Tool testing and tuning

Our molds are the result of a very complex industrial process itself made up of the stacking of numerous of non-less complex elementary processes which all have to be perfectly controlled to enable the achievement of the expected result which is a high precision plastic gear. To succeed in the industrialization of such tools, it is mandatory to be able to rely with the highest confidence level on each of these elementary processes that are the tests, parts measurements, definition and carrying out of tool corrections.

The first test is the foundation of the overall industrialization process

Among all these elementary processes, the first test is a basis for all the following ones and has to be considered as the foundations of the overall industrialization process. For that reason we attach a peculiar care to this first test of our new tools, checking the injection balancing, the good venting, the appropriate ejection that not stresses too much the parts, the plotting weighting curve, the checking of the kinematics... all activities which finally have to be done to define the injection parameters sheet for the whole life of the project.

Example of tool adjustments

Molds for precision gears requires significant correction works of toothed elements, especially when they are developed to process filled materials (materials filled with glass fibers, carbon fibers or aramid fibers for example) ITWSmpi is very experienced in tooth-to-tooth correction and have developed a unique method to correct the toothed elements on the basis of special scanning measurements of teeth flanks. Depending on the gear structure (i.e. the rim of the wheel), but also on the material type (if it is filled or not), and on injection system (position and number of injection gates), we may be forced for example, to implement a different correction of helix angle on right flank compared to the left one and this, in a different way for each tooth. Precision gears can then be obtained only with a great knowledge of molding, gear metrology, defect analysis, correction definition and fine adjustment of gear cavity.