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Case Study / Topic 34 MoldMaking Technology —— APRIL 2017 Case Study / Mold Maintenance and Repair Operating the mold separator is easy, according to Youngblom, and he says the Die-Sep mimics a molding press without the tonnage. It opens the molds using a small cylin- der and 110-volt electrical magnets that hold the tool securely against its platens. These magnets are custom fitted for the size tools being opened. For example, only two magnets per side may be needed for small tools, but very large tools may require a dozen per side. The Die-Sep can be built with core pulls, which helps with tool disassembly, he adds. It's a hydraulic system for cores or cams that are actuated by cylinders. It also will tip one half of the mold for working on it horizontally at tabletop height. Bigger machines require a platform around the work area. Basically, there are two hydraulic control levers used to open and close a mold, and two switches that turn the heavy-duty magnets on and off. An added benefit that Youngblom says his team never anticipated is that the Die-Sep doesn't have enough power to damage a tool when opening or closing it. "If there are mold components such as leader pins, cam pins, locks or telescoping shutoffs that are bent, broken or misaligned, this machine won't damage that tool." According to Louis Bowler, executive vice president of sales at Die-Sep, the hydraulic system pressure is set at the factory at a pressure low enough to stop the platen long before that happens. In addition, the magnets will release from a mold if there is excessive force required when attempting to open a mold. "Excessive force when opening a mold usually indicates there is some internal mold component in the wrong posi- tion or jammed," he says. "The Die-Sep's hydraulic gauge is conveniently located beneath the hydraulic controls and indicates the system's pressure while using the unit. For example, the maximum pressure 3M has for 5,000-pound molds is 500 psi with a two-inch cylinder, but this can change depending on the size of each machine and its intended use. "Each of our Die-Sep machines is custom built based on the size range of molds we work with," he continues. "It's relatively light at under 800 pounds, so we can move it around with a fork truck. It runs on 110 volts, so we can plug it into any outlet and use it anywhere in the shop. It now takes just one person, instead of three, to safely open and close each mold, saving about 20 minutes per mold in the process. It also reduces the risk of damaging the tooling and has increased our productivity by simplifying the process. I can't say enough good things about it." Sneaky Leaks Productivity again became an issue at 3M New Ulm due to undetected water leaks in molds that had just returned from the company's toolroom after hav- ing repair and maintenance work performed, Youngblom says, but that side of the tool was never touched. "It was keeping the molds out of production longer and it made our team look bad." Dave Hergenrader, 3M toolmaker, tests a mold for leaks using the Die-Sep Water Leak Tester. Since purchasing the system, the company says it has alleviated any surprise water leaks and gained additional benefits of water jacket cleaning and flow monitoring (see inset). Images courtesy of 3M New Ulm.