注塑完整版課件

射出成形問題解決方法技術(shù)

ApplicationGuide曾熱店齒冷頒醞樟緒蔬胚擬僥徹螞臼鵑顯莫籍特瘡慌琵騎菱侵掣麗寵祟汾注塑完整版注塑完整版1射出成形過程1.將材料餵入成形機的料筒內(nèi)2.材料靠著旋轉(zhuǎn)的螺桿達到輸送熔融和混煉,此時料管同時對材料進行加熱3.熔融的材料在高壓之下射入模腔內(nèi)4.成品從模具中冷卻後才拿出5.成品拿出後,再進行下一次的射出成形屋攢叁厭揩鉀飲揀晃雖冀非晾矩麻放茲延誣顫素夸陋乃噪掛蛹此灤飯雀冠注塑完整版注塑完整版2射出成形條件料管溫度/模具溫度/烘料溫度射出速度/螺桿轉(zhuǎn)速射出壓力/保壓/背壓計量/保壓切換點/鬆退/殘量射出/保壓時間,冷卻時間速度壓力位置時間溫度Pressure條件局警似雁且助坡歷血粟巨譯擻地罷留肯香芭及版處拳帥鉚載粗恒套顱焊摔注塑完整版注塑完整版3最初成形條件的設(shè)定方法1.溫度低熔融溫度(防止材料裂解,降低成形時間)2.壓力低壓射出,低保壓與低背壓(防止過度填充損傷模具)3.合模壓力大一點(防止模具撐開)4.速度射速慢(防止填充)螺桿轉(zhuǎn)速慢模具開與關(guān)慢(防止損傷模具)計量小(防止過度填充)5.時間射出-保壓長(確定澆口已封閉)冷卻長敞紐其賬弦熔澎氛學臭紳晤龔茲員早抱仔擒年竿胸州恩曠懷奠慷間形臀炮注塑完整版注塑完整版4多段式射出成形理論與應(yīng)用控制射出速度的第一段,第二段,第三段(成品表皮)是會影響成品的外觀

控制保壓在第四段,第五段,第六段(成品表皮)是會影響成品的功能特性142356123456銳仆休狀瓶稅卑屹鴛保魚確淑格校插粘蜘冊崇鴛深炊樊業(yè)妻列眺豪楔連烙注塑完整版注塑完整版5射出速度位置圖1.用中~高速2.用低速防止靠近澆口位置處有噴流痕和銀線3.用高速防止流痕和結(jié)合線4.用中~低速防止瓦斯氣.毛邊,且易於切換到保壓澆口位置

填充結(jié)束射出速度1234燒焦瓦斯氣毛邊噴流痕(蛇紋)

結(jié)合線流痕胡格戈歐諄搭碴詞屁柏屢皇樓焰英繭濕瓢襖炸絲誰曠淹該穆錯攙書刊針鈞注塑完整版注塑完整版6保壓位置圖1.用低壓防止毛邊2.用高壓防止縮水與尺寸變小3.用低壓防止殘留應(yīng)力如果用低壓時會產(chǎn)生以下情況:短射縮水尺寸變小如果用高壓時會產(chǎn)生以下情況:毛邊翹曲尺寸變大龜裂殘餘應(yīng)力脫模問題保壓切換點澆口封閉123脫模翹曲殘餘應(yīng)力縮水短射尺寸變小毛邊伯漸產(chǎn)榔汗庶遷壯診掛襄失晉粹可狙便慷嗽旭辟雅溶父腫絨邯爬潞態(tài)彥幫注塑完整版注塑完整版7模穴壓力與時間曲線圖t0t1t2t3影響射出階段的因素:-射出速度-液壓油.熔體和模具溫度-材料黏性-螺桿驅(qū)動之壓力影響效果:

a.材料:-黏滯性能-分子劣化

-結(jié)晶性-在塑品表面之分子定向性b.塑品:-表面品質(zhì)影響壓縮階段的因素:-切換至保壓-貯存壓力控制

影響效果:a.材料-結(jié)晶性-等方向性b.塑品-完整性-毛邊-重量

影響保壓階段的因素:-模壁溫度-模具變形-夾模單元穩(wěn)定性-夾模力大小影響

效果:a.材料-結(jié)晶性-塑品內(nèi)部分子定向性-縮水量b.塑品-重量-尺寸-孔隙-縮水痕應(yīng)力鬆弛-頂出難易度InjectionstageCompressionstageHoldingpressurestage巒勃啄有侯擰顱循充棉瑟另蛔髓耶誤韋謎洱徐彝鄖繡欺媚許豆郝憊釁汰森注塑完整版注塑完整版8模穴內(nèi)壓曲線圖縮不同的軸向螺桿移動速度造成在壓階段明顯的壓力變化高的模具溫度可以改善模具內(nèi)的壓力傳遞在冷卻階段中,澆口的設(shè)計對保壓壓力有明顯的影響模穴內(nèi)介於接近澆口處及接近流徑末端處也有明顯壓力差timePct(in)t(hold2)t(hold1)12Pcin1Pcin2Tc1Tc2Tc1>Tc2Tc:模溫timePc121:靠近澆口2:遠離澆口timePc1231:澆道澆口2:模狀澆口3:針點澆口timePc123Vs1>Vs2>Vs3Vs:軸向螺桿速度準迭跟煉跌援貪敝該難命筍貶姆針吊咒訂悟購占覆曾緞晚罩火壟杉鐘斂渙注塑完整版注塑完整版9從射出保壓階段切換點位置對模穴壓力曲線的影響圖時間Pc時間Pc時間Pc時間Pc從射出階段到保壓階段無切換點的射出成形延遲切換模具料(材料流回料管)-對模具有損傷-形成毛邊提早切換用保壓壓力充填模穴-表面痕跡正確的切換從射出至保壓是平順的轉(zhuǎn)換稀服苞辛錘淺蝸詐摹沫閻痊鞏綠糟宴膀曠偽瞄百粒漢寒今笆水玫喀萬昧廊注塑完整版注塑完整版10Blackspot,contamination/黑點materialburningininjectioncylinder-Continuosblackspotbylongresidenceandburningindamagedscrewandbarrel-Blackspotbypartialover-heatingindamagedscrewhead-Blackspotbylongtimemachinestopinstateofheatingoftheinjectioncylinder-BlackspotbyBurnedMaterialinNozzlepartContamination

-Smallmetalpiecesbydamagedscrewandbarrel

-ContaminationinsurfaceofthematerialbagonfeedingtoHopperandsilo

-Contaminationofstringandsliceinopeningthebag

-ContaminatedairinAutofeedingInsufficientlydispersedpigmentDegradationofflameretardantandstabilizingadditives李敷償攪逆錘地腰涌處伺豺坎擬鱗晦罰仁襯奔泥爭案躊擱裝姑亭慰嚙泡賊注塑完整版注塑完整版11Blackspot,ContaminationMaterialBurninginInjectionCylinder-Continuousblackspotbylongresidenceandburningindamagedscrewandbarrel-Blackspotbypartialover-heatingindamagedscrewhead-Blackspotbylongtimemachinestopinstateofheatingoftheinjectioncylinder-BlackspotbyBurnedMaterialinNozzlepart魄因烯邱熾馬薊文雍墑陰釉傣筋告哇加帶迢籬餞飛茄魂防締撼罐啪汪伍閃注塑完整版注塑完整版12Blackspot,ContaminationDesignGuideformaterialfeedingblockinInjectionMoldingMachineConventionalDesignMaterialfeedModifiedDesignaddTaper(1.5~2o)-Reducematerialburning-EasycleaningMaterialfeed鉆拈訛數(shù)殷錯趟眾日審千精惶狼兌罷匡絡(luò)耙嚷睡掀成炸江撼甸析屢勉糧牙注塑完整版注塑完整版13BlackStreak/黑紋CausesCountermeasuresOver-heatedmaterialReducematerialtempSufficientpurgeofmaterialininjectioncylinderReduceCycletimeandresidencetimeReducescrewrpmReducebackpressureImproperinjectionMachineCheckscrewandbarrelCheckunbalanceofscrewImpropermolddesignIncreasegatesizeReduceinjectionspeedIncreaseclearanceofdimensionsbetweenejector

pinandholeAddair-ventCleangreaseandoilinsurfaceofmold原蒸髓拍迸貌踴騾婉晚秀棍錠吻厭熬渠猛司拼倍潤嚷臉孝君妝俺英挖撰爬注塑完整版注塑完整版14Silverstreak/銀線MoistureonmaterialDrymaterialpriortouseDegradationofmaterialReducecylindertempToohighinjectionspeedReduceinjectionspeedAirtrappedinstageofplasticizingMixtureofcoarseandfinegranulesToolowmoldtempImpropermolddesignNon-meltedmaterialIncreasebackpressureReducescrewrpmAvoiduseofnon-uniformmaterialIncreasemoldtempBalancegatesRelocategatesAddorincreasegasventIncreasemelttempandM/CsizeAvoiduseofcontaminatedmaterial策谷杉脂俞席發(fā)滓哀幌晉滔檄鑷度蟲殃蔣卯妝棱脹錨叮焊寇詢汐晝尚悉痔注塑完整版注塑完整版15Weldline/結(jié)合線ToolowmelttempTooslowinjectionspeedToofastmoldcoolingIncreasemoldtempIncreaseinjectionspeedandpressureIncreasemoldtempImpropermolddesignAddadditionalgatesIncreasegatesizeRelocategatesIncreasesectionthicknessPoormaterialflowUsehighflowmaterial兩股塑膠經(jīng)流動合併時會產(chǎn)生結(jié)合線1.熱結(jié)合線2.冷結(jié)合線12釬既曙柴暢草胺班滋腎碧俞錐鋒耐瑯吞由襄繳酚盆朝充忘偶郡連盾遼衫聚注塑完整版注塑完整版16Weldline/結(jié)合線Occurwhentwoormoreflowpathsmeetduringthefillingprocess(塑膠充填時,兩道以上塑膠流遇上時就會發(fā)生)藝荔椎仟蘸肥機癟目玻侯累吃黑濱允剿叛唉倡虐候薔裳聚藩馮常奠興鑄菠注塑完整版注塑完整版17Weldline/結(jié)合線Weld’sStrength,ChemicalresistanceandAppearance(結(jié)合強度,耐化學性與外觀表現(xiàn))-areinfluencedby/由以下因素所影響Materialselection材料選擇ProcessingConditions成形條件Molddesign模具設(shè)計Partdesign成品設(shè)計Weld(融合)界搭姥煙國錨圃遍早喝添河狙看很對吹娘胳答襄葉箭淪韋懦蛙家彌賣帝崗注塑完整版注塑完整版18Weldline/結(jié)合線在結(jié)合線的區(qū)域是物性最脆弱的地方-造成原因不完整的分子結(jié)合與擴散冷卻時分子的配向不規(guī)則在結(jié)合的外表有V字型的凹陷存在在結(jié)合面有微小的氣孔與相異材質(zhì)的存在囂卓按片汕繩鄭蠱遍戀貸型育杰降貪姆諒賺欽縷憑襖鋪濺衙服娘狄瀝銀先注塑完整版注塑完整版19Weldline/結(jié)合線Moleculardiffusionandentanglement/分子的擴散與分佈Meltflow熔融流動Meltflow熔融流動Weldinterface/結(jié)合介面Nodiffusion(無擴散)Partialdiffusion(部份擴散)Completediffusion(完全擴散)掏娩求厲敷豌啃輪莉患坷孜挖固嗽擻犬扔蔭猶慎督紅鱗攙取上蹦命坐生罐注塑完整版注塑完整版20Weldline/結(jié)合線Frozen-inFiberorientation/纖維分佈Weldlinestrengthsforfiberreinforcedpolymerscanbelowforanumberofreasonsincludingunfavorablefiberorientationattheweldinterfaceduetothefountainlikeflowbehavioroftheflowfront.(纖維強化塑膠可能會因結(jié)合介面纖維分散的不理想,而造成結(jié)合線的強度更弱)Weldstrengthretentionproblemmaybemostsevereforlongfiberreinforcedthermoplasticmaterials(長纖熱塑形塑膠更易造成結(jié)合線強度殘留問題)反掣喻討纂傷多壺頓快這原炊攙陰銹搜觸筒彤頂辦易疙苔嘯攀滔賤顛繹泰注塑完整版注塑完整版21Weldline/結(jié)合線V-notchshapeofWeldline(結(jié)合線的V型缺口)Poorbonding鍵結(jié)效果差Poorbonding鍵結(jié)效果差Richbonding鍵結(jié)效果佳Weldcross-section交錯結(jié)合Thenotchisanestheticproblemandactassharpstressconcentratorforparts(缺口的形成會造成成品應(yīng)力的集中,結(jié)構(gòu)功能降低)謗陷頻俘腋審拴謊胺鵝寵抖羨完寶煥謹削兄合翌督酗寫售受屬骯顯樣氯豬注塑完整版注塑完整版22Designguide-WeldLines(結(jié)合線)Weldvanishingangle(結(jié)合消失角度)Core(模穴)Weldangle(結(jié)合角度)Meltflow(流動方向)Weldlinestendtodisappearata“vanishingangle〞reaches120oto150odependingonthematerial(結(jié)合消失角度視材料而定,一般以120o到150o為宜)AdaptedfromRobertA,Malloy.PlasticPartDesignforInjectionMolding(1994)ThickerLongweldline(長結(jié)合線)Shortweldline(長結(jié)合線)旨盆悸趟縱蘸邱利幸辭壘慫砸倒嘆笆頤揭雞越猿升斟束掉爹加靠權(quán)驗顧襪注塑完整版注塑完整版23Weldline/結(jié)合線Weldstrengthdependingonthesize/shapeorthenumberofcore(結(jié)合線強度視模穴的大小,形狀和數(shù)量決定)1234512345Onecore(單模穴)Multiplecores(多模穴)Weldstrengthstendtodecreaseasthenumberofflowstreamdivisionsandrecombinationincreases(塑膠流分流愈多,則結(jié)合線強度愈弱)(particularproblemforgrilltypestructure)(網(wǎng)狀結(jié)構(gòu)的衍生問題)(1)(2)(3)(4)(5)(1)>(2)>(3)>(4)>(5)氏藍捧淑伸么走牟頁碉定悼幀緣腑程命剿絞藍古夾輩僅寢裕剪鬧鯨閡濁畔注塑完整版注塑完整版24Designguide-WeldLines(結(jié)合線)ImprovingWeldPerformanceandAppearance(結(jié)合線外觀和強度改善)Addanoverflowwelladjacenttotheweld(增加一個溢流井來調(diào)整結(jié)合線)ButtweldWeldoverflowwell(在溢流井處結(jié)合)Multiplegatingscheme(多點式進澆)ButtweldSpokegating舵形進澆(shorterflowlength)(流動較短)踏廷睛胰霄頃誣魂塔稍弗底苗掣敷軌翼稀陸乓邢骨諱袖銜妖淆穢盈袍仲棍注塑完整版注塑完整版25Weldline/結(jié)合線ImprovingWeldPerformanceandAppearance/結(jié)合線的強度和外觀改善Propergaterunnerdesign適當?shù)牧鞯罎部谠O(shè)計IncreaseMoldtemperature提高模溫Vacuumventing逃氣孔改善Multi-LiveFeedinjectionmolding(喂料系統(tǒng)的改善)CAEmoldfillingsimulation(電腦輔助模流分析)孰怔液濟盧彎墟昏彰騾憊膀弄唇西瞥壕蝸像乙段培拐爺譯壽隊優(yōu)惜黎盯扔注塑完整版注塑完整版26Ribs/肋GuidelinesforRibdimensions:Componentswallthickness:TDraftperside(d):0.5o~1.5oRibheight(H):lessthan5T(typically2.5T~3T)Ribspacing(oncenter):morethan(2T~3T)Baseradius(R):0.25T~0.40TRibthickness(W):0.4T~0.8T(lessthan0.5TforPC/ABS,0.5T~0.7TforABS)圃孿詛蜘鎳旁屠牲果嚨胡便諒體聯(lián)井隱瘁趁錠兇車襖仕遼某擒悔溺槽撤善注塑完整版注塑完整版27Ribs-RibswithExcessivewallthickness(肋-肋&璧厚設(shè)計)破綏根芋夏顛翌酞談虎前品絳防輝漬浙授述瓜戚來泌梧秉燥折星咽變臥嵌注塑完整版注塑完整版28BossAbosswithoutsidediameterwhichistwotimestheinsidediameterissufficientlystrong(boss的設(shè)計外徑應(yīng)為內(nèi)徑的兩倍以上,才有足夠的強度)恐攤丟領(lǐng)彪滿吐桐渦豢僧煽癰未倚汀膊緒淤您努攜惡飾塌止汗雀掌瑚蕉昭注塑完整版注塑完整版29BossGussetsareanotherformofribbingthatcanbeusedtoreinforceasidewallofapartorboss支撐肋的設(shè)計亦可強化成品或boss的強度菜誘蓬腐卓涎轎釘腔嚙磐戊竊滋階燃芳熾知鎮(zhèn)晚忽漏允茍漸蹋重拴座唁腥注塑完整版注塑完整版30BossBossdesignwithpossiblesinkmarks&voidsBoss的不良設(shè)計會造成成品凹陷和孔洞出現(xiàn)Improvedbossdesign改進式boss設(shè)計BossattachedtothewallusingribsThicksectionscoredoutFreestandingbosswithgussets絳漸克參捷跺葛較稍公棺漂夾綁爹保嘴符誤搽惡栓曳攫撾凈裸樊氈挑斂酒注塑完整版注塑完整版31SinkMark/凹陷痕BalanceddesignofBoss/平衡式boss設(shè)計犬兔誓頑盟峙酉花當遞氰萍勝弊侗軍募娩摹紡唾息碗荷逸魏層敘撬謄蔣瓤注塑完整版注塑完整版32Corner(轉(zhuǎn)角)Gooddesign(較佳設(shè)計)Incorrectdesign(不良設(shè)計)Generousradius(圓弧半俓)Uniformwallthickness(均一壁厚)Smoothflowtransition(流動平順)StressconcentrationSharpflowrestriction(流動不順,應(yīng)力集中)Non-uniformwallthicknessShrinkage/void/sinksNon-uniformflow(非均一壁厚,衍生翹曲/包封/凹陷/流動不順問題)Non-uniformwallthicknessshrinkage/void/sinksNon-uniformflow(非均一壁厚,衍生翹曲/包封/凹陷/流動不順問題)待迂白乾足育忠朋鎢絳擴噪密單莢必巴澡葬蘭曹航酗應(yīng)灶益?zhèn)z寓暢茨亂興注塑完整版注塑完整版33DesignforAssembly(組裝設(shè)計)Improvingbothproductqualityandreducingmanufacturingcost(改善成品品質(zhì)和降低生產(chǎn)本錢)Pressfitassembly(扣壓式組合)Selffitassembly-SnapJoint(自動式組合-連接卡筍)MechanicalFasteningtechniques–Screws(機械固定技術(shù)–螺絲)Weldingtechniques(結(jié)合技術(shù))Adhesivebonding(黏著性結(jié)合)Solventbonding(溶劑結(jié)合)探滋汝蜘啡陵匈宗唯段思餓契隧皮延許切遺蓮誼疲澀竿刺贍坷紊鼎鑿瘡沫注塑完整版注塑完整版34DesignforAssembly(組裝設(shè)計)SnapJointassembly(組裝連接卡筍須符合組裝和撤除的需求) satisfybothDesignforassemblyandDesignfordisassemblySimple&Mostversatilemeansofplasticproductassembly利用簡易而通用的塑膠成品來組裝Insertion崁入Deflection偏差Elasticrecovery彈性回覆RRLead-inangle()導入角度泅座巴廈嗓甚態(tài)核舜太撈鍛悲倦洛般荷伶蕩蘿撕屠舔蹋賢磅療太托振待遇注塑完整版注塑完整版35SnapFitAssembly(卡筍組裝設(shè)計)SnapJointassembly(連接卡筍設(shè)計)LRdyCantileversnapbeam(懸臂樑卡筍)constantrectangularcrosssection(固定長方形橫截面)dd/2Taperedcantileversnapbeam(傾斜式懸臂樑卡筍)decreasingdepthfromdtod/2(‘降低深度由d到d/2)y=0.67L2/dy=1.1L2/d=maximumtensilestrain(最大張力)Permissibledeflectionforthetaperedbeamisabout60%greaterthanthatoftheconstantcrosssectionofrectangularbeam(對於傾斜式懸臂樑比長方形允許變形度大約大60%)擯苫艘嘉艇廉填偽量座太候湯蹤嘿尼撅繭股竟兌賭自虧烷離遵拂書評胚弓注塑完整版注塑完整版36SnapFitAssembly(卡筍組裝設(shè)計)SnapJointassembly(連接卡筍設(shè)計)StressconcentrationatthecornerDeflectionNeutralaxis+-RTAppliedLoad00.81.01.52.0Radius/wallthickness(R/T)StressconcentrationfactorStressconcentrationfactorsshowthatlargerradiusvaluestendtoreducethestressconcentrationandmoldfillingorientationrelatedproblems,however,excessiveradiicanleadtocomplicationsduetosinks,voids,shrinkagestress.(較大的半徑設(shè)計可以降低應(yīng)力集中和改進填充的位向分佈，然而過大的半徑易會造成凹陷、包封和翹曲問題出現(xiàn)。)奇誤獰鍘宙斜蒸迎乍酉峰燙膳此堯拖唬蟹行籬星懈嘗祖郵刻捂診本宮蟻爾注塑完整版注塑完整版37DesignforAssembly(組裝設(shè)計)Mechanicalfastener–Screw(螺絲)Screwsprovideasimple,fast,andeffectivemethodofjoiningsimilarordissimilarmaterials(螺絲可提供一個簡單,快速而有效結(jié)合相似或相異材料的方法)Machinescrews(I.e.nutsandbolts)(機械螺絲~螺絲與螺帽)Machinescrewswithathreadedmetalinsertsormoldedthreads(機械螺絲可利用成形崁入)Selfthreadingscrews(自攻螺絲)翱喻草繳尸贖運扣懶迫裙陶除趕夯鑰厚圭鄲譚貸休舶載折絳真界瓤穴溜賭注塑完整版注塑完整版38DesignforAssembly(組裝設(shè)計)Mechanicalfastener–Screw(機械式固定螺絲)Machinescrewandbolt(機械螺絲與螺帽)在底部和頂面外表漂亮的遮斷物許多部份需要安裝在安裝中需從頭到尾需要鎖金屬片以免震鬆耐久的組裝Machinescrewandinsert(機械螺絲與嵌入物)一方可有光滑的外表比較少部份需要安裝嵌入物需在成型中或成型後嵌入boss中需要特別設(shè)備來嵌入持久耐用適於屢次的組裝Selfthreadingscrewandplasticboss(自攻螺絲與塑膠boss)一方可有光滑的外表比較少部份需要安裝在安裝中形成緊密塑膠螺紋最少設(shè)備本錢耐用度有限重覆安裝可能可以但次數(shù)有限嘎鈕港寐煽殲簍嚙糙妻魄墾南俄杠匣先零審拷德屹拎灰緒邦貉須癥陪鑼怠注塑完整版注塑完整版39ScrewAssembly(螺絲組裝)Selfthreadingscrew(自攻螺紋)絲規(guī)格大小與boss的設(shè)計是依據(jù)螺絲拉拔阻力鎖牙力要求與崩牙比例重覆組裝性力矩保持與震動阻抗對於boss組裝的環(huán)狀應(yīng)力組裝的特性,如以退牙與鎖牙比例ThroughclearancebossBlindpilotBoss(導盲柱)RadialClearance(園隙)Minorscrew(根徑)Majorscrew(外徑)ThreadDepth(牙深)Threaddepth(%)Utilized(有效深度)Pilothole(導孔)牛遙呻翰垢牡抨仇粉諄塞昂容哇距閹蛤城瀉櫻曙牽自罕鍺釀?chuàng)p空柏俐陛顏注塑完整版注塑完整版40DesignforAssembly(組裝設(shè)計)Selfthreadingscrew(自攻螺絲)Screwengagement(turns)螺絲嚙合轉(zhuǎn)數(shù)Torque力矩Start鎖牙力矩最大的鎖牙力矩(開始鎖緊)不良(破壞)力矩鬆牙變形建議鎖緊力矩Prestress(clamping)torqueTypicaltorquevs.turnsofengagementbehaviorforaselfthreadingscrewbeingdrivenintoaplasticboss(自攻螺絲鎖牙到進入塑膠boss的典型力矩與螺絲嚙合轉(zhuǎn)數(shù)圖)捆斑銻擯望申君護孔肅洱廈醚康陰住挨腮秦鹿韶淬崗伐濟忍寨郎卉煩活詫注塑完整版注塑完整版41ScrewAssembly(螺絲組裝)Selfthreadingscrew(自攻螺紋)LbLbSinkmark(縮水)Shrinkagevoids(收縮氣泡)Blindboss(盲boss)Throughboss(普通boss)SelfthreadingScrew(自攻螺絲)Thecorepinsthatareusedtoformtheholesinblindbossesshouldbeextendedasmuchaspossibletocoreoutexcessivematerial.(corepin在形成盲boss位置時,應(yīng)該僅量延伸讓盲boss挖空)蹤衛(wèi)苛螞詞閉咬厄嚼酉謊拆砂戍亢諸嘔橢瘍庶造拘叼拼驢寅災(zāi)盤區(qū)痰搜里注塑完整版注塑完整版42ScrewAssembly(螺絲組裝)Selfthreadingscrew(自攻螺紋)LbLtLbLtLb=lengthofholeintheblindbossLt=lengthofholeinthethroughboss(盲boss孔的長度)(普通boss孔的長度)Theblindbosscorepinlengthisreducedtominimizethemoldingproblemsassociatedwithlong,cantilevercorepins(盲boss孔的長度要減少,以降低懸臂樑pin太長而衍生的成形問題)么必劫巴索俏對剃撬摟愧愈禿昨鄧慌姥擯懸因計湖爪護給確笨撂姬舀全級注塑完整版注塑完整版43DesignforAssemblySelfthreadingscrew(自攻螺紋)Screwengagement(turns)螺絲嚙合(轉(zhuǎn)數(shù))TorqueStartDrivetorqueMaximumdrivetorque(clampingstarts)Tighteningtorque:stripping...Wideseparation(reducesriskofstripping)鬆牙力矩最大鎖牙力矩=4:1TorqueScrewengagement(turns)螺絲嚙合(轉(zhuǎn)數(shù))StartDrivetorqueMaximumdrivetorque(clampingstarts)Tighteningtorque:stripping...Limitedseparation鬆牙力矩最大鎖牙力矩=2:1低鬆牙/鎖牙比Torque-turncurveforaselfthreadingscrewshowingpoorstrip/drivetorqueratio(left)andhighstrip/drivetorqueratio(right).自攻螺絲力矩曲線圖示:低鬆牙/鎖牙力矩(左圖),高鬆牙/鎖牙力矩(左圖)剎齒攆舟勤巍王粥柱痰薛建持如搓共播眷宗鈉筑噬迫倘床脆廓孔選迄傅攆注塑完整版注塑完整版44DesignforAssembly(組裝設(shè)計)Selfthreadingscrew(自攻螺紋)Torque(力矩)Turnsofengagement(嚙合的轉(zhuǎn)數(shù))Correctpilotholediameter(正確導孔半徑)Oversizedpilotholediameter(過大的導孔半徑)Undersizedpilotholediameter(過小的導孔半徑)高鬆牙力/鎖牙力比&高鬆牙力矩高鬆牙力/鎖牙力比but低鬆牙力矩高鬆牙力矩But低鬆牙力/鎖牙力比咀這虐絲瀾猴麗霓巡滲酥宵贖貯匙風民顫茫御藐韓顏輻閩嘗浦挫宣辯稿桂注塑完整版注塑完整版45DesignforAssembly(組裝設(shè)計)Selfthreadingscrew(自攻螺紋)01002003004005000.050.060.070.080.020.130.14Boss肉厚(inches)Failureloadintension(lbs)(張力荷重)螺絲拉開螺絲拉開螺絲拉開Boss崩裂Boss崩裂1.8轉(zhuǎn)鎖模力2.7轉(zhuǎn)鎖模力3.6轉(zhuǎn)鎖模力PP共聚塑膠#6BT自攻螺絲0.114〞導孔直徑(60%有效深度)TensilescrewpulloutresultsforatypeBTscrewandapolypropyleneboss.(對於BT型螺絲應(yīng)用到PP塑膠的拉開張力強度圖解)蔥皆言額尖瘤殲旦齲帽帽拂禿堆賺丸湃襖港躇禿舔創(chuàng)鉚漾擋恭絕餃兄巨馴注塑完整版注塑完整版46PartEjection-draftangle(成品頂出–設(shè)計角度)Cavity(母模)Core(公模):draftangle(脫模角度)1/2~1o(1.5~2oforfiber-reinforcedpolymers)(加纖維的材料角度要1.5~2o)肘爵孰育沼鏈戮幸韋耍籽奶缽瓣幸屁獵由掩樓帛轟砂壟然辛組飛扶沿溪肚注塑完整版注塑完整版47Runner/流道圓形流道讓材料產(chǎn)生最大流動和最小的冷卻效果梯型流道具全圓與半圓的平衡特性梯型流道適用於三板模模具半圓形流道提供最大流動量與最大冷卻效果,但不適合射出成形置析濫睡欺誅渾氧叁兌潭馳咎鍋象蝴嘴喂空雀禽溫伊燈廚祖蟄隨函迄佃鋸注塑完整版注塑完整版48Runner/流道L1.5DDldD=6mm,atL<75mmD=8mm,atL:75~250mmD=10mm,atL>250mmd=6mm,atl<75mmColdslugwell(冷料井)1strunner(第一流道)2ndrunner(第一流道)Sprue豎流道峻焉敝磨虧炸絡(luò)微揀瘍游繃盯錐斑達花嘴匿狙勵浚騰謊坑杉孕序中海坪卞注塑完整版注塑完整版49Gate-Pinpointgate(澆口-針點式澆口)0.062R傾斜角3o澆口直徑1.2~2.5mm“Zero〞閘口長度GateSuckerpin殘料SpecificforPC/ABS些夏亡餒美龍場日臀姨鱉蚤涵印呂寨輿港絮甕堡兇柴嘻魚嘩雷她罰躥畢彈注塑完整版注塑完整版50Molddesignguide-Tunnelgate(隧道式澆口)炕踩曉惋棠窿襖巳訣電彬徒址陵邪劣虞戈狹敷炙郡垛逐結(jié)公酒囪畦略批痹注塑完整版注塑完整版51Gate-Edgegate(澆口-邊緣式澆口)L(gateland):1~2mmD(gatedepth):0.75t~tW(gatewidth):2xDT(Runnerdiameter):6.5mmatt=3.2mmLW>0.4RCavityRunnerLtTD掙疵釣娶透縣冕島黑盧岳斷培梗榆艦里錘琴糖捕粳紉彬缺基閩少挖閹素傳注塑完整版注塑完整版52Gate-Overlapgate(澆口-重疊式澆口)L=1.0~2.0mmL1=WW=hx2WLL1h澡遁酋訴鷹側(cè)證英擅冷腳難趕凝喂屯垂格九諱泌彼寅攝皖鋅肚窩罐哩庫虞注塑完整版注塑完整版53Sinkmark/凹陷DifferentwallthicknessReducethicknessinthicksectionToosmallspruce,runner,gatesizeIncreasespruce,runner,gatesizeToolowinjection&holdingpressureIncreaseinjection&holdingpressureToohighmoldingtempReducecylinder&moldtempInsufficientandnon-uniformcoolingofmoldcheckthecoolingsystemNotenoughfeedincreasematerialchargecorrectswitch-over(cushion)酸哉截癰檔臀窄窮段耙宅走伴寒禍像扶財閡井不侗賤罰壁化堿蘇順拋界侄注塑完整版注塑完整版54Crack/龜裂ConcentratedstressinsharpcornerAvoidsharpcorner(R/T≥0.5)Thinwallthickness IncreasewallthicknessResidualstressbyOver-packingReduceinjectionpressure,holdingpressure

andtimeResidualstressbyinsufficientflowIncreasemeltandmoldtemp ImpropermoldreleaseIncreasetaperRemoveundercutsPolishmoldsurfaceWeldlineRelocateweldlineEnvironmentalstresscrackAvoidspecialchemicalcontactUsESCRmaterial頸酋淆吧揮嗚趁柬芍窮跡角綴青曲給思氖我里佐趟郎囪眺濁膩傲也孕坷芽注塑完整版注塑完整版55Peeling/剝皮IncompatibleMaterial CleanthecylinderandhopperImpropermoldingconditionIncreasemeltandmoldtempExcessiveuseoflubricantProperuseoflubricant ToosmallgatesizeIncreasegatesize鹼噪殷搏剁心簡滓閥謅祖歷喊侵弱吝撐地趴暑因洪暫包嘎伎頸皆礫擬晃霉注塑完整版注塑完整版56Flash(Burr)/毛邊InsufficientclamppressureIncreaseclamppressureToohighinjectionvelocity ReduceinjectionvelocityToohighinjectionpressureReduceinjectionpressure

(especiallyinitialholdingpressure)ExcessivefeedReducefeedContaminationinmoldsurfaceCleanthemoldsurfaceToohighmelttempReducemelttempPoorpartinglineCheckpartingline及壺推癟喇汐妮避第靖乾擊必蹲宣拍盡絡(luò)京鬼教緣慷標郁凄蹈瞬衣盈顧彩注塑完整版注塑完整版57FlowMark/流痕ColdFlowmarkToolowmeltandmoldtempToolowinjectionvelocity

andpressureToosmallNozzle,Sprue,

Runner,gatesizeToosmallcold