注塑成型介紹課件

GEAMPlasticsINJECTIONMOLDING注射模塑技術eGEAMPlasticsINJECTIONMOLDING

=由GE塑料生產(chǎn)PSOPEIPEI/PCPCPPOPC/ABSABSPSLCPPPSPPO/PAPC/PBTPC/ASAASAPPPVCPEPAPOM

無定形PET工程級普通級結晶性高性能Ultem*樹脂heatresistanceLexan*樹脂impactresistanceNoryl*樹脂impactresistancehydrolyticstability

processabilityCycolac*樹脂colorabilityandvisualfxXenoy*樹脂impactresistance

chemicalresistancePBTGE塑料提供非常廣泛的工程塑料選擇=由GE塑料生產(chǎn)PSOPEIPEI/PCPCPPOPInjectionMoldingIntroduction注塑成型介紹GOODPARTMaterial材料Tooling模具Processing工藝Design設計好產(chǎn)品InjectionMoldingIntroduction注塑成型介紹生產(chǎn)速度高可以大批量生產(chǎn)人工成本低容易自動化2次加工量小可以生產(chǎn)很小的零件廢品損失小尺寸變化小Molded-inInsertsAvailableGlass,Carbon,etc.FillersComplexPartCapabilityGoodDecorationPossible注塑成型優(yōu)點注塑成型介紹生產(chǎn)速度高廢品損失小注塑成型優(yōu)點InjectionMoldingIntroductionToolingCostsareHighHighMachineryandAuxiliaryCostsHighPressureProcessLimitedLargePartCapabilityDisadvantagesofInjectionMoldingInjectionMoldingIntroductionEquipment設備InjectionMoldingEquipmentEquipmentInjectionMoldingEqInjectionMoldingEquipmentInjectionUnitClampUnitScrew&BarrelInjectionMoldingEquipmentInInjectionMoldingEquipmentTheInjectionUnitProvidesInjectionandPackingPressureProvidesTorquetoTurntheScrewTheScrewBarrelMeltingandHomogenizingtheResinInjectionofthePlasticIntotheMoldInjectionMoldingEquipmentThInjectionMoldingEquipmentTheClampingUnitOpenandClosesMoldHoldstheMoldClosedDuringInjectionCoolsandSolidifiesPartInjectionMoldingEquipmentThInjectionMoldingEquipmentClampingMechanismsDoubleToggleClampingSystemInjectionMoldingEquipmentClInjectionMoldingEquipmentClampingMechanismsHydraulicClampingSystemInjectionMoldingEquipmentClMACHINESHOTSIZE機器注射容量PartWeight=30-80%ofMachineShotSize制件重量=30-80%機器注射容量OptimalPartWeight=40~60%ofMachineShotSize制件重量=40-60%機器注射容量InjectionMoldingEquipmentMACHINESHOTSIZE機器注射容量InjectCLAMPSIZE鎖模力MaterialSelection選料ProjectedArea投影面積3~5噸/平方英寸PartDesign產(chǎn)品設計WallThickness壁厚FlowLength流動長度InjectionPressure&Speed注射壓力和速度InjectionMoldingEquipmentCLAMPSIZE鎖模力InjectionMoldinScrewTypeMachinesAreRecommended推薦采用的螺桿類型UniformPlasticizing

均勻塑化LessPressureLoss

低壓力損耗FasterCycles更快成型周期UniformStockTemperature

均勻儲料溫度StreamlinedMeltFlow

線性熔融流動InjectionMoldingEquipmentScrewTypeMachinesAreRecommMetering計量Feed進料ScrewandCylinderDesign螺桿和料筒設計hfhmL/D=20:1(18~24:1)CompressionRatio壓縮比=hf/hm=2.5:1(2.0:1~3.0:1)Cylinderbi-metallicforAbrasionResistance雙金屬料筒Transition過渡LDInjectionMoldingEquipmentMeteringFeedScrewandCylinder往復式螺桿頭結構檢查環(huán)類型:止回環(huán)熔融樹脂流過開放檢查環(huán)檢查環(huán)關閉,防止在注塑過程中料的回流建議采用止逆閥InjectionMoldingEquipment往復式螺桿頭結構熔融樹脂流過檢查環(huán)關閉,防止在建議采用止逆StandardCylinderNozzles標準料筒噴嘴HeatingBand加熱環(huán)CylinderBore料筒主體ToMoldProvidesMechanicalandThermalConnectionFromHotCylindertoColderMold提供從熱的料筒到相對冷的模具的機械和熱連接到模具InjectionMoldingEquipmentStandardCylinderNozzles標準料筒SprueBushing主流道襯套Nozzle噴嘴Radius半徑Orifice主流道孔口InjectionMoldingEquipmentSprueBushingNozzle噴嘴Radius半Nozzle噴嘴LandLength0.0to3/16inch(4.76mm)過渡段長度不大于3/16inch(4.76mm)Opening3/16inch(4.76mm)to3/8inch(9.52mm)

開口:4.76~9.52mmSprueBushingis0.8mmLargerthanDimensiononNozzle

主流道襯套孔口要比噴嘴口徑大0.8mmAsShortasPossible

盡可能地短AccurateheatingcontrolandGoodHeaterBandCovering

精確的加熱控制和好的加熱帶覆蓋InjectionMoldingEquipmentNozzle噴嘴LandLength0.0to3/通用噴嘴InjectionMoldingEquipment通用噴嘴InjectionMoldingEquipmeGEAMPlasticseGEAMPlasticseInjectionMoldingProcessInjectionMoldingSteps:DryingthePelletsLoadingIntoMoldingMachineHeatingandShearingMaterialIntoaMeltInjectingtheMeltIntotheMoldCavityPartCooling,SolidificationEjectingtheFinishedPartFromtheMoldInjectionMoldingProcessInjeProcessing工藝Start-up:開機:PurgewiththeCorrectMaterial

用正確料清洗

UseCorrectProcessingConditions

采用正確加工參數(shù)Downtime:停機:

Shorttime:HoldMaterialinBarrelfor10~15min

短期：存料10~15分鐘

Longtime:CleantheBarrel

長期：用正確方法和次序徹底清理InjectionMoldingProcessProcessing工藝InjectionMoldingRecommendedPurgeMaterials推薦清洗料Polymer PurgeMaterialCycolac/Cycoloy PMMA,PS,SANLexan PC,HDPE,PMMANorylPS,PPInjectionMoldingProcessRecommendedPurgeMaterialsPolImportantProcessVariables重要加工參數(shù)MeltTemperature熔融溫度MoldTemperature模具溫度TemperatureProfiles溫度曲線ResidenceTime停留時間InjectionSpeed注射速度InjectionPressure注射壓力PackPressure保壓ClampTonnage鎖模力Cushion緩沖料墊InjectionMoldingProcessImportantProcessVariables重要DryingDryingtemperatureandtimeareanimportantkeyfactorforgoodproductsinourproduction在生產(chǎn)得到好的產(chǎn)品，干燥溫度和時間是一重要因素TypicalLexan(PC):典型PC MoistureLevel:Lessthan0.02% 1210C/3~4Hrs

水分含量小于0.02%1210

C/3~4HrsInjectionMoldingProcessDryingInjectionMoldingProceHowisheataddedtothepolymer?外熱如何作用于高分子材料ElectricalHeat:電加熱HeaterBands加熱帶MechanicalHeat機械熱ScrewSpeed螺桿速度BackPressure背壓InjectionPressure/Speed注射速度/壓力InjectionMoldingProcessHowisheataddedtothepolymModelofAmorphousPolymersAddingHeatIncreasesSpaceBetweenMolecularChainsRaiseTemperatureofPolymer

TGLocked固態(tài)EntanglementsStiffFlow難于流動EasierFlow較易流動InjectionMoldingProcessModelofAmorphousPolymersAddMeltTemperature熔融溫度35302520151050.030 .060 .090 .120 .150 .180 .210 .240WallThicknessinInches壁厚(In)MeltFlow(in.)LEXAN?101550degF.101@600deg.FIncreasedMeltTemperatureyieldsincreasedFlow.提高熔融溫度導致增加流動However,TooHighaMeltTemperatureMayCauseDegradation.但,過高熔融溫度造成降解InjectionMoldingVariablesMeltTemperature熔融溫度35.030 .0InjectionMoldingEquipmentResidenceTimeTomeasurethis,coloredpelletsaredroppedintothebaseofthehopper.Timeismeasureduntilthepointwhencoloredextrudantispurgedfromthenozzle.Theamountoftimethatmoltenmaterialresidesinthebarrel.Residencetime[min]=

(2.2~2.5)MaxPlasticisingstrokePlasticisingstroke-cushion*Cycletime60InjectionMoldingEquipmentResThermoplasticsandDegradation熱塑性塑料和降解Degradation降解TemperatureTime時間InjectionMoldingProcessThermoplasticsandDegradationBarrelUnitTheReciprocatingScrew(Filling)ThroatHeatingCoilsNozzleHopperScrewBarrelForce,TorqueFromInjectionUnit料筒組件回轉式螺桿噴嘴螺桿加熱料斗加料口料筒來自注塑單元的力和力矩InjectionMoldingBarrelUnit(Filling)ThroatHeaScrewRotationFeedsandShearsMaterialIntoaMelt.MeltCollectsIntoFrontofBarrel,ForcingScrewBackShotRotationandBackPressure出量通過螺桿回轉，熔體聚集于料筒前部，反作用力使螺桿后退。回轉力矩和背壓InjectionMoldingBarrelUnitTheReciprocatingScrewScrewRotationFeedsandShear15010050255075125150100ScrewDiainmmRPMSCREWSPEEDSuggestions(8in/sec)推薦螺桿轉速螺桿直徑轉速InjectionMolding15010050255075125150100ScrewMeltRequiredtoFillMoldReadyforInjectionShotInjectionPressure注射壓力InjectionMoldingEquipmentBarrelUnitTheReciprocatingScrewMeltRequiredtoFillMoldReaScrewPushesForward:InjectCushionPackingPressure緩沖墊保壓注射InjectionMoldingEquipmentBarrelUnitTheReciprocatingScrewScrewPushesForward:InjectCuInjectionSpeed注射速度100010010100 1000 10000LEXAN?141@644degFLEXAN?141@608degFLEXAN?141@572degFApparentViscosity(Pa/s)ShearRate(1/s)InjectionSpeedaffectstheviscosityofthemoltenmaterial.注射速度影響熔體粘度表觀粘度剪切速率InjectionMoldingVariablesInjectionSpeed注射速度1000100 10InjectionPressureProfile注射壓力曲線HydraulicPressureTimeFillTimeScrewRunTimeBackPressurePeakInjectionPressurePressureAppliedbyInjectionRamtoForcethePlasticFromtheBarreltotheMold.注射壓力峰值液壓壓力填充時間InjectionMoldingVariablesInjectionPressureProfile注射壓Cushion緩沖墊CushionMaterialremaininginbarrelwhentheejectionphaseiscompleted.注塑過程結束后，殘于料筒前端的熔體Theinjectionmoldingprocessshouldallowacushiontoprovidesufficientpackingpressureinthemold注塑過程必須要有緩沖墊以保證有效的保壓InjectionMoldingVariablesCushion緩沖墊CushionMaterialremInjectionFlow熔體流動InjectionMoldingProcessInjectionFlow熔體流動InjectionMoInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecMoldTempeature模溫MoldTemperatureiscriticalinproducingqualifiedpart.模溫對得到合格的制件很重要InjectionMoldingProcessMoldTempeature模溫InjectionMoPartCoolingandSolidificationHotMeltCooledMoldSolidPart制件冷卻和固化熱熔體溫度較低的模具固化的制件InjectionMoldingProcessPartCoolingandSolidificatioMoldTemperature模溫MoldTemperatureiscriticalinglossaryandresiduestrainofpart模溫對制件的光潔度和模塑殘余應力等級很重要Uniformmoldtemperaturereducestheeffectsofwarpage.均勻的模溫可以減少翹曲Commonlycontrolledbywatercoolingchannels.模溫通常冷卻水孔道來控制InjectionMoldingCoolingMoldTemperature模溫MoldTemperInjectionMoldingCooling120125125135135145130140140130150145OOOOOOOOOOOOINOUTInjectionMoldingCooling12012InjectionMoldingCoolingMOLDManifold“In”Manifold“Out”Water“In”Water“Out”InjectionMoldingCoolingMOLDMTheMoldTemperatureMustBeBelowTGtoSolidifyPartTGProcessingTemperatureRangeDegradationCooling:AmorphousResin無定型塑料的冷卻降解加工溫度范圍模具溫度必須低于玻璃化轉變溫度InjectionMoldingCoolingTheMoldTemperatureMustBeBDegradationTMTGProcessingTemperatureRangeMoldTemperatureDeterminesCoolingTimeandThereforeDegreeofCrystallinity模溫決定了冷卻時間和結晶度CoolingThroughtheCrystallinizationRangeTooQuicklyWillResultinReducedCrystallinity(Quenching)過快冷卻將造成結晶度低CrystallinizationCoolingRange結晶性塑料的冷卻InjectionMoldingCoolingDegradationTMTGProcessingMoldInjectionMoldingEjectionInjectionMoldingEjectionREGRINDSUGGESTIONS對材料回收使用的建議UseOnlyCleanNon-degraded只使用未降解材料UncontaminatedResinforRegrind回收料不能有污染KeepItAsNewMaterial要象保存新料一樣Normally25%ofRegrindcanbeUsed通常允許添加25%的回收料ScreenSizesshouldbe7to9mm過濾網(wǎng)應該在7至9MMInjectionMoldingRegrindREGRINDSUGGESTIONS對材料回收使用的建議ITenDoforMoldingEngineeringResinsKnowYourMaterial了解你所使用的材料DryProperly正確地干燥UseRecommendedProcessingConditions使用推薦的加工參數(shù)UseProperlySizedEquipment選擇恰當?shù)脑O備UseProperlyDesignedTooling正確設計模具UseAdequateRunners澆口尺寸充分UseProperVenting良好的排氣UseNozzleswithProperHeatControls對噴嘴施以良好的溫控UseProperScrewDesign恰當?shù)穆輻U結構ScheduleAnnualorBi-AnnualEquipmentMaintenance正確維護保養(yǎng)設備十大準則InjectionMoldingTenDoforMoldingEngineeringInjectionMoldingQ&AInjectionMoldingQ&ADISCLAIMER:THEMATERIALSANDPRODUCTSOFTHEBUSINESSESMAKINGUPTHEGEADVANCEDMATERIALSUNITOFGENERALELECTRICCOMPANY,ITSSUBSIDIARIESANDAFFILIATES(“GEAM”),ARESOLDSUBJECTTOGEAM’SSTANDARDCONDITIONSOFSALE,WHICHAREINCLUDEDINTHEAPPLICABLEDISTRIBUTOROROTHERSALESAGREEMENT,PRINTEDONTHEBACKOFORDERACKNOWLEDGMENTSANDINVOICES,ANDAVAILABLEUPONREQUEST.ALTHOUGHANYINFORMATION,RECOMMENDATIONS,ORADVICECONTAINEDHEREINISGIVENINGOODFAITH,GEAMMAKESNOWARRANTYORGUARANTEE,EXPRESSORIMPLIED,(I)THATTHERESULTSDESCRIBEDHEREINWILLBEOBTAINEDUNDEREND-USECONDITIONS,OR(II)ASTOTHEEFFECTIVENESSORSAFETYOFANYDESIGNINCORPORATINGGEAMMATERIALS,PRODUCTS,RECOMMENDATIONSORADVICE.EXCEPTASPROVIDEDINGEAM’SSTANDARDCONDITIONSOFSALE,GEAMANDITSREPRESENTATIVESSHALLINNOEVENTBERESPONSIBLEFORANYLOSSRESULTINGFlameRetardantORANYUSEOFITSMATERIALSORPRODUCTSDESCRIBEDHEREIN.

EachuserbearsfullresponsibilityformakingitsowndeterminationastothesuitabilityofGEAM’smaterials,products,recommendations,oradviceforitsownparticularuse.EachusermustidentifyandperformalltestsandanalysesnecessarytoassurethatitsfinishedpartsincorporatingGEAMmaterialsorproductswillbesafeandsuitableforuseunderend-useconditions.Nothinginthisoranyotherdocument,noranyoralrecommendationoradvice,shallbedeemedtoalter,vary,supersede,orwaiveanyprovisionofGEAM’sStandardConditionsofSaleorthisDisclaimer,unlessanysuchmodificationisspecificallyagreedtoinawritingsignedbyGEAM.Nostatementcontainedhereinconcerningapossibleorsuggesteduseofanymaterial,productordesignisintended,orshouldbeconstrued,tograntanylicenseunderanypatentorotherintellectualpropertyrightofGeneralElectricCompanyoranyofitssubsidiariesoraffiliatescoveringsuchuseordesign,orasarecommendationfortheuseofsuchmaterial,productordesignintheinfringementofanypatentorotherintellectualpropertyright.Somegradesnotedinthispresentationarenotcommercialandarestillindevelopment.Sincetheirformulationmaychange,theymayneverbeavailableforsaleasnotedherein.DisclaimerDISCLAIMER:THEMATERIALSANDGEAMPlasticsINJECTIONMOLDING注射模塑技術eGEAMPlasticsINJECTIONMOLDING

=由GE塑料生產(chǎn)PSOPEIPEI/PCPCPPOPC/ABSABSPSLCPPPSPPO/PAPC/PBTPC/ASAASAPPPVCPEPAPOM

無定形PET工程級普通級結晶性高性能Ultem*樹脂heatresistanceLexan*樹脂impactresistanceNoryl*樹脂impactresistancehydrolyticstability

processabilityCycolac*樹脂colorabilityandvisualfxXenoy*樹脂impactresistance

chemicalresistancePBTGE塑料提供非常廣泛的工程塑料選擇=由GE塑料生產(chǎn)PSOPEIPEI/PCPCPPOPInjectionMoldingIntroduction注塑成型介紹GOODPARTMaterial材料Tooling模具Processing工藝Design設計好產(chǎn)品InjectionMoldingIntroduction注塑成型介紹生產(chǎn)速度高可以大批量生產(chǎn)人工成本低容易自動化2次加工量小可以生產(chǎn)很小的零件廢品損失小尺寸變化小Molded-inInsertsAvailableGlass,Carbon,etc.FillersComplexPartCapabilityGoodDecorationPossible注塑成型優(yōu)點注塑成型介紹生產(chǎn)速度高廢品損失小注塑成型優(yōu)點InjectionMoldingIntroductionToolingCostsareHighHighMachineryandAuxiliaryCostsHighPressureProcessLimitedLargePartCapabilityDisadvantagesofInjectionMoldingInjectionMoldingIntroductionEquipment設備InjectionMoldingEquipmentEquipmentInjectionMoldingEqInjectionMoldingEquipmentInjectionUnitClampUnitScrew&BarrelInjectionMoldingEquipmentInInjectionMoldingEquipmentTheInjectionUnitProvidesInjectionandPackingPressureProvidesTorquetoTurntheScrewTheScrewBarrelMeltingandHomogenizingtheResinInjectionofthePlasticIntotheMoldInjectionMoldingEquipmentThInjectionMoldingEquipmentTheClampingUnitOpenandClosesMoldHoldstheMoldClosedDuringInjectionCoolsandSolidifiesPartInjectionMoldingEquipmentThInjectionMoldingEquipmentClampingMechanismsDoubleToggleClampingSystemInjectionMoldingEquipmentClInjectionMoldingEquipmentClampingMechanismsHydraulicClampingSystemInjectionMoldingEquipmentClMACHINESHOTSIZE機器注射容量PartWeight=30-80%ofMachineShotSize制件重量=30-80%機器注射容量OptimalPartWeight=40~60%ofMachineShotSize制件重量=40-60%機器注射容量InjectionMoldingEquipmentMACHINESHOTSIZE機器注射容量InjectCLAMPSIZE鎖模力MaterialSelection選料ProjectedArea投影面積3~5噸/平方英寸PartDesign產(chǎn)品設計WallThickness壁厚FlowLength流動長度InjectionPressure&Speed注射壓力和速度InjectionMoldingEquipmentCLAMPSIZE鎖模力InjectionMoldinScrewTypeMachinesAreRecommended推薦采用的螺桿類型UniformPlasticizing

均勻塑化LessPressureLoss

低壓力損耗FasterCycles更快成型周期UniformStockTemperature

均勻儲料溫度StreamlinedMeltFlow

線性熔融流動InjectionMoldingEquipmentScrewTypeMachinesAreRecommMetering計量Feed進料ScrewandCylinderDesign螺桿和料筒設計hfhmL/D=20:1(18~24:1)CompressionRatio壓縮比=hf/hm=2.5:1(2.0:1~3.0:1)Cylinderbi-metallicforAbrasionResistance雙金屬料筒Transition過渡LDInjectionMoldingEquipmentMeteringFeedScrewandCylinder往復式螺桿頭結構檢查環(huán)類型:止回環(huán)熔融樹脂流過開放檢查環(huán)檢查環(huán)關閉,防止在注塑過程中料的回流建議采用止逆閥InjectionMoldingEquipment往復式螺桿頭結構熔融樹脂流過檢查環(huán)關閉,防止在建議采用止逆StandardCylinderNozzles標準料筒噴嘴HeatingBand加熱環(huán)CylinderBore料筒主體ToMoldProvidesMechanicalandThermalConnectionFromHotCylindertoColderMold提供從熱的料筒到相對冷的模具的機械和熱連接到模具InjectionMoldingEquipmentStandardCylinderNozzles標準料筒SprueBushing主流道襯套Nozzle噴嘴Radius半徑Orifice主流道孔口InjectionMoldingEquipmentSprueBushingNozzle噴嘴Radius半Nozzle噴嘴LandLength0.0to3/16inch(4.76mm)過渡段長度不大于3/16inch(4.76mm)Opening3/16inch(4.76mm)to3/8inch(9.52mm)

開口:4.76~9.52mmSprueBushingis0.8mmLargerthanDimensiononNozzle

主流道襯套孔口要比噴嘴口徑大0.8mmAsShortasPossible

盡可能地短AccurateheatingcontrolandGoodHeaterBandCovering

精確的加熱控制和好的加熱帶覆蓋InjectionMoldingEquipmentNozzle噴嘴LandLength0.0to3/通用噴嘴InjectionMoldingEquipment通用噴嘴InjectionMoldingEquipmeGEAMPlasticseGEAMPlasticseInjectionMoldingProcessInjectionMoldingSteps:DryingthePelletsLoadingIntoMoldingMachineHeatingandShearingMaterialIntoaMeltInjectingtheMeltIntotheMoldCavityPartCooling,SolidificationEjectingtheFinishedPartFromtheMoldInjectionMoldingProcessInjeProcessing工藝Start-up:開機:PurgewiththeCorrectMaterial

用正確料清洗

UseCorrectProcessingConditions

采用正確加工參數(shù)Downtime:停機:

Shorttime:HoldMaterialinBarrelfor10~15min

短期：存料10~15分鐘

Longtime:CleantheBarrel

長期：用正確方法和次序徹底清理InjectionMoldingProcessProcessing工藝InjectionMoldingRecommendedPurgeMaterials推薦清洗料Polymer PurgeMaterialCycolac/Cycoloy PMMA,PS,SANLexan PC,HDPE,PMMANorylPS,PPInjectionMoldingProcessRecommendedPurgeMaterialsPolImportantProcessVariables重要加工參數(shù)MeltTemperature熔融溫度MoldTemperature模具溫度TemperatureProfiles溫度曲線ResidenceTime停留時間InjectionSpeed注射速度InjectionPressure注射壓力PackPressure保壓ClampTonnage鎖模力Cushion緩沖料墊InjectionMoldingProcessImportantProcessVariables重要DryingDryingtemperatureandtimeareanimportantkeyfactorforgoodproductsinourproduction在生產(chǎn)得到好的產(chǎn)品，干燥溫度和時間是一重要因素TypicalLexan(PC):典型PC MoistureLevel:Lessthan0.02% 1210C/3~4Hrs

水分含量小于0.02%1210

C/3~4HrsInjectionMoldingProcessDryingInjectionMoldingProceHowisheataddedtothepolymer?外熱如何作用于高分子材料ElectricalHeat:電加熱HeaterBands加熱帶MechanicalHeat機械熱ScrewSpeed螺桿速度BackPressure背壓InjectionPressure/Speed注射速度/壓力InjectionMoldingProcessHowisheataddedtothepolymModelofAmorphousPolymersAddingHeatIncreasesSpaceBetweenMolecularChainsRaiseTemperatureofPolymer

TGLocked固態(tài)EntanglementsStiffFlow難于流動EasierFlow較易流動InjectionMoldingProcessModelofAmorphousPolymersAddMeltTemperature熔融溫度35302520151050.030 .060 .090 .120 .150 .180 .210 .240WallThicknessinInches壁厚(In)MeltFlow(in.)LEXAN?101550degF.101@600deg.FIncreasedMeltTemperatureyieldsincreasedFlow.提高熔融溫度導致增加流動However,TooHighaMeltTemperatureMayCauseDegradation.但,過高熔融溫度造成降解InjectionMoldingVariablesMeltTemperature熔融溫度35.030 .0InjectionMoldingEquipmentResidenceTimeTomeasurethis,coloredpelletsaredroppedintothebaseofthehopper.Timeismeasureduntilthepointwhencoloredextrudantispurgedfromthenozzle.Theamountoftimethatmoltenmaterialresidesinthebarrel.Residencetime[min]=

(2.2~2.5)MaxPlasticisingstrokePlasticisingstroke-cushion*Cycletime60InjectionMoldingEquipmentResThermoplasticsandDegradation熱塑性塑料和降解Degradation降解TemperatureTime時間InjectionMoldingProcessThermoplasticsandDegradationBarrelUnitTheReciprocatingScrew(Filling)ThroatHeatingCoilsNozzleHopperScrewBarrelForce,TorqueFromInjectionUnit料筒組件回轉式螺桿噴嘴螺桿加熱料斗加料口料筒來自注塑單元的力和力矩InjectionMoldingBarrelUnit(Filling)ThroatHeaScrewRotationFeedsandShearsMaterialIntoaMelt.MeltCollectsIntoFrontofBarrel,ForcingScrewBackShotRotationandBackPressure出量通過螺桿回轉，熔體聚集于料筒前部，反作用力使螺桿后退。回轉力矩和背壓InjectionMoldingBarrelUnitTheReciprocatingScrewScrewRotationFeedsandShear15010050255075125150100ScrewDiainmmRPMSCREWSPEEDSuggestions(8in/sec)推薦螺桿轉速螺桿直徑轉速InjectionMolding15010050255075125150100ScrewMeltRequiredtoFillMoldReadyforInjectionShotInjectionPressure注射壓力InjectionMoldingEquipmentBarrelUnitTheReciprocatingScrewMeltRequiredtoFillMoldReaScrewPushesForward:InjectCushionPackingPressure緩沖墊保壓注射InjectionMoldingEquipmentBarrelUnitTheReciprocatingScrewScrewPushesForward:InjectCuInjectionSpeed注射速度100010010100 1000 10000LEXAN?141@644degFLEXAN?141@608degFLEXAN?141@572degFApparentViscosity(Pa/s)ShearRate(1/s)InjectionSpeedaffectstheviscosityofthemoltenmaterial.注射速度影響熔體粘度表觀粘度剪切速率InjectionMoldingVariablesInjectionSpeed注射速度1000100 10InjectionPressureProfile注射壓力曲線HydraulicPressureTimeFillTimeScrewRunTimeBackPressurePeakInjectionPressurePressureAppliedbyInjectionRamtoForcethePlasticFromtheBarreltotheMold.注射壓力峰值液壓壓力填充時間InjectionMoldingVariablesInjectionPressureProfile注射壓Cushion緩沖墊CushionMaterialremaininginbarrelwhentheejectionphaseiscompleted.注塑過程結束后，殘于料筒前端的熔體Theinjectionmoldingprocessshouldallowacushiontoprovidesufficientpackingpressureinthemold注塑過程必須要有緩沖墊以保證有效的保壓InjectionMoldingVariablesCushion緩沖墊CushionMaterialremInjectionFlow熔體流動InjectionMoldingProcessInjectionFlow熔體流動InjectionMoInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecInjectionMoldingProcessInjectionFlow熔體流動InjectionMoldingProcessInjecMoldTempeature模溫MoldTemperatureiscriticalinproducingqualifiedpart.模溫對得到合格的制件很重要InjectionMoldingProcessMoldTempeature模溫InjectionMoPartCoolingandSolidificationHotMeltCooledMoldSolidPart制件冷卻和固化熱熔體溫度較低的模具固化的制件InjectionMoldingProcessPartCoolingandSolidificatioMoldTemperature模溫MoldTemperatureiscriticalinglossaryandresiduestrainofpart模溫對制件的光潔度和模塑殘余應力等級很重要Uniformmoldtemperaturereducestheeffectsofwarpage.均勻的模溫可以減少翹曲Commonlycontrolledbywatercoolingchannels.模溫通常冷卻水孔道來控制InjectionMoldingCoolingMoldTemperature模溫MoldTemperInjectionMoldingCooling120125125135135145130140140130150145OOOOOOOOOOOOINOUTInjectionMoldingCooling12012InjectionMoldingCoolingMOLDManifold“In”Manifold“Out”Water“In”Water“Out”InjectionMoldingCoolingMOLDMTheMoldTemperatureMustBeBelowTGtoSolidifyPartTGProcessingTemperatureRangeDegradationCooling:AmorphousResin無定型塑料的冷卻降解加工溫度范圍模具溫度必須低于玻璃化轉變溫度InjectionMoldingCoolingTheMoldTemperatureMustBeBDegradationTMTGProcessingTemperatureRangeMoldTemperatureDeterminesCoolingTimeandThereforeDegreeofCrystallinity模溫決定了冷卻時間和結晶度CoolingThroughtheCrystallinizationRangeTooQuicklyWillResultinReducedCrystallinity(Quenching)過快冷卻將造成結晶度低CrystallinizationCoolingRange結晶性塑料的冷卻InjectionMoldingCoolingDegradationTMTGProcessingMoldInjectionMoldingEjectionInjectionMoldingEjectionREGRINDSUGGESTIONS對材料回收使用的建議UseOnlyCleanNon-degraded只使用未降解材料UncontaminatedResinforRegrind回收料不能有污染KeepItAsNewMaterial要象保存新料一樣Normally25%ofRegrindcanbeUsed通常允許添加25%的回收料ScreenSizesshouldbe7to9mm過濾網(wǎng)應該在7至9MMInjectionMoldingRegrindREGRINDSUGGESTIONS對材料回收使用的建議ITenDoforMoldingEngineeringResinsKnowYourMaterial了解你所使用的材料DryProperly正確地干燥UseRecommendedProcessingConditions使用推薦的加工參數(shù)UseProperlySizedEquipment選擇恰當?shù)脑O備UseProperly