To change an injection mold, you will need to follow these steps:

Preparatory work before mold change

According to the production plan of the workshop, do a good job in the preparation work before the entire mold change process.

1. Wear a safety helmet and prepare demolding tools such as rags, anti-rust agents, and wrenches;

2. Check the mold to be installed:

1) According to the layman’s size of the mold, select the machine that can be installed (generally, the machine is designated by the workshop plan, and there is no need to choose by yourself);

2) Whether the cooling water pipe joint of the mold is installed well, and whether the water path is smooth (check by connecting the upper air path);

3) Whether the injection mold uses the function of pulling the spigot, if so, please prepare the oil pipe and the oil pipe joint, and check them. 

If you find that the threaded opening is not good, please do not use it, so as not to damage the good thread, and there will be oil leakage;

4) Install the lifting ring (the curved lifting ring is not used). The depth of the lifting ring screwed into the mold must be greater than 1.5 times the diameter of the lifting ring. 

If the surface of the lifting ring and the mold have not been pasted and the gasket must be used to prevent the bending and breaking of the lifting ring.

3. To check the crane:

Check the operation status of the crane and whether the functions of each button are sound and normal, especially the emergency stop button should be tested. 

If any problem is found, it should be stopped immediately, hang up the “no use” notice, and notify the monitor to report for repair.

4. Check the wire rope and shackle:

Are there broken strands or loops in the steel wire rope used, and is the suspended mold overweight? If necessary, replace the wire rope immediately.

The shackle used for lifting must not have bending deformation, which does not match the tonnage of the lifting mold.

Hoisting Safety Points

Take heed to the crucial details of mold lifting, ensuring success in this vital step.

From proper equipment inspection and usage to safety precautions such as wearing protective gear, be sure that your process is thorough for optimal results!

1. Heavy-duty injection molds over 10 tons require double steel wire rope configurations, as well as two sturdy rings and a load capacity of no less than ten tons per shackle.

Meanwhile, lighter projects below this weight requirement utilize a single wire rope with dual lifting rings for balanced support.

2. When installing the hook, it is paramount to exercise caution and abstain from crane operation. Neglecting to do so could lead to hazardous consequences such as fingers being trapped between the wire rope and its accompanying hook. Play it safe – always prioritize safety!

3. After carefully lifting the mold, it must be examined for levelness. Any tilting to either side or forward is prohibited; however, a slight backward tilt is acceptable.

4. Careful consideration should be taken when lifting a single mold.

Utilizing the mold clamping connecting piece allows for an effective and safe separation of moving and fixed molds, all while avoiding any potential shaking or accidents caused by pressing incorrect buttons.

Strategic focus on directionality is essential in order to avoid unfortunate occurrences during this process.

5. At the beginning of the injection mold lifting, it should be lifted slowly (not fast and suddenly). The height should be below 80mm from the ground. 

After the mold is moved to the front of the machine, it can only be raised and moved to the middle of the formwork after it is shaken stably. 

Before entering the Green column, it must There is a person who directs and stabilizes the mold above the fixed template of the machine. 

It is strictly forbidden for the injection mold to collide with the Corinthian pillar, which will cause the Corinthian pillar to be bruised and damage the copper sleeve of the template.

6. It is strictly forbidden to operate under the suspended mold. When lifting the mold, the operator should keep a distance of more than 1 meter from the mold (horizontal direction). 

When installing the nozzle under the mold, except for the palm, no part of the body is allowed to be in the mold falling area.

7. During the process of lifting the mold, the people in the aisle should be notified to get out of the way, and the lifted mold is strictly prohibited to pass over the person or the machine.

8. It is strictly forbidden for the injection mold to stay in the air for a long time (more than 10 minutes) or for the lifter to leave the site.

9. When the crane breaks down and there are abnormal phenomena (such: as abnormal noise, burning smell, automatic sliding of the suspended object, short-term movement after the button is released).

The suspended object should be put down immediately, stop using the crane, and hang up the “prohibited” button. Use the sign to notify the monitor to report for repairs.

Mold installation and machine adjustment

1. Before lowering the mold, ensure that it is completely cleaned and lubricated, as well as properly rust-proofed.

Additionally, verify that the length of steel wire rope can safely lift the mold from its place on the machine table to prevent slippage afterward.

2. To ensure successful installation, take the mold opening/closing speed down to 25%, switch the operated button into manual mode and adjust pressure control settings to low-pressure manual.

3. Before hoisting the injection mold into its designated spot, take a quick measurement of its thickness and make any necessary adjustments.

Then confirm that all ejector pins are adequately aligned with holes to ensure successful operation once in place.

4. While mold adjustment is essential to production, unless it’s a minor tweak of 10mm or less, driving the mold isn’t permitted.

5. To properly load a mold into the injection machine, ensure to turn off the oil pump beforehand.

Be mindful of any force applied when repositioning so as not to damage your equipment; adding in a positioning ring could prove beneficial should you need to reverse direction after closing it up.

6. Avoid the risk of injury and ensure optimal mold alignment – it is essential to switch off heating when inspecting “mold sheet”, as placing hands between the nozzle and injection molds without positioning rings could be hazardous.

7. To ensure optimal mold performance and durability, the installation of 8-16 hydraulic clamps is essential.

For injection molds weighing over 450 tons a minimum of 8 clamps must be applied; this figure increases to 12 for those over 600 tons in weight. Finally, 16 should be used for all molds exceeding 1600 tonnes.

8. To ensure a secure and reliable fix, the screw teeth must have greater than 1.5x their diameter depth; while the pad iron or foot should be slightly higher, up to 3mm max compared to the bottom of compressed molding plate.

The compression-molding screws need to be placed at the front near the injection mold with its accompanying iron placed at the rear for best results!

9. Do not use an open-end wrench to tighten the screws, bent pressure plates, and slipping nut screws must not be used.

10. To prevent the screws from being subjected to excessive torque, the length of the casing used is required to be: 25-30CM for M16 screws, 40-45CM for M20 screws, and 50-55CM for M24 screws.

11. The hook shackle is removed before the injection mold is opened when the mold is installed, and the wire rope and the shackle cannot be driven to open the mold. 

Remember: Release the locking piece before opening the injection mold.

12. The mold was maintained with a hot runner that had to be cooled by water before being heated electrically in order to maintain the seal and avoid splitting.

13. When someone is cleaning or overhauling the mold in the machine, no one is allowed to start the power supply or operate the panel to adjust the parameters.

14. Molds shall not be stacked in two layers, and shall be placed in designated positions according to numbers, and new molds shall be temporarily placed in the injection mold repairing area for external trial molds.

15. After the mold is installed, the mold core must be opened (it is forbidden to keep the machine hinge in a locked state for a long time).

Adjust the position of the mechanical safety lever, connect the water pipe, and connect the oil pipe if there is a core puller, and adjust the action to avoid oil leakage. Leakage phenomenon.

Tidy up machine environmental sanitation

1. All tools such as screws, pressure plates, positioning rings, wrenches, and sleeves on the machine table should be placed in the specified positions.

2. The mold cooling water pipe should not be too long, just put a margin of about 20 cm according to the actual length of the mold after opening.

3. When disassembling the oil pipe for the mold equipped with a ferrule, a small plastic box must be prepared to contain the leaked hydraulic oil. 

If the oil pipe is not in use, the oil in the oil pipe should be poured out first, and then the oil pipe should be placed in the specified position.

4. Finally, wipe the dirty places on the machine table and the ground with a rag.

Debug reasonable injection molding parameters and prepare for production

1. Connect the power to the machine and turn it on.

2. Adjust the settings on the injection molding machine to match the specifications for the new mold.

3. Test the existing mold to ensure it is functioning properly before starting the injection molding production line.

Conclusion

It is important to follow these steps carefully to avoid damaging the injection mold or the machine. 

It may also be helpful to consult the machine’s manual or seek assistance from a qualified technician if you are unsure of how to properly change an injection mold.