Understanding Mold Saving

Mold saving refers to the process of making fine adjustments to a mold that does not meet design accuracy during assembly. When a mold fails to produce parts with the required precision, mold saving is essential to correct abnormalities and achieve the desired accuracy.

The Mold Saving Process

The process of mold saving must adhere to standard operating procedures. Here’s a detailed look at the essential steps involved:

Initial Cleaning:

Kerosene Cleaning: Start by cleaning the new mold thoroughly with kerosene. This removes oil stains and any other contaminants that may affect the mold’s surface integrity.

Alcohol Wiping: Follow up with wiping the mold using alcohol. This step ensures that the mold surface is completely clean and free from residue, providing an ideal surface for the subsequent steps.

Sequence of Mold Saving:

Addressing Critical Areas First: Begin by focusing on the bottom corners, bone pits, and dead corners of the mold. These areas require precise attention to ensure the mold’s functionality and integrity.

Handling Protrusions and Large Flat Areas: Once the critical areas are addressed, proceed to handle protrusions and large flat areas of the mold. These parts may require different techniques or tools to achieve smooth and consistent surfaces.

Module Handling: For molds with modular components, ensure that each module is properly handled. This includes rough or fire polishing along the edges of individual die openings before clamping all modules together for final smoothing.

Quality Checks: Throughout the mold saving process, perform regular quality checks. Use tools like red lead to verify surface uniformity and ensure there are no discrepancies that could affect the molding process.

Final Touches: Use copper or bamboo tools with sandpaper to make final adjustments. Pay attention to maintaining even surfaces and avoiding over-polishing, which can alter the mold’s design and functionality.

Handling Embedded Modules:

Embedded modules in multiple pieces require careful handling to ensure uniformity and smoothness in the final product. Here’s how to tackle this process effectively:

1.Punching Rough Patterns:

Begin by punching rough or fire patterns along the edges of individual die openings. This initial step prepares the modules for further smoothing and refinement.

1.Clamping for Smoothing:

Ensuring uniformity and smoothness in mold surfaces is crucial to prevent defects in the final products.

Checking for Unevenness:

Ensuring uniformity and smoothness in mold surfaces is crucial to prevent defects in the final products. Follow these steps to detect and address any unevenness effectively:

Utilizing Flat Steel Sheets:

Use flat steel sheets in conjunction with red lead to check for uneven surfaces. This method provides a visual indicator of any irregularities that may affect the mold’s performance.

Inspecting for Mold Spores After Grain Removal:

After the initial removal of rough grains from the mold surface, it’s crucial to conduct a thorough inspection to ensure uniformity and smoothness, similar to a mold cleanup process to prevent mold exposure, especially where mold spores land and start growing. Here’s how to effectively inspect and manage the surface:

1.Thorough Inspection：

Carefully examine the entire mold surface under adequate lighting conditions. Look for any remaining rough spots or irregularities that could compromise the mold’s performance.

2.Addressing Discrepancies:

If unevenness or imperfections are detected, take immediate corrective action. Use appropriate tools and techniques to smooth out these areas to prevent potential issues such as sticking or dragging during the molding process.

Protecting Non-Saving Areas to Prevent Mold Growth:

Preserving areas of the mold that should not undergo the saving process is essential to maintain its integrity and functionality, similar to mold prevention techniques. Just as mold can grow above ceiling tiles due to roof leaks or insufficient insulation, addressing any moisture problem in these areas is crucial to prevent mold growth and ensure the mold’s longevity. Follow these steps to safeguard non-saving areas effectively:

1.Application of Double-Sided Adhesive Tape: Apply double-sided adhesive tape to cover and protect designated areas of the mold. This ensures that only specific regions receive the necessary treatment with sandpaper, minimizing the risk of unintentional alterations to other parts of the mold. Addressing any moisture problem in these areas is crucial to prevent mold growth and ensure the mold’s longevity.

Sandpaper and Tool Handling:

Proper handling of sandpaper and tools is critical to achieving precise mold-saving results, much like the careful techniques used in mold removal. Here’s how to manage these materials effectively:

1.Choosing the Right Tools:

Use copper or bamboo tools to press the sandpaper against the mold surface. The choice of tool should correspond to the shape and size of the area being worked on to avoid inadvertently affecting adjacent parts of the mold.

2.Matching Sandpaper Area:

Ensure that the size of the sandpaper matches the area being treated by the tool. This practice prevents excess sandpaper from overlapping into non-saving areas, maintaining the mold’s intended shape and surface quality.

Shaping Tools for Molds:

The precise shaping of tools used in the mold-saving process is vital to ensure the mold’s surface is accurately treated and maintained. Here’s how to properly align tools with the mold’s surface:

1.Aligning Tool Shape with Mold Surface:

The tool’s shape must correspond to the specific area of the mold being treated. For flat surfaces, utilize flat tools to ensure even and consistent pressure. For curved or rounded surfaces, opt for round tools that can conform to the contours without causing any distortions or unevenness.

2.Tool Selection:

Select tools made of appropriate materials like copper or bamboo. Flat bamboo tools are ideal for flat areas, while small or round bamboo tools are best suited for processing curved or intricate surfaces. This careful selection helps in maintaining the mold’s integrity and achieving a smooth finish

Avoiding Deep Holes:

Preventing the formation of deep holes or gouges during the mold-saving process is crucial to avoid a mold problem and maintain the mold’s functional surface. Here’s how to handle this aspect effectively:

Additionally, managing excess moisture during the process is essential to prevent mold growth and ensure the mold’s integrity.

1.Correct Angle Application:

When using sandpaper or oilstone, apply it at a 15 to 30-degree angle relative to protruding positions on the mold. This angled approach helps in distributing the pressure more evenly and prevents the creation of deep holes next to these protrusions.

2.Consistent Technique:

Ensure consistent technique and pressure while striking the sandpaper or oilstone. This consistency is key to avoiding unwanted deep holes that could affect the final product’s quality and appearance.

Oil Stone and Sandpaper Use:

Proper use of oil stones and sandpaper is essential for achieving the desired surface finish on the mold, ensuring that no mold spores remain. Here’s how to manage these materials correctly:

Ensuring adequate ventilation and fresh air in the working environment can also help in preventing mold growth and maintaining the mold’s surface quality. Consulting a mold remediation expert can provide additional insights into maintaining a mold-free environment.

1.Using Firewater for Rough Oil Stones:

For rough oil stones such as 150#, 180#, and 220#, use firewater (kerosene) to facilitate the grinding process. The firewater helps to keep the oilstone surface clean and prevents it from clogging with debris, ensuring effective material removal.

2.Dry Use for Lighter Stones:

For lighter oil stones, typically 320# and above, use them dry. The finer grit of these stones does not require lubrication and can achieve a polished finish without the need for additional fluids.

3.Manual Adjustments and Environment:

When making manual adjustments, consider the working environment and the specific materials in use. Ensure that the work area is clean and free from contaminants that could affect the mold’s surface. Adapt techniques as necessary to account for environmental factors and material properties to achieve the best possible results.

Removing Fire Patterns:

1.Detecting Fire Patterns:

Copper Acid Application: To detect fire patterns, apply copper acid evenly on the mold surface using a brush. Let it sit for 3-5 minutes.

Cleaning and Inspection: After the waiting period, wash the mold with water and dry it with an air gun. Inspect the surface for shiny spots, which indicate the presence of fire patterns.

2.Removing Fire Patterns:

Using Oilstone or Sandpaper: Use an oilstone or sandpaper to remove the detected fire patterns. Work methodically to ensure all patterns are addressed.

Repeating the Process: Repeat the application of copper acid and the cleaning process until the mold is completely free of fire patterns. The mold surface should appear consistently darkened after the copper acid test, indicating the absence of fire patterns.

Handling Copper Males:

1.Focusing on Protruding Parts:

Selective Saving: When handling copper males, concentrate on the protruding parts that need saving. Avoid unnecessary work on concave areas to prevent damage or alteration of the mold’s intended design.

2.Protection During Fixture Placement:

Using Soft Materials: Place soft materials, such as cloth or paper, under the copper male when positioning it on fixtures. This prevents scratches and other damage during movement or setup.

Final Sanding and Polishing:

1.Preparing for Final Polishing:

Using High-Grit Sandpaper: Utilize sandpaper with a grit rating of 400# or higher for the final polishing stages. This ensures a smooth and refined finish.

Ensuring Clean Environment: Maintain a clean working environment to prevent contamination during the polishing process. Cleanliness is crucial for achieving a high-quality surface finish.

2.Optimizing Sandpaper Use:

Prepping Sandpaper Rolls: Before cutting sandpaper, rub the rolls to remove any slightly coarse particles. This step minimizes the risk of introducing new rough spots during polishing.

Reporting Abnormalities:

1.Immediate Reporting:

Supervisor Notification: If any abnormalities or issues are detected during the mold-saving process, report them immediately to the supervisor. Prompt reporting ensures that problems are addressed quickly, preventing further complications.

2.Completion and Final Check:

Manager Notification: Once the mold-saving process is complete, notify the manager. Ensure that the mold undergoes a thorough final inspection before it is handed over. This step guarantees that all aspects of the mold are checked and verified for quality and accuracy.

Conclusion

Mold saving is a critical process in ensuring molds meet the precise design specifications required for high-quality production. By following meticulous steps and maintaining a clean and precise working environment, the accuracy and reliability of molds can be significantly enhanced. For more information or assistance with your mold saving needs, contact Sino-Mold Industrial Co., Ltd. at sales02@sino-mold.com.

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