Mathematics (product 3D)

Mathematics is reviewed and optimized together with the customer, aiming at the best mold and product construction and performance.

 

Mold Design

Mold is fully designed (mold-holder, dyes, dummies, extractors, drawers, accessories, locks, etc.) in 3D and 2D, using the Solidworks software, reducing possible design errors and making easier a possible product modification during the product design development and further maintenance. Note: The design data (2D and 3D) will de delivered and will always be available to our customers for studies of future modifications and enhancements

 

CAM Programming

The Machining Centers programming is done by using the Power Mill/Delcam Europe Software, and for the Wire Electro-erosion programming, the Pitagoras Software is used.

 

Materials used for mold construction

- Mold-holder: mold-holder according to Polimold standards (1045 - DIN 1.1730 or P20 steel). Mold-holder consists of the following items:
Plates: PBS, P1, P2, PS, PE, CPE, PBI and spacing shims. (When the mold contains Hot Runner System (hot chamber) one more plate named PPM is added).

Note: We use the mold-holder as framework for dyes and their respective components; we do not use the mold-holder plates as dyes.

- Dyes: (H13) W302 Isobloc - Bohler with 52-54 HRC hardness.
Chemical composition:
C = 0.40 - Si = 0.95 - Mn = 0.35 - Cr = 5.20 - Mo = 1.50 - V= 0.90.

 

Similar Standards:

ASTM A 681 Type H13 ABNT H13; AISI H13; DIN X 40 CrMoV 51e- WNr 1,2344;
BS 4659:1971 Type BH 13; JIS G 4404-72 Type SKD 61.

- Dyes for transparent products (Lens, pointers, light diffusers, etc.): (P420) M333 – Bohler or STAVAX SUPREME – Uddeholm.

Chemical composition:
C = 0.40 - Mn = 0.50 - Cr = 13.50 - Si = 1.50 - V= 0.25.

 

Similar Standards:

AISI 420 modified; WNr 1,2083.
Note: Dyes are housed in the mold-holder plates, P1 and P2; we do not machine cavities directly onto the mold-holder plates, and we use dummies on the details, easing their maintenance and/or modification and extending the mold life cycle.
- Dummies: (H13) W302 Isobloc – Bohler.
- Pins, bushings and extractor blades: H13 nitrated or tempered.
Note: Pins, bushings and extractor blades according to DIN or AISI standard (Polymold standard)
- Drawers: (H13) W302 Isobloc – Bohler.
- Drawer guides, wedges and special extractors: AMPCO 21 (low friction coefficient with high hardness), assuring better sliding and low wear to drawer guides and wedges.

 

Heat Treatment:

- All heat treatment is done in vacuum ovens at companies having ISO 9000 certification and with guarantee certificate regarding the heat treatment conduct to all pieces.
Dyes and dummies hardness: 50 – 54 HRC (H13) W302 Isobloc – Bohler.
Dyes and dummies hardness: 46 – 48 HRC (P420) M333 – Bohler.

 

Hot Runner System (Hot chamber).

- Vendors: Husky, Polimold, Mold Masters and Yudo (According to customer’s order)

 

Accessories

- All accessories used with molds, such as: Pincers, Locks, Springs, etc., are Polimold standard.

 

Machining

- All dyes, drawers, dummies and electrodes machining is developed via CAM Programming, using the Power Mill/ Delcam (Europe) software and Mazak Machining Centers provided with High Speed (HSM) technology, thus assuring high quality level, and surfaces and dimensional finish. All CAM machining programming is dine aided by graphical simulation core preventing human failures during the CNC machines operation and setup
– We use 3R System, same as used in Europe and in the USA, which assures the fabrication process repeatability, with reduced tolerances, thus assuring the tool and product quality.

 

Note: The entire mold closing process id made in machining centers, grinding machines, wire and electro-erosion. Manual pneumatic turbines (whips) are not used for closing the mold, aiming at assuring higher quality and extending the tool life-cycle. By using all these technologies, we guarantee 1,000,000 filer cycles to the mold and an excellent quality product at the 1st try-out.