In the plastic extrusion production process, the die head is a key forming component, and its working condition directly determines the product's appearance quality and dimensional stability. However, dies operate under high temperature, high pressure, and high shear conditions for extended periods, making them prone to problems such as carbon buildup, material blockage, and dimensional deviations. Inadequate maintenance can even lead to serious consequences such as production stoppages and scrapping.
Below, we'll discuss the key points for maintaining and caring for extrusion dies to extend their lifespan and reduce equipment failure rates!
一、Why is mold maintenance important?
Keeping the die runner clean ensures uniform melt distribution, preventing issues like uneven thickness, ripples, and surface defects in the product. Proper maintenance slows down die wear, corrosion, and deformation, extending its lifespan.
Scientific maintenance is far more cost-effective than frequent major repairs or die replacements, reducing operating costs for businesses. Early detection and resolution of problems avoid production line downtime due to die malfunctions, ensuring production stability.
二、Routine maintenance points
1. Check the following for 10 minutes daily:
• Whether the die head temperature control is normal, and whether there is overheating or uneven heating;
• Whether there is material leakage, dripping, or hanging;
• Whether the die head surface is clean, and whether there are carbon deposits or residues attached;
• Whether the fasteners are loose, and whether the screws, flanges, and other parts are intact.
2. Daily Cleaning Recommendations:
•Use a special copper scraper or wooden stick to gently scrape away any residual material adhering to the die head opening;
•Do not use steel tools to prevent scratching the die cavity surface;
•Regularly wipe the outer surface of the die head with a non-woven cloth dampened with alcohol to keep it clean and tidy.
When producing extrusion equipment such as flat dies, JVR fully considers the convenience of daily maintenance. Its die structure is reasonably designed, making it easy for staff to clean and inspect, thus providing convenience for efficient maintenance from the source.
三、Regular maintenance (recommended every 3 months)
1.Mold Internal Cleaning:
After shutdown, disassemble the mold head and clean the carbon deposits and coke from the runner. Use a specialized cleaning agent (such as a mold release agent or extrusion cleaner) or a low-melting-point cleaner for internal rinsing. If the blockage is severe, place the mold in a heating oven to soften the residue before manually removing it.
2.Check for Wear and Corrosion:
Focus on inspecting the mold lip and cavity for obvious wear or corrosion spots. If slight wear is found, polishing can be performed. Severe damage should be repaired or the part replaced immediately.
3.Lubrication and Rust Prevention:
When the mold head is not used for a long period, be sure to apply rust-preventive oil to the surface and seal it for storage. Apply high-temperature grease to the screws to prevent jamming or corrosion.
四、Common problems and solutions
•Note that the heating and cooling processes should be carried out gradually to avoid mold cracking due to excessive temperature difference;
•Extrusion is prohibited before the die head reaches the set temperature to prevent damage caused by forced pushing;
•When assembling and disassembling the mold, pay attention to applying force symmetrically and evenly to prevent misalignment and deformation;
• Train operators to master the correct mold usage specifications and maintenance procedures.
| Problem | Cause Analysis | Suggested Solutions |
| Uneven product thickness | Clogged flow channels or uneven temperature in the die head | Clean the flow channels and check the temperature controller in the heating zone |
| Black spots and impurities appear | Carbon deposits inside the die head fall off | Stop the machine and clean the mold using cleaning material |
| Mold lip material accumulation | Melt overheating, excessive shear | Lower melt temperature and optimize flow rate |
| Die head leakage | Loose fasteners and aging seals | Inspect and replace gaskets or screws |
The die is the "heart" of extrusion production, and even the most advanced equipment requires meticulous daily maintenance. A scientifically sound maintenance process ensures your die head remains in optimal condition, guaranteeing the continuous production of high-quality products.
Suzhou Jwell Precision Machinery is committed to providing customers with high-quality extrusion equipment and related services. If you encounter any problems during die use or maintenance, please leave a message or contact our technical service team. We will be happy to assist you!
