1、INJECTION MOLDING注射模塑技術注射模塑技術 = 由由 GE 塑料生產(chǎn)塑料生產(chǎn)PSOPEIPEI/PCPCPPOPC/ABSABSPSLCPPPSPPO/PAPC/PBTPC/ASAASAPPPVCPEPAPOM無定形無定形PET工程級工程級普通級普通級結晶性結晶性高性能高性能Ultem* 樹脂樹脂heat resistanceLexan*樹脂樹脂impact resistanceNoryl*樹脂樹脂impact resistancehydrolytic stabilityprocessabilityCycolac*樹脂樹脂colorability and visualfxXen

2、oy*樹脂樹脂impact resistancechemical resistancePBTGE塑料提供非常廣泛的工程塑料選擇塑料提供非常廣泛的工程塑料選擇Injection Molding Introduction注塑成型介紹GOODPARTMaterial 材料Tooling 模具Processing 工藝Design設計好產(chǎn)品注塑成型介紹生產(chǎn)速度高可以大批量生產(chǎn)人工成本低容易自動化2次加工量小可以生產(chǎn)很小的零件廢品損失小尺寸變化小Molded-in Inserts AvailableGlass, Carbon, etc. FillersComplex Part CapabilityGoo

3、d Decoration Possible注塑成型優(yōu)點注塑成型優(yōu)點Injection Molding IntroductionTooling Costs are HighHigh Machinery and Auxiliary CostsHigh Pressure ProcessLimited Large Part CapabilityDisadvantages of Injection MoldingEquipment設備設備Injection Molding EquipmentInjection Molding EquipmentInjection UnitClamp UnitScrew

4、& BarrelInjection Molding EquipmentThe Injection UnitProvides Injection and Packing PressureProvides Torque to Turn the ScrewThe Screw BarrelMelting and Homogenizing the ResinInjection of the Plastic Into the MoldInjection Molding EquipmentThe Clamping UnitOpen and Closes MoldHolds the Mold Clos

5、ed During InjectionCools and Solidifies PartInjection Molding EquipmentClamping MechanismsDouble Toggle Clamping SystemInjection Molding EquipmentClamping MechanismsHydraulic Clamping SystemMACHINE SHOT SIZE 機器注射容量機器注射容量Part Weight = 30 - 80 % of Machine Shot Size制件重量 = 30 - 80 % 機器注射容量Optimal Part

6、Weight = 40 60 % of Machine Shot Size制件重量 = 40- 60 % 機器注射容量Injection Molding EquipmentCLAMP SIZE 鎖模力鎖模力Material Selection 選料Projected Area 投影面積 35噸/平方英寸Part Design 產(chǎn)品設計Wall Thickness 壁厚Flow Length 流動長度Injection Pressure & Speed 注射壓力和速度Injection Molding EquipmentScrew Type Machines Are Recommende

7、d推薦采用的螺桿類型推薦采用的螺桿類型Uniform Plasticizing 均勻塑化均勻塑化Less Pressure Loss 低壓力損耗低壓力損耗Faster Cycles 更快成型周期更快成型周期Uniform Stock Temperature 均勻儲料溫度均勻儲料溫度Streamlined Melt Flow 線性熔融流動線性熔融流動Injection Molding EquipmentMetering計量計量Feed進料進料Screw and Cylinder Design 螺桿和料筒螺桿和料筒設計設計hf hm L/D = 20:1 (18 24 :1)Compression

8、 Ratio壓縮比壓縮比 = hf / hm =2.5:1 (2.0:1 3 .0:1)Cylinder bi-metallic for Abrasion Resistance 雙金屬料雙金屬料筒筒Transition過渡過渡LDInjection Molding Equipment往復式螺桿頭結構往復式螺桿頭結構檢查環(huán)類型: 止回環(huán)熔融樹脂流過開放檢查環(huán)檢查環(huán)關閉, 防止在注塑過程中料的回流建議采用止逆閥建議采用止逆閥Injection Molding EquipmentStandard Cylinder Nozzles 標準料筒標準料筒噴嘴噴嘴Heating Band加熱環(huán)加熱環(huán)Cylin

9、derBore料筒料筒主體主體To MoldProvides Mechanical and Thermal Connection FromHot Cylinder to Colder Mold提供從熱的料筒到相對冷的模具的機械和熱連接提供從熱的料筒到相對冷的模具的機械和熱連接到模具到模具Injection Molding EquipmentSprue Bushing主流道襯套主流道襯套Nozzle 噴嘴噴嘴Radius 半徑Orifice 主流道孔口Injection Molding EquipmentNozzle 噴嘴噴嘴Land Length 0.0 to 3/16inch(4.76mm)

10、過渡段長度不大于3/16inch(4.76mm)Opening 3/16inch(4.76mm) to 3/8inch(9.52mm) 開口: 4.76 9.52mmSprue Bushing is 0.8mm Larger than Dimension on Nozzle主流道襯套孔口要比噴嘴口徑大0.8mmAs Short as Possible盡可能地短Accurate heating control and Good Heater Band Covering 精確的加熱控制和好的加熱帶覆蓋Injection Molding Equipment通用噴嘴通用噴嘴Injection Mold

11、ing EquipmentGEAM PlasticseInjection Molding ProcessInjection Molding Steps:Drying the PelletsLoading Into Molding MachineHeating and Shearing Material Into a MeltInjecting the Melt Into the Mold CavityPart Cooling, SolidificationEjecting the Finished Part From the MoldProcessing 工藝工藝Start-up: 開機開機:

12、 Purge with the Correct Material 用正確料清洗 Use Correct Processing Conditions 采用正確加工參數(shù)Downtime: 停機停機: Short time: Hold Material in Barrel for 10 15 min 短期： 存料10 15 分鐘 Long time: Clean the Barrel 長期： 用正確方法和次序徹底清理Injection Molding ProcessRecommended Purge Materials推薦清洗料推薦清洗料PolymerPurge MaterialCycolac/Cy

13、coloy PMMA, PS,SANLexan PC, HDPE,PMMANoryl PS,PPInjection Molding ProcessImportant Process Variables 重要加工參重要加工參數(shù)數(shù)Melt Temperature 熔融溫度Mold Temperature 模具溫度Temperature Profiles 溫度曲線Residence Time 停留時間Injection Speed 注射速度Injection Pressure 注射壓力Pack Pressure 保壓Clamp Tonnage 鎖模力Cushion 緩沖料墊Injection Mol

14、ding ProcessDryingDrying temperature and time are an important key factor for good products in our production在生產(chǎn)得到好的產(chǎn)品， 干燥溫度和時間是一重要因素Typical Lexan (PC): 典型PCMoisture Level: Less than 0.02%- 121 0 C/3 4 Hrs水分含量小于0.02% - 121 0 C/3 4 HrsInjection Molding ProcessHow is heat added to the polymer?外熱如何作用于高

15、分子材料外熱如何作用于高分子材料Electrical Heat: 電加熱電加熱Heater Bands 加熱帶Mechanical Heat 機械熱機械熱Screw Speed 螺桿速度Back Pressure 背壓Injection Pressure / Speed 注射速度/壓力Injection Molding ProcessModel of Amorphous PolymersAdding Heat Increases Space Between Molecular ChainsRaise Temperature of Polymer TGLocked 固態(tài)固態(tài)Entanglemen

16、tsStiff Flow難于流動難于流動Easier Flow 較易流動較易流動Injection Molding ProcessMelt Temperature 熔融溫熔融溫度度35302520151050.030.060.090.120.150.180.210.240Wall Thickness in Inches壁厚(In)MeltFlow(in.)LEXAN?101550 deg F.101 600 deg. FIncreased Melt Temperature yields increased Flow.提高熔融溫度導致增加流動However, Too High a Melt Te

17、mperature May Cause Degradation.但,過高熔融溫度造成降解Injection Molding VariablesInjection Molding EquipmentResidence TimeTo measure this, colored pellets are dropped into the base of the hopper. Time is measured until the point when colored extrudant is purged from the nozzle. The amount of time that molten

18、material resides in the barrel.Residence time min = (2.22.5)Max Plasticising strokePlasticising stroke - cushion* Cycletime60Thermoplastics and Degradation熱塑性塑料和降解熱塑性塑料和降解Degradation 降解降解TemperatureTime 時間時間Injection Molding ProcessBarrel UnitThe Reciprocating Screw(Filling) ThroatHeating CoilsNozzl

19、eHopperScrewBarrelForce, TorqueFrom Injection Unit料筒組件料筒組件回轉式螺桿回轉式螺桿噴嘴螺桿加熱料斗加料口料筒來自注塑單元的力和力矩Injection MoldingScrew Rotation Feeds and ShearsMaterial Into a Melt. Melt Collects Into Front of Barrel, Forcing Screw BackShotRotation and Back Pressure出量通過螺桿回轉，熔體聚集于料筒前部，反作用力使螺桿后退。回轉力矩和背壓Injection MoldingB

20、arrel UnitThe Reciprocating Screw15010050255075125150100Screw Dia in mmRPMSCREW SPEED Suggestions(8in/sec)推薦螺桿轉速推薦螺桿轉速螺桿直徑轉速Injection MoldingMelt Required to Fill Mold Ready for InjectionShotInjection Pressure注射壓力注射壓力Injection Molding EquipmentBarrel UnitThe Reciprocating ScrewScrew Pushes Forward:

21、InjectCushionPacking Pressure緩沖墊緩沖墊保壓保壓注射注射Injection Molding EquipmentBarrel UnitThe Reciprocating ScrewInjection Speed 注射速度注射速度100010010100100010000LEXAN?141 644 deg FLEXAN?141 608 deg FLEXAN?141 572 deg FApparentViscosity(Pa/s)Shear Rate (1/s)Injection Speed affects the viscosity of the molten mat

22、erial.注射速度影響熔體粘度表觀粘度表觀粘度剪切速率剪切速率Injection Molding VariablesInjection Pressure Profile 注射壓力曲線注射壓力曲線HydraulicPressureTimeFill TimeScrew Run TimeBack PressurePeak Injection PressurePressure Applied by Injection Ram to Force the Plastic From the Barrel to the Mold.注射壓力峰值注射壓力峰值液液壓壓壓壓力力填充時間Injection Moldi

23、ng VariablesCushion 緩沖墊緩沖墊CushionMaterial remaining in barrel whenthe ejection phase is completed.注塑過程結束后，殘于料筒注塑過程結束后，殘于料筒前端的熔體前端的熔體The injection molding process should allow a cushion to provide sufficient packing pressure in the mold注塑過程必須要有緩沖墊以保注塑過程必須要有緩沖墊以保證有效的保壓證有效的保壓Injection Molding Variables

24、Injection Flow熔體流動熔體流動Injection Molding ProcessInjection Molding ProcessInjection Flow熔體流動熔體流動Injection Molding ProcessInjection Flow熔體流動熔體流動Injection Molding ProcessInjection Flow熔體流動熔體流動Injection Molding ProcessInjection Flow熔體流動熔體流動Mold Tempeature 模溫模溫Mold Temperature is critical in producing qua

25、lified part.模溫對得到合格的制件很重要Injection Molding ProcessPart Cooling and SolidificationHot MeltCooled MoldSolid Part制件冷卻和固化制件冷卻和固化熱熔體溫度較低的模具固化的制件Injection Molding ProcessMold Temperature 模溫模溫Mold Temperature is critical in glossary and residue strain of part模溫對制件的光潔度和模塑殘余應力等級很重要Uniform mold temperature re

26、duces the effects of warpage.均勻的模溫可以減少翹曲Commonly controlled by water cooling channels.模溫通常冷卻水孔道來控制Injection Molding CoolingInjection Molding Cooling120125125135135145130140140130150145OOOOOOOOOOOOINOUTInjection Molding CoolingMOLDThe Mold Temperature Must Be Below TG to Solidify PartTGProcessingTemp

27、eratureRangeDegradationCooling: Amorphous Resin 無定型塑料的冷卻無定型塑料的冷卻降解加工溫度范圍模具溫度必須低于玻璃化轉變溫度Injection Molding CoolingDegradationTMTGProcessingTemperatureRangeMold Temperature Determines Cooling Time and Therefore Degree of Crystallinity 模溫決定了冷卻時間和結晶度Cooling Through the Crystallinization Range Too Quickly

28、 Will Result in Reduced Crystallinity (Quenching) 過快冷卻將造成結晶度低Crystallinization Cooling Range結晶性塑料的冷卻結晶性塑料的冷卻Injection Molding CoolingInjection Molding EjectionREGRIND SUGGESTIONS對材料回收使用的建議 Use Only Clean Non-degraded 只使用未降解材料只使用未降解材料 Uncontaminated Resin for Regrind回收料不能有污染回收料不能有污染 Keep It As New Ma

29、terial要象保存新料一樣要象保存新料一樣 Normally 25% of Regrind can be Used通常允許添加通常允許添加25%的回收料的回收料 Screen Sizes should be 7 to 9 mm過濾網(wǎng)應該在過濾網(wǎng)應該在7至至9MMInjection Molding RegrindTen Do for Molding Engineering Resins Know Your Material 了解你所使用了解你所使用的材料的材料 Dry Properly 正確地干燥正確地干燥 Use Recommended Processing Conditions 使用推薦的

30、加工參數(shù)使用推薦的加工參數(shù) Use Properly Sized Equipment 選擇恰當?shù)脑O備選擇恰當?shù)脑O備 Use Properly Designed Tooling 正確設計模具正確設計模具 Use Adequate Runners 澆口尺寸充分澆口尺寸充分 Use Proper Venting 良好的排氣良好的排氣 Use Nozzles with Proper Heat Controls 對噴嘴施以良好的溫對噴嘴施以良好的溫控控 Use Proper Screw Design 恰當?shù)穆輻U結構恰當?shù)穆輻U結構 Schedule Annual or Bi-Annual Equipmen

31、t Maintenance 正確維護正確維護保養(yǎng)設備保養(yǎng)設備十大準則十大準則Injection MoldingInjection MoldingQ & ADISCLAIMER: THE MATERIALS AND PRODUCTS OF THE BUSINESSES MAKING UP THE GE ADVANCED MATERIALS UNIT OF GENERAL ELECTRIC COMPANY, ITS SUBSIDIARIES AND AFFILIATES (“GEAM”), ARE SOLD SUBJECT TO GEAMS STANDARD CONDITIONS OF S

32、ALE, WHICH ARE INCLUDED IN THE APPLICABLE DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, GEAM MAKES NO WARRANTY OR GUARANTEE, EX

33、PRESS OR IMPLIED, (I) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (II) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING GEAM MATERIALS, PRODUCTS, RECOMMENDATIONS OR ADVICE. EXCEPT AS PROVIDED IN GEAMS STANDARD CONDITIONS OF SALE, GEAM AND ITS REPRESEN

34、TATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS RESULTING Flame Retardant OR ANY USE OF ITS MATERIALS OR PRODUCTS DESCRIBED HEREIN. Each user bears full responsibility for making its own determination as to the suitability of GEAMs materials, products, recommendations, or advice for its own particular use. Each us