培訓(xùn)課程 2 工藝參數(shù)的優(yōu)化

培訓(xùn)課程2工藝參數(shù)的優(yōu)化培訓(xùn)課程2工藝參數(shù)的優(yōu)化受訓(xùn)者手冊(cè)德馬格注塑機(jī)工藝參數(shù)優(yōu)化的步驟指導(dǎo)頁(yè)面周期分析3注塑工藝參數(shù)優(yōu)化6步驟1找出轉(zhuǎn)壓點(diǎn)7步驟1結(jié)果8步驟2找出保壓時(shí)間澆口冷凝時(shí)間9步驟2結(jié)果10步驟3優(yōu)化注射速度11步驟3結(jié)果12步驟4采用正確的螺桿轉(zhuǎn)速13步驟4結(jié)果14步驟5優(yōu)化多級(jí)螺桿轉(zhuǎn)速和背壓曲線15步驟5結(jié)果16步驟6優(yōu)化松退17步驟6結(jié)果18步驟7優(yōu)化保壓曲線19步驟7結(jié)果20TABULATEDRESULTS21步驟8優(yōu)化鎖模力22步驟8結(jié)果22步驟9設(shè)定注射壓力23步驟9結(jié)果23典型工藝參數(shù)公差設(shè)定24成型周期分析采用下面表格估計(jì)注塑過(guò)程中的每一階段對(duì)周期的影響然后去機(jī)床看正在運(yùn)行的模具,寫下實(shí)際的時(shí)間并計(jì)算出百分比哪一階段在整個(gè)周期中占最多的時(shí)間那里可以是最有效的縮短成型周期模具1估計(jì)實(shí)際實(shí)際評(píng)價(jià)合模射臺(tái)前進(jìn)和后退注射時(shí)間保壓時(shí)間冷卻時(shí)間開模頂出整個(gè)成型周期100SECONDS100模具2估計(jì)實(shí)際實(shí)際評(píng)價(jià)合模射臺(tái)前進(jìn)和后退注射時(shí)間保壓時(shí)間冷卻時(shí)間開模頂出整個(gè)成型周期100SECONDS100工藝參數(shù)優(yōu)化目標(biāo)一步步改進(jìn)工藝過(guò)程穩(wěn)定性評(píng)估各個(gè)參數(shù)的更改對(duì)工藝過(guò)程穩(wěn)定性的影響TODEMONSTRATETHECUMULATIVEIMPROVEMNTINTHEPROCESSANDPRODUCTCONSISTENCY方法ATEACHSTAGE,AFTERTHEPROCESSHASBEENGIVENSUFFICIENTTIMETOSTABILISE,ARUNOFSIXTEENCONSECUTIVEMOULDINGSISTOBEMADETHESEMOULDINGSWILLBEASSESSEDFORCONSISTENCYBYWEIGHTADIMENSION,APHYSICALPROPERTYORSOMEOTHERATTRIBUTECOULDEQUALLYWELLBEUSED,WEIGHTISSIMPLYTHEMOSTWIDELYAPPLICABLE穩(wěn)定性通過(guò)計(jì)算重量的標(biāo)準(zhǔn)偏差來(lái)衡量同時(shí)打印出機(jī)床IBED上的過(guò)程統(tǒng)計(jì)數(shù)據(jù)找出轉(zhuǎn)壓點(diǎn)找出澆口冷卻時(shí)間優(yōu)化注射速度采用正確的螺桿轉(zhuǎn)速優(yōu)化多級(jí)預(yù)塑曲線優(yōu)化松推優(yōu)化多級(jí)保壓曲線優(yōu)化鎖模力設(shè)定注射壓力限定步驟1找出轉(zhuǎn)壓點(diǎn)在沒(méi)有保壓壓力和保壓時(shí)間的基礎(chǔ)上填滿產(chǎn)品9598,然后設(shè)定一定的保壓和保壓時(shí)間生產(chǎn)16模初始設(shè)置時(shí)的指導(dǎo)1采用行程切換2設(shè)定切換位置為1012MM逐步增加預(yù)塑量直到產(chǎn)品打滿9598的位置3設(shè)置注射壓力為最大值4設(shè)定保壓壓力和保壓時(shí)間均為05設(shè)定注射速度60MMS16設(shè)定松推速度為最大值7設(shè)定鎖模力為最大值8選擇適當(dāng)?shù)穆輻U轉(zhuǎn)速9根據(jù)材料物性表,設(shè)定料桶溫度10配置過(guò)程統(tǒng)計(jì)控制11設(shè)定保壓壓力和保壓時(shí)間生產(chǎn)完整的產(chǎn)品稱12模產(chǎn)品的重量,計(jì)算標(biāo)準(zhǔn)偏差打印頁(yè)面20工藝參數(shù)優(yōu)化頁(yè)面50工藝過(guò)程統(tǒng)計(jì)步驟1結(jié)果輸入實(shí)際值平均值范圍最小最大沒(méi)保壓時(shí)的重量有保壓后的重量填充的百分比標(biāo)準(zhǔn)偏差16模G料墊平均值和范圍預(yù)塑時(shí)間平均值和范圍螺桿停止位置平均值和范圍注射時(shí)間平均值和范圍注射壓力峰值,PINJMAX轉(zhuǎn)壓壓力,PNPRESS轉(zhuǎn)壓位置步驟2找出澆口冷凝時(shí)間設(shè)定保壓壓力為步驟1上找出的注射壓力峰值的50左右設(shè)定保壓時(shí)間為1S生產(chǎn)數(shù)模產(chǎn)品使過(guò)程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量和平均值增加保壓時(shí)間至2S,生產(chǎn)數(shù)模產(chǎn)品使過(guò)程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量在保壓時(shí)間3S,4S5S時(shí)重復(fù)上述過(guò)程直到產(chǎn)品重量不再增加作出產(chǎn)品重量和保壓時(shí)間的關(guān)系圖記錄RECORDTHETCUSETTINGANDTHEACTUALMOULDTEMPERATURE打印頁(yè)面30溫度XLSPREADSHEETGRAPH為什么記錄模具溫度很重要還有什么因素會(huì)影響澆口冷凝時(shí)間步驟2結(jié)果輸入實(shí)際值TCUSETTINGFHTEMPERATUREMHTEMPERATURECCC重量1重量2重量3重量4重量5平均重量時(shí)間保壓重量1重量2重量3重量4重量5平均重量時(shí)間保壓所需的保壓時(shí)間S步驟3優(yōu)化注射速度采用多級(jí)注射曲線,使注射行程最后的1020采用逐步降低的注射速度每次更改注射速度,必須重新建立轉(zhuǎn)壓點(diǎn)注意每次保壓和保壓時(shí)間都設(shè)定為0連續(xù)取16模,計(jì)算出標(biāo)準(zhǔn)偏差打印頁(yè)面24MWE使用和沒(méi)使用多級(jí)保壓時(shí)的曲線頁(yè)面26多級(jí)注射頁(yè)面50工藝過(guò)程統(tǒng)計(jì)為什么轉(zhuǎn)壓點(diǎn)要更改注射壓力發(fā)生了什么為什么在數(shù)社的末端采用逐步降低的注射速度是有用的步驟3結(jié)果輸入實(shí)際值平均值范圍最小最大沒(méi)有保壓時(shí)的重量采用保壓的重量填充百分比標(biāo)準(zhǔn)偏差16模G料墊平均值和范圍預(yù)塑時(shí)間平均值和范圍螺桿停止位置平均值和范圍注射時(shí)間平均值和范圍注射壓力峰值,PINJMAX轉(zhuǎn)壓壓力,PNPRESS轉(zhuǎn)換位置步驟4采用正確的螺桿轉(zhuǎn)速SELECTTHECORRECT,OPTIMUMSCREWSPEEDFORTHEMATERIALBEINGPROCESSEDSEET01NOTES,SECTION5USETHISSINGLESPEEDFORTHEWHOLEPLASTICISINGSTROKESETABACKPRESSUREOF5TO10BARHYDRAULICREADJUSTDOSINGSTROKETOACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE50PROCESSSTATISTICSWHYISITIMPORTANTTOUSETHEMANUFACTURERSRECOMMENDEDSCREWSPEEDSTEPFOURRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPFIVEOPTIMISESCREWSPEEDANDBACKPRESSUREPROFILEUSETHEDOSINGPROFILEPAGETOSLOWDOWNTHESCREWROTATIONSPEEDFORTHELAST10OFTHEMETERINGSTROKEREADJUSTDOSINGSTROKETOACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE21DOSINGPROFILESPAGE50PROCESSSTATISTICSWHATHASHAPPENEDTOTHEDOSINGSTOPPOSITIONSTEPFIVERESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPSIXOPTIMISEDECOMPRESSIONFINDTHEDECOMPRESSIONSPEEDWHICHGIVESBESTSCREWSTROKEANDMELTCUSHIONCONSISTENCYSETADECOMPRESSIONSTROKEOF5MMCHECKTHATYOUSTILLACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE21DOSINGPROFILESPAGE50PROCESSSTATISTICSWHATHASHAPPENEDTOTHESCREWSTOPPOSITIONWHATISHAPPENINGTOTHECHECKRINGSTEPSIXRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPSEVENOPTIMISEHOLDINGPRESSUREPROFILEUSETHEHOLDINGPROFILEPAGETOSETAHOLDINGPRESSUREPROFILEWHICHENSURESASMOOTHTRANSITIONFROMINJECTIONTOTHEHOLDINGPRESSUREPHASEANDUSEAHIGHENOUGHPRESSURETOPACKTHEPARTPROPERLYADDASTEPWHICHREDUCESHOLDINGPRESSUREGRADUALLYTOZEROTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE24MWEPAGE27HOLDINGPROFILEPAGE50PROCESSSTATISTICSWHYDOYOUNEEDASMOOTHTRANSITIONFROMINJECTIONTOHOLDINGPRESSUREWHYBOTHERTOREDUCETHEPRESSUREGRADUALLYIFTHEGATEHASALREADYFROZENSTEPSEVENRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKETABULATEDRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESTHERANGEVALUE,R,ISTHEMAXIMUMMINUSTHEMINUMUM,TAKENFROMTHESEVENSTEPS1234567MEANRMEANRMEANRMEANRMEANRMEANRMEANRMELTCUSHIONDOSINGTIMESCREWENDPOSITIONINJECTIONTIMEINJECTIONPRESSUREPHYDMAXINECTIONPRESSUREPNHYDRAULICCHANGEOVERSTROKESTANDARDDEVIATION16SHOTSCANYOUSEEATRENDWHICHSTEPHADTHEGREATESTEFFECTONTHECONSISTENCYOFTHEMOULDINGSTEPEIGHTOPTIMISINGTHECLAMPFORCEREDUCETHECLAMPFORCEBYSTEPSOF50KN100KNFORMACHINESOVER100TONNESUSINGTHESETTINGSFAROPTIMISEDINTHESEVENSTEPSABOVEALLOWTHEPROCESSTOSTABILISEEACHTIMEANDTHENWEIGHFIVEMOULDINGSTABULATEYOURRESULTSBELOWANDPLOTAGRAPHOFTONNAGEAGAINSTPARTWEIGHTDOESTHEMOULDREQUIRETHEEXPECTEDCLAMPFORCEWHATARETHEADVANTAGESOFRUNNINGATREDUCEDTONNAGESTEPEIGHTRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESENTERRESULTSINXLSPREADSHEETPRINTOUTGRAPHWEIGHT1WEIGHT2WEIGHT3WEIGHT4WEIGHT5MEANWEIGHTCLAMPFORCEREQUIREDCLAMPFORCEKNSTEPNINESETINJECTIONPRESSUREUNTILNOWTHEINJECTIONPRESSUREHASBEENSETTOTHEMACHINESMAXIMUMVALUEFROMTHEPROCESSSTATISTCSPAGEITCANBESEENTHATTHEMACHINEDOESNOTNEEDALLTHATPRESSURETOFILLTHEMOULDGRADUALLYDECREASETHESETINJECTIONPRESSUREUNTILTHEINJECTIONTIMESTARTSTOINCREASEINCREASETHEPRESSUREAGAINUNTILTHEPREVIOUSINJECTIONTIMEISESTABLISHEDWITHACONSISTENCYOF008SORBETTERPREFERABLY002TO003SVARIATIONWHATISTHEPURPOSEOFLIMITINGTHEINJECTIONPRESSURESTEPNINERESULTSACTUALPEAKINJECTIONPRESSUREBARSETINJECTIONPRESSUREBARAPPENDIX1TYPICALPROCESSTOLERANCESSHOTWEIGHTDEVIATION005010204PLASTICISINGTIME004S006S008S013SINJECTIONTIME002S002S004S006SCYCLETIME050511SCREWPOSITION,DOSINGSTOP01MM01MM02MM03MMMELTCUSHION01MM01MM02MM03MMMELTTEMPERATURE2C2C3C5CMOULDTEMPERATURE1C1C2C4CBARRELTEMPERATURE1C1C2C4CFEEDZONETEMPERATURE1C2C3C4CHOTRUNNERTEMPERATURE1C2C3C4CHYDRAULICOILTEMPERATURE1C1C2C2CROOMTEMPERATURE2C2C3C4CMOULDCAVITYPRESSURE3BAR4BAR6BAR8BARPRESSUREINTEGRAL200300600900INJECTIONFILLINGPRESSURE1BAR2BAR3BAR4BARHOLDINGPRESSURE1BAR1BAR15BAR2BARBACKPRESSURE05BAR05BAR1BAR1BARFILLINGDIFFERENCESBALANCEOFFILLFOREACHCAVITYONMULTICAVITYTOOLS1125MOULDBREATHE001MM001MM002MM004MMCHANGEOVERPRESSUREPNVALUE1BAR2BAR3BAR4BARSCREWSURFACESPEED10MMS115MMS120MMS130MMS1MELTTEMPERATUREPEAKVALUE03C04C05C06CMELTTEMPERATUREVALUEATCHANGEOVER03C04C05C06CTHEACHIEVABLEPARTQUALITYISMUCHINFLUENCEDBYTHECONDITIONOFTHEMATERIALPROCESSEDITISIMPORTANTTHATMOISTURECONTENT,PROPORTIONOFREGRINDANDPROPORT