Can Burrs Be Automatically Detected In Injection Molding Procedures?

Burrs are fairly common during the prototyping processes such as die-casting, injection molding, and machining. For instance, when two mold prototypes do not completely meld in the plastic injection molding process, burrs can usually occur due to inconsistencies and incompatibilities in injection parameters. As a result, this could result in consequences such as limiting the workpieces’ functionality and viability or blemishing the workpieces’ visual aesthetics.

In any case, the automatic detection of burrs has always posed a challenge to engineers and designers. This is especially problematic in plastic injection workpieces, where extra precautions have to be taken to reduce the formation of burrs. Therefore, many solutions integrate automatic detection targeted at specific parameters and work areas.

Detection in the Measuring Process

As the saying goes, prevention is better than cure. In most cases, it might be best to avoid the issue before it has even occurred – and this could start during the measuring sequence, where software is used in conjunction with the consideration of position deviations and forms to reduce the possibility of burrs. Then, with computed tomography (CT), the designer will be able to detect burrs in a cross-sectional fashion, where they will determine the workpiece volume. Subsequently, they will be able to indicate the inspection areas or parameters with either 2D or 3D windows.

The main benefit of this method is that it can be taught automatically to the software offline by an operator. The coordinate measurement machine can generate the measurement sequence before creating the first workpiece. At this stage, the designer or operator can determine the allowances for the burr thickness. Usually, burrs that fall under the minimum thickness will not be considered.

Multi-Object Measuring and Detection during Production

CT measurements are made to workpieces manufactured in larger quantities during the production process. This methodology is more commonly used in the packaging industry, where mass amounts of packaging such as food lids and pots and plastic boxes for medical, cosmetic or healthcare products are inspected and measured. The measurement process is automated and reduced to a short period of a few seconds for each piece. One huge benefit of this method is the ability to refer to the display of the 3D CAD fixture model, where the software can determine and assign workpieces depending on whether they are out of tolerance.

Visual Inspection and Assessment

One of the other ways you can detect burrs in your workpieces is through a visual assessment by the software, where analysis markers can set flags that contain alphanumeric data and connotations. In addition, this computer vision (CV) software or technology should be able to determine the size of the burrs within specified intervals through SEM (scanning electron microscopy) images. Through this, you can examine the deviations in the burr tolerances.

Work with Willrich Precision

Willrich Precision has more than four decades of experience in the inspection, metrology, and gaging field. It offers customers a wide range of services and products, including sophisticated metrology technology and measuring tools in vision and laser systems. Moreover, we take immense pride in establishing ourselves as a leader in measurement instrumentation technology and, therefore can cater to a wide range of clients from different industries. We prioritize every relationship with every client. That is why we provide you with a free consultation and access to our team of experienced staff, who are highly skilled and can provide you with the assistance you require.

For more information about our range of inspection and metrology services and products, please contact us at [email protected] today!

by George Chitos