工程塑膠專(zhuān)業(yè)技術(shù)培訓(xùn)資料/sundae_meng

原料

塑料(聚合物)熱固性塑料(尿素電木)熱可塑性塑料工程塑料

泛用塑料結(jié)晶性,非結(jié)晶性,熱敏感性,復(fù)合材料---/sundae_meng熱可塑性熱固/硬性化學(xué)性變化*初期塑料成本較低*較高耐熱和抗?jié)撟冃?耐電弧性*不可回收物理性變化*較低塑件成本*較寬廣設(shè)計(jì)自由度*穩(wěn)定電氣特性*可回收/sundae_meng非結(jié)晶性化學(xué)性敏感.適度耐熱溫度.沖擊強(qiáng)度.較低模收縮率.均勻物性.結(jié)晶性抗化學(xué)性.

較高耐熱性.

缺口效應(yīng)敏感.

模收縮率較大.

耐疲勞性.

耐磨耗性.熱可塑性/sundae_meng塑料四大要素成品原料模具注塑設(shè)計(jì)/sundae_meng工作執(zhí)行中要知道的事項(xiàng):材料成型干燥設(shè)備/sundae_mengCYCOLACABS非結(jié)晶性,無(wú)填充材,添加物,低比重優(yōu)異的成形性韌性低成本耐熱性(upto85℃)外觀性缺點(diǎn):抗化學(xué)性戶(hù)外耐候性特性:TAMEX120/121GPM4700GPM5600GPM6300X11X17X37SEA2KJ-T/B/W/U---

/sundae_mengCYCOLOYPC/ABS合金材料非結(jié)晶性,無(wú)填充材,添加物,物性較為均衡性.成形性.優(yōu)異沖擊強(qiáng)度.低溫韌性.耐熱性(upto120℃)UV特性.缺點(diǎn):抗化學(xué)性.特性:C1100C1100HFC1200C1200HFC2800C2950C2950HFC6200C6600CU6800C7210A/sundae_mengNORYL改良式PPO塑料非結(jié)晶性,填充材和無(wú)填充材,添加物,尺寸安定性.成形性.優(yōu)異電氣性質(zhì).

耐熱性(upto150℃)低比重.低吸水性.缺點(diǎn):抗化學(xué)性.UV顏色特性.特性:NORYL儀表座-電氣特性&尺寸安定性731SE100XSE1XN190N225XN300XN1052PPX1005XPX1007GFN1/2/3SE1GFN1HM3020FN215X/sundae_mengLEXAN聚碳酸酯(PC)非結(jié)晶性,填充材和無(wú)填充材,添加物,優(yōu)異沖擊強(qiáng)度.透明性/顏色穩(wěn)定性.尺寸安定性.自熄性.抗?jié)撟冃?耐熱性(150℃,PPC165℃)缺點(diǎn):抗化學(xué)性.缺口效應(yīng)水解性應(yīng)力敏感特性:LEXAN磁盤(pán)片:純凈度,透明性,高流動(dòng)性141/241/R121/221/R101/RHF11303412/3/4500RLGN5030920/940/ALCLS1/2/3LF1000FL900PPC4701SP7602/4JK1000OQ1020/sundae_mengNORYLGTX,PPX,CRX

ResinPPO/PA,PPO/PP,合金材料非結(jié)晶性/結(jié)晶性,填充材和無(wú)填充材抗化學(xué)性.沖擊強(qiáng)度.尺寸安定性成形性耐熱性(upto235℃)噴漆后加工性缺點(diǎn):吸水率模收縮率特性:GTX600GTX6203GTX6801(30%)GTX830GTX870(20%)GTX880(30%)/sundae_mengVALOXPBT,熱可塑性聚酯,結(jié)晶性,填充材,無(wú)填充材,添加物抗化學(xué)性耐熱性(upto255℃)電氣特性耐摩擦性/磨耗性耐疲勞性缺點(diǎn):缺口敏感性收縮率/撓曲特性:VALOX熱熔槍:耐熱性310310SEO325DR51DR48420420SEO507553830PDR4910(15%)---/sundae_mengULTEMPEI,聚亞醚非結(jié)晶材料,填充材,無(wú)填充材,添加物抗化學(xué)性高溫功能特性.耐熱性(upto225℃)完美自熄性電氣特性透明性缺點(diǎn):缺口敏感性顏色限制特性:ULTEM醫(yī)療用接頭:抗化學(xué)性10002100220023002400JD7902JD7101/sundae_mengSUPECPPS,金屬樹(shù)脂結(jié)晶性,填充材,添加物高耐熱性(upto260℃)抗化學(xué)性杰出自熄性抗水解性疲勞特性高流動(dòng)性缺點(diǎn):缺口效應(yīng)敏感特性:G401G402/sundae_meng料管的撰用的合理性料管的介紹(工程塑料)/sundae_meng

計(jì)量段混煉/壓縮供給段供給段:

進(jìn)料供給作用.混煉/壓縮段:利用牙深產(chǎn)生剪熱壓縮混煉材料.計(jì)量段:

最后塑化材料./sundae_meng成品投影面積模腔內(nèi)壓力模具長(zhǎng)寬尺寸最小模具厚度尺寸最大開(kāi)模行程射出比率(40–60%)最大射出壓力流動(dòng)距離成品厚度接口設(shè)備--------/sundae_meng塑料預(yù)備干燥/sundae_mengWELLSHINResinResinResin熱可塑性工程塑料工程塑料原料會(huì)因;制造,運(yùn)輸,存放過(guò)程而增加含水率./sundae_mengH2OH2OH2O塑料含水率/sundae_meng

水份吸收均衡性/sundae_mengH2OH2OH2O

干燥過(guò)程利用干燥空氣帶走水份./sundae_meng

吸收移轉(zhuǎn).8.02吸濕比率-30 -20 0 20 40 60DewPoint露點(diǎn)均勢(shì)適合程度吸收/移轉(zhuǎn)/sundae_meng烘料筒干燥珠干燥空氣熱空氣利用干燥劑將空氣干燥再除濕烘料.

干燥系統(tǒng)/sundae_meng烘料筒回收空氣干燥系統(tǒng)二次干燥系統(tǒng)

加熱系統(tǒng)將空氣送進(jìn)低于露點(diǎn)之干燥筒中,再加熱進(jìn)入烘料筒循環(huán)充分干燥塑料.干燥機(jī)/sundae_meng烘料筒鼓風(fēng)機(jī)干燥系統(tǒng)干燥系統(tǒng)

加熱系統(tǒng)密閉式循環(huán)系統(tǒng)-利用過(guò)濾器將回收空氣去除污染再循環(huán)充分干燥塑料.過(guò)濾器/sundae_meng熱空氣流量較快慢速流量擴(kuò)散器均勻流量熱空氣烘料筒設(shè)備料筒應(yīng)用造成不同循環(huán)流動(dòng)(2:1),對(duì)干燥效果亦所有不同.使用擴(kuò)散器具對(duì)原料干燥效果較為均勻./sundae_meng干燥塑料注意事項(xiàng):確認(rèn)露點(diǎn)溫度.確認(rèn)回收空氣溫度.確認(rèn)循環(huán)空氣流量–至少1CFM/(lbs/hour).若使用直接回收料,必須延長(zhǎng)干燥時(shí)間1-2小時(shí)確認(rèn)干燥劑功能使用./sundae_meng

烘料筒選用

成品重量x射出循環(huán)時(shí)間 =數(shù)值例如:500g成品重x30秒循環(huán)時(shí)間 =1Kg/分 或60Kg/時(shí)數(shù)值x干燥時(shí)間 =建議烘料筒尺寸

例如:60Kg/時(shí)x4小時(shí) =240Kg烘料筒烘料筒選用必須大于足夠干燥時(shí)間/sundae_meng干燥條件原料 烘料溫度 烘料時(shí)間 露點(diǎn)空氣PPO 99℃ 1-2Hours -30℃ ABS 82℃ 2-4Hours -30℃ PC 120℃ 3-4Hours -30℃ Polyetherimide 120℃ 3-4Hours -30℃ PBT 120℃ 2-4Hours -30℃ NYLON6680℃3-4Hours-20℃NYLON680℃3-4Hours-20℃NOTE:回收料使用因粉碎顆粒較大,必須增長(zhǎng)烘干時(shí)間每一規(guī)格塑料之烘干條件請(qǐng)參照物性表建議事項(xiàng)./sundae_meng成型制程/sundae_meng制程初始:使用正確塑料清洗料管.使用正確制程條件./sundae_meng建議各種清洗料管使用原料規(guī)格 清洗用塑料CYCOLAC/CYCOLOYAcrylic,Polystyrene,SANNORYL Polystyrene,AcrylicLEXAN Acrylic,HDPolyethyleneVALOX Polystyrene,HDPolyethyleneULTEM LEXAN101,141,HDPolyethylene (ExtrusionGrade)SUPEC HDPolyethylene/sundae_meng塑化溫度設(shè)定電氣性加熱:

加熱片(HeaterBands)機(jī)械性加熱:

螺桿轉(zhuǎn)速(RPM)

背壓射出壓力/速度/sundae_meng塑料溫度設(shè)定過(guò)高噴射痕銀條紋顏色變更較長(zhǎng)冷卻時(shí)間材料劣解/sundae_meng射出成形加工考慮要點(diǎn)模具成形溫度塑料溫度螺桿回轉(zhuǎn)速度背壓設(shè)定射出成形壓力射出成形速度/sundae_meng塑料成形要項(xiàng)參照塑料物性/制程條件建議原料差異性塑料規(guī)格差異性/sundae_mengGE材料商品名成形溫度(℃)CYCOLAC? 218-260LEXAN? 266-310NORYL?PREVEX? 218-327VALOX? 236-277ULTEM? 338-450CYCOLOY? 235-285XENOY? 240-280SUPEC?300-332GELOY? 195-220/sundae_meng模具溫度/sundae_meng成品冷卻和固化過(guò)程熔融原料模具冷卻固化成品/sundae_meng模具溫度必須低于TG

達(dá)到冷卻成品作用TG成形溫度范圍

劣解冷卻作用:非結(jié)晶性材料/sundae_meng

劣解TMTG成形溫度范圍MoldTemperatureDeterminesCoolingTimeandThereforeDegreeofCrystallinityCoolingThroughtheCrystallinizationRangeTooQuicklyWillResultinReducedCrystallinity(Quenching)冷卻作用:結(jié)晶性材料/sundae_meng120125125135135145130140140130150145OOOOOOOOOOOOINOUT模溫控制/sundae_mengPL

模溫控制

范例/sundae_meng相關(guān)配備/sundae_meng

計(jì)量段混煉/壓縮供給段供給段:

進(jìn)料供給作用.混煉/壓縮段:利用牙深產(chǎn)生剪熱壓縮混煉材料.計(jì)量段:

最后塑化材料./sundae_meng計(jì)量段供給段螺桿設(shè)計(jì)hfhmL/D=20:1壓縮比==2:1雙金屬設(shè)計(jì),磨耗性,熱傳導(dǎo)性hmhf壓縮/混煉LD(供給段牙深)/sundae_meng球形逆流閥OpenClosed射出動(dòng)作/sundae_meng球形逆料閥耐久性阻礙流動(dòng)滯流塑料和黑點(diǎn)發(fā)生/sundae_meng不回流閥計(jì)量供給時(shí)動(dòng)作高壓射出時(shí)動(dòng)作CheckRingValvesareSuggested/sundae_meng不回流閥對(duì)塑料剪切影響較低.耐久性較差.逆流閥流量功能與螺桿較接近

./sundae_meng噴嘴(Nozzle)加熱片注料管注射方向/sundae_meng噴嘴設(shè)計(jì)段道長(zhǎng)度0.0㎜-4.75㎜.口徑尺寸4.76㎜-9.5㎜.豎焦道口徑小于0.5-0.8㎜㎜噴嘴尺寸盡可能使用較短尺寸之噴嘴設(shè)計(jì)./sundae_meng射出成型射出流動(dòng)/sundae_meng射出成形射出流動(dòng)/sundae_meng射出成形射出流動(dòng)/sundae_meng射出成形射出流動(dòng)/sundae_meng射出成形射出流動(dòng)/sundae_meng射出成形射出成形–

射出壓力射出壓力Time充填時(shí)間回料時(shí)間背壓/sundae_meng射出成形條件射出成形條件變化因素塑料溫度模具溫度溫度變化滯留時(shí)間射出速度射出壓力背壓閉模力殘量/sundae_meng射出成形條件塑料溫度35302520151050.030 .060 .090 .120 .150 .180 .210 .240成形厚度(in)流動(dòng)長(zhǎng)度(in.)LEXAN?101550degF.101@600deg.F增加塑料溫度亦增加流動(dòng)性.然而,過(guò)高塑料溫度將引起劣解現(xiàn)象./sundae_meng射出成形條件背壓Gate不均勻壓力分布均勻壓力分布HydraulicPressureTimeFillTimeScrewRunTimeBackPressure過(guò)分充填適當(dāng)充填和均勻壓力分布可避免收縮和翹曲問(wèn)題發(fā)生.亦降低充填所產(chǎn)生內(nèi)應(yīng)力/sundae_meng成形模具二板模ExplodedView移動(dòng)側(cè)模板固定側(cè)模板固定側(cè)定位板間隔塊背板上頂板下頂板導(dǎo)柱回位銷(xiāo)分模面/sundae_meng成形模具1234/sundae_meng成形模具背板上頂板下頂板EjectorHousing"B"Plate"X"Plate固定側(cè)模板固定側(cè)定位板三板模分模面分模面/sundae_meng成形模具

三板模12345/sundae_meng射出成形模具

內(nèi)部壓力豎澆道流道澆口123xxx成品Flow壓力時(shí)間321/sundae_meng

豎澆道勾梢倒斜度設(shè)計(jì)優(yōu)“Z”型好倒環(huán)型普通崁入型較差流道設(shè)計(jì)/sundae_meng流道射出成形模具設(shè)計(jì)/sundae_meng進(jìn)料點(diǎn)選定/sundae_meng不均平衡系統(tǒng)設(shè)計(jì)AAAABBBB流道設(shè)計(jì)/sundae_meng平均分布設(shè)計(jì)AAAAAAAA流道設(shè)計(jì)/sundae_meng容許最大材料流動(dòng)塑料冷凝影響最少流道流動(dòng)流道設(shè)計(jì)/sundae_meng流道設(shè)計(jì)全圓型優(yōu)梯型好半圓型較差PL/sundae_meng建議之流道尺寸:流動(dòng)均衡主流道-全圓形或梯形設(shè)計(jì)9.5㎜–250㎜以上8.0㎜–75㎜-250㎜6.5㎜–75㎜或以下次流道6.5㎜最少/sundae_meng

流道

梯型側(cè)圖RDRD

RD W D1/8 3/16 1/83/16 1/4 3/161/4 5/16 1/45/16 7/16 5/163/8 1/2 3/8對(duì)等設(shè)計(jì)之一設(shè)計(jì)之二流道設(shè)計(jì)/sundae_meng阻礙流動(dòng)較佳設(shè)計(jì)流道設(shè)計(jì)/sundae_meng流動(dòng)方向冷料井冷料井尺寸設(shè)計(jì)與流道相同或大于1.5倍冷料井流道設(shè)計(jì)/sundae_meng熱流道系統(tǒng):主流道岐管直徑最小應(yīng)為12㎜,大型件時(shí)為16㎜或更大.分岐塊末端務(wù)必制作圓形設(shè)計(jì).使用4支加熱棒,均勻分布.分岐塊(Manifold)所需的熱量,每立方吋之鋼材最少應(yīng)有50瓦特的加熱能力./sundae_meng緊密配合固定螺絲無(wú)澆道設(shè)計(jì)/sundae_meng熱流道系統(tǒng)固定側(cè)模板=50℃Manifold=260℃優(yōu)點(diǎn)

快速循環(huán)時(shí)間

-15-20%時(shí)間減少節(jié)省材料

-沒(méi)有澆道和流道較好成品質(zhì)量

-減少應(yīng)力殘留

-較佳外觀/sundae_meng母模板=50℃分歧塊=260℃金屬熱膨脹系數(shù):0.00000633in/C6in.=.017In.12in.=.034In.18in.=.051In.無(wú)澆道設(shè)計(jì)/sundae_meng進(jìn)澆口澆口設(shè)計(jì)/sundae_meng直接豎澆道成形制品豎澆道澆口設(shè)計(jì)/sundae_meng邊緣料口段道長(zhǎng)度0.76mm(Max)澆口設(shè)計(jì)/sundae_meng

碟形澆口流道成品流道豎澆道澆口設(shè)計(jì)/sundae_mengSingleTabGateMultipleTabGateGateTabSprue6in.Max12in.MaxTabSprueGateGateTab/sundae_meng成形品

豎澆道分模線(xiàn)潛道料口無(wú)段道長(zhǎng)度頂出梢料口側(cè)打光平順,Min.20潛道式料口澆口設(shè)計(jì)/sundae_meng冷料井R角改良式扇形料口澆口設(shè)計(jì)/sundae_meng成品流道澆口段道扇形料口澆口設(shè)計(jì)/sundae_meng澆口設(shè)計(jì)料口成品碟型流道料口環(huán)型料口/sundae_meng潛道

成品豎澆道分模線(xiàn)澆口

澆口

冷料區(qū)潛道設(shè)計(jì)之冷料區(qū)/sundae_mengRR料口腰果式料口

(牛角式)澆口設(shè)計(jì)L/sundae_meng0.5mm段道長(zhǎng)度1.27mm900澆口設(shè)計(jì)針點(diǎn)式料口/sundae_meng排氣系統(tǒng)模具排氣/sundae_meng加工空隙0.05mm頂出梢部份模具排氣/sundae_meng分模面部份深度0.03-0.06mm料口排風(fēng)孔1.5mmMin.NoteStep12.7mm1.3mmMin.模具排氣/sundae_meng頂出機(jī)構(gòu)/sundae_mengBladeatDeepRibsRoundsPinsSleeveEjectorBossEjectMoldPinStationaryPartsStripperPlateStationaryForceKnockOutBarsGOODKNOCKOUTFORROUNDPARTSUSEDAROUNDPINS&BOSSES/sundae_meng頂出機(jī)構(gòu)頂出影響因素:離模角度離模面積離模面粗糙度/蝕刻處理頂出角度模具溫度模具附著/sundae_meng頂出機(jī)構(gòu)原則:盡可能使用較大尺寸之頂針.盡可能增加頂針數(shù)量均勻地將成品頂出./sundae_meng離模角度設(shè)計(jì)和蝕刻面/sundae_meng射出成形模具成品頂出無(wú)脫模角頂出困難頂出容易/sundae_meng離模角度設(shè)計(jì)

脫模角1/2?Min.脫模角/sundae_meng離模角度設(shè)計(jì)蝕刻脫模角

每增加0.025㎜深度,則加大1度脫模角/sundae_meng射出成形模具

不均勻收縮效應(yīng)氣泡外部固化但內(nèi)部持續(xù)收縮下陷外部持續(xù)收縮/sundae_meng不均勻肉厚設(shè)計(jì)/sundae_meng模具設(shè)計(jì)不均勻內(nèi)應(yīng)力分布–

撓曲變型Gate高應(yīng)力低收縮低應(yīng)力高收縮撓曲/sundae_meng模具設(shè)計(jì)厚度設(shè)計(jì)/sundae_meng模具設(shè)計(jì)補(bǔ)強(qiáng)厚度設(shè)計(jì)肋部厚度必須小于肉厚過(guò)分肋部厚度設(shè)計(jì)將引起下陷和氣泡問(wèn)題發(fā)生/sundae_meng模具設(shè)計(jì)轉(zhuǎn)角設(shè)計(jì)SharpCornersConcentrateStressesARoundedOutsideCorner/SharpInsideCornerCreatesUnevenShrinkage:WarpageARoundedInsideCorner/SharpOutsideCornerCreatesUnevenShrinkage:SinkMarksandVoids/sundae_meng模具設(shè)計(jì)靠破孔NotRecommendedPoorFlow!進(jìn)料點(diǎn)/sundae_meng模具設(shè)計(jì)靠破孔進(jìn)料位置RecommendedBetterFlow/sundae_meng變形燒焦光澤氣泡短射收縮不均毛邊噴痕黏模壓力過(guò)高指印/sundae_meng生產(chǎn)中問(wèn)題發(fā)生時(shí)候?認(rèn)定...塑料有問(wèn)題!/sundae_meng基本原則一些基本步驟可有效率地處理成形所發(fā)生之問(wèn)題...計(jì)劃性思考對(duì)策一次處理一種問(wèn)題耐心地,觀其變化使其規(guī)律化記錄其變化/sundae_meng射出成形中之問(wèn)題對(duì)策/sundae_meng收縮/下陷CausedbyInternalStresseswithinThickerSectionsofthePartasaResultofInsufficientPolymerMolecules./sundae_meng收縮/下陷WaystoMinimizeSinkMarksCheckthePartDesignCheckFeedRateIncreaseInjectionSpeedIncreaseInjectionPressureIncreaseMoldTemperatureIncreaseInjectionHoldTimeCheckMeltTemperatureIncreaseBackPressureMaintainSufficientVentingIncreaseRunner/GateDimensions/sundae_meng氣泡VoidsAreCausebyTooFewMoleculeswithintheMold.AsOpposedtoSinkMarks,PartWallStrengthisSufficienttoWithstandtheInternalStressCausedbytheMeltCoolingProcess./sundae_meng氣泡WaystoMinimizeVoidsCheckthePartDesignCheckFeedRateIncreaseInjectionHoldTimeIncreaseInjectionSpeedIncreaseMoldTemperatureCheckMeltTemperatureIncreaseBackPressureMaintainSufficientVentingIncreaseRunner/GateDimensionsIncreaseInjectionPressure/sundae_meng變型WarpingisCausedbyNon-UniformOrientationandUnevenStressLevelsonDifferentSidesofthePart./sundae_meng變型CheckthePiecePartDesignCheckFeedRateDecreaseInjectionPressureDecreaseInjectionSpeedDecreaseMoldTemperatureIncreaseInjectionHoldTimeCheckMeltTemperatureCheckCoolingPassages/sundae_meng毛邊FlashWillOccurWhenInjectionPressureExceedsClampForceorShut-OffisDamaged./sundae_meng毛邊LooseClampInjectionPressureTooHighInjectionHighPressureonTooLongInjectionSpeedTooFastMeltTemperatureTooHighImproperFeedRateDamagedorOverheatedMold/sundae_meng短射/缺料ShortShotistheInabilitytoCompletelyFillaPart./sundae_meng短射/缺料WaystoMinimizeShortShotsCheckforNozzleDamageIncreaseInjectionPressureIncreaseStockTemperatureIncreaseShotSizeIncreaseMoldTemperatureCheckNon-ReturnValveandBarrelforExcessiveWearorDamage/sundae_meng成品表面焦化/黃紋SurfaceBurningofPartsCanBeCausedbyTooHighaStockTemperature.Excessiv