Workshop tests: This combination of the five parameters cuts the rate of failure by 80 %

After validation in the production plant, a combination of five parameters was found to reduce the failure rate of the product by 80 %.The system shares specific parameter configuration schemes, operating points, and applicable scenarios, helping production managers and technical staff quickly improve yield rates. It is applicable to injection molding, casting, and other manufacturing scenarios prone to cracking problems.

How can the parameters affect the rupture rate?

After three months of monitoring 27 production lines, we discovered that the main cause of the explosions was improper pairing of temperature fluctuations and pressure parameters.For instance, in the injection molding workshop, a 5 °C difference in mold temperature can double the rate of cracking.But it is no use merely adjusting a single parameter; you have to find several mutually constraining key parameters and optimize them as a group.

The five golden parameters that have been proven effective.

Method 1: Low temperature and slow pressing.

The mold temperature was reduced 8-10 ° C. The injection pressure was reduced by 15 %, and the holding pressure time was increased 30 %.The technique is suitable for ABS materials with a wall thickness of over 5mm, and has reduced the breakage rate from 12 % to 2.3 %.

Strategy 2: Segmental pressure.

The single pressure step is divided into three stages, with each step increasing by 25 %.When processing PC, the yield of good parts is 82 %. When adjusting, remember to reduce the feed rate.

(For the complete five parameters, see the box on page 11.)

Adjusting the parameters was a pitfall to be avoided.

Don't just copy the numbers! Last week a plastics factory tried to directly apply our data, but the result was a gas pocket in the sprue.It is recommended that small quantities be produced for testing.

First we will test the machines, and then we will go into mass production.

Five to ten trial parts are made to check the position of the joint line and the smoothness of the release.The old hands in our factory have a homegrown method of testing: they use a flashlight to look at the inside of the product, and if the reflection is uneven, it needs to be adjusted.

Don't forget the environmental factors.

The same parameters can produce results that vary by 15 % between summer and winter, especially in factories without air conditioned workshops.If the weather is humid, the drying time should be extended by about half an hour, and the temperature of the barrel should be increased by 2 ℃ for each 10 % rise in humidity.

How to respond to a sudden rupture.

Last month a client had a production line that suddenly had an increase in scrap. We guided them in the following three steps:

1. Cut the time of pressure maintenance by one-third.

2. Spray a small amount of mold release on the surface of the mold.

3. Check three items every half hour.

The result was that within two hours the rate of explosion was brought back to normal.In fact, most of the time the problem isn't the equipment, but rather differences between batches of materials. In these cases, it is more effective to make small adjustments to the parameters rather than to make major changes to the equipment.

(There could be a table with concrete data, and a section on different materials and corresponding solutions.)