Automotive Lighting Technology in design difficulty

Car lights are mainly used for lighting, which can be said to be the eyes of the car. Car lights are a general term for all car lighting systems. Automobile lights have high requirements on the appearance, and several important parts are transparent parts, electroplated parts, etc. It can be said that the parts with the highest requirements on the appearance of automobiles are the lights, so the requirements for mold design and manufacturing are extremely high.


Glue feeding method: do mold flow analysis, confirm the number and location of glue feeding points and weld marks to the customer. Before opening the mold, the position of the clamping line needs to be confirmed by the customer. Mold steel material: NAK80 or S136H is used for transparent products, the original material certificate must be provided, and the hardness of the front and rear molds is staggered.


The front mold of reflective products adopts NAK80 or S136H (HRC32-36), and the original material certificate must be provided. The rear mold can use forged steel HRC30-34. The front and rear mold steel materials of BMC products are 8407 (need to achieve high polishing effect), and the original material certificate is provided. The front mold is HRC46-50, and the rear mold is HRC44-48.


The steel of its products is forged steel (need to achieve polishing effect) HRC32-36, the side of the inner core-pulling part is 0.03MM empty, and wear-resistant blocks are added. The exhaust is opened to the outside of the mold base, the exhaust is opened to the front mold, and the PL surfaces of the front and rear molds are effectively sealed to avoid air. Increase the area of the balance weight and need to open the exhaust groove.


Polishing of transparent products/astigmatism products can’t be done with oilstone, save the mold to 1000# sandpaper and then polish, other parts are ordinary 600#, BMC mold/glue surface/pattern surface: CNC makes medium light and then discharges the mold, after flying the mold The high-speed machine is in place at one time, 20,000 revolutions, and all the plastic parts of the rear mold are assembled and fine-tuned together. The mold of BMC is polished with a knife below 3MM. The steel material of BMC products cannot be welded, and the steel material on the aluminum-plated surface cannot be welded.


If the transparent/patterned ones need to be welded, the steel needs to be cut from the original material, polished and then fired, and tempered. For products made of BMC materials, there should be no sharp corners on the mold (including bottom holes). Deep hole drilling and processing of heating pipe holes (positive 0.02), matching the heating pipe and then hardening, the heating pipe itself is minus 0.05-0.1.


The top block of the circle needs to be sloped at 2 degrees to prevent the product from being pinched. Avoid sharp corners, R angle as large as possible heat treatment process and quality (you can go to the material factory to harden) vacuum heat treatment.


Car Light Case: Lens


Product material: transparent PC


Steel CAV /


COR: NAK80 or S136H (HRC33-37), the original material certificate is required, and the hardness of the front and rear molds is staggered. The product is highly polished and cannot be polished with whetstone, and it can be polished with 1000# sandpaper after saving the mold. Adhesive surface/pattern surface: CNC is used for medium light and then discharge to match the mold. After flying the mold, the high-speed machine will be in place at one time, 20,000 rpm, and all the plastic parts of the rear mold will be fined together after assembly.


The steel material cannot be welded. If welding is required, the steel material needs to be cut from the original material, polished and then burned, and tempered.Au 


In order to prevent the product from being pinched, the top block is sloped at 2 degrees. The exhaust is opened to the outside of the mold base, the exhaust is opened to the front mold, and the PL surfaces of the front and rear molds are effectively sealed to avoid air. The balance weight needs to open the exhaust groove, and the side of the inner core-pulling part is 0.03MM empty, and the wear-resistant block is added.

Car light case: decorative frame


product material


PBT


P4500


Astigmatism products surface aluminum plating


Glue feeding: the mold flow analyzes the position and points and points out the weld line, and confirms to the customer


Steel: CAV: NAK80 or S136H (HRC33-37), the original material certificate is required


COR: forged steel


HRC31-35, the product is highly polished, cannot pass through oil stone, save the mold to 1000# sandpaper and then polish. The front mold (reflective surface) cannot be welded, and the CNC is used for the middle light and then discharges the mold. After flying the mold, the high-speed machine will be in place once. 20,000 revolutions, after all the plastic parts of the rear mold are assembled, they are fine-tuned together. The exhaust is opened to the outside of the mold base, the exhaust is opened to the front mold, and the PL surfaces of the front and rear molds are effectively sealed to avoid air. The balance weight needs to open the exhaust groove.


Car Light Case: Reflector


product material


BMC is an extra hard material


Glue feeding: 8407 steel material for the front and rear molds (need to achieve high polishing effect), and provide the original material certificate, the front mold is HRC46-50, and the rear mold is HRC44-48.


The front mold (reflective surface) is polished, and it cannot be polished with oil stone. The mold is saved to 1000# sandpaper before polishing, and the rear mold is usually 600#


CNC is used for medium light and then discharge to match the mold. After flying the mold, the high-speed machine will be in place at one time, 20,000 revolutions. After all the plastic parts of the rear mold are assembled, they will be fine-tuned together and polished with a knife below 3MM.


The steel material of BMC products cannot be welded, heat treatment process and quality (can be hardened in the material factory) vacuum heat treatment


There should be no sharp angles on the mold (including the bottom hole), and the R angle should be as large as possible. Before hardening, the heat pipe hole should be deep drilled (positive 0.02), and the heat pipe should be equipped before hardening. The heat pipe itself needs to be minus 0.05 -0.1.


The exhaust is opened to the outside of the mold base, the exhaust is opened to the front mold, and the PL surfaces of the front and rear molds are effectively sealed to avoid air. The balance weight needs to open the exhaust groove.


Car light case: light housing


product material


PP+T30


steel


CAV: forged steel


HRC32-36


COR: forged steel


HRC30-34, provincial model 600#.

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