.take apart the water plug of mold,Use electric drill to clean the
41、cooling channel in mold core/cavity.六.用圓銅刷清洗公模仁內頂針孔,斜梢孔,用去漬油清洗再用棉花擦拭乾淨.Use round copper brush to clean ejector hole,lifter hole in the core of mold.Use solvent liquid to clean them,then,wipe them with cotton.七.用砂紙拋光頂針,去除頂針毛刺.Use sandpaper to polish ejector pin,remove the burr on ejector pin.八.用油石清除模
42、板，頂針板的銹斑及油污.(大磨石)Use oilstone to polish off dust and dirt on moldboard and ejector plate.,附1:,九.用小電鉆清洗模板上水孔內污垢.Use small electric drill to clean the cooling channel of moldboard.十.將模仁上的澆道及澆口倒角.Chamfer runner and gate of mold.十一.將閉合器孔倒角拋光.(三板模)Chamfer hole of high loading“P”lock,then polish it.十二.將圓頂
43、針磨排氣.(頂針彎掉,需更換)Grind air-vents on round ejector pin(Change new ejector pins if it is bend).十三.將回位梢倒角並拋光.(夾在車床上,用150#砂紙研磨嚴禁戴手套操作,違者一律開除).Chamfer return pin and polish it(Clamp it on lathe machine to polish with#150 sandpaper),Do not wear gloves when operating machine,offenders will be dismissed!)十四.將
44、下固定板上四支定位柱拋光(夾在車床上,用150#砂紙研磨)Polish 4 locating post of the bottom plate(Clamp it on lathe machine and polish with#150sandpaper).十五.在導套與模板之間開排氣.Grind air-vents between moldboard and guide cover.十六.將母模板四支拉杆磨板手定位槽.Grind the four ram of cavity board to be flat for location of the spanner(3plate mold).十七
45、.檢查彈簧彈力是否足夠.(滑塊內彈簧及固位梢之彈簧).Check whether the elasticity of the spring is sufficient,附2:,十八.檢查O形環有無破損.Check whether the“O”ring is damaged.十九.檢查母模板四支拉杆長度是否一樣,母模板上拉杆孔深度是否一樣.Check whether the four rams of cavity board is equal in length and whether the ram is equal in depth.二十.拋光灌嘴.(檢查灌嘴是否太小,入澆口是否太小.Pol
46、ish nozzle(check whether nozzle is too small,whether the nozzle gate is too small).二十一.清模后負責人確認並簽名,每周五將全部之清模狀況回報並電腦存檔備查.After tool maintained,person in charge must sign and put the mold condition into computer every Friday to prepare to be checked.二十二.現場整理.put the scene in order.,附3:,The End Thank You,
