注塑模具简介

GE

PlasticsInjection

MoldTooling射出成型模具eTOOLING

DEVELOPMENT塑膠模具發展Tooling模具ProcessingProblems製程上所遇之問題Black

Specks黑點Gloss光澤度Jetting噴射現象Delamination分層Fingerprinting手紋Plate-Out電鍍Tooling

Development模具發展ProcessingProblems製程上所遇之問題Weld

Lines結合線Burn

Marks燒痕Dimensional

Control尺寸控制Streaking流痕Sticking黏模Brittleness脆性Tooling

Development模具發展Short

Shots短射Flash毛邊Sinks/Voids縮水Warpage翹曲Splay裂開/Silver

Streaking銀Gate

Blush進澆白化/HaloProcessingProblems製程上所遇之問題Tooling

Development模具發展Inconsistent

Cycle周期不一致THE

WORST

PROBLEM最嚴重的問題ProcessingProblems製程上所遇之問題Tooling

Development模具發展-Anonymous佚名The

CHEAPESTTool

is

The

OneThat

WORKS左圖為最便宜之只有一個模板Tooling

Development模具發展Customs

andPracticesof

theMoldmakingIndustryClassificationsof

InjectionMolds

forThermoplasticMaterialsA

Guide

for

the

Purchaseror

Manufacturer

of

Thermo-plastic

InjectionMoldsUp

to

400

Tons

and

400

tonsand

over.S

IPTooling

Development模具發展熱塑性模具分類400到400噸以上熱塑性模具購買指南模具行業海關分類標準MOLD

TYPES模具種類Tooling模具Types

of

Molds模具型式(Tools)(Dies)SeriesSeriesSeriesSeriesClass

AClass

BCollapsible

CoreTwo

Plate二板模Three

Plate三板模Acceleration

KO?Side

InjectionLifterCAMRunnerlessInternally

HeatedExternally

HeatedPrototypeMUDEtc.Tooling

Mold

Types模具型式Tooling

Mold

Types模具型式Two

Plate

Design二板模設計Exploded

Vie爆炸"B"Plate母模板"APlate公模板Top

ClampingPlate上模板Elector

RetainerPlate下頂出板Ejector

Plate上頂Leader

Pin導柱Support

Plate承板Return

Pin回位銷EjectorHousing下模板Tooling

Mold

Types模具成型型式Two

PlateMoldEjection二板模分模情形1.開模(公母模分開)Injection

Molding

Tooling射出成型模具3.頂針退回，準備合模Tooling

Mold

Types模具成型型式1.脫料板分開，將水口與成品分開三板模分模情形Parting

Line

1第一合模面Main

Leader

Pin主要導柱Tooling

Mold

Types模具成型型式Parting

Line

1第一分模面Parting

Line

2第二分模面三板模分模情形2.公母模分開Tooling

Mold

Types模具成型型式Parting

Line

1第一分模面Parting

Line

2第二分模面三板模分模情形3.公模頂出板將成品頂出SPRUEBUSHINGS射嘴Tooling

Sprue

Bushings模具射嘴Heated

Sprue加熱式射嘴-Helical

Heaters螺旋電熱片式加熱-Gas

Pipe瓦斯管加熱Non-heated

Sprue無熱式射嘴SPRUE

BUSHINGS射嘴Tooling

Sprue

Bushings模具射嘴COLD

SPRUE

BUSHING冷式射嘴Tooling

Sprue

Bushings模具射嘴SPRUE

BUSHING射嘴Gas

Pipe瓦斯管Heater

Band電熱環Gas

Pipes瓦斯管Tooling

Sprue

Bushings模具射嘴Helical

Heater螺旋式電熱片Hot

Sprue

Bushing熱射嘴Thermal

Shutoff電熱開關Tooling

Sprue

Bushings模具射嘴RUNNERS澆道Tooling

Runners模具澆道MaterialFlows

OnlyThroughMoltenPortion

ofRunnerOuter

SkinChills

onContact

withmold

SurfaceRunners

Flow膠粒於澆道流動狀態Tooling

Runners模具澆道一開始膠粒接觸模腔表面部份將冷卻形成固化層。後續膠粒藉著澆道內部未固化之部份進行填充模腔。Runners

Design澆道設計1.Full

Round

Most

Efficient澆道剖面為圓形者，為最佳流動狀態2.Trapezoidal

Good澆道剖面為梯形流動性良好3.Half

Round

Not

Good澆道部面為半圓形流動性不佳P.L分模線Tooling

Runners模具澆道r

dr

dRunners澆道Trapezoid

Profiles梯形剖面澆道r/dW

D1/83/161/83/161/43/161/45/161/45/167/165/163/81/23/8Equivalent

Round

Runner同效果之圓形與梯形剖面Design

Alternative設計上可選擇二種其中之一Tooling

Runners模具澆道WDSprue

Puller料頭倒扣1.REVERSE

TAPER

BEST倒錐形倒扣效果最佳2.Z

PULLER

GOODz型倒扣效果良好3.GROOVETROUBLESOME環狀倒扣不易脫模4.SUCKER

PIN

NOT

RECOMMENDED無設計倒扣不建議使用Tooling

Runners模具澆道RESTRICTIVE限制性PREFERRED首選Tooling

Runners模具澆道Q=Volumetric

Flow

Rate單位體積流動速率R=Radius半徑A

small

increase

in

radius

dramatically

increases

theflow

through

the

runner.少量增加澆道半徑，Q值流動速率會大幅增加Q

=Q

Proportional

to

R2Q與R2成正比n

R

2

P8n

LTooling

Runners模具澆道Artificially

Balanced人工設計平衡澆道1/81/43/81/21/2英吋

Dia直徑Tooling

Runners模具澆道RUNNERLESS

MOLDING無澆道系統Tooling

Runnerless

Molding模具無澆道系統Hot

Runner

Benefits熱澆道的優點Faster

Cycles成型周期減少15~20%15-20%

FasterEliminates

Material

Waste排除材料浪費No

Sprues

or

Runners無注口或澆道Improves

Part

Quality改進成形品品質Less

Stress較低殘留內應力Better

Appearance較佳之外觀Tooling

Runnerless

Molding模具無澆道系統RUNNERLESS

MOLDING

SYSTEMS:無澆道系統INCOED-M-EHot

OneCool

OneMOLDMASTERSPEARKONAPLASTHINGRAMAHUSKYFASTHEATEUROPE

&

ASIASPRUELESSHOMEMADECompression

Seal高壓密封Plug插銷

Moldmakers

Choice模具製造商自行選擇Diameter

Fit

Seal直徑合適密封Tooling

Runnerless

Molding模具無澆道成型Manifold

=

5000Cavity

Plate=

500Thermal

Expansion

of

Steel.00000633

Per

Inch

Per

Degree6

in.12

in.18

in.=

.017

In.=

.034

In.=

.051

In.Tooling

Runnerless

Molding模具無澆道成型GATING進澆口Tooling

Gating模具進膠Direct

Sprue

Gate直接進膠Edge

Gate側邊進膠Fan

Gate扇形進膠Tunnel

Gate潛入進膠Single單點進膠MultipleTab

Gates多點進膠Disk

GateRing

Gate環形進膠lash

GateiaphragmGate?Gateodifiedin

Gateump

Gatealve

GateEtc.Types

of

Gating進膠口之種類Tooling

Gating模具進膠Molded

Part成形品Direct

Sprue

Gate直接進膠式Sprue進膠口Tooling

Gating模具進膠PART成形品RUNNER澆道GATE進膠

LAND進膠緩沖帶Fan

Gate扇形進膠Tooling

Gating模具進膠COLD

SLUG

WELL較佳之冷料井RADIUS半徑Fan

Gate扇形進膠Tooling

Gating模具進膠LandLength進膠口長度0.030InchesMaximum最大距離0.03英吋Edge

Gate側面進膠Tooling

Gating模具進膠Single

Tab

Gate單點進膠Multiple

Tab

Gate多點進膠Tab6

in.Max12

in.MaxTabGate澆道Sprue注口Sprue注口Gate澆道Gate澆道TabTooling

Gating模具進澆Knit

Line結合線Multiple

Tab

Gate多點進膠Tooling

Gating模具進膠Disk

or

Diaphragm

GateRunnerPartRunnerSprueTooling

Gating模具進膠RunnerParallelRunnerGateFlash

GateParallelRunnerTooling

Gating0.020

LandLength0.050900Tooling

GatingPin

Point

GatingSpruePartingLineZero

Land

LengthTunnelGateKnock

Out

PinGrind

Flat

on

GateSide,

Min.

20Fasten

Pin

Head

ToPrevent

TurningTunnel

GateMolded

PartTooling

GatingSpruePartingLineTunnelGateKnock

Out

PinZero

Land

LengthGrind

Flat

on

GateSide,

Min.

20Fasten

Pin

Head

ToPrevent

TurningTunnel

GateMolded

PartTooling

GatingKnitLineGate

AreaHighStresses•Cosmetics•ImpactTooling

GatingKnit

Line

and

Gate

AreaInjection

Molding

ToolingValve

Gate

Shut

Off

SystemB

Fills,

Bushing

B

ClosesVENTINGTooling

VentingParting

Line.001-.0025DepthGateVent.060Min.NoteStep.500.050Min.Tooling

VentingTEMPERATURECONTROLTooling

Temperature

ControlThe

Most

Efficient

Cooling

Systems

Are

Those

Which

OperateSuch

That

The

Inlet

and

Outlet

Coolant

Temperatures

AreWithin 100

Of

Each

OtherFluid

Velocity

Ft./Sec.TurbulentFlowTransitionAreaHeat

Transfer

EfficiencyWater

CoolantHeat

TransferBTUHr

x

Ft2

x0F1.0

1.52.0LaminarFlow0.5Tooling

Temperature

Control120130OOO130140

OO140150

O125O125OO135O135O145O145INOUTTooling

Temperature

ControlBalanced

CoolingUniform

Cooling

Maximum

TemperatureDifferential

of

10oFTooling

Temperature

ControlInjection

Molding

ToolingMold

Cooling

Series

BubblerINOUTPOORPinBladeInjection

Molding

ToolingMold

Cooling

Parallel

BubblerINCorrectOUTPinTubeEJECTORMECHANISMSTooling

Ejector

MechanismsPin

Diameter

is

as

Large

as

PossiblePins

Are

as

Numerous

as

PossiblePins

Exert

a

Uniform

Force

on

MoldedPartsTooling

EjectorMechanismsFactors

Effecting

Ejection

ForceSidewall

DraftSidewall

Contact

AreaSidewall

Polish/TexturingDegree

of

PackingMold

TemperatureMold

ReleaseTooling

Ejector

MechanismsTEXTURING

AND

DRAFT

ANGLETooling

Texture

and

Draft

AngleDRAFT

ANGLEDRAFT

ANGLE1/2o

MINTooling

Texture

and

Draft

AngleAdditional

1

Degree

per

Mil

in

Depth

of

TextureDraft

Angle

for

Textured

SidewallTooling

Texture

and

Draft

AngleTexturing

Guidelines

Quality

of

Texture

Varieswith

Type

of

Steel

Identical

Grades

of

SteelCan

Etch

DifferentlyTooling

Texture

and

Draft

AngleTexturing

Mold

FinishesEnhances

Styling

and

AestheticsReduces

RejectsTooling

Texture

and

Draft

AngleCORE

PULLSTooling

Core

PullsHydraulic

Core

PullsPlasticCorePinCored

HoleCoreHydraulic

CylinderCavityTooling

Core

PullsTooling

Core

PullsTooling

Core

PullsPROTOTYPINGTooling

PrototypingPrototypeTool

MaterialsAluminumBeryllium

AlloysMild

SteelP20Steel956526219.4Thermal

Conductivity(BTU/hr

ft2

oF)Aluminum

Thermal

Conductivity

Is

4.5

Times

That

of

P20

SteelTooling

PrototypingParts

Cool

More

Quickly

in

Aluminum

ToolingParts

Shrink

Less

in

Aluminum

ToolingShrink

Is

Different

in

Steel

and

AluminumTooling

PrototypingChoose

Prototype

Tool

Materials

AfterConsideration

of

:Dimensional

Criteriaof

PartSurfaceFinishRequiredWear

ResistanceTooling

PrototypingTooling

SummaryPlastic

Part

ProductionPart

Design

Dictates

PerformancePerformance

Dictates

MaterialMaterial

Dictates

ToolingMold

TypesMold

MaterialsSprue

BushingsRunnersGatesVentingEjectorsDraft

AngleMold

FinishesTemperature

ControlPrototypingShrinkageTooling

SummaryMold

DesignGE

PlasticsEJECTOR

MECHANISMS

DESIGNPINDIAMETER1/81/43/8?PIN

BEARINGSURFACE1

in21

in21

in2PinBearing

SurfaceNUMBER

OF

PINS8220980

to

100

I2n

REQUIRES

1

In2Sidewall

ContactTooling

Ejector

MechanismsINTERNAL

THREADSNAP

LIDCOMMON

UNDERCUTSTooling

Ejector

MechanismsLatch

or

HookBobbin

or

SpoolCOMMON

UNDERCUTSTooling

Ejector

MechanismsBlade

atDeep

RibsRounds

PinsSleeveEjectorBossEjectStationaryPartsStripper

Mold

PinPlateKnock

OutBarsGOOD

KNOCK

OUTFOR

ROUND

PARTSUSED

AROUNDPINS

&