GE注塑成型介绍

INJECTIONMOLDING注射模塑技术

=由GE塑料生产PSOPEIPEI/PCPCPPOPC/ABSABSPSLCPPPSPPO/PAPC/PBTPC/ASAASAPPPVCPEPAPOM

无定形PET工程级普通级结晶性高性能Ultem*树脂heatresistanceLexan*树脂impactresistanceNoryl*树脂impactresistancehydrolyticstability

processabilityCycolac*树脂colorabilityandvisualfxXenoy*树脂impactresistance

chemicalresistancePBTGE塑料提供非常广泛的工程塑料选择InjectionMoldingIntroduction注塑成型介绍GOODPARTMaterial材料Tooling模具Processing工艺Design设计好产品注塑成型介绍生产速度高可以大批量生产人工成本低容易自动化2次加工量小可以生产很小的零件废品损失小尺寸变化小Molded-inInsertsAvailableGlass,Carbon,etc.FillersComplexPartCapabilityGoodDecorationPossible注塑成型优点InjectionMoldingIntroductionToolingCostsareHighHighMachineryandAuxiliaryCostsHighPressureProcessLimitedLargePartCapabilityDisadvantagesofInjectionMoldingEquipment设备InjectionMoldingEquipmentInjectionMoldingEquipmentInjectionUnitClampUnitScrew&BarrelInjectionMoldingEquipmentTheInjectionUnitProvidesInjectionandPackingPressureProvidesTorquetoTurntheScrewTheScrewBarrelMeltingandHomogenizingtheResinInjectionofthePlasticIntotheMoldInjectionMoldingEquipmentTheClampingUnitOpenandClosesMoldHoldstheMoldClosedDuringInjectionCoolsandSolidifiesPartInjectionMoldingEquipmentClampingMechanismsDoubleToggleClampingSystemInjectionMoldingEquipmentClampingMechanismsHydraulicClampingSystemMACHINESHOTSIZE机器注射容量PartWeight=30-80%ofMachineShotSize制件重量=30-80%机器注射容量OptimalPartWeight=40~60%ofMachineShotSize制件重量=40-60%机器注射容量InjectionMoldingEquipmentCLAMPSIZE锁模力MaterialSelection选料ProjectedArea投影面积3~5吨/平方英寸PartDesign产品设计WallThickness壁厚FlowLength流动长度InjectionPressure&Speed注射压力和速度InjectionMoldingEquipmentScrewTypeMachinesAreRecommended推荐采用的螺杆类型UniformPlasticizing

均匀塑化LessPressureLoss

低压力损耗FasterCycles更快成型周期UniformStockTemperature

均匀储料温度StreamlinedMeltFlow

线性熔融流动InjectionMoldingEquipmentMetering计量Feed进料ScrewandCylinderDesign螺杆和料筒设计hfhmL/D=20:1(18~24:1)CompressionRatio压缩比=hf/hm=2.5:1(2.0:1~3.0:1)Cylinderbi-metallicforAbrasionResistance双金属料筒Transition过渡LDInjectionMoldingEquipment往复式螺杆头结构检查环类型:止回环熔融树脂流过开放检查环检查环关闭,防止在注塑过程中料的回流建议采用止逆阀InjectionMoldingEquipmentStandardCylinderNozzles标准料筒喷嘴HeatingBand加热环CylinderBore料筒主体ToMoldProvidesMechanicalandThermalConnectionFromHotCylindertoColderMold提供从热的料筒到相对冷的模具的机械和热连接到模具InjectionMoldingEquipmentSprueBushing主流道衬套Nozzle喷嘴Radius半径Orifice主流道孔口InjectionMoldingEquipmentNozzle喷嘴LandLength0.0to3/16inch(4.76mm)过渡段长度不大于3/16inch(4.76mm)Opening3/16inch(4.76mm)to3/8inch(9.52mm)

开口:4.76~9.52mmSprueBushingis0.8mmLargerthanDimensiononNozzle

主流道衬套孔口要比喷嘴口径大0.8mmAsShortasPossible

尽可能地短AccurateheatingcontrolandGoodHeaterBandCovering

精确的加热控制和好的加热带覆盖InjectionMoldingEquipment通用喷嘴InjectionMoldingEquipmentGEAMPlasticseInjectionMoldingProcessInjectionMoldingSteps:DryingthePelletsLoadingIntoMoldingMachineHeatingandShearingMaterialIntoaMeltInjectingtheMeltIntotheMoldCavityPartCooling,SolidificationEjectingtheFinishedPartFromtheMoldProcessing工艺Start-up:开机:PurgewiththeCorrectMaterial

用正确料清洗

UseCorrectProcessingConditions

采用正确加工参数Downtime:停机:

Shorttime:HoldMaterialinBarrelfor10~15min

短期：存料10~15分钟

Longtime:CleantheBarrel

长期：用正确方法和次序彻底清理InjectionMoldingProcessRecommendedPurgeMaterials推荐清洗料Polymer PurgeMaterialCycolac/Cycoloy PMMA,PS,SANLexan PC,HDPE,PMMANorylPS,PPInjectionMoldingProcessImportantProcessVariables重要加工参数MeltTemperature熔融温度MoldTemperature模具温度TemperatureProfiles温度曲线ResidenceTime停留时间InjectionSpeed注射速度InjectionPressure注射压力PackPressure保压ClampTonnage锁模力Cushion缓冲料垫InjectionMoldingProcessDryingDryingtemperatureandtimeareanimportantkeyfactorforgoodproductsinourproduction在生产得到好的产品，干燥温度和时间是一重要因素TypicalLexan(PC):典型PC MoistureLevel:Lessthan0.02% 1210C/3~4Hrs

水分含量小于0.02%1210

C/3~4HrsInjectionMoldingProcessHowisheataddedtothepolymer?外热如何作用于高分子材料ElectricalHeat:电加热HeaterBands加热带MechanicalHeat机械热ScrewSpeed螺杆速度BackPressure背压InjectionPressure/Speed注射速度/压力InjectionMoldingProcessModelofAmorphousPolymersAddingHeatIncreasesSpaceBetweenMolecularChainsRaiseTemperatureofPolymer

TGLocked固态EntanglementsStiffFlow难于流动EasierFlow较易流动InjectionMoldingProcessMeltTemperature熔融温度35302520151050.030 .060 .090 .120 .150 .180 .210 .240WallThicknessinInches壁厚(In)MeltFlow(in.)LEXAN?101550degF.101@600deg.FIncreasedMeltTemperatureyieldsincreasedFlow.提高熔融温度导致增加流动However,TooHighaMeltTemperatureMayCauseDegradation.但,过高熔融温度造成降解InjectionMoldingVariablesInjectionMoldingEquipmentResidenceTimeTomeasurethis,coloredpelletsaredroppedintothebaseofthehopper.Timeismeasureduntilthepointwhencoloredextrudantispurgedfromthenozzle.Theamountoftimethatmoltenmaterialresidesinthebarrel.Residencetime[min]=

(2.2~2.5)MaxPlasticisingstrokePlasticisingstroke-cushion*Cycletime60ThermoplasticsandDegradation热塑性塑料和降解Degradation降解TemperatureTime时间InjectionMoldingProcessBarrelUnitTheReciprocatingScrew(Filling)ThroatHeatingCoilsNozzleHopperScrewBarrelForce,TorqueFromInjectionUnit料筒组件回转式螺杆喷嘴螺杆加热料斗加料口料筒来自注塑单元的力和力矩InjectionMoldingScrewRotationFeedsandShearsMaterialIntoaMelt.MeltCollectsIntoFrontofBarrel,ForcingScrewBackShotRotationandBackPressure出量通过螺杆回转，熔体聚集于料筒前部，反作用力使螺杆后退。回转力矩和背压InjectionMoldingBarrelUnitTheReciprocatingScrew15010050255075125150100ScrewDiainmmRPMSCREWSPEEDSuggestions(8in/sec)推荐螺杆转速螺杆直径转速InjectionMoldingMeltRequiredtoFillMoldReadyforInjectionShotInjectionPressure注射压力InjectionMoldingEquipmentBarrelUnitTheReciprocatingScrewScrewPushesForward:InjectCushionPackingPressure缓冲垫保压注射InjectionMoldingEquipmentBarrelUnitTheReciprocatingScrewInjectionSpeed注射速度100010010100 1000 10000LEXAN?141@644degFLEXAN?141@608degFLEXAN?141@572degFApparentViscosity(Pa/s)ShearRate(1/s)InjectionSpeedaffectstheviscosityofthemoltenmaterial.注射速度影响熔体粘度表观粘度剪切速率InjectionMoldingVariablesInjectionPressureProfile注射压力曲线HydraulicPressureTimeFillTimeScrewRunTimeBackPressurePeakInjectionPressurePressureAppliedbyInjectionRamtoForcethePlasticFromtheBarreltotheMold.注射压力峰值液压压力填充时间InjectionMoldingVariablesCushion缓冲垫CushionMaterialremaininginbarrelwhentheejectionphaseiscompleted.注塑过程结束后，残于料筒前端的熔体Theinjectionmoldingprocessshouldallowacushiontoprovidesufficientpackingpressureinthemold注塑过程必须要有缓冲垫以保证有效的保压InjectionMoldingVariablesInjectionFlow熔体流动InjectionMoldingProcessInjectionMoldingProcessInjectionFlow熔体流动InjectionMoldingProcessInjectionFlow熔体流动InjectionMoldingProcessInjectionFlow熔体流动InjectionMoldingProcessInjectionFlow熔体流动MoldTempeature模温MoldTemperatureiscriticalinproducingqualifiedpart.模温对得到合格的制件很重要InjectionMoldingProcessPartCoolingandSolidificationHotMeltCooledMoldSolidPart制件冷却和固化热熔体温度较低的模具固化的制件InjectionMoldingProcessMoldTemperature模温MoldTemperatureiscriticalinglossaryandresiduestrainofpart模温对制件的光洁度和模塑残余应力等级很重要Uniformmoldtemperaturereducestheeffectsofwarpage.均匀的模温可以减少翘曲Commonlycontrolledbywatercoolingchannels.模温通常冷却水孔道来控制InjectionMoldingCoolingInjectionMoldingCooling120125125135135145130140140130150145OOOOOOOOOOOOINOUTInjectionMoldingCoolingMOLDManifold“In”Manifold“Out”Water“In”Water“Out”TheMoldTemperatureMustBeBelowTGtoSolidifyPartTGProcessingTemperatureRangeDegradationCooling:AmorphousResin无定型塑料的冷却降解加工温度范围模具温度必须低于玻璃化转变温度InjectionMoldingCoolingDegradationTMTGProcessingTemperatureRangeMoldTemperatureDeterminesCoolingTimeandThereforeDegreeofCrystallinity模温决定了冷却时间和结晶度CoolingThroughtheCrystallinizationRangeTooQuicklyWillResultinReducedCrystallinity(Quenching)过快冷却将造成结晶度低CrystallinizationCoolingRange结晶性塑料的冷却InjectionMoldingCoolingInjectionMoldingEjectionREGRINDSUGGESTIONS对材料回收使用的建议UseOnlyCleanNon-degraded只使用未降解材料UncontaminatedResinforRegrind回收料不能有污染KeepItAsNewMaterial要象保存新料一样Normally25%ofRegrindcanbeUsed通常允许添加25%的回收料ScreenSizesshouldbe7to9mm过滤网应该在7至9MMInjectionMoldingRegrindTenDoforMoldingEngineeringResinsKnowYourMaterial了解你所使用的材料DryProperly正确地干燥UseRecommendedProcessingConditions使用推荐的加工参数UseProperlySizedEquipment选择恰当的设备UseProperlyDesignedTooling正确设计模具UseAdequateRunners浇口尺寸充分UseProperVenting良好的排气UseNozzleswithProperHeatControls对喷嘴施以良好的温控UseProperScrewDesign恰当的螺杆结构ScheduleAnnualorBi-AnnualEquipmentMaintenance正确维护保养设备十大准则InjectionMoldingInjectionMoldingQ&ADISCLAIMER:THEMATERIALSANDPRODUCTSOFTHEBUSINESSESMAKINGUPTHEGEADVANCEDMATERIALSUNITOFGENERALELECTRICCOMPANY,ITSSUBSIDIARIESANDAFFILIATES(“GEAM”),ARESOLDSUBJECTTOGEAM’SSTANDARDCONDITIONSOFSALE,WHICHAREINCLUDEDINTHEAPPLICABLEDISTRIBUTOROROTHERSALESAGREEMENT,PRINTEDONTHEBACKOFORDERACKNOWLEDGMENTSANDINVOICES,ANDAVAILABLEUPONREQUEST.ALTHOUGHANYINFORMATION,RECOMMENDATIONS,ORADVICECONTAINEDHEREINISGIVENINGOODFAITH,GEAMMAKESNOWARRANTYORGUARANTEE,EXPRESSORIMPLIED,(I)THATTHERESULTSDESCRIBEDHEREINWILLBEOBTAINEDUNDEREND-USECONDITIONS,OR(II)ASTOTHEEFFECTIVENESSORSAFETYOFANYDESIGNINCORPORATINGGEAMMATERIALS,PRODUCTS,RECOMMENDATIONSORADVICE.EXCEPTASPROVIDEDINGEAM’SSTANDARDCONDITIONSOFSALE,GEAMANDITSREPRESENTATIVESSHALLINNOEVENTBERESPONSIBLEFORANYLOSSRESULTINGFlameRetardantORANYUSEOFITSMATERIALSORPRODUCTSDESCRIBEDHEREIN.

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