Definitions and Why We Need Mold Trial?
Following the new mold’s tooling process and mold assembly, we will proceed with the initial mold tryout process. Aimed at verifying the mold’s performance and ensuring the production of high-quality parts.
During the initial mold tryout, we will assess the performance of the mold’s injection system, ejection system, side action, and other functions. This evaluation will determine if these systems are functioning correctly within the mold.
Key Evaluation Points During T1 Test
Mold Functionality
Firstly, check if the mold opens and closes smoothly without any sticking or jamming.
Additionally, verify the cooling system’s efficiency to ensure efficient mold cooling.
We will also test the injection system to ensure consistent and accurate injection of plastic material.
Furthermore, evaluate the ejection system for proper ejection of molded parts.
and checking the side-core system, if applicable, to ensure proper functioning.
Injection Parameters:
Adjusting the settings of the injection molding machine, such as pressure, temperature, and time for quality, will also fine-tune the melt temperature and screw speed for material flow.
Moreover, we will ensure appropriate temperatures to avoid any potential issues.
Mold and Sample Quality:
We will inspect the molded samples for defects such as flashes, short shots, sink marks, or gas traps.
We will evaluate the dimensional accuracy of the parts to ensure they meet the required specifications.
Furthermore, we will check if the parting line is clean and free from burrs or excess material.
Lastly, we will verify if the mold surfaces are polished and free from scratches or imperfections.
Correction and optimization:
We will identify areas where improvements or adjustments are needed to enhance the quality.
We will make the necessary corrections to eliminate any molding issues or defects.
while recording and documenting all modifications and changes made during the tryout process.
Lastly, we will prepare an FAI dimension report summarizing the tryout results, including injection parameters, sample evaluation, and corrective actions. Additionally, we will take a video for customer reference. It’s important to note that the specific checking items on an injection Mold Trial Checklist may vary depending on the mold’s complexity, the part’s requirements, and the customer’s specifications.
| Mold Trial Process Checklist | |||
|---|---|---|---|
| Part Name: | Project Engineer | ||
| Mold Number: | Mold Trial Date: | ||
| Preparation for mold trial | Check | ||
| Material | 1 | Confirm material type /model,based on the part drawing or BOM | □ |
| 2 | Confirm the materbatch number and proportions ( if need masterbatch ) | □ | |
| 3 | Check the drying barrel if it’s correct material | □ | |
| 4 | Confirm the raw material drying temperature and time, the proportion of recycle, this requirment is based on the material datasheet and part requirments | □ | |
| Mold | 5 | Mold number | □ |
| 6 | If the mold have inserts; core pulling etc special requirements | □ | |
| 7 | Inspect the mold, for example if the locating ring and hot runner connectors etc are ok ? | □ | |
| 8 | Check the standard parts, for example the water pipe diameter and lenth, plates;screws and suspension bridge etc. | □ | |
| 9 | If the mold sprue R match the molding press ? | □ | |
| Molding Machine | 10 | if the mold can be load on the machine ? Check the clamping force, mold capacity;injection volume;mold thickness;core pulling function; blowing system etc. | □ |
| 11 | If the ejector rod is fit for the mold ? | □ | |
| 12 | If the screw has been cleaned ? | □ | |
| 13 | If the mold temperature controller; robot hand;mixing machine; automatic suction machine can work normally | □ | |
| Others | 14 | Print out the part drawng | □ |
| 15 | Prepare measurement tools, such as calipers and other related tools | □ | |
| Mold Trial Process Checklist | |||
|---|---|---|---|
| Part Name: | Project Engineer: | ||
| Mold Number: | Mold Trial Date: | ||
| Process for mold trial | Check | ||
| Mold Installation | 1 | Before loading the mold, 5S clean the machine and check whether the location ring, hot runner interface and other mold appearance are OK. | □ |
| 2 | After confirming that there is no problem with the machine, lift the mold | □ | |
| 3 | Place the mold between the moving and fixed plates and maintain it at a certain height. Connect the water pipes and related interfaces under the mold (if any). | □ | |
| 4 | Align the positioning holes, adjust the level and align the mold into the positioning holes of the machine. After determining the horizontal balance, first slightly lock the two sides of the fixed mold | □ | |
| 5 | Close the operating door, close the mold, and start automatic mold adjustment | □ | |
| 6 | Clamping force adjustment | □ | |
| 7 | After completion, open the operating door and lock the moving and fixed mold platens. | ||
| 8 | Loosen the suspension rope and remove the suspension bridge | □ | |
| 9 | Connect the water pipes and related equipment on both sides of the mold (if any) | □ | |
| 10 | Connect the hot runner plug and preheat the mold in advance | ||
| 11 | Close the operating door and set the mold to a lower temperature to preheat the mold. [Tips] Do not set it directly for final molding. | □ | |
| Mold Open and Close / Ejection | 12 | The ejector rod must be tightened when closing the mold. Otherwise, the slider may be damaged when the mold is opened. | □ |
| 13 | Open the mold and check the parting surface | □ | |
| 14 | Adjust the ejector pin position to zero, adjust the ejector pin strength and speed, and push out numbers. | □ | |
| 15 | Mold opening and closing adjustment (mold opening and closing speed, position, low voltage protection position, monitoring time) 【Tips】*Find the correct speed – start fast when closing the mold ==> slow ==> then slower, and slow first when opening the mold ==> fast ==>Deceleration *Mold clamping slow position switching selects the contact point between the guide pillar and the guide sleeve *The smaller the low-pressure protection pressure, the better *During monitoring The time can be 0.1s longer than the actual mold closing time. | □ | |
| 16 | Check the operating conditions in idling state and adjust to smooth and appropriate conditions. | □ | |
| Parameter Setting | 17 | Enter process parameter data (Follow Data Sheet) [Tips] Please make adjustments within a smaller error range.it is not necessary to follow the exact same values on the process card. For the temperature setting range of various properties of materials, please refer to Related Material Temperature Settings Reference Table | □ |
| 18 | Loading [Tips] Before loading, verify whether the material number of the raw material is correct. | □ | |
| 19 | Return to the turret and spray to prevent mold sticking | □ | |
| 20 | Top the fort and return the fort to zero | □ | |
| 21 | For hot runner molds, hot runner injection must be done before this to ensure that the flow channel is unobstructed. [Tips] *Must use cardboard to cushion the moving station.between the molds to catch the injected material; * before injecting the runner, the temperature can be appropriately raised (after confirming that it is normal, then adjust it back to the normal temperature) | □ | |
| 22 | Semi-automatic production, check whether the injection molding condition is normal, and adjust the injection pressure and injection rate.【Tips】*For smaller parts, it is necessary to Use covers to block both sides of the mold to prevent parts from splashing. *Set the maximum injection pressure according to the actual displayed injection pressure;* | □ | |
| 23 | Find the pressure-holding switching point [Tips] Make the product 95%~98% full, then add pressure-holding. | □ | |
| 24 | Adjust the melt back pressure and screw speed [Tips] *The best measurement time is 65%~75% of the cooling time, and the best time is 75% | □ | |
| Sampling/ Submit for inspection | 25 | Turn on monitoring and set counter | □ |
| 26 | Weigh the product weight at the conversion point and record the weight comparison with the weight at the conversion point on the process card [Tips] PPAP must be collected 2 shots products, 1 shot product are placed in the mold sample bag, and the 1 shot process engineer keeps it for future reference. | □ | |
| 27 | Compare the sample with printed drawings [Tips] If you change the mold core, be sure to confirm the product number | □ | |
| 28 | Send QA inspection [Tips] Send 5 shots of products to QA for inspection, providing a total of 300 shots samples | □ | |
| 29 | After production is completed, collect the last shot product and put it into the mold sample bag before shutting down the machine. | □ | |
| Record /Save | 30 | During PPAP, the project engineer needs to record the process parameters and fill in the blank “Injection Molding Process Parameter Card”, and set the process parameters.The data is sent from the machine to the server host for next setup | □ |
| 31 | If the process has been optimized for formal production, the new process parameters need to be sent from the machine to the host as an update. | □ | |
| Note In Production | 32 | If there is an alarm or shutdown during production and it is necessary to open the safety door, return the turret first to prevent material spraying. | □ |
| 33 | Injection is required when restarting the machine. If the hot runner mold requires hot runner injection to prevent mold sticking | □ | |
| shutdown/ Lower mold | 34 | Stop the machine and open the mold for maintenance | □ |
| 35 | Close the mold and return to the turret; turn off the mold temperature controller and hot runner | □ | |
| 36 | After cleaning the screw, turn off the electric heat | □ | |
| 37 | Loosen the ejector rod [Tips] You must loosen the ejector rod when closing the mold, otherwise the slider may cause the ejector pin to be damaged. | □ | |
| 38 | Open the operation door, install the suspension bridge, and tighten the mold. [Tips] The suspension rope should not be too tight, just shake it slightly. | □ | |
| Lower mold | 39 | Release the pressure plate and remove the mold | □ |
| 40 | Lift the mold and place it in the lower mold area | □ | |
| 41 | Clean the injection molding table,handle the runners and scraps for recylcing | □ | |