List of Problems and Processing Sequence for T0 Trial Mold of Structural Components

List of Problems and Processing Sequence for T0 Trial Mold of Structural Components
The goal of T0 trial molding is to expose problems rather than delivering qualified parts. Processing in the order of filling, solidification, size, and demolding can reduce rework.
First, check if the charging is complete
First, let's take a look at the appearance of the first item. Shortage of materials, cold insulation, and insufficient pouring are considered as filling problems, with the highest priority, and other issues should be prioritized later.
Check the pouring temperature and mold temperature first for incomplete filling. When the temperature is below 680 ℃, the thin-walled distal end is easily not fully filled.
Check the exhaust again. Blocked exhaust plugs can cause an increase in back pressure in the mold cavity and a decrease in filling speed, resulting in unclear formation of the distal corner.
Looking at solidification and internal quality again
Perform X-ray sampling after the appearance is complete. Shrinkage is concentrated in the hot spot, indicating insufficient filling; Dispersed pores point towards high gas content in rolled air or aluminum liquid.
The adjustment sequence for insufficient shrinkage is: first change the sprue, then add some cooling, and finally consider pressurization. Reversing the order will waste trial rounds.
The problem of gas entrapment requires first reducing the speed of the sprue and then changing the direction of the sprue. When the speed decreases from 0.6m/s to 0.4m/s, the probability of entrainment decreases significantly.
The size issue comes in third place
The dimensions in the T0 stage exceed the tolerance, and some of them are normal shrinkage and unstable. The data from the first three models cannot be used as a criterion, and it needs to be tested after running 10 consecutive models.
If the dimensional deviation after stabilization is systematic, it indicates that the shrinkage rate value is incorrect and the mold should be modified. If there is a random deviation, first check the uniformity of the mold temperature.
During the T0 stage of the structural component mold, Xinfeng Mold will record the key dimensions of each mold and use trends to determine whether it is a systematic deviation or a process fluctuation.
The demolding issue will be dealt with last, but it will have the greatest impact on the pace
Pulling, sticking to the mold, and top cracking are demolding issues. Stretching is often caused by insufficient demolding slope or rough surface, and sticking to the mold is often related to high mold temperature.
If there is a top crack, it is necessary to check the synchronization of the top out and the arrangement of the top rod. If the synchronization deviation exceeds 0.5mm, thin-walled areas are prone to cracking.
The demolding issue does not affect the first piece qualification, but it will affect the production pace and mold life, and cannot be ignored just because the first piece is qualified.
Control of trial rounds
The regular project schedule consists of three rounds: T0, T1, and T2. Leave 5-10 days between each round for mold modification, and the modification content should focus on one type of problem.
T0 solves filling and obvious defects, T1 solves size and internal quality, T2 conducts small batch verification. Cross round mixed modifications can lead to difficulty in attributing issues.
If it has not converged after three rounds, it should be returned to design review instead of continuing the trial. Design defects cannot be fixed by trial molding.
Record and transfer
Each round of mold testing requires recording three sets of information: process parameters, defect location, and mold modification content. This record is the baseline for mass production debugging.
When handing over, the parameter library should be delivered together, including pressure curve, mold temperature setting, and cooling time. Without a parameter library, mass production debugging will start from scratch.
What should a qualified T0 leave behind
In addition to the first physical item, a process parameter table, defect photos, and a list of mold modifications should also be left. Only when all three are complete can T1 have a control basis.
The parameter table should record actual values rather than set values. The conclusion will be completely different if the set pressure is 0.05MPa but the actual pressure is only 0.04MPa.
Frequently Asked Questions
Q: Does T0 have to produce qualified parts?
Answer: Not necessarily, the T0 goal is to expose the problem.
Q: How many rounds of trial molding are usually conducted?
Answer: Conventional T0-T2 three wheels may have more complex parts.
Q: When will the size be measured?
Answer: Run 10 molds continuously and test again after the mold temperature stabilizes.
Question: What should be changed first to reduce looseness?
Answer: First change the gate, then add some cooling, and finally consider applying pressure.
Q: How to deal with sprains?
Answer: Check the demolding slope and surface roughness of the mold cavity.
Q: Do I need to submit the trial mold record?
Answer: It should be handed over along with the mold as a production baseline.
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