Lamp is an indispensable set of auto parts. Whether it is a traditional or scientific and technological fashion model, the main parts of lamp are inseparable from headlamp body, reflector, decorative frame and light distribution mirror. As the most demanding parts of automobile appearance parts, the requirements of mold design and manufacturing process are also very high. First, the challenge comes from the headlight body.
The automobile lamp body is an internal functional part. Although the appearance requirements are not high, there are many assembly holes and buckles, which means that there may be the following risks in the design and manufacture of the lamp body mold:
1. There are many die inclined tops, sliders and inserts, which are easy to break and flash;
2. Complex water transportation structure / difficult cooling;
3. Large amount of discharge motor / more monomer electrodes
Secondly, for the mirror, we need to combine the particularity of product specifications to carry out mold design.
The reflector, also known as the reflector, is a part of the automobile headlamp lighting system to reflect and avoid direct light. It is an appearance part. The surface is electroplated with high gloss and has a large area of texture for surface decoration. Because the mirror needs to work in a high temperature environment, it is required to be beautiful while realizing the purpose of reflection and concentration. Therefore, automobile manufacturers often choose prefabricated integral molding compound (BMC) thermosetting plastic with heat resistance, flame retardancy and strong creep resistance to form the mirror.
In view of the manufacturing requirements of mirror with strict light distribution and direct aluminum plating, Hanyi industry suggests that attention should be paid to the following in mold design:
1. The parting surface of the die cannot be avoided, and it is easy to have flash;
2. The intersection position and welding line shall be accurately analyzed in the early stage;
3. The front and rear mold heating rods are evenly and reasonably distributed to prevent deformation;
4. Jacketing shall be added to prevent high temperature burning;
5. The surface texture contour requires high precision;
6. The mold core shall not be easily disassembled as far as possible to avoid internal batch edge of the product.
Thirdly, for the lamp decorative frame, we should pay attention to the realization of its high surface requirements to do the mold design.
The lamp decorative frame is a decorative part of the automobile headlamp lighting system. It is located inside the lens and assembled with the lens. People can see the decorative frame from the outside of the lamp through the lens. Generally, the manufacturing materials of the lamp decorative frame are PC, PBT + GF, PBT + pet, PA + GF, and the surface plating is required.
Therefore, the experience of Hanyi industry is to select high-quality mold materials, and pay attention to:
1. The intersection position and welding line shall be accurately analyzed in the early stage;
2. The front mold shall be smooth and prevent sticking to the front mold;
3. Water transportation and ejection design to prevent deformation;
4. Pay attention to the texture depth to prevent flow print
Finally, the lens also needs high-quality mold design and mold manufacturing to complete the product molding.
Light distribution mirror, also known as lens, is the outermost transparent part of automobile headlamp. Generally, the headlights of automobiles are white and transparent, and the rear combination lamps are red (or multi-color) and transparent. The surface of the light distribution mirror is a class a curved surface (i.e. the gap between adjacent curved surfaces is 0.001 ~ 0.005mm, the curvature change is less than 0.005 degrees, and the shear change is less than 0.16 degrees). The outer surface has superhard coating, and the transparency of the inner and outer surfaces is very high.
Key points of mould:
1. The intersection position and welding line shall be accurately analyzed in the early stage;
2. There is line printing control of internal drawing line, inclined top line and thimble line;
3. The design of two-color / three-color and multi-color parting sealing surface is very important;
4. Pay attention to the texture depth to prevent flow print;
5. The exhaust design shall be sufficient, reasonable and effective;
Based on the above product requirements and mold characteristics, immetech has perfect solutions from raw materials to mold delivery:
All materials are selected from professional automobile die steel manufacturers such as smubagen in Germany / Datong in Japan / yishengbai in Sweden;
The machining adopts high-precision and high-end imported equipment: DMG (CNC) and Fanuc (CNC) / Mitsubishi mirror and Makino (EDM) / Sodick (WEDM) / EROWA processing system
Selection of standard parts: the mold embryo is DME / HASCO / Futaba / LKM; 2. The hot runner is synthetic / INCOE / mold Masters / YUDO; 3. The oil cylinder is Parker / SMC / Heb / Merkle / HPS
Professional and scientific inspection methods are adopted in each link from design to mold delivery: design is verified by professional UG design software and Moldflow verification software / steel is verified by ht110 hardness tester / machining is verified by hexcon three-dimensional measurement system / surface is verified by jd520 surface roughness instrument / assembly is verified by shunxin200t flying mold machine / product molding feasibility is verified by 1920t three-color injection molding machine.