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成型工艺流程及条件介绍Moldingtechniqueprocedureandparameterintroduction第一節成型工艺Section1moldingtechnique.1.成型工艺参数类型Sortsofmoldingparameter.(1).注塑参数Injectionparameter.a.注射量Injectionrate.b.计量行程Screwbackpositionc.余料量Cushiond.防诞量Suckingbackratee.螺杆转速Screwspeedf.塑化量Plastic0rateg.预塑背压Screwbackpressureh.注射压力和保压压力Injectionpressureandholdingpressurei.注射速度Injectionspeed(2)合模参数Clampingparametera.合模力Clampingforceb.合模速度Clampingspeedc.合模行程.Clampingstroked.开模力Openingforcee.开模速度Openingspeedf.开模行程Openingpositiong.顶出压力Ejectoradvancepressureh.顶出速度Ejectoradvancespeedi.顶出行程Ejectoradvanceposition2.温控参数Temperatureparametera.烘料温度Dryresinmaterialtemperatureb.料向与喷嘴温度Cylindertemperatureandnozzletemperaturec.模具温度Moldtemperatured.油温Oiltemperature3.成型周期Moldingcyclea.循环周期Cycletimeb.冷却时间Cooltimec.注射时间Injectiontimed.保压时间Holdingpressuretimee.塑化时间Planttimef.顶出及停留时间Knockingoutanddelaytimeg.低压保护时间Moldprotecttime成型工艺参数的设定须根据产品的不同设置.Moldingtechniqueparametersettingdiffersdependingontypeofproduct第二节成型条件设定Section2MoldingparameterSetting按成型步骤:可分为开锁模,加热,射出,顶出四个过程.Moldingsteps:moldopening/closing,heatinginjectionandknockingout.开锁模条件:Moldopeningparameter:快速段中速度低压高压速度High-speedmid-speedLowpressurehighpressurespeed锁模条件设定:Moldclosingparametersetting1锁模一般分:快速→中速→低压→高压Moldclosing:high-speed→low-speed→lowpressure→highpressure2.快锁模一般按模具情况分,如果是平面二板模具,快速锁模段可用较快速度,甚至于用到特快,当用到一般快速时,速度设到55-75%,完全平面模可设定到80-90%,如果用到特快就只能设定在45-55%,压力则可设定于50-75%,位置段视产品的深浅(或长短)不同,一般是开模宽度的1/3.Inhigh-speedsection,Moldclosingspeeddependsontypeofmold.Fortwo–platemolditcansetquickandevenespeciallyquickusually,itsetspeedwithin55-75%.Forfull-platemolditsetspeedwithin80-90%whileusingespeciallyhighspeeditsetspeedwithin45-55%andpressurewithin50-75%positiondistancesettingdiffersdependingonthevolumeofproductandusuallyitcanbeset1/3ofmoldopeningposition.3.中速段,在快速段结束后即转换成中速,中速的位置一般是到模板(包括三板模,二板模)合在一块为止,具体长度应视模板板间隔,速度一般设置在30%-50%间,压力则是20%-45%间.Inmid-speedsection:Moldclosingspeedchangesintomid-speedafterhigh-speedsectionfinish.Mid-speedstartpositioniswheretwoplatesmeet(includethree-platemoldandtwo-platemold)Distanceofmid-speedisuptodistanceoftwoplatesplateitspeedwithin30-50%andpressure20-45%.4.低压设定,低速设定一般是在模板接触的一瞬间,具体位置就设在机台显示屏显示的一瞬间的数字为准,这个数字一般是以这点为标准,,即于此点则起不了高压,高于此点则大,轻易起高压.设定的速度一般是15%-25%,视乎不同机种而定,压力一般设定于1-2%,有些机则可设于5-15%,也是视乎不同机种不同.Low-pressuresection:Moldclosingsetslow-pressurewhenplatesmeeting.Thispositionissettothedataofmachinescreenonthistime.Thispointisthegageofthedata.Datalowerthepointthereisnohigh-pressure.Datahigherthepointthereishigh-pressureeasily.Itsetspeedwithin15-25%andpressurewithin1-2%dependingontypewithin1-2%dependingontypeofinjectionmoldingmachine.5.高压设定,按一般机台而言,高压位置机台在出厂时都已作了设定,相对来讲,是不可以随便更改的,比如震雄机在50P.速度相对低压略高,大约在30-35%左右,而压力则视乎模具而定,可在55-85%中取,比如完全平面之新模,模具排气良好,甚至于设在55%即可,如果是滑块较多,原来生产时毛边也较多,甚至于可设在90%还略显不足.High-pressuresection:Tonormalinjectionmoldingmachine,high-pressurepositionhadbeensetbeforetheyweresenttocustomer.Itcannotbemodified.Forexamplehigh-pressurepositionofCHENHSONGmachineis50P.Thespeedofhigh-pressuresectionisabout30-35%andhigherthanthatoflow-pressure.Thepressureisuptomold,itcansetwithin55-85%Forfull-platemold,it’sejectairwell,itcansetpressure55%.Ifmoldhasalotofslidesandflashratehighinproduction,pressurecanset90%.加热工艺条件设定Heatingtechniqueparametersetting1.加热段温度设定必须按照产品所使用的原料的不同而不同,但却必须遵循一个这样的规则,即由射口筒到进科段温度是逐步递减的.且递减温度是以10.度为单位.Thepropertemperaturesettingdiffersdependingontypeofresinmaterial,butitmustbeabidebyarulethattemperaturesettingshoulddiminishinstep1０.Cfromnozzletofeedingresinmaterialposition.2特殊情况下.如料头抽丝,则射口筒温度应降低,如果是比较特殊的原料冷凝比较快的.则射口筒温度则不止比第二节法兰温度高10度.比如PPS.尼龙等.Nozzletemperaturesettingshouldlowifproductline.IfresinmaterialsuchasPPS,PA,coolverysoon,Nozzletemperatureshouldhighermore10.Cthanthesecondcylindertemperature.3.机台马达启动温度视乎机台不同而不同,一般出于对机台油路中的油封保护需要,油温最好能控制在40度-60度,以免油封长期高压而变化,缩短使用寿命,造成成型不稳定.Pumpturningontemperatureisdifferentdependingontypeofinjectionmoldingmachine.Toprotectoilsealofmachineitsetoiltemperaturewithin40.C-60.C,IfoilsealworkonconditionthathighpressureanddamagedIt’sworktimewillbeshorter,itcancausemoldingstable.第三节注射及熔胶(加料)工艺条件设定InjectionandplasticTechniqueparametersetting一.注射Injection第四节常见塑料原料的有关温度值.原料Resin名称Name熔点℃Melt’s成型温度℃MoldingTemperature(’c)分解温度℃DecomposingTemperature(‘C)模具温度℃MoldTemperature(‘c)干燥温度℃Resindrytemperature(‘c)注射是把塑料原料经加热后射进模腔的过程,它一般可分为第一级,第二级,第三级,第四级及保压几段:Injectionisastepwhichinjectmeltresinmaterialintomold.Itconsistsofstepl,step2,step3,step4andholdingpressurestep:1.第一级注射一般是注射料头段.具注射量一般可根据料头的轻重来估计其行程,当然也可以依据公式来计算,如公式:Steplinjectsusuallytunnelmaterial,InjectionVolumecanbeestimatedaccordingtotheweightofcourseitcanbecalculatedbyformula:L=Si=Vi/0.785Ds2L:注射行程;Si:注射行程;L:injectionstrokeSi:injectionstrokeVi:理论注射容积;Ds:螺杆直径;Vi:injectionvolumeoftheoreticalDs:diameterofscrew0.785:是Ω/4的值.0.785:valueofΩ/4.当然,如果我们在成型时每设定一个参数都要计算一次,要成型出一个产品就要几个小时才能完成了.Butitcostalotoftimetoproduceoneproductifeverytimemoldingparameterissettingbycalculation.2.第二级是注塑产品约2/3的阶段,当然,根据产品特殊需要,也允许成型不到2/3阶段,比如避免结合线问题,这一阶段的成型速度及压力一般是整个成型段的最大值段,如果排的产品与机台基本是相吻合的.模具结构合理,排气良好,这一段的压力一般