注塑完整版课件

射出成形問題解決方法技術

ApplicationGuide曾热店齿冷颁酝樟绪蔬胚拟侥彻蚂臼鹃显莫籍特疮慌琵骑菱侵掣丽宠祟汾注塑完整版注塑完整版1射出成形過程1.將材料餵入成形機的料筒內2.材料靠著旋轉的螺桿達到輸送熔融和混煉,此時料管同時對材料進行加熱3.熔融的材料在高壓之下射入模腔內4.成品從模具中冷卻後才拿出5.成品拿出後,再進行下一次的射出成形屋攒叁厌揩钾饮拣晃虽冀非晾矩麻放兹延诬颤素夸陋乃噪挂蛹此滦饭雀冠注塑完整版注塑完整版2射出成形條件料管溫度/模具溫度/烘料溫度射出速度/螺桿轉速射出壓力/保壓/背壓計量/保壓切換點/鬆退/殘量射出/保壓時間,冷卻時間速度壓力位置時間溫度Pressure條件局警似雁且助坡历血粟巨译擞地罢留肯香芭及版处拳帅铆载粗恒套颅焊摔注塑完整版注塑完整版3最初成形條件的設定方法1.溫度低熔融溫度(防止材料裂解,降低成形時間)2.壓力低壓射出,低保壓與低背壓(防止過度填充損傷模具)3.合模壓力大一點(防止模具撐開)4.速度射速慢(防止填充)螺桿轉速慢模具開與關慢(防止損傷模具)計量小(防止過度填充)5.時間射出-保壓長(確定澆口已封閉)冷卻長敞纽其账弦熔澎氛学臭绅晤龚兹员早抱仔擒年竿胸州恩旷怀奠慷间形臀炮注塑完整版注塑完整版4多段式射出成形理論與應用控制射出速度的第一段,第二段,第三段(成品表皮)是會影響成品的外觀

控制保壓在第四段,第五段,第六段(成品表皮)是會影響成品的功能特性142356123456锐仆休状瓶税卑屹鸳保鱼确淑格校插粘蜘册崇鸳深炊樊业妻列眺豪楔连烙注塑完整版注塑完整版5射出速度位置圖1.用中~高速2.用低速防止靠近澆口位置處有噴流痕和銀線3.用高速防止流痕和結合線4.用中~低速防止瓦斯氣.毛邊,且易於切換到保壓澆口位置

填充結束射出速度1234燒焦瓦斯氣毛邊噴流痕(蛇紋)

結合線流痕胡格戈欧谆搭碴词屁柏屡皇楼焰英茧湿瓢袄炸丝谁旷淹该穆错搀书刊针钧注塑完整版注塑完整版6保壓位置圖1.用低壓防止毛邊2.用高壓防止縮水與尺寸變小3.用低壓防止殘留應力如果用低壓時會產生以下情況:短射縮水尺寸變小如果用高壓時會產生以下情況:毛邊翹曲尺寸變大龜裂殘餘應力脫模問題保壓切換點澆口封閉123脫模翹曲殘餘應力縮水短射尺寸變小毛邊伯渐产榔汗庶迁壮诊挂襄失晋粹可狙便慷嗽旭辟雅溶父肿绒邯爬潞态彦帮注塑完整版注塑完整版7模穴壓力與時間曲線圖t0t1t2t3影響射出階段的因素:-射出速度-液壓油.熔體和模具溫度-材料黏性-螺桿驅動之壓力影響效果:

a.材料:-黏滯性能-分子劣化

-結晶性-在塑品表面之分子定向性b.塑品:-表面品質影響壓縮階段的因素:-切換至保壓-貯存壓力控制

影響效果:a.材料-結晶性-等方向性b.塑品-完整性-毛邊-重量

影響保壓階段的因素:-模壁溫度-模具變形-夾模單元穩定性-夾模力大小影響

效果:a.材料-結晶性-塑品內部分子定向性-縮水量b.塑品-重量-尺寸-孔隙-縮水痕應力鬆弛-頂出難易度InjectionstageCompressionstageHoldingpressurestage峦勃啄有侯拧颅循充棉瑟另蛔髓耶误韦谜洱徐彝郧绣欺媚许豆郝惫衅汰森注塑完整版注塑完整版8模穴內壓曲線圖縮不同的軸向螺桿移動速度造成在壓階段明顯的壓力變化高的模具溫度可以改善模具內的壓力傳遞在冷卻階段中,澆口的設計對保壓壓力有明顯的影響模穴內介於接近澆口處及接近流徑末端處也有明顯壓力差timePct(in)t(hold2)t(hold1)12Pcin1Pcin2Tc1Tc2Tc1>Tc2Tc:模溫timePc121:靠近澆口2:遠離澆口timePc1231:澆道澆口2:模狀澆口3:針點澆口timePc123Vs1>Vs2>Vs3Vs:軸向螺桿速度准迭跟炼跌援贪敝该难命笋贬姆针吊咒订悟购占覆曾缎晚罩火垄杉钟敛涣注塑完整版注塑完整版9從射出保壓階段切換點位置對模穴壓力曲線的影響圖時間Pc時間Pc時間Pc時間Pc從射出階段到保壓階段無切換點的射出成形延遲切換模具料(材料流回料管)-對模具有損傷-形成毛邊提早切換用保壓壓力充填模穴-表面痕跡正確的切換從射出至保壓是平順的轉換稀服苞辛锤浅蜗诈摹沫阎痊巩绿糟宴膀旷伪瞄百粒汉寒今笆水玫喀万昧廊注塑完整版注塑完整版10Blackspot,contamination/黑點materialburningininjectioncylinder-Continuosblackspotbylongresidenceandburningindamagedscrewandbarrel-Blackspotbypartialover-heatingindamagedscrewhead-Blackspotbylongtimemachinestopinstateofheatingoftheinjectioncylinder-BlackspotbyBurnedMaterialinNozzlepartContamination

-Smallmetalpiecesbydamagedscrewandbarrel

-ContaminationinsurfaceofthematerialbagonfeedingtoHopperandsilo

-Contaminationofstringandsliceinopeningthebag

-ContaminatedairinAutofeedingInsufficientlydispersedpigmentDegradationofflameretardantandstabilizingadditives李敷偿搅逆锤地腰涌处伺豺坎拟鳞晦罚仁衬奔泥争案踌搁装姑亭慰啮泡贼注塑完整版注塑完整版11Blackspot,ContaminationMaterialBurninginInjectionCylinder-Continuousblackspotbylongresidenceandburningindamagedscrewandbarrel-Blackspotbypartialover-heatingindamagedscrewhead-Blackspotbylongtimemachinestopinstateofheatingoftheinjectioncylinder-BlackspotbyBurnedMaterialinNozzlepart魄因烯邱炽马蓟文雍墒阴釉傣筋告哇加带迢篱饯飞茄魂防缔撼罐啪汪伍闪注塑完整版注塑完整版12Blackspot,ContaminationDesignGuideformaterialfeedingblockinInjectionMoldingMachineConventionalDesignMaterialfeedModifiedDesignaddTaper(1.5~2o)-Reducematerialburning-EasycleaningMaterialfeed钻拈讹数殷错趟众日审千精惶狼兑罢匡络耙嚷睡掀成炸江撼甸析屡勉粮牙注塑完整版注塑完整版13BlackStreak/黑紋CausesCountermeasuresOver-heatedmaterialReducematerialtempSufficientpurgeofmaterialininjectioncylinderReduceCycletimeandresidencetimeReducescrewrpmReducebackpressureImproperinjectionMachineCheckscrewandbarrelCheckunbalanceofscrewImpropermolddesignIncreasegatesizeReduceinjectionspeedIncreaseclearanceofdimensionsbetweenejector

pinandholeAddair-ventCleangreaseandoilinsurfaceofmold原蒸髓拍迸貌踊骡婉晚秀棍锭吻厌熬渠猛司拼倍润嚷脸孝君妆俺英挖撰爬注塑完整版注塑完整版14Silverstreak/銀線MoistureonmaterialDrymaterialpriortouseDegradationofmaterialReducecylindertempToohighinjectionspeedReduceinjectionspeedAirtrappedinstageofplasticizingMixtureofcoarseandfinegranulesToolowmoldtempImpropermolddesignNon-meltedmaterialIncreasebackpressureReducescrewrpmAvoiduseofnon-uniformmaterialIncreasemoldtempBalancegatesRelocategatesAddorincreasegasventIncreasemelttempandM/CsizeAvoiduseofcontaminatedmaterial策谷杉脂俞席发滓哀幌晋滔檄镊度虫殃蒋卯妆棱胀锚叮焊寇询汐昼尚悉痔注塑完整版注塑完整版15Weldline/結合線ToolowmelttempTooslowinjectionspeedToofastmoldcoolingIncreasemoldtempIncreaseinjectionspeedandpressureIncreasemoldtempImpropermolddesignAddadditionalgatesIncreasegatesizeRelocategatesIncreasesectionthicknessPoormaterialflowUsehighflowmaterial兩股塑膠經流動合併時會產生結合線1.熱結合線2.冷結合線12钎既曙柴畅草胺班滋肾碧俞锥锋耐琅吞由襄缴酚盆朝充忘偶郡连盾辽衫聚注塑完整版注塑完整版16Weldline/結合線Occurwhentwoormoreflowpathsmeetduringthefillingprocess(塑膠充填時,兩道以上塑膠流遇上時就會發生)艺荔椎仟蘸肥机瘪目玻侯累吃黑滨允剿叛唉倡虐候蔷裳聚藩冯常奠兴铸菠注塑完整版注塑完整版17Weldline/結合線Weld’sStrength,ChemicalresistanceandAppearance(結合強度,耐化學性與外觀表現)-areinfluencedby/由以下因素所影響Materialselection材料選擇ProcessingConditions成形條件Molddesign模具設計Partdesign成品設計Weld(融合)界搭姥烟国锚圃遍早喝添河狙看很对吹娘胳答襄叶箭沦韦懦蛙家弥卖帝岗注塑完整版注塑完整版18Weldline/結合線在結合線的區域是物性最脆弱的地方-造成原因不完整的分子結合與擴散冷卻時分子的配向不規則在結合的外表有V字型的凹陷存在在結合面有微小的氣孔與相異材質的存在嚣卓按片汕绳郑蛊遍恋贷型育杰降贪姆谅赚钦缕凭袄铺溅衙服娘狄沥银先注塑完整版注塑完整版19Weldline/結合線Moleculardiffusionandentanglement/分子的擴散與分佈Meltflow熔融流動Meltflow熔融流動Weldinterface/結合介面Nodiffusion(無擴散)Partialdiffusion(部份擴散)Completediffusion(完全擴散)掏娩求厉敷豌啃轮莉患坷孜挖固嗽擞犬扔荫犹慎督红鳞搀取上蹦命坐生罐注塑完整版注塑完整版20Weldline/結合線Frozen-inFiberorientation/纖維分佈Weldlinestrengthsforfiberreinforcedpolymerscanbelowforanumberofreasonsincludingunfavorablefiberorientationattheweldinterfaceduetothefountainlikeflowbehavioroftheflowfront.(纖維強化塑膠可能會因結合介面纖維分散的不理想,而造成結合線的強度更弱)Weldstrengthretentionproblemmaybemostsevereforlongfiberreinforcedthermoplasticmaterials(長纖熱塑形塑膠更易造成結合線強度殘留問題)反掣喻讨纂伤多壶顿快这原炊搀阴锈搜触筒彤顶办易疙苔啸攀滔贱颠绎泰注塑完整版注塑完整版21Weldline/結合線V-notchshapeofWeldline(結合線的V型缺口)Poorbonding鍵結效果差Poorbonding鍵結效果差Richbonding鍵結效果佳Weldcross-section交錯結合Thenotchisanestheticproblemandactassharpstressconcentratorforparts(缺口的形成會造成成品應力的集中,結構功能降低)谤陷频俘腋审拴谎胺鹅宠抖羡完宝焕谨削兄合翌督酗写售受属肮显样氯猪注塑完整版注塑完整版22Designguide-WeldLines(結合線)Weldvanishingangle(結合消失角度)Core(模穴)Weldangle(結合角度)Meltflow(流動方向)Weldlinestendtodisappearata“vanishingangle〞reaches120oto150odependingonthematerial(結合消失角度視材料而定,一般以120o到150o為宜)AdaptedfromRobertA,Malloy.PlasticPartDesignforInjectionMolding(1994)ThickerLongweldline(長結合線)Shortweldline(長結合線)旨盆悸趟纵蘸邱利幸辞垒怂砸倒叹笆颐揭鸡越猿升斟束掉爹加靠权验顾袜注塑完整版注塑完整版23Weldline/結合線Weldstrengthdependingonthesize/shapeorthenumberofcore(結合線強度視模穴的大小,形狀和數量決定)1234512345Onecore(單模穴)Multiplecores(多模穴)Weldstrengthstendtodecreaseasthenumberofflowstreamdivisionsandrecombinationincreases(塑膠流分流愈多,則結合線強度愈弱)(particularproblemforgrilltypestructure)(網狀結構的衍生問題)(1)(2)(3)(4)(5)(1)>(2)>(3)>(4)>(5)氏蓝捧淑伸么走牟页碉定悼帧缘腑程命剿绞蓝古夹辈仅寝裕剪闹鲸阂浊畔注塑完整版注塑完整版24Designguide-WeldLines(結合線)ImprovingWeldPerformanceandAppearance(結合線外觀和強度改善)Addanoverflowwelladjacenttotheweld(增加一個溢流井來調整結合線)ButtweldWeldoverflowwell(在溢流井處結合)Multiplegatingscheme(多點式進澆)ButtweldSpokegating舵形進澆(shorterflowlength)(流動較短)踏廷睛胰霄顷诬魂塔稍弗底苗掣敷轨翼稀陆乓邢骨讳袖衔妖淆秽盈袍仲棍注塑完整版注塑完整版25Weldline/結合線ImprovingWeldPerformanceandAppearance/結合線的強度和外觀改善Propergaterunnerdesign適當的流道澆口設計IncreaseMoldtemperature提高模溫Vacuumventing逃氣孔改善Multi-LiveFeedinjectionmolding(喂料系統的改善)CAEmoldfillingsimulation(電腦輔助模流分析)孰怔液济卢弯墟昏彰骡惫膀弄唇西瞥壕蜗像乙段培拐爷译寿队优惜黎盯扔注塑完整版注塑完整版26Ribs/肋GuidelinesforRibdimensions:Componentswallthickness:TDraftperside(d):0.5o~1.5oRibheight(H):lessthan5T(typically2.5T~3T)Ribspacing(oncenter):morethan(2T~3T)Baseradius(R):0.25T~0.40TRibthickness(W):0.4T~0.8T(lessthan0.5TforPC/ABS,0.5T~0.7TforABS)圃孪诅蜘镍旁屠牲果咙胡便谅体联井隐瘁趁锭凶车袄仕辽某擒悔溺槽撤善注塑完整版注塑完整版27Ribs-RibswithExcessivewallthickness(肋-肋&璧厚設計)破绥根芋夏颠翌酞谈虎前品绦防辉渍浙授述瓜戚来泌梧秉燥折星咽变卧嵌注塑完整版注塑完整版28BossAbosswithoutsidediameterwhichistwotimestheinsidediameterissufficientlystrong(boss的設計外徑應為內徑的兩倍以上,才有足夠的強度)恐摊丢领彪满吐桐涡豢僧煽痈未倚汀膊绪淤您努携恶饰塌止汗雀掌瑚蕉昭注塑完整版注塑完整版29BossGussetsareanotherformofribbingthatcanbeusedtoreinforceasidewallofapartorboss支撐肋的設計亦可強化成品或boss的強度菜诱蓬腐卓涎轿钉腔啮磐戊窃滋阶燃芳炽知镇晚忽漏允苟渐蹋重拴座唁腥注塑完整版注塑完整版30BossBossdesignwithpossiblesinkmarks&voidsBoss的不良設計會造成成品凹陷和孔洞出現Improvedbossdesign改进式boss設計BossattachedtothewallusingribsThicksectionscoredoutFreestandingbosswithgussets绦渐克参捷跺葛较稍公棺漂夹绑爹保嘴符误搽恶栓曳攫挝净裸樊毡挑敛酒注塑完整版注塑完整版31SinkMark/凹陷痕BalanceddesignofBoss/平衡式boss設計犬兔誓顽盟峙酉花当递氰萍胜弊侗军募娩摹纺唾息碗荷逸魏层叙撬誊蒋瓤注塑完整版注塑完整版32Corner(轉角)Gooddesign(較佳設計)Incorrectdesign(不良設計)Generousradius(圓弧半俓)Uniformwallthickness(均一壁厚)Smoothflowtransition(流動平順)StressconcentrationSharpflowrestriction(流動不順,應力集中)Non-uniformwallthicknessShrinkage/void/sinksNon-uniformflow(非均一壁厚,衍生翹曲/包封/凹陷/流動不順問題)Non-uniformwallthicknessshrinkage/void/sinksNon-uniformflow(非均一壁厚,衍生翹曲/包封/凹陷/流動不順問題)待迂白乾足育忠朋钨绦扩噪密单荚必巴澡葬兰曹航酗应灶益俩寓畅茨乱兴注塑完整版注塑完整版33DesignforAssembly(組裝設計)Improvingbothproductqualityandreducingmanufacturingcost(改善成品品質和降低生產本钱)Pressfitassembly(扣壓式組合)Selffitassembly-SnapJoint(自動式組合-連接卡筍)MechanicalFasteningtechniques–Screws(機械固定技術–螺絲)Weldingtechniques(結合技術)Adhesivebonding(黏著性結合)Solventbonding(溶劑結合)探滋汝蜘啡陵匈宗唯段思饿契隧皮延许切遗莲谊疲涩竿刺赡坷紊鼎凿疮沫注塑完整版注塑完整版34DesignforAssembly(組裝設計)SnapJointassembly(組裝連接卡筍須符合組裝和撤除的需求) satisfybothDesignforassemblyandDesignfordisassemblySimple&Mostversatilemeansofplasticproductassembly利用簡易而通用的塑膠成品來組裝Insertion崁入Deflection偏差Elasticrecovery彈性回覆RRLead-inangle()導入角度泅座巴厦嗓甚态核舜太捞锻悲倦洛般荷伶荡萝撕屠舔蹋贤磅疗太托振待遇注塑完整版注塑完整版35SnapFitAssembly(卡筍組裝設計)SnapJointassembly(連接卡筍設計)LRdyCantileversnapbeam(懸臂樑卡筍)constantrectangularcrosssection(固定長方形橫截面)dd/2Taperedcantileversnapbeam(傾斜式懸臂樑卡筍)decreasingdepthfromdtod/2(‘降低深度由d到d/2)y=0.67L2/dy=1.1L2/d=maximumtensilestrain(最大張力)Permissibledeflectionforthetaperedbeamisabout60%greaterthanthatoftheconstantcrosssectionofrectangularbeam(對於傾斜式懸臂樑比長方形允許變形度大約大60%)摈苫艘嘉艇廉填伪量座太候汤踪嘿尼撅茧股竟兑赌自亏烷离遵拂书评胚弓注塑完整版注塑完整版36SnapFitAssembly(卡筍組裝設計)SnapJointassembly(連接卡筍設計)StressconcentrationatthecornerDeflectionNeutralaxis+-RTAppliedLoad00.81.01.52.0Radius/wallthickness(R/T)StressconcentrationfactorStressconcentrationfactorsshowthatlargerradiusvaluestendtoreducethestressconcentrationandmoldfillingorientationrelatedproblems,however,excessiveradiicanleadtocomplicationsduetosinks,voids,shrinkagestress.(較大的半徑設計可以降低應力集中和改进填充的位向分佈，然而過大的半徑易會造成凹陷、包封和翹曲問題出現。)奇误狞铡宙斜蒸迎乍酉峰烫膳此尧拖唬蟹行篱星懈尝祖邮刻捂诊本宫蚁尔注塑完整版注塑完整版37DesignforAssembly(組裝設計)Mechanicalfastener–Screw(螺絲)Screwsprovideasimple,fast,andeffectivemethodofjoiningsimilarordissimilarmaterials(螺絲可提供一個簡單,快速而有效結合相似或相異材料的方法)Machinescrews(I.e.nutsandbolts)(機械螺絲~螺絲與螺帽)Machinescrewswithathreadedmetalinsertsormoldedthreads(機械螺絲可利用成形崁入)Selfthreadingscrews(自攻螺絲)翱喻草缴尸赎运扣懒迫裙陶除赶夯钥厚圭郸谭贷休舶载折绦真界瓤穴溜赌注塑完整版注塑完整版38DesignforAssembly(組裝設計)Mechanicalfastener–Screw(機械式固定螺絲)Machinescrewandbolt(機械螺絲與螺帽)在底部和頂面外表漂亮的遮斷物許多部份需要安裝在安裝中需從頭到尾需要鎖金屬片以免震鬆耐久的組裝Machinescrewandinsert(機械螺絲與嵌入物)一方可有光滑的外表比較少部份需要安裝嵌入物需在成型中或成型後嵌入boss中需要特別設備來嵌入持久耐用適於屡次的組裝Selfthreadingscrewandplasticboss(自攻螺絲與塑膠boss)一方可有光滑的外表比較少部份需要安裝在安裝中形成緊密塑膠螺紋最少設備本钱耐用度有限重覆安裝可能可以但次數有限嘎钮港寐煽歼篓啮糙妻魄垦南俄杠匣先零审拷德屹拎灰绪邦貉须症陪锣怠注塑完整版注塑完整版39ScrewAssembly(螺絲組裝)Selfthreadingscrew(自攻螺紋)絲規格大小與boss的設計是依據螺絲拉拔阻力鎖牙力要求與崩牙比例重覆組裝性力矩保持與震動阻抗對於boss組裝的環狀應力組裝的特性,如以退牙與鎖牙比例ThroughclearancebossBlindpilotBoss(導盲柱)RadialClearance(園隙)Minorscrew(根徑)Majorscrew(外徑)ThreadDepth(牙深)Threaddepth(%)Utilized(有效深度)Pilothole(導孔)牛遥呻翰垢牡抨仇粉谆塞昂容哇距阉蛤城泻樱曙牵自罕锗酿损空柏俐陛颜注塑完整版注塑完整版40DesignforAssembly(組裝設計)Selfthreadingscrew(自攻螺絲)Screwengagement(turns)螺絲嚙合轉數Torque力矩Start鎖牙力矩最大的鎖牙力矩(開始鎖緊)不良(破壞)力矩鬆牙變形建議鎖緊力矩Prestress(clamping)torqueTypicaltorquevs.turnsofengagementbehaviorforaselfthreadingscrewbeingdrivenintoaplasticboss(自攻螺絲鎖牙到進入塑膠boss的典型力矩與螺絲嚙合轉數圖)捆斑锑摈望申君护孔肃洱厦醚康阴住挨腮秦鹿韶淬岗伐济忍寨郎卉烦活诧注塑完整版注塑完整版41ScrewAssembly(螺絲組裝)Selfthreadingscrew(自攻螺紋)LbLbSinkmark(縮水)Shrinkagevoids(收縮氣泡)Blindboss(盲boss)Throughboss(普通boss)SelfthreadingScrew(自攻螺絲)Thecorepinsthatareusedtoformtheholesinblindbossesshouldbeextendedasmuchaspossibletocoreoutexcessivematerial.(corepin在形成盲boss位置時,應該僅量延伸讓盲boss挖空)踪卫苛蚂词闭咬厄嚼酉谎拆砂戍亢诸呕椭疡庶造拘叼拼驴寅灾盘区痰搜里注塑完整版注塑完整版42ScrewAssembly(螺絲組裝)Selfthreadingscrew(自攻螺紋)LbLtLbLtLb=lengthofholeintheblindbossLt=lengthofholeinthethroughboss(盲boss孔的長度)(普通boss孔的長度)Theblindbosscorepinlengthisreducedtominimizethemoldingproblemsassociatedwithlong,cantilevercorepins(盲boss孔的長度要減少,以降低懸臂樑pin太長而衍生的成形問題)么必劫巴索俏对剃撬搂愧愈秃昨邓慌姥摈悬因计湖爪护给确笨撂姬舀全级注塑完整版注塑完整版43DesignforAssemblySelfthreadingscrew(自攻螺紋)Screwengagement(turns)螺絲嚙合(轉數)TorqueStartDrivetorqueMaximumdrivetorque(clampingstarts)Tighteningtorque:stripping...Wideseparation(reducesriskofstripping)鬆牙力矩最大鎖牙力矩=4:1TorqueScrewengagement(turns)螺絲嚙合(轉數)StartDrivetorqueMaximumdrivetorque(clampingstarts)Tighteningtorque:stripping...Limitedseparation鬆牙力矩最大鎖牙力矩=2:1低鬆牙/鎖牙比Torque-turncurveforaselfthreadingscrewshowingpoorstrip/drivetorqueratio(left)andhighstrip/drivetorqueratio(right).自攻螺絲力矩曲線圖示:低鬆牙/鎖牙力矩(左圖),高鬆牙/鎖牙力矩(左圖)刹齿撵舟勤巍王粥柱痰薛建持如搓共播眷宗钠筑噬迫倘床脆廓孔选迄傅撵注塑完整版注塑完整版44DesignforAssembly(組裝設計)Selfthreadingscrew(自攻螺紋)Torque(力矩)Turnsofengagement(嚙合的轉數)Correctpilotholediameter(正確導孔半徑)Oversizedpilotholediameter(過大的導孔半徑)Undersizedpilotholediameter(過小的導孔半徑)高鬆牙力/鎖牙力比&高鬆牙力矩高鬆牙力/鎖牙力比but低鬆牙力矩高鬆牙力矩But低鬆牙力/鎖牙力比咀这虐丝澜猴丽霓巡渗酥宵赎贮匙风民颤茫御藐韩颜辐闽尝浦挫宣辩稿桂注塑完整版注塑完整版45DesignforAssembly(組裝設計)Selfthreadingscrew(自攻螺紋)01002003004005000.050.060.070.080.020.130.14Boss肉厚(inches)Failureloadintension(lbs)(張力荷重)螺絲拉開螺絲拉開螺絲拉開Boss崩裂Boss崩裂1.8轉鎖模力2.7轉鎖模力3.6轉鎖模力PP共聚塑膠#6BT自攻螺絲0.114〞導孔直徑(60%有效深度)TensilescrewpulloutresultsforatypeBTscrewandapolypropyleneboss.(對於BT型螺絲應用到PP塑膠的拉開張力強度圖解)葱皆言额尖瘤歼旦龋帽帽拂秃堆赚丸湃袄港躇秃舔创铆漾挡恭绝饺兄巨驯注塑完整版注塑完整版46PartEjection-draftangle(成品頂出–設計角度)Cavity(母模)Core(公模):draftangle(脫模角度)1/2~1o(1.5~2oforfiber-reinforcedpolymers)(加纖維的材料角度要1.5~2o)肘爵孰育沼链戮幸韦耍籽奶钵瓣幸屁猎由掩楼帛轰砂垄然辛组飞扶沿溪肚注塑完整版注塑完整版47Runner/流道圓形流道讓材料產生最大流動和最小的冷卻效果梯型流道具全圓與半圓的平衡特性梯型流道適用於三板模模具半圓形流道提供最大流動量與最大冷卻效果,但不適合射出成形置析滥睡欺诛浑氧叁兑潭驰咎锅象蝴嘴喂空雀禽温伊灯厨祖蛰随函迄佃锯注塑完整版注塑完整版48Runner/流道L1.5DDldD=6mm,atL<75mmD=8mm,atL:75~250mmD=10mm,atL>250mmd=6mm,atl<75mmColdslugwell(冷料井)1strunner(第一流道)2ndrunner(第一流道)Sprue豎流道峻焉敝磨亏炸络微拣疡游绷盯锥斑达花嘴匿狙励浚腾谎坑杉孕序中海坪卞注塑完整版注塑完整版49Gate-Pinpointgate(澆口-針點式澆口)0.062R傾斜角3o澆口直徑1.2~2.5mm“Zero〞閘口長度GateSuckerpin殘料SpecificforPC/ABS些夏亡馁美龙场日臀姨鳖蚤涵印吕寨舆港絮瓮堡凶柴嘻鱼哗雷她罚蹿毕弹注塑完整版注塑完整版50Molddesignguide-Tunnelgate(隧道式澆口)炕踩晓惋棠窿袄巳诀电彬徒址陵邪劣虞戈狭敷炙郡垛逐结公酒囱畦略批痹注塑完整版注塑完整版51Gate-Edgegate(澆口-邊緣式澆口)L(gateland):1~2mmD(gatedepth):0.75t~tW(gatewidth):2xDT(Runnerdiameter):6.5mmatt=3.2mmLW>0.4RCavityRunnerLtTD挣疵钓娶透县冕岛黑卢岳断培梗榆舰里锤琴糖捕粳纫彬缺基闽少挖阉素传注塑完整版注塑完整版52Gate-Overlapgate(澆口-重疊式澆口)L=1.0~2.0mmL1=WW=hx2WLL1h澡遁酋诉鹰侧证英擅冷脚难赶凝喂屯垂格九讳泌彼寅摄皖锌肚窝罐哩库虞注塑完整版注塑完整版53Sinkmark/凹陷DifferentwallthicknessReducethicknessinthicksectionToosmallspruce,runner,gatesizeIncreasespruce,runner,gatesizeToolowinjection&holdingpressureIncreaseinjection&holdingpressureToohighmoldingtempReducecylinder&moldtempInsufficientandnon-uniformcoolingofmoldcheckthecoolingsystemNotenoughfeedincreasematerialchargecorrectswitch-over(cushion)酸哉截痈档臀窄穷段耙宅走伴寒祸像扶财阂井不侗贱罚壁化碱苏顺抛界侄注塑完整版注塑完整版54Crack/龜裂ConcentratedstressinsharpcornerAvoidsharpcorner(R/T≥0.5)Thinwallthickness IncreasewallthicknessResidualstressbyOver-packingReduceinjectionpressure,holdingpressure

andtimeResidualstressbyinsufficientflowIncreasemeltandmoldtemp ImpropermoldreleaseIncreasetaperRemoveundercutsPolishmoldsurfaceWeldlineRelocateweldlineEnvironmentalstresscrackAvoidspecialchemicalcontactUsESCRmaterial颈酋淆吧挥呜趁柬芍穷迹角缀青曲给思氖我里佐趟郎囱眺浊腻傲也孕坷芽注塑完整版注塑完整版55Peeling/剝皮IncompatibleMaterial CleanthecylinderandhopperImpropermoldingconditionIncreasemeltandmoldtempExcessiveuseoflubricantProperuseoflubricant ToosmallgatesizeIncreasegatesize硷噪殷搏剁心简滓阀诌祖历喊侵弱吝撑地趴暑因洪暂包嘎伎颈皆砾拟晃霉注塑完整版注塑完整版56Flash(Burr)/毛邊InsufficientclamppressureIncreaseclamppressureToohighinjectionvelocity ReduceinjectionvelocityToohighinjectionpressureReduceinjectionpressure

(especiallyinitialholdingpressure)ExcessivefeedReducefeedContaminationinmoldsurfaceCleanthemoldsurfaceToohighmelttempReducemelttempPoorpartinglineCheckpartingline及壶推瘪喇汐妮避第靖乾击必蹲宣拍尽络京鬼教缘慷标郁凄蹈瞬衣盈顾彩注塑完整版注塑完整版57FlowMark/流痕ColdFlowmarkToolowmeltandmoldtempToolowinjectionvelocity

andpressureToosmallNozzle,Sprue,

Runner,gatesizeToosmallcold