2022年2022年工艺流程及成型条件设定EC .pdf

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1、1成型工藝流程及條件介紹 Introduction to technique and parameter of molding 第一節成型工藝 Section 1 technique of molding.1.成型工藝參數類型 types of molding parameter.(1).注塑參數 parameter of Injection.a.注射量 amount of Injection.b.計量行程 Screw back position c.餘料量 Cushion d.防誕量 Sucking back rate e.螺杆轉速 Screw speed f.塑化量 Plastic rat

2、e g.預塑背壓 Screw back pressure h.注射壓力和保壓壓力 Injection pressure and holding pressure i.注射速度 Injection speed(2)合模參數 Clamping parameter a.合模力 Clamping force b.合模速度 Clamping speed c.合模行程.Clamping stroke d.開模力 Opening force e.開模速度 Opening speed f.開模行程 Opening position 名师资料总结-精品资料欢迎下载-名师精心整理-第 1 页，共 8 页 -2g.

3、頂出壓力 Ejector advance pressure h.頂出速度 Ejector advance speed i.頂出行程 Ejector advance position 2.溫控參數 Temperature parameter a.烘料溫度 Dry resin material temperature b.料溫與噴嘴溫度 Cylinder temperature and nozzle temperature c.模具溫度 Mold temperature d.油溫 Oil temperature 3.成型周期 Molding cycle a.循環周期 Cycle time b.冷卻

4、時間 Cool time c.注射時間 Injection time d.保壓時間 Holding pressure time e.塑化時間 Plastic time f.頂出及停留時間 Knocking out and delay time g.低壓保護時間 Mold protect time 成型工藝參數的設定須根據產品的不同設置.The setting of molding parameter are different by types of product 第二節 成型條件設定 Section 2 Molding parameter Setting 按成型步驟:可分為開鎖模,加熱,射

5、出,頂出四個過程.Molding steps:mold opening/closing,heating,injection and knocking out.開鎖模條件:Mold opening parameter:名师资料总结-精品资料欢迎下载-名师精心整理-第 2 页，共 8 页 -3快速段 中速度 低壓 高壓速度 High-speed mid-speed Low pressure high pressure speed 鎖模條件設定:Mold closing parameter setting 1.鎖模一般分:快速中速低壓高壓 Mold closing:high-speed low-sp

6、eed low pressure high pressure 2.快速鎖模一般按模具情況分,如果是平面二板模具,快速鎖模段可用較快速度,甚至於用到特快,當用到一般快速時,速度設到 55-75%,完全平面模可設定到 80-90%,如果用到特快就只能設定在45-55%,壓力則可設定於50-75%,位置段視產品的深淺(或長短)不同,一般是開模寬度的1/3.Mold closing speed depends on type of mold in high-speed section.For two plate mold,it can set on the mode of quick or extra

7、 quick.The speed was set within 55-75%in the mode of quick.For full-plate mold,the speed can be set within 80-90%.While in the mode of extra quick,the speed only can be set within 45-55%and pressure can be set within 50-75%,The setting of position distance differs depending on the volume of product.

8、Generally,it can be set by the digit about 1/3 of mold opening position.3.中速段,在快速段結束后即轉換成中速,中速的位置一般是到模板(包括三板模,二板模)合在一塊為止,具體長度應視模板板間隔,速度一般設置在30%-50%間,壓力則是 20%-45%間.Mid-speed section:Mold closing speed changes into mid-speed after high-speed section finish.Start position of mid-speed is where two plat

9、es meets(include three-plate mold and two-plate mold).Distance of mid-speed was decided by the distance of two plates.The speed is set within 30-50%and pressure is set within 20-45%.4.低壓設定,低速設定一般是在模板接觸的一瞬間,具體位置就設在機臺顯示屏顯示的一瞬間的數字為準,這個數字一般是以這點為標準,即於此點則起不了高壓,高於此點則大,輕易起高壓.設定的速度一般是15%-25%,視乎不同機种而定,壓力一般設定於

10、1-2%,有些機則可設於5-15%,也是視乎不同機种不同.Low-pressure section:Mold closing sets low-pressure when plates meeting.This position is set by the data of machine s display screen on this time.This point is the gauge of the data.If the data is lower than the point,there is no high-pressure.If the data is higher than

11、the point,there is high-pressure easily.The speed is set within 15-25%and the pressure is set within 1-2%which depends on type 名师资料总结-精品资料欢迎下载-名师精心整理-第 3 页，共 8 页 -4of injection machine.Another kind of machine can be set within 5-15%.5.高壓設定,按一般機臺而言,高壓位置機臺在出廠時都已作了設定,相對來講,是不可以隨便更改的,比如震雄機在 50P.速度相對低壓略高,

12、大約在 30-35%左右,而壓力則視乎模具而定,可在 55-85%中取,比如完全平面之新模,模具排氣良好,甚至於設在 55%即可,如果是滑塊較多,原來生產時毛邊也較多,甚至於可設在90%還略顯不足.High-pressure section:Generally speaking,high-pressure position had been set before the injection molding machines were sent to customer.It cannot be modified unless necessary.For example,high-pressure

13、 position of CHENHSONG machine is 50P.The speed of high-pressure section is about 30-35%and higher than that of low-pressure.The pressure depends on mold,it can set within 55-85%.For fully-platen mold,the exhaustion is good enough that the pressure can be set about 55%.If the mold had a lot of slide

14、s and burr rate was high in production,the pressure can be set more than 90%.加熱工藝條件設定 Heating parameter setting 1.加熱段溫度設定必須按照產品所使用的原料的不同而不同,但卻必須遵循一個這樣的規則,即由射口筒到進科段溫度是逐步遞減的.且遞減溫度是以100C為單位.The proper temperature setting was different depends on type of resin,Usually,the temperature setting should be r

15、educed by a unit of 10 C from nozzle to the section of feeding resin.2.特殊情況下.如料頭抽絲,則射口筒溫度應降低,如果是比較特殊的原料冷凝比較快的.則射口筒溫度則不止比第二節法蘭溫度高100C.比如PPS.尼龍等.Nozzle temperature setting should low down if product lines.If resin cool down very soon such as PPS,PA.Nozzle s temperature should be higher than that of th

16、e second cylinder at least 100C.3.机台馬達啟動溫度視乎機臺不同而不同,一般出於對機台油路中的油封保護需要,油溫最好能控制在400C-600C,以免油封長期高壓而變化,縮短使用壽命,造成成型不穩定.The starting temperature of Pump is different depends on type of injection molding machine.Oil temperature was set within 400C-600C to protect oil seal of machine,If the temperature of

17、oil are too high that will damage the oil seal and reduce its life-span which makes molding unstable.注射及熔膠(加料)工藝條件設定 名师资料总结-精品资料欢迎下载-名师精心整理-第 4 页，共 8 页 -Injection and plastic technique parameter setting 一.注射 Injection 常見塑膠原料的有關溫度值.原料 Resin 名稱 Name 熔點 Melt s 成型溫度 Molding Temperature(c)分解溫度 Decomposin

18、g Temperature(C)模具溫度 干燥溫度 Mold Temperature(c)Resin dry temperature(c)HDPE 低衛壓聚乙烯 108-126 160-222 310 45-60 70-80 HOPE 高衛壓聚乙烯 135 180-240 310 50-80 70-80 PC 聚碳酸脂 polycarbonate 220-240 260-310 320 80-120 90-120 干燥時間:4H 干燥溫度:120 ABS 160 180-230 270 45-80 70-90 干燥時間:2-4H.干燥溫度:80-100 PC/ABS PC與 ABC共混物 20

19、0 220-250 300 50-90 80-100 干燥時間:3-4H 干燥溫度:80-110 PP 聚丙烯 160-170 200-260 300 30-45 PS 聚苯乙烯 140 180-230 300 30-45 65-80 PVC 聚氯乙烯 140 180-215 300 20-40 90-100 AS 160 200-250 280 45-75 70-90 PA6 尼龍 6 215-220 225-245 300 40-80 95-110 PA66 尼能 66 260-265 260-275 300 40-80 95-110 PPS 聚苯硫酸 265-280 300-330 37

20、0 100-120 100-130 PBT 聚對苯二甲酸丁二脂 225-235 240-260 280 70-80 105-140 POM 聚甲醛 170 180-210 240 80-120 PMMA 有機玻璃 160 180-240 270 40-65 70-80 注射是把塑膠原料經加熱後射進模腔的過程,它一般可分為第一級,第二級,第三級,第四級及保壓幾段:Injection is a process which inject melting resin into mold which.includes step l to step 4 or step 1to step 6 and hol

21、ding pressure steps:1.第一級注射一般是注射料頭段.具注射量一般可根据料頭的輕重來估計其行程,當然也可以依据公式來計算,如公式:Step l injections:tunnel material.Injection Volume can be estimated according to the weight of tunnel material or it can be calculated by formula:L=Si=Vi/0.785Ds2 L:注射行程;Si:注射行程;L:injection stroke Si:injection stroke Vi:理論注射容積

22、;Ds:螺杆直徑;Vi:injection volume of theoretical Ds:diameter of screw 0.785:是/4 的值.0.785:value of/4.當然,如果我們在成型時每設定一個參數都要計算一次,要成型出一個產品就要幾個小時才能完成了.It cost a lot of time to produce one product if molding parameter is setting by calculation every time.5名师资料总结-精品资料欢迎下载-名师精心整理-第 5 页，共 8 页 -62.第二級是注塑產品約2/3 的階段,

23、當然,根据產品特殊需要,也允許成型不到2/3 階段,比如避免結合線問題,這一階段的成型速度及壓力一般是整個成型段的最大值段,如果排的產品與機台基本是相吻合的.模具結構合理,排气良好,這一段的壓力一般也不會超過80%.速度側視產品需變,可能大到 95%也可,自然一般都是在55%-80%間.Step 2:Injecting 2/3 stage of product.It can be lower than 2/3 stage of product according to requirement of product such as preventing welding line.Molding

24、speed and pressure on this step is the maximum of whole molding section.If the mold are suitable for the injection molding machine and mold s structure are reasonable and exhaustion are well,the pressure of this step should be lower than 80%.The speed was set within 55-80%,but it can be set at 95%fo

25、r special product.3.第三段是注射餘下的1/3 段,其速度和壓力根据產品的需要,一般是小于第二段,速度和壓力存在於一個往下降的過程.主要是為了防止產品毛邊的產生,但同時又必須把產品充填飽滿.Step3:injecting the rest 1/3 of product.Molding speed and pressure depends on the difference of product which are lower than that of step2.Speed and pressure should decrease but it can t be shot-s

26、hort or burred.4.第四段:一般有機臺還有第五,第六段,這段的成型速度和壓力相同前,都存在兩段一個遞減過程.其作用都是起到一個再次充滿的作用.Step4 section:Some injection machines have step5,step6.Step 4 are similar to former molding speed and pressure.In step 4 the speed and pressure was in aprocess of reduction.Its main function is to refill the product.5.保壓段:

27、不論成型什麼產品,都存在一個保壓過程.任何產品都不同程度的存在一個厚薄不一的問題,正常情況下,較厚的部分都可能存在一個收縮凹陷的現象,為了解決這種現象,就應應用到保壓,保壓一般來講都應用較慢的射速,而壓力的設置則應看縮水的情況如何,小到 25%,大到 80%都有可能.Holding pressure step:No matter what product it is,there is a holding pressure step.Every product have a problem of different thickness.In normal condition ,a part wi

28、th a bigger thickness will have the phenomenon of sink mark.We should turn the mode to holding pressure to prevent this defect.The injection speed of holding pressure step is slow But holding pressure depends on sink mark and the range is 25%to 80%.熔膠段工藝 Plastic Technique 1.再復雜的熔膠旋轉過程最多不會超過三段,因為熔膠本身

29、就是存在於把膠熔進料筒的過程,如果原料粘度大,熔膠壓力則大,但速度則應取決於原料的分解溫度,熔膠速度越快,原料中的剪切力則會越大,料管溫度則越高,局部原料產生分解的可能性則會越大,故一般熔膠會采用中速為宜,如45%-75%,熔膠同時會碰到一個比較重要的環節,那就是背壓的使用,產品精度要求越大,背壓的使用則更大,背壓可使原料分子間結构更緊密,成型出的產品則尺寸更穩定,外觀越好.當然,背壓太大,則會產生流涎,所以背壓的使用又應考虙到其它原因.Plastic melting process are less than 3 steps,because plastic is a step which a

30、dd melting resin to cylinder.Higher stickness of resin will cause higher screw back pressure.Screw speed are different depends on decomposing temperature of resin.And higher screw speed will cause higher trim force of resin and higher temperature of cylinder.Some resin may decomposes if the screw sp

31、eed is too high.So the melting speed is set On the mode of mid-speed at about 45-75%,In plastic step setting screw back pressure is very important 名师资料总结-精品资料欢迎下载-名师精心整理-第 6 页，共 8 页 -7too.Higher back pressure of screw will produce higher quality of product.Screw back pressure made resin structure be

32、came closer.But it may flow if screw back pressure is too high.While setting screw back pressure,we have to consider another factor that influence quality.2.熔膠過程還有一個比較重要的環節,那就是松退,松退分前松退和后松退,其作用一般是為了防止流涎和抽絲,設定值速度和壓力都在20%-50%間,設定的行程一般在 2-5cm間,太長的行程可能會使料筒里面貯存空气,導致下一模出現不期望的气泡.In plastic step there is an

33、other important factor named sucking back.Sucking back includes front sucking back and back sucking back.Its function is to prevent flow and line.Sucking back speed and pressure were set within 20-50%and distance within 2-5cm.If the distance are too long will make cylinder produce air which cause bu

34、bble at next molding that we don t expect.頂出的工藝設定 knocking out technique setting 產品經冷卻定型後則有一個開模的過程,開模基本上是合模的反過程.開模的未段則有一個慢速設置,開模完成后,產品必須頂出的過程.There is a mold opening step after product cooling and formalization.Mold opening is a reverse step of mold closing.The last step of mold opening speed should

35、 set on slow mode.Product will be knocked out after mold opened.一.頂前:Knocking out 頂前最好分兩個階級,第一階可分為中壓慢速,即是把產品輕輕頂出一部分,然后是中壓中速頂,中壓中速一般指的是 35%-55%,而低速則有可能低到5%,這需視產品不同而言,頂出行程設定是頂出長度稍比產品垂直深度大 1-2cm即可.Knocking out includes two steps.Step 1:We should set the speed on slow and the pressure on middle section

36、and knock out product partly.Step 2:we set the speed on middle and the pressure on middle section at about 35%-55%which depends on product.Lower speed can set at about 5%.Distance of knocking out will be 1-2 cm longer than the vertical thickness of product.二.退針 Back 頂退包括兩個過程與頂落的過程基本一致,頂退的終點應預留1-3cm的

37、空間,以保護頂針油管不被頂坏.The process of ejector moving backward includes 2 steps which are almost the same as knocking out.To protect the ejector oil pipe,it should preserve a distance of 1-3 mm at the ending point of ejector moving backward.三.頂針方式還包括一個多次頂,單次頂及頂針停留的選擇,機械手取產品,脫模順利的情況都采取多項,為了頂針 油缸 壽命的延長,多次頂就以不超

38、過三次為宜,頂針停留一般用在頂針帶著產品退回有可能對增品產生損傷的模具,同時為配合機械手使用,有時也需要較短的頂針停留.The way of knocking out includes knocking out one time,repeat knocking out and ejector delay.Product was taken out by robot and product left the mold easily,we adopted knocking out one time.Repeat knocking out was less than three times in o

39、rder to extend the lifespan of the ejector cylinder.Ejector stay temporarily used when product will be damaged if ejector go back or match up to robot.成型時間的設定 名师资料总结-精品资料欢迎下载-名师精心整理-第 7 页，共 8 页 -8Molding time setting 在保証產品品質的前提下,周期時間是越短越好,周期時間又包括如下几項:射膠時間,保壓時間,熔膠時間,冷卻時間,頂出時間,鎖模低壓時間,甚至乎關系到時間因素的還有開模與鎖

40、模,及頂出的快慢.If the quality of product is qualified,cycle time should be shorter.Cycle time includes:injection time,holding pressure time,plastic time,cooling time,knocking out time and mold protect time.Mold opening and closing speed and knocking out speed also affect cycle.1.射膠時間包含保壓時間,一般看起來,射膠時間越長,產品

41、越飽和,但我們在講求品質時,同時也須考量產能,更何況,射膠時間過長,有可能會造成產品過於飽滿而尋致粘模頂的變形呎寸偏大等一系列問題,故我們在設置射膠時間時應綜合考慮,盡量在合乎品質要求時縮短射膠時間.Injection time includes holding pressure time.The longer injection time it is,the higher density of product it will be.We should consider the output of quantity when we pay attention to quality.If inj

42、ection time is too long,it may cause a series of defects suck as deformation and burr of product.So we should consider all kinds of factors thus we can shorten the injection time under the requirement of quality.2.熔膠時間的長短取決於熔膠速度設定的快慢,背壓設定的大小,但有一點,熔膠時間控制的長短一定要比冷卻時間短.Plastic time depends on plastic me

43、lting speed and screw back pressure,but plastic time must be shorter than cooling time.3.冷卻時間:冷卻時間的長短直接影響到成型的周期,冷卻時間越長,成型時間就越長,造成產能就越低,故我們在設定高壓冷卻時間時,只要能保證到產品成型順利,不會直接影響到變形等問題,設定的時間也是越短越好.Cooling time:Cooling time affects cycle time.Cycle time will increase if the cooling time increases.Thus the quan

44、tity of output will go down.So cooling time should be set shortly to ensure the quality of product.4.在大量使用機械手的富金公司,我們的頂出時間一般是與機械手配合為宜,全自動使用機械手時頂出停留時間一般保持 1.5-2 秒,半自動生產,如因頂針退回會導致產品掉落或卡緊,而取不下產品,停留時間則應保持5秒左右.In Foxconn,robots were used extensively.Knocking out time should match up with robot,Knocking o

45、ut delay keeps at about 1.5-2 second when robot is full-automatic.If ejector go back,product will fall down or can t be taken off.Knocking out delay keeps at about 5 second while robot is semi-automatic.5.低壓保護時間對保護我們人身安全,模具安全起很大作用,配合好模具低壓位置和低壓壓力的調整,低壓保護的時間應取 1-2 秒,保護時間越短,可能造成的危害則越小.Low-pressure protect time is very important for our safety and mold,Mold protect time should be adjusted within 1-2 second to match with low pressure and position of mold protect.The shorter protect time it is,the less damage it will happen.名师资料总结-精品资料欢迎下载-名师精心整理-第 8 页，共 8 页 -