注塑成型流程及常用模具结构.ppt

《注塑成型流程及常用模具结构.ppt》由会员分享，可在线阅读，更多相关《注塑成型流程及常用模具结构.ppt（87页珍藏版）》请在三一办公上搜索。

1、Injection Molding(注塑成型),Injection Molding Introduction(注塑機的介紹),Injection molding makes possible mass production of intricate,high performance,tight tolerance parts with very little secondary labor and minimal waste.(注塑機能在占次要地位的人的工作下大批量的生產復雜的,高性能的,公差小的產品,而且壞品少),Injection Molding Parts(注塑成型的產品),Detail

2、ed Parts Including Ribs,Holes,and Bosses(詳細的部件包括加強筋,孔和突起),Injection Molding Parts(注塑成型的產品),Small Parts with Tight Tolerances(較小公差的小尺寸產品),Injection Molding Parts(注塑成型的產品),Larger Parts:Car Fender(長的產品:汽車的擋泥板),Injection Molding(注塑成型),GOODPART(好的產品),Material(原料),Tooling(工模),Processing(工藝),Design(設計),Inj

3、ection Molding Advantages(注塑機的優勢),High Production Rates(高的生產效率)Large Volume Production Possible(大地的生產能力)Low Labor Cost(低的人工)Easily Automated(容易實行自動化操作)Minimum Secondary Operations(少的二次加工)Permits Very Small Parts(允許生產很小的產品),Minimal Scrap Loss(很小的壞品損失)Tight Tolerances Can Be Maintained(能維持很小地公差)Molded

4、-in Inserts Available(工模內可以利用鑲件)Glass,Carbon,etc.FillersComplex Part Capability(有生產復雜產品的能力)Good Decoration Possible(優良的裝鈽能力),Injection Molding Disadvantages(注塑成型的缺點),Tooling Costs are High(高的模具費用)High Machinery and Auxiliary Costs(高的機器和輔助設備的費用)High Pressure Process(高壓工藝)Limited Large Part Capability

5、(能生產的產品,大是有限的),Injection Molding(注塑成型),The Process(工藝),Injection Molding Process(注塑成型工藝),Injection Molding Steps:(注塑成型的步驟:),Drying the Pellets(膠珠的烘干)Loading Into Molding Machine(將膠珠 裝入注塑機內)Heating and Shearing Material Into a Melt(加熱和剪切原料至其塑化)Injecting the Melt Into the Mold Cavity(將塑化的膠料射入模腔內)Part

6、Cooling,Solidification(產品冷卻,凝固)Ejecting the Finished Part From the Mold(將完成的產品從工模內頂出),Injection Molding Process(注塑成型的工藝),Loading of pellets through the Hopper(在料桶裝入膠珠),Injection Molding Process(注塑成型的工藝),Engineering Thermoplastic Pellets Absorb MoistureDuring Manufacturing,Transportation,and Storage.

7、工程熱塑性膠珠在制造,運輸,儲存的過程中會吸收濕氣,Pellets Not Dried May:(不需要烘干的膠珠:)Produce Substandard Parts in Terms of Surface Appearance and Property Performance(生產的產品外觀要求在條款之下和有特殊性能的)Cause Series Inconsistency During Processing烘干工藝會導致一系列變化的,Drying the Pellets(膠珠的烘干),Injection Molding Process(注塑成型的工藝),Drying Removes Moi

8、sture(烘干除濕氣),MoistureMigratesout of Pellet When Exposed to Dry Air.(當暴露在干燥地空氣中時濕氣就會從膠珠中移除),Injection Molding Process(注塑成型的工藝),Model of Amorphous Polymers(無定形聚合物的成型),Raise Temperature of Polymer,T,G,Locked Entanglements(相互糾纏),Stiff Flow(流動困難),Easier Flow(流動容易),Raise Temperature of Polymer(提高聚合物的溫度),I

9、njection Molding Process(注塑成型的工藝),Heating and Melting the Material,Conversion of Mechanical Energy by Shearing the Plastic(注塑機螺杆在旋轉過程中和塑料剪切產生的能量)Conduction of Heat From the Heater Bands Through the Barrel and Into The Resin加熱圈的熱量通過桶傳入到塑料里,Heater Coils on the Screw Barrel(在螺杆桶上的加熱圈),Injection Molding

10、 Process(注塑成型的工藝),Injection Flow(注塑流程),Injection Molding Process(注塑成型的工藝),Injection Flow(注塑流程),Injection Molding Process(注塑成型的工藝),Injection Flow(注塑流程),Injection Molding Process(注塑成型的工藝),Injection Flow(注塑流程),Injection Molding Process(注塑成型的工藝),Injection Flow(注塑流程),Injection Molding Process(注塑成型的工藝),Pa

11、rt Cooling and Solidification(產品的冷卻和凝固),Hot Melt受熱塑化,Cooled Mold(冷的工模),Solid Part堅實的產品,Injection Molding Process(注塑成型的工藝),1,2,3,Part Ejection(產品被頂出),2 plate mold example(盤子模塑實例),Knock-out pins eject the part from the mold.(頂針將產品從工模中頂出),Injection Molding Process(注塑成型的工藝),SimplifiedPressure History-In

12、jection Molding簡化的注塑成型壓力歷史記錄,Filling PackingCooling Ejection,Pressure,Time,Injection Molding Process(注塑成型的工藝),Important Process Variables(重要的工藝變量),Melt Temperature(塑化溫度)Mold Temperature(模具溫度)Temperature Profiles(溫度曲線圖)Resident Time(占用時間)Injection Speed(注塑速度)Injection Pressure(注塑壓力)Pack Pressure(保壓壓力

13、)Clamp Tonnage(鎖模力)Cushion(緩沖量),Injection Molding(注塑成型),The Equipment(設備),Injection Molding Equipment(注塑成型的設備),Injection Unit(注塑部分),Clamp Unit(鎖模部分),Screw Barrel(螺杆桶),Injection Molding Equipment(注塑成型的設備),The Injection Unit(注塑部分),Provides Injection and Packing Pressure提供注塑壓力和保壓壓力Provides Torque to Tu

14、rn the Screw螺杆的旋轉提供扭矩力,Injection Molding Equipment(注塑成型的設備),Screw Drives,Injection Molding Equipment(注塑成型的設備),Hydraulic Injection Cylinders(油機的注塑料筒),Injection Molding Equipment(注塑成型的設備),The Screw Barrel(螺杆桶),Melting and Homogenizing the Resin(塑化和攪均勻塑料)Injection of the Plastic Into the Mold(將塑料射入工模內)

15、,Injection Molding Equipment(注塑成型的設備),The Barrel Unit(料筒部分)(Plunger Machine)活塞式注塑機,Heating Coils(加熱圈),Torpedo(魚雷梭),Plunger（活塞）,Plastic Pellets(膠珠),To Mold,Passing Through Heated Channels Around the Torpedo,The Pellets Melt膠珠在通過魚雷梭周圍的加熱通道時被塑化,Pellet Input Stopped（膠珠停止進入),Injection Molding Equipment(注

16、塑成型的設備),Continuously Rotating Screw(連續地旋轉螺杆),Barrel Unit(料筒部分)Screw PlasticizingMachines(注塑機螺杆的塑化能力),Pellets(膠珠),Plunger(活塞）,Nozzle(射嘴),Injection Molding Equipment(注塑成型的設備),Barrel Unit(料筒部分)The Reciprocating Screw(往復式螺杆),(Filling)Throat(加料口),Heating Coils(加熱圈),Nozzle(射嘴),Hopper(料斗）,Screw(螺杆),Barrel(

17、料筒),Force,TorqueFrom Injection Unit(壓力,扭拒力來自注塑部分),Injection Molding Equipment(注塑成型的設備),Barrel Unit(料筒部分)The Reciprocating Screw(往復式螺杆),Screw Rotation Feeds and ShearsMaterial Into a Melt.Melt Collects Into Front of Barrel,Forcing Screw Back(螺杆旋轉進料和剪切原料使之塑化.螺杆的向背后的壓力使得塑化的原料被集中到料筒的前端),Shot(射出量),Rotati

18、on and Back Pressure,(旋轉和背壓),Injection Molding Equipment(注塑成型的設備),Barrel Unit(料筒部分)The Reciprocating Screw(往復式螺杆),Melt Required to Fill Mold Ready for Injection(塑化后的原料必須要通過注射才能填充模具),Shot(射出量),Injection Pressure(注塑壓力),Injection Molding Equipment(注塑成型的設備),Barrel Unit(料筒部分)The Reciprocating Screw(往復式螺杆

19、),Screw Pushes Forward:Inject(螺杆向前推:注射),Cushion(緩沖量),Packing Pressure(保壓壓力),Injection Molding Equipment(注塑成型的設備),Screw Type Machines Are Recommended(推荐使用螺旋式注塑機),Injection Molding Equipment(注塑成型的設備),Metering計量段,Transition轉換段,Feed進料段,Feed Section:Picks up pellets and carries them forward.進料段:獲得膠珠和將它們向

20、前傳送.Transition Section:Reduced channel depth which compresses and shears plastic,eliminating air pockets,melting pellets.轉換段:縮小分流槽的深度,剪切和壓縮塑料,消除空氣,塑化膠珠Metering Section:Final Plasticizing of melt.計量段:最終的塑化量,Injection Molding Equipment(注塑成型的設備),Metering,Feed,Screw and Cylinder Design螺杆和料筒的設計,hf,hm,Tra

21、nsition,L,D,Injection Molding Equipment(注塑成型的設備),Reciprocating Screw Tip Assemblies(往復式螺杆尖端的裝配)Plain Tip(簡單的尖端),Highly Viscous Materials高粘性的塑料Heat Sensitive Material對熱敏感的塑料Rapid Forward Motion Prevents Back Flow快速的前進運動防止倒流,Injection Molding Equipment(注塑成型的設備),Reciprocating Screw Tip Assemblies(往復式螺杆

22、尖端的裝配)Ball Type Non-return Valves(球式止回闊),Open(開),Closed for Injection,Injection Molding Equipment(注塑成型的設備),Reciprocating Screw Tip Assemblies(往復式螺杆尖端的裝配)Check Ring Type Non-return Valve(鎖環式止回閥),Material Flows PastOpen Check Ring打開鎖環塑料流過,Check Ring SlidesBack To PreventBlack Flow DuringInjection鎖環滑到后

23、面防止射膠時倒流,Check Ring Valves are Suggested建議使用鎖環式止回閥,Injection Molding Equipment(注塑成型的設備),Standard Cylinder Nozzles(標準料筒射嘴),Heating Band(加熱圈),CylinderBore(料筒端),To Mold(至模具),Provides Mechanical and Thermal Connection FromHot Cylinder Much Colder Mold(在熱的料筒和冷得多的模具之間提供機械和熱的連接),Injection Molding Equipment

24、(注塑成型的設備),The Clamping Unit(鎖模部分),Open and Closes Mold(開和關模)Holds the Mold Closed During Injection(在注射過程中保持模具始終處于閉合狀態)Cools and Solidifies Part(冷卻和使產品凝固),Injection Molding Equipment(注塑成型的設備),Clamping Mechanisms(鎖模機構)Single Toggle Clamping System(單鉸鏈鎖模系統),Injection Molding Equipment(注塑成型的設備),Clamping

25、 Mechanisms(鎖模機構)Double Toggle Clamping System(雙鉸鏈鎖模系統),Injection Molding Equipment(注塑成型的設備),Clamping Mechanisms(鎖模機構)Hydraulic Clamping System(液壓鎖模系統),Injection Molding Equipment(注塑成型的設備),Clamping Mechanisms(鎖模機構)Hydraulic Clamping System(液壓鎖模系統),Injection Molding Tooling(注塑成型工模),The Mold(工模),Injec

26、tion Molding Tooling(注塑成型工模),Two Plate Design(兩板模設計)Exploded View(分解圖),Support Plate(支撐板),Ejector Plate(頂針板),Leader Pin(導柱),Return Pin(回程柱),PARTING LINE(分模線),Injection Molding Tooling(注塑成型工模),Two Plate Mold(兩板模),Injection Molding Tooling(注塑成型工模),1,2,3,4,Injection Molding Tooling(注塑成型工模),Support Plat

27、e(支撐板),Ejector,Retainer Plate(頂針固定板),Ejector Plate(頂針板),Ejector Housing(頂針板支架),B Plate,X Plate,A Plate,Three Plate Design(三板模的設計),PARTING LINE(分模線),PARTING LINE(分模線),Injection Molding Tooling(注塑成型工模),Three Plate Design(三板模的設計),1,2,3,4,5,Injection Molding Tooling(注塑成型工模),Sprue Bushing(注入口襯套)-唧嘴,Nozzl

28、e(射嘴),Radius(半徑),Orifice(孔),Injection Molding Tooling(注塑成型工模),Sprue Bushings(唧嘴),Helical Heater(螺旋發熱絲),Thermal Shut-Off(熱切斷),Heated Sprues(熱注入口),Cold Sprue(泠注入口),Heater Band(電熱圈),Gas Pipes(氣體小管),Injection Molding Tooling(注塑成型工模),Runner Systems(流道系統),Runners carry the molten resin from the sprue to t

29、he gates.(流道就是將熔化的塑料從注入口運送到澆品的通道),Injection Molding Tooling(注塑成型工模),Gating(澆口),Direct Sprue(直接注入品),Fan(扇形入澆口),Edge(刀口式入澆口),Tab(加耳入澆口),Disk(圓形入澆口),Pin Point(針式點澆口),Injection Molding Tooling(注塑成型工模),Manifold Recommendations(推荐使用有很多支路的流道),Passages Externally Heated(4 Heaters)通道外加熱(4個發熱器)Bore Size.5”or

30、Larger(內徑0.5“或更大)50 Watts/in3 Minimum 最小50瓦/in3,Injection Molding Tooling(注塑成型工模),Hot Runner Systems(熱流道系統),BENEFITS(好處),Faster Cycles(更快的周期)-15-20%Faster,Eliminates Material Waste(消除了塑料的浪費)-No Sprues or Runners-沒有注入口和流道料(沒有水口料),Improves Part Quality(改善了產品的品質)-Less Stress(較低的壓力)-Better Appearance(較好

31、的外觀),Injection Molding Tooling(注塑成型工模),Venting(排氣),Gate,Parting Line Vents(分模線排氣),Allows Trapped Air to Escape(允許收集的空氣排出)Prevents Burn Marks防止有燒焦的痕跡Located:(位置:)On the Parting Line(在分模線上)At Ejector Pins(在頂針上)End of Runners(在流道的末端)Special Venting Pins(專門的排氣針),Injection Molding Tooling(注塑成型工模),Cam Act

32、ions(抽芯裝置)Hydraulic(液壓),Injection Molding Tooling(注塑成型工模),Cam Actions(抽芯裝置)Slide(滑塊),1,2,3,Injection Molding Material(注塑成型原料),Material Considerations原料需要考盧的事項,Injection Molding Material(注塑成型原料),Thermoplastics and Degradation熱塑性材料的老化,Injection Molding Material(注塑成型原料),Thermoplastics and Shrinkage熱塑性材

33、料的收縮,Post-Mold Dimensions of Plastic Parts Differ From MoldCavity Dimensions(塑料產品的尺寸與模腔的尺寸不同),Vpart,Vmold,lpart,lmold,Sv=,vmold-vpart,vmold,or,Injection Molding Material(注塑成型原料),Shrinkage and Injection Molding收縮和注塑成型的關系,Simplified Pressure History-Injection Molding簡化的注塑成型壓力歷史記錄,Filling注射 Packing保壓 C

34、ooling冷卻 Ejection頂出,Pressure,Material原料,A,B,C,D,E,Injection Molding Material(注塑成型原料),Materials PVT Diagram(原料的PVT圖表),High Packing Pressure Low Shrinkage高的保壓壓力,低的收縮,Pressure,Volume,Temperature壓力,用量,溫度,Injection Molding Material(注塑成型原料),Shrinkage and Materials收縮與材料的關系,Amorphous無定形Typical Shrinkage(收縮率

35、)LEXAN(PC)5-7 mm/mNORYL(PPO)CYCOLAC(ABS)Semi-crystalline(半結晶體)VALOX(PET/PBT)5-25Blends(結晶)XENOY(PBT/PC)5-10NORYL GTX(PPO/Nylon)CYCOLOY(PC/ABS),Injection Molding Material(注塑成型原料),Thermoplastics and Viscosity熱塑性材料的粘性,Viscosity=Materials Resistance to Flow粘性=塑料的粘性阻抗塑料的流動Lower Viscosity=Easier Flow低粘性=易

36、流動Low Viscosity=High Melt Flow Rate(MFR)低粘性=高塑化流動率Warning:MFR and Viscosity are Valid Only at a Single Condition 注意:當僅僅考盧單個因素時塑化流動率和粘性才有效性,Injection Molding Material(注塑成型原料),Thermoplastics and Viscosity 熱塑性材料與粘性,AppViscosityPa-sec,Shear Rate(sec-1)(剪切率),Injection Molding Material(注塑成型原料),Amorphous M

37、aterials無定形材料,All Materials are Amorphous at Injection(所有的無定形材料都可以用于注塑成型),Lower Tensile,Higher Impact Strength(低的可拉長性能,高的抗撞擊力)Lower Shrinkage(低的收縮率),Raise Temperature of Polymer(提高聚合物的溫度),TG,ProcessingTemperatureRange(加工的溫度范圍),Degradation(老化),Injection Molding Material(注塑成型原料),Injection Molding Mate

38、rial(注塑成型原料),Semi-Crystalline Materials(半結晶體材料),All Materials are Semi-Crystalline at Injection(所有的半結晶體材料都可以用于注塑成型),Higher Tensile,Lower Impact Strength(低的可拉長性能,高的抗撞擊力)Higher Shrinkage(低的收縮率),Regulating Crystallinity:Mold Temperature,Cycle Time,Injectionand Holding Temperature,Cooling Method After R

39、emoval From Mold控制結晶度:模具溫度,周期時間,注塑和保壓溫度,從模具內取出后的冷卻方法.,Raise Temperature of Polymer(提高聚合物的溫度),Injection Molding Material(注塑成型原料),Degradation(老化),TM,TG,ProcessingTemperatureRange(加工的溫度范圍),Injection Molding Design Moldability注塑成型的模具能力設計,Design Considerations設計上需要考盧的事項,Injection Molding Design Moldabili

40、ty注塑成型的模具能力設計,Uneven Shrinkage Defects不均勻收縮的缺陷,Voids(空心)Already Cooled SurfaceWill Not Yield to ShrinkingInterior(產品的表面已冷卻但里面還在收縮),Sink Marks(凹陷)Surface Yields to theStill Shrinking Interior Mass(產品的表面向內部大量的收縮),Injection Molding Design Moldability注塑成型的模具能力設計,Warpage Due to Uneven Thickness因為不均勻地厚度引起

41、的變形,Alternatives(可選擇的方法),Injection Molding Design Moldability注塑成型的模具能力設計,Uneven Pressure(不均勻地壓力),Flow,Injection Molding Design Moldability注塑成型的模具能力設計,Warpage Due to Uneven Pressure因不均勻地壓力引起的變形,Gate澆口,High PressureLow Shrinkage產品的中心壓力高,收縮小,Low PressureHigh Shrinkage產品的周邊,壓力低,收縮大,Warped Result(結果變形),I

42、njection Molding Design Moldability注塑成型的模具能力設計,Wall Design(壁的設計),Core Thick Sections(型芯厚度的截面)Gradual Transitions(逐漸過渡),Injection Molding Design Moldability注塑成型的模具能力設計,Reinforcement Thickness(加強筋的厚度),Rib Thickness Should beLess than the Wall Thickness(加強筋的厚度要比小壁厚),Excessive Rib ThicknessMay Cause Sin

43、k Marks and Voids(過大的加強筋可能引起凹陷痕跡和空心),Injection Molding Design Moldability注塑成型的模具能力設計,Corner Design(拐角的設計),Sharp Corners Concentrate Stresses(尖的拐角會引起應力集中),A Rounded Outside Corner/Sharp Inside Corner Creates Uneven Shrinkage:Warpage(外面為內圓角和里面為尖角就會造成收縮不均勻:變形),A Rounded Inside Corner/Sharp Outside Corn

44、er Creates Uneven Shrinkage:Sink Marks and Voids(里面為內圓角和外面為尖角就會造成收縮不均勻:凹陷痕跡和空心),Injection Molding Design Moldability注塑成型的模具能力設計,Holes(洞),Not RecommendedPoor Flow!不推荐使用,流動性不好!,Gate-Melt Entry Point澆口-塑化進入點,Injection Molding Design Moldability注塑成型的模具能力設計,Gate-Melt Entry Point澆口-塑化進入點,RecommendedBetter

45、 Flow推荐采用-有好的流動性,Holes,Injection Molding Design Moldability注塑成型的模具能力設計,No Draft Angle(沒有脫模斜度),Difficult Ejection(頂出困難),Easier Ejection(頂出容易),Ejecting the Part(頂出產品),Generous draft angles will facilitate part ejection.(大的脫模斜度使產品地頂出變得容易),Injection Molding Design Moldability注塑成型的模具能力設計,Draft Angle(脫模斜度

46、),Textured Sidewall(蝕紋地側牆),當側牆有饋紋時深度每增加0.001英寸脫模度要增加1度.,Injection Molding Closing(注塑成型結束),Ten Dos for Molding Engineering Resins注塑工程的樹酯時要做的十點,Know Your Material(熟悉你的原料)Dry Properly(適當地干燥)Use Recommended Processing Conditions(使用推荐的注塑參數表)Use Properly Sized Equipment(使用適當大小的設備)Use Properly Designed Tooling(使用設計適當的模具)Use Adequate Runners(使用適當的流道)Use Proper Venting(使用適當的排氣)Use Nozzles with Proper Heat Controls(使用適當的熱控制射嘴)Use Proper Screw Design(使用設計適當的螺杆)Schedule Annual or Bi-Annual Equipment Maintenance(一年一次的或一年二次的設備維修時間表),