Zero-R-angle injection mold and manufacturing process thereof

Abstract

According to the manufacturing process of the zero-R-angle injection mold, a CNC machining center is adopted for rough machining, a spark machine is adopted for finish machining, the CNC machining center and the spark machine are adopted for alternate machining, then mirror face machining and grinding and polishing are conducted, it is ensured that a plurality of triangular blocks are formed on the side face and the bottom face of a mold plate, and it is ensured that the triangular blocks achieve the zero-R-angle effect in all directions; the problem that the zero R angle effect of the corner angle cannot be achieved through an existing single CNC machining technology is solved. The invention further provides the zero-R-angle injection mold.

Description

Technical field

[0001] In the manufacturing of products such as speaker enclosures or radiators, triangular shapes are often designed to meet specific functional or aesthetic requirements. However, triangular shapes involve multiple complex angles and curved surfaces, making mold cavities of this shape extremely challenging.

[0002] Currently, traditional mold processing primarily relies on direct CNC machining. However, when processing various triangles on bevels and bases, CNC machining is limited by the physical properties of the tool and inherent limitations of the machining process. This inevitably creates varying degrees of rounded corners at the edges of the triangles. These rounded corners prevent plastic injection molded products from achieving the ideal zero-rounded corner effect, thus affecting the product's visual precision and functional performance. [Summary of the invention] The purpose of the present invention is to provide a zero R angle injection mold manufacturing process to solve the problem that the current single CNC processing technology cannot achieve the zero R angle effect on corners.

[0003] The present invention is achieved by the following technical solutions: A zero R angle injection mold manufacturing process is characterized by comprising the following steps: S1. Roughing: The template is rough-machined using a CNC machining center to obtain a plurality of triangular blocks with R angles; S2, forming: using a spark machine to fine-process the triangular block along the three sides of the triangular copper, and after fine-processing, using a CNC machining center to grind the triangular block to obtain a prototype template; S3, mirror polishing: using a spark machine to mirror-process the prototype template in step S2, and then using a CNC machining center and a spark machine to grind and polish the prototype template to obtain a forming template with a zero R angle triangle block.

[0004] In the above-mentioned zero R angle injection mold manufacturing process, the single-side machining allowance of the triangular block in step S1 is 0.2mm. R Corner radius is 0.25mm .

[0005] As described above in the zero R angle injection mold manufacturing process, the single-side machining allowance of the triangular block in the prototype template in step S2 is 0.01 mm.

[0006] As described above in the zero R angle injection mold manufacturing process, the material of the triangular copper male in step S2 is tungsten copper.

[0007] As described above, in the zero R angle injection mold manufacturing process, the speed of the spark machine in step S2 is 0.02 mm / s.

[0008] As described above, in the zero R angle injection mold manufacturing process, the speed of the spark machine in step S3 is 0.001-0.005 mm / s.

[0009] As described above, in the zero R angle injection mold manufacturing process, when the CNC machining center performs grinding and polishing in step S3, diamond grinding paste is added, and the feed amount is 0.0001 mm.

[0010] Another object of the present invention is to provide a zero R angle injection mold.

[0011] A zero R angle injection mold produced by the zero R angle injection mold production process includes a molding component arranged between an upper mold component and a lower mold component, the molding component includes an upper template and a lower template, a molding block is provided between the upper template and the lower template, and the upper template, the molding block and the lower template form a triangular molding cavity for zero R angle molding.

[0012] As described above, in the zero R angle injection mold, the molding block is provided with a plurality of molding holes for zero R angle molding.

[0013] As described above, in the zero R angle injection mold, the upper template and the lower template are respectively provided with a plurality of first protrusions and fourth protrusions abutting against the molding holes, and the first protrusions, the molding holes and the fourth protrusions form a triangular molding cavity for zero R angle molding.

[0014] Compared with the prior art, the present invention has the following advantages: The present invention proposes a zero R angle injection mold manufacturing process. First, a CNC machining center is used to perform rough processing on the template so that the side and bottom surfaces thereof form a plurality of triangular block prototypes, providing a structural basis for subsequent operations. Second, a spark machine is used for fine processing to ensure that the side and bottom surfaces of the triangular blocks reach the required shape and size. Third, a CNC machining center and a spark machine are used for interlaced processing to ensure that the triangular blocks achieve a zero R angle effect in all directions. Finally, a spark machine is used for mirror processing to obtain a smooth surface quality, and then the CNC machining center is used for grinding and polishing to ensure that the surface reaches the required smoothness and precision, thereby obtaining a molding template with a zero R angle mirror effect, which solves the problem that the current single CNC machining process cannot achieve a zero R angle effect on sharp corners.

[0015] The present invention also proposes a zero-R angle injection mold. First, the combined structure of an upper mold plate, a lower mold plate, and a forming block achieves zero-R angle molding of the product. Second, a triangular molding cavity is formed by a first protrusion, a forming hole, and a fourth protrusion, ensuring precise zero-R angle molding of the product and improving product dimensional consistency and structural stability.

Brief Description of the Drawings

[0016] A zero R angle injection mold manufacturing process comprises the following steps: S1. Roughing: The template is rough-machined using a CNC machining center so that the template obtains a plurality of triangular blocks with a single-side machining allowance of 0.2 mm and a corner radius of 0.25 mm; S2, forming: using a spark machine to finish-process the triangular block along the three sides of the triangular tungsten-copper copper rod at 0.02 mm / s. After finishing, the triangular block is ground using a CNC machining center until the single-side machining allowance of the triangular block is 0.01 mm, thereby obtaining a prototype template; S3, mirror polishing: The prototype template of step S2 is mirror-processed by using a spark machine at 0.001-0.005 mm / s, and the prototype template is ground and polished by a CNC machining center with 3.5# diamond grinding paste at a feed rate of 0.0001 mm, and then the prototype template is ground and polished by using a spark machine to obtain an upper template 31 and a lower template 33 with zero R angle triangle blocks (such as Figure 1-9 shown).

[0017] The present invention first uses a CNC machining center to perform rough processing on the template, so that the side and bottom surfaces thereof form a plurality of triangular block prototypes, providing a structural basis for subsequent operations. Secondly, a spark machine is used for fine processing to ensure that the side and bottom surfaces of the triangular blocks reach the required shape and size, thereby improving processing efficiency. Thirdly, a CNC machining center and a spark machine are used for interlaced processing to ensure that the triangular blocks achieve a zero R angle effect in all directions. Finally, a spark machine is used for mirror processing, and the CNC machining center is used for grinding and polishing to ensure the smoothness and precision of the surface, which helps to improve the quality of subsequent injection molding products, thereby obtaining a molding template with a zero R angle mirror effect.

[0018] Specifically, step S1 optimizes the machining path of the CNC machining center by setting a machining allowance of 0.2 mm and an R corner radius of 0.25 mm to ensure the consistency and controllability of rough machining and improve efficiency.

[0019] Specifically, step S2 adopts tungsten copper as the copper material, which has excellent wear resistance and good conductivity, which can not only improve the efficiency and quality of spark processing, but also extend the service life of the spark machine; through extremely small processing allowances, the accuracy of the prototype template is ensured, which provides a basis for subsequent finishing and polishing, and can also reduce material waste and reduce production costs; and by selecting a suitable processing speed, the stability and consistency of spark processing are ensured, which helps to improve the quality of the processed surface and reduce the subsequent polishing workload.

[0020] Specifically, step S3 uses low-speed machining to reduce minor surface defects, ensuring surface smoothness and achieving a mirror-like finish. Secondly, during grinding and polishing, the CNC machining center adds diamond abrasive paste to ensure a high surface finish. Using minimal tool feed reduces surface scratches and extends the life of the mold.

[0021] Figure 1-9 The zero R angle injection mold shown is obtained by the zero R angle injection mold manufacturing process, including a molding component 3 arranged between the upper mold component 1 and the lower mold component 6, the molding component 3 includes an upper template 31 and a lower template 33, and a molding block 32 is provided between the upper template 31 and the lower template 33. The upper template 31, the molding block 32 and the lower template 33 form a triangular molding cavity for zero R angle molding.

[0022] In this embodiment, the upper and lower mold assemblies provide the overall framework, while the molding assembly achieves product formation. Specifically, the molding assembly supports and secures the molding blocks via the upper and lower mold plates. The molding blocks, tightly fitted with the upper and lower mold plates, together form a triangular molding cavity, ensuring the consistency and precision of the product's corners. After injection molding and cooling, the resulting molded product has a three-dimensional appearance with zero R angles.

[0023] Furthermore, the forming block 32 includes a first forming surface 321 for zero R angle forming and a first inclined surface 322 and a second inclined surface 323 for connection. The first forming surface 321 is provided with a plurality of forming holes 3211 for zero R angle forming.

[0024] Specifically, the shape of the forming hole 3211 is a zero R angle triangle. The zero R angle triangle can be specifically configured according to product requirements. Preferably, a zero R angle triangle with a bone width of 1.2 mm and a height of 1.5 mm is used.

[0025] In this embodiment, the forming block utilizes partitioned forming surfaces and inclined surfaces, achieving zero-R angle forming through the forming surfaces. The inclined surfaces facilitate tight connection with the upper and lower mold plates, enhancing connection reliability and structural stability. This enhances the multifunctional integration of the forming block and optimizes the internal structural space of the forming assembly. Furthermore, the multiple forming holes on the first forming surface abut against the upper and lower mold plates, forming multiple triangular forming cavities for zero-R angle forming, improving dimensional accuracy and consistency.

[0026] Furthermore, the first molding surface 321 is further provided with a plurality of first connection grooves 3212 connected to the upper mold plate 31 ; the first inclined surface 322 and the second inclined surface 323 are both provided with a plurality of second connection grooves 3220 connected to the upper mold plate 31 .

[0027] Specifically, the first connection groove 3212 and the second connection groove 3220 are both triangular in shape.

[0028] In this embodiment, by setting the first connecting groove and the second connecting groove on the forming surface and the front side of the inclined surface, multi-point connection between the forming block and the upper template is achieved, which increases the contact area and mechanical engagement of the connection, thereby enhancing the strength and stability of the connection.

[0029] Furthermore, the first molding surface 321 is further provided with a first connecting member 3213 and a second connecting member 3214 connected to the lower template 33 ; the first inclined surface 322 and the second inclined surface 323 are both provided with a third connecting member 3230 connected to the lower template 33 .

[0030] In this embodiment, by providing a first, second, and third connector on the molding surface and the bottom surface of the inclined surface, a multi-point connection is achieved between the molding block and the lower mold plate. This increases the contact area and mechanical engagement of the connection, thereby enhancing the strength and stability of the connection. Secondly, by rationally utilizing the front and back surfaces of the molding block and optimizing the structural layout of the connecting grooves and connectors, the space utilization rate of the internal structure of the molding assembly is improved, while also enhancing the sealing performance of the connection between the molding block and the upper and lower mold plates, ensuring a smooth injection molding process.

[0031] Furthermore, the upper template 31 is provided with a second molding surface 311 abutting against the first molding surface 321 , and a third inclined surface 312 and a fourth inclined surface 313 connected to the first inclined surface 322 and the second inclined surface 323 respectively.

[0032] In this embodiment, the first molding surface and the second molding surface are abutted to jointly form a triangular molding cavity, and the third inclined surface and the fourth inclined surface are used to achieve a multi-faceted connection between the upper template and the molding block, providing a precise positioning reference to ensure the correct assembly between the two, improve the assembly accuracy of the mold, and reduce dimensional deviation and quality fluctuations.

[0033] Furthermore, the second molding surface 311 is provided with a first protrusion 3111 abutting against the molding hole 3211 and a second protrusion 3112 connected to the first connecting groove 3212; the third inclined surface 312 and the fourth inclined surface 313 are both provided with a third protrusion 3130 connected to the second connecting groove 3220.

[0034] Specifically, the first protrusion 3111 , the second protrusion 3112 , and the third protrusion 3130 are all triangular in shape and match the shapes of the first connecting groove 3212 and the second connecting groove 3220 .

[0035] In this embodiment, the first protrusion abuts against the forming hole to form a triangular forming cavity, and the second protrusion cooperates with the first connecting groove and the third protrusion cooperates with the second connecting groove to form a mechanical interlocking structure, thereby reducing stress concentration and enhancing connection strength and stability.

[0036] Furthermore, the lower template 33 is provided with a third molding surface 331 abutting against the first molding surface 321 , and a fifth inclined surface 332 and a sixth inclined surface 333 connected to the first inclined surface 322 and the second inclined surface 323 respectively.

[0037] In this embodiment, the first molding surface and the third molding surface are abutted to form a triangular molding cavity. The fifth and sixth inclined surfaces realize a multi-faceted connection between the lower template and the molding block, providing a precise positioning reference to ensure the correct assembly between the two, improve the assembly accuracy of the mold, and reduce dimensional deviation and quality fluctuations. Secondly, the molding surfaces and inclined surfaces of the upper template, the molding block, and the lower template cooperate with each other to form a triangular molding cavity with a tight fit inside, ensuring the zero R angle molding quality of the product. The overall stability and reliability of the molding assembly are ensured by the concave-convex cooperation between the lower template and the upper template.

[0038] Furthermore, the third molding surface 331 is provided with a fourth protrusion 3311 abutting against the molding hole 3211 ; the fifth inclined surface 332 and the sixth inclined surface 333 are both provided with a third connecting groove 3312 connected to the third connecting member 3230 .

[0039] Specifically, the fourth protrusion 3311 is triangular and matches the shape of the forming hole 3211 .

[0040] In this embodiment, the fourth protrusion abuts against the forming hole to form a triangular forming cavity, and is connected to the third connecting member through the third connecting groove to achieve a tight connection between the lower template and the forming block to prevent loosening and dislocation.

[0041] Furthermore, the lower template 33 is further provided with a fourth connecting groove 3313 connected to the first connecting member 3213 , and a fifth connecting groove 3314 connected to the second connecting member 3214 .

[0042] In this embodiment, the fourth connecting groove and the first connecting member, and the fifth connecting groove and the second connecting member are connected to each other, so as to achieve multi-point tight connection between the lower template and the forming block to prevent loosening and dislocation.

[0043] Furthermore, the upper mold component 1 is connected to a pouring component 2, which passes through the upper template 31 and is connected to the lower template 33; the lower mold component 6 is connected to a stripping component 4, which passes through the lower template 33 and abuts against the forming block 32.

[0044] Among them, the casting assembly 2 includes a pouring gate 21, a main channel 22 connected to the pouring gate 21 and passing through the upper template 31, a branch channel 23 connected to the main channel 22 and passing through the lower template 33, and a feed port 24 connected to the branch channel 23 and connected to the lower template 33.

[0045] The stripping assembly 4 includes a plurality of ejector pins 41 that penetrate the lower template 33 and abut against the forming block 32. Specifically, the ejector pins 41 are arranged at the intersection of the corners of the forming hole 3211.

[0046] The upper mold plate 31 is provided with a first receiving groove 310 for accommodating the branch channel 23 .

[0047] The lower template 33 is provided with a second accommodating groove 330 for accommodating the branch channel 23 , a third accommodating groove 331 for accommodating the feed port 24 , and a plurality of fixing holes 410 for fixing the ejector pins 41 .

[0048] In this embodiment, the pouring assembly and the stripping assembly cooperate with the molding assembly respectively to optimize the flow path of the plastic in the mold cavity, reduce flow resistance and air entrapment, and improve product quality and production efficiency.

[0049] When the present invention is used, plastic is injected from the pouring gate 21, flowing through the main channel 22 and the branch channel 23 in sequence, and flows from the lower template 33 into the multiple molding holes 3211 of the molding block 32 through the feed port 24. Under the cooperation of the second molding surface 311 of the upper template 31 and the third molding surface 331 of the lower template 33, a closed triangular molding cavity is formed with the molding holes 3211. After the plastic is cooled, a molded product with a zero R angle appearance and a three-dimensional effect is obtained.

[0050] The zero R angle injection mold of the present invention forms a precise triangular molding cavity by optimizing the internal structure of the upper mold plate, the lower mold plate and the molding block, thereby realizing the zero R angle molding of the product and improving the dimensional consistency and structural stability of the product. The pouring component and the stripping component cooperate with the molding component respectively to optimize the flow path of the plastic in the mold cavity, reduce the flow resistance and the air entrapment phenomenon, improve the quality and production efficiency of the product, and solve the problem that the current triangular mold cavity cannot achieve the zero R angle effect of the edges and corners.

[0051] The above descriptions are provided in conjunction with specific content. The specific implementation of the present invention is not limited to these descriptions. At the same time, due to differences in industry nomenclature, it is not limited to the above nomenclature, nor is it limited to English nomenclature. Any similarity or similarity to the methods and structures of the present invention, or any technical deduction or substitution based on the concept of the present invention, shall be considered within the scope of protection of the present invention.

Claims

1. A zero R angle injection mold manufacturing process, characterized by: The following steps are involved: S1. Roughing: The template is rough-machined using a CNC machining center to obtain a plurality of triangular blocks with R angles; S2, forming: using a spark machine to fine-process the triangular block along the three sides of the triangular copper, and after fine-processing, using a CNC machining center to grind the triangular block to obtain a prototype template; S3, mirror polishing: using a spark machine to mirror-process the prototype template in step S2, and then using a CNC machining center and a spark machine to grind and polish the prototype template to obtain a forming template with a zero R angle triangle block.

2. The zero R angle injection mold manufacturing process according to claim 1, characterized in that: The single-side machining allowance of the triangular block in step S1 is 0.2 mm, and the R corner radius is 0.25 mm.

3. The zero R angle injection mold manufacturing process according to claim 1, characterized in that: The single-side machining allowance of the triangular block in the prototype template in step S2 is 0.01 mm.

4. The zero R angle injection mold manufacturing process according to claim 1, characterized in that: The material of the triangular copper rod in step S2 is tungsten copper.

5. The zero R angle injection mold manufacturing process according to claim 1, characterized in that: The speed of the spark machine in step S2 is 0.02 mm / s.

6. The zero R angle injection mold manufacturing process according to claim 1, characterized in that: The speed of the spark machine in step S3 is 0.001-0.005 mm / s.

7. The zero R angle injection mold manufacturing process according to claim 1, characterized in that: When the CNC machining center performs grinding and polishing in step S3, diamond grinding paste is added, and the feed amount is 0.0001 mm.

8. A zero R angle injection mold manufactured by the zero R angle injection mold manufacturing process according to any one of claims 1 to 7, characterized in that: The invention comprises a forming assembly (3) arranged between an upper mold assembly (1) and a lower mold assembly (6), wherein the forming assembly (3) comprises an upper template (31) and a lower template (33), a forming block (32) is provided between the upper template (31) and the lower template (33), and the upper template (31), the forming block (32) and the lower template (33) form a triangular forming cavity for zero R angle forming.

9. The zero R angle injection mold according to claim 8, characterized in that: The forming block (32) is provided with a plurality of forming holes (3211) for zero R angle forming.

10. The zero R angle injection mold according to claim 9, characterized in that: The upper template (31) and the lower template (33) are respectively provided with a plurality of first protrusions (3111) and fourth protrusions (3311) that abut against the forming holes (3211), and the first protrusions (3111), the forming holes (3211) and the fourth protrusions (3311) form a triangular forming cavity for zero R angle forming.

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