The failure of molds in fact is due to the reasons such as local material wear on the surface layer and thus scrapping. Moreover, the processing cycle of molds is very long, and the processing cost is extremely high (especially for precision complex molds or large mold manufacturing processing costs which can reach hundreds of thousands of yuan or even millions of yuan). Therefore, performing surface strengthening on specific parts of the mold that truly endure wear can significantly extend and improve the service life of the mold and die, undoubtedly a method with significant economic significance. In addition, most molds become ineffective and are scrapped because only a very thin layer of material on the surface has been worn out. Thus, by repairing the locally worn areas of the mold and key metal parts, and during the repair process, applying a layer of high hardness and highly wear-resistant metal coating on the mold's surface that actually endures wear, it can "turn waste into treasure." Not only does this allow the mold to be repaired, but the service life of the repaired mold will also be significantly improved compared to the original mold, resulting in enormous economic benefits (for example: repairing a large shaft of a power plant motor, including all preparation time, only takes a few days using a micro-beam cold welder, but can generate economic benefits of over a million yuan).
1: After long-term use of the mold, the blade must be ground. After grinding, the blade surface must undergo demagnetization and cannot have any magnetism, otherwise, it may cause blockage.
2: Springs and other elastic parts are prone to damage during use, usually showing breakage and deformation. The measure adopted is replacement, and during the replacement process, attention must be paid to the specifications and model of the spring. The specifications and model of the spring are confirmed through three items: color, outer diameter, and length. Replacement can only occur when all three items are identical.
Mold repair machines enhance mold life and offer good economic benefits. They can be used for surface strengthening and repair of various metal materials molds and workpieces such as iron-based alloys (carbon steel, alloy steel, cast iron), nickel-based alloys, etc., significantly improving their service life.
Application scope: mechanical, automotive, light industry, home appliances, petroleum, chemical, electric power and other industrial equipment manufacturing sectors and application sectors, aviation engine key wear-resistant parts, hot extrusion molds, warm extrusion molds, hot forging dies, rolling steel turning guides, rolls, automobile engine camshafts and other parts and molds.
Source: Mold Network http://www.9ygz.com/mojujiagong/weihu.html
3: During the use of molds, punches are prone to breaking, bending, and being damaged. Punch sleeves are generally damaged by biting. Replacements for punches and punch sleeves generally use parts of the same specification. The parameters of the punch mainly include working part size, installation part size, and length size.
4: Fastening parts, check if there are any loose or damaged fastening parts. The measure adopted is finding parts of the same specification for replacement.
5: Pressing parts such as pressing plates, urethane foam, unloading parts such as unloading plates, pneumatic top materials, etc. During maintenance, check the relationship and condition of accessories in all parts and repair the damaged parts. Check for air leakage in pneumatic top materials and take measures according to the specific situation. Replace the air pipe if it is damaged.
How to repair molds? According to incomplete statistics, the annual consumption value of molds in the mechanical processing industry is five times the total value of all machine tools, indicating how enormous the mold market is in industries such as machinery, metallurgy, light industry, and electronics. For example, in the metallurgical industry, the annual consumption of hot-rolled rolls alone exceeds 300,000 tons, and the value of hot-rolled rolls accounts for more than 5% of the cost of steel production. The large consumption of molds not only directly increases production costs but also causes greater economic losses due to frequent shutdowns of production lines caused by frequent changes in working molds.
A mold repair machine is a high-tech device for repairing surface wear and processing defects of molds. The principle of the mold repair machine is to use the high-frequency electric spark discharge principle to perform heat-free welding on the workpiece, thereby repairing surface defects and wear of metal molds. The main characteristics are a small heat-affected area, no deformation of the mold after repair, no annealing, no stress concentration, no cracks, ensuring the integrity of the mold; its strengthening function can also be used to perform surface strengthening treatment on mold workpieces, achieving wear resistance, heat resistance, and corrosion resistance of the mold.
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