In the production of disposable tableware sets, reducing burrs on product edges is a key step in improving quality. Burrs not only affect the product's appearance but can also scratch consumers during use and even harbor bacteria due to residual stains. Therefore, comprehensive control requires comprehensive measures across multiple dimensions, including mold design, process parameters, tool selection, equipment maintenance, operating procedures, and inspection procedures.
Mold design is the key to controlling burrs. Disposable tableware set molds must ensure precise parting surface accuracy and cavity finish to avoid burrs caused by excessive mold clearance or rough surfaces. The runner system should be optimized during design to ensure uniform filling of the cavity by the molten material, minimizing flash caused by uneven pressure. Furthermore, the mold's venting slots should be properly designed to prevent air entrapment, which can lead to material burning or irregular edges, indirectly reducing the risk of burrs.
Precise control of process parameters directly impacts burr formation. During the injection molding process, melt temperature, injection pressure, holding time, and cooling rate must be optimized in a coordinated manner. Excessively high temperatures or insufficient pressure can lead to poor material flow and incomplete edge fill, while excessively rapid cooling can cause uneven material shrinkage and tearing at the edges. By adjusting the process window to ensure stable material molding conditions, burr generation can be significantly reduced. Furthermore, using multi-stage injection technology to control the filling speed in stages can further reduce edge stress concentration.
Tool selection and maintenance are key aspects of the cutting process. The cutting process for disposable cutlery and forks requires high-precision tools, whose cutting edge angles, rake angles, and relief angles must be customized to the material properties. For example, carbide tools are suitable for machining hard plastics, while high-speed steel tools are more suitable for softer materials. Regular sharpening of tools maintains cutting edge sharpness to prevent wear and tear that increases cutting forces and can lead to material tearing. Coated tools can also reduce frictional heat and the risk of material deformation.
Equipment condition and operating procedures are crucial for burr control. The clamping force of the injection molding machine or stamping press must be matched to the mold to avoid flash caused by insufficient pressure. After long-term operation, the hydraulic system, transmission components, and electrical components must be regularly inspected to ensure operational stability. Operators must receive professional training and be familiar with process parameter adjustment methods to avoid quality issues caused by incorrect operation. For example, when changing molds or materials, equipment parameters need to be recalibrated to prevent burrs caused by poor compatibility.
Post-processing is the final line of defense for burr control. For existing burrs, mechanical deburring, chemical etching, or laser deburring can be used. Mechanical deburring, including vibration grinding and drum polishing, is suitable for batch processing of small parts. Chemical etching selectively removes burrs using an etchant, but the reaction time must be controlled to avoid excessive corrosion. Laser deburring offers high precision but is more expensive and is suitable for high-end products. Companies can choose the appropriate post-processing method based on their product positioning.
Improving inspection processes is the foundation of quality assurance. Establish a comprehensive inspection system, from raw material storage to finished product shipment, and inspect each batch for edge finish. Visual inspection, magnifying glass observation, or automated optical inspection equipment can be used to ensure that burr height is below industry standards. For defective products, the production process must be traced back to identify the root cause and make improvements.
Reducing the edge burr rate of disposable tableware sets requires a coordinated effort across multiple aspects: design, process, equipment, operation, and inspection. By optimizing mold design, precisely controlling process parameters, selecting appropriate cutting tools, maintaining equipment status, standardizing operating procedures, and improving the testing system, the product qualification rate can be significantly improved to meet the market demand for high-quality disposable tableware.
