注塑成型工艺

Hifax注塑成型什么是Hifax填料增强剂化学改性剂稳定剂(UV和oxidative稳定)颜料Hifax是Basell公司出产的一种热塑性聚烯烃材料。含有聚烯烃和乙烯-丙烯橡胶成分。根据用途的不同还可能含有其他的添加剂。RubberDispersionMagnificationis2000X.CrosssectionofunfilledTPE-CA287.Rubberparticlesizesrunfrom1to3micronsor0.4tenthousandsto1.2tenthousandsofaninchindiameter.Fastinjection,highmelttemporhighshearratescanelongate/ripapartorcenterlayertherubber.Thiscanchangethematerialpropertiesorcausepaintadhesioninconsistencies.注塑成型大制品的时候的成型工艺推荐nozzleendcapheaterbandsbarrelhoppermagnetconcentrateloaderhopperAdapterZone1Zone2NozzleZone3Zone4温度范围210°to245°材料融化温度对熔体温度的测试热电偶测温仪红外测温仪，不适合测试熔体温度注塑阶段通常在7.0到9.0秒之间在注塑的结束阶段98%到100%的型腔被充满.如果不能达到上述要求，可能会导致浇口附近过饱和，并随后带来变形问 题 快递公司问题件快递公司问题件货款处理关于圆的周长面积重点题型关于解方程组的题及答案关于南海问题 。注塑压力范围-550到900公斤力所需的注塑压力取决于诸多因素，例如：熔体温度/模具温度/填充速度/材料流动性/充模的最长 流程 快递问题件怎么处理流程河南自建厂房流程下载关于规范招聘需求审批流程制作流程表下载邮件下载流程设计 /壁厚等因素.injectionunit...nozzleendcapheaterbandsbarrelhoppermagnetconcentrateloaderhopperMenu#17典型的注塑速度分布VELOCITY(6.50in/smax)0.42in.8.42in.%ERRORCORRECTION0ADAPTIVESHOTCONTROLOFFCUSHION0.28IN0.30IN1285psiFILLTIMEsec.8.75TRANSFERin.0.25CUSHIONin.0.4111.5SHOTSIZEin.90%25%20%150.42TRANSFERin.%1.402.302.201.951.00in/sin/sin/sin/sin/s54321背压背压的作用是压实螺杆前段的熔体，排除空气或不密实的因素，从而使每模注塑的熔体密度和产品的稳定性保持一致。另外也可以通过背压的增加，提高剪切程度，从而提高熔体温度，避免融化不充分的成分。但可能带来的不利因素是：成型周期将因此而延长，所以目前更多的是选择适合的螺杆 设计 领导形象设计圆作业设计ao工艺污水处理厂设计附属工程施工组织设计清扫机器人结构设计 ，提高融化效率以及优化成型周期。3to10bar模具温度一般需要通过循环水的作用把模具定模温度控制在30~35C°。动模温度通常需要比型腔温度低10C°左右。通过这样的温度设定可以防止产品因冷却不好导致壁厚不匀的问题。WaterTemp.Controller动模定模材料干燥要求对于有矿物填充的规格来说，由于矿物会吸收水分，所以可能会需要对材料预先加以干燥处理。通常需要的干燥条件为：85~90C°条件下干燥45分钟到1hour.在此温度下干燥更长时间也不会对材料性能产生影响。但如果干燥温度超过105°C,塑料粒子表面可能会发粘，从而导致加料困难。如何判断是否水分带来的问题Toconfirmthattheproblemismoisturefirsteliminatethepack/holdpressureortime.Nextmovethebooststagetransferpositionupwardtocreateashortshot.Ifmoistureispresentenoughtocausesplaythereshouldbebubblesontheleadingedgeoftheflowfront.Shavetheflowfront,asshown,withatrimknife.Ifmoistureispresentvoidsshouldbevisiblealongtheedgeofthematerialflowfront.可能影响到最终产品尺寸的成型因素主要有四个因素会影响到产品的尺寸.对产品重量会产生影响的成型条件.制品的烘烤温度.材料的先天收缩特性.产品的壁厚.下列成型条件的变化可能会减少产品的尺寸.减少注塑成型的填充时间，这也意味着增加注塑速度和注塑压力。减少保压时间，同时将需要提高保压压力。减少冷却时间，需要注意产品的变形情况和螺杆回退所需要的时间。增加熔体温度.增加模具温度，这往往会带来周期的延长。Thesechangeswilldecreasethepartweight.以下成型条件的变化将可能增加产品的尺寸.降低熔体温度.降低模具温度增加模具填充时间（降低填充速度和压力）增加保压压力和时间在增加压力和时间的时候，需要注意防止浇口附近的过饱和现象。Thesechangeswillincreasethepartweight.烘烤温度对产品尺寸的影响Theredlineistheovenambienttemperature.Theblueandgreenlinesaretheparttemperaturesmeasuredbyinsulatedthermocouples.Thisgraphshowsthatthedatapackreadingsreflectaparttemperatureof270°.Dependentonthematerialtype,forevery10°Fabove250°apartwillshrinkanadditional0.3to1.1milinch/inch.Datasheetshrinkcalculationsarebasedonplaquesbakedat250°.Figure1.TheEffectofBakeTemperatureontheShrinkageofRockerPanelsMoldedFromHifaxCB252ACBlack(78in.length/3.0mmnominalwallthickness)101112131415250255260265270275280285290PaintOvenBakeTemperature,°FAfterbakeMoldShrinkage,mils/inAdditionalShrinkage=0.8mils/in/10°FBakeInfluenceOfOvenTemperaturesOnPartSizeInfluenceOfOvenTemp&WallStockOnMaterialShrinkCB252isamediumfilledmaterialusedinrockerpanelsandcladdings.Howmuchapartwillshrinkisdependentuponthemake-upofthematerial,theprocessconditions,thepartwallstock,thebaketemperatureandetc.Howmuchtimeisrequiredbeforeapartreachesfullshrinkisgenerallyconsideredtobe48hours.Partcurewilltakelongeriftheambienttemperatureisabove70°.Thegraphillustratesshrinkageoveratimeperiodof360minuteswiththeambienttempat70/72°.Totalpartshrinkafter24hoursis0.012inch/inch.Thegraphrepresentsapercentageofthetotalshrinkthatoccurafteranumberofminutes.0.0102shrink@5minutesfor85%oftotalshrink.0.0109shrink@10minutesfor91%oftotalshrink.0.0112shrink@15minutesfor93%oftotalshrink.0.0113shrink@30minutesfor94%oftotalshrink.0.01165shrink@120minutesfor97%oftotalshrink.0.0119shrink@360minutesfor99.9%oftotalshrink.ShrinkVsTimeAcommonquestionis“Howfastwillthepartshrink”?1010.51111.51212.55154590180360ShrinkTimeinMinutes型腔的排气排气槽尺寸排气槽宽度一般为0.5inch.排气槽深度一般至少需要为0.020inch.必须定期检查排气槽的情况改善熔接痕强度.降低填充型腔所需要的压力.降低成型应力.降低熔体流动前沿的降解.提高制品性能的一致稳定.ScrewRecommendationsinjectionunit...meteringcompressionfeedscrewtipO.D.flightpitchshanknozzleendcapheaterbandsbarrelhoppermagnetconcentrateloaderhopperL/DRatiostandsforthelengthoverdiameter.ForaGPdesigntheminimumL/Dis24to1.Themaximumshotsizeshouldbe45%ofbarrelcapacity,dependentoncycletimeorunmeltedpellets,withinthecavity,maybeaproblem.Noteanexampleonthefollowingpage.CompressionRatiostandsforthefeedstagedepthoverthemeterstagedepth.ForaGPdesignthecompressionratioshouldbe3to1upto31/2to1.通用型螺杆的缺陷不能把熔胶和塑料未融颗粒区分开.制品性能的稳定性不够好,容易出现波动.为保证排除未融化颗粒影响,需要提高背压和温度,从而导致周期过长.ExampleOfAnUnmeltedPelletMicrotomedcrosssectionofanunmeltinafascia.Thescrewusedisa20to1L/Dand3to1compressionratiousing80%capacity.Thedarkenedareaaroundtheunmeltisavoidcausedbythemeltedmaterialshrinkingawayfromtheunmeltedpellet.Thiswillshowasaraisedareaveryvisibleafterbake/paint.Theturbulencereflectsthematerialflowaroundtheunmeltafteritstoppedmoving.Magnificationisat30X.ExamplesOfUnmeltedPelletsPhoto,left,isasectionofasnowmobilehood.Theunmeltisthreeinchesinfrontofagate.EnlargementPhoto,top,isa30Xmagnificationofanunmeltfromasectionedwallofthesamesnowmobilehood.MoldingDepartmentwasrunninghighscrapnumbersalongwithhighmelttempsandbackpressure.Problemwascompletelyeliminated,andimprovedpresscycletime,byswitchingtoaCincinnatiMeltStarBarrierScrew.GP/BarrierScrewComparisonFeedSectionCompressionSectionMeteringSectionRearofthescrew.Normalbarrierscrewdesign.ExamplesaretheCincinnatiMilacronMeltStarandtheSpirexMeltPro.Notethescrewflightthatseparatesthematerialmeltfromthepellets.GPDesign.常见问题 分析 定性数据统计分析pdf销售业绩分析模板建筑结构震害分析销售进度分析表京东商城竞争战略分析 制品粘模成型方面因素:1.填充不足,导致过度收缩.2.过度填充.3.冷却不足.4.熔体温度过高.模具因素:1.脱模斜度不够.2.顶针不够(数量,顶出面积).3.由于孔/凸台等结构导致脱模困难.料柄取出困难设备原因:1.喷嘴与浇口之间衔接不好.2.喷嘴口径大于浇口口径成型加工条件:1.熔体温度过高.2.注塑/保压压力过大3.模具温度太高.模具方面因素:1.浇口尺寸太大.2.浇口表面粗糙.3.斜度不够.充模不足/缩痕设备方面:1.加料口/喷嘴堵塞.2.加工不连贯.3.喷嘴/料筒加热不足.4.喷嘴口太小,设备改变.成型加工条件:1.进入保压状态太早2.注塑压力/速度不够.3.料筒/模具温度设定偏低.4.保压不足其他:排气壁厚不均匀浇口尺寸/分布与流程的关系螺杆止逆阀的磨损表面缺陷成型条件:1.进入保压太早.2.注塑速度过慢.3.注塑/保压压力太大.翘曲4.注塑保压时间太长.5.加工温度太低.6.模具温度太低.7冷却不足8.加工周期不稳定.模具原因:1.模具温度不均匀.2.浇口不适合.A.Gatedepthistoothin.B.Landlengthistoolong.3.流程太长.4.壁厚不均匀.5.排气.6.顶出问题.SurfaceDefectsDISTORTIONDodgeDRFrontAirDeflectorProblemWhenthepartwasadequatelypackedaglossandraisedappearanceshowedoverthetopoftheknockoutpins.CoreSideTheknockoutpinswereprotrudingcausingadepressioninthepartsurfaceonthecorepartside.Thepinsprotrudedintothepart0.015”to0.020”.表面缺陷设备问题:1.Obstruction,suchasmetalinthenozzleorifice.2.Nozzlebandnotfunctioningproperly,toolowortoohightemperaturesettings.SPLAYMARKS3.Lossofheatsuchaslosingafuseandthusabankofheaterbands.4.Nozzleorificeistoosmall.Notthesamesizeaspreviouslyusedinproduction.ProcessConditions:1.Materialneedstobedried.2.Injectionboostvelocityinitiallysettoofastatthestartoftheinjectionprofile.3.Contamination.4.Nozzledrool,whichsolidifiesthenbreaksupgoingthroughthegateonthenextshot.5.Excessivemoldsprayormoldlubricant.6.Waterleakageintothecavityfromwaterlinecondensation,crackinthetool,etc.7.Materialmelttemperatureabovetherecommendedsettings.8.Excessivefinesfromregrind.9.Decompressiontimersettoohigh.10.Backpressureabovetherecommendedsetting.SurfaceDefectsMoldRelated:1.ImproperGate.A.Gatedepthistoothink.B.Landlengthistoolong.2.Coldmaterialbreakingupgoingthroughthegate.A.Nocoldslugwellatthegateends.B.Ifhotdrop,inadequatecontrolofthetemperaturesetting.SPLAYMARKS3.Runneristoosmall.4.Materialflowoverribsorother“barriers”causingturbulencetrappingcavityair.5.Areainthetoolhaswallstockundernominalortoothincausingturbulencetrappingcavityair.Splay-ProcessRelatedSplayDefectDodgeDRFrontFasciaAirDeflector.ProblemSmallsplaymarksnearthejunctionofthespruerunnertotheedgegate.Themolderwasusing0.75”ofscrewdecompression.Generallyanythingover0.2”willcauseanairvoidthatwillinjectintothecavitygivingasplayappearance.WeldLinesPressProblems:1.Lossofbarrelornozzleheat.2.Obstruction,suchasmetalinthenozzleorifice.POORKNITSTRENGTHORAPPEARANCE3.Nozzleorificeistoosmall.Notthesamesizeaswhatwasruninpreviousruns.4.Malfunctioningofthescrewvalve.ProcessConditions:1.Toolowofamaterialmelttemperature.2.Fillingthecavitywithtoolowofabooststagevelocity.3.Fillingthecavitywithtoohighabooststagevelocity.4.Notcompletingthefillofthecavitywiththebooststageresultingintoolowcavitypressureattheknitlocations.5.Inadequatepackpressureorpackpressuretime.6.MoldistoocoldWeldLinesMoldRelated:1.Insufficientventinginthetoolandontheweld.2.Hotmanifoldtoocoldorthedropsizeistoosmall.Also,therecouldbeanobstructioninoneofthehotdrops.POORKNITSTRENGTHORAPPEARANCE3.Runnersizeistoosmall.4.Wallstockistoothinattheweldarearesultinginthelossofcavitypressure.5.Impropergate.A.Thegatedepthistoothin.B.Thelandlengthistoolong.C.Toolongofaflowdistancefromthegatetotheweldarea.6.Unbalancedfillofthecavity,usuallyeithertemperatureorwallstockdifferentialrelated.Weld(Flow)LinesGMT370ISUZURearDoorTrimProblemMaterialflowlinesoffofamountingholeandabossthatretainstheparttothepaintbuck.FlowLinesChryslerRSRearFasciaStepPad.ProblemFlowlinescomingoffofthegate.Shortshootingthecavityshowedthattheflowlineswereactuallytrappedairpocketsfromaribthatrunsalongthepartdirectlyinfrontofthegate.FlowLinesChryslerDRRearFasciaStepPadProblemFlowlinesoriginatingfromthegatearea.Ejectorbossescauseaturbulenceintheflow,whichcausesabreakintheflowfrontintothepart.FlashConditionPressProblems:1.Injectionstartingbeforeadequateclamptonnageisreached.2.Losingclamptonnageduringinjection.A.Onecauseofthiscanbeinadequatehydraulicoilorthehydraulicoilistoohot.MATERIALFLASHINGATTHEPARTINGLINE3.Machineplatensarenotparallel.4.Unequaltensiononthe(4)tiebars.ProcessConditions:1.Injectionbooststagetime/transfersetpastthepointofjustfillingthecavity.2.Injectionbooststagevelocityissettoohigh.3.Packpressureissettoohigh.4.Materialmelttemperatureisovertherecommendedlimits.5.Tooltemperatureissettoohigh.6.Shotsizeissettoohighresultingintoomuchcushioncausingalackofshottoshotconsistency.7.Inconsistentcycle,usuallyoperatorrelated.FlashConditionMoldRelated:1.Inadequateventingofthecavityairrequiringhigherinjectionpressureinallstagesofinjection.2.Ventsarecutintoodeep.MATERIALFLASHINGATTHEPARTINGLINE3.Projectedsquareinchesofpartsurfaceexceedstheclampingcapacityofthepress.4.Foreignobject,notallowingthetooltocompletelyclose.5.Partinglinesinneedofrepair.6.Insufficientmoldsupports.Generally,flashistracedtoamoldproblem,suchaspartinglinewear.Ifitisprocessrelated,theflashshouldbeatthefirstplaceoffill,suchasaroundthegatearea.Processingaroundaflashproblem,whenitistoolrelated,narrowstheprocesswindowconsiderablyinreferencetoconsistencyinshotweightandthusdimensionalcontrolandoverallappearance.