Scratches on the product surface

In the '2079851475616104458 (vacuum forming) production process, the product exhibits the quality defect of "Scratches on the product surface". The specific manifestation is that scratches appear on the product surface. This defect is relatively common when processing materials such as PP, PS, PET, PVC, ABS sheets, and its occurrence conditions are usually related to the unreasonable settings of sheet heating temperature, forming pressure/vacuum level, mold temperature, and cooling time. When the "Scratches on the product surface" situation is severe, it will cause a series of chain quality defects in the product in terms of appearance, dimensional accuracy, mechanical properties, etc., which not only reduces the functionality and safety of the product in use, but also directly increases the scrap rate and production cost. Therefore, this problem requires systematic diagnosis and optimization from multiple dimensions such as material selection, the status of the '2079851475616104458 machine, heating oven, mold, and vacuum/air pressure system, and sheet heating temperature, forming pressure/vacuum level, mold temperature, and cooling time.

1. Damage on the mold surface. The mold is the core tool that gives the product its shape and surface quality. Unreasonable mold design, such as improper runner/gate dimensions, insufficient venting, and inadequate draft angle, will directly cause molding defects. The machining accuracy, surface treatment quality, and daily maintenance status of the mold also directly affect product quality. 2. Friction with the mold during demolding. The mold is the core tool that gives the product its shape and surface quality. Unreasonable mold design, such as improper runner/gate dimensions, insufficient venting, and inadequate draft angle, will directly cause molding defects. The machining accuracy, surface treatment quality, and daily maintenance status of the mold also directly affect product quality. 3. Improper handling. This factor causing the problem reflects that certain process conditions or material characteristics in '2079851475616104458 (vacuum forming) processing have not met the optimal molding requirements. Such problems are often cumulative and hidden, and should be investigated and verified as key focus items during process debugging and finalization to ensure that hidden dangers are eliminated at the source. In terms of equipment maintenance, the regular overhaul and precision confirmation of the '2079851475616104458 machine, heating oven, mold, and vacuum/air pressure system are not in place, causing the actual operating parameters of the equipment to deviate from the process requirements, which will also become a potential inducement of the "Scratches on the product surface" problem.

1. Polish the mold surface. Polishing operations should be carried out step by step from coarse to fine; each time a finer abrasive is changed, the polishing direction should be changed to eliminate the texture traces of the previous step. The final surface roughness should be tested with a roughness meter to confirm it meets the standard. After polishing is completed, it should be thoroughly cleaned to remove abrasive and grinding agent residues to prevent them from entering the melt and contaminating the product. 2. Optimize the demolding method. Optimization work must be based on an accurate diagnosis of the root cause of the problem, and blind attempts must be avoided. It is recommended to first determine the key influencing factors and their interactions through the process DOE test method or historical production data analysis, and then carry out parameter optimization and structural improvement in a targeted manner to achieve twice the result with half the effort. 3. Improve handling. Optimization work must be based on an accurate diagnosis of the root cause of the problem, and blind attempts must be avoided. It is recommended to first determine the key influencing factors and their interactions through the process DOE test method or historical production data analysis, and then carry out parameter optimization and structural improvement in a targeted manner to achieve twice the result with half the effort. In terms of material management, incoming inspection of raw materials upon arrival and in-process inspection of work-in-progress should be strengthened, and the key performance indicators of PP, PS, PET, PVC, ABS sheets should be strictly controlled to ensure the stability of molding quality from the source.

In summary, the causes of the "Scratches on the product surface" problem can be attributed to the combined action of multiple factors such as Damage on the mold surface, Friction with the mold during demolding. Solving this problem requires starting from aspects such as Polish the mold surface, Optimize the demolding method and adopting systematic governance measures. In actual production, it is recommended to establish a prevention and rapid response mechanism for this problem, and achieve stable production and continuous improvement through sheet heating uniformity and stretch ratio control.