TOOLINGBASICSFORULTEM(PEI)INJECTIONMOLDINGGOODPARTToolingConsiderations

模具設(shè)計(jì)考量塑料成型條件模具設(shè)計(jì)InjectionToolingStructureToolingTypeandStructure(模具型式及結(jié)構(gòu))RunnerSystemandGating(進(jìn)料系統(tǒng))CoolingSystem(溫度控制系統(tǒng))Ejectorsystem(頂出系統(tǒng))Ventingandothers(逃氣及其他)TwoPlateMold兩板模BASICTOOLTYPES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1234ToolThermalManagementPEI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頂出板機(jī)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ThreePlate(三板模)InjectionMoldingToolingCamActions(滑塊機(jī)構(gòu))Hydraulic(油壓驅(qū)動(dòng))PlasticCorePinCoredHoleCoreHydraulicCylinderCavityCamActionsSlide機(jī)構(gòu)式滑塊123PEI模具常用之鋼材SprueBushingNozzle(射嘴)RadiusOrificeSPRUEBUSHING(注道襯套)SprueBushings(注道襯套)HelicalHeaterThermalShut-OffHeatedSprues加熱式注道襯套ColdSprue冷注道襯套

SpruePuller(注道拉料銷)REVERSETAPER最佳ZPULLER好GROOVE尚可SUCKERPIN不建議使用甚麼是料道系統(tǒng)?B:能量緩衝區(qū)A:塑料由射出機(jī)射嘴至成品間旳通道RunnerSystems(料道系統(tǒng))PEIRunnerDesign(料道設(shè)計(jì))圓形流動(dòng)效能最佳PL梯形流動(dòng)效能可半圓形流動(dòng)效能最差不建議使用塑料流動(dòng)方向PEI塑料建議料道結(jié)面積(4.0~8.0MM“Dia.)冷料井之長(zhǎng)度1.5X料道直徑ColdSlugWell(冷料井)ColdSlugWell(冷料井)冷料井建議尺寸UnbalancedSystem(不平衡料道)AAAABBBBBALANCINGRUNNERS料道流動(dòng)平衡BalancedSystem(平衡料道)AAAAAAAABALANCINGRUNNERSHotrunnerTooling熱膠道系統(tǒng)WhomakesaHotRunner?KonaHuskyDMECoolOneFastHeatIncoeSpearInsulatedRunnerHeatedSprueBushingOSCOPETSGuntherEwiKonMoldMastersRAMAETC……

ExtendedNozzles(射嘴旳延伸)甚麼是熱膠道系統(tǒng)?HeatedSprueBushing(加熱式注道襯套)多點(diǎn)進(jìn)膠方式InjectionMoldingTooling熱流板(分流板)Manifold建議由外部提功均勻熱源(如右圖示4Heaters)加熱器至少提供50Watts/in3

InjectionMoldingToolingHotRunnerSystemsCavityPlate=1500CManifold=3800C使用熱膠道好處

降低生產(chǎn)時(shí)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(nèi)應(yīng)力-較好外觀Gating(進(jìn)澆口)GATING在何處?由成品肉厚處;接近轉(zhuǎn)角處;遠(yuǎn)離負(fù)載區(qū)或應(yīng)力集中處;質(zhì)量中心處(非成品中心處)進(jìn)料點(diǎn)數(shù)量?依成品厚度及塑料流動(dòng)指數(shù)成品外觀需求成品設(shè)計(jì)肉厚模穴數(shù)需求進(jìn)料點(diǎn)形式?HOTRUNNER;HOTTIP;VALVEGATE;THREEPLATE;EDGEGATE;CASHEWGATE;DIAPHRAGMGATESUBGATE;TUNNELGATE;FLASHGATE;FANGATE;HOTEDGEGATE;DIRECTSPRUE;ETC.ETC.ETC.DirectSprueGate(直接澆道)建議使用於ULTEMMoldedPartSprueEdgeGate(側(cè)邊澆口)建議使用於ULTEMLandLength2.5mmMaximumCOLDSLUG(冷料井)RADIUSFanGate(扇形澆口)建議使用於ULTEMFLASHGATE(板形澆口)建議使用於ULTEMPARTFLASHGATEFANGATEPRIMARYRUNNERSECONDARYRUNNERSPRUETunnelGateKnockOutPin(頂出銷)MoldedPartSpruePartingLineTunnelGate(潛伏式澆口)不建議使用於ULTEMGATEBLUSHCOMMONX0.250x“X”RRGateCashewGateCashewGate(牛角澆口)不建議使用於ULTEM0.5mmLandLength1.2mm~2.5mm900PinPointGating(針點(diǎn)澆口)不建議使用於ULTEMDIAPHRAGMGATE(盤形澆口)建議使用於ULTEM澆口位置與流動(dòng)方向澆口位置InjectionMoldingDesignMoldabilityHoles靠破孔設(shè)計(jì)會(huì)阻礙塑料流動(dòng)Gate-MeltEntryPointInjectionMoldingDesignMoldabilityGate-MeltEntryPoint塑料可得到較好流動(dòng)HolesSingleGate20,000psiMultipleGates7,000psiWhyuseMultipleGates?MOLDTEMPERATURE模具溫度PartCoolingandSolidification溶融塑料模具冷卻成品(熱轉(zhuǎn)移)MoldCooling隔板式噴水式導(dǎo)熱棒冷卻水路製作方式InjectionMoldingTooling連續(xù)式水路INOUTPinBladeInjectionMoldingTooling噴泉式冷卻INOUTPinTube冷卻效率佳至少尺寸為水路直徑兩倍連續(xù)式水路連結(jié)INOUTOOOOOOOOOOOO120125125135135145130140140130150145WATERLINECONNECTIONS不建議使用MOLDManifold“In”Manifold“Out”Water“In”Water“Out”RecommendedWaterConnections成形PEI塑料之模具溫度建議為150C

低模溫成形

高模溫成形

不易充填

較高射出壓力料管設(shè)定溫度較高

高頂出壓力較高內(nèi)應(yīng)力

成品肉厚處內(nèi)部有空孔易充填較低射出壓力料管設(shè)定溫度較低易頂出

較低內(nèi)應(yīng)力

表面外觀佳肉厚表面縮水SHRINKAGE:UNFILLEDPOLYCARBONATE: .005-.007“/”UNFILLEDPEI: .005-.007“/”UNFILLEDNORYL: .005-.007“/”UNFILLEDVALOX: .015-.023“/”DATASHEETTHESESTATEMENTSARENOTALWAYSACCURATEINTHEREALWORLD!成品縮水率依據(jù)下列原因綜合考量

1.成品設(shè)計(jì)

2.澆口位置及尺寸 3.塑料成形溫度 4.塑料流動(dòng)指數(shù)5.射出壓力6.保壓壓力及時(shí)間7.模具溫度

Venting排氣(逃氣)ToolingandProcessingDesignandProcessingDictatePartPerformanceApplyFullPartingLineVenting降低射出壓力防止氣體在充料末端匯集成品外觀較佳排氣間隙0.04~0.07mmEjectorPin頂針逃氣頂出機(jī)構(gòu)考量原因

成品側(cè)邊拔模斜度

成品側(cè)邊面積

成品外觀型式(打光面或咬花面)

寶壓程度

模具溫度

是否易離模頂出機(jī)構(gòu)設(shè)計(jì)

頂針盡可能大

頂針數(shù)目盡可能多盡量接近轉(zhuǎn)角處及補(bǔ)強(qiáng)結(jié)構(gòu)處(Rib,Boss..)

頂針分布盡可能均勻?qū)σr無(wú)拔模斜度

不易頂出易頂出EjectingthePartDraftAngle

拔模斜度至少1/2O

拔模斜度拔模斜度DraftAngle咬花側(cè)邊角度

每增長(zhǎng)0.025mm咬花深度拔模斜度追加1度PartTextureWILLChangewithPressureWILLChangewithTemperatureWILLVarywithToolAgeWILLVaryTooltoToolWILLVaryMoldertoMolderStainlessorHardenedP-20withSPI1FinishToolingSurfaceTreatmentMostoftheindustryuses420stainlesssteelwithamininumhardnessof46Rc.Thisapproachoffersgoodsurfaceappearancewithalowriskforcorrosion.Somesuppliersusehigh-purityP20steel.WhilewearenotawareofanyrustingorcorrosionissuesassociatedwithP20steel,thismaterialwillrustfairlyeasilyascomparedwithstainlesssteel.Finkel,doublevacuumre-meltsteelhasbeenusedsuccessfully.Thevacuumre-meltprocessreportedlyremovessulfidesthatcanleadtosurfacepitting.Intermsofsurfacenitriding,therearesomeunconfirmedreportsthatULTEMhasanaffinityforNitridedsurfaces.WeRecommendThatYouDoNotUseNitridedMaterialsPolishedTool