塑料注塑成型加工介绍课件

塑料注塑成型加工向明四川大学高分子研究所高分子材料工程国家重点实验室塑料注塑成型加工向明1良好的注塑件质量获得的条件适合的注塑设备适宜的螺杆结构良好的材料预处理工艺合适的注塑工艺条件合理的模具结构良好的注塑件质量获得的条件适合的注塑设备2塑料注塑基础注塑加工涉及的过程1、塑料胶粒的软化和塑化（螺杆塑化过程）螺杆结构的设计必须保证得到均匀一致的熔体2、塑料熔体计量螺杆转速，背压3、塑料熔体向锁闭型腔注射锁模力比型腔压力高20%，熔体以均衡的方式充填模具型腔，以避免内应力的产生多级注塑、充模流动行为、型腔压力分布、熔体PVT性质4、冷却—熔体凝固并保持模具型腔形状均匀的模具表面温度，避免制件翘曲、保证尺寸精度5、制件顶出塑料注塑基础注塑加工涉及的过程3塑化过程塑化过程4最大计量行程最大计量行程5屏障螺杆屏障螺杆6关于塑料的特征分子量熔体指数PVT性质剪切稀化行为热稳定性收缩行为最大流动比吸湿性关于塑料的特征分子量7PVT性质PVT性质8材料的收缩特性温度引起的体积变化结晶高分子29%

无定型高分子8%压力引起的体积变化

10-15%材料的收缩特性温度引起的体积变化9塑料注塑成型加工介绍课件10Poly-merDensityRoomTemp.Processtemp.degreecDensityprocesstemp%ageinjectionutilisa-tioncapacityPermissibleresidencetime-min.Max-flowratiofor1mmwallthicknessScrewcushionmmShrinkage%OutputratiorelatedtoPsScrewrpmrelatedtoPsABS1.05220-2600.9640-80

100-1404-60.4-0.70.830.83CA1.29170-2501.1050-805-830030.4-0.7NANAPOM1.42192-2151.1630-8015100-2302-62NANAPMMA1.18220-2601.0935-804-8100-1302-60.4-0.80.940.74PPO1.06250-290NA30-808100-1403-40.4-0.7NANAPA6/61.14220-2800.9540-805100-2302-4NA0.580.50PC1.22280-3101.0850-802-360-10040.7-0.80.670.57PES1.37330-400NANANA60-1204-50.60.950.83PBT1.31220-270NA40-803-4125-1854NANANAPPS1.5-2.1300-360NA50-802-4120-1504-60.2NANAPETP1.38260-3001.250-802-450-9041.3-4PS1.05220-2700.9525-902-4150-20040.451.001.00HDPE0.95220-2800.7410-85

1702-61.5-20.730.94LDPE0.92180-2800.7410-95

2002-6NA0.821.05PP0.91250-2750.7310-85

17041.2-2.20.630.86RPVC1.3-1.6170-190NA25-802060

0.5-0.2NANASPVC1.1-1.14180-200NA20-801518041.2NANASAN1.08240-2700.9940-805-6140-18040.50.961.12TPU1.20180-225NA40-80305031-1.15NANAPoly-merDensityProcesstemp.De11剪切变稀行为剪切变稀行为12螺杆压缩区的剪切稀化螺杆压缩区的剪切稀化13喷嘴的剪切稀化喷嘴的剪切稀化14热稳定性热稳定性15Kx最大射胶体停留时间=----------------------------x成型周期型腔体积Kx最大射16注塑过程充模过程85-98%注塑行程切换过程压实过程冷却过程注塑过程充模过程85-98%注塑行程17注塑过程中的收缩行为注塑过程中的收缩行为18加工过程对收缩的影响加工过程对收缩的影响19不同材料的收缩率MATERIALS%SHRINKAGEMATERIALS%SHRINKAGENylon61-1.5Polycarbonate0.8Nylon6-GR0.5Acetal2Nylon6/61-2PVC-Rigid0.5-0.7Nylon6/6-GR0.5PVC-Soft1-3LDPE1.5-3ABS0.4-0.6HDPE2-3PP1.2-2Polystyrene0.5-0.7Celluloseacetate0.5Styrene-acrylonitrile0.4-0.6Celluloseacetate..........butyrate0.5Acrylic0.3-0.6Cellulosepropionate0.5

不同材料的收缩率MATERIALS%SHRINKAGEMA20塑料注塑成型加工介绍课件21收缩收缩22收缩与翘曲收缩与翘曲23收缩与结晶收缩与结晶24收缩与加工过程收缩与加工过程25收缩与取向收缩与取向26收缩与冷却收缩与冷却27充模与冷却充模与冷却28均衡流动均衡流动29塑料注塑成型加工介绍课件30塑料注塑成型加工介绍课件31调整均衡性调整均衡性32调整均衡性调整均衡性33塑料注塑成型加工介绍课件34与模具和机台相关的注塑缺陷缩痕壁厚设计不均匀可通过注塑压力、保压压力、注塑速度调整尺寸变化冷却不均匀，调整保压压力、时间、强化冷却均匀性翘曲熔接缝降解重量变化与模具和机台相关的注塑缺陷缩痕35POSITIONSPEEDPRESSUREFILLINGPHASEAlsoknownasSpeedphase.Selectendof1ststepandstartof2ndstep.SetSPEED1Trytosethigh.OnlyonepressuresettingisrequiredduringFILLINGPHASE.PressureSettingshouldbemorethanactualfillingpressure.asreliefvalveshouldnotbeactuated.Ifitisactuated,thenspeedcontrolwillbelost.Fillingpressuredependsonresistancetomovethemelt.Itdependsonflowratioandviscosityofmelt.AlsoknownasSpeedphase.Theremaybeno.ofstepsavailableonmachine.Selectendof2ndstepandstartof3rdstepSetSPEED2Lowerspeedforcrossingnarrowpassage/gateStepsarepositioncontrolled.Selectendof3rdstepandstartofSWITCHOVERPOINT.Thispointisataround80-95%oftheinjectionstroke.SetSPEED3Reducetolowersinkmark/increasetoshiftweldline.PRESSUREPHASE-Holdingphase.Theremaybeno.ofstepsavailableonmachine.TimercontrolstheHoldingpressurestepsifavailableonmachine.Holdingpressuretimeforstep1issetonatimer,SetSPEEDlowvaluesayupto35%notmore.ThiscanbeonestepofspeedfordifferentHoldingsteps.Speedsetislow,asthereislessornospacetomovethemelt.

Holdingpressure1setjustenoughtofillcavitywithoutoverpacking.Stepsaretimerscontrolled.Holdingpressuretimeforstep2issetonatimer,Holdingpressure2setjustenoughtofillcavitywithoutoverpacking.

Holdingpressuretimeforstep3issetonatimer,Holdingpressure3setjustenoughtofillcavitywithoutoverpacking.POSITIONSPEEDPRESSUREFILLINGP36均衡热交换均衡热交换37塑料注塑成型加工介绍课件38塑料注塑成型加工介绍课件39均衡凝固均衡凝固40熔接缝熔接缝41改变熔接缝位置改变熔接缝位置42成型周期成型周期43塑料注塑成型加工介绍课件44Thepredominantlymaterialcausesinvolvedinfailurewere:Thepredominatingprocessfaultswere:EnvironmentalStressCracking,Excessivemoulded-instresses,CyclicFatigue,Voiding,NotchSensitivity,Poorweldlines,ChemicalAttackand;StressCracking,AdverseOrientation,UVDegradation,Materialcontamination,ThermalDegradation,LongerResidencetimeinthemachine,Creep,Wrongmaterialselectionorpoorpartdesign,Buckling,WrongmaterialselectionorpoorpartdesignThepredominantlymaterialcau45工程塑料的加工缺陷及解决方法工程塑料的加工缺陷及解决方法46热塑性工程塑料的加工材料加工在材料应用中处于举足轻重的地位

特定用途材料选择依据材料性能的准确测试但在实际的过程中,加工过程并不能完整的将材料性能表达到具体的制件上特定用途材料选择加工条件热塑性工程塑料的加工材料加工在材料应用中处于举足轻重的地位47如果选择的工程塑料的加工窗口过窄,塑料会在加工过程中发生力学、物理、化学的变化通常,加工窗口越窄,制件的不合格率越高一般在塑料加工过程中，制件的质量控制主要通过将其与已知性能的好样品进行比较如果选择的工程塑料的加工窗口过窄,塑料会在加工过程中发生力学48热塑性工程塑料的加工缺陷的发现目测表面、外观质量力学性能测试材料性能和加工条件对制件使用性能的影响重量比较尺寸稳定性观察内应力的表征热塑性工程塑料的加工缺陷的发现目测49加工缺陷表观缺陷外观、尺寸、重量变化、制件发脆等隐性缺陷导致材料过早失效加工缺陷表观缺陷50热塑性工程塑料加工的表观缺陷黑点原因

downtimetoolongbarrelswitchedoffoveralongperiodoftimepoorpurgingofbarreldirtyplasticizingunitinadequatenozzledeadedgesingate/runnersystemgranuleimpuritiesdegradationbyotherresinspick-upofdegradedmaterialfromcylinderwallduringcooling热塑性工程塑料加工的表观缺陷黑点51气泡

injectionpressuretoolowinadequatefunctioningofbackflowvalvesuck-backtoolongplasticizingtoofastairtrapinthehopperfeedimproperfeedvolatilesandtrappedgasmouldtemperaturetoolowthintothicktransitionmeltoverheating1.controlholding/injectionpressure2.increasebackpressure3.increasemouldtemperature4.checkbackflowvalve5.allowforadequateventing6.enlargegate7.shortenlandlength气泡52流痕injectionspeedtooslowortoofastinjectionpressuretoolowholdpressuretoolonginadequatemouldcoolingmouldtoohotaroundgatemouldtoocoldgatetoosmallwronggatelocationgatelandlengthtoolongwronghotrunnersystemmelttemperaturetoolow

1.adaptinjectionspeed2.addalargecoldslugarea3.addcoldwellsattheendofrunnersystems4.controlnozzleheatbetter:ifnecessaryaddberylliumcoppertip(notrecommendedforFRresins)5.shortenoreliminatestandardspruebushing:useahotspruebushing6.cleanflowmustexistfromthecylinder,adaptor,nozzleandtip:avoidandeliminateanydeadpocketsorsections流痕53胶烧problemswithbackflowvalveinjectionspeedtoofastbackpressuretoohighinadequateventing:entrappedairfrictionalburningcheckspruediametermelttoohotortoocold:maycreateshear胶烧54起层injectionspeedtoohighmelttoohotpoorlymeltedIncompatiblecolourdyescrosscontaminationwithotherpolymerstoomuchuseofrecycledmaterial起层55变色飞边变色56射流纹路

射流57缩痕缺料缩痕58银丝银丝59热塑性工程塑料加工的隐性缺陷收缩率、翘曲热塑性工程塑料加工的隐性缺陷收缩率、翘曲60塑料注塑成型加工介绍课件61塑料注塑成型加工介绍课件62后收缩率大后收缩率大63塑料注塑成型加工介绍课件64空洞空洞65ZIPPERZIPPER66塑料注塑成型加工介绍课件67塑料注塑成型加工介绍课件68在正确选用材料的前提下，热塑性工程塑料加工中的缺陷是造成制件失效的主要原因。%SHRINKAGE%SHRINKAGEinjectionspeedtoofastasreliefvalveshouldnotbeactuated.充模过程85-98%注塑行程PRESSUREPHASE-SetSPEED3inadequatefunctioningofbackflowvalvepick-upofdegradedmaterialfromcylinderwallduringcoolingPRESSUREPHASE-inadequatemouldcoolingholdpressuretoolongStyrene-acrylonitrileLongerResidencetimeinthemachine,不熔颗粒及熔体不均匀性在正确选用材料的前提下，热塑性工程塑料加工中的缺陷是造成制件69塑料注塑成型加工介绍课件70塑料注塑成型加工介绍课件71塑料注塑成型加工介绍课件72熔接痕强度低熔接痕强度低73塑料注塑成型加工介绍课件74模温设定不正确引起的性能劣化模温设定不正确引起的性能劣化75塑料注塑成型加工介绍课件76其他加工条件引起的性能劣化其他加工条件引起的性能劣化77飞边引起的缺口效应飞边引起的缺口效应78塑料注塑成型加工介绍课件79残留内应力提高生产效率---减少成型周期---低模温

----高内应力----应力开裂残留内应力80检查内应力ABS冰醋酸，甲醇SAN甲苯/异丙醇（1/5）PA6，PA66氯化锌饱和水溶液，50℃POM硫酸，50℃PC甲苯/异丙醇（1/3）检查内应力ABS81结语

在正确选用材料的前提下，热塑性工程塑料加工中的缺陷是造成制件失效的主要原因。可以通过优化加工条件、模具设计的改善、以及材料的流动特征及冷却凝固行为的控制，来避免加工过程产生的缺陷减少制件的失效破坏。结语在正确选用材料的前提下，热塑性工程塑料加工中的缺陷82谢谢！塑料注塑成型加工介绍课件83塑料注塑成型加工向明四川大学高分子研究所高分子材料工程国家重点实验室塑料注塑成型加工向明84良好的注塑件质量获得的条件适合的注塑设备适宜的螺杆结构良好的材料预处理工艺合适的注塑工艺条件合理的模具结构良好的注塑件质量获得的条件适合的注塑设备85塑料注塑基础注塑加工涉及的过程1、塑料胶粒的软化和塑化（螺杆塑化过程）螺杆结构的设计必须保证得到均匀一致的熔体2、塑料熔体计量螺杆转速，背压3、塑料熔体向锁闭型腔注射锁模力比型腔压力高20%，熔体以均衡的方式充填模具型腔，以避免内应力的产生多级注塑、充模流动行为、型腔压力分布、熔体PVT性质4、冷却—熔体凝固并保持模具型腔形状均匀的模具表面温度，避免制件翘曲、保证尺寸精度5、制件顶出塑料注塑基础注塑加工涉及的过程86塑化过程塑化过程87最大计量行程最大计量行程88屏障螺杆屏障螺杆89关于塑料的特征分子量熔体指数PVT性质剪切稀化行为热稳定性收缩行为最大流动比吸湿性关于塑料的特征分子量90PVT性质PVT性质91材料的收缩特性温度引起的体积变化结晶高分子29%

无定型高分子8%压力引起的体积变化

10-15%材料的收缩特性温度引起的体积变化92塑料注塑成型加工介绍课件93Poly-merDensityRoomTemp.Processtemp.degreecDensityprocesstemp%ageinjectionutilisa-tioncapacityPermissibleresidencetime-min.Max-flowratiofor1mmwallthicknessScrewcushionmmShrinkage%OutputratiorelatedtoPsScrewrpmrelatedtoPsABS1.05220-2600.9640-80

100-1404-60.4-0.70.830.83CA1.29170-2501.1050-805-830030.4-0.7NANAPOM1.42192-2151.1630-8015100-2302-62NANAPMMA1.18220-2601.0935-804-8100-1302-60.4-0.80.940.74PPO1.06250-290NA30-808100-1403-40.4-0.7NANAPA6/61.14220-2800.9540-805100-2302-4NA0.580.50PC1.22280-3101.0850-802-360-10040.7-0.80.670.57PES1.37330-400NANANA60-1204-50.60.950.83PBT1.31220-270NA40-803-4125-1854NANANAPPS1.5-2.1300-360NA50-802-4120-1504-60.2NANAPETP1.38260-3001.250-802-450-9041.3-4PS1.05220-2700.9525-902-4150-20040.451.001.00HDPE0.95220-2800.7410-85

1702-61.5-20.730.94LDPE0.92180-2800.7410-95

2002-6NA0.821.05PP0.91250-2750.7310-85

17041.2-2.20.630.86RPVC1.3-1.6170-190NA25-802060

0.5-0.2NANASPVC1.1-1.14180-200NA20-801518041.2NANASAN1.08240-2700.9940-805-6140-18040.50.961.12TPU1.20180-225NA40-80305031-1.15NANAPoly-merDensityProcesstemp.De94剪切变稀行为剪切变稀行为95螺杆压缩区的剪切稀化螺杆压缩区的剪切稀化96喷嘴的剪切稀化喷嘴的剪切稀化97热稳定性热稳定性98Kx最大射胶体停留时间=----------------------------x成型周期型腔体积Kx最大射99注塑过程充模过程85-98%注塑行程切换过程压实过程冷却过程注塑过程充模过程85-98%注塑行程100注塑过程中的收缩行为注塑过程中的收缩行为101加工过程对收缩的影响加工过程对收缩的影响102不同材料的收缩率MATERIALS%SHRINKAGEMATERIALS%SHRINKAGENylon61-1.5Polycarbonate0.8Nylon6-GR0.5Acetal2Nylon6/61-2PVC-Rigid0.5-0.7Nylon6/6-GR0.5PVC-Soft1-3LDPE1.5-3ABS0.4-0.6HDPE2-3PP1.2-2Polystyrene0.5-0.7Celluloseacetate0.5Styrene-acrylonitrile0.4-0.6Celluloseacetate..........butyrate0.5Acrylic0.3-0.6Cellulosepropionate0.5

不同材料的收缩率MATERIALS%SHRINKAGEMA103塑料注塑成型加工介绍课件104收缩收缩105收缩与翘曲收缩与翘曲106收缩与结晶收缩与结晶107收缩与加工过程收缩与加工过程108收缩与取向收缩与取向109收缩与冷却收缩与冷却110充模与冷却充模与冷却111均衡流动均衡流动112塑料注塑成型加工介绍课件113塑料注塑成型加工介绍课件114调整均衡性调整均衡性115调整均衡性调整均衡性116塑料注塑成型加工介绍课件117与模具和机台相关的注塑缺陷缩痕壁厚设计不均匀可通过注塑压力、保压压力、注塑速度调整尺寸变化冷却不均匀，调整保压压力、时间、强化冷却均匀性翘曲熔接缝降解重量变化与模具和机台相关的注塑缺陷缩痕118POSITIONSPEEDPRESSUREFILLINGPHASEAlsoknownasSpeedphase.Selectendof1ststepandstartof2ndstep.SetSPEED1Trytosethigh.OnlyonepressuresettingisrequiredduringFILLINGPHASE.PressureSettingshouldbemorethanactualfillingpressure.asreliefvalveshouldnotbeactuated.Ifitisactuated,thenspeedcontrolwillbelost.Fillingpressuredependsonresistancetomovethemelt.Itdependsonflowratioandviscosityofmelt.AlsoknownasSpeedphase.Theremaybeno.ofstepsavailableonmachine.Selectendof2ndstepandstartof3rdstepSetSPEED2Lowerspeedforcrossingnarrowpassage/gateStepsarepositioncontrolled.Selectendof3rdstepandstartofSWITCHOVERPOINT.Thispointisataround80-95%oftheinjectionstroke.SetSPEED3Reducetolowersinkmark/increasetoshiftweldline.PRESSUREPHASE-Holdingphase.Theremaybeno.ofstepsavailableonmachine.TimercontrolstheHoldingpressurestepsifavailableonmachine.Holdingpressuretimeforstep1issetonatimer,SetSPEEDlowvaluesayupto35%notmore.ThiscanbeonestepofspeedfordifferentHoldingsteps.Speedsetislow,asthereislessornospacetomovethemelt.

Holdingpressure1setjustenoughtofillcavitywithoutoverpacking.Stepsaretimerscontrolled.Holdingpressuretimeforstep2issetonatimer,Holdingpressure2setjustenoughtofillcavitywithoutoverpacking.

Holdingpressuretimeforstep3issetonatimer,Holdingpressure3setjustenoughtofillcavitywithoutoverpacking.POSITIONSPEEDPRESSUREFILLINGP119均衡热交换均衡热交换120塑料注塑成型加工介绍课件121塑料注塑成型加工介绍课件122均衡凝固均衡凝固123熔接缝熔接缝124改变熔接缝位置改变熔接缝位置125成型周期成型周期126塑料注塑成型加工介绍课件127Thepredominantlymaterialcausesinvolvedinfailurewere:Thepredominatingprocessfaultswere:EnvironmentalStressCracking,Excessivemoulded-instresses,CyclicFatigue,Voiding,NotchSensitivity,Poorweldlines,ChemicalAttackand;StressCracking,AdverseOrientation,UVDegradation,Materialcontamination,ThermalDegradation,LongerResidencetimeinthemachine,Creep,Wrongmaterialselectionorpoorpartdesign,Buckling,WrongmaterialselectionorpoorpartdesignThepredominantlymaterialcau128工程塑料的加工缺陷及解决方法工程塑料的加工缺陷及解决方法129热塑性工程塑料的加工材料加工在材料应用中处于举足轻重的地位

特定用途材料选择依据材料性能的准确测试但在实际的过程中,加工过程并不能完整的将材料性能表达到具体的制件上特定用途材料选择加工条件热塑性工程塑料的加工材料加工在材料应用中处于举足轻重的地位130如果选择的工程塑料的加工窗口过窄,塑料会在加工过程中发生力学、物理、化学的变化通常,加工窗口越窄,制件的不合格率越高一般在塑料加工过程中，制件的质量控制主要通过将其与已知性能的好样品进行比较如果选择的工程塑料的加工窗口过窄,塑料会在加工过程中发生力学131热塑性工程塑料的加工缺陷的发现目测表面、外观质量力学性能测试材料性能和加工条件对制件使用性能的影响重量比较尺寸稳定性观察内应力的表征热塑性工程塑料的加工缺陷的发现目测132加工缺陷表观缺陷外观、尺寸、重量变化、制件发脆等隐性缺陷导致材料过早失效加工缺陷表观缺陷133热塑性工程塑料加工的表观缺陷黑点原因

downtimetoolongbarrelswitchedoffoveralongperiodoftimepoorpurgingofbarreldirtyplasticizingunitinadequatenozzledeadedgesingate/runnersystemgranuleimpuritiesdegradationbyotherresinspick-upofdegradedmaterialfromcylinderwallduringcooling热塑性工程塑料加工的表观缺陷黑点134气泡

injectionpressuretoolowinadequatefunctioningofbackflowvalvesuck-backtoolongplasticizingtoofastairtrapinthehopperfeedimproperfeedvolatilesandtrappedgasmouldtemperaturetoolowthintothicktransitionmeltoverheating1.controlholding/injectionpressure2.increasebackpressure3.increasemouldtemperature4.checkbackflowvalve5.allowforadequateventing6.enlargegate7.shortenlandlength气泡135流痕injectionspeedtooslowortoofastinjectionpressuretoolowholdpressuretoolonginadequatemouldcoolingmouldtoohotaroundgatemouldtoocoldgatetoosmallwronggatelocationgatelandlengthtoolongwronghotrunnersystemmelttemperaturetoolow

1.adaptinjectionspeed2.addalargecoldslugarea3.addcoldwellsattheendofrunnersystems4.controlnozzleheatbetter:ifnecessaryaddberylliumcoppertip(notrecommendedforFRresins)5.shortenoreliminatestandardspruebushing:useahotspruebushing6.cleanflowmustexistfromthecylinder,adaptor,nozzleandtip:avoidandelim