27.1 Introduction:
Mould polishing is a very important step in producing a mould that works properly and a
part that is functional and visually attractive. Proper finishing of the mould is important for
the release of the part. Polishing insures that the part is not damaged during ejection.
For example, scratches from rough surfaces or dents from ejector pin. It also prevents
damage to the mould that could occur if the mould closed on a part stuck in the mould.
The finish of the molding largely depends on the finish of the cavity and core.
27.2 Release:
Release is the ability of the mould to eject the component. To accomplish this, all cutter
marks must be removed from the moulding surface of the cavities and cores. Further, the
finish should be vertical, from bottom of the cavity or core to the parting surface, to aid in
the ease of ejection. This is called draw stone. This also will speed up the moulding
cycle.
27.3 Appearance:
There are different types of appearance required after finishing. They are
a) Rough finishing:
There are mainly three types of rough finish. The first is called draw stone. This is the
most basic of all finishes. It is strictly for release. Te second is a sand blast or glass bead.
This produces a matte finish, creating non-slippery, non-reflective surfaces. The third
type is a textured finish. This is done to create a specific appearance, such as wood
grain, leather or pebbly textures.
b) Mirror finishing:
A mirror finish is called diamond finish. There are three basic diamond finishes. The first,
a rough diamond, is primarily used for release or as a preparation for a very fine texture.
A diamond, the most often specified, is used to enhance the appearance of opaque parts
and the ability to see through clear and translucent parts. A high shine or #1 diamond is
necessary for optical or highly reflective parts.
c) Texturing:
To prepare a surface for texturing, you must know what the texture will be. This is
necessary to prevent over or under polishing. Basically, the finer the texture, the finer the
finish needs to be.
The product designer of a finished plastics product desires some sort of surface finish to
the component. As a general rule it is considered that all moulding surfaces of a mould
must be provide a mirror polish. A mirror polished moulding surface helps the moulds in
many ways as given below
Easy flow of molten plastics material ( melt) into the moulds
Easy ejection of finished product from the mould
Glazing attractive surface for a commercial product
Good transparency for clear plastics materials
High brilliance and reflectability for optical and automobile lamp reflectors
Rough surface of moulds would be liable to retain acids and leading to localized
corrosion
27.4 Overview of the process:
The polishing process involves a number of steps that must be performed in the proper
order. This will ensure the best finish in the least amount of time. Remember, polishing is
replacing one set of scratches with finer set of scratches until the desired finish is
reached.
Polishing can be done by following method
Lap first with rough grade lapping paste (emery paper) to remove machining
marks
After that medium and fine grade of lapping pastes (emery paper) are applied to
give good finish
Final polishing is done by chrome powder
Diamond pastes of different grades are also used
Amount of material removal is only a few hundredth
Care must be taken to remove all machining marks initial stage itself to save time.
They are used with the same cutter and abrasives as die and pencil grinders. They are
useful for getting into tight places like cavity side walls. They also
afford the polisher more control when using abrasive discs. Right
angled heads are available in air-drive and electric with flexible
shafts.
d) 45 Degree Head:
The 45 degree head is a variation of the right angle head. It is used
with the same cutters and abrasives as the right angle head. They
are good for getting into tight spots and the bottom surfaces of
deep cavities. 45 degree heads are available in air drive and
electric with flexible shafts.
e) Profiler:
The profiler is a reciprocating hand piece. It reciprocates 2000 to 10000 times per
minute. Stroke length is set on a cam inside the body. Profilers are the most frequently
used piece of polishing equipment. They are used to push small files, polishing stones,
wood and brass laps, and felt buffs. Profilers are available in air and electric with flexible
shafts.
a) Mill bastards
Large files, called mill bastards, are rarely used in polishing but they deserve a mention
because on occasion they are used during the benching process. Mill bastards came in
four basic shapes. Flat, round, triangle and oval. Typically 8 to 12 inches long, they have
coarse teeth and can remove larger amount of steel. Because of this, caution should be
used with these tools. They are used for flattening, initial smoothening or large radii and
cleaning out corners. They are always pushed by hands.
b) Refflers
Small files, called refflers, are used much more frequently than larger files. Rifflers are
used in the benching phase of polishing. They come in many shapes and configurations.
Typically rifflers are six inch long with a small cutting surface on each end. They are used
for initial smoothing in hard to reach and detail areas. Rifflers can be used by hand or
with a profiler.
c) Diamond files
The name diamond file refers to the cutting medium not the shape. They are used in both
benching and smoothening phases. Diamond files are 3 to 6 long with a cutting
surface if 1 to 4. They come in four shapes flat, round, half round and triangle. Diamond
files are made by electroplating diamond particles to a file blank. They are excellent for
use during an EDM process. Diamond files can also be used to install all
radii. They can be used by hand removing cutter marks from thin ribs, especially when
the ribs have been burned during EDM process. Diamond files can be used by hand but
are most effective when driven by a profiler.
d) Grinding wheels
These are wheels mounted at the tip of a shank. Different shapes are available depends
on the usage. These wheels are clamped on air grinders and can be used for removing
material during benching. Deep cutter marks can be removed by this process.
e) Flap wheels
Flap wheels are strips of emery with one end epoxied to an arbor. Flap wheels are 1 t0
4 in diameter. They are used with the die grinders. Because they are resilient, flap
wheels works well on flat and contoured surfaces. Flap wheels are not aggressive
enough to remove cutter marks. They are used to take out disc and cartridge roll marks.
Flap wheels work best when only light pressure is applied.
f) Stones
Stones are manufactured sticks. Aluminum oxide and silicon carbide are the abrasive
particles used. They are used in the final finishing phase of polishing. Stones are square,
rectangular or round. Sizes range from x 1/8 to 1 square inch, but all are 6 long.
Grits range from 120 very coarse to 1200 very fine. Coarse stones (120 400) are for
removing cutter marks and benching marks. Finer stones are used to refine the finish
and to prepare for diamond finishing. Stones are used with a profiler and by hand for a
draw stone finish. Stones should be used with a lubricant such as mineral spirit to
prevent loading up.
g) Emery
Emery is a cloth with abrasive material glued to one side and is used in the final finishing
phase. Emery comes I 1 and 2 widths on rolls of varying lengths. Grits range from 60 to
600. Emery is pushed by hand or by wrapping it over a stick. When wrapped over a stick,
a rubber pad should be glued to the contact surface. The emery should be used with
lubricant to prevent loading and to produce a finer finish. Emery is used to smooth large
h) Diamond compound
Diamond compound is a mixture of diamond particles and a grease base. Diamond
i) Brushes
Brushes are made from animal hair, nylon and brass. Brushes are available from coarse
to soft. They come in three shapes- cup, wheel and end. They are available in many
sizes. Brushes are the most common way of driving diamond compound. Cup brushes
are used to diamond corners and flat surfaces. Wheel brushes are used in inside
diameters, side walls, parting lines, radii and round pins. End brushes are used on flat or
lightly curved surfaces. Brushes are driven with die or pencil grinders, right angle and 45
degree angle heads. Light pressure and slow speeds of 2000 to 3000RPM are
recommended.
j) Buffs
Buffs are available in many different sizes and shapes. Buffs are used to eliminate brush
marks and to increase the shine. Buffs come in hard, medium and soft. The harder the
buff, the more cut. The softer the buff, the more shine. Buffs are driven with die and
pencil grinders, right angle and 45 degree angle head. Light pressure and a speed of
4000 to 6000 RPM are best.
b) Stone Finishing
Stone finishing, also called stoning, refines all surfaces of the work piece. When each
phase of stoning is completed, all surfaces should have the same uniform surface. Stone
finishing is done with a profiler. To get the best possible finish in the least amount of time,
stoning should always be done in the following order, starting with the deepest area and
working out.
1) Stone all corners and detail such as radii
2) Stone all horizontal surfaces
3) Stone all vertical surfaces
e) Buffing
Buffing is the final step. It is done both mechanically and by hand. Buffing begins when
you have completed your last diamonding step. When buffing, a mould polisher will start
with the same grade of diamond as the last brushing steps. Techniques are same as
diamonding -working from details to large surfaces using the large buff possible. Light
pressure and a sped of 4000 to 6000 RPM will produce the best results. When
mechanical buffing is complete, hand rubbing with soft felt ot a cotton ball will remove
any swirl marks left by the buffing process.
Chrome Plating
It is another method to for finishing the metal moulds other than polishing. The thichness
of the plating should be grater than 0.025mm. The followings are the advantages of
chrome plating
1) Chrome plating has a low co-efficient of friction and thus facilitates
27.9 problems in mould polishing and solutions
The best solution to a polishing problem is not to create a problem in the first place. A
good mould polisher will always follow proper techniques and procedures as outlined in
this session. Some problems such as EDM burns can not be avoided, but if handled
properly they become easier to remedy. Estimating surface condition is the hardest
problem to overcome. It is very difficult to estimate the depth of a cutter marks. Only with
experience can reasonable guesses be made.
27.10 Revision
a) Proper finishing of the mould is important for the _________of the part
(release)
e) _________are used to drive small mounted points, carbide burrs, etc (pencil
grinders)
g) _______ is the process of preparing the work piece for actual polishing
(benching)
h) The finish of the component largely depends on the finish of the _______ and
___________ (cavity , core)