工艺流程及成型条件设定EC

1成型工藝流程及條件介紹Introductiontotechniqueandparameterofmolding第一節成型工藝Section1techniqueofmolding.1.成型工藝參數類型typesofmoldingparameter.(1).注塑參數parameterofInjection.a.注射量amountofInjection.b.計量行程Screwbackpositionc.餘料量Cushiond.防誕量Suckingbackratee.螺杆轉速Screwspeedf.塑化量Plasticrateg.預塑背壓Screwbackpressureh.注射壓力和保壓壓力Injectionpressureandholdingpressurei.注射速度Injectionspeed(2)合模參數Clampingparametera.合模力Clampingforceb.合模速度Clampingspeedc.合模行程.Clampingstroked.開模力Openingforcee.開模速度Openingspeedf.開模行程Openingposition2g.頂出壓力Ejectoradvancepressureh.頂出速度Ejectoradvancespeedi.頂出行程Ejectoradvanceposition2.溫控參數Temperatureparametera.烘料溫度Dryresinmaterialtemperatureb.料溫與噴嘴溫度Cylindertemperatureandnozzletemperaturec.模具溫度Moldtemperatured.油溫Oiltemperature3.成型周期Moldingcyclea.循環周期Cycletimeb.冷卻時間Cooltimec.注射時間Injectiontimed.保壓時間Holdingpressuretimee.塑化時間Plastictimef.頂出及停留時間Knockingoutanddelaytimeg.低壓保護時間Moldprotecttime成型工藝參數的設定須根據產品的不同設置.Thesettingofmoldingparameteraredifferentbytypesofproduct第二節成型條件設定Section2MoldingparameterSetting按成型步驟:可分為開鎖模,加熱,射出,頂出四個過程.Moldingsteps:moldopening/closing,heating,injectionandknockingout.開鎖模條件:Moldopeningparameter:3快速段中速度低壓高壓速度High-speedmid-speedLowpressurehighpressurespeed鎖模條件設定:Moldclosingparametersetting1.鎖模一般分:快速→中速→低壓→高壓Moldclosing:high-speed→low-speed→lowpressure→highpressure2.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.Moldclosingspeeddependsontypeofmoldinhigh-speedsection.Fortwo–platemold,itcansetonthemodeofquickorextraquick.Thespeedwassetwithin55-75%inthemodeofquick.Forfull-platemold,thespeedcanbesetwithin80-90%.Whileinthemodeofextraquick,thespeedonlycanbesetwithin45-55%andpressurecanbesetwithin50-75%,Thesettingofpositiondistancediffersdependingonthevolumeofproduct.Generally,itcanbesetbythedigitabout1/3ofmoldopeningposition.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-speedsection:Moldclosingspeedchangesintomid-speedafterhigh-speedsectionfinish.Startpositionofmid-speediswheretwoplatesmeets(includethree-platemoldandtwo-platemold).Distanceofmid-speedwasdecidedbythedistanceoftwoplates.Thespeedissetwithin30-50%andpressureissetwithin20-45%.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1-2%,有些機則可設於5-15%,也是視乎不同機种不同.Low-pressuresection:Moldclosingsetslow-pressurewhenplatesmeeting.Thispositionissetbythedataofmachine’sdisplayscreenonthistime.Thispointisthegaugeofthedata.Ifthedataislowerthanthepoint,thereisnohigh-pressure.Ifthedataishigherthanthepoint,thereishigh-pressureeasily.Thespeedissetwithin15-25%andthepressureissetwithin1-2%whichdependsontype4ofinjectionmachine.Anotherkindofmachinecanbesetwithin5-15%.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,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-pressuresection:Generallyspeaking,high-pressurepositionhadbeensetbeforetheinjectionmoldingmachinesweresenttocustomer.Itcannotbemodifiedunlessnecessary.Forexample,high-pressurepositionofCHENHSONGmachineis50P.Thespeedofhigh-pressuresectionisabout30-35%andhigherthanthatoflow-pressure.Thepressuredependsonmold,itcansetwithin55-85%.Forfully-platenmold,theexhaustionisgoodenoughthatthepressurecanbesetabout55%.Ifthemoldhadalotofslidesandburrratewashighinproduction,thepressurecanbesetmorethan90%.加熱工藝條件設定Heatingparametersetting1.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.Thepropertemperaturesettingwasdifferentdependsontypeofresin,Usually,thetemperaturesettingshouldbereducedbyaunitof10∘Cfromnozzletothesectionoffeedingresin.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.Nozzletemperaturesettingshouldlowdownifproductlines.IfresincooldownverysoonsuchasPPS,PA.Nozzle’stemperatureshouldbehigherthanthatofthesecondcylinderatleast100C.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.ThestartingtemperatureofPumpisdifferentdependsontypeofinjectionmoldingmachine.Oiltemperaturewassetwithin400C-600Ctoprotectoilsealofmachine,Ifthetemperatureofoilaretoohighthatwilldamagetheoilsealandreduceitslife-spanwhichmakesmoldingunstable.注射及熔膠(加料)工藝條件設定Injectionandplastictechniqueparametersetting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℃MoldingTemperature(’c)分解溫度℃DecomposingTemperature(‘C)模具溫度℃干燥溫度℃MoldTemperature(‘c)Resindrytemperature(‘c)HDPE低衛壓聚乙烯108-126160-22231045-6070-80HOPE高衛壓聚乙烯135180-24031050-8070-80PC聚碳酸脂polycarbonate220-240260-31032080-12090-120干燥時間:4H干燥溫度:120℃ABS160180-23027045-8070-90干燥時間:2-4H.干燥溫度:80-100℃PC/ABSPC與ABC共混物200220-25030050-9080-100干燥時間:3-4H干燥溫度:80-110℃PP聚丙烯160-170200-26030030-45PS聚苯乙烯140180-23030030-4565-80PVC聚氯乙烯140180-21530020-4090-100AS160200-25028045-7570-90PA6尼龍6215-220225-24530040-8095-110PA66尼能66260-265260-27530040-8095-110PPS聚苯硫酸265-280300-330370100-120100-130PBT聚對苯二甲酸丁二脂225-235240-26028070-80105-140POM聚甲醛170180-21024080-120PMMA有機玻璃160180-24027040-65