注塑成型工艺流程及条件介绍外文文献翻译、中英文翻译、外文翻译

注塑 成型工艺流程及条件介绍 成型条件设定 按成型步骤 :可分为开锁模 ,加热 ,射出 ,顶出四个过程 . 锁模条件设定 : 1， 锁模一般分 : 快速 中速 低压 高压 2.， 快锁模一般按模具情况分 ,如果是平面二板模具 ,快速锁模段可用较快速度 ,甚至于用到特快 ,当用到一般快速时 ,速度设到 55-75%,完全平面模可设定到 80-90%,如果用到特快就只能设定在 45-55%,压力则可设定于 50-75%,位置段视产品的深浅 (或长短 )不同 ,一般是开模宽度的 1/3. 3， 中速段 ,在快速段结束后即转换成中速 ,中速的位置一般是到模板 (包括三板模 ,二板模 )合在一块为止 ,具体长度应视模板板间隔 ,速度一般设置在 30%-50%间 ,压力则是 20%-45%间 . 4， 低压设定 ,低速设定一般是在模板接触的一瞬间 ,具体位置就设在机台显示屏显示的一瞬间的数字为准 ,这个数字一般是以这点为标准 ,即于此点则起不了高压 ,高于此点则大 ,轻易起高压 .设定的速度一般是 15%-25%,视乎不同机种而定 ,压力一般设定于 1-2%,有些机则可设于 5-15%,也是视乎不同机种不同 . 5.高压设定 ,按一般机台而言 ,高压位置机台在出厂时都已作了设定 ,相对来讲 ,是不可以随便更改的 ,比如震雄机在 50P.速度相对低压略高 ,大约在 30-35%左右 ,而压力则视乎模具而定 ,可在 55-85%中取 ,比如完全平面之新模 ,模具排气良好 ,甚至于设在 55%即可 ,如果是滑块较多 ,原来生产时毛边也较多 ,甚至于可设在 90%还略显不足 . 加热工艺条件设定 1.加热段温度设定必须按照产品所使用的原料的不同而不同 ,但却必须遵循一个这样的规则 ,即由射口筒到进科段温度是逐步递减的 .且递减温度是以 10.度为单位 . 2 特殊情况下 .如料头抽丝 ,则射口筒温度应降低 ,如果是比较特殊的原料冷凝比较快的 .则射口筒温度则不止比第二节法兰 温度高 10度 .比如 PPS. 尼龙等 . 3.机台马达启动温度视乎机台不同而不同 ,一般出于对机台油路中的油封保护需要 ,油温最好能控制在 40 度 -60 度 ,以免油封长期高压而变化 ,缩短使用寿命 ,造成成型不稳定 . 注射是把塑料原料经加热后射进模腔的过程 ,它一般可分为第一级 ,第二级 ,第三级 ,第四级及保压几段 : 1 .第一级注射一般是注射料头段 .具注射量一般可根据料头的轻重来估计其行程 ,当然也可以依据公式来计算 ,如公式 L=Si=Vi/0.785Ds2: L:注射行程 ； Si: 注射行程 ； Vi:理论注射容积 ； Ds:螺杆 直径 ； 0.785:是 /4的值 . 当然 ,如果我们在成型时每设定一个参数都要计算一次 ,要成型出一个产品就要几个小时才能完成了 . 2. 第二级是注塑产品约 2/3 的阶段 ,当然 ,根据产品特殊需要 ,也允许成型不到 2/3 阶段 ,比如避免结合线问题 ,这一阶段的成型速度及压力一般是整个成型段的最大值段 ,如果排的产品与机台基本是相吻合的 .模具结构合理 ,排气良好 ,这一段的压力一般也不会超过 80%.速度侧视产品需变 ,可能大到 95%也可 ,自然一般都是在 55%-80%间 . 3. 第三段是注射余下的 1/3 段 ,其速度和压力根据产品的需要 ,一般是小于第二段 ,速度和压力存在于一个往下降的过程 .主要是为了防止产品毛边的产生 ,但同时又必须把产品充填饱满 . 4.第四段 :一般有机台还有第五 ,第六段 ,这段的成型速度和压力相同前 ,都存在两段一个递减过程 .其作用都是起到一个再次充满的作用 . 5.保压段 :不论成型什么产品 ,都存在一个保压过程 .任何产品都不同程度的存在一个厚薄不一的问题 ,正常情况下 ,较厚的部分都可能存在一个收缩凹陷的现象 ,为了解决这种现象 ,就应应用到保压 ,保压一般来讲都应用较慢的射速 ,而压力的设置则应看缩水的情况如何 ,小到 25%,大到 80%都 有可能 . 产品经冷却定型后则有一个开模的过程 ,开模基本上是合模的反过程 .开模的未段则有一个慢速设置 ,开模完成后 ,产品必须顶出的过程 . 一 .顶前 : 顶前最好分两个阶级 ,第一阶可分为中压慢速 ,即是把产品轻轻顶出一部分 ,然后是中压中速顶 ,中压中速一般指的是35%-55%,而低速则有可能低到 5%,这需视产品不同而言 ,顶出行程设定是顶出长度稍比产品垂直深度大 1-2cm即可 . 二 .退针 顶退包括两个过程与顶落的过程基本一致 ,顶退的终点应预留 1-3cm的空间 ,以保护顶针油管不被顶坏 . 三 .顶针 顶针方式还包括一个多次顶 ,单次顶及顶针停留的选择 ,机械手取产品 ,脱模顺利的情况都采取多项 ,为了顶针油缸 寿命的延长 ,多次顶就以不超过三次 为宜 ,顶针停留一般用在顶针带着产品退回有可能对增品产生损伤的模具 ,同时为配合机械手使用 ,有时也需要较短的顶针停留 . Injection molding technical process and condition introduction Section Molding parameter Setting Molding steps: mold opening/closing, heating injection and knocking out. Mold closing parameter setting 1.Mold closing: high-speed low -speed low pressurehigh pressure 2.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 especially 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.In mid-speed 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.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 the 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. 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 CHENHSONG 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 can set 90%. Heating technique parameter setting 1.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 nozzle to feeding resin material position. 2 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. 3. 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 damaged Its work time will be shorter, it can cause molding stable. Injection is a step which inject melt resin material into mold. It consists of stepl,step2 ,step3,step4 and holding pressure step: 1. 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: injection stroke Si: injection stroke Vi: injection volume of theoretical Ds: diameter of screw 0. 785: value of /4. But it cost a lot of time to produce one product if every time molding parameter is setting by calculation. 2. 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 speed 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. 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. Step 4 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. 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 pressure setting within 25-80% depending on sink mark. 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. one.Knocking out Knocking out includes two steps, Step1 section setting mid-speed, knocks product out partly step2 section