塑膠設(shè)計原理ppt課件

1、OLE Technology Corporation射出成型塑膠產(chǎn)品與模具設(shè)計射出成型塑膠產(chǎn)品與模具設(shè)計 Injection Molding Plastic Part & Mold DesignOLE Technology Corporation澆注系統(tǒng)設(shè)計澆注系統(tǒng)設(shè)計Filling System DesignOLE Technology Corporation模具設(shè)計的優(yōu)先順序模具設(shè)計的優(yōu)先順序Priorities of Mold Design澆注系統(tǒng)設(shè)計 (Filling System Design)排氣系統(tǒng)設(shè)計 (Venting System Design)冷卻系統(tǒng)設(shè)計 (Cooling

2、 System Design)脫模系統(tǒng)設(shè)計 (Ejecting System Design)OLE Technology Corporation澆注系統(tǒng)設(shè)計的優(yōu)先順序澆注系統(tǒng)設(shè)計的優(yōu)先順序Priorities of Filling System Priorities of Filling System DesignDesign產(chǎn)品設(shè)計 (Part Design)型腔設(shè)計 (Cavity Design)澆口設(shè)計 (Gate Design)流道設(shè)計 (Runner Design)豎澆道設(shè)計 (Sprue Design)噴嘴設(shè)計 (Nozzle Design)OLE Technology Corpo

3、ration豎澆道Sprue主流道Main Runner廢品Part澆口Gate冷料井Cold Slug Well支流道Branch Runner典型的澆注系統(tǒng)典型的澆注系統(tǒng)Typical Filling SystemOLE Technology Corporation壁厚不均是注塑成形中最大的麻煩製造者。 這對薄壁零件尤然。 這些麻煩包括了遲滯現(xiàn)象、短射、凹陷、發(fā)赤、噴流、翹曲及長冷卻時間等；目前都可用CAE以直接或間接的方式預(yù)測。Non-uniform wall thickness is the biggest trouble maker in plastic injection mold

4、ing. This is especially true to thin-wall part. The troubles, including hesitation, short shot, sink mark, blush, jetting, warpage and long cooling time etc., can be predicted, directly or indirectly, by using CAE. 壁厚不均壁厚不均Non-uniform Wall ThicknessOLE Technology Corporation壁厚設(shè)計壁厚設(shè)計Wall Thickness De

5、sign差 Poor較好 Better最好 BestOLE Technology Corporation掏空設(shè)計掏空設(shè)計(1) Coring Out Design (1)改進(jìn)設(shè)計 Improved原設(shè)計 OriginalOLE Technology Corporation差 Poor改進(jìn) Improved掏空設(shè)計掏空設(shè)計(2) Coring Out Design (2)OLE Technology Corporation氣泡或氣泡或/和凹陷的構(gòu)成和凹陷的構(gòu)成Void or/and Sink Mark Forming氣泡氣泡 ( Void )凹陷凹陷 ( Sink Mark )OLE Techn

6、ology Corporation肋厚和內(nèi)圓角半徑的影響肋厚和內(nèi)圓角半徑的影響The Effect of Rib Thickness & Fillet RadiusOLE Technology Corporation肋的底部厚度肋的底部厚度Bottom Thickness of RibW0.5W2.5WW1.2WD1.5WD(A)(B)OLE Technology Corporation肋的設(shè)計肋的設(shè)計 (一一 )Rib Design ( 1 )t = wall thichnessB = 0.5tC = 3 tAAD = 2 BE = 0.13 mm(radius)F = 1.5 - 2 de

7、g假設(shè)需求更大的強(qiáng)度假設(shè)需求更大的強(qiáng)度,可添加肋的數(shù)目可添加肋的數(shù)目If more strength is required, add additional ribs.FBDECtOLE Technology Corporation 肋的設(shè)計 (二 )Rib Design ( 2 )OLE Technology Corporation肋的設(shè)計肋的設(shè)計 (三三 )Rib Design ( 3 )OLE Technology Corporation與側(cè)壁相連之凸轂與側(cè)壁相連之凸轂(熱塑性塑膠熱塑性塑膠)Boss at Wall ( Thermoplastics )A =凸轂附著處壁厚凸轂附著處壁厚

8、 wall thicknessB =凸轂外環(huán)直徑凸轂外環(huán)直徑 dia. of boss over radiiC = 0.5 AD = 2 BE = 1 2 degF = 0.13 mm ( radius )G = DH = 0.8 AI = A / 4J = 2 BK = 0.3 1 JL = 0.5 A LHAAKEIGJDAFCBSection A-AOLE Technology Corporation遠(yuǎn)離側(cè)壁之凸轂遠(yuǎn)離側(cè)壁之凸轂( (熱塑性塑膠熱塑性塑膠) )Boss Away From Wall( Thermoplastics Boss Away From Wall( Thermopl

9、astics ) ) A =凸轂附著處壁厚凸轂附著處壁厚 wall thicknessB =凸轂外環(huán)直徑凸轂外環(huán)直徑 (含底部修整圓弧半徑含底部修整圓弧半徑) dia. of boss over radiiC = 0.5 AD = 2 BE = 1 - 2 degF = 0.13 mm ( radius )G = 0.95 DH = 0.3 G min. to G max.I = 0.5 AHEFDFGCBAIOLE Technology Corporation外側(cè)凸轂外側(cè)凸轂Outside Boss AAA ( DIA )BB = AB= 2A ( max. )Section A-AOLE

10、Technology CorporationEIMr1Where 1/r : 樑的曲率 curvature of the beamM: 彎曲力矩 bending momentE : 彈性模數(shù) modulus of elasticityI : 斷面積對中立軸的慣性矩 moment of inertia of the cross- sectional area with respect to the neutral axisEI : 撓曲剛性 flexural rigidity撓曲剛性撓曲剛性Flexural RigidityOLE Technology CorporationIWLyEIWLCm

11、ax3max3Wmax樑樑 BeamLOLE Technology CorporationWhere : 最大偏移 maximum deflection W : 負(fù)荷 load L : 樑長 length of beam E : 彈性模數(shù) modulus of elasticity I : 斷面積對中立軸的慣性矩 moment of inertia of the cross- sectional area with respect to the neutral axis EI : 撓曲剛性 flexural rigidity: 最大應(yīng)力 maximum stress: 中立軸到到其斷面離其最遠(yuǎn)

12、的點的距離 distance from the extreme point of a cross section to the neutral axis of this cross section maxmaxyCOLE Technology Corporation 密度 Density (g/cm3) 熱擴(kuò)散率 Thermal Diffusivity (cm2/s) 抗拉強(qiáng)度 Tensile Strength (Mpa) 比強(qiáng)度 Specific Strength 彈性模數(shù) E (Mpa) 鋼 Steel 7.86 0.117 517 80 200,000 鎂合金 Mg Alloy 1.81

13、 0.289 240 154 45,000 PC 1.23 0.0010 104 102 6,700 ABS 1.03 0.0007 35 41 2,100 OLE Technology CorporationcyNeutral AxisOLE Technology Corporation?10.8l9.18.519.988.518.48.108.4?9.9812?8.101233platelAIAdbIOLE Technology Corporation I A I/A tmax 平板 Plain Plate 98.9 51.8 1.9 4.8 肋板 Ribbed Plate 98.9 29

14、.5 3.4 1.2 平板和肋板的比較平板和肋板的比較Comparison between Plain & Ribbed PlatesOLE Technology Corporation和平板比，假設(shè)基於一樣的慣性矩(剛性)，肋板需料少了43%，I/A卻添加了1.79倍。肋板的最大厚度減為平板的1/4 ，使得冷卻時間驟降15/16 (94%)。Based on the same moment of inertia (stiffness), ribbed plate needs 43% less material but boost I/A by 1.79 times comparing wit

15、h plane plate. The maximum thickness of ribbed plate is only 1/4 of plain plates; showing a dramatic cooling time reduction of 94% (15/16) .平板和肋板的比較平板和肋板的比較Comparison between Plain & Ribbed PlatesOLE Technology CorporationA variety of molded-ininterlocks can add stiffness to thin-wall housing design

16、s.各種一體成形的內(nèi)鎖件能添加薄殼的剛性。OLE Technology Corporation結(jié)構(gòu)設(shè)計是薄殼成形零件的基礎(chǔ)。Structural design is the base of thin-wall molding parts.薄殼成形零件不僅僅是一趨勢，而且也是降低本錢和提高競爭力的有效途徑。Thin-wall molding part is not only a trend but also an effective way to achieve cost reduction and competitiveness increase.結(jié)構(gòu)設(shè)計和薄殼成形零件Structural D

17、esign & Thin-wall Molding PartsOLE Technology Corporation每添加一個澆口，至少添加一條熔接線，同時添加一個澆口痕跡、添加流道的體積以及添加較多的積風(fēng)。Every time one gate is added, one weld line, at least, one gate mark, more runner volume and more air traps will be added.在型腔能夠完滿充填的前提下，澆口數(shù)目是愈少愈好。As long as the cavity is able to be filled appropri

18、ately, gates are the less the better.為了減少澆口數(shù)目，每一澆口應(yīng)就塑流力所能及的流長/壁厚比之內(nèi)，找出可以涵蓋最大零件面積的進(jìn)澆位置。In order to reduce the number of gates, each gate shall be located at where the melt is able to cover maximum part area based on the largest melt flow length/thickness ratio .澆口數(shù)目The Number of Gates OLE Technology

19、Corporation熔膠波前推進(jìn)熔膠波前推進(jìn)Melt-Front AdvancementMelt-Front Advancement充填方式,積風(fēng)和熔接線Filling Patterns, Air-Traps and Weld Lines LocationOLE Technology Corporation熔接線熔接線Weld LinesWeld LinesOLE Technology Corporation資料 Material : PC-GF50原設(shè)計 Original更改設(shè)計 Revised更改澆口位置以重新定位熔接線更改澆口位置以重新定位熔接線Weld Lines Can Be Re

20、located Weld Lines Can Be Relocated By Changing Gate LocationBy Changing Gate LocationOLE Technology Corporation典型對頭熔接線伸張強(qiáng)度保管值典型對頭熔接線伸張強(qiáng)度保管值Typical Butt Weld Tensile Strength Retention Typical Butt Weld Tensile Strength Retention ValuesValuesMaterialTypeReinforcementTypeTensile StrengthRetention (%)

21、PP0%GF86%PP20%GF47%PP30%GF34%SAN0%GF80%SAN30%GF40%PC0%GF99%PC10%GF86%PC30%GF64%PSF0%GF100%PSF30%GF62%PPS0%GF83%PPS10%GF38%PPS40%GF20%PA660%GF83-100%PA6610%GF87-93%PA6630%GF56-64%OLE Technology Corporation熔接線冷料井熔接線冷料井Weld Slug WellWeld Slug Well對頭熔接線 Butt weld熔接線冷料井Weld slug wellOLE Technology Corpor

22、ation積風(fēng)積風(fēng)Air TrapsAir TrapsOLE Technology Corporation排氣排氣VentVent大部份熱塑性塑膠Most ThermoplasticsA 0.08 mmB 3.18 mmC 12.7 mmD 0.25 mm耐隆和聚縮醛 ( POM )Nylon and Acetal ( POM ) A 0.04 mmB 3.18 mmC 12.7 mmD 0.25 mm進(jìn)料流道Feed Runner塑膠廢品Plastic PartAD排氣孔VentBSEC. A-ACAAOLE Technology Corporation充填平衡Flow Balance熔膠波

23、前於同一時間抵達(dá)型腔各末端。Melt front reaches the ends of cavity at the same time.OLE Technology Corporation洗衣機(jī)圈板洗衣機(jī)圈板OLE Technology Corporation洗衣機(jī)圈板洗衣機(jī)圈板OLE Technology Corporation冷氣通風(fēng)飾罩冷氣通風(fēng)飾罩-原始設(shè)計原始設(shè)計Air-conditioner Grille - Original18 gatespressure: 76 MPaOLE Technology Corporation冷氣通風(fēng)飾罩冷氣通風(fēng)飾罩-修正設(shè)計修正設(shè)計Air-cond

24、itioner Grille - Revised8 gatespressure: 75 MPaOLE Technology Corporation分析結(jié)果比較表分析結(jié)果比較表Comparison of Analysis ResultsOLE Technology Corporation原始設(shè)計Original Design十二澆口設(shè)計十二澆口設(shè)計12 Gate Design電子零件置物箱資料 Material：ABSOLE Technology Corporation四澆口設(shè)計四澆口設(shè)計4 Gate Design修正設(shè)計Revised Design電子零件置物箱資料 Material：ABSO

25、LE Technology Corporation電子零件置物箱四澆口電子零件置物箱四澆口和十二澆口設(shè)計比較表和十二澆口設(shè)計比較表原始設(shè)計修正設(shè)計澆口數(shù)目124充填時間 (s)22最大射壓 (MPa)58.461.8鎖模力需求 (Ton)950820產(chǎn)品重量 (g)41364136流道系統(tǒng)重量 (g)29498OLE Technology Corporation 論語論語 季氏第十六季氏第十六 不患寡而患不均，不患寡而患不均， 不患貧而患不安。不患貧而患不安。 - - 孔子孔子 - -OLE Technology Corporation如何快速平衡眾多模穴之流道如何快速平衡眾多模穴之流道How

26、 to Balance Flow In A Multi-cavity Mold 首先調(diào)整一排支流道內(nèi)之次支流道尺寸，使此支流道內(nèi)之各模穴可平衡充填。First, adjust runner size in one branch to make flow balanced in this branch. 再調(diào)整各支流道前段之尺寸，使各支流道可平衡充填。Then, adjust the first sections runner size in each branch to make flow balanced in all branches.OLE Technology Corporation一

27、排支流道之不平衡充填一排支流道之不平衡充填Unbalanced Flow In A Branch OLE Technology Corporation一排支流道平衡後之充填一排支流道平衡後之充填Balanced Flow In A BranchOLE Technology Corporation全模具全模具(128模穴模穴)之不平衡充填之不平衡充填Unbalanced Flow In A MoldOLE Technology Corporation全模具全模具(128模穴模穴)平衡後之充填平衡後之充填Balanced Flow In A MoldOLE Technology Corporati

28、onThe melt fills the inside cavities before filling the outside cavities.OLE Technology CorporationThe runner system shows that warmer, low-viscosity material (yellow and red) follows the inside wall when the melt splits at an intersection.OLE Technology Corporation剪切速率剪切速率Shear RateOLE Technology C

29、orporation剪剪 切切 應(yīng)應(yīng) 力力shear Stressshear Stress黏黏 度度viscosityviscosity剪剪 切切 速速 率率shear rateshear rate剪切應(yīng)力剪切應(yīng)力Shear StressOLE Technology CorporationOLE Technology CorporationOLE Technology CorporationOLE Technology CorporationOLE Technology Corporation澆口種類澆口種類Gate Types針點澆口Pin Gate扇型澆口Fan Gate潛伏澆口Subma

30、rine Gate邊緣(薄膜)澆口Edge ( Film ) Gate凸片澆口Tab Gate閥澆口Valve Gate環(huán)狀澆口Ring GateOLE Technology Corporation導(dǎo)致平直零件的澆口設(shè)計導(dǎo)致平直零件的澆口設(shè)計Gate Design for Flat Part中心澆口Center Gate扇形澆口Fan Gate最壞的Worst壞的Worse較好的Better最好的Best側(cè)澆口Edge Gate薄模澆口Film GateOLE Technology Corporation澆口設(shè)計澆口設(shè)計(減少滯流效應(yīng)減少滯流效應(yīng))Gate Design to Avoid He

31、sitation澆口gate薄thin厚thick差的設(shè)計Poor好的設(shè)計Good薄thin厚thick澆口gateOLE Technology Corporation0.94秒時，遲滯現(xiàn)象在1.2mm厚凸片處發(fā)生公稱厚度3.2mm幫浦零件(Part, Pump)塑料(Polymer): POMOLE Technology Corporation沒有遲滯現(xiàn)象幫浦零件(Part, Pump)塑料(Polymer): POMOLE Technology Corporation澆口設(shè)計澆口設(shè)計(防止凹陷和氣泡防止凹陷和氣泡)Gate Design to Avoid Sink Mark & Void澆

32、口gate澆口gate差的Poor好的GoodOLE Technology Corporation運(yùn)用重疊澆口以防止噴流運(yùn)用重疊澆口以防止噴流Avoid Jetting by Using Overlap Gate差的Poor好的GoodOLE Technology Corporation正確的澆口位置以防止噴流正確的澆口位置以防止噴流Avoid Jetting by Locating Gate Correctly差的Poor好的GoodOLE Technology Corporation運(yùn)用凸片澆口以防止噴流運(yùn)用凸片澆口以防止噴流Avoid Jetting by Using Tab GateO

33、LE Technology Corporation運(yùn)用適當(dāng)?shù)臐部谛螤钜苑乐箛娏鬟\(yùn)用適當(dāng)?shù)臐部谛螤钜苑乐箛娏鰽void Jetting by Profiling Gate Properly差的Poor好的GoodOLE Technology Corporation幫浦零件(Part, Pump)塑料(Polymer): POM進(jìn)澆處(Polymer entrance)： 澆口厚(Gate thickness) 1.2mm，模穴厚(Cavity thickness) 3.2mm問題 (Problem)： 噴流(Jetting)OLE Technology CorporationPoor Desig

34、n Causing JettingGatePart : Handle, RefrigeratorMaterial : ABSProblem : Jetting Mark Gas PinOLE Technology Corporation氣輔成型冰箱把手氣輔成型冰箱把手澆口及氣針入口澆口太小,導(dǎo)致噴流痕產(chǎn)生厚度差異過大,導(dǎo)致二次噴流痕產(chǎn)生R角過小,氣體通路接近把手內(nèi)側(cè),外側(cè)則因體積收縮呵斥凹陷痕跡OLE Technology Corporation閥澆口閥澆口Valve GateValve Gate1. 閥澆口梢 Valve-Gate Pin2. 加熱管 Heater3. O型環(huán) #610 0

35、Ring4. 流道歧管模板 Manifold Plate5. 軸封環(huán) Seal Retainer6. 套筒軸封 Sleeve Seal7. 枕塊 Support Pillar8. 油壓缸 Hydraulic CylinderOLE Technology Corporation閥澆口閥澆口 ( (一一) )Valve Gate ( 1 Valve Gate ( 1 ) )全部閥澆口同時打開時之充填狀況Mold filling with all the valve gates ( shut-off gates ) opened at the same time.OLE Technology Cor

36、poration閥澆口閥澆口 ( (二二) )Valve Gate ( 2 )Valve Gate ( 2 )部份閥澆口延遲打開，改變充填方式Mold filling with delayed valve gate opening; filling pattern, weld lines and air traps are changed.OLE Technology Corporation多澆口設(shè)計多澆口設(shè)計 Multi-Gate DesignOLE Technology Corporation閥式澆口閥式澆口Valve GateOLE Technology Corporation矩形邊緣澆

37、口設(shè)計矩形邊緣澆口設(shè)計Rectangular Edge Gate DesignL = 0.5 0.75 mmW = 澆口寬度 ( mm ) gate width in mmA = 型腔外表積 ( mm2 ) surface area of cavity in mm2n = 資料常數(shù) material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVCh = n th = 澆口厚度( gate thick. in mm )t = 零件壁厚( wall thick. in mm )WtLh30An

38、W OLE Technology Corporation扇形澆口設(shè)計扇形澆口設(shè)計Fan Gate DesignL= 1.3mmW= w= 澆口寬度 mm gate width in mmA= 型腔外表積 mm2 surface area of cavity in mm2n= 資料常數(shù) material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC澆口厚度 gate thick. in mmt= 零件壁厚 wall thick. in mm 30n h1 = n t h2 = wh1/DO

39、LE Technology Corporation重疊式澆口設(shè)計重疊式澆口設(shè)計Overlap Gate DesignW= w= 澆口寬度 mm gate width in mmA= 型腔外表積 mm surface area of cavity in mmn= 資料常數(shù) material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC澆口厚度 gate thick. in mm = nt澆口長度 land length in mm t= 零件壁厚 wall thick. in mm 2 2

40、30n L1 = 0.50.75L2 = h+( w/2 )OLE Technology Corporation凸耳澆口設(shè)計凸耳澆口設(shè)計Tab Gate DesignL= 0.50.75mmW= w= 澆口寬度 mm gate width in mmA= 型腔外表積 mm2 surface area of cavity in mm2n= 資料常數(shù) material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC澆口厚度 gate thick. in mm t= 零件壁厚 wall thic

41、k. in mm 30nh1 = n t h2 = 0.9 tOLE Technology CorporationL = 0.5 0.75 mmd = 澆口直徑( mm ) gate diameter in mmt = 零件壁厚( mm ) wall thick. in mmA = 型腔外表積 ( mm ) surface area of cavity in mmn = 資料常數(shù) material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC針點澆口設(shè)計針點澆口設(shè)計Pin Gate De

42、signdLtd0.206n tA4OLE Technology Corporation潛伏式澆口設(shè)計潛伏式澆口設(shè)計Subgate DesignW= w= 澆口寬度 mm gate width in mmA= 型腔外表積 mm2 surface area of cavity in mm2n= 資料常數(shù) material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC澆口厚度 gate thick. in mm = ntt= 零件壁厚 wall thick. in mm 30n30 15 2

43、5OLE Technology Corporation水力直徑水力直徑 Hydraulic DiameterPADH4Where is the hydraulic diameter 水力直徑 A is the cross-sectional area of the flow 流路斷面積 P is the wetted perimeter 濕周長HDOLE Technology Corporation水力直徑水力直徑 Hydraulic Diameter在不同剖面形狀，一樣斷面積下之變化Various runner profiles, based on the same cross-sectio

44、nal areaOLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計 (1) Runner Sizing (1)D : 流道直徑 ( mm ) runner diameter in mmW: 下游塑膠分量 ( g ) downstream plastic weight L : 流道長度 ( mm ) runner length in mmDWL3.74OLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計(2) Runner Sizing (2)OLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計(3) Runner Siz

45、ing (3)mmDgcmcmcmgWmmLLWD338. 214.144102 . 0/9 . 0307 . 31223114111OLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計(4) Runner Sizing (4)mmDgggcmcmcmgWWmmLLWD533. 466.28219. 014.14243 . 03/9 . 0807 . 322231224222OLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計(A1) Runner Sizing (A1)G : 分量 weightS : 零件厚度 thicknessD : 參考直

46、徑 reference diameterG( g ) D ( mm )for PS, ABS, SAN, CABOLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計(A2) Runner Sizing (A2) G( g ) D ( mm )for PE, PP, PA, POMG : 分量 weightS : 零件厚度 thicknessD : 參考直徑 reference diameterOLE Technology Corporation流道尺寸設(shè)計流道尺寸設(shè)計(B) Runner Sizing (B)D : 參考直徑 reference diameterL :

47、長度 lengthfL :長度係數(shù) Length coefficientD : 流道直徑 runner diameterfLL (mm)D = D fLOLE Technology Corporation冷料井設(shè)計冷料井設(shè)計Cold Slug Well Design2d次流道Secondary runnerd主流道Primary runner澆口Gate型腔CavityOLE Technology Corporation倒椎度冷料井豎澆道拉料桿Reverse taper cold slug-well sprue pullerZ型冷料井豎澆道拉料桿 Z - taper cold slug-wel

48、l sprue puller溝型冷料井豎澆道拉料桿Grooved cold slug-well sprue puller冷料井設(shè)計冷料井設(shè)計Cold Slug Well DesignOLE Technology Corporation澆道襯套尺寸澆道襯套尺寸Sprue Bushing SizingOLE Technology Corporation熱澆道設(shè)計熱澆道設(shè)計Hot Runner DesignOLE Technology Corporation熱澆道的問題似乎發(fā)生在三處: 1. 澆口直徑 2. 澆口長度 3. 噴嘴孔徑Problems with hot runner seems to

49、be in three places: 1. Gate diameter 2. Gate land 3. Nozzle orifice diameter熱澆道的問題所在熱澆道的問題所在Where Causes Problems with of RunnerOLE Technology Corporation任何發(fā)生在澆口處的發(fā)赤或噴流，表示澆口太小。 變褐則表示資料過熱而劣解。Any blush or jetting at the gate means the gate is too small, and brown discolorations mean the material is be

50、ing degraded by too much heat.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology CorporationBROWN STREAKWITH FLOW LINESA brown streak on thepart molded from easy-flow polycarbonate withthe flow lines.OLE Technology Corporation為了堅持澆口暢通而格外加熱塑料，加上塑料在射出時通過長澆口時接受的剪切力，有能夠呵斥褐線。It was probably a combination o

51、f shear through the long land of the gate during injection and the extra heat needed to keep the gates open that are causing the brown streak.褐線褐線Brown Streak OLE Technology Corporation只以噴嘴口徑去配合熱澆道口徑是不對的。 首先要將澆道口徑加大，以配合下游塑流通道口徑，然後再加大噴嘴口徑以配合澆道口徑。It isnt just sizing the nozzle orifice to match the hol

52、e in the hot sprue bushing . First you might have to increase the hole size of the sprue bushing to match the flow channel diameter, then drill the nozzle out to match the sprue diameter.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology Corporation理想的澆道襯套設(shè)計理想的澆道襯套設(shè)計Optimized Sprue Bushing DesignOLE T

53、echnology Corporation當(dāng)塑流通道受限於小或長的澆口，成型技術(shù)員常將設(shè)定溫度調(diào)高，以確保型腔充填、保壓無虞。When the flow path is restricted by a small gate diameter or a long land length, you will usually see higher heat settings being used by the molding technicians to get the parts to fill and pack out.這樣的作法產(chǎn)生的問題有製品的翹曲，澆口的外觀缺陷和長的成型時間。The pr

54、oblem with this approach is that it usually causes warpage of the parts, cosmetic defects around the gate area, and long molding cycles.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology Corporation假設(shè)歧管溫度設(shè)定得比料管前區(qū)為高，澆口尺寸或許有問題。 假設(shè)必須將噴嘴溫度設(shè)定得特別高，噴嘴口徑或許沒配合上熱澆道口徑。If you find you have to run the manifold hea

55、ts higher than the front zone of the barrel, you probably have gate sizing problems. If you have to run the heats up on the nozzle, the nozzle orifice probably hasnt been drilled out to match the hot sprue bushing diameter.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology Corporation假設(shè)塑流通道的尺寸正確，料管的前區(qū)

56、、噴嘴和加熱歧管的溫度可以設(shè)定得一樣；ABS：232 C、易流PC：274 C。If the flow path is sized correctly, you will be able to set the heat settings on the front zone of the barrel, the nozzle, and the heated manifold, such as 232C across the board for ABS or 274C for easy-flow PC.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology

57、 Corporation易流的PE和PP : 壁厚的50%50% of wall thickness for easy-flow PE and PPABS, SAN和壓克力: 壁厚的75%75% of wall thickness for ABS, SAN, and acrylicsPC/acetal/PVC/加玻纖資料和PPO : 壁厚的90%90% of wall thickness for PC/acetal/PVC/glass-filled materials and PPOs熱澆道模具的澆口直徑熱澆道模具的澆口直徑Gate Diameter for Hot Runner MoldsO

58、LE Technology Corporation澆口長度應(yīng)小於0.125mm。 Land should be no longer than 0.125mm.諮詢熱澆道製造廠，以獲得正確的澆口長度。Consult with your hot runner manufacturer for correct land length.熱澆道模具的澆口長度熱澆道模具的澆口長度Gate Land Length for Gate Land Length for Hot Runner MoldsHot Runner MoldsOLE Technology Corporation排氣系統(tǒng)設(shè)計排氣系統(tǒng)設(shè)計Ven

59、ting System Design徐鑫XUXINOLE Technology Corporation為何排氣依然還是一個問題？Why venting is still a problem ?因為降低射速，讓積風(fēng)有較多的時間逃氣，是一件太容易的事。但是Because it is too easy to slow down the injection speed and give the trapped air more time to escape. But .排氣排氣VentOLE Technology Corporation射速一降，熔膠溫度很快降低，射壓必須提高，殘餘應(yīng)力隨之提高，翹曲的

60、能夠性添加。 假設(shè)想藉提高料溫，以降低射壓，料溫必須升得很高，這樣又會引起塑料裂解。When injection speed is lower, melt temperature goes down very fast, injection pressure has to be increased, residual stress is increased and the possibility getting warppage becomes higher. If one would like to increase barrel temperature to reduce the requ