成形工艺流程及条件介绍

成形工艺流程及条件介绍（中英文对照）。:lol::P


成型工艺流程及条件介绍
Molding technique procedure and parameter introduction

第一節 成型工艺
Section 1 molding technique.

1. 成型工艺参数类型

Sorts of molding parameter.
(1). 注塑参数
Injection parameter.
a. 注射量
Injection rate.
b. 计量行程
Screw back position
c. 余料量
Cushion
d. 防诞量
Sucking back rate
e. 螺杆转速
Screw speed
f. 塑化量
Plastic0 rate
g. 预塑背压
Screw back pressure
h. 注射压力和保压压力
Injection pressure and holding pressure
i. 注射速度
Injection speed
(2) 合模参数
Clamping parameter
a. 合模力
Clamping force
b. 合模速度
Clamping speed
c. 合模行程.
Clamping stroke
d. 开模力
Opening force
e. 开模速度
Opening speed
f. 开模行程
Opening position
g. 顶出压力
Ejector advance pressure
h. 顶出速度
Ejector advance speed
i. 顶出行程
Ejector advance position

1. 温控参数

Temperature parameter
a. 烘料温度
Dry resin material temperature
b. 料向与喷嘴温度
Cylinder temperature and nozzle temperature
c. 模具温度
Mold temperature
d. 油温
Oil temperature

1. 成型周期

Molding cycle
a. 循环周期
Cycle time
b. 冷却时间
Cool time
c. 注射时间
Injection time
d. 保压时间
Holding pressure time
e. 塑化时间
Plant time
f. 顶出及停留时间
Knocking out and delay time
g. 低压保护时间
Mold protect time
成型工艺参数的设定须根据产品的不同设置.
Molding technique parameter setting differs depending on type of product
第二节 成型条件设定
Section 2 Molding parameter Setting
按成型步骤:可分为开锁模,加热,射出,顶出四个过程.
Molding steps: mold opening/closing, heating injection and knocking out.
开锁模条件:
Mold opening parameter:
快速段中速度
低压 高压速度
High-speedmid-speed

Low pressure high pressure speed
锁模条件设定:
Mold closing parameter setting

1. 锁模一般分: 快速→中速→低压→高压

Mold closing: high-speed →low-speed →low pressure→high pressure

1. 快锁模一般按模具情况分,如果是平面二板模具,快速锁模段可用较快速度,甚至于用到特快,当用到一般快速时,速度设到55-75%,完全平面模可设定到 80-90%,如果用到特快就只能设定在45-55%,压力则可设定于50-75%,位置段视产品的深浅(或长短)不同,一般是开模宽度的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% while using especially high speed it set speed within 45-55% and pressure within 50-75% position distance setting differs depending on the volume of product and usually it can be set 1/3 of mold opening position.

1. 中速段,在快速段结束后即转换成中速,中速的位置一般是到模板(包括三板模,二板模)合在一块为止,具体长度应视模板板间隔,速度一般设置在30%-50%间,压力则是20%-45%间.

In mid-speed section: Mold closing speed changes into mid-speed after high-speed section finish. Mid-speed start position is where two plates meet (include three-plate mold and two-plate mold ) Distance of mid-speed is up to distance of two plates plate it speed within 30-50% and pressure 20-45%.

1. 低压设定,低速设定一般是在模板接触的一瞬间,具体位置就设在机台显示屏显示的一瞬间的数字为准,这个数字一般是以这点为标准,,即于此点则起不了高压,高于此点则大,轻易起高压.设定的速度一般是15%-25%,视乎不同机种而定,压力一般设定于1-2%,有些机则可设于5-15%,也是视乎不同机种不同.

Low-pressure section: Mold closing sets low-pressure when plates meeting. This position is set to the data of machine screen on this time. 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 1-2% depending on type of injection molding machine.

1. 高压设定,按一般机台而言,高压位置机台在出厂时都已作了设定,相对来讲,是不可以随便更改的,比如震雄机在50P.速度相对低压略高,大约在30-35%左右,而压力则视乎模具而定,可在55-85%中取,比如完全平面之新模,模具排气良好,甚至于设在55%即可,如果是滑块较多,原来生产时毛边也较多,甚至于可设在90%还略显不足.

High-pressure section: To normal injection molding machine, high-pressure position had been set before they were sent to customer. It can not 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% .If mold has a lot of slides and flash rate high in production, pressure can set 90%.
加热工艺条件设定
Heating technique parameter setting

1. 加热段温度设定必须按照产品所使用的原料的不同而不同,但却必须遵循一个这样的规则,即由射口筒到进科段温度是逐步递减的.且递减温度是以100C为单位.

The proper temperature setting differs depending on type of resin material, but it must be abide by a rule that temperature setting should diminish in step 1０.C from nozzle to feeding resin material position.

1. 特殊情况下.如料头抽丝,则射口筒温度应降低,如果是比较特殊的原料冷凝比较快的.则射口筒温度则不止比第二节法兰温度高100C.比如PPS. 尼龙等.

Nozzle temperature setting should low if product line. If resin material such as PPS, PA, cool very soon , Nozzle temperature should higher more 10.C than the second cylinder temperature.
3.机台马达启动温度视乎机台不同而不同,一般出于对机台油路中的油封保护需要,油温最好能控制在400C-600C,以免油封长期高压而变化,缩短使用寿命,造成成型不稳定.
Pump turning on temperature is different depending on type of injection molding machine. To protect oil seal of machine it set oil temperature 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.
注射及熔胶(加料)工艺条件设定
Injection and plastic Technique parameter setting
一.注射
Injection
常见塑料原料的有关温度值.
原料
Resin名称
Name熔点℃
Melt’s成型温度℃
Molding Temperature(’c)分解温度℃
Decomposing Temperature(‘C)模具温度℃
Mold Temperature(‘c)干燥温度℃
Resin dry temperature(‘c)
HDPE低卫压聚乙烯108-126160-22231045-6070-80
HOPE高卫压聚乙烯135180-24031050-8070-80
PC聚碳酸脂
polycarbonate 220-240
260-310
320
80-120
90-120
ABS 160 180-230 270 45-80 70-90
PC/ABSPC与ABC共混物200 220-250 300 50-90 80-100
PP聚丙烯160-170200-26030030-45
PS聚苯乙烯140180-23030030-4565-80
PVC聚氯乙烯140180-21530020-4090-100
AS 160200-25028045-7570-90
PA6尼龙6215-220225-24530040-8095-110
PA66尼龙66260-265260-27530040-8095-110
PPS聚苯硫酸265-280300-330370100-120100-130
PBT聚对苯二甲酸丁二脂225-235240-26028070-80105-140
POM聚甲醛170180-21024080-120
PMMA有机玻璃160180-24027040-6570-80

注射是把塑料原料经加热后射进模腔的过程,它一般可分为第一级,第二级,第三级,第四级及保压几段:
Injection is a step which inject melt resin material into mold. It consists of stepl,step2 ,step3,step4 and holding pressure step:

1. 第一级注射一般是注射料头段.具注射量一般可根据料头的轻重来估计其行程,当然也可以依据公式来计算,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:
L=Si=Vi/0.785Ds2
L:注射行程; Si: 注射行程;
L: injection stroke Si: injection stroke
Vi:理论注射容积; Ds:螺杆直径;
Vi: injection volume of theoretical Ds: diameter of screw
0.785:是Ω/4的值.

1. 785: value of Ω/4.

当然,如果我们在成型时每设定一个参数都要计算一次,要成型出一个产品就要几个小时才能完成了.
But it cost a lot of time to produce one product if every time molding parameter is setting by calculation.
2.第二级是注塑产品约2/3的阶段,当然,根据产品特殊需要,也允许成型不到2/3阶段,比如避免结合线问题,这一阶段的成型速度及压力一般是整个成型段的最大值段,如果排的产品与机台基本是相吻合的.模具结构合理,排气良好,这一段的压力一般也不会超过80%.速度侧视产品需变,可能大到95%也可,自然一般都是在55%-80%间.
Step 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 and pressure on this step is the maximum of whole molding section. If Mold suit the injection molding machine and mold structure reasonable and 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.第三段是注射余下的1/3段,其速度和压力根据产品的需要,一般是小于第二段,速度和压力存在于一个往下降的过程.主要是为了防止产品毛边的产生,但同时又必须把产品充填饱满.
Step3 inject remain 1/3 of product. According to product molding speed and pressure lower than that of step2 To prevent flash speed and pressure should decrease but it can’t shot short.
4.第四段:一般有机台还有第五,第六段,这段的成型速度和压力相同前,都存在两段一个递减过程.其作用都是起到一个再次充满的作用.
Step4 section: Some injection machines have step5,step6 which are same as former molding speed and pressure this step should diminish and inject once more.
5.保压段:不论成型什么产品,都存在一个保压过程.任何产品都不同程度的存在一个厚薄不一的问题,正常情况下,较厚的部分都可能存在一个收缩凹陷的现象,为了解决这种现象,就应应用到保压,保压一般来讲都应用较慢的射速,而压力的设置则应看缩水的情况如何,小到25%,大到80%都有可能.
Holding pressure step: No matter what product there is a holding pressure step. Any product can’t molding a same thickness. Usually the deeper section may sink mark . To prevent this defect it should set holding pressure, The injection speed of holding pressure step is slow but holding pressure setting within 25-80% depending on sink mark.