Introduction
Molds are a vital part of any manufacturing operation as they aid in the production process. They are made in various shapes and sizes to meet specific requirements, from small plastic hooks to massive plane parts. When a mold breaks, it can result in increased costs, delays in manufacturing, and poor quality control. Therefore, it is essential to identify the common reasons for premature mold failure and develop strategies to avoid them.
The Causes of Premature Mold Failure
1. Temperature Fluctuations
The press temperature is one of the most common causes of premature mold failure. If the mold is exposed to temperature swings between the extrusion and casting temperatures, the tool will age prematurely. This is because the metals used in the mold expand and contract when exposed to sudden changes in temperature, leading to increased wear and tear. Therefore, it is important to maintain consistent temperatures while the mold is running in order to ensure the longevity of the tool.
2. Improper Maintenance
Inadequate maintenance is another common cause of premature mold failure. Poorly maintained molds run with hardened tool surfaces which can lead to increased friction and excessive heat. This can be caused by a lack of proper lubrication, which worsens with time, leading to broken mold parts and shortening the lifespan of the tool. To ensure the longevity of the mold, it is important to adhere to set maintenance schedules and regularly lubricate the mold.
3. Improper Cleaning
A neglected mold can often lead to failure as build-up occurring between the mating surfaces as well as on the runner system can cause difficulty in the ejection of molded parts. This is because the dirt and foreign objects trapped in the mold fill up the cavities, leading to the failure of the molded part. To reduce the chances of this happening, molds should be cleaned on a regular basis to prevent accumulation and the resulting increased wear and tear on the mold.
4. Substandard Tooling
Substandard tooling is a major cause of premature mold failure. Molds that are made with low-grade materials are more prone to wear and tear than those made with high-grade materials. Substandard parts can lead to premature wear and tear due to poor metal-to-metal contact and can be a major source of wear failure on a mold in a short amount of time. In addition, if the metal used is subject to a low hardness during the tooling process, it can be easily deformed and chipped, leading to decreased tool life.
5. Lubricants and Coolants
The wrong kind of lubricants and coolants can also be a major cause of premature mold failure. When the wrong lubricants or coolants are used, the mold can experience wear and tear due to inappropriate compatibility with the tooling material. Additionally, if the lubricant is not applied to the proper areas, excessive heat generation can occur, leading to premature failure.
Conclusion
It is important to identify the common causes of premature mold failure and develop strategies to avoid them in order to ensure the longevity of the tool. Molds should maintain consistent temperatures, be regularly maintained and cleaned in order to prevent build-up and wear, and should be made with high-grade materials to withstand heavy use. Finally, the correct lubricants and coolants should always be used for the optimal functioning of the mold. By following these simple yet vital steps, manufacturers can significantly reduce the chances of premature mold failure.
