Definition of inserts
Insert is a mold term, also called insert, and also called into the sub, called differently. The mold specifically refers to the mold accessories used to be embedded in the mold core. The inserts can be square, round, and sheet-shaped, and like all mold accessories, the requirements for precision are very high. Generally, there is no finished product, and it is customized according to the needs of the mold.
Types of inserts: Pins, blocks, posts, rings, etc.;
Material: SKD61, SKH51, ASP23, SKD11, etc., or the same as the corresponding mold core material;
Hardness: above 50HRC;
Standard accuracy: ±0.01mm, depending on the specific mold accuracy requirements.
In terms of processing efficiency. Some large molds are inlaid into several small pieces and processed separately, which can save time. In general, there are two types of inserts, through and blind. For some smaller inserts, Y-CUT wire cutting can be used, and the changing table can be used for positioning. For some larger inserts, such as those above 60X60, blind inserts can be adopted, with screw hanging. The processing is relatively difficult, but the strength of the mold is guaranteed.
What is the need for inserts
1. Save mold material
We all know that when the mold is set, it is determined by a piece of steel with a relatively regular shape, but the material of the front and rear molds is determined by the highest point, so whether it is the front mold or the back mold, if one place is relative to other places It is relatively high. In this place, the height of the mold core can be reduced by making inserts, so that the fixed material of the mold core does not need to be set so high, thus saving the mold material.
2, Easy to change the mold
Where the mold is frequently modified, it can be disassembled and made into inserts. In the future, when the mold is changed, only the inserts need to be replaced, and even several spare parts of the inserts can be made for replacement when the mold is opened, which is convenient for modifying the mold. For example, for some ODM manufacturers, the appearance of the product remains unchanged, and it only needs to change the LOGO to become a product of another brand. At this time, the mold can be removed from the LOGO piece to make an insert, so that there is no need to re-open a set of molds.
3. It is beneficial to the exhaust of the mold
It is very important to exhaust the mold. If the exhaust is not good, air trapping will occur in the mold cavity, especially in the deep bone position, which is more likely to be trapped. When injection molding, the product is prone to bubbles or shrinkage, lack of glue, and whitening. Or black spots and other undesirable phenomena, so you can add inserts where the mold needs to be vented, and use the matching gap of the inserts to exhaust.
4. Convenient mold processing
We know that in some deep bone positions in the injection mold, it is difficult for the tool to be processed. For example, EDM EDM is used. We all know that EDM processing is the slowest and the processing efficiency is too low, so it is generally selected here. Make inserts, reduce the difficulty of processing, and also facilitate exhaust. There is also the saving of molds in the deep bone position. It is quite inconvenient to save the molds in the places where the molds must be saved, but it is much more convenient to set up inserts in these places and remove them separately.
5. Increase the service life of the mold
Under normal circumstances, the places where the mold needs to design inserts are often easily damaged places, such as some sharp steel and thin steel places. Once the inserts are damaged, they can be replaced, thereby extending the service life of the mold.
6. Conduction mold temperature
Under normal circumstances, the mold is cooled by designing water channels, but in some places, water channels cannot be designed or water channels cannot be reached. These places can be dissipated by making inserts. Of course, the material of the inserts must be selected with good thermal conductivity. Materials, such as beryllium copper, or the technology of metal 3D printing mold inserts, can greatly improve the cooling efficiency and shorten the injection molding time. The cooling time can generally be shortened by about 20%-80%, which greatly improves the injection molding efficiency.
Metal 3D printed electronic cigarette mold inserts, the cooling time is shortened by 50%-80%
Disadvantages of making inserts
1. Increase the difficulty of mold assembly;
2. It is easy to produce glue overflowing flash around the insert;
3. The inlay structure of the mold will sometimes increase the cost of mold design and processing, thereby increasing the cost;
4. Too many inlaid structures will affect the design of the cooling water circuit of the mold;
5. Too many inlay structures will affect the strength of the mold core.
Inserts are already a very common structure in molds. Although they are defective, they have obvious advantages. When designing the mold, it is necessary to judge which places need to be inserted according to the specific product structure, and which places can be left as they are. When making inserts, it should be noted that there are generally insert marks or insert lines in the place where inserts are made. Customers need to confirm whether they are acceptable during the mold opening review.
https://www.china-3dprinting.com/metal-3d-printing/conformal-cooling-for-3d-printing-mold.html