《模具的保养》PPT课件.ppt

塑模保養維修講義moldmaintenancehandout,前述preface,重點:判斷力(外觀及組立之公差)Weightbearingpoint:judgment(outwardappearanceandtoleranceofassembly),方法:維修之方法影響到速度和效果Method:methodeffectsthevelocityandresult,對策:“快”“準”“精”,以便能力之提升Countermeasures:“quick”“accurate”“master”,toimproveability,1:使模具保持良好的工作狀態.Keepmoldingoodworkingstate2:保証生產產品品質,減少不良.Ensurethequalityofproducts3:延長模具使用壽命.Lengthentheusagelifeofmold4:避免臨時搶修,提高生產效率.Avoidtemporaryrepairing,raiseproductionefficiency5:達到的目的.Reachthepurposeof“costdown”.,保養目的()/為什么要保養?purpose,Costdown,PURPOSE,適用範圍及責任單位suitablescopeandresponsibilityunit,適用範圍:suitablescope:HPQ/內銷成型廠-塑膠模具.HPQ/insidemarketmoldingfactory-plasticmold2.責任單位:responsibilityunit:模修單位toolmaker成型加工單位moldingdepartment,保養作業內容maintenanceoperationcontents,塑模保養Moldmaintenance,日常保養Dailymaintenance,定時日常保養Timelydailymaintenance,每班保養Everyclassmaintenance,公模面coresurface,母模面cavitysurface,滑塊外側復位杆頂針outersurfaceofslidingblock,resetram,ejectpine,模具外表面outersurfaceofmold,細部保養Detailsmaintenance,定時細部保養Timelydetailsmaintenance,工令結束時Endofworkorder,模仁core模板plate,組立assembly,熱澆道hotrunner,水路清洗cleanwaterroute,清洗排氣系統cleanairsystem,頂針及滑塊ejectpinandslidingblock,日常保養時機dailymaintenanceopportunity(定時保養和每班保養)(timelymaintenanceandeveryclassmaintenance),1.定時保養模面清潔:Timelymaintainmoldsurface生產中之模具-每隔1小時一次.moldinproduction-onetimeevery1hour2.每班保養:everyclassmaintenance生產中之模具-每班保養一次.moldinproduction-onetimeeachclass,細部保養時機opportunityfordetailsmaintenance,1.工令結束theendofworkorder2.定時保養:timelymaintenance:大型外觀件模具-每隔四萬模次large-sizedmold-every40thousandstimesPVC模具-每隔二萬模次PVCmold-every20thousandstimes其它模具-每隔五萬模次.othermold-every50thousandstimes,細部保養時機,常用保養工具maintenancetoolincommonuse,扳手spanner氣槍airguns油石oilstone去漬油eliminatespotoil棉花/棉布cotton/cottoncloth銅錘/銅棒copperhammer/copperclub,模具保養的一般步驟stepsofmoldmaintenance,Separatemold拆模Clearup清理Lubricate潤滑Assembly組立Settoformerposition歸位,一:日常保養dailymaintenance,日常保養主要內容maincontentsofdailymaintenance,公,母模面及排氣槽的清洗cleanthesurfaceofmoldandairvent,1.用氣槍吹乾凈公模面,母模面及排氣槽內的料屑.Cleanthematerialtriflesofmoldsurfaceandairventbyairgun.2.用沾去漬油的棉布擦拭乾淨公.母模面Cleanmoldsurfacewiththecottonclothsoakedeliminatespotoil.,3.用氣槍吹乾凈排氣槽內的料屑.Cleanthematerialtriflesinairventbyairgun.,one,1.用氣槍吹乾凈導套、頂針、滑塊等部位cleanbush、ejectpineandslidingblocketc.withairgun,導套、頂針、滑塊的清洗Cleanbush、ejectpine、slidingblock,2.用沾去漬油的棉布擦拭乾淨Cleanitwithcottonclothsoakedeliminatespotoil.,2nd,3.給公模導柱、复位桿、頂針、滑塊等部位抹上一層潤滑油Addlubricantforguidepost、resetram、ejectpineandslidingblockofcore,4.給母模導柱、導套等部位抹上一層潤滑油Addlubricantforguidepostandbushofcavity,5.從頂針固定板間隙噴頂針潤滑油Spurtlubricantonejectpinefromthespaceofpinesstableplate,3rd,模具外表面的保養maintenanceofmoldsoutersurface,用噴槍吹模具表面上的粉塵,使其保乾凈Blowthedustofmoldsurfacebyairgunandkeepitclean,end,NOTICES,日常保養注意事項mattersneedingattentionindailymaintenance,一.保養前要注意確認:Confirmbeforemaintenance:射座退出,料管內無料,液壓馬達關閉.Injectionseatfallsback,nomaterialinpipe,motorisoff.二.保養時注意:Attentionsinmaintenance:1鏡面和噴砂紋面不能用棉布擦拭;Dontcleanmirrorsurfaceandlinessurfacespurtedsandswithcottoncloth.2擦拭過程不能碰傷咬花面和鏡面;Textureandmirrorsurfacecantbedamagedincleaningit.3禁止在模面直接噴射潤滑油,使模面殘留油漬.Forbidtodirectlyspraylubricantonmoldsurface.Makesurethereisnooilsludgeremainedonmoldsurface.保養后注意:Attentionsaftermaintenance:成品外觀有無異常,模面有無損傷等不良,登記結果于記錄表.Confirmthereisunusualofouterappearanceornot,thereisinjuryanddefectetc.onmoldsurfaceornot.Fillthedataonrecordlist.,二:細部保養Detailsmaintenance,細部保養主要內容Maincontentsindetailsmaintenance,因各模具的結構不同,保養時應依次對模具的模仁、模板、頂針、滑塊、鑲塊、水路、導柱等作相應保養Docorrespondingmaintenanceforcore、plate、ejectpine、slidingblock、embeddedlump、waterroute、guidepostinturnbecauseofthedifferenceofmoldsstructure.下面以電鍍件為例,對細部保養作例圖說明(因為電鍍件對油污敏感性要求比一般塑件要高.因此,清理保養更加徹底.)Useelectroplatedpartasexampletointroducedetailsmaintenance.(Themaintenanceofelectroplatedpartismorethoroughthanothersbecauseitsrequestsofgreasydirtsensitivityismorethanothers.),contents,從拆模開始.Startfromseparatingmold.,首先,用天車將模具放在整洁的工作台面上,准備好拆模工具.Setmoldontheclearworkingtablebyworkshoptravelerfirstlyandpreparethetools.然后,將公模與母模分開,准備拆公模Thenseparatethecoreandcavity,preparetoseparatecore.,第一步,公模底板上與模框連接的螺栓卸下然后將公模固定板和模腳一起拉出放于一旁Separatethescrewsthatjoincoresbaseplatewithmoldframethenpulloutthestableplateandmoldfoottogether.注意點mattersneedingattention:對于大模具,直接拉出比較困難,可以先用拔模器拔掉底板上的導柱.拉出時要平穩,防止折彎折斷型芯.所卸螺釘導柱等放在預備好的工作盤中.Itisdifficulttopulloutthebigmold.Hadbetterpullouttheguidepostonthebaseplatefirstly.Pullitsmoothlytoavoiddamagingthecore.Mustsetthescrewandguidepostinthepreparedplate.,將,頂出底板上的螺釘卸下拆出頂出底板Separatethescrewofejectbaseplatethenseparateit.注意點:Mattersneedingattention:如果復位彈簧是在導柱中內置的,卸螺釘時應該先卸對角,以免頂出板卡死,不易脫出.Separatethescrewsonthediagonallinefirstlytoavoidthatejectplatewillbejammediftheresetspringisinbuiltinguidepost.,再將,頂出板從模板中脫出放于安全的地方防止踫傷頂針和斜梢Pullouttheejectplatefrommoldplateandsetitonthesafeplacetoavoiddamagingejectpineandslantingpin.注意點:Mattersneedingattention:有斜梢時要先卸掉斜梢后的滑塊(注意編號).拉出時要平穩,不要踫傷頂針或斜梢.Separatetheslidingblockonthebackofslantingpin(payattentiontotheNO.)ifthereisit.Pulltheslidingblocksmoothly,dontdamageejectpinorslantingpin.,此時要將,將模板上的模仁固定螺栓拆下Separatethescrewfixedcoreonthemoldplate.用兩個較長的螺釘鎖入模仁對角并交替敲擊兩個螺釘以取出模仁Settwolongerscrewinthediagonalofcorethenhitthesetwoscrewbyturnstopulloutthecore.注意點:Mattersneedingattention:如果模仁生銹太緊,可以先用防銹油浸潤一會.模仁取出后要注意保護好成型面.Soakthecorewithagainstrustoilifthecorewithrust.Payattentiontoprotectthemoldingsurfaceafterpullingoutthecore.,然後,將模仁上的入子依次取出,對于配合比較緊不易取出的入子可以用小銅棒輕輕敲出.Takeoutthecorepinsatlast,tapoutitlightlywithsmallcopperstickifthecorepinassembledtightly.注意點:Mattersneedingattention要看清入子、鑲塊、模仁對應部位是否已經標示,如果沒有,要用磨棒在非成型面上刻上,以免混淆.Confirmthecorepin、embeddedlump、corearemarkedornot.Ifnot,markitwithgrindstick.,最後,開始公模部分清洗作業Startthecleanoperationofcore,第二步,Cleanwaterproofringandwaterroute注意點:Mattersneedingattention要檢查防水圈是否良好,對于已經損坏的要及時更換.防水圈一定要放在工作盤中以免丟失.Inspectthewaterproofringsaregoodornot.Replacethedamagedringstimely.Setthewaterproofringsintheworkingplate.,防水圈及水路清理,Cleantherustdirtofcoresurface用油石將模仁外表的銹污清除.Cleantherustdirtofcoresurfacewithoilstone.注意點:Mattersneedingattention:檢查水塞是否密閉良好,對于損坏的水塞及時更換.Inspectthewaterstopperisairtightcorrectlyornot,replacethedamagedwaterstoppertimely.,模仁外表的銹污清除.,Cleartheholeofembeddedlump用小油石裝有鋼刷的電轉除去鑲塊孔中的銹污.Cleantherustdirtintheholeofembeddedlumpwithsmalloilstoneandelectricdrillassembledsteelbrush.用小油石(320#以上)除去鑲塊表面的銹,并用噴槍清洗,吹乾.Usesmalloilstone(over320#)tocleantherustonthesurfaceofembeddedlumpandcleanitwithspraygun.,頂針孔或是小型芯孔內的銹污也可用頂針或型芯來清理,只要用相應的頂針或者小型芯在孔內反复抽動几次即可.Cancleantherustdirtinejectpinholeorsmallholeofthecorewithejectpinorcorepin,justusethecorrespondingejectpinorsmallcorepintotwitchseveraltimesinthehole.,頂針孔及小型芯孔清洗,用去漬油對模仁和模框噴洗乾淨后吹乾,尤其是模仁孔內部一定要清洗乾淨.Spurtcleaningoiloncoreandmoldframetowashitthendryit,especiallycleantheholdofcore.注意點:Mattersneedingattention:清理的順序一般是先側面,再正面,再反面,最后又正面.Ingeneralthecleanorderisflankfirstly,thenfront,thenreversesideandfrontagainatlast.,模仁和模框清洗,開始公模部分組裝Starttoassemblethecore組裝時注意導柱入子等清潔,潤滑Payattentiontocleanandlubricateguidepostandcorepinetc.whenassemblingit.,接下來,Assembleembeddedlumpandcorepin用乾淨的手裝上鑲塊及入子.Usecleanhandstoassembleembeddedlumpandcorepin.注意點:Mattersneedingattention:注意鑲塊入子的編號要和模仁上保持一致,裝入后要檢查是否裝正确.Confirmtheno.ofembeddedlumpandcorepinissameasthecore,inspecttheassemblyiscorrectlyornot.,裝上鑲塊及入子.,將模仁裝入裝好防水圈的模框中,并用螺釘緊固好.Assemblecoreinthemoldframeinstalledwaterproofringsandfixitwithscrews.,裝防水圈及模仁,用乾淨的布條將頂針及導柱擦乾淨,在導柱上塗上少許白油潤滑.再將頂出板裝入公模板,并將所有的頂針依次裝好.Cleanguidepostandejectpinwithcleancloth,smearalotofwhiteoilonguideposttolubricateit.Theninstallejectplateincoreplate,assembleallejectpininturns.注意點:Mattersneedingattention:注意頂針是否裝反,對于有斜梢的模具還要檢查斜梢是否裝正确.Inspecttheinstallingconditionofejectpinandslantingpin.,裝頂針及公模板,用乾淨的布條對頂出底板稍作擦拭,再將頂出板和頂出底板合好并用螺釘緊固好.Slightlycleanejectbaseplatewithcleancloththenassembletheejectplatewithbaseplateandfixitwithscrews.注意點:Mattersneedingattention:頂出底板裝入時要平穩,否則容易使裝好的頂針震出.鎖螺釘時先鎖對角.鎖好后最好再次檢查頂針等是否裝正确.Installejectbaseplatesmoothly,otherwisetheinstalledpinwillbeshakenout.Installthescrewsondiagonallinefirstly.Atlastinspecttheinstallconditionofejectpinetc.,頂出板和頂出底板組立,用油石將模腳和底板上的銹除去并用布擦乾淨.再在導柱上塗上白潤滑油.Useoilstonetocleantherustonmoldfootandbaseplateandcleanitwithcloth.Thensmearwhitelubricantonguidepost.,導柱潤滑,將模腳及公模底板推入合好,并用螺釘緊固好.Assemblemoldfootandcorebaseplateandfixitwithscrewscorrectly.注意點:Mattersneedingattention:對于有型芯的底板要注意檢查型芯是否轉到位,确認后用小螺釘緊固好.Makesurethelocationofcorepiniscorrectifthecorehascorepin,thenfixitwithsmallscrewafterconfirmingit.,模腳及公模底板組立,用乾淨的布條擦拭模面,除去模面上所粘的塑膠、屑等雜質.Usecleanclothtowipemoldsurface,getridoftheplastics、triflesetc.impurities.裝好后,應該將模具放倒,用天車吊起頂出板,以檢查頂出和復位是否順利.Placemolddownafterassembling,useworkshoptravelerhanguptheejectplatetoinspectitgoesforwardandfallsbacksmoothlyornot.,模面清潔,該模具的公模就保養完成了!Nowthemaintenanceofcoreisfinished!,用同樣的方法保養母模Usesamemethodtodothemaintenanceofcavity,至此,接下來,保養作業注意事項mattersneedingattentioninmaintenance,1.模修人員應將保養結果及模況記錄在上.Toolmakershouldtakedownmaintenanceresultandmoldconditioninthe.2.模修單位應每月底依據生產計劃制定次月之模具細部保養計劃表,並經主管單位核準並作為模具保養作業之參考.Toolmakerdepartmentshouldworkoutdetailsmaintenanceplanfornextmonthattheendofmonthaccordingtotheproductionplan,whichmustbeapprovedbysupervisorthenuseitasreferenceformaintenance.3.模修單位應每日稽核生產中模具已生產模數,以落實定時保養制度Toolmakerdepartmentshouldcheckthenumberofthemoldusedtimes,soastocarryouttimelymaintenanceplan.4.模修單位應將模具實際執行細部保養之日期記錄在模具細部保養計劃表里,以方便保養作業之追蹤.Toolmakerdepartmentshouldfilltheactualdateofdetailsmaintenanceinthemolddetailsmaintenanceplaninordertofollowit.5.在模具細部保養時,如出現模具異常,需要維修時,參考執行.Ifthereareproblemsofmoldwhendoingmolddetailsmaintenanceandmoldneedrepair,doitreferringto.,以上是普通二板模具一般保養內容,對三板模具和PVC料等特殊模,除以上常規保養以外,還另作要求.Above-mentionedcontentsareaboutthegeneralmaintenanceofcommon2platesmold,theremustbemorerequestsofthemaintenancefor3platesandPVCmold.,例:Forexample:,對PVC模ForPVCmold除常規作業外,每日需用專用中和劑(SPRAYNO.816)均勻噴洗母模面和排氣槽一次,待3分種酸鹼中和后,用氣槍吹乾凈模面,詳細要求參考:Spurtneutralizerforaspecialpurposeoncavitysurfaceandairvent1time,after3minutesuseairguncleanmoldsurface.Detailedrequestaccordingto:,例:Forexample:,對客戶有特殊要求之模具除常規作業外,依之要求進行保養,其重點在清潔与潤滑作業.Maintainthemoldthatcustomerhasspecialrequestaccordingtoexceptstandardoperation,theweight-bearingpointiscleaningandlubricating.,常用清模作業英語MOLDCLEANINGPROCEDUREENGLISH,一.准備清模工具:噴槍,氣槍,手電鉆,去漬油,砂紙,碎布,油石,煤油,圓銅刷,棉花.Preparemoldcleaningtools:Enginecleaner,Airgun,electrichanddrill,Cleaningoil,brokenClothSandpaper,Oilstone,Kerosene,Roundcopperbrush,Cotton.二.用油石將公母模入子的油污清除.(400#油石)Useoilstoneandkerosenetopolishdirtontheinserts,whichisfixedinmoldcavityorcore.三.用油石清除排氣槽內瓦斯.(400#油石)Useoilstonetopolishgasoff,whichtrappedinair-vents.四.用噴槍吸去漬油清洗模仁入子,用棉花擦乾淨.Usesprayguntocleansolventliquid,washmoldinserts,wipeitoffwithcotton五.拆出水塞將鉆頭裝在手電鉆上,清除公母模仁水孔內污垢.takeapartthewaterplugofmold,Useelectricdrilltocleanthecoolingchannelinmoldcore/cavity.六.用圓銅刷清洗公模仁內頂針孔,斜梢孔,用去漬油清洗再用棉花擦拭乾淨.Useroundcopperbrushtocleanejectorhole,lifterholeinthecoreofmold.Usesolventliquidtocleanthem,then,wipethemwithcotton.七.用砂紙拋光頂針,去除頂針毛刺.Usesandpapertopolishejectorpin,removetheburronejectorpin.八.用油石清除模板，頂針板的銹斑及油污.(大磨石)Useoilstonetopolishoffdustanddirtonmoldboardandejectorplate.,附1:,九.用小電鉆清洗模板上水孔內污垢.Usesmalle