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During the stamping production process, mold failure is one of the most common problems. Taking the factory of Hanai Company as an example, our mold technicians are constantly modifying, repairing and debugging molds in the mold workshop every day. Because molds directly affect production efficiency and costs.

1. Mold damage

Mold damage refers to situations such as cracking, breaking, and expansion of the mold. This is the most serious type of fault.

Excessive temperature of materials and heat treatment, improper number and duration of tempering, can all lead to excessive internal stress in the mold, which is prone to damage during production; in terms of design, insufficient size or depth of the blanking hole can easily cause blockage of the slot hole; including incorrect installation of parts during use, improper tightening of bolts, too low working height adjustment, and failure to handle foreign objects in the mold in time, all can damage the mold.

During the initial inspection, we must ensure that each process meets the requirements and keep work records. Moreover, we should strengthen the training of operators, and inspect the mold status before and after each production run to promptly identify potential hazards. Regular maintenance of molds is like having regular physical examinations for us humans. Only in this way can we increase the lifespan of the molds.

2.Die Failure

Die failure refers to the situation where the die fails to close smoothly or gets stuck during the stamping process, significantly affecting the production cycle.

Common causes:

• Poor die guidance or foreign objects between the templates

• Insufficient strength design of the die or uneven force distribution

• Insufficient strength of the punch, or the positions of the large and small punches being too close resulting in unbalanced lateral force 

Solution:

• Regularly clean the interior of the mold, and inspect the wear of the guide pins and guide sleeves.

• Reassess the structural strength of the mold and, if necessary, add reinforcing ribs.

• Adjust the layout of the punch to balance the lateral forces.

• Use lubricants to reduce friction.

3. Mold Life Management

Mold life refers to the number of parts that a mold can produce under normal usage conditions. Reasonable management of mold life can reduce production costs and improve product quality.

The main factors affecting mold life are:

The material of the mold, processing technology, stamping speed, and lubrication degree all affect its lifespan. Excessive speed will increase impact loads, and poor lubrication will exacerbate wear.

We need to carry out regular repair measures to extend mold life:

• Select appropriate mold materials based on the requirements of the stamped parts

• Optimize heat treatment processes to achieve a good match of hardness and toughness

• Control the stamping speed to avoid overloading

• Regularly add lubricants to reduce friction

• Establish mold maintenance files to record each use and repair situation

Summary

Mould failures are inevitable issues in the production process. However, by following standardized operations, conducting timely maintenance, and implementing scientific management, the occurrence rate of failures can be significantly reduced.

✅Hainan Company has achieved the following:

1. Established a daily inspection system for moulds

2. Trained operators to have basic fault diagnosis capabilities

3. Recorded the causes and handling methods of each failure, forming a knowledge base

4. Regularly invited professionals to conduct comprehensive inspections of the moulds

Go to:  One-stop service - hainamould Mould Company Limted

If you have encountered other typical failures in actual production, please feel free to leave a message for communication.