模具設(shè)計(jì)的優(yōu)先順序PrioritiesofMoldDesign澆注系統(tǒng)設(shè)計(jì)

(FillingSystemDesign)排氣系統(tǒng)設(shè)計(jì)

(VentingSystemDesign)冷卻系統(tǒng)設(shè)計(jì)

(CoolingSystemDesign)脫模系統(tǒng)設(shè)計(jì)

(EjectingSystemDesign)澆注系統(tǒng)設(shè)計(jì)的優(yōu)先順序PrioritiesofFillingSystemDesign產(chǎn)品設(shè)計(jì)(PartDesign)型腔設(shè)計(jì)(CavityDesign)澆口設(shè)計(jì)(GateDesign)流道設(shè)計(jì)(RunnerDesign)噴嘴設(shè)計(jì)(NozzleDesign)豎澆道Sprue主流道MainRunner成品Part澆口Gate冷料井ColdSlugWell支流道BranchRunner典型的澆注系統(tǒng)TypicalFillingSystem壁厚不均是注塑成型中最大的麻煩製造者。這對(duì)薄壁產(chǎn)品尤然。這些麻煩包括了遲滯現(xiàn)象、短射、凹陷、發(fā)赤、噴流、翹曲及長(zhǎng)冷卻時(shí)間等；目前都可用CAE以直接或間接的方式預(yù)測(cè)。Non-uniformwallthicknessisthebiggesttroublemakerinplasticinjectionmolding.Thisisespeciallytruetothin-wallpart.Thetroubles,includinghesitation,shortshot,sinkmark,blush,jetting,warpageandlongcoolingtimeetc.,canbepredicted,directlyorindirectly,byusingCAE.壁厚不均

Non-uniformWallThickness壁厚設(shè)計(jì)WallThicknessDesign差[Poor]較好[Better]最好[Best]掏空設(shè)計(jì)(1)CoringOutDesign(1)改進(jìn)設(shè)計(jì)[Improved]原設(shè)計(jì)[Original]差[Poor]改進(jìn)[Improved]掏空設(shè)計(jì)(2)CoringOutDesign(2)氣泡或/和凹陷的形成Voidor/andSinkMarkForming氣泡(Void)凹陷(SinkMark)肋厚和內(nèi)圓角半徑的影響TheEffectofRibThickness&FilletRadius肋的底部厚度BottomThicknessofRibW0.5W2.5WW1.2WD1.5WD(A)(B)肋的設(shè)計(jì)計(jì)(1)RibDesign(1)t =wallthichnessB=0.5tC =3tAAD=2BE=0.13mm(radius)F=1.5-2deg假如需要更大的強(qiáng)度,可增加肋的數(shù)目Ifmorestrengthisrequired,addadditionalribs.FBDECt肋的設(shè)計(jì)計(jì)(2)RibDesign(2)肋的設(shè)計(jì)計(jì)(3)RibDesign(3)與側(cè)壁相相連之凸凸轂(熱塑性性塑膠)BossatWall(Thermoplastics)A =凸轂附著處壁厚 wallthicknessB =凸轂外環(huán)直徑 dia.ofbossoverradiiC =0.5AD =2BE =1~2degF =0.13mm(radius)G =DH =0.8AI =A/4J =2BK =0.3~1JL =0.5ALHA'A'KEIGJDAFCBSectionA'-A'遠(yuǎn)離側(cè)壁壁之凸轂轂(熱熱塑性塑塑膠)BossAwayFromWall(Thermoplastics)A =凸轂附著處壁厚 wallthicknessB =凸轂外環(huán)直徑

(含底部修整圓弧半徑) dia.ofbossoverradiiC=0.5AD=2BE =1-2degF =0.13mm(radius)G=0.95DH=0.3Gmin.toGmax.I =0.5AHEFDFGCBAI外側(cè)凸轂轂OutsideBossA'A'A(DIA)BB=AB=2A(max.)SectionA'-A'Where1/r :樑的曲率

curvatureofthebeamM :彎曲力矩

bendingmomentE :彈性模數(shù)

modulusofelasticityI :斷面積對(duì)中立軸的慣性矩

momentofinertiaofthecross-sectionalareawithrespecttotheneutralaxisEI :撓曲剛性flexuralrigidity撓曲剛性性FlexuralRigidityAvarietyofmolded-ininterlockscanaddstiffnesstothin-wallhousingdesigns.各種一體體成型的的內(nèi)鎖件件能增加薄薄殼的剛剛性。結(jié)構(gòu)設(shè)計(jì)計(jì)是薄殼殼成型零零件的基基礎(chǔ)。Structuraldesignisthebaseofthin-wallmoldingparts.薄殼成型型產(chǎn)品不不僅僅是是一趨勢(shì)勢(shì)，而且且也是降降低成本本和提高高競(jìng)爭(zhēng)力力的有效效途徑。。Thin-wallmoldingpartisnotonlyatrendbutalsoaneffectivewaytoachievecostreductionandcompetitivenessincrease.結(jié)構(gòu)設(shè)計(jì)計(jì)和薄殼殼成型產(chǎn)產(chǎn)品StructuralDesign&Thin-wallMoldingParts熔膠波前前推進(jìn)Melt-FrontAdvancement充填模式式,積風(fēng)風(fēng)和熔接接線FillingPatterns,Air-TrapsandWeldLinesLocation熔接線WeldLines材料[Material]:PC-GF50原設(shè)計(jì)[Original]更改設(shè)計(jì)計(jì)[Revised]更改澆口口位置以以重新定定位熔接接線WeldLinesCanBeRelocatedByChangingGateLocation典型對(duì)頭頭熔接線線伸張強(qiáng)強(qiáng)度保留留值TypicalButtWeldTensileStrengthRetentionValues熔接線冷冷料井WeldSlugWell對(duì)頭熔接接線[Buttweld]熔接線冷冷料井[Weldslugwell]積風(fēng)AirTraps排氣Vent大部份熱塑性塑膠MostThermoplastics A0.08mm B3.18mm C12.7mm D0.25mm耐隆和聚縮醛

(POM)NylonandAcetal(POM) A0.04mm B3.18mm C12.7mm D0.25mm進(jìn)料流道FeedRunner塑膠成品PlasticPartAD排氣孔VentBSEC.A'-A'CA'A'每增加一一個(gè)澆口口，至少少增加一一條熔接接線，同同時(shí)增加加一個(gè)澆澆口痕跡跡、增加加流道的的體積以以及增加加較多的的積風(fēng)。。Everytimeonegateisadded,oneweldline,atleast,onegatemark,morerunnervolumeandmoreairtrapswillbeadded.在型腔能能夠完滿滿充填的的前提下下，澆口口數(shù)目是是愈少愈愈好。Aslongasthecavityisabletobefilledappropriately,gatesarethelessthebetter.為了減少少澆口數(shù)數(shù)目，每每一澆口口應(yīng)就塑塑流力所所能及的的流長(zhǎng)/壁厚比比之內(nèi)，，找出可可以涵蓋蓋最大產(chǎn)產(chǎn)品面積積的進(jìn)澆澆位置。。Inordertoreducethenumberofgates,eachgateshallbelocatedatwherethemeltisabletocovermaximumpartareabasedonthelargestmeltflowlength/thicknessratio.澆口數(shù)目目TheNumberofGates充填均衡衡FlowBalance熔膠波前前於同一一時(shí)間抵抵達(dá)型腔腔各末端端。Meltfrontreachestheendsofcavityatthesametime.洗衣衣機(jī)機(jī)圈圈板板洗衣衣機(jī)機(jī)圈圈板板冷氣氣通通風(fēng)風(fēng)飾飾罩罩-原原始始設(shè)設(shè)計(jì)計(jì)Air-conditionerGrille-Original18gatespressure:76MPa冷氣通風(fēng)風(fēng)飾罩-修正設(shè)設(shè)計(jì)Air-conditionerGrille-Revised8gatespressure:75MPa分析結(jié)果果比較表表ComparisonofAnalysisResults十二澆口口設(shè)計(jì)12GateDesign原始設(shè)計(jì)OriginalDesign電子零件置物箱材料Material：ABS四澆口設(shè)設(shè)計(jì)4GateDesign修正設(shè)計(jì)RevisedDesign電子零件置物箱材料Material：ABS電子零件件置物箱箱四澆口口和十二澆澆口設(shè)計(jì)計(jì)比較表表如何快速速平衡眾眾多模穴穴之流道道HowtoBalanceFlowInAMulti-cavityMold首先調(diào)整一排支流道內(nèi)之次支流道尺寸，使此支流道內(nèi)之各模穴可平衡充填。 First,adjustrunnersizeinonebranchtomakeflowbalancedinthisbranch.再調(diào)整各支流道前段之尺寸，使各支流道可平衡充填。 Then,adjustthefirstsection’srunnersizeineachbranchtomakeflowbalancedinallbranches.一排支流流道之不不平衡充充填UnbalancedFlowInABranch一排支流流道平衡衡後之充充填BalancedFlowInABranch全模具(128模穴)之不平平衡充填填UnbalancedFlowInAMold全模具(128模穴)平衡後後之充填填BalancedFlowInAMoldThemeltfillstheinsidecavitiesbeforefillingtheoutsidecavities.Therunnersystemshowsthatwarmer,low-viscositymaterial(yellowandred)followstheinsidewallwhenthemeltsplitsatanintersection.Melt”Flipper””導(dǎo)致平直直產(chǎn)品的的澆口設(shè)設(shè)計(jì)GateDesignforFlatPart中心澆口CenterGate扇形澆口FanGate最壞的Worst壞的Worse較好的Better最好的Best側(cè)澆口EdgeGate薄模澆口FilmGate澆口設(shè)計(jì)計(jì)(減少少滯流效效應(yīng))GateDesigntoAvoidHesitation澆口gate薄thin厚thick差的設(shè)計(jì)Poor好的設(shè)計(jì)Good薄thin厚thick澆口gate0.94秒時(shí)，遲滯現(xiàn)象在1.2mm厚凸片處發(fā)生公稱厚度3.2mm幫浦零件(Part,Pump)塑料(Polymer):POM沒有遲滯滯現(xiàn)象幫浦零件件(Part,Pump)塑料(Polymer):POM澆口設(shè)計(jì)計(jì)(避免免凹陷和和氣泡)GateDesigntoAvoidSinkMark&Void澆口gate澆口gate差的Poor好的Good使用重重疊澆澆口以以避免免噴流流AvoidJettingbyUsingOverlapGate差的Poor好的Good正確的的澆口口位置置以避避免噴噴流AvoidJettingbyLocatingGateCorrectly差的Poor好的Good使用凸凸片澆澆口以以避免免噴流流AvoidJettingbyUsingTabGate使用適適當(dāng)?shù)牡臐部诳谛螤顮钜员鼙苊鈬妵娏鰽voidJettingbyProfilingGateProperly差的Poor好的Good幫浦零零件(Part,Pump)塑料(Polymer):POM進(jìn)澆處處(Polymerentrance)：澆口厚厚(Gatethickness)1.2mm，模模穴厚厚(Cavitythickness)3.2mm問題(Problem)：噴流(Jetting)PoorDesignCausingJettingPart :Handle,RefrigeratorMaterial :ABSProblem :JettingMarkGasPinGate氣輔成成型冰冰箱把把手澆口及氣針入口澆口太小,導(dǎo)致噴流痕產(chǎn)生厚度差異過大,導(dǎo)致二次噴流痕產(chǎn)生R角過小,氣體通路接近把手內(nèi)側(cè),外側(cè)則因體積收縮造成凹陷痕跡閥澆口口ValveGate1.閥閥澆澆口梢梢Valve-GatePin2.加加熱管管Heater3.O型環(huán)環(huán)#610"0"Ring4.流流道歧歧管模模板ManifoldPlate5.軸軸封環(huán)環(huán)SealRetainer6.套套筒軸軸封SleeveSeal7.枕枕塊SupportPillar8.油油壓缸HydraulicCylinder閥澆澆口口(1)ValveGate(1)全部部閥閥澆澆口口同同時(shí)時(shí)打打開開時(shí)時(shí)之之充充填填狀狀況況Moldfillingwithallthevalvegates(shut-offgates)openedatthesametime.閥澆澆口口(2)ValveGate(2)部份份閥閥澆澆口口延延遲遲打打開開，，改改變變充充填填模模式式Moldfillingwithdelayedvalvegateopening;fillingpattern,weldlinesandairtrapsarechanged.多澆澆口口設(shè)設(shè)計(jì)計(jì)Multi-GateDesign閥式式澆澆口口ValveGate針點(diǎn)澆口PinGate扇型澆口FanGate潛伏澆口SubmarineGate邊緣(薄膜)澆口Edge(Film)Gate凸片澆口TabGate閥澆口ValveGate環(huán)狀澆口RingGate澆口口種種類類GateTypes矩形形邊邊緣緣澆澆口口設(shè)設(shè)計(jì)計(jì)RectangularEdgeGateDesignL=0.5~0.75mmW=澆口寬度(mm)gatewidthinmmA=型腔表面積(mm2

)surfaceareaofcavityinmm2n=材料常數(shù)materialconstant0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVCh=nth=澆口厚度(gatethick.inmm)t=零件壁厚(wallthick.inmm)WtLh扇形形澆澆口口設(shè)設(shè)計(jì)計(jì)FanGateDesignL=1.3mmW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]t=零件壁厚[wallthick.inmm]h1=nth2=wh1/D重疊疊式式澆澆口口設(shè)設(shè)計(jì)計(jì)OverlapGateDesignW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]=nt澆口長(zhǎng)度[landlengthinmm]t=零件壁厚[wallthick.inmm]

L1=0.5~0.75L2=h+(w/2)凸耳耳澆澆口口設(shè)設(shè)計(jì)計(jì)TabGateDesignL=0.5~0.75mmW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]t=零件壁厚[wallthick.inmm]h1=nth2=0.9t針點(diǎn)點(diǎn)澆澆口口設(shè)設(shè)計(jì)計(jì)PinGateDesignL =0.5~0.75mmd =澆口直徑(mm)gatediameterinmmt =零件壁厚(mm)wallthick.inmmA =型腔表面積(mm2)surfaceareaofcavityinmm2n =材料常數(shù)materialconstant0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVCdLt潛伏伏式式澆澆口口設(shè)設(shè)計(jì)計(jì)SubgateDesignW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]=ntt=零件壁厚[wallthick.inmm]30~15o~25o剪切切速速率率ShearRate剪切應(yīng)力shearStress黏度viscosity剪切速率shearrate剪切切應(yīng)應(yīng)力力ShearStress水力力直直徑徑HydraulicDiameterWhereisthehydraulicdiameter水力直徑Aisthecross-sectionalareaoftheflow

流路斷面積Pisthewettedperimeter濕周長(zhǎng)水力力直直徑徑HydraulicDiameter在不不同同剖剖面面形形狀狀，，相相同同斷斷面面積積下下之之變變化化Variousrunnerprofiles,basedonthesamecross-sectionalarea流道尺寸設(shè)計(jì)計(jì)(1)RunnerS