Implementation of Bronze Bushings to Resolve Galling in High-Tonnage(1000T) Injection Molding Tools

In May 2023, a high-tonnage injection molding tool in a 1,000-ton press experienced a sudden lock-up, disrupting production and threatening supply chain continuity. A detailed investigation revealed excessive galling on steel bushings, while the steel leader pin only required polishing. This paper outlines the corrective actions taken to resolve the issue by replacing the steel bushings with bronze bushings and polishing the leader pin, highlighting the importance of material selection and preventive measures in high-tonnage applications. These actions resulted in increased tool reliability, uninterrupted supply chains, and customer satisfaction, ultimately strengthening the company’s position in the industry. Keywords Injection molding, galling, bronze bushings, steel bushings, high-tonnage tools, tool reliability, preventive maintenance.