模具介绍（PPT75页)

JRFGEP10/10/00TOOLINGBASICSFORULTEM(PEI)INJECTIONMOLDINGJRFGEP10/10/00GOODPARTToolingConsiderations模具設計考量塑料成型條件模具設計JRFGEP10/10/00InjectionToolingStructureToolingTypeandStructure(模具型式及結構)RunnerSystemandGating(進料系統)CoolingSystem(溫度控制系統)Ejectorsystem(頂出系統)Ventingandothers(逃氣及其它)JRFGEP10/10/00TwoPlateMold兩板模BASICTOOLTYPESJRFGEP10/10/00頂出板基座及下夾模板頂出板公模座TwoPlateDesign(兩板模)公模仁成品分模線母模板上夾模板注口襯套JRFGEP10/10/002JRFGEP10/10/003JRFGEP10/10/004JRFGEP10/10/00ToolThermalManagementPEI塑料之模具建議使用隔熱裝置以利模溫控制公模母模附加額外隔熱板隔熱板隔熱板JRFGEP10/10/00頂出板機基座及下夾模板頂出板公模仁成品分模線ThreePlateDesign(三板模)母模板料頭分模線撥料板上夾模板注口襯套公模座JRFGEP10/10/00JRFGEP10/10/00JRFGEP10/10/00JRFGEP10/10/00JRFGEP10/10/00InjectionMoldingToolingCamActions(滑塊機構)Hydraulic(油壓驅動)PlasticCorePinCoredHoleCoreHydraulicCylinderCavityJRFGEP10/10/00CamActionsSlide機構式滑塊123JRFGEP10/10/00PEI模具常用之鋼材硬度鋼材特性運用範圍ASSABAISIHRC718P-2030-33高鎳鉻鉬合金工具鋼拋光行可可熱處理至HRC52大型熱塑性塑料模具TV,LCD,Monitor,儀錶板,家用品模具壽命約30萬模次740HP-2035-40718改良型拋光性較718好高拋光性高硬度模具預硬合金鋼模具壽命約35萬模次8407-MSH-1350-54結晶組織細緻化處理耐熱疲勞性佳高硬度模具要求表面亮度模具之塑膠模模具壽命約50萬模次STAVAXESR不鏽鋼模具鋼材鏡面拋光性佳光學鏡片PVC模光碟片醫療器材模具壽命約50萬模次CORRAX耐腐蝕性好熱處理此寸穩定性佳鏡面拋光性佳PVC模具車燈模具醫療器材模具壽命約50萬模次NAK-80(JIS)NAK-8035-40結晶組織細緻化處理鏡面拋光性佳光學鏡片PVC模光碟片醫療器材車燈模具模具壽命約50萬模次鋼材42032-50JRFGEP10/10/00SprueBushingNozzle(射嘴)RadiusOrificeSPRUEBUSHING(注道襯套)JRFGEP10/10/00SprueBushings(注道襯套)HelicalHeaterThermalShut-OffHeatedSprues加熱式注道襯套ColdSprue冷注道襯套JRFGEP10/10/00SpruePuller(注道拉料銷)REVERSETAPER最佳ZPULLER好GROOVE尚可SUCKERPIN不建議使用JRFGEP10/10/00甚麼是料道系統?B:能量緩衝區A:塑料由射出機射嘴至成品間的通道JRFGEP10/10/00RunnerSystems(料道系統)JRFGEP10/10/00PEIRunnerDesign(料道設計)圓形流動效能最佳PL梯形流動效能可半圓形流動效能最差不建議使用JRFGEP10/10/00塑料流動方向PEI塑料建議料道結面積(4.0~8.0MM“Dia.)冷料井之長度1.5X料道直徑ColdSlugWell(冷料井)ColdSlugWell(冷料井)冷料井建議尺寸JRFGEP10/10/00UnbalancedSystem(不平衡料道)AAAABBBBBALANCINGRUNNERS料道流動平衡JRFGEP10/10/00BalancedSystem(平衡料道)AAAAAAAABALANCINGRUNNERSJRFGEP10/10/00HotrunnerTooling熱膠道系統JRFGEP10/10/00WhomakesaHotRunner?KonaHuskyDMECoolOneFastHeatIncoeSpearInsulatedRunnerHeatedSprueBushingOSCOPETSGuntherEwiKonMoldMastersRAMAETC……JRFGEP10/10/00ExtendedNozzles(射嘴的延伸)甚麼是熱膠道系統?JRFGEP10/10/00HeatedSprueBushing(加熱式注道襯套)JRFGEP10/10/00多點進膠方式JRFGEP10/10/00InjectionMoldingTooling熱流板(分流板)Manifold建議•由外部提功均勻熱源(如右圖示4Heaters)•加熱器最少提供50Watts/in3JRFGEP10/10/00InjectionMoldingToolingHotRunnerSystemsCavityPlate=1500CManifold=3800C使用熱膠道好處•降低生產時間-降低約10-15%•減少塑料浪廢-沒有料道及注道塑料•改善成品外觀-低內應力-較好外觀JRFGEP10/10/00Gating(進澆口)JRFGEP10/10/00GATING在何處?由成品肉厚處;接近轉角處;遠離負載區或應力集中處;質量中心處(非成品中心處)進料點數量?依成品厚度及塑料流動指數成品外觀需求成品設計肉厚模穴數需求進料點形式?HOTRUNNER;HOTTIP;VALVEGATE;THREEPLATE;EDGEGATE;CASHEWGATE;DIAPHRAGMGATESUBGATE;TUNNELGATE;FLASHGATE;FANGATE;HOTEDGEGATE;DIRECTSPRUE;ETC.ETC.ETC.JRFGEP10/10/00DirectSprueGate(直接澆道)建議使用於ULTEMMoldedPartSprueJRFGEP10/10/00EdgeGate(側邊澆口)建議使用於ULTEMLandLength2.5mmMaximumJRFGEP10/10/00COLDSLUG(冷料井)RADIUSFanGate(扇形澆口)建議使用於ULTEMJRFGEP10/10/00TunnelGateKnockOutPin(頂出銷)MoldedPartSpruePartingLineTunnelGate(潛伏式澆口)不建議使用於ULTEMGATEBLUSHCOMMONX0.250x“X”JRFGEP10/10/00RRGateCashewGateCashewGate(牛角澆口)不建議使用於ULTEMJRFGEP10/10/000.5mmLandLength1.2mm~2.5mm900PinPointGating(針點澆口)不建議使用於ULTEMJRFGEP10/10/00澆口位置與流動方向JRFGEP10/10/00澆口位置JRFGEP10/10/00InjectionMoldingDesignMoldabilityHoles靠破孔設計會阻礙塑料流動Gate-MeltEntryPointJRFGEP10/10/00InjectionMoldingDesignMoldabilityGate-MeltEntryPoint塑料可得到較好流動HolesJRFGEP10/10/00SingleGate20,000psiMultipleGates7,000psiWhyuseMultipleGates?JRFGEP10/10/00MOLDTEMPERATURE模具溫度JRFGEP10/10/00PartCoolingandSolidification溶融塑料模具冷卻成品(熱轉移)JRFGEP10/10/00MoldCooling隔板式噴水式導熱棒冷卻水路製作方式JRFGEP10/10/00InjectionMoldingTooling連續式水路INOUTPinBladeJRFGEP10/10/00InjectionMoldingTooling噴泉式冷卻INOUTPinTube冷卻效率佳JRFGEP10/10/00最少尺寸為水路直徑兩倍JRFGEP10/10/00JRFGEP10/10/00連續式水路連結INOUTOOOOOOOOOOOO120125125135135145130140140130150145WATERLINECONNECTIONS不建議使用JRFGEP10/10/00MOLDManifold“In”Manifold“Out”Water“In”Water“Out”RecommendedWaterConnections成形PEI塑料之模具溫度建議為150CJRFGEP10/10/00低模溫成形高模溫成形•不易充填•較高射出壓力•料管設定溫度較高•高頂出壓力•較高內應力•成品肉厚處內部有空孔•易充填•較低射出壓力•料管設定溫度較低•易頂出•較低內應力•表面外觀佳•肉厚表面縮水JRFGEP10/10/00成品縮水率依據下列因素綜合考量1.成品設計2.澆口位置及尺寸3.塑料成形溫度4.塑料流動指數5.射出壓力6.保壓壓力及時間7.模具溫度JRFGEP10/10/00Venting排氣(逃氣)JRFGEP10/10/00ToolingandProcessingDesignandProcessingDictatePartPerformanceApplyFullPartingLineVenting•降低射出壓力•避免氣體在充料末端聚集•成品外觀較佳0.038-0.075mmdepthGateVent1.5mmminLandLengthNoteStep12.7mm1.27mmVentPlacementEvery25mmto50mmIntervalJRFGEP10/10/00排氣間隙0.04~0.07mmEjectorPin頂針逃氣JRFGEP10/10/00無拔模斜度不易頂出易頂出EjectingthePartDraftAngleJRFGEP10/10/00拔模斜度最少1/2O拔模斜度拔模斜度JRFGEP10/10/00DraftAngle咬花側邊角度每增加0.025mm咬花深度拔模斜度追加1度JRFGEP10/10/00PartTextureWILLChangewithPressureWILLChangewithTemperatureWILLVarywithToolAgeWILLVaryTooltoToolWILLVaryMoldertoMolderJRFGEP10/10/00StainlessorHardenedP-20withSPI1FinishToolingSurfaceTreatmentMostoftheindustryuses420stainlesssteelwithamininumhardnessof46Rc.Thisapproachoffersgoodsurfaceappearancewithalowriskforcorrosion.Somesuppliersusehigh-purityP20steel.WhilewearenotawareofanyrustingorcorrosionissuesassociatedwithP20steel,thismaterialwillrustfairlyeasilyascomparedwithstainlesssteel.Finkel,doublevacuumre-meltsteelhasbeenusedsuccessfully.Thevacuumre-