Installation requirements for mold cooling pipes during mold processing

1. Preparation and Verification Phase

• Design Documentation Verification:

• Confirm cooling pipe layout matches approved 3D mold design

• Verify pipe diameter, length, and routing against engineering drawings

• Cross-check interference with other mold components (ejector pins, guide pins, etc.)

• Material and Tooling Preparation:

• Cooling pipe material: Stainless steel 316L (corrosion-resistant grade)

• Sealing materials: FKM O-rings with temperature resistance ≥180°C

• Special tools: Tube bending fixtures, flaring tools, orbital welding equipment

2. Machining and Positioning Requirements

• Bore Hole Machining Specifications:

• Straightness tolerance: ≤0.02mm/100mm

• Surface finish: Ra 0.8-1.6μm

• Perpendicularity: ≤0.03mm relative to mounting surface

• Counterbore depth control: ±0.05mm

• Positioning Accuracy:

• Coordinate positioning error: ≤±0.1mm

• Depth positioning: Use depth stop fixtures during drilling

• Angular alignment: Laser alignment for inclined cooling channels

3. Pipe Installation Procedures

• Cleaning Protocol:

1. Degreasing: Ultrasonic cleaning in acetone bath (15 minutes)

2. Rinsing: Deionized water flush (conductivity <5 μS/cm)

3. Drying: Nitrogen blow-dry followed by oven drying at 80°C

• Installation Sequence:

1. Apply high-temperature anti-seize compound to threads

2. Install backup rings before O-rings (for high-pressure applications)

3. Use guided insertion tools to prevent seal damage

4. Progressive tightening in star pattern

4. Connection and Sealing Standards

• Connection Types and Requirements:

  Connection Type	Torque Specification	Sealant Required	Testing Pressure
  Flare Fitting	25-30 Nm	No	1.5× working pressure
  SAE O-ring Boss	40-45 Nm	Yes	2.0× working pressure
  Weld Fitting	N/A	N/A	2.5× working pressure

• Welding Requirements (for welded connections):

• Gas purging: Argon purity ≥99.995%

• Weld penetration: 100% with no undercut

• Post-weld cleaning: Remove all oxidation and slag

5. Pressure and Flow Testing

• Step Testing Procedure:

1. Initial test: 25% working pressure for 5 minutes

2. Intermediate test: 50% working pressure for 10 minutes

3. Final test: 100% working pressure for 30 minutes

4. Proof test: 150% working pressure for 15 minutes (if required)

• Acceptance Criteria:

• Pressure drop: ≤0.5 bar during 30-minute test

• Flow rate: Achieve design flow ±10%

• Temperature uniformity: ΔT ≤3°C across parallel circuits

6. Quality Control Documentation

• Required Records:

• Material certificates (mill certificates for pipe material)

• Welding procedure specifications (WPS) and records (PQR)

• Pressure test charts with time-pressure curves

• Dimensional inspection reports

• Cleanliness certification (ISO 8573-1 Class 2)

• Inspection Checklist:
  □ Pipe supports installed every 300mm maximum
  □ Expansion loops provided for thermal expansion
  □ Proper labeling of all circuits (in/out markings)
  □ No sharp bends (minimum radius = 3× pipe diameter)
  □ All connections accessible for maintenance

7. Safety and Compliance

• Safety Requirements:

• Pressure testing area must be barricaded

• All high-pressure connections must have safety shields

• Emergency shut-off valves within 3 meters of each circuit

• Personal protective equipment: Face shields during pressure testing

• Industry Standards Compliance:

• ASME B31.3 for process piping

• ISO 4413 for hydraulic systems

• SP-93 for leak testing standards

• Local pressure vessel codes

8. Post-Installation Requirements

• System Flushing:

• Flush velocity: 2-3 m/s

• Flush duration: Minimum 30 minutes per circuit

• Particle count: ≤ NAS Class 8 after flushing

• Commissioning Procedure:

1. Cold circulation test (8 hours minimum)

2. Thermal cycling test (3 cycles from 20°C to 80°C)

3. Performance verification against design parameters

4. Operator training on system operation and maintenance

Critical Installation Principles

1. Cleanliness First: Contamination is the primary cause of cooling system failure

2. Proper Support: Unsupported pipes will fail from vibration-induced fatigue

3. Thermal Expansion Accommodation: All systems must have expansion compensation

4. Accessibility: Design for maintenance from initial installation

5. Documentation: Complete records are essential for troubleshooting and warranty

Final Verification: All cooling pipe installations must be verified by both the mold maker and an independent quality inspector before mold closure. Any deviation from specifications requires engineering approval and documentation.