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The quality of the hydraulic system of the injection molding machine not only depends on the rationality of the system design and the performance of the system components, but also due to the pollution protection and treatment of the system, the pollution of the system directly affects the reliability of the hydraulic system of the injection molding machine and the use of components According to statistics, about 70% of hydraulic system failures of injection molding machines at home and abroad are caused by pollution.

The main hazards of oil pollution to the system are as follows:

1) Contamination and wear of components
Various contaminants in the oil cause various forms of wear of the components, and solid particles enter the gap of the moving pair, causing cutting wear or fatigue wear on the surface of the part. The impact of solid particles in the high-speed liquid flow on the surface of the component causes erosion and wear. The water in the oil and the oxidation and deterioration products of the oil have a corrosive effect on the components. In addition, the air in the oil of the system causes cavitation, which leads to erosion and damage to the surface of the components.

2) Cnc steel parts blockage and clamping failure
Solid particles block the gaps and orifices of the hydraulic valve, causing blockage and clamping of the valve core, affecting the performance of plastic machining, and even causing serious accidents.

3) Accelerate the deterioration of oil performance
The water and air in the oil are the main conditions for oil oxidation due to their thermal energy, and the metal particles in the oil play an important role in the oxidation of the oil. In addition, the water and suspended bubbles in the oil significantly reduce the movement. The strength of the oil film reduces the lubrication performance.

Pollution is the primary culprit for the failure of the injection molding machine hydraulic system!

  1. Types of pollutants

Pollutants are substances that are harmful to the system in the hydraulic system of the injection molding machine. They exist in different forms in the oil. According to their physical forms, they can be divided into solid pollutants, liquid pollutants, and gaseous pollutants.

Solid pollutants can be divided into hard pollutants, including: diamond, cutting, silica sand, dust, wear metals and metal oxides; soft pollutants: additives, water condensate, oil decomposition products and uhmw machining polymers And the cotton thread and fiber brought in during maintenance.

Liquid contaminants are usually grooving oil, water, paint, and chlorine and its halides that do not meet the system requirements. It is usually difficult for us to remove them. Therefore, when choosing hydraulic oil, choose hydraulic oil that meets the system standards to avoid unnecessary failure.

Gaseous pollutants are mainly air mixed into the system.

These particles are often so small that they cannot settle down and are suspended in the oil, and are finally squeezed into the gaps of various valves. For a reliable injection molding machine hydraulic system, these gaps have a limited effect. Control, importance and accuracy are extremely important.

  1. The source of pollutants:

The sources of pollutants in the system oil mainly include the following aspects:

1) Externally invading pollutants: The externally invading pollutants are mainly sand or dust in the atmosphere, which usually enter the system through the air holes of the fuel tank, the sealing shaft of the oil cylinder, and the shaft of the pump and the motor. Mainly the impact of the use environment.

2) Internal contaminants: The contaminants remaining in the components during processing, assembly, debugging, packaging, storage, transportation and installation. Of course, these processes cannot be avoided, but they can be minimized. Some special components are in the assembly and Debugging needs to be carried out in a clean room or clean bench environment.

3) Pollutants generated by the hydraulic system of the injection molding machine: particles generated by the wear of the components during the operation of the system, sand particles falling off castings, metal particles falling off pumps, valves and joints, and corrosion and spalling in the pipeline. The particles and jelly produced by the oxidation and decomposition of the oil, and more serious, are the large amounts of impurities in the system pipelines that have not been flushed before they are officially put into operation.

  1. System maintenance

A system is generally flushed before it is officially put into use. The purpose of flushing is to remove the contaminants, metal chips, fiber compounds, iron cores, etc. remaining in the system. During the first two hours of work, even if the system is not completely damaged, it will Cause a series of failures. Therefore, the oil circuit of the system should be cleaned according to the following steps:

1) Clean the oil tank with an easy-to-dry cleaning solvent, and then use filtered air to remove solvent residues.
2) Clean all pipelines of the system. In some cases, it is necessary to immerse the pipelines and joints.
3) Install oil filter in the pipeline to protect the oil supply pipeline and pressure pipeline of the valve.
4) Install a flushing plate on the collector to replace the sandcasting valve, such as an electro-hydraulic servo valve.
5) Check whether all pipelines are of proper size and connected correctly.

If an electro-hydraulic servo valve is used in the system, I might as well say a few more words. The flushing plate of the servo valve should enable the oil to flow from the oil supply line to the collector and return directly to the oil tank, so that the oil can circulate repeatedly. Flush the system to allow the oil filter to filter out solid particles. During the flushing process, check the oil filter every 1 to 2 hours to prevent the oil filter from being blocked by contaminants. Do not open the bypass at this time. If it is found that the oil filter starts to block Change the oil filter immediately.

The cycle of flushing is determined by the structure of the system and the degree of system pollution. If the sample of the filter medium has no or few foreign pollutants, install a new oil filter, remove the flushing plate, and install the valve to work!

Planned maintenance: Establish a regular system maintenance system. The suggestions for a better maintenance system for the hydraulic system of the injection molding machine are as follows:

1) The oil filter should be inspected and replaced at most 500 hours or three months.
2) Flush the imported oil filter of the oil pump regularly.
3) Check whether the hydraulic oil is contaminated by acidification or other pollutants. The smell of the hydraulic oil can roughly identify whether it has deteriorated.
4) Repair leaks in the system.
5) Ensure that no foreign particles enter the fuel tank from the vent cap of the fuel tank, the plug seat of the oil filter, the sealing gasket of the oil return line and other openings of the fuel tank.

Pollution is the primary culprit for the failure of the injection molding machine hydraulic system!The quality of the hydraulic system of the injection molding machine not only depends on the rationality of the system design and the performance of the system components, but also due to the pollution protection and treatment of the system, the pollution of the system directly affects the reliability of the hydraulic system of the injection molding machine and the use of components According to statistics, about 70% of hydraulic system failures of injection molding machines at home and abroad are caused by pollution.

The main hazards of oil pollution to the system are as follows:

1) Contamination and wear of components
Various contaminants in the oil cause various forms of wear of the components, and solid particles enter the gap of the moving pair, causing cutting wear or fatigue wear on the surface of the part. The impact of solid particles in the high-speed liquid flow on the surface of the component causes erosion and wear. The water in the oil and the oxidation and deterioration products of the oil have a corrosive effect on the components. In addition, the air in the oil of the system causes cavitation, which leads to erosion and damage to the surface of the components.

2) Cnc steel parts blockage and clamping failure
Solid particles block the gaps and orifices of the hydraulic valve, causing blockage and clamping of the valve core, affecting the performance of plastic machining, and even causing serious accidents.

3) Accelerate the deterioration of oil performance
The water and air in the oil are the main conditions for oil oxidation due to their thermal energy, and the metal particles in the oil play an important role in the oxidation of the oil. In addition, the water and suspended bubbles in the oil significantly reduce the movement. The strength of the oil film reduces the lubrication performance.

  1. Types of pollutants

Pollutants are substances that are harmful to the system in the hydraulic system of the injection molding machine. They exist in different forms in the oil. According to their physical forms, they can be divided into solid pollutants, liquid pollutants, and gaseous pollutants.

Solid pollutants can be divided into hard pollutants, including: diamond, cutting, silica sand, dust, wear metals and metal oxides; soft pollutants: additives, water condensate, oil decomposition products and uhmw machining polymers And the cotton thread and fiber brought in during maintenance.

Liquid contaminants are usually grooving oil, water, paint, and chlorine and its halides that do not meet the system requirements. It is usually difficult for us to remove them. Therefore, when choosing hydraulic oil, choose hydraulic oil that meets the system standards to avoid unnecessary failure.

Gaseous pollutants are mainly air mixed into the system.

These particles are often so small that they cannot settle down and are suspended in the oil, and are finally squeezed into the gaps of various valves. For a reliable injection molding machine hydraulic system, these gaps have a limited effect. Control, importance and accuracy are extremely important.

  1. The source of pollutants:

The sources of pollutants in the system oil mainly include the following aspects:

1) Externally invading pollutants: The externally invading pollutants are mainly sand or dust in the atmosphere, which usually enter the system through the air holes of the fuel tank, the sealing shaft of the oil cylinder, and the shaft of the pump and the motor. Mainly the impact of the use environment.

2) Internal contaminants: The contaminants remaining in the components during processing, assembly, debugging, packaging, storage, transportation and installation. Of course, these processes cannot be avoided, but they can be minimized. Some special components are in the assembly and Debugging needs to be carried out in a clean room or clean bench environment.

3) Pollutants generated by the hydraulic system of the injection molding machine: particles generated by the wear of the components during the operation of the system, sand particles falling off castings, metal particles falling off pumps, valves and joints, and corrosion and spalling in the pipeline. The particles and jelly produced by the oxidation and decomposition of the oil, and more serious, are the large amounts of impurities in the system pipelines that have not been flushed before they are officially put into operation.

  1. System maintenance

A system is generally flushed before it is officially put into use. The purpose of flushing is to remove the contaminants, metal chips, fiber compounds, iron cores, etc. remaining in the system. During the first two hours of work, even if the system is not completely damaged, it will Cause a series of failures. Therefore, the oil circuit of the system should be cleaned according to the following steps:

1) Clean the oil tank with an easy-to-dry cleaning solvent, and then use filtered air to remove solvent residues.
2) Clean all pipelines of the system. In some cases, it is necessary to immerse the pipelines and joints.
3) Install oil filter in the pipeline to protect the oil supply pipeline and pressure pipeline of the valve.
4) Install a flushing plate on the collector to replace the sandcasting valve, such as an electro-hydraulic servo valve.
5) Check whether all pipelines are of proper size and connected correctly.

If an electro-hydraulic servo valve is used in the system, I might as well say a few more words. The flushing plate of the servo valve should enable the oil to flow from the oil supply line to the collector and return directly to the oil tank, so that the oil can circulate repeatedly. Flush the system to allow the oil filter to filter out solid particles. During the flushing process, check the oil filter every 1 to 2 hours to prevent the oil filter from being blocked by contaminants. Do not open the bypass at this time. If it is found that the oil filter starts to block Change the oil filter immediately.

The cycle of flushing is determined by the structure of the system and the degree of system pollution. If the sample of the filter medium has no or few foreign pollutants, install a new oil filter, remove the flushing plate, and install the valve to work!

Planned maintenance: Establish a regular system maintenance system. The suggestions for a better maintenance system for the hydraulic system of the injection molding machine are as follows:

1) The oil filter should be inspected and replaced at most 500 hours or three months.
2) Flush the imported oil filter of the oil pump regularly.
3) Check whether the hydraulic oil is contaminated by acidification or other pollutants. The smell of the hydraulic oil can roughly identify whether it has deteriorated.
4) Repair leaks in the system.
5) Ensure that no foreign particles enter the fuel tank from the vent cap of the fuel tank, the plug seat of the oil filter, the sealing gasket of the oil return line and other openings of the fuel tank.

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