The methods to ensure and improve the processing accuracy of injection molds can be roughly summarized as the following:
1. Reduce raw error
Improving the geometric accuracy of the machine tools used in parts processing, improving the accuracy of fixtures, measuring tools and tools themselves, controlling the force of the process system, thermal deformation, tool wear, deformation caused by internal stress, and measurement errors are all direct reductions in original errors. In order to improve machining accuracy, it is necessary to analyze various original errors that cause machining errors, and take different measures to solve the main original errors that cause machining errors according to different situations. For the processing of precision parts, the geometric accuracy, rigidity and control of thermal deformation of the precision machine tools used should be improved as much as possible; for the processing of parts with formed surfaces, it is mainly how to reduce the shape error of the forming tool and the installation error of the tool.
This method is a basic method widely used in production. It is to try to eliminate or reduce these factors after identifying the main factors that produce processing errors.
2. Compensate the original error
The error compensation method is to artificially create a new error to offset the original error in the original process system. When the original error is negative, the man-made error takes a positive value, otherwise, take a negative value, and try to make the two equal in size; or use one original error to offset another original error, and try to make the two equal in size , in the opposite direction, so as to achieve the purpose of reducing machining errors and improving machining accuracy.
3. Transfer the original error
The error transfer method is essentially to transfer the geometric error, force deformation and thermal deformation of the process system. There are many examples of error transfer methods. For example, when the accuracy of the machine tool does not meet the processing requirements of the parts, it is often not to blindly improve the accuracy of the machine tool, but to find a way from the process or the fixture to create conditions so that the geometric error of the machine tool can be transferred to the aspect that does not affect the machining accuracy.
4. Average raw error
In processing, due to the existence of errors in the blank or the previous process, the processing error of this process is often caused, or due to changes in the properties of the workpiece material, or changes in the process of the previous process (such as canceling the original cutting process after the blank is refined) ), causing a large change in the original error. To solve this problem, the method of grouping to adjust the average error is adopted. The essence of this method is to divide the original error into n groups according to its size, and the blank error range of each group is reduced to the original 1/n, and then adjust the processing according to each group.
5. Average raw error
Grinding process is often used for shafts and holes that require high matching accuracy. The grinding tool itself does not require high precision, but it can perform micro-cutting on the workpiece during relative movement with the workpiece, and the high point will be gradually worn off (of course, part of the mold is also worn off by the workpiece), so that the workpiece can reach a high accuracy. This process of friction and wear between surfaces is a process of continuous error reduction, which is the error averaging method.
6. In situ processing method
In processing and assembly, some precision problems involve the relationship between parts or components, which is quite complicated. If you blindly improve the precision of parts and components themselves, sometimes it is not only difficult, but even impossible. If you use the in-situ processing method (also known as self- Processing repair method), it may be very convenient to solve the seemingly very difficult precision problems. The in-situ processing method is often used in the processing of mechanical parts as an effective measure to ensure the processing accuracy of parts.
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