Examples of reverse machining of molds made by other companies
Introduction
When you have trouble with an old machine, the most common problem is repairing broken parts.
If a blueprint for the part exists, it can be recreated based on that, but with old molds, blueprints often do not exist, and many people give up on repairs at this point.
In such cases, reverse engineering can be used to create part drawings and restore the mold. By utilizing the experience of the mold maker and restoring the parts and adjusting the mold fit, it may be possible to restore a mold that can mold the original product.
1. Understanding the current situation
We will listen to the details of the problem that is currently occurring and check the condition of the mold.
In this case, the defect was that the shape of the convex part of the mold, which is one of the parts that form the square hole shape of the product (the convex part of the fixed side mold and the concave part of the movable side mold), was torn off for some reason, and the square hole shape was not formed in the product.
2. Consideration of restoration, reflection of new structure, elimination of cause
The original manufacturer of this mold had gone out of business, and the client had a 2D assembly drawing (paper), a 3D model of the product, and 2D data (.dxf). Therefore, instead of carrying out costly 3D scanning, we first performed Z-axis mold measurement, which was the missing information, based on the information they provided, and then placed the 3D product model on the 2D data, carrying out design work to solidify the Z-axis coordinates. After that, we considered ways to nest the relevant parts, created new nests, and machined inlay pockets for the nests in the main mold, creating a base that would allow the shape to be restored.
Furthermore, simply fitting a new insert does not resolve the original cause of the tearing, and there is a risk of further damage. Therefore, we proceeded to check the butt joint of the mold and discovered that the side of the inlay on the other side (the concave side of the butt mold) had become uneven due to years of molding, and that the welding marks that had been repaired as a temporary fix were causing a strong contact in one direction on the square-shaped side. To eliminate this cause, we uniformly welded the concave side and then used electrical discharge machining to correct the shape and dimensions. After the correction, checking the butt joint of the mold revealed a uniform contact, and we successfully eliminated the cause of the damage.
If you have any problems with old molds, please contact us!
In addition to creating drawings for mold parts, we also accept consultations regarding machinery, such as old machines that have become out of order. If you are having trouble with old molds or machines, please feel free to contact us using the inquiry form below!
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