I. Anchoring Method for Baseline Parameters
Begin by adjusting the temperatures of the barrel and mould in accordance with the official material specifications. Initially, the injection pressure was set to 60% of the maximum value of the equipment, the holding pressure to 30% of the maximum value, and the injection speed to 40% of the maximum value. Regulate the back pressure within the range of 3 to 8 bar.
This bypasses the extensive and ineffective trial and error process, securing the machine adjustment's starting point within a reasonable process window that is appropriate for the majority of common injection moulding scenarios.
II. Boundary Locking Method with a Single Factor:
Maintain the same values for all other parameters and individually modify a single core parameter. Determine the upper and lower limits of the parameter in the event that it has a defect, and select the middle safe range as the optimal setting.
This method can rapidly establish the safe range of core parameters, including injection speed and holding pressure, thereby preventing the variable pandemonium that results from simultaneously adjusting multiple parameters.
II. Method for Positioning the Rapid Pressure Transfer Point
Set the holding pressure to 0 for a temporary period and progressively increase the injection pressure until the mould is fully filled without any short shots. The optimal pressure transfer point is in the screw stop position at this point.
The switching boundary between filling and holding pressure can be precisely secured within 10 minutes, thereby preventing insufficient filling due to premature switching or excessive holding pressure due to late switching, which can cause flash.
III. Method for Determining Gate Cooling Time
Gradually increase the holding pressure duration until the product weight no longer experiences a substantial increase. The holding pressure time is determined by the gate cooling period.
This prevents the formation of contraction marks as a result of insufficient holding pressure and the squandering of moulding cycle time as a result of excessive holding pressure, thereby securing the optimal holding pressure time in a single step.
IV. Method for Optimising Cooling Time
While verifying that the product is not deformed, cracked, or whitening upon ejection, gradually decrease the cooling time. The optimal cooling time is the shortest possible at this juncture.
This directly reduces unnecessary cooling redundancy, thereby maximising the reduction of moulding cycle time and ensuring product quality.
V. The Method of Mature Formula Reuse and Adjustment
Record material batch numbers and environmental temperature and humidity information in the formula database, where previously verified and qualified parameter sets for the same material and mould are stored. These can be directly recalled with a single click during production changeovers, necessitating only ±5% fine-tuning to quickly restore stable production.
This universal adjustment method is seamlessly integrated with the precision multi-cavity mould injection production line that you are currently operating. The original setup time of several hours can be reduced to less than 30 minutes by ordinary maintenance engineers, who can rapidly begin.
