精密注塑技术课件

精密注塑技术

AspectsforPreciseInjectionMoldingStarlitePlasticProducts(Kunshan)co.,ltd.MichaelYang内容提要Overview

精密注塑的定义

DefinitionPreciseInjectionMolding锁模系统ClampingUnit

锁模力

ClampingForce选择注射装置的准则CriteriatoSelecttheInjectionUnit

SELOGICA®

控制器

SELOGICA®Controller模具设计MoldDesign

模具温度控制MoldTemperatureControl2精密注塑的定义DefinitionPreciseInjectionMolding小的尺寸和公差轻的部件重量为特定产品配备注塑设备

灵活的机器配备（一台机器可适用于多种模具)

稳定的质量，高的重复性

SmallpartdimensionandtoleranceLowweightAdaptationofmachineperformancetothepartsFlexiblemachineconfiguration(manymoldssuitableforonemachine)Stablequality,reproducibility

3锁模力ClampingForce 精密注塑的另一个重要因素是锁模力。原因是：模腔更好的排气（90%的空气从分型面排出）减少机器和模具的磨损节省能源Oneotherimportantaspectforpreciseinjectionmoldingistheclampingforce.Reasonsforthatare:Muchbetterventingofthecavitiesduringinjection.(ca.90%oftheairinsidethecavityescapeoverthepartingline)Topreventmachineandmoldfromunnecessarywear.Savingenergy5锁模力ClampingForce 怎样计算锁模力锁模力=单位锁模力X(产品投影面积+流道投影面积）如果有滑块，需要将滑块投影面积的30%加入产品投影面积Howtocalculatetheclampingforce?Ifthemoldcontainssliders!Youhavetoadd30%oftheprojectedsliderareatotheprojectedareaofmoldedpart.6锁模力ClampingForce单位锁模力的确定可使用以下图表Todefinethenecessaryspecificclampingforce,useoneofthepicturesbelow.

Forstandardparts forthinwalledpartswithlongflowpaths7选择注射单元规格的准则

CriteriatoSelecttheInjectionUnitShotweightCycletimeMaterialInjectionpressure9每一机器尺寸Each

machine

size三个注射单元3injection

units三个料筒规格3cylinder

sizes选择注射单元规格的准则

CriteriatoSelecttheInjectionUnit模块化Modularity10选择注射单元规格的准则

CriteriatoSelecttheInjectionUnit注射单元的欧洲橡塑机械协会(EUROMAP)规格表示注射单元的最大注射功。计算方法最大注射压力X最大行程容量/1000举例按注塑机320C600-250规格表最大注射压力(35mm螺杆）：1820bar最大行程容量144ccm1820barX144ccm/1000250ThesizeoftheinjectionunitisaccordingtoEUROMAPandindicatestheworkingperformanceoftheinjectionunit.Theworkingperformanceiscalculatemax.spec.injectionpressurexmax.strokevolume/1000Example:Accordingtothetechnicaldataof320C600-250Max.Injectionpressure(screwdiameter35mm)=1820barMax.Strokevolume=144cm31820barx144cm3/100025011选择注射量的准则Selectioncriteriashotvolume最大计量容量max.dosagevolume20–80%最佳工作范围opt.workingrange10–20%bzw.80–90%可接受的范围conditionalsuited<10%bzw.>90%不推荐的范围notrecommended选择注射单元规格的准则

CriteriatoSelecttheInjectionUnit13选择注射单元规格的准则

CriteriatoSelecttheInjectionUnitExample:Connector(PA6),8cavities,26.5gshotweight

Resultsaccordingthelistbelow:(1)Theinjectionvolumemustbeonaverage25%greaterthanthevolumeoftheinjectedpart(incl.sprue)duetoshrinkageduringsolidifyingandduetothecompressionofthemeltduringinjection.Injectionunit100100250250Screwdiameter20mm25mm30mm40mmMax.injectionvolume31cm349cm3106cm3188cm3Percentageofcapacity95%60%28%16%14选择注射单元规格的准则

CriteriatoSelecttheInjectionUnitExample:Connector(PA6),8cavities,26.5gshotweight

2ndexample,calculationwithshotweight

Resultsaccordingthelistbelow:Injectionunit100100250250Screwdiameter20mm25mm30mm40mmMoldedpartweight26g41g89g158gPercentageofcapacity100%64%30%17%15选择注射单元规格的准则

CriteriatoSelecttheInjectionUnitExample:Connector(PA6),8cavities,26.5gshotweight(29.31

cm3)

Resultaccordingtothelistbelow,dwelltimeforPA6min.60sec.Injectionunit100100250250Screwdiameter20mm25mm30mm40mmScrewchannelvolume60cm385cm3185cm3265cm3Cycletime15s/dwelltime25sec.35sec.75sec.109sec.Cycletime25s/dwelltime41sec.58sec.126sec.181sec.Remarks:anextendedscrewandcylindercanincreasethedwelltime!17选择注射单元规格的准则

CriteriatoSelecttheInjectionUnitSelectioncriteriamaterialthroughput

Example:Connector(PA6),8cavities,26.5gshotweightInjectionunit100100100250250Screwdiameter20mm25mm30mm30mm40mmMax.Throughput/h(PA-GF30)3.5kg/h5kg/h6kg/h11kg/h15,5kg/hThroughput(cycletime15s)6.4kg/h6.4kg/h6.4kg/h6.4kg/h6.4kg/hThroughput(cycletime25s)3.8kg/h3.8kg/h3.8kg/h3.8kg/h3.8kg/hMax.Throughput/h(PS)5.5kg/h8kg/h9.5kg/h17kg/h24.5kg/hThroughput(cycletime15s)6.4kg/h6.4kg/h6.4kg/h6.4kg/h6.4kg/hThroughput(cycletime25s)3.8kg/h3.8kg/h3.8kg/h3.8kg/h3.8kg/h18错误的选择会造成Mistakesinselectioncausese.g.to

-不完全熔化的粒料 -Unmeltedgranulate -混色不均 -Colorsteaks -烧焦 -Burntstreaks选择注射单元规格的准则

CriteriatoSelecttheInjectionUnit19选择注射单元规格的准则

CriteriatoSelecttheInjectionUnits

-注射控制的方式--conceptionsofinjectionregulation-标准方式：注射闭环控制basicconfiguration injectionregulation扩展方式（可选件）：螺杆精确定位extensionstage(option) positionregulationscrew(PRS)21注射闭环控制的原理Functionprincipleoftheinjectionregulation选择注射单元规格的准则

CriteriatoSelecttheInjectionUnits

螺杆精确定位Positionregulatedscrew22螺杆精确定位的原理Functionprincipleofthepositionregulatedscrew选择注射单元规格的准则

CriteriatoSelecttheInjectionUnits

Injectioncontrol

注射控制Positionregulatedscrew螺杆精确定位230,005ccm0,025ccm0,010ccm0,040ccm0,035ccm0,015ccm效果举例（改变进料量）Examplefortheefficiency(variationdosagevolume):选择注射单元规格的准则

CriteriatoSelecttheInjectionUnits25注射闭环控制与螺杆精确定位比较

InjectionregulationincomparisonwithpositionregulationInjectionspeedcurvepressurecurveinjectionspeedscrewpositionpressurecurvepositionregulationpressurecurveinjectionregulation26模具设计方面

AspectofMouldDesign流道设计(特别是小产品)用冷流道流道长度取决于模具刚性和复杂程度必须选择足够的横截面积用热流道加热的流道增加材料滞留时间热流道需要足够的空间延长的喷嘴需要注意事项与热流道相同需要附加的加热圈SprueDesign(especiallysmallparts)Viacold-runnersystemSpruelengthistheresultfrommoldstabilityandmoldcomplexityThespruesectionmustbeselectedbigenough

Viahot-runnersystemsHeatedspruechannelincreasesthedwelltimeProblemswithspaceViaextendednozzletipSameproblemlikewithhot-runnersystemsAdditionalheaterbandnecessary!27模具设计方面

AspectofMouldDesign研磨方向互相交叉排气容易,90%空气从分型面排出

Easyventing.approx.90%ofairescapesoverpartingline

空气可从整个模腔接触面排出Theaircanescapeoverthecompletecavityarea

成本低Lowcosts1–分型面光洁度0.007–0.009mm1–partinglineroughness0.007–0.009mm2–模芯光洁度0.003–0.004mm2–cavityinsertroughness0.003–0.004mm29排气槽Ventingchannel

在流道终点或熔体相交处Attheendoftheflowpathorwherethemeltfrontsmeetstogether

可随时开出Afterwardscreationpossible

会积累脏物，需定时清理

Problemsofdirtdepositionthusoftencleaning

模具设计方面

AspectofMouldDesign1–ventingchannel(0.01–0.02mm)30溢流槽排气Overspillventing在流道终点或熔体相交处Attheendoftheflowpathorwherethemeltfrontsmeettogether排气效果好Goodventing

防止熔合线Preventionfromweldlinesinthatarea

需切掉余料Afterwardsremovalofoverspillchannel模具设计方面

AspectofMouldDesign1–meetpointwithenclosedair

2–injectionpoint

3–overspillchannel(ventingthroughmeltfrontmeetpointshiftingintooverspillchannel31模具设计方面

AspectofMouldDesign对中系统centeringsystem对中系统centeringsystem32模具设计方面

AspectofMouldDesign对中系统centeringsystem33模温控制

MoldTemperatureControl模具温度直接影响产品质量的稳定性Themoldtemperaturehasadirectinfluenceofthereproduciblequalityofthemoldedparts.34

温度感应器安装于模具内利于优化控制模温机与机器通讯

如模温机故障，机器停机整个系统内存水量少（3升），传热好，调节稳定模腔温度公差±1流量监视OptimalmoldtemperaturecontrolviaexternalsensorplacedinthemoldCommunicationfromtemperaturecontrolunittomachineincaseofmalfunctionproductionstop!Besttemperatureregulationthroughreductionofheattransfermediumtoapprox.3literinthe