模具成型英语.docx

1、模具成型英语成型工藝流程及條件介紹 Molding technique procedure and parameter introduction第1節 成型工藝Section 1 molding technique.1. 成型工藝參數類型Sorts of molding parameter.(1). 注塑參數Injection parameter.a. 注射量Injection rate.b. 計量行程Screw back positionc. 餘料量Cushiond. 防誕量Sucking back ratee. 螺杆轉速Screw speedf. 塑化量Plastic rateg. 預塑背

2、壓Screw back pressureh. 注射壓力和保壓壓力Injection pressure and holding pressurei. 注射速度Injection speed(2) 合模參數Clamping parametera. 合模力 Clamping forceb. 合模速度Clamping speedc. 合模行程. Clamping stroked. 開模力Opening forcee. 開模速度Opening speedf. 開模行程Opening positiong. 頂出壓力Ejector advance pressureh. 頂出速度Ejector advance

3、 speedi. 頂出行程Ejector advance position2. 溫控參數Temperature parametera. 烘料溫度Dry resin material temperatureb. 料筒與噴嘴溫度Cylinder temperature and nozzle temperaturec. 模具溫度Mold temperatured. 油溫Oil temperature3. 成型周期Molding cyclea. 循環周期Cycle timeb. 冷卻時間Cool timec. 注射時間Injection timed. 保壓時間Holding pressure time

4、e. 塑化時間Plant timef. 頂出及停留時間Knocking out and delay timeg. 低壓保護時間Mold protect time成型工藝參數的設定須根據產品的不同設置.Molding technique parameter setting differs depending on type of product 第二節 成型條件設定 Section 2 Molding parameter Setting按成型步驟:可分為開鎖模,加熱,射出,頂出四個過程.Molding steps: mold opening/closing, heating injection

5、and knocking out.開鎖模條件:Mold opening parameter:快速段中速度 低壓 高壓速度High-speedmid-speed Low pressure high pressure speed鎖模條件設定:Mold closing parameter setting 1. 鎖模一般分: 快速中速低壓高壓Mold closing: high-speed low-speed low pressurehigh pressure2. 快鎖模一般按模具情況分,如果是平面二板模具,快速鎖模段可用較快速度,甚至於用到特快,當用到一般快速時,速度設到55-75%,完全平面模可設

6、定到 80-90%,如果用到特快就只能設定在45-55%,壓力則可設定於50-75%,位置段視產品的深淺(或長短)不同,一般是開模寬度的1/3.In high-speed section, Mold closing speed depends on type of mold. For two plate mold it can set quick and even especially quick usually, it set speed within 55-75%. For full-plate mold it set speed within80-90% while using espe

7、cially high speed it set speed within 45-55% and pressure within 50-75% position distance setting differs depending on the volume of product and usually it can be set 1/3 of mold opening position.3. 中速段,在快速段結束后即轉換成中速,中速的位置一般是到模板(包括三板模,二板模)合在一塊為止,具體長度應視模板板間隔,速度一般設置在30%-50%間,壓力則是20%-45%間.In mid-speed

8、section: Mold closing speed changes into mid-speed after high-speed section finish. Mid-speed start position is where two plates meet (include three-plate mold and two-plate mold ) Distance of mid-speed is up to distance of two plates plate it speed within 30-50% and pressure 20-45%. 4. 低壓設定,低速設定一般是

9、在模板接觸的一瞬間,具體位置就設在機臺顯示屏顯示的一瞬間的數字為準,這個數字一般是以這點為標準,即於此點則起不了高壓,高於此點則大,輕易起高壓.設定的速度一般是15%-25%,視乎不同機种而定,壓力一般設定於1-2%,有些機則可設於5-15%,也是視乎不同機种不同.Low-pressure section: Mold closing sets low-pressure when plates meeting. This position is set to the data of machine screen on this time. This point is the gage of th

10、e data. Data lower the point there is no high-pressure. Data higher the point there is high-pressure easily. It set speed within 15-25% and pressure within 1-2% depending on type within 1-2% depending on type of injection molding machine.5. 高壓設定,按一般機臺而言,高壓位置機臺在出廠時都已作了設定,相對來講,是不可以隨便更改的,比如震雄機在50P.速度相對

11、低壓略高,大約在30-35%左右,而壓力則視乎模具而定,可在55-85%中取,比如完全平面之新模,模具排氣良好,甚至於設在55%即可,如果是滑塊較多,原來生產時毛邊也較多,甚至於可設在90%還略顯不足.High-pressure section: To normal injection molding machine, high-pressure position had been set before they were sent to customer. It can not be modified. For example high-pressure position of CHENHS

12、ONG machine is 50P.The speed of high-pressure section is about 30-35% and higher than that of low-pressure. The pressure is up to mold, it can set within 55-85% For full-plate mold, its eject air well, it can set pressure 55% .If mold has a lot of slides and flash rate high in production, pressure c

13、an set 90%.加熱工藝條件設定Heating technique parameter setting1. 加熱段溫度設定必須按照產品所使用的原料的不同而不同,但卻必須遵循一個這樣的規則,即由射口筒到進科段溫度是逐步遞減的.且遞減溫度是以100C為單位.The proper temperature setting differs depending on type of resin material, but it must be abide by a rule that temperature setting should diminish in step 1.C from nozzl

14、e to feeding resin material position. 2. 特殊情況下.如料頭抽絲,則射口筒溫度應降低,如果是比較特殊的原料冷凝比較快的.則射口筒溫度則不止比第二節法蘭溫度高100C.比如PPS. 尼龍等.Nozzle temperature setting should low if product line. If resin material such as PPS, PA, cool very soon , Nozzle temperature should higher more 10.C than the second cylinder temperature

15、.3.机台馬達啟動溫度視乎機臺不同而不同,一般出於對機台油路中的油封保護需要,油溫最好能控制在400C-600C,以免油封長期高壓而變化,縮短使用壽命,造成成型不穩定.Pump turning on temperature is different depending on type of injection molding machine. To protect oil seal of machine it set oil temperature within 40.C-60.C, If oil seal work on condition that high pressure and da

16、maged Its work time will be shorter, it can cause molding stable. 注射及熔膠(加料)工藝條件設定Injection and plastic Technique parameter setting1. 注射Injection 常見塑膠原料的有關溫度值.原料Resin名稱Name熔點Melts成型溫度Molding Temperature(c)分解溫度Decomposing Temperature(C)模具溫度Mold Temperature(c)干燥溫度Resin dry temperature(c)HDPE低衛壓聚乙烯108-1

17、26160-22231045-6070-80HOPE高衛壓聚乙烯135180-24031050-8070-80PC聚碳酸脂polycarbonate 220-240260-31032080-12090-120ABS160180-23027045-8070-90PC/ABSPC與ABC共混物200220-25030050-9080-100PP聚丙烯160-170200-26030030-45PS聚苯乙烯140180-23030030-4565-80PVC聚氯乙烯140180-21530020-4090-100AS160200-25028045-7570-90PA6尼龍6215-220225-24

18、530040-8095-110PA66尼能66260-265260-27530040-8095-110PPS聚苯硫酸265-280300-330370100-120100-130PBT聚對苯二甲酸丁二脂225-235240-26028070-80105-140POM聚甲醛170180-21024080-120PMMA有機玻璃160180-24027040-6570-80 注射是把塑膠原料經加熱後射進模腔的過程,它一般可分為第一級,第二級,第三級,第四級及保壓幾段:Injection is a step which inject melt resin material into mold. It

19、 consists of stepl,step2 ,step3,step4 and holding pressure step:1. 第一級注射一般是注射料頭段.具注射量一般可根据料頭的輕重來估計其行程,當然也可以依据公式來計算,如公式: Step l injects usually tunnel material, Injection Volume can be estimated according to the weight of course it can be calculated by formula: L=Si=Vi/0.785Ds2 L:注射行程; Si: 注射行程; L: i

20、njection stroke Si: injection stroke Vi:理論注射容積; Ds:螺杆直徑; Vi: injection volume of theoretical Ds: diameter of screw 0.785:是/4的值.1. 785: value of /4.當然,如果我們在成型時每設定一個參數都要計算一次,要成型出一個產品就要幾個小時才能完成了.But it cost a lot of time to produce one product if every time molding parameter is setting by calculation.2

21、.第二級是注塑產品約2/3的階段,當然,根据產品特殊需要,也允許成型不到2/3階段,比如避免結合線問題,這一階段的成型速度及壓力一般是整個成型段的最大值段,如果排的產品與機台基本是相吻合的.模具結構合理,排气良好,這一段的壓力一般也不會超過80%.速度側視產品需變,可能大到95%也可,自然一般都是在55%-80%間.Step 2 inject 2/3 of product. It can lower 2/3 of product according to requirement of product. For example to prevent weld line. Molding spee

22、d and pressure on this step is the maximum of whole molding section. If Mold suit the injection molding machine and mold structure reasonable and eject air well, pressure of this step should lower 80%. Molding speed setting within 55-80% but it may setting 95% for especial product.3.第三段是注射餘下的1/3段,其速

23、度和壓力根据產品的需要,一般是小于第二段,速度和壓力存在於一個往下降的過程.主要是為了防止產品毛邊的產生,但同時又必須把產品充填飽滿.Step3 inject remain 1/3 of product. According to product molding speed and pressure lower than that of step2 To prevent flash speed and pressure should decrease but it cant shot short.4.第四段:一般有機臺還有第五,第六段,這段的成型速度和壓力相同前,都存在兩段一個遞減過程.其作用

24、都是起到一個再次充滿的作用.Step4 section: Some injection machines have step5,step6 which are same as former molding speed and pressure this step should diminish and inject once more.5.保壓段:不論成型什麼產品,都存在一個保壓過程.任何產品都不同程度的存在一個厚薄不一的問題,正常情況下,較厚的部分都可能存在一個收縮凹陷的現象,為了解決這種現象,就應應用到保壓,保壓一般來講都應用較慢的射速,而壓力的設置則應看縮水的情況如何,小到25%,大到8

25、0%都有可能.Holding pressure step: No matter what product there is a holding pressure step. Any product cant molding a same thickness. Usually the deeper section may sink mark . To prevent this defect it should set holding pressure, The injection speed of holding pressure step is slow but holding pressur

26、e setting within 25-80% depending on sink mark.2. 熔膠段工藝Plastic Technique2. 再復雜的熔膠旋轉過程最多不會超過三段,因為熔膠本身就是存在於把膠熔進料筒的過程,如果原料粘度大,熔膠壓力則大,但速度則應取決於原料的分解溫度,熔膠速度越快,原料中的剪切力則會越大,料管溫度則越高,局部原料產生分解的可能性則會越大,故一般熔膠會采用中速為宜,如45%-75%,熔膠同時會碰到一個比較重要的環節,那就是背壓的使用,產品精度要求越大,背壓的使用則更大,背壓可使原料分子間結构更緊密,成型出的產品則尺寸更穩定,外觀越好.當然,背壓太大,則會產

27、生流涎,所以背壓的使用又應考虙到其它原因.Plastic should lower 3 steps, because plastic is a step to add melt resin material to cyclinder , Higher stick of resin material ,higher screw back pressure. Screw speed differs depending on decomposing temperature of resin material ,Higher screw speed ,Higher trim force of resi

28、n, higher cyclinder temperature. Some resin material may decomposes so it set screw speed in mid-speed such as 45-75%, In plastic step setting screw back pressure is very important, Higher screw back pressure ,higher quality of product screw back pressure make resin structure order, Molding product

29、is beautiful and volume stable. But ,it maybe flow if screw back pressure too high . So all factors should be considered when using screw back pressure. 3. 熔膠過程還有一個比較重要的環節,那就是松退,松退分前松退和后松退,其作用一般是為了防止流涎和抽絲,設定值速度和壓力都在20%-50%間,設定的行程一般在2-5cm間,太長的行程可能會使料筒里面貯存空气,導致下一模出現不期望的气泡.In plastic step sucking back

30、is very important too. Sucking back include front sucking back and back sucking back It setting sucking back to prevent flow and line. It sets sucking back speed and pressure within 20-50% and distance within 2-5cm. TOO long distance make cyclinder reserve air and cause bubble at next molding.頂出的工藝設

31、定knocking out technique setting產品經冷卻定型後則有一個開模的過程,開模基本上是合模的反過程.開模的未段則有一個慢速設置,開模完成后,產品必須頂出的過程.There is a mold opening step after product cooling taking shape. Mold opening is a reverse step of mold closing. The last step of mold opening speed set slow. Product should be knocked out after mold opened.1. 頂前:Knocking out頂前最好分兩個階級,第一階可分為中壓慢速,即是把產品輕輕頂出一部分,然后是中壓中速頂,中壓中速一般指的是35%-55%,而低速則有可能低到5%,這需視產品不同而言,頂出行程