培訓(xùn)課程2工藝參數(shù)的優(yōu)化

受訓(xùn)者手冊(cè)德馬格注塑機(jī)工藝參數(shù)優(yōu)化的步驟指導(dǎo)頁(yè)面周期分析3注塑工藝參數(shù)優(yōu)化6步驟1:找出轉(zhuǎn)壓點(diǎn)7步驟1結(jié)果8步驟2:找出保壓時(shí)間（澆口冷凝時(shí)間）9步驟2結(jié)果10步驟3:優(yōu)化注射速度11步驟3結(jié)果12步驟4:采用正確的螺桿轉(zhuǎn)速13步驟4結(jié)果14步驟5:優(yōu)化多級(jí)螺桿轉(zhuǎn)速和背壓曲線15步驟5結(jié)果16步驟6:優(yōu)化松退17步驟6結(jié)果18步驟7:優(yōu)化保壓曲線19步驟7結(jié)果20TABULATEDRESULTS21步驟8:優(yōu)化鎖模力22步驟8結(jié)果22步驟9:設(shè)定注射壓力23

步驟9結(jié)果23典型工藝參數(shù)公差設(shè)定24采用下面表格估計(jì)注塑過(guò)程中的每一階段對(duì)周期的影響.然后去機(jī)床看正在運(yùn)行的模具,寫下實(shí)際的時(shí)間并計(jì)算出百分比.哪一階段在整個(gè)周期中占最多的時(shí)間那里可以是最有效的縮短成型周期

估計(jì)％實(shí)際實(shí)際％評(píng)價(jià)合模射臺(tái)前進(jìn)和后退注射時(shí)間保壓時(shí)間冷卻時(shí)間開模

頂出整個(gè)成型周期100%seconds100%

估計(jì)%實(shí)際實(shí)際％評(píng)價(jià)合模射臺(tái)前進(jìn)和后退注射時(shí)間保壓時(shí)間冷卻時(shí)間開模頂出整個(gè)成型周期100%seconds100%目標(biāo)：一步步改進(jìn)工藝過(guò)程穩(wěn)定性.評(píng)估各個(gè)參數(shù)的更改對(duì)工藝過(guò)程穩(wěn)定性的影響todemonstratethecumulativeimprovemntintheprocessandproductconsistency方法：Ateachstage,aftertheprocesshasbeengivensufficienttimetostabilise,arunofsixteenconsecutivemouldingsistobemade.Thesemouldingswillbeassessedforconsistencybyweight(adimension,aphysicalpropertyorsomeotherattributecouldequallywellbeused,weightissimplythemostwidelyapplicable).穩(wěn)定性通過(guò)計(jì)算重量的標(biāo)準(zhǔn)偏差來(lái)衡量.同時(shí)打印出機(jī)床IBED上的過(guò)程統(tǒng)計(jì)數(shù)據(jù).找出轉(zhuǎn)壓點(diǎn)找出澆口冷卻時(shí)間優(yōu)化注射速度采用正確的螺桿轉(zhuǎn)速優(yōu)化多級(jí)預(yù)塑曲線優(yōu)化松推優(yōu)化多級(jí)保壓曲線優(yōu)化鎖模力設(shè)定注射壓力限定找出轉(zhuǎn)壓點(diǎn)在沒有保壓壓力和保壓時(shí)間的基礎(chǔ)上填滿產(chǎn)品95%-98%,然后設(shè)定一定的保壓和保壓時(shí)間生產(chǎn)16模.初始設(shè)置時(shí)的指導(dǎo)1采用行程切換2設(shè)定切換位置為10-12mm（逐步增加預(yù)塑量直到產(chǎn)品打滿95%-98%的位置）3設(shè)置注射壓力為最大值4設(shè)定保壓壓力和保壓時(shí)間均為05設(shè)定注射速度60mms-16設(shè)定松推速度為最大值7設(shè)定鎖模力為最大值8選擇適當(dāng)?shù)穆輻U轉(zhuǎn)速9根據(jù)材料物性表，設(shè)定料桶溫度10配置過(guò)程統(tǒng)計(jì)控制11設(shè)定保壓壓力和保壓時(shí)間生產(chǎn)完整的產(chǎn)品稱12模產(chǎn)品的重量，計(jì)算標(biāo)準(zhǔn)偏差打?。喉?yè)面20工藝參數(shù)優(yōu)化頁(yè)面 50 工藝過(guò)程統(tǒng)輸入實(shí)際值平均值范圍最小最大沒保壓時(shí)的重量有保壓后的重量填充的百分比%標(biāo)準(zhǔn)偏差（16模）g料墊（平均值和范圍）預(yù)塑時(shí)間（平均值和范圍）螺桿停止位置（平均值和范圍）注射時(shí)間（平均值和范圍）注射壓力峰值，Pinj.max轉(zhuǎn)壓壓力，PNpress.

轉(zhuǎn)壓位置找出澆口冷凝時(shí)間設(shè)定保壓壓力為步驟1上找出的注射壓力峰值的50%左右.設(shè)定保壓時(shí)間為1s.生產(chǎn)數(shù)模產(chǎn)品使過(guò)程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量和平均值增加保壓時(shí)間至2s,生產(chǎn)數(shù)模產(chǎn)品使過(guò)程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量.在保壓時(shí)間3s,4s5s...時(shí)重復(fù)上述過(guò)程直到產(chǎn)品重量不再增加作出產(chǎn)品重量和保壓時(shí)間的關(guān)系圖.記錄RecordtheTCUsettingandtheactualmouldtemperature.打印：頁(yè)面30溫度XLSpreadsheetgraph為什么記錄模具溫度很重要還有什么因素會(huì)影響澆口冷凝時(shí)間

輸入實(shí)際值TCUsettingFHtemperatureMHtemperatureCCC

所需的保壓時(shí)間s優(yōu)化注射速度采用多級(jí)注射曲線，使注射行程最后的10-20%采用逐步降低的注射速度.每次更改注射速度，必須重新建立轉(zhuǎn)壓點(diǎn).（注意每次保壓和保壓時(shí)間都設(shè)定為0.）連續(xù)取16模，計(jì)算出標(biāo)準(zhǔn)偏差.打?。喉?yè)面24MWE使用和沒使用多級(jí)保壓時(shí)的曲線頁(yè)面26多級(jí)注射頁(yè)面50工藝過(guò)程統(tǒng)計(jì)為什么轉(zhuǎn)壓點(diǎn)要更改注射壓力發(fā)生了什么為什么在數(shù)社的末端采用逐步降低的注射速度是有用的

輸入實(shí)際值平均值范圍最小最大沒有保壓時(shí)的重量采用保壓的重量填充百分比%標(biāo)準(zhǔn)偏差（16模）g料墊（平均值和范圍）預(yù)塑時(shí)間（平均值和范圍）螺桿停止位置（平均值和范圍）注射時(shí)間（平均值和范圍）注射壓力峰值，Pinj.max轉(zhuǎn)壓壓力，PNpress.轉(zhuǎn)換位置采用正確的螺桿轉(zhuǎn)速Selectthecorrect,optimumscrewspeedforthematerialbeingprocessed(seenotes,Section5).UsethissinglespeedforthewholeplasticisingstrokeSetabackpressureof5to10bar(hydraulic).Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page50ProcessStatisticsWhyisitimportanttousethemanufacturer’srecommendedscrewspeedSTEPFOURRESULTSInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.

ChangeoverstrokeSTEPFIVEOptimisescrewspeedandback-pressureprofileUsetheDosingProfilepagetoslowdownthescrewrotationspeedforthelast10%ofthemeteringstroke.Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtotheDosingStoppositionSTEPFIVERESULTSInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.

ChangeoverstrokeSTEPSIXOptimisedecompressionFindthedecompressionspeedwhichgivesbestscrewstrokeandmeltcushionconsistency.Setadecompressionstrokeof5mm.Checkthatyoustillachieve95-98%fill.Takesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtothescrewstoppositionWhatishappeningtothecheckringInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPSEVENOptimiseholdingpressureprofileUsetheHoldingProfilepagetosetaholdingpressureprofilewhichensuresasmoothtransitionfrominjectiontotheholdingpressurephaseanduseahighenoughpressuretopackthepartproperly.Addastepwhichreducesholdingpressuregraduallytozero.Takesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page24MWEPage27HoldingProfilePage50ProcessStatisticsWhydoyouneedasmoothtransitionfrominjectiontoholdingpressureWhybothertoreducethepressuregraduallyifthegatehasalreadyfrozenInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeboxesInsertactualvaluesintherelevantboxesTherangevalue,R,isthemaximumminustheminumum,takenfromthesevenTherangevalue,R,isthemaximumminustheminumum,takenfromthesevensteps.1234567meanRmeanRmeanRmeanRmeanRmeanRmeanRMeltcushionDosingtimeScrewendpositionInjectiontimeInjectionpressurePhydmaxInectionpressurePNhydraulicChangeoverstrokeStandarddeviation(16shots)CanyouseeatrendWhichstephadthegreatesteffectontheconsistencyofthemouldingSTEPEIGHTOptimisingtheclampforceReducetheclampforcebystepsof50kN(100kNformachinesover100tonnes)usingthesettingsfaroptimisedinthesevenstepsabove.Allowtheprocesstostabiliseeachtimeandthenweighfivemouldings.Tabulateyourresultsbelowandplotagraphoftonnageagainstpartweight.DoesthemouldrequiretheexpectedclampforceWhataretheadvantagesofrunningatreducedtonnageSTEPEIGHTRESULTSInsertactualvaluesintherelevantboxesEnterresultsinXLspreadsheet.Printoutgraph.Weight1Weight2Weight3Weight4

Weight5MeanweightClampforceRequiredclampforcekNSTEPNINESetinjectionpressureUntilnowtheinjectionpressurehasbeensettothemachine’smaximumvalue.FromtheProcessStatistcspageitcanbeseenthatthemachinedoesnotneedallthatpressuretofillthemould.Graduallydecreasethesetinjectionpressureuntiltheinjectiontimestartstoincrease.Increasethepressureagainuntilthepreviousinjectiontimeisestablishedwithaconsistencyofsorbetter-preferablytosvariation.WhatisthepurposeoflimitingtheinjectionpressureSTEPNINERESULTSActualpeakinjectionpressurebarSetinjectionpressurebarTYPICALPROCESSTOLERANCESShot-weightdeviation%%%%Plasticisingtime+土Injectiontime+土土土Cycletime土%土%土1%土1%Screwposition,dosingstop+土土土Meltcushion土土土土Melttemperature土2°C土2°C土3°C土5°CMouldtemperature土1°C土1°C土2°C土4°CBarreltemperature土1°C土1°C土2°C土4°CFeedzonetemperature土1°C土2°C土3°C土4°CHotrunnertemperature土1°C土2°C土3°C土4°CHydraulicoiltemperature土1°C土1°C土2°C土2°CRoomtemperature土2°C土2°C土3°C土4°CMouldcavitypressure土3bar土4bar土6bar土8barPressureintegral土200土300土600土900Injectionfillingpressure土1bar土2bar土3bar土4barHoldingpressure土1bar土1bar土bar土2barBackpressure土bar土bar土1bar土1barFillingdifferences(Balanceoffillforeachcavity)onmulticavitytools土1%土1%土2%土5%MouldbreatheChangeoverpressure(PnValue)土1bar土2bar土3bar土4barScrewsurfacespeed土10mms-i土15mms-1土20mms-1土30mms-1Melttemperaturepeakvalue土°C土°C土°C土°CMelttemperaturevalueatchangeover土°C土°C土°C土°CTheachievablepartqualityismuchinfluencedbytheconditionofthematerialprocessed.Itisimportantthatmoisturecontent,proportionofregrindandproportionofcolour(masterbatch)areconstant.—Demag岫/MnAcceptabletolerancesofprincipal