MoldingProcessIntroduce注塑工艺介绍课件.ppt

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1、Pacific ADS Design Training November 20031Molding Process IntroduceDaniel zuoPacific ADS Design Training November 20032Process SelectionProcessing of Engineering Thermoplastics:Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisonsPacific ADS Design Tr

2、aining November 20033Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-InjectionPacific ADS Design Training November 20034Injection Molding IntroductionInjectio

3、n molding makes possible mass production of intricate,high performance,tight tolerance parts with very little secondary labor and minimal waste.Process Selection-InjectionPacific ADS Design Training November 20035HopperMoldClampExtruder Barrel withHeating BandsInjection Molding MachineProcess Select

4、ion-InjectionPacific ADS Design Training November 20036Injection UnitThe Reciprocating ScrewPelletsFeed SectionMeltProcess Selection-InjectionPacific ADS Design Training November 20037Injection UnitThe Reciprocating ScrewScrew Pushes Forward:InjectScrew Slides Back:Feed,Melt(Filling)ThroatHeating Co

5、ilsNozzleRotationInjection ForceBack PressureProcess Selection-InjectionPacific ADS Design Training November 20038Injection UnitThe Reciprocating ScrewScrew Slides Back:Feed,MeltProcess Selection-InjectionPacific ADS Design Training November 20039Injection UnitThe Reciprocating ScrewReady for Inject

6、ionReady for InjectionProcess Selection-InjectionPacific ADS Design Training November 200310Injection UnitThe Reciprocating ScrewScrew Pushes Forward:InjectProcess Selection-InjectionPacific ADS Design Training November 200311Feed Section:Picks up pellets and carries them forward.Transition Section:

7、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 DescriptionMeteringCompressionFeedProcess Selection-InjectionPacific ADS Design Training November 200312Clam

8、ping SystemMoldMovablePlatenStationaryPlatenProvides motion and force to open and close moldClamping Force:maximum holding force in tons that a machine can maintainNozzleProcess Selection-InjectionPacific ADS Design Training November 200313Standard Injection MoldingFast Cycle TimesComplex PartsHigh

9、VolumeAestheticsAdvantagesDisadvantagesHigh Pressure ProcessLimited Large Part CapabilityHigh Tooling CostProcess Selection-InjectionPacific ADS Design Training November 200314Co-Injection MoldingTwo-ComponentTwo-ComponentCo-Injection MoldingCo-Injection MoldingPacific ADS Design Training November 2

10、00315Co-Injection MoldingThree Component Three Component Co-Injection MoldingCo-Injection MoldingPacific ADS Design Training November 200316Co-Injection MoldingFour ComponentFour ComponentCo-Injection MoldingCo-Injection MoldingPacific ADS Design Training November 200317LEXAN FOAMABLE RESIN Business

11、 Machine ChassisStructural Foam PartHigh Strength and Rigidity in Larger PartsProcess Selection-InjectionPacific ADS Design Training November 200318Mucell微孔发泡设备微孔发泡设备Pacific ADS Design Training November 20031901 Needle valve nozzle02 Gas injector03 MuCell-plasticizing screw(L/D ratio:22:124:1)04 Hom

12、ogenizing section for gas/melt mixture05 Plastics granules without blowing agent0105030204Mucell微孔发泡工艺的塑化单元微孔发泡工艺的塑化单元Pacific ADS Design Training November 200320Mucell微孔发泡的产品表现形式微孔发泡的产品表现形式Pacific ADS Design Training November 200321Structural Foam Injection MoldingLarge Part CapabilityLow Pressure P

13、rocessHigh Stiffness to Weight RatioAdvantagesDisadvantagesLonger Cycle Time AestheticsBlending RequiredInert GasBlowing Agent with ResinRelative to Standard Injection MoldingProcess Selection-InjectionPacific ADS Design Training November 200322Structural Foam Increases the attainable wall thickness

14、Gas expands inside plasticized material to create foam coreSKINSKINCOREProcess Selection-InjectionPacific ADS Design Training November 200323Gas Assist Injection MoldingGas Introduced After Short Shot to Pack out PartImproved Aesthetics Low Pressure ProcessLower Part WeightReduced Cycle TimeAdvantag

15、esDisadvantagesDefect on Every Part More Complex ProcessHigh Tooling CostsLicensing CostsProcess Selection-InjectionPacific ADS Design Training November 200324Gas Assist Injection Molded Shipping ContainerGas Assist Molded RibInjection Molded RibGas Created CavityGas Injection DefectSinkGas Assist I

16、njection MoldingProcess Selection-InjectionPacific ADS Design Training November 200325Vicat Softening pointMold TemperatureProcesscloseinjectplasticizationcoolopentemperature risecloseinjectplasticizationcoolValve unithot waterhot waterhot waterwaitwaitcold watercold waterHeat&Cool SystemProcess Sel

17、ection-InjectionPacific ADS Design Training November 200326Heat&Cool EquipmentsHeat&Cool EquipmentsValve UnitValve Unit 1 1 2 2 3 3BoilerCoolingCooling Water Water：ChannelChannelPartPartCooling ChannelCooling ChannelNeed special equipmentProcess Selection-InjectionPacific ADS Design Training Novembe

18、r 200327Advantage of Heat&Cool Advantage of Heat&Cool Heat&CoolGood Surface Finishing with Filled MaterialNo Weld lineIncrease Weld strengthEliminate Jetting&Flow markPaint lessNo stressIncrease FlowabilityNote PCHandphoneDoor mirrorDoor handleBezelHousingHousingLensLight guide plateThin wallProcess

19、 Selection-InjectionPacific ADS Design Training November 200328GCompressionGoPreset GapInjectionTimePositionScrewClampf=0GoInjection Compression MoldingPacific ADS Design Training November 200329TimeScrewCoreCompressionPreset GapGf=0GoGoInjectionPositionSelective ICM or CoiningPacific ADS Design Tra

20、ining November 200330FeatureProcess BenefitsFilling at a larger effective thicknessCompression assisted filling and packShort shot processLower shearLonger fill lengthLower fill pressureLower clamp forceThinner wall capabilityBi-axial flowReduction of residual stressesMaterial savingsWeight reductio

21、nCycle time reductionBetter impact propertiesAdvantages Dimensional stability Optical QualityWeld linestrengthLower CavityPressureIn-mold decorating with“soft touch”Why Use ICM?Pacific ADS Design Training November 200331InjectionICMNozzle PressureNozzle PressureCavity PressureCavity PressureMold Pos

22、itionMold Position25k15.5kPSIPSI2.00.004InchTime(sec)Time(sec)0.0400.321kInch3.7kExperimental Cavity Pressure ProfilePacific ADS Design Training November 200332Lexan 141-1.5mm thicknessICMIMImproved Flow in Wheel CoversDecrease Molded-in StressPacific ADS Design Training November 200333Injection Mol

23、dingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-ExtrusionPacific ADS Design Training November 200334ExtrusionExtrusion is the act of squeezing,pressing,or pushing material

24、 through a die in order to make a shape.Process Selection-ExtrusionPacific ADS Design Training November 200335The ExtruderPelletsPartHeating CoilsScrewDieContinuous ProcessProcess Selection-ExtrusionPacific ADS Design Training November 200336The Profile Extrusion DieContinuous FlowUniform Cross-Sect

25、ionProcess Selection-ExtrusionPacific ADS Design Training November 200337Extruded Through DieSupported and Cooled by a Stack of Polishing RollsCut and Trimmed Once Below Glass Transition TemperatureSheet May be Used in Thermoforming and Compression MoldingSheet ExtrusionDieExtrusion CutawayViewRigid

26、SheetRollStackProcess Selection-ExtrusionPacific ADS Design Training November 200338DieDieOther Roll Stack OptionsProcess Selection-ExtrusionPacific ADS Design Training November 200339Thermoplastic and Glass Composite SheetGlass Fiber MatGlass Impregnated SheetSheet ExtruderA Combination of Glass Ma

27、t and Thermoplastic Resin Having BothHigh Stiffness and Good Impact Strength.Process Selection-ExtrusionPacific ADS Design Training November 200340The ExtruderPelletsPartHeating CoilsScrewDieLow Tooling Die CostsLarge Part CapabilityContinuous Process AdvantagesDisadvantagesHigh Set-up CostConstant

28、Cross SectionLimited ComplexityProcess Selection-ExtrusionPacific ADS Design Training November 200341Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary OperationsComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-Compressi

29、onPacific ADS Design Training November 200342Softened sheet isplaced in a mold thenpressed into shape bycompressive force.Process Selection-CompressionCompression MoldingPacific ADS Design Training November 200343231Soft SheetTrimmingCompressive ForcePartProcess Selection-CompressionCompression Mold

30、ingPacific ADS Design Training November 200344Large Part CapabilityVariable Wall ThicknessUses Conventional Stamping EquipmentLow Warpage and DistortionAdvantagesDisadvantagesHigh Tooling Cost (Cheaper than Injection Molding)Secondary TrimmingAestheticsProcess Selection-CompressionCompression Moldin

31、gPacific ADS Design Training November 200345Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess Selection-ThermoformingPacific ADS Design Training November 200346Vacuum For

32、mingAtmospheric Pressure(14.7 psi)Softened SheetMoldPartVacuumProcess Selection-ThermoformingPacific ADS Design Training November 200347Pressure FormingSoftened SheetCompressed AirPressure FormedPart atm pressureProcess Selection-ThermoformingPacific ADS Design Training November 200348Low Tooling Co

33、stLarge Part CapabilityLow Pressure ProcessAdvantagesDisadvantagesLow Part ComplexityLonger Cycle TimesVacuumProcess Selection-ThermoformingThermoformingCompressed AirPacific ADS Design Training November 200349Injection MoldingExtrusionCompression MoldingThermoformingBlow Molding Secondary Operation

34、sComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingDouble Walled,Hollow partsProcess Selection BlowPacific ADS Design Training November 200350Pinch BarParison DropPre BlowFull PressureReleaseMoldPart12345Process Selection BlowBlow MoldingPacific ADS Design Training Nov

35、ember 200351MandrelParisonControlling Wall ThicknessRaised MandrelLowered MandrelThinner WallThicker WallProcess Selection BlowPacific ADS Design Training November 200352Double Wall Geometry(Hollow Parts)Good Stiffness to Weight RatioLow Tooling CostLarge Part CapabilityAdvantagesDisadvantagesLonger

36、 Cycle TimesSecondary TrimmingPurging Start-up CostProcess Selection BlowBlow MoldingPacific ADS Design Training November 200353Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessing

37、PAINTINGPAINTINGCHEMICAL AND SCRATCHCHEMICAL AND SCRATCHRESISTANT COATINGSRESISTANT COATINGSPRINTINGPRINTINGMETALIZINGMETALIZINGMACHININGMACHININGProcess Selection Sec.OperationInjection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsPacific ADS Design Tr

38、aining November 200354Injection MoldingExtrusionCompression MoldingThermoformingBlow MoldingSecondary Operations ComparisonsProcessing of Engineering Thermoplastics:MaterialsProcessingProcessingProcess SelectionPacific ADS Design Training November 200355 Size Part Complexity Wall Thickness Productio

39、n Quantity CostsProcess Selection CriteriaProcess SelectionPacific ADS Design Training November 200356Part Complexity vs.Part SizeIMFMCMBMTFEXPart SizePARTCOMPLEXITYProcess SelectionPacific ADS Design Training November 200357.300.250.200.150.100.050 0BM IM FM CM EX TFWall ThicknessProcess SelectionPacific ADS Design Training November 200358Tooling CostRankingExtrusionThermoformingBlow MoldingFoam MoldingCompression MoldingInjection MoldingLeast ExpensiveProcess Selection