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成型工藝流程及條件介紹
成型工藝流程及條件介紹Molding technique procedure and parameter introduction第一節 成型工藝Section 1 molding technique.1.成型工藝參數類型Sorts of molding parameter.(1).注塑件參數※※※※ction parameter.a.注射量※※※※ction rate.b.計量行程Screw back positionc.余料量Cushiond.防誕量Sucking back ratee.螺桿轉速Screw speedf.塑化量Plastic0 rateg.預塑背壓Screw back pressureh.注射壓力和保壓壓力※※※※ction pressure and holding pressurei.注射速度※※※※ction speed(2)合模參數Clamping parametera.合模力Clamping forceb.合模速度Clamping speedc.合模行程.Clamping stroked.開模力Opening forcee.開模速度Opening speedf.開模行程Opening positiong.頂出壓力Ejector advance pressureh.頂出速度Ejector advance speedi.頂出行程Ejector advance position2.溫控參數Temperature parametera.烘料溫度Dry resin material temperatureb.料向與噴嘴溫度Cylinder temperature and nozzle temperaturec.注塑件模具溫度Mold temperatured.油溫Oil temperature3.成型周期Molding cyclea.循環周期Cycle timeb.冷卻時間Cool timec.注射時間※※※※ction timed.保壓時間Holding pressure timee.塑化時間Plant timef.頂出及停留時間Knocking out and delay timeg.低壓保護時間Mold protect time成型工藝參數的設定須根據產品的不同設置.Molding technique parameter setting differs depending on type of product第二節成型條件設定Section 2 Molding parameter Setting按成型步驟:可分為開鎖模,加熱,射出,頂出四個過程.Molding steps: mold opening/closing, heating ※※※※ction and knocking out.開鎖模條件:Mold opening parameter:快速段中速度低壓高壓速度High-speedmid-speedLow pressure high pressure speed鎖模條件設定:Mold closing parameter setting1鎖模一般分:快速→中速→低壓→高壓Mold closing: high-speed →low-speed →low pressure→high pressure2.快鎖模一般按注塑件模具情況分,如果是平面二板注塑件模具,快速鎖模段可用較快速度,甚至于用到特快,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%,壓力則可設定于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.In high-speed section, Mold closing speed depends on type of mold. For two –plate mold it can set quick and even especially quick usually, it set speed within 55-75%. For full-plate mold it set speed within80-90% while using especially high speed it set speed within 45-55% and pressure within 50-75% position distance setting differs depending on the volume of product and usually it can be set 1/3 of mold opening position.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.In mid-speed section: Mold closing speed changes into mid-speed after high-speed section finish. Mid-speed start position is where two plates meet (include three-plate mold and two-plate mold ) Distance of mid-speed is up to distance of two plates plate it speed within 30-50% and pressure 20-45%.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,,即于此點則起不了高壓,高于此點則大,輕易起高壓.設定的速度一般是15%-25%,視乎不同機種而定,壓力一般設定于1-2%,有些機則可設于5-15%,也是視乎不同機種不同.Low-pressure section: Mold closing sets low-pressure when plates meeting. This position is set to the data of machine screen on this time. This point is the gage of the data. Data lower the point there is no high-pressure. Data higher the point there is high-pressure easily. It set speed within 15-25% and pressure within 1-2% depending on type within 1-2% depending on type of ※※※※ction molding machine.5.高壓設定,按一般機臺而言,高壓位置機臺在出注塑件加工時都已作了設定,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,而壓力則視乎注塑件模具而定,可在55-85%中取,比如完全平面之新模,注塑件模具排氣良好,甚至于設在55%即可,如果是滑塊較多,原來生產時毛邊也較多,甚至于可設在90%還略顯不足.High-pressure section: To normal ※※※※ction molding machine, high-pressure position had been set before they were sent to customer. It can not be modified. For example high-pressure position of CHENHSONG machine is 50P.The speed of high-pressure section is about 30-35% and higher than that of low-pressure. The pressure is up to mold, it can set within 55-85% For full-plate mold, it’s eject air well, it can set pressure 55% .If mold has a lot of slides and flash rate high in production, pressure can set 90%.加熱工藝條件設定Heating technique parameter setting1.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10.度為單位.The proper temperature setting differs depending on type of resin material, but it must be abide by a rule that temperature setting should diminish in step 10.C from nozzle to feeding resin material position.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10度.比如PPS.尼龍等.Nozzle temperature setting should low if product line. If resin material such asPPS, PA, cool very soon , Nozzle temperature should higher more 10.C than the second cylinder temperature.3.機臺馬達啟動溫度視乎機臺不同而不同,一般出于對機臺油路中的油封保護需要,油溫最好能控制在40度-60度,以免油封長期高壓而變化,縮短使用壽命,造成成型不穩定.Pump turning on temperature is different depending on type of ※※※※ction molding machine. To protect oil seal of machine it set oil temperature within 40.C-60.C, If oil seal work on condition that high pressure and damaged It’s work time will be shorter, it can cause molding stable. 第三節注射及熔膠(加料)工藝條件設定※※※※ction and plastic Technique parameter setting一.注射※※※※ction第四節常見塑料原料的有關溫度值.原料Resin名稱Name熔點℃Melt’s成型溫度℃Molding Temperature(’c)分解溫度℃Decomposing Temperature(‘C)注塑件模具溫度℃Mold Temperature(‘c)干燥溫度℃Resin dry temperature(‘c)注射是把塑料原料經加熱后射進模腔的過程,它一般可分為第一級,第二級,第三級,第四級及保壓幾段:※※※※ction is a step which ※※※※ct melt resin material into mold. It consists of stepl,step2 ,step3,step4 and holding pressure step:1.第一級注射一般是注射料頭段.具注射量一般可根據料頭的輕重來估計其行程,當然也可以依據公式來計算,如公式:Step l ※※※※cts usually tunnel material, ※※※※ction Volume can be estimated according to the weight of course it can be calculated by formula:L=Si=Vi/0.785Ds2L:注射行程; Si:注射行程;L: ※※※※ction stroke Si: ※※※※ction strokeVi:理論注射容積; Ds:螺桿直徑;Vi: ※※※※ction volume of theoretical Ds: diameter of screw0.785:是Ω/4的值.0. 785: value ofΩ/4.當然,如果我們在成型時每設定一個參數都要計算一次,要成型出一個產品就要幾個小時才能完成了.But it cost a lot of time to produce one product if every time molding parameter is setting by calculation.2.第二級是注塑件產品約2/3的階段,當然,根據產品特殊需要,也允許成型不到2/3階段,比如避免結合線問題,這一階段的成型速度及壓力一般是整個成型段的最大值段,如果排的產品與機臺基本是相吻合的.注塑件模具結構合理,排氣良好,這一段的壓力一般也不會超過80%.速度側視產品需變,可能大到95%也可,自然一般都是在55%-80%間.Step 2 ※※※※ct 2/3 of product. It can lower 2/3 of product according to requirement of product. For example to prevent weld line. Molding speed and pressure on this step is the maximum of whole molding section. If Mold suit the ※※※※ction molding machine and mold structure reasonable and eject air well, pressure of this step should lower 80%. Molding speed setting within 55-80% but it may setting 95% for especial product.3.第三段是注射余下的1/3段,其速度和壓力根據產品的需要,一般是小于第二段,速度和壓力存在于一個往下降的過程.主要是為了防止產品毛邊的產生,但同時又必須把產品充填飽滿.Step3 ※※※※ct remain 1/3 of product. According to product molding speed and pressure lower than that of step2 To prevent flash speed and pressure should decrease but it can’t shot short.4.第四段:一般有機臺還有第五,第六段,這段的成型速度和壓力相同前,都存在兩段一個遞減過程.其作用都是起到一個再次充滿的作用.Step4 section: Some ※※※※ction machines have step5,step6 which are same as former molding speed and pressure this step should diminish and ※※※※ct once more.5.保壓段:不論成型什么產品,都存在一個保壓過程.任何產品都不同程度的存在一個厚薄不一的問題,正常情況下,較厚的部分都可能存在一個收縮凹陷的現象,為了解決這種現象,就應應用到保壓,保壓一般來講都應用較慢的射速,而壓力的設置則應看縮水的情況如何,小到25%,大到80%都有可能.Holding pressure step: No matter what product there is a holding pressure step. Any product can’t molding a same thickness. Usually the deeper section may sink mark . To prevent this defect it should set holding pressure, The ※※※※ction speed of holding pressure step is slow but holding pressure setting within 25-80% depending on sink mark.二.熔膠段工藝Plastic Technique1.再復雜的熔膠旋轉過程最多不會超過三段,因為熔膠本身就是存在于把膠熔進料筒的過程,如果原料粘度大,熔膠壓力則大,但速度則應取決于原料的分解溫度,熔膠速度越快,原料中的剪切力則會越大,料管溫度則越高,局部原料產生分解的可能性則會越大,故一般熔膠會采用中速為宜,如45%-75%,熔膠同時會碰到一個比較重要的環節,那就是背壓的使用,產品精度要求越大,背壓的使用則更大,背壓可使原料分子間結構更緊密,成型出的產品則尺寸更穩定,外觀越好.當然,背壓太大,則會產生流涎,所以背壓的使用又應考虙到其它原因.Plastic should lower 3 steps, because plastic is a step to add melt resin material to cyclinder , Higher stick of resin material ,higher screw back pressure. Screw speed differs depending on decomposing temperature of resin material ,Higher screw speed ,Higher trim force of resin, higher cyclinder temperature. Some resin material may decomposes so it set screw speed in mid-speed such as 45-75%, In plastic step setting screw back pressure is very important, Higher screw back pressure ,higher quality of product screw back pressure make resin structure order, Molding product is beautiful and volume stable. But ,it maybe flow if screw back pressure too high . So all factors should be considered when using screw back pressure.2.熔膠過程還有一個比較重要的環節,那就是松退,松退分前松退和后松退,其作用一般是為了防止流涎和抽絲,設定值速度和壓力都在20%-50%間,設定的行程一般在2-5cm間,太長的行程可能會使料筒里面貯存空氣,導致下一模出現不期望的氣泡.In plastic step sucking back is very important too. Sucking back include front sucking back and back sucking back It setting sucking back to prevent flow and line. It sets sucking back speed and pressure within 20-50% and distance within 2-5cm. TOO long distance make cyclinder reserve air and cause bubble at next molding.頂出的工藝設定knocking out technique setting產品經冷卻定型后則有一個開模的過程,開模基本上是合模的反過程.開模的未段則有一個慢速設置,開模完成后,產品必須頂出的過程.There is a mold opening step after product cooling taking shape. Mold opening is a reverse step of mold closing. The last step of mold opening speed set slow. Product should be knocked out after mold opened.一.頂前:Knocking out頂前最好分兩個階級,第一階可分為中壓慢速,即是把產品輕輕頂出一部分,然后是中壓中速頂,中壓中速一般指的是35%-55%,而低速則有可能低到5%,這需視產品不同而言,頂出行程設定是頂出長度稍比產品垂直深度大1-2cm即可.Knocking out includes two steps, Step1 section setting mid-speed, knocks product out partly step2 section setting mid-pressure and mid-speed . Depending on different product, mid-pressure and mid-speed sets within 35-55% but low-speed can set 5%. Distance of knocking out longer 1-2cm than the vertical thickness of product.二.退針Back頂退包括兩個過程與頂落的過程基本一致,頂退的終點應預留1-3cm的空間,以保護頂針油管不被頂壞.The same as knocking out, ejector back includes 2 steps. To protect the ejector oil jar, it should make a 1-3mm distance in the ending point of ejector back.三.頂針方式還包括一個多次頂,單次頂及頂針停留的選擇,機械手取產品,脫模順利的情況都采取多項,為了頂針油缸 壽命的延長,多次頂就以不超過三次為宜,頂針停留一般用在頂針帶著產品退回有可能對增品產生損傷的注塑件模具,同時為配合機械手使用,有時也需要較短的頂針停留.The way of knocking out includes knocking out once, Knocking out repeat and ejector delay. Take product by manipulator or take product easy, it should select knocking out once. To longer the work time of ejector oiljar, times of knocking out lower 3 times. Ejector delay used when product will be damaged if ejector back or suit manipulator.成型時間的設定Molding time setting在保證產品質量的前提下,周期時間是越短越好,周期時間又包括如下幾項:射膠時間,保壓時間,熔膠時間,冷卻時間,頂出時間,鎖模低壓時間,甚至乎關系到時間因素的還有還開模與鎖模,及頂出的快慢.Cycle time should shorter on condition that product quality well. Cycle time includes: ※※※※ction time , holding pressure time, plastic time, cure time, knocking out time and mold protect time. Even mold opening closing sopeed and knocking out speed affect cycle.1.射膠時間包含保壓時間,一般看起來,射膠時間越長,產品越飽和,但我們在講求質量時,同時也須考慮產能,更何況,射膠時間過長,有可能會造成產品過于飽滿而尋致粘模頂的變形呎寸偏大等一系列問題,故我們在設置射膠時間時應綜合考慮,盡量在合乎質量要求時縮短射膠時間.※※※※ction time consists holding pressure time. Longer ※※※※ction time, fuller product, we should consider production quantity when we suit for quality. If ※※※※ction time too long, it may cause a series of defects suck as flash strain. So all sorts of factors should be considered, ※※※※ction time should be shout if quality suit for requirement.2.熔膠時間的長短取決于熔膠速度設定的快慢,背壓設定的大小,但有一點,熔膠時間控制的長短一定要比冷卻時間短.Plastic time depends on plastic speed and screw back pressure, but plastic time must shorter than cure time.3.冷卻時間:冷卻時間的長短直接影響到成型的周期,冷卻時間越長,成型時間就越長,造成產能就越低,故我們在設定高壓冷卻時間時,只要能保證到產品成型順利,不會直接影響到變形等問題,設定的時間也是越短越好.Cure time: Cure time affects molding cycle. Longer cure time, longer molding cycle, lower production quantity. So it sets cure time short on condition that product molding succed and can’t deformation..4.在大量使用機械手的塑膠公司,我們的頂出時間一般是與機械手配合為宜,全自動使用機械手時頂出停留時間一般保持1.5-2秒,半自動生產,如因頂針退回會導致產品掉落或卡緊,而取不下產品,停留時間則應保持5秒左右.In PCE company, for using manipulator in abundence , knocking out time suits manipulator, Knocking out delay keeps 1.5-2 second when using manipulator full-manipulator, knocking out delay keeps about 5 second when using manipulator semi-manipulator and product will fall or can’t be taken off if ejector back.5.低壓保護時間對保護我們人身安全,注塑件模具安全起很大作用,配合好注塑件模具低壓位置和低壓壓力的調整,低壓保護的時間應取1-3秒,保護時間越短,可能造成的危害則越小.Low-pressure protect is very important for safety and protect mold, Mold protect time should adjust within 1-3 second suit low pressure and position of mold protect, shorter protect time, make damaged
