As per today's evolving technologies, we come across several techniques and tools being used for manufacturing plastic and metal products. The products can be as toys for children, tools for factory workers, jewellery for women, bigger machines like lathe machines drillers.
Several mold making companies which are working on very large scale
work for product manufacturing. For product manufacturing the need is of large
machines and working men who can easily operate these large machines. Machines
are a big working system which gives an optimized result as per the requirement
of the product. The big machine is composed of several numbers of small tools
as nut and bolts and many more.
These tools are being made in many of the mechanical
industries. The biggest requirement for
the production of these die casting parts is the machines. Machines take in an idea of the
design to be made. Then comes the metal or material of which the product is to
be made. The metal is checked up its properties by which it fulfils the
requirement of the metal or material.
Metal tool manufacturing cycle goes through many situations
and decision which are very important to consider getting the optimized
product. The main steps which play a vital role in the manufacturing process
cycle of the product are :
Feasibility Study for Technology &
Available Resources
Feasibility study is done for the product to be made, what
comes under this study is the capability of the mold making company that if
they are capable of manufacturing the required product as per their resources
they have in their industry. In this
stage it is made a thought on the technologies which are in need for
manufacturing cycle. All the capabilities for the process are considered in
this initial stage.
Main focus in this stage is on :
a.
Technology to be used,
b.
Tools required for manufacturing process,
c.
Skilled workers requirement,
d.
Will
they be able to give a optimized final product with available technology and
resources.
Requirement Analysis of Final
Product
This field includes all the major decision to be made for
the final product to be made. Here it is needed to discuss about the main and
all requirement which should be fulfilled by the product for the user using it.
As for example a screw driver should open the nuts, screw driver should be easy
to handle, it should be durable and many more requirements are to be reached.
All the requirements are evaluated in this stage.
Tolerance :
Tolerance is actually strength of the material which it can withstand while the
manufacturing process being done.
Durability :
Durability stands for the time period for which a metal or material can
withstand after product manufacturing.
Elasticity : The
property of elasticity in a metal or material tell that if metal is flexible
means if it can have shape regaining property. It actually helps in regaining
the original shape and size if the exerted force is removed. For example an
elastic band, it regains its shape and size if the exerted force is removed.
Malleability &
Ductility : These properties are common in metals, these properties are the
expanding of the metals into sheets or wires. The metal when is beaten by a
high force then it changes in sheets and wire forms.
These are some of the characteristics needed to be kept in
mind while selecting a metal for product manufacturing, after this metal is
selected for the starting process of prototyping manufacturing and tooling. Selecting the
metal is followed by the process or technology to be used to manufacture the
product using raw materials.
After the requirement Analysis of the manufacturing cycle is
done then comes the Designing machining
and tooling part which includes the process of selecting right raw material and
creating a base design which is the very main part of manufacturing cycle. All
the implementation of the processes are done according to the design made.
Designing is a process of making as base structure upon
which all the work is dependent, the skilled workers capture this design in
their minds because they should know , about what they are going to craft after
a hard work. “Design of a product can be said as a 2D view of usable product or tool”. For example using a hammer is a product made
whereas seeing a picture of a hammer is a design of the same hammer which is
used.
With the latest technology of Machining and Tooling now-days
many soft-wares are being used in the field of manufacturing machines and tools.
Some of the famous soft-wares being used for designing purpose in 2d as well as
3D are :
Design-Spark Mechanical : This soft-wares I designing a 3D design of
any tool with their best tools.
Auto CAD
: This soft-wares is also a very good designing soft-ware. It also allows 2d as
well as 3D designing with best tools as dimensions ruler, xyz dimensions
implementations and many more.
As these there are several
computerized platform made to develop a great design of product. Using these we
are also able to rotate and move the product to see how it looks from several
positions. The best thing we are able to see or upcoming product before it is
made.
Now the stage comes which is considered to be the heart of
manufacturing cycle. The working area is used now. All the bigger machines and
tools are ready to be used now. These machines are of different purposes to be
used. There are so many processes and methods on which manufacturing cycle is
dependent .
Some of the Services on which mold making companies work are
as follows :
Rapid Prototyping :
Rapid Prototyping is the technology used to fabricate the
raw materials into a final product using several techniques for example 3D
Printing or cnc machining.
Processes which comes under Rapid Prototyping are :
1.
3D
Printing : It can easily print the product in 3D. Small products with low
strengths are printed with these printers which can print 3D products.
2.
CNC
Machining : CNC stands for Computer Numerical Controls, this includes the
designs being made for the products. Designs are made using these technologies
of CNC machining parts with the best 2D and 3D designing soft-wares as are Auto
CAD. These soft-wares can make a 3D viewable design which almost resembles the
real product to be made.
3.
SLA &
SLS Prototyping : It includes Stereo lithography and Selective Laser
Sintering prototyping. This is also a
technique which comes under CNC machining.
4.
Polyurethane
Casting Process : This is another type of prototyping manufacturing process
which include use of Polyurethane for casting a new product.
Mold is actually said to be a soft
basic structure of the product to be made. Injection Mold making includes several steps
as they are:
Preparing molten metal :
metal of which the product is to be made is heated at a very high temperature
to melt it into molten form(semi-liquid ).
Mold Cavity Selection
:Mold Cavity is referred to as the structure as same as we need the product to
be made, the required shape and size is in between the mold cavity in which the
molten metal is filled to gain the shape and size of the required shape of the
product.
Flow of Molten Metal :
Now the molten metal prepared after melting is made to flow into the cavity to
fill in the space of required shape and size of mold cavity.
Solidifying of Molten Metal :
After inserting the molten metal the metal is kept under cooling procedure
under pressure to solidify it and harden it, increasing its stability and
strength.
Product ejecting : After
solidification product is ready to take out from mold cavity. The product is
then taken for final touches to make it attractive.
Final Finishes : Now the
product is painted and polished for the attraction attributes. Polishing and
painting the product protect it from Rustin and Corrosion and make it
attractive.
CNC Machining :
CNC Machining Service refers to ComputerNumerical Controls for the design made or the measurements required for the
design or basic structure. Some very useful Computer Soft-wares come under this
category. These soft-wares are expert in preparing a design in 2D as well as in
3D model. The best benefit of using these soft-wares is we can interpret the
real design and final product to be used. A design made can be viewed from
several sides vertically and horizontally. This explains all the requirement
and improvements to be done before the completion of the product manufacturing
cycle.
Some of the basic Advantages of
CNC Machining are :
1.
CNC Machining service is more precise than
manual machining.
2.
It can be repeated several times in the same
manner again and again.
3.
Complex 3D designs can be made easily.
4.
High precision machining parts are delivered
even after repetitive works done.
Die Casting Process :
Die Casting manufacturing is a process of casting a metal using Dies. Dies
are big tools through which metal plate or in other forms are passed to give a
basic structure to the metal. Dies can convert a metal flat plate into a
circular rim structure by a force at the ends of the metal plate using dies.
Die casting can be done different manners.
Depending on the
manner in which Die casting can be implemented main 2 types of Die Casting
Processes and these are as follows :
1.
Hot Chamber Die Casting : In this
process injection system which exerts the pressure is inserted into the
circular area of molten cavity. It takes less time period having a plus point.
Low melting point metals are best to implement Hot Chamber Die Casting.
2.
Cold Chamber Die Casting : This
process uses a ladle to transport the molten metal into molten cavity. This
process is primarily used for aluminums parts and products.
Durability of Die Casting Parts is much better as they are
stronger than plastic manufactured products. Instead of product having thin
walls, they are rough enough to withstand the tolerance maintaining their
strength.
Testing includes the checkup of
the product that if it is giving the best fit result or not. Testing is done in
two ways:
Industry side : The
testers in industry only check the whole product after its final creation,
testing is the processes done just before delivering the product to the
customers. In this category workers those are In factory where the product is
made check the whole product.
Customer Side : Customer
side testing including the full testing of the product by the Customer by using
it. In this the customer or client operates the products and use to test
whether it is delvering the right result or not.
Delivery of the
Product
After all the testing done when product passes the testing
criteria it is ready to be delivered to the customer whomsoever it concerns.
There are a numberof injection molding companies in China which are working on the concept of injection molding parts,
precision machining parts, cnc machining parts and die casting parts. The steps
here explained in metal product manufacturing cycle are followed by all the
injection molding companies all around the world. Mold making in China is
somewhat done in many of the industries.
Some common services provided by these
industries are as follows :
1.
Plastic Mold Manufacturer,
2.
Plastic Injection Molding,
3.
Injection Mold Manufacturing,
4.
Rapid Prototyping Services,
5.
Precision Machining Services,
6.
Die Casting Parts, and many more.
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