注塑成型介绍

INJECTIONMOLDING注射模塑技术=由GE塑料生产PSOPEIPEI/PCPCPPOPC/ABSABSPSLCPPPSPPO/PAPC/PBTPC/ASAASAPPPVCPEPAPOM无定形PET工程级普通级结晶性高性能Ultem*树脂heatresistanceLexan*树脂impactresistanceNoryl*树脂impactresistancehydrolyticstabilityprocessabilityCycolac*树脂colorabilityandvisualfxXenoy*树脂impactresistancechemicalresistancePBTGE塑料提供非常广泛的工程塑料选择InjectionMoldingIntroduction注塑成型介绍GOODPARTMaterial材料Tooling模具Processing工艺Design设计好产品注塑成型介绍生产速度高可以大批量生产人工成本低容易自动化2次加工量小可以生产很小的零件废品损失小尺寸变化小Molded-inInsertsAvailableGlass,Carbon,etc.FillersComplexPartCapabilityGoodDecorationPossible注塑成型优点InjectionMoldingIntroductionToolingCostsareHighHighMachineryandAuxiliaryCostsHighPressureProcessLimitedLargePartCapabilityDisadvantagesofInjectionMoldingEquipment设备InjectionMoldingEquipmentInjectionMoldingEquipmentInjectionUnitClampUnitScrew&BarrelInjectionMoldingEquipmentTheInjectionUnit•ProvidesInjectionandPackingPressure•ProvidesTorquetoTurntheScrewTheScrewBarrel•MeltingandHomogenizingtheResin•InjectionofthePlasticIntotheMoldInjectionMoldingEquipmentTheClampingUnit•OpenandClosesMold•HoldstheMoldClosedDuringInjection•CoolsandSolidifiesPartInjectionMoldingEquipmentClampingMechanismsDoubleToggleClampingSystemInjectionMoldingEquipmentClampingMechanismsHydraulicClampingSystemMACHINESHOTSIZE机器注射容量PartWeight=30-80%ofMachineShotSize制件重量=30-80%机器注射容量OptimalPartWeight=40~60%ofMachineShotSize制件重量=40-60%机器注射容量InjectionMoldingEquipmentCLAMPSIZE锁模力MaterialSelection选料ProjectedArea投影面积3~5吨/平方英寸PartDesign产品设计WallThickness壁厚FlowLength流动长度InjectionPressure&Speed注射压力和速度InjectionMoldingEquipmentScrewTypeMachinesAreRecommended推荐采用的螺杆类型•UniformPlasticizing均匀塑化•LessPressureLoss低压力损耗•FasterCycles更快成型周期•UniformStockTemperature均匀储料温度•StreamlinedMeltFlow线性熔融流动InjectionMoldingEquipmentMetering计量Feed进料ScrewandCylinderDesign螺杆和料筒设计hfhm•L/D=20:1(18~24:1)•CompressionRatio压缩比=hf/hm=2.5:1(2.0:1~3.0:1)•Cylinderbi-metallicforAbrasionResistance双金属料筒Transition过渡LDInjectionMoldingEquipment往复式螺杆头结构检查环类型:止回环熔融树脂流过开放检查环检查环关闭,防止在注塑过程中料的回流建议采用止逆阀InjectionMoldingEquipmentStandardCylinderNozzles标准料筒喷嘴HeatingBand加热环CylinderBore料筒主体ToMoldProvidesMechanicalandThermalConnectionFromHotCylindertoColderMold提供从热的料筒到相对冷的模具的机械和热连接到模具InjectionMoldingEquipmentSprueBushing主流道衬套Nozzle喷嘴Radius半径Orifice主流道孔口InjectionMoldingEquipmentNozzle喷嘴•LandLength0.0to3/16inch(4.76mm)•过渡段长度不大于3/16inch(4.76mm)•Opening3/16inch(4.76mm)to3/8inch(9.52mm)•开口:4.76~9.52mm•SprueBushingis0.8mmLargerthanDimensiononNozzle主流道衬套孔口要比喷嘴口径大0.8mm•AsShortasPossible尽可能地短•AccurateheatingcontrolandGoodHeaterBandCovering精确的加热控制和好的加热带覆盖InjectionMoldingEquipment通用喷嘴InjectionMoldingEquipmentGEAMPlasticseInjectionMoldingProcessInjectionMoldingSteps:•DryingthePellets•LoadingIntoMoldingMachine•HeatingandShearingMaterialIntoaMelt•InjectingtheMeltIntotheMoldCavity•PartCooling,Solidification•EjectingtheFinishedPartFromtheMoldProcessing工艺Start-up:开机:•PurgewiththeCorrectMaterial用正确料清洗•UseCorrectProcessingConditions采用正确加工参数Downtime:停机:•Shorttime:HoldMaterialinBarrelfor10~15min短期：存料10~15分钟•Longtime:CleantheBarrel长期：用正确方法和次序彻底清理InjectionMoldingProcessRecommendedPurgeMaterials推荐清洗料PolymerPurgeMaterialCycolac/CycoloyPMMA,PS,SANLexanPC,HDPE,PMMANorylPS,PPInjectionMoldingProcessImportantProcessVariables重要加工参数•MeltTemperature熔融温度•MoldTemperature模具温度•TemperatureProfiles温度曲线•ResidenceTime停留时间•InjectionSpeed注射速度•InjectionPressure注射压力•PackPressure保压•ClampTonnage锁模力•Cushion缓冲料垫InjectionMoldingProcessDryingDryingtemperatureandtimeareanimportantkeyfactorforgoodproductsinourproduction在生产得到好的产品，干燥温度和时间是一重要因素TypicalLexan(PC):典型PCMoistureLevel:Lessthan0.02%----1210C/3~4Hrs水分含量小于0.02%------1210C/3~4HrsInjectionMoldingProcessHowisheataddedtothepolymer?外热如何作用于高分子材料ElectricalHeat:电加热HeaterBands加热带MechanicalHeat机械热ScrewSpeed螺杆速度BackPressure背压InjectionPressure/Speed注射速度/压力InjectionMoldingProcessModelofAmorphousPolymersAddingHeatIncreasesSpaceBetweenMolecularChainsRaiseTemperatureofPolymerTGLocked固态EntanglementsStiffFlow难于流动EasierFlow较易流动InjectionMoldingProcessMeltTemperature熔融温度35302520151050.030.060.090.120.150.180.210.240WallThicknessinInches壁厚(In)MeltFlow(in.)LEXAN?[e-mail]eyieldsincreasedFlow.提高熔融温度导致增加流动However,TooHighaMeltTemperatureMayCauseDegradation.但,过高熔融温度造成降解InjectionMoldingVariablesInjectionMoldingEquipmentResidenceTimeTomeasurethis,coloredpelletsaredroppedintothebaseofthehopper.Timeismeasureduntilthepointwhencoloredextrudantispurgedfromthenozzle.Theamountoftimethatmoltenmaterialresidesinthebarrel.Residencetime[min]=(2.2~2.5)MaxPlasticisingstrokePlasticisingstroke-cushion*Cycletime60ThermoplasticsandDegradation热塑性塑料和降解Degradation降解TemperatureTime时间InjectionMoldingProcessBarrelUnitTheReciprocatingScrew(Filling)ThroatHeatingCoilsNozzleHopperScrewBarrelForce,TorqueFromInjectionUnit料筒组件回转式螺杆喷嘴螺杆加热料斗加料口料筒来自注塑单元的力和力矩InjectionMoldingScrewRotationFeedsandShearsMaterialIntoaMelt.MeltCollectsIntoFrontofBarrel,ForcingScrewBackShotRotationandBackPressure出量通过螺杆回转，熔体聚集于料筒前部，反作用力使螺杆后退。回转力矩和背压InjectionMoldingBarrelUnitTheReciprocatingScrew15010050255075125150100Scr