It was found that in-mould punching and forming could be achieved by utilising the sleep pin and centre pin. However, a new problem arose in the implementation of continuous moulding for mass production.
Mass production assumption issues① Punched resin tabs do not cut off.
The punching pin tip angle was set at 60°, but when repeated forming was carried out
The tabs did not cut away and could only be crushed.
However, when the tip angle was sharpened to 30°, the tip became brittle and easily chipped.
Therefore, an angle of 45° was set so that the resin would not be crushed and the tip would not be applied.
Mass production assumption issues②-1 The punched resin tabs remain on the CAV side.
If the next moulding is carried out with resin tabs remaining on the CAV side, the resin tabs will be pinched.
In the worst case, damage is left on the mould side, such as pins.
Therefore, an undercut is provided so that the punched resin tab remains on the COR side.
Mass production assumption issues②-2 The punched-out resin tabs remain on the COR side.
The resin tabs are now left on the COR side, but if they fall out as they are when the product is extruded
However, if they fall out when the product is ejected, there is a possibility of them being caught in the mould.
Therefore, the machine is set to pick up the cut resin tabs before the product is ejected with a suction cup during the automatic ejecting phase.
The above measures enabled mass production to commence without problems.
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