During the stamping process, if the mold does not close smoothly or even gets stuck, production must be immediately halted to identify the cause of the jam and rectify the fault. Failure to do so may exacerbate the issue, leading to mold damage. The primary causes of mold jamming include: poor mold guidance or inclination, foreign objects between the mold templates preventing them from lying flat, insufficient mold strength design or uneven distribution of forces, causing deformation such as the mold base or template hardness and thickness being too small, making them prone to deformation from external impacts; incorrect mold positioning with excessive alignment errors between the upper and lower dies; or the press's poor accuracy causing interference with the mold; insufficient strength of the punches, or the nearness of the large and small punch positions, leading to unbalanced lateral forces on the mold. At this point, the punch strength should be increased and the guide protection of the ejector plate should be enhanced.
Tape vulcanizing machine mold damage and repair, as well as the high costs of molds for stamping production, typically account for 1/5 to 1/4 of the total cost of the parts. This is due to the high difficulty and cost of mold manufacturing, as well as the significant expenses for repair and maintenance after production, which only represent about 40% of the original mold cost. Therefore, timely mold repair and preventing damage can significantly reduce the mold costs for stamping production. After mold damage, there is also the issue of repair versus scrapping. Generally, non-natural wear and tear failures of stamping molds, such as the destruction of non-critical parts, as well as issues like broken small punches, punches deformed and shortened, cracking of the die face, and chipping of the cutting edge, can mostly be fully restored through repair and reintroduced into production. However, when critical mold parts are severely damaged, sometimes both the punch and die are affected simultaneously, and the one-time repair cost exceeds 70% of the original mold cost, or the mold's lifespan is nearly over, the significance of repair diminishes. In such cases, considering scrapping the mold is advisable: except for large molds and complex continuous molds, when mold repair technology is overly complex, repair costs are excessive, and the difficulty leads to a prolonged repair cycle, severely impacting normal production, it is advisable to opt for early failure and scrapping, and then remanufacture the mold.
Under normal circumstances, the primary form of failure for tape vulcanizing machine dies is excessive wear. Once the new mold is manufactured and put into use, it will go through multiple repairs and sharpenings until the burrs on the parts exceed the standard, or the part dimensions and positional accuracy are out of tolerance. If the mold can no longer be repaired or is of no repair value, it must be scrapped. The time from the introduction of a new mold to its failure and scrapping generally involves several repairs and sharpenings.
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