I. Fundamental Preparation Prior to Debugging
Verify that the material is sufficiently dry, the barrel and mould temperatures are calibrated in accordance with the material's properties, and the fundamental parameters, including the ejection distance and equipment operation, are verified and are found to be accurate.
Set the initial baseline parameters as follows: The injection pressure is set to 60% of the maximum value, the holding pressure is set to 30% of the maximum value, the injection speed is set to 40% of the maximum value, the back pressure is approximately 10 kg/cm², and the holding pressure switching position is set to 30% of the screw diameter.
II. Accurately Determine the Switching Point
Set the holding pressure to 0 and progressively increase the injection pressure until the mould is fully filled without any short shots. The switching point is the position at which the screw stops.
This procedure can promptly secure the boundary parameters of the filling stage, thereby preventing short shots or overflow issues during consecutive machine adjustments.
III. Calculate the Gate Cooling Time
Gradually increase the holding pressure duration until the product's weight no longer experiences a substantial increase. The gate cooling time is represented by this duration.
This will prevent contraction marks caused by insufficient holding pressure and prevent the waste of moulding cycles due to excessive holding pressure by using this as a baseline to establish the holding pressure time.
IV. Optimise Injection Speed While maintaining the holding pressure as the initial baseline, alter the injection speed up and down to determine the minimum speed at which short shots occur and the maximum speed at which burrs appear. Choose the pace that is halfway between these two values as the optimal injection speed.
This procedure rapidly stabilises the optimal filling speed, thereby achieving a balance between the quality of the product and the efficiency of the filling process.
V. Secure the holding pressure To determine the minimum pressure at which surface depressions occur and the maximum pressure at which burrs appear, adjust the holding pressure upward and downward. Choose the midpoint between these two pressures as the optimal holding pressure.
Without the need for repeated large-scale trial and error, this method rapidly establishes holding pressure parameters that strike a balance between dimensional accuracy and appearance.
VI. Maximise Cooling Time While guaranteeing that the mould temperature remains stable and balanced, gradually decrease the cooling time to prevent whitening, cracking, or deformation during ejection. The optimal chilling duration is the shortest possible time under these circumstances.
The optimal process combination that optimises production efficiency and product quality is represented by the final set of parameters.
The precision multi-cavity mould injection production line you are operating is optimally suited to this standardised setup process. The setup time can be reduced from several hours to less than 30 minutes by ordinary maintenance engineers, who can rapidly begin.
