May 2010 Archives

#043 On the 400th Issue of These Courses

We wish to send you all readers a message on the event of the 400th issue of this series of courses.

We have been issuing this series of technical courses on plastic molds for about seven years now. Perhaps this is the first time in the world that such internet contents related to the plastic molding technology have been continuing for so long with uploading frequency of once a week. The contents of these courses were left to the free will of the author, and while they covered a wide range of topics such as molding materials, steels, strength calculations, thermodynamics, odd but general knowledge, or technology trends, etc., perhaps it was difficult for the readers to read because of the succession of rambling topics, and the author is also contrite feeling that it might have been hard for the readers to keep up with the topics.

At the time that series of courses was started, the economies in Japan and in the world were healthy, and it was not possible at all to predict that an economic shuddering such as the present would ever happen. However, looking back, over the past seven years, the environment surrounding the molds for plastic molding have definitely changed although gradually, such as advances in computers, progresses in machine tools and machining, appearance of new plastic materials, etc. Although it is this author's opinion that sudden changes such as economic fluctuations will continue to affect in the future the mold technology and it is certain that there will be gradual and definite changes.

Even under such wild economic fluctuations such as the present one, there are mold manufacturers who are extremely busy. These companies have one thing in common among all of them, that is, these companies have been steadily and definitely carrying out research and technology development from some time before. Although it is thought that technology development and research require large sums of money, it is the author's opinion that irrespective of whether small or large sums of money are spent, the crucial factor is whether or not the topic paid attention to is the right one or the wrong one.

In addition, how fast the actions are taken and the acceleration of actions is very important. One of the most important factors that obstruct technology development is that decision making and acceleration of activities are stagnant. In particular, in large companies, there is a terrible phenomenon in which the wasteful time spent on indirect work such as drawing the conclusions, preparing the documents for decision making, getting them signed by various parties concerned, circulating preliminary documents for decision making and getting consensus, etc., delay research and development by putting them on the back burner. On the other hand, in a medium scale or small scale company, many opportunities come to the people if experiments and verifications are made at an accelerated pace.

Although these days it is possible to reach easily 90% of the design and fabrication of molds using publicly available information and technology, the approaches for coming closer to 100% become the differences in technology. The strength to meet the remaining 10% becomes the competitive strength of the company. It is not sufficient merely to compete about the speed of reaching up to 90%. We wish that you become technicians who compete abut how quickly and definitely the completion of the final 10% is made.

Enhancing this technology depends on how highly reliable technical information is gathered. Prototype preparation and experiments are a typical example. It is also very important to build up the ability to spot the real thing from among a lot of technical information that is going around. Since the range and depth of the information given to all of you readers through these courses are limited, we will continue to send the maximum possible information within the permissible range.

Further, we have also heard that there are many Japanese readers who are active in foreign countries. We wish to touch upon the technological trends in Japan at suitable times.

Although this time the discussion was wandering about various aspects, the author's wish is only that all of you will continue to manufacture products that support the happy lives of people all over the world using expert and refined mold technology. As a mold technologist, the author wishes to carry out the pursuit over one's own entire life.

#042 Filing Work

Correct work procedure is very important for carrying out filing work appropriately. The key points of filing work are the following.


1.Posture during filing

When filing, first the posture should be correct. Otherwise, it will not be possible to do accurate and precision work.

(1)Adjust the height of the work to be at the height of your elbows and fix it firmly using a vice, etc.

(2)Stand in front of the work and place your body so that the tip of the file is at the center of the work.

(3)Place your right foot along the center line of the work, and tilt the right foot so that is at an angle of 70° to 80° to the center line.

(4)Open your left foot and step it forward in the direction of the work by half a step, and place the step so that the tip of the foot is about 200mm to 300mm distant from the work.

(5)Relax the arm muscles, and make fine adjustment of the body and legs so as to be in a position where the file can be moved forwards and backwards lightly with respect to the work.


2.Filing work

There are three types of filing work.

(1)Straight movement method
 This is the most common method of moving the file in the straight forward direction.
 The finished surface becomes clean and neat.

(2)Oblique movement method
 This is the method of moving the file in a direction that is inclined towards the left.
 This method is suitable for rough scraping because the amount cut is large.

(3)Combined movement method
 This method is suitable for long objects with small widths.


3.Removing the filing dust from the file

Since the cut dust gets clogged in the grooves of the file, frequently the grooves of the file must be cleaned during filing. Brush away the fining dust clogged in the grooves of the file using a wire brush or the dust can also be blown off using a compressed air blast. Another technique of preventing clogging of the file grooved by filing dust is to coat the file before working using charcoal or chalk.

#041 Hand Finishing Work

While the parts of plastic molds are mostly prepared by machining carbon steels, after the machining work is completed, final adjustment by hand finishing will be necessary to a small or a large extent. In recent machining operations, the NC data are supplied easily by CAD or CAM, and it has become possible to carry out relatively easily the machining operations at high accuracies due to the development of CNC machines or tools. However, it is necessary to carry out the final finishing by experienced and skilled hands, and since their automation is difficult, mastering this requires considerable expertise.

The details of hand finishing work are given below.

Details of hand finishing work:
Filing
Lapping
Assembling
Scraping
Marking
Drilling
Reaming
Thread cutting
Slicing
Shaving


Measuring instruments used:
Calipers
Micrometer
Dial gauge
Block gauge
Pin gauge
Metal scale
Long metal scale
Calipers
Metallurgical microscope


In order to learn hand finishing, the most definite method is to learn by working with an experienced technician having an accurate knowledge (a person having a special technician certificate or a Grade 1 technician certificate). Although finishing can be done to some extent by looking at and copying an experienced technician, if it is not possible to work with the correct knowledge and using the correct procedure, it is difficult to carry out precision work or work that is highly paid.

 

#040 Linear Expansion Coefficients of Materials

Although materials based on carbon steels are used for molds, some times non-ferrous metals of non-metallic materials are used for molds for the purpose of thermal insulation. At the time of assembling molds, although it is possible to adjust the dimensions at room temperature, since the temperature is increased and decreased during injection molding, the parts tend to undergo thermal expansion (either linear expansion or volume expansion). If the margin for expansion is not considered, the operation of the mold can become bad or the parts can break. The following data is available for the linear thermal expansion coefficients of materials.

Material nameLinear thermal expansion coefficient: Unit: x10-6, 1/K-1, 293K = 20°C
S55C11.7
SKD1111.7
Pre-hardened steel11.5
18-8 stainless steel17〜18
Nickel steel0.9
Iron11.8
Nichrome18
Ultra Invar−0.01
Duralumin23
Copper16.5
Brass18〜23
Bronze17.3
Titanium8.2
Silver18.9
Gold14.2
Platinum8.9
Tin20
Silicon2.6
Zirconia5.4
Diamond1.0
Carbon3.1
Tungsten4.5
Porcelain6.8
Marble3〜15
Brick3〜6
Glass9
Quartz glass0.5
Concrete7〜13
Acrylic resin70〜90
Bakelite21〜33

About this Archive

This page is an archive of entries from May 2010 listed from newest to oldest.

April 2010 is the previous archive.

June 2010 is the next archive.

Find recent content on the main index or look in the archives to find all content.