注塑工艺参数优化

培训课程2工艺参数的优化

受训者手册德马格注塑机工艺参数优化的步骤指导页面周期分析3注塑工艺参数优化6步骤1:找出转压点7步骤1结果8步骤2:找出保压时间（浇口冷凝时间）9步骤2结果10步骤3:优化注射速度11步骤3结果12步骤4:采用正确的螺杆转速13步骤4结果14步骤5:优化多级螺杆转速和背压曲线15步骤5结果16步骤6:优化松退17步骤6结果18步骤7:优化保压曲线19步骤7结果20TABULATEDRESULTS21步骤8:优化锁模力22步骤8结果22步骤9:设定注射压力23

步骤9结果23典型工艺参数公差设定24采用下面表格估计注塑过程中的每一阶段对周期的影响.然后去机床看正在运行的模具,写下实际的时间并计算出百分比.哪一阶段在整个周期中占最多的时间那里可以是最有效的缩短成型周期

估计％实际实际％评价合模射台前进和后退注射时间保压时间冷却时间开模

顶出整个成型周期100%seconds100%

估计%实际实际％评价合模射台前进和后退注射时间保压时间冷却时间开模顶出整个成型周期100%seconds100%目标：一步步改进工艺过程稳定性.评估各个参数的更改对工艺过程稳定性的影响todemonstratethecumulativeimprovemntintheprocessandproductconsistency方法：Ateachstage,aftertheprocesshasbeengivensufficienttimetostabilise,arunofsixteenconsecutivemouldingsistobemade.Thesemouldingswillbeassessedforconsistencybyweight(adimension,aphysicalpropertyorsomeotherattributecouldequallywellbeused,weightissimplythemostwidelyapplicable).稳定性通过计算重量的标准偏差来衡量.同时打印出机床IBED上的过程统计数据.找出转压点找出浇口冷却时间优化注射速度采用正确的螺杆转速优化多级预塑曲线优化松推优化多级保压曲线优化锁模力设定注射压力限定找出转压点在没有保压压力和保压时间的基础上填满产品95%-98%,然后设定一定的保压和保压时间生产16模.初始设置时的指导1采用行程切换2设定切换位置为10-12mm（逐步增加预塑量直到产品打满95%-98%的位置）3设置注射压力为最大值4设定保压压力和保压时间均为05设定注射速度60mms-16设定松推速度为最大值7设定锁模力为最大值8选择适当的螺杆转速9根据材料物性表，设定料桶温度10配置过程统计控制11设定保压压力和保压时间生产完整的产品称12模产品的重量，计算标准偏差打印：页面20工艺参数优化页面 50 工艺过程统输入实际值平均值范围最小最大没保压时的重量有保压后的重量填充的百分比%标准偏差（16模）g料垫（平均值和范围）预塑时间（平均值和范围）螺杆停止位置（平均值和范围）注射时间（平均值和范围）注射压力峰值，Pinj.max转压压力，PNpress.

转压位置找出浇口冷凝时间设定保压压力为步骤1上找出的注射压力峰值的50%左右.设定保压时间为1s.生产数模产品使过程稳定后连续取5模产品称出每模重量和平均值增加保压时间至2s,生产数模产品使过程稳定后连续取5模产品称出每模重量.在保压时间3s,4s5s...时重复上述过程直到产品重量不再增加作出产品重量和保压时间的关系图.记录RecordtheTCUsettingandtheactualmouldtemperature.打印：页面30温度XLSpreadsheetgraph为什么记录模具温度很重要还有什么因素会影响浇口冷凝时间

输入实际值TCUsettingFHtemperatureMHtemperatureCCC

所需的保压时间s优化注射速度采用多级注射曲线，使注射行程最后的10-20%采用逐步降低的注射速度.每次更改注射速度，必须重新建立转压点.（注意每次保压和保压时间都设定为0.）连续取16模，计算出标准偏差.打印：页面24MWE使用和没使用多级保压时的曲线页面26多级注射页面50工艺过程统计为什么转压点要更改注射压力发生了什么为什么在数社的末端采用逐步降低的注射速度是有用的

输入实际值平均值范围最小最大没有保压时的重量采用保压的重量填充百分比%标准偏差（16模）g料垫（平均值和范围）预塑时间（平均值和范围）螺杆停止位置（平均值和范围）注射时间（平均值和范围）注射压力峰值，Pinj.max转压压力，PNpress.转换位置采用正确的螺杆转速Selectthecorrect,optimumscrewspeedforthematerialbeingprocessed(seenotes,Section5).UsethissinglespeedforthewholeplasticisingstrokeSetabackpressureof5to10bar(hydraulic).Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page50ProcessStatisticsWhyisitimportanttousethemanufacturer’srecommendedscrewspeedSTEPFOURRESULTSInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.

ChangeoverstrokeSTEPFIVEOptimisescrewspeedandback-pressureprofileUsetheDosingProfilepagetoslowdownthescrewrotationspeedforthelast10%ofthemeteringstroke.Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtotheDosingStoppositionSTEPFIVERESULTSInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.

ChangeoverstrokeSTEPSIXOptimisedecompressionFindthedecompressionspeedwhichgivesbestscrewstrokeandmeltcushionconsistency.Setadecompressionstrokeof5mm.Checkthatyoustillachieve95-98%fill.Takesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtothescrewstoppositionWhatishappeningtothecheckringInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPSEVENOptimiseholdingpressureprofileUsetheHoldingProfilepagetosetaholdingpressureprofilewhichensuresasmoothtransitionfrominjectiontotheholdingpressurephaseanduseahighenoughpressuretopackthepartproperly.Addastepwhichreducesholdingpressuregraduallytozero.Takesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page24MWEPage27HoldingProfilePage50ProcessStatisticsWhydoyouneedasmoothtransitionfrominjectiontoholdingpressureWhybothertoreducethepressuregraduallyifthegatehasalreadyfrozenInsertactualvaluesintherelevantboxesMeanvalueRangeminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeboxesInsertactualvaluesintherelevantboxesTherangevalue,R,isthemaximumminustheminumum,takenfromthesevenTherangevalue,R,isthemaximumminustheminumum,takenfromthesevensteps.1234567meanRmeanRmeanRmeanRmeanRmeanRmeanRMeltcushionDosingtimeScrewendpositionInjectiontimeInjectionpressurePhydmaxInectionpressurePNhydraulicChangeoverstrokeStandarddeviation(16shots)CanyouseeatrendWhichstephadthegreatesteffectontheconsistencyofthemouldingSTEPEIGHTOptimisingtheclampforceReducetheclampforcebystepsof50kN(100kNformachinesover100tonnes)usingthesettingsfaroptimisedinthesevenstepsabove.Allowtheprocesstostabiliseeachtimeandthenweighfivemouldings.Tabulateyourresultsbelowandplotagraphoftonnageagainstpartweight.DoesthemouldrequiretheexpectedclampforceWhataretheadvantagesofrunningatreducedtonnageSTEPEIGHTRESULTSInsertactualvaluesintherelevantboxesEnterresultsinXLspreadsheet.Printoutgraph.Weight1Weight2Weight3Weight4

Weight5MeanweightClampforceRequiredclampforcekNSTEPNINESetinjectionpressureUntilnowtheinjectionpressurehasbeensettothemachine’smaximumvalue.FromtheProcessStatistcspageitcanbeseenthatthemachinedoesnotneedallthatpressuretofillthemould.Graduallydecreasethesetinjectionpressureuntiltheinjectiontimestartstoincrease.Increasethepressureagainuntilthepreviousinjectiontimeisestablishedwithaconsistencyofsorbetter-preferablytosvariation.WhatisthepurposeoflimitingtheinjectionpressureSTEPNINERESULTSActualpeakinjectionpressurebarSetinjectionpressurebarTYPICALPROCESSTOLERANCESShot-weightdeviation%%%%Plasticisingtime+土Injectiontime+土土土Cycletime土%土%土1%土1%Screwposition,dosingstop+土土土Meltcushion土土土土Melttemperature土2°C土2°C土3°C土5°CMouldtemperature土1°C土1°C土2°C土4°CBarreltemperature土1°C土1°C土2°C土4°CFeedzonetemperature土1°C土2°C土3°C土4°CHotrunnertemperature土1°C土2°C土3°C土4°CHydraulicoiltemperature土1°C土1°C土2°C土2°CRoomtemperature土2°C土2°C土3°C土4°CMouldcavitypressure土3bar土4bar土6bar土8barPressureintegral土200土300土600土900Injectionfillingpressure土1bar土2bar土3bar土4barHoldingpressure土1bar土1bar土bar土2barBackpressure土bar土bar土1bar土1barFillingdifferences(Balanceoffillforeachcavity)onmulticavitytools土1%土1%土2%土5%MouldbreatheChangeoverpressure(PnValue)土1bar土2bar土3bar土4barScrewsurfacespeed土10mms-i土15mms-1土20mms-1土30mms-1Melttemperaturepeakvalue土°C土°C土°C土°CMelttemperaturevalueatchangeover土°C土°C土°C土°CTheachievablepartqualityismuchinfluencedbytheconditionofthematerialprocessed.Itisimportantthatmoisturecontent,proportionofregrindandproportionofcolour(masterbatch)areconstant.—Demag岫/MnAcceptabletolerancesofprincipal