Molding Process Introduce 注塑工艺介绍.ppt

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1、Molding Process Introduce,Daniel zuo,Process Selection,Processing of Engineering Thermoplastics:,Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisons,Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations Compariso

2、ns,Processing of Engineering Thermoplastics:,Process Selection-Injection,Injection Molding Introduction,Injection molding makes possible mass production of intricate,high performance,tight tolerance parts with very little secondary labor and minimal waste.,Process Selection-Injection,Hopper,Mold,Cla

3、mp,Extruder Barrel withHeating Bands,Injection Molding Machine,Process Selection-Injection,Injection UnitThe Reciprocating Screw,Pellets,Feed Section,Melt,Process Selection-Injection,Injection UnitThe Reciprocating Screw,Screw Pushes Forward:Inject,Screw Slides Back:Feed,Melt,(Filling)Throat,Rotatio

4、nInjection ForceBack Pressure,Process Selection-Injection,Injection UnitThe Reciprocating Screw,Screw Slides Back:Feed,Melt,Process Selection-Injection,Injection UnitThe Reciprocating Screw,Ready for Injection,Process Selection-Injection,Injection UnitThe Reciprocating Screw,Screw Pushes Forward:Inj

5、ect,Process Selection-Injection,Feed Section:Picks up pellets and carries them forward.Transition Section:central portion of the screw with reduced channel depth which compresses plastic,eliminating air between pellets and heating and melting them.Metering Section:Final plasticizing of melt.,Screw D

6、escription,Process Selection-Injection,Clamping System,Mold,MovablePlaten,StationaryPlaten,Provides motion and force to open and close moldClamping Force:maximum holding force in tons that a machine can maintain,Nozzle,Process Selection-Injection,Standard Injection Molding,Fast Cycle TimesComplex Pa

7、rtsHigh VolumeAesthetics,Advantages,Disadvantages,High Pressure ProcessLimited Large Part CapabilityHigh Tooling Cost,Process Selection-Injection,Co-Injection Molding,Two-Component,Co-Injection Molding,Co-Injection Molding,Three Component,Co-Injection Molding,Co-Injection Molding,Four Component,Co-I

8、njection Molding,LEXAN FOAMABLE RESIN Business Machine Chassis,Structural Foam Part,High Strength and Rigidity in Larger Parts,Process Selection-Injection,Mucell微孔发泡设备,01 Needle valve nozzle02 Gas injector03 MuCell-plasticizing screw(L/D ratio:22:124:1)04 Homogenizing section for gas/melt mixture05

9、Plastics granules without blowing agent,01,05,03,02,04,Mucell微孔发泡工艺的塑化单元,Mucell微孔发泡的产品表现形式,Structural Foam Injection Molding,Large Part CapabilityLow Pressure ProcessHigh Stiffness to Weight Ratio,Advantages,Disadvantages,Longer Cycle Time AestheticsBlending Required,Inert Gas,Blowing Agent with Res

10、in,Relative to Standard Injection Molding,Process Selection-Injection,Structural Foam,Increases the attainable wall thicknessGas expands inside plasticized material to create foam core,SKIN,SKIN,CORE,Process Selection-Injection,Gas Assist Injection Molding,Gas Introduced After Short Shot to Pack out

11、 Part,Improved Aesthetics Low Pressure ProcessLower Part WeightReduced Cycle Time,Advantages,Disadvantages,Defect on Every Part More Complex ProcessHigh Tooling CostsLicensing Costs,Process Selection-Injection,Gas Assist Injection Molded Shipping Container,Gas Assist Molded Rib,Injection Molded Rib,

12、Gas Created Cavity,Gas Injection Defect,Sink,Gas Assist Injection Molding,Process Selection-Injection,Vicat Softening point,Mold Temperature,Process,close,inject,plasticization,cool,open,temperature rise,close,inject,plasticization,cool,Valve unit,hot water,hot water,hot water,wait,wait,cold water,c

13、old water,Heat&Cool System,Process Selection-Injection,Heat&Cool Equipments,Valve Unit,1,2,3,Boiler,Cooling Water,：Channel,Part,Cooling Channel,Need special equipment,Process Selection-Injection,Advantage of Heat&Cool,Heat&Cool,Good Surface Finishing with Filled Material,No Weld line,Increase Weld s

14、trength,Eliminate Jetting&Flow mark,Paint less,No stress,Increase Flowability,Note PCHandphone,Door mirrorDoor handle,BezelHousing,Housing,LensLight guide plate,Thin wall,Process Selection-Injection,G,Compression,Preset Gap,Injection,Time,Position,ScrewClamp,Injection Compression Molding,Time,ScrewC

15、ore,Compression,Preset Gap,G,o,Go,Injection,Position,Selective ICM or Coining,Feature,Process Benefits,Filling at a larger effective thickness,Compression assisted filling and pack,Short shot process,Lower shear,Longer fill length,Lower fill pressure,Lower clamp force,Thinner wall capability,Bi-axia

16、l flow,Reduction of residual stresses,Material savings,Weight reduction,Cycle time reduction,Better impact properties,Advantages,Warpage,Dimensional stability,Optical Quality,Weld linestrength,Lower CavityPressure,In-mold decorating with“soft touch”,Why Use ICM?,Injection,ICM,Nozzle Pressure,Nozzle

17、Pressure,Cavity Pressure,Cavity Pressure,Mold Position,Mold Position,25k,15.5k,PSI,PSI,2.0,0.004,Inch,Time(sec),Time(sec),0.040,0.3,21k,Inch,3.7k,Experimental Cavity Pressure Profile,Lexan 141-1.5mm thickness,ICM,IM,Improved Flow in Wheel Covers,Decrease Molded-in Stress,Injection MoldingExtrusionCo

18、mpression MoldingThermoformingBlow Molding Secondary OperationsComparisons,Processing of Engineering Thermoplastics:,Process Selection-Extrusion,Extrusion,Extrusion is the act of squeezing,pressing,or pushing material through a die in order to make a shape.,Process Selection-Extrusion,The Extruder,P

19、ellets,Part,Heating Coils,Screw,Die,Continuous Process,Process Selection-Extrusion,The Profile Extrusion Die,Continuous FlowUniform Cross-Section,Process Selection-Extrusion,Extruded Through DieSupported and Cooled by a Stack of Polishing RollsCut and Trimmed Once Below Glass Transition TemperatureS

20、heet May be Used in Thermoforming and Compression Molding,Sheet Extrusion,Die,Extrusion CutawayView,RollStack,Process Selection-Extrusion,Other Roll Stack Options,Process Selection-Extrusion,Thermoplastic and Glass Composite Sheet,Glass Fiber Mat,Glass Impregnated Sheet,Sheet Extruder,A Combination

21、of Glass Mat and Thermoplastic Resin Having BothHigh Stiffness and Good Impact Strength.,Process Selection-Extrusion,The Extruder,Pellets,Part,Heating Coils,Screw,Die,Low Tooling Die CostsLarge Part CapabilityContinuous Process,Advantages,Disadvantages,High Set-up CostConstant Cross SectionLimited C

22、omplexity,Process Selection-Extrusion,Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisons,Processing of Engineering Thermoplastics:,Process Selection-Compression,Softened sheet isplaced in a mold thenpressed into shape bycompressive force.,Process S

23、election-Compression,Compression Molding,2,3,1,Soft Sheet,Trimming,Compressive Force,Part,Process Selection-Compression,Compression Molding,Large Part CapabilityVariable Wall ThicknessUses Conventional Stamping EquipmentLow Warpage and Distortion,Advantages,Disadvantages,High Tooling Cost(Cheaper th

24、an Injection Molding)Secondary TrimmingAesthetics,Process Selection-Compression,Compression Molding,Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection-Thermoforming,Vacuum Forming,Atmosphe

25、ric Pressure(14.7 psi),Softened Sheet,Mold,Part,Vacuum,Process Selection-Thermoforming,Pressure Forming,Softened Sheet,Compressed Air,Pressure FormedPart,atm pressure,Process Selection-Thermoforming,Low Tooling CostLarge Part CapabilityLow Pressure Process,Advantages,Disadvantages,Low Part Complexit

26、yLonger Cycle Times,Vacuum,Process Selection-Thermoforming,Thermoforming,Compressed Air,Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisons,Processing of Engineering Thermoplastics:,Double Walled,Hollow parts,Process Selection Blow,Pinch Bar,Parison

27、 Drop,Pre Blow,Full Pressure,Release,Mold,Part,1,2,3,4,5,Process Selection Blow,Blow Molding,Mandrel,Parison,Controlling Wall Thickness,Raised Mandrel,Lowered Mandrel,Thinner Wall,Thicker Wall,Process Selection Blow,Double Wall Geometry(Hollow Parts)Good Stiffness to Weight RatioLow Tooling CostLarg

28、e Part Capability,Advantages,Disadvantages,Longer Cycle TimesSecondary TrimmingPurging Start-up Cost,Process Selection Blow,Blow Molding,Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection

29、Sec.Operation,Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations Comparisons,Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations Comparisons,Processing of Engineering Thermoplastics:,Process Selection,Size Part Complexity

30、 Wall Thickness Production Quantity Costs,Process Selection Criteria,Process Selection,Part Complexity vs.Part Size,Process Selection,.300.250.200.150.100.050 0,BM IM FM CM EX TF,Wall Thickness,Process Selection,Tooling CostRanking,ExtrusionThermoformingBlow MoldingFoam MoldingCompression MoldingInjection Molding,Process Selection,