Process Division and Processing Sequence Arrangement

Optimizing manufacturing workflows for precision and efficiency in moulding vs molding processes

Introduction to Manufacturing Process Planning

In modern manufacturing, the efficient division of processes and careful arrangement of processing sequences are fundamental to achieving high-quality products at optimal costs. This is particularly true when considering moulding vs molding techniques, where precision and consistency are paramount. The organization of manufacturing steps directly impacts production time, resource utilization, and final product quality.

This comprehensive guide explores the principles of process division and the strategic arrangement of manufacturing sequences, with specific emphasis on how these principles apply to moulding vs molding operations. Whether dealing with complex mold components or standard parts production, understanding these concepts is essential for any manufacturing professional.

Manufacturing process planning diagram showing workflow optimization

1. Principles of Process Division

Based on the design requirements of machined surfaces in each stage and combined with the selected surface processing methods, the processing of each surface in the same stage can be combined into different processes. When dividing processes, the principles of process concentration or process dispersion can be adopted, each with implications for moulding vs molding efficiency.

Process Concentration Principle

If each process includes a large amount of processing content, the processing of a part can be completed in a few processes, which is called process concentration. This approach offers specific advantages in moulding vs molding scenarios where precision alignment is critical.

After clamping the workpiece once, multiple surfaces can be processed, which can better ensure the mutual position accuracy between surfaces
Reduces the number of workpiece clamping operations and auxiliary time, decreases the number of workpiece transfers between machines, which helps shorten the production cycle
Reduces the number of machine tools and operators, saves workshop production space, and simplifies production planning and organization
Requires complex equipment and tooling structures, involves large investment, and presents greater difficulty in adjustment and maintenance, demanding higher technical skills from workers

Process Dispersion Principle

If each process includes a small amount of processing content, the processing of a part is completed in many processes, which is called process dispersion. This method has different applications in moulding vs molding contexts depending on production volume and part complexity.

Machine tools and tooling are relatively simple, easy to adjust, and easy for production workers to master
Allows the use of the most reasonable cutting parameters, reducing machining time
Requires more equipment, more operators, and larger production area

Comparison of process concentration vs dispersion in manufacturing

Due to the high precision requirements of mold processing and the fact that it mostly belongs to single-piece or small-batch production, it is more suitable to divide processes according to the principle of process concentration. This is particularly evident when comparing moulding vs molding approaches for complex components.

Professional manufacturers of standard mold parts, however, employ both process concentration and process dispersion. The decision between these approaches, as in many aspects of moulding vs molding, requires technical and economic analysis based on specific circumstances to determine the optimal strategy.

2. Arrangement of Processing Sequence

The mechanical processing process of a workpiece involves cutting processing, heat treatment, and auxiliary processes. Therefore, when formulating the process route, it is necessary to reasonably and comprehensively arrange the sequence of cutting processing, heat treatment, and auxiliary processes. This sequence planning is crucial in both moulding vs molding environments to ensure quality and efficiency.

① Arrangement of Cutting Processing Procedures

The processed surfaces of mold parts not only have their own precision requirements but also have certain positional accuracy requirements between surfaces. During the processing of parts, attention must be paid to the selection and conversion of datums. This is a critical consideration in moulding vs molding operations where precision is paramount.

The following principles should be followed when arranging the processing sequence:

a. Rough processing first, then finishing

When mold parts are processed in stages, rough processing should be performed first, followed by semi-finishing, and finally finishing and precision processing. This approach minimizes the impact of workpiece deformation on final dimensions, which is especially important in moulding vs molding where tight tolerances are common. Starting with rough processing removes most of the machining allowance and releases internal stresses, while subsequent finishing operations achieve the required precision and surface quality.

b. Datum surfaces first, then other surfaces

At each stage of mold part processing, the datum surfaces should be processed first to serve as positioning datums for subsequent processes when processing other surfaces. Establishing reliable datums early in the process ensures consistent positioning throughout the manufacturing sequence, a factor that significantly affects dimensional accuracy in both moulding vs molding processes. Proper datum selection reduces cumulative errors and improves overall part quality.

c. Main surfaces first, then secondary surfaces

In part processing, main surfaces should be processed first, followed by secondary surfaces. For example, the working surfaces and assembly datum surfaces of parts should be processed first, while pin holes, screw holes, etc., which often have positional requirements relative to the main surfaces, should generally be processed after the main surfaces. This priority ensures that critical functional surfaces meet their specifications before processing secondary features that depend on them, a principle that applies equally to both moulding vs molding methodologies.

d. Planes first, then inner holes

For mold bases, templates, and similar parts, the plane contour size is relatively large. Positioning with these planes is stable and reliable. Therefore, the planes are generally processed first as precision datums, and then the inner holes are processed. This sequence provides a stable, flat surface for locating the workpiece when machining holes, ensuring better perpendicularity and positional accuracy between holes and planes – a critical consideration in moulding vs molding for proper part assembly and function.

Processing sequence diagram showing from rough to finish operations

② Arrangement of Auxiliary Processes

Auxiliary processes mainly include inspection, deburring, rust prevention, cleaning, etc. Among them, inspection is the main content of auxiliary processes, which plays an extremely important role in ensuring the processing quality of parts. These auxiliary steps are vital in maintaining consistency and quality control in both moulding vs molding production environments.

Inspection Processes

In addition to the operator's self-inspection according to the processing requirements of each工序, special inspection processes should also be arranged under the following circumstances:

After rough or semi-finishing of parts
Before and after processing of important processes
Before parts are sent to external workshops (such as heat treatment)
After all processing of parts is completed

Inspection is critical in moulding vs molding to catch defects early and maintain quality standards.

Deburring Processes

Deburring processes are usually arranged after processes that are prone to producing burrs, before inspection and heat treatment processes. However, for single-piece and small-batch production, deburring is generally only arranged after the parts are processed, with inter-process burrs handled by cutting workers. Proper deburring is essential in both moulding vs molding to ensure part safety, proper fit, and prevent damage to mating components.

Rust Prevention Processes

Rust prevention is divided into inter-process rust prevention and product storage rust prevention. Inter-process rust prevention is generally arranged when parts are prone to rusting after finishing and have a long circulation time. The product storage rust prevention process is arranged before the product is stored in the warehouse. Effective rust prevention is crucial for maintaining part integrity during production and storage, whether in moulding vs molding operations.

Cleaning Processes

Cleaning processes are only arranged where cleaning is needed, such as before surface magnetic particle inspection and before oil sealing, packaging, and assembly. Thorough cleaning removes contaminants that could affect part quality, function, or appearance, a standard practice in both moulding vs molding to ensure final product reliability.

Practical Applications in Modern Manufacturing

Understanding the principles of process division and sequence arrangement is essential for optimizing manufacturing workflows, particularly when evaluating moulding vs molding techniques for specific applications. These principles find practical application across various manufacturing scenarios, from complex mold production to high-volume component manufacturing.

Modern manufacturing facility showing optimized production workflow

In mold manufacturing, where precision requirements are extremely high and production volumes are often low, the principle of process concentration is typically favored. This approach minimizes the number of setups, reducing the potential for errors and ensuring better dimensional accuracy between related features. This is particularly important in moulding vs molding applications where complex geometries must align perfectly.

For standard mold components produced in higher volumes, manufacturers often employ a hybrid approach, combining elements of both process concentration and dispersion. Critical features might be processed in concentrated operations to ensure precision, while simpler, less critical features are handled through more dispersed processes to optimize production rates. This balanced approach is often the most economically viable when considering moulding vs molding for standard components.

Regardless of the specific approach, the fundamental principles of process sequencing – rough before finish, datums first, main features before secondary, and planes before holes – remain consistent across most manufacturing scenarios. These principles ensure that parts meet their design specifications while minimizing production time and cost, whether utilizing moulding vs molding techniques or other manufacturing processes.

Conclusion

The effective division of manufacturing processes and strategic arrangement of processing sequences are fundamental to achieving high-quality products at optimal costs. By understanding and applying the principles of process concentration and dispersion, manufacturers can make informed decisions about the most appropriate approach for their specific production requirements, whether evaluating moulding vs molding or other manufacturing methods.

Proper sequence arrangement, following established principles, ensures that parts are produced efficiently while meeting all design specifications. Attention to auxiliary processes such as inspection, deburring, rust prevention, and cleaning further ensures that the final product meets quality standards and is ready for its intended application. In the ongoing comparison of moulding vs molding, these process principles provide a common framework for quality and efficiency.

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Manufacturing Principles

Key principles to remember when planning manufacturing processes:

Prioritize datum surfaces early in the process
Process main features before secondary features
Always follow rough-to-finish progression
Include appropriate inspection points