塑胶成型工艺流程及条件中英介绍

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塑胶成型工艺流程及条件中英介绍
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成型工藝流程及條件介紹/Molding technique procedure and parameter introduction
第一節 成型工藝
Section 1 molding technique.
1.成型工藝參數類型
Sorts of molding parameter.
5 B+ r/ o' q3 b3 y0 A* w(1  注塑參數
! }3 \+ {! a' X. g! k; n3 dInjection parameter.
3 G3 V8 r, M! K8 i! La.注射量
, [' x, S2 I  q5 q9 F7 |7 JInjection rate.
b.計量行程
( R, _, p$ Y2 G  \& }Screw back position
9 G% h6 ]; F3 z1 a: hc.餘料量
Cushion
d.防誕量
9 d# d6 M& E) _& cSucking back rate
9 b- L; t, L- B! }& }/ se.螺杆轉速
Screw speed
% L1 s. t. F+ ^8 o' A$ }f.塑化量
Plastic0 rate
' D1 I7 [$ `, {g.預塑背壓
' Z( F" q5 ^* m" M3 x- B2 z. D6 V9 RScrew back pressure
h.注射壓力和保壓壓力
% I! y- ~9 a- z8 |" w' u0 tInjection pressure and holding pressure
/ m8 o8 y8 y7 w* {1 Ai.注射速度
Injection speed
7 F6 s$ C; x. a$ _(2)合模參數
Clamping parameter
a.合模力
+ G5 M% D( @2 _; PClamping force
, X. h, T: L$ A9 f* bb.合模速度
Clamping speed
  _! I6 D9 ^$ |0 X6 Rc.合模行程.
4 N( w) j- w0 U4 x: sClamping stroke
d.開模力
Opening force
e.開模速度
" |3 S2 s9 g7 \$ LOpening speed
f.開模行程
Opening position
g.頂出壓力
) ?. {! X2 g& EEjector advance pressure
. f# z" E& v. I* u7 z# th.頂出速度
- R3 v0 e: P' `5 V+ [. j$ yEjector advance speed
' S& j5 F6 ?5 |i.頂出行程
Ejector advance position
2.溫控參數
* q9 T3 U6 K+ S5 ]0 UTemperature parameter
a.烘料溫度
Dry resin material temperature
b.料向與噴嘴溫度
' Z, f6 x: S4 q6 d. g7 D5 j3 T  iCylinder temperature and nozzle temperature
) X! S  v$ F7 k5 r' k/ qc.模具溫度
, r$ q* R& J4 D1 YMold temperature
d.油溫
, K: M5 O! w0 m  t* hOil temperature
9 d- R3 I' ]! r9 Y! ~7 {5 }3.成型周期
Molding cycle
a.循環周期
Cycle time
' ~! Z& y& f; N' ~# Y9 o7 x% fb.冷却時間
Cool time
c.注射時間
Injection time
! C3 t* z% ]9 Id.保壓時間
Holding pressure time
e.塑化時間
Plant time
f.頂出及停留時間
' Z+ K$ |5 `, _2 I3 y1 mKnocking out and delay time
/ X' G, `; R5 Lg.低壓保護時間
Mold protect time
9 {  P8 D1 g, v6 d. z, P3 m6 O成型工藝參數的設定鬚根據産品的不同設置.
, ?3 c5 b$ X2 KMolding technique parameter setting differs depending on type of
product
第二節成型條件設定
0 s4 W6 M" e& q! [, ~8 q7 ^% ~: V# KSection 2 Molding parameter Setting
按成型步驟:可分爲開鎖模,加熱,射出,頂出四個過程.
' S2 X3 Z/ a! gMolding steps: mold opening/closing, heating injection and knocking
out.
' o+ l) T: X+ T# N' z) U開鎖模條件:
Mold opening parameter:
/ r4 r; w- F4 y/ W% ^快速段中速度
9 n" t: p% N  m( [. t7 l- N. O$ F5 N低壓高壓速度
High-speedmid-speed
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Low pressure high pressure speed
鎖模條件設定:
Mold closing parameter setting
1鎖模一般分: 快速→中速→低壓→高壓
Mold closing: high-speed →low-speed →low pressure→high pressure
2.快鎖模一般按模具情况分,如果是平面二板模具,快速鎖模段可用較快速度,甚至于用到特快,當用到一般快速時,速度設到55-75%,完全平面模可設定到
80-90%,如果用到特快就只能設定在45-55%,壓力則可設定于50-75%,位置段視産品的深淺(或長短)不同,一般是開模寬度的1/3.
In high-speed section, Mold closing speed depends on type of mold. For
two –plate mold it can set quick and even especially quick usually, it
set speed within 55-75%. For full-plate mold it set speed within80-90%
! Z% T9 u+ _7 ~1 c3 P) Fwhile using especially high speed it set speed within 45-55% and
- e, h5 C2 l$ B" A+ Fpressure within 50-75% position distance setting differs depending on the
5 Z. N. X1 t3 d: Avolume of product and usually it can be set 1/3 of mold opening position.
8 f6 @! @. ~: ~, j3.中速段,在快速段結束後即轉換成中速,中速的位置一般是到模板(包括三板模,二板模)合在一塊爲止,具體長度應視模板板間隔,速度一般設置在30%-50%間,壓力則是20%-45%間.
# U! q/ P5 @: G% Q; F) k* w( jIn mid-speed section: Mold closing speed changes into mid-speed after
9 V$ Z" w& l, O0 N; H+ t8 Q/ e: F3 ghigh-speed section finish. Mid-speed start position is where two plates
9 D  D$ [+ o! r# [9 H: ], Gmeet (include three-plate mold and two-plate mold ) Distance of
. ?% W, N+ V/ \. D. Vmid-speed is up to distance of two plates plate it speed within 30-50% and
pressure 20-45%.
2 w+ t7 F9 w0 R' e4.低壓設定,低速設定一般是在模板接觸的一瞬間,具體位置就設在機台顯示屏顯示的一瞬間的數字爲准,這個數字一般是以這點爲標準,,即于此點則起不了高壓,高于此點則大,輕易起高壓.設定的速度一般是15%-25%,視乎不同機種而定,壓力一般設定于1-2%,有些機則可設于5-15%,也是視乎不同機種不同.
Low-pressure section: Mold closing sets low-pressure when plates
4 U: T8 H* i$ g2 Y% a  Nmeeting. This position is set to the data of machine screen on this time.
  q$ R' B7 N# n1 _6 P% F  [This point is the gage of the data. Data lower the point there is no
high-pressure. Data higher the point there is high-pressure easily. It set
speed within 15-25% and pressure within 1-2% depending on type within
; ]4 \" C0 c. O2 _* |' g1-2% depending on type of injection molding machine.
5.高壓設定,按一般機台而言,高壓位置機台在出廠時都已作了設定,相對來講,是不可以隨便更改的,比如震雄機在50P.速度相對低壓略高,大約在30-35%左右,而壓力則視乎模具而定,可在55-85%中取,比如完全平面之新模,模具排氣良好,甚至于設在55%即可,如果是滑塊較多,原來生産時毛邊也較多,甚至于可設在90%還略顯不足.
/ s6 L) N0 _- J5 [! n# FHigh-pressure section: To normal injection molding machine,
& I) M& t: H3 @6 ~  u- x1 c/ C5 R2 J. qhigh-pressure position had been set before they were sent to customer. It can not
1 f; ~/ x! G( X/ @be modified. For example high-pressure position of CHENHSONG machine is
50P.The speed of high-pressure section is about 30-35% and higher than
that of low-pressure. The pressure is up to mold, it can set within
55-85% For full-plate mold, it’s eject air well, it can set pressure 55%
  Q- d2 E( w' E, v.If mold has a lot of slides and flash rate high in production,
6 a7 i* z! J' f, O3 l- T: u8 ?pressure can set 90%.

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加熱工藝條件設定
Heating technique parameter setting
1.加熱段溫度設定必須按照産品所使用的原料的不同而不同,但却必須遵循一個這樣的規則,即由射口筒到進科段溫度是逐步遞减的.且遞减溫度是以10.度爲單位.
, s3 n# ^1 e& P( l+ IThe proper temperature setting differs depending on type of resin
material, but it must be abide by a rule that temperature setting should
+ U! U+ ?6 r/ c) q; c& |) q" Xdiminish in step 1０.C from nozzle to feeding resin material position.
1 h/ e6 ^/ e% [- Z+ v* @5 V2特殊情况下.如料頭抽絲,則射口筒溫度應降低,如果是比較特殊的原料冷凝比較快的.則射口筒溫度則不止比第二節法蘭溫度高10度.比如PPS.
尼龍等.
Nozzle temperature setting should low if product line. If resin
material such as PPS, PA, cool very soon , Nozzle temperature should higher
1 c* ?8 S# V( ?0 S8 {7 zmore 10.C than the second cylinder temperature.
3.機台馬達啓動溫度視乎機台不同而不同,一般出于對機台油路中的油封保護需要,油溫最好能控制在40度-60度,以免油封長期高壓而變化,縮短使用壽命,造成成型不穩定.
Pump turning on temperature is different depending on type of injection
molding machine. To protect oil seal of machine it set oil temperature
第三節注射及熔膠(加料)工藝條件設定
Injection and plastic Technique parameter setting
& F9 j7 \  B9 Q9 J一.注射
Injection
1 L6 u6 g* P# q6 K+ A2 L注射是把塑料原料經加熱後射進模腔的過程,它一般可分爲第一級,第二級,第三級,第四級及保壓幾段:
Injection is a step which inject melt resin material into mold. It
1 g& Q& z" I9 `5 Gconsists of stepl,step2 ,step3,step4 and holding pressure step:
: b7 R( d9 p! L1.第一級注射一般是注射料頭段.具注射量一般可根據料頭的輕重來估計其行程,當然也可以依據公式來計算,如公式:
Step l injects usually tunnel material, Injection Volume can be
estimated according to the weight of course it can be calculated by formula:
* e; x: L/ s! W) H" q( d& Y) tL=Si=Vi/0.785Ds2
L:注射行程; Si: 注射行程;
# w+ F& j8 X; h) G/ b3 X; sL: injection stroke Si: injection stroke
Vi:理論注射容積; Ds:螺杆直徑;
Vi: injection volume of theoretical   Ds: diameter of screw
0.785:是Ω/4的值.
0. 785: value of Ω/4.
當然,如果我們在成型時每設定一個參數都要計算一次,要成型出一個産品就要幾個小時才能完成了.
2 Z" Y- A. L9 @0 Z1 R- cBut it cost a lot of time to produce one product if every time molding
: z) h4 @) j" Oparameter is setting by calculation.
2.第二級是注塑産品約2/3的階段,當然,根據産品特殊需要,也允許成型不到2/3階段,比如避免結合綫問題,這一階段的成型速度及壓力一般是整個成型段的最大值段,如果排的産品與機台基本是相吻合的.模具結構合理,排氣良好,這一段的壓力一般也不會超過80%.速度側視産品需變,可能大到95%也可,自然一般都是在55%-80%間.
( u- v- @2 y0 Y8 e% NStep 2 inject 2/3 of product. It can lower 2/3 of product according to
requirement of product. For example to prevent weld line. Molding speed
$ L; W' w+ O( w3 y/ ^8 R: m) Uand pressure on this step is the maximum of whole molding section. If
Mold suit the injection molding machine and mold structure reasonable
) A- d: K! S* q* rand eject air well, pressure of this step should lower 80%. Molding speed
setting within 55-80% but it may setting 95% for especial product.
3.第三段是注射餘下的1/3段,其速度和壓力根據産品的需要,一般是小于第二段,速度和壓力存在于一個往下降的過程.主要是爲了防止産品毛邊的産生,但同時又必須把産品充填飽滿.
0 d- e$ l; Z* z2 xStep3 inject remain 1/3 of product. According to product molding speed
9 ^8 ?8 s- @) n9 Z9 |2 \4 \9 k+ t$ l" xand pressure lower than that of step2 To prevent flash speed  and
7 T# b3 H7 e$ Epressure should decrease but it can’t shot short.
5 T  P& Z( a$ G# K% O3 N# ?/ `4.第四段:一般有機台還有第五,第六段,這段的成型速度和壓力相同前,都存在兩段一個遞减過程.其作用都是起到一個再次充滿的作用.
- `/ _& N2 M5 L" nStep4 section: Some injection machines have step5,step6 which are same
$ K2 ]: U) K' @% @+ was former molding speed and pressure this step should diminish and
inject once more.
5.保壓段:不論成型什麽産品,都存在一個保壓過程.任何産品都不同程度的存在一個厚薄不一的問題,正常情况下,較厚的部分都可能存在一個收縮凹陷的現象,爲了解决這種現象,就應應用到保壓,保壓一般來講都應用較慢的射速,而壓力的設置則應看縮水的情况如何,小到25%,大到80%都有可能.
4 @% J) @3 s( n( W3 ?9 s' @Holding pressure step: No matter what product there is a holding
) d- z0 c4 V3 x0 M! rpressure step. Any product can’t molding a same thickness. Usually the
deeper section may sink mark . To prevent this defect it should set holding
% Y) y' L. p0 x/ G2 Npressure, The injection speed of holding pressure step is slow but
* }2 _/ a9 _1 m6 Mholding pressure setting within 25-80% depending on sink mark

within 40.C-60.C, If oil seal work on condition that high pressure and
damaged It’s work time will be shorter, it can cause molding stable.
) P  v7 X: D' O; m二.熔膠段工藝
* X1 V% }6 i: [Plastic Technique
/ L) w, f( s2 r4 Y3 r) r2 h1.再複雜的熔膠旋轉過程最多不會超過三段,因爲熔膠本身就是存在于把膠熔進料筒的過程,如果原料粘度大,熔膠壓力則大,但速度則應取决于原料的分解溫度,熔膠速度越快,原料中的剪切力則會越大,料管溫度則越高,局部原料産生分解的可能性則會越大,故一般熔膠會采用中速爲宜,如45%-75%,熔膠同時會碰到一個比較重要的環節,那就是背壓的使用,産品精度要求越大,背壓的使用則更大,背壓可使原料分子間結構更緊密,成型出的産品則尺寸更穩定,外觀越好.當然,背壓太大,則會産生流涎,所以背壓的使用又應考虙到其它原因.
Plastic should lower 3 steps, because plastic is a step to add melt
  r% n  ?$ C0 g8 |% X1 r% [resin material to cyclinder , Higher stick of resin material ,higher screw
. Z  L8 [4 k, y, T5 dback pressure. Screw speed differs depending on decomposing temperature
2 r% @- M9 K, ~- Dof resin material ,Higher screw speed ,Higher trim force of resin,
higher cyclinder temperature. Some resin material may decomposes so it set
screw speed in mid-speed such as 45-75%, In plastic step setting screw
2 P5 T# O  Q0 b% W7 s: xback pressure is very important, Higher screw back pressure ,higher
  T3 t: a; B* `; N2 r: ~9 S- Wquality of product screw back pressure make resin structure order, Molding
product is beautiful and volume stable. But ,it maybe flow if screw
. [7 ~9 D: [. [8 j2 T4 jback pressure too high . So all factors should be considered when using
+ t: r" ?) R( J( R8 _8 i0 z' }screw back pressure.
2.熔膠過程還有一個比較重要的環節,那就是松退,松退分前松退和後松退,其作用一般是爲了防止流涎和抽絲,設定值速度和壓力都在20%-50%間,設定的行程一般在2-5cm間,太長的行程可能會使料筒裏面貯存空氣,導致下一模出現不期望的氣泡.
In plastic step sucking back is very important too. Sucking back
5 D3 D6 z* q& r; X* s8 ?! Zinclude front sucking back and back sucking back It setting sucking back to
prevent flow and line. It sets sucking back speed and pressure within
20-50% and distance within 2-5cm. TOO long distance make cyclinder
reserve air and cause bubble at next molding.

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頂出的工藝設定
$ P4 w; N. O2 T, Eknocking out technique setting
9 M9 d, U8 s- K3 Y. P) }0 P産品經冷却定型後則有一個開模的過程,開模基本上是合模的反過程.開模的未段則有一個慢速設置,開模完成後,産品必須頂出的過程.
There is a mold opening step after product cooling taking shape. Mold
opening is a reverse step of mold closing. The last step of mold opening
speed set slow. Product should be knocked out after mold opened.
一.頂前:
Knocking out
, y2 D1 \/ C7 ?6 [1 n2 D頂前最好分兩個階級,第一階可分爲中壓慢速,即是把産品輕輕頂出一部分,然後是中壓中速頂,中壓中速一般指的是35%-55%,而低速則有可能低到5%,這需視産品不同而言,頂出行程設定是頂出長度稍比産品垂直深度大1-2cm即可.
Knocking out includes two steps, Step1 section setting mid-speed,
knocks product out partly step2 section setting mid-pressure and mid-speed .
' o) I# D$ @- c# `Depending on different product, mid-pressure and mid-speed sets within
35-55% but low-speed can set 5%. Distance of knocking out longer 1-2cm
than the vertical thickness of product.
二.退針
% W3 u; @( {( s1 tBack
" P: ?$ b# t$ [* S7 ^, b頂退包括兩個過程與頂落的過程基本一致,頂退的終點應預留1-3cm的空間,以保護頂針油管不被頂壞.
7 x* w7 t" ]  r+ ?; C3 B1 G: oThe same as knocking out, ejector back includes 2 steps. To protect the
ejector oil jar, it should make a 1-3mm distance in the ending point of
+ b+ k& ~' C2 ]. W, f1 q0 i2 nejector back.
9 {7 H, J% [) L4 C1 ]$ P$ T& v三.頂針方式還包括一個多次頂,單次頂及頂針停留的選擇,機械手取産品,脫模順利的情况都采取多項,爲了頂針油缸
壽命的延長,多次頂就以不超過三次爲宜,頂針停留一般用在頂針帶著産品退回有可能對增品産生損傷的模具,同時爲配合機械手使用,有時也需要較短的頂針停留.
* @5 U4 d& M/ P$ a/ R# |The way of knocking out includes knocking out once, Knocking out repeat
6 h# r1 n0 l; q+ ]/ m# |$ M' A- dand ejector delay. Take product by manipulator or take product easy, it
0 F# e( c* Y6 wshould select knocking out once. To longer the work time of ejector
oiljar, times of knocking out lower 3 times. Ejector delay used when
product will be damaged if ejector back or suit manipulator.
成型時間的設定
Molding time setting
在保證産品質量的前提下,周期時間是越短越好,周期時間又包括如下幾項:射膠時間,保壓時間,熔膠時間,冷却時間,頂出時間,鎖模低壓時間,甚至乎關係到時間因素的還有還開模與鎖模,及頂出的快慢.
Cycle time should shorter on condition that product quality well. Cycle
: f  k- n3 O8 H7 _time includes: injection time , holding pressure time, plastic time,
cure time, knocking out time and mold protect time. Even mold opening
closing sopeed and knocking out speed affect cycle.
1.
射膠時間包含保壓時間,一般看起來,射膠時間越長,産品越飽和,但我們在講求質量時,同時也須考慮産能,更何况,射膠時間過長,有可能會造成産品過于飽滿而尋致粘模頂的變形呎寸偏大等一系列問題,故我們在設置射膠時間時應綜合考慮,儘量在合乎質量要求時縮短射膠時間.
! m% i6 w3 K* l- k4 jInjection time consists holding pressure time. Longer injection time,
, ]/ k/ j/ F+ a/ X% Jfuller product, we should consider production quantity when we suit for
' y7 a% ]8 x) F9 Y% Vquality. If injection time too long, it may cause a series of defects
3 ~2 I+ h" e6 d5 K1 z/ k) Zsuck as flash strain. So all sorts of factors should be considered,
$ P; v. m0 c! W  cinjection time should be shout if quality suit for requirement.
2.
/ h2 ?% @, _; C, q5 ]熔膠時間的長短取决于熔膠速度設定的快慢,背壓設定的大小,但有一點,熔膠時間控制的長短一定要比冷却時間短.
2 d) o6 \8 g: FPlastic time depends on plastic speed and screw back pressure, but
# U9 w8 E/ P7 [plastic time must shorter than cure time.
3.
( F; y: n; d! i# _- S  F6 [' ?冷却時間:冷却時間的長短直接影響到成型的周期,冷却時間越長,成型時間就越長,造成産能就越低,故我們在設定高壓冷却時間時,只要能保證到産品成型順利,不會直接影響到變形等問題,設定的時間也是越短越好.
Cure time: Cure time affects molding cycle. Longer cure time, longer
& N: h- Z8 d' x" \7 S" J: j$ Bmolding cycle, lower production quantity. So it sets cure time short on
condition that product molding succed and can’t deformation..
* \2 p0 A/ c8 ?4.
在大量使用機械手的塑膠公司,我們的頂出時間一般是與機械手配合爲宜,全自動使用機械手時頂出停留時間一般保持1.5-2秒,半自動生産,如因頂針退回會導致産品掉落或卡緊,而取不下産品,停留時間則應保持5秒左右.
5 j' p/ O6 |( J5 p) X* i; DIn PCE company, for using manipulator in abundence , knocking out time
suits manipulator, Knocking out delay keeps 1.5-2 second when using
manipulator  full-manipulator, knocking out delay keeps about 5 second
5 q3 U# @- I7 \8 Fwhen using manipulator semi-manipulator and product will fall or can’t be
taken off if ejector back.
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: t9 e0 m2 m0 O0 ?# R; n. b" v低壓保護時間對保護我們人身安全,模具安全起很大作用,配合好模具低壓位置和低壓壓力的調整,低壓保護的時間應取1-3秒,保護時間越短,可能造成的危害則越小.
Low-pressure protect is very important for safety and protect mold,
% B% r6 K1 ^" N' M$ X; E9 G! E2 FMold protect time should adjust within 1-3 second suit low pressure and