注塑成型與模具知識介紹Injection Molding Introduction 設備與模具 Equipment and Tool 0 Ma te ria 1 材料 / / o o / Q — / o o / GOOD PART Processing 工艺 好产品 Design 设计Equipment 设备-•1.®量之選擇.2.鎖模壓力之確認.3.機械安裝尺寸確認.4.模厚與開模行程確認5.頂出行程確認6.機台螺杆介紹一射出成型机器注射容量選擇:（MachineShot size）1 •注塑量確定：G=產品重（依3D計算）+料頭重（依流道計算）2.與機台注塑量確認：2-1.Part Weight = 30 - 80 % of Machine Shot Size制件重量=30- 80%机器最大注射量（實際）2-2.機器最大注塑量（實際）：楼栗注朔忘畠（害腔僅離粟注朔宏畠任田机器塑模力確定：(Machine Clamp Size)1 •機台最大鎖模力選擇:依機台參數取得.2.產品所需鎖模力計算：F二Q*SF ---- 產品所需鎖模力.Q——模腔內注塑壓力須考量模腔內流道的壓力損力S——制品加上澆注系統在分型面上的總投影面積，cm22槿淮亜機器安裝尺寸確認:1 •機台噴嘴舉懐曲戶逹口襯套尺寸:Nozzle喷嘴Orifice主流道孔口Sprue Bushing 千主流道衬套機器安裝尺寸確認：備注a澆口襯套球形凹坑半徑R應比機台噴嘴球形頭半徑T大1〜2mmb.澆口襯套注道小端直徑D應比機台噴嘴直徑d大1mm.2.模具定位環尺寸：比對機台與模具定位環尺寸.3.模具外形尺寸與機台哥林柱間距.4.機台模板鎖模螺絲與模具冷卻水管位置確認.模厚與開模行程確認:1 •確認工式：S k>=Hm+H ]+曰2+3+5 ~ 1 Omm.S k------ 注塑機模板全開距離(移動模板與固定模板之間的最大開距).H m ------ 模具厚度(nrni).Hl ------- 頂出距離,通常等于型芯的高度H2 ------- 制品高度，包括澆注系統在內a ------- 僅三板模具需取此值，為母模板與撥料模具頂針行程與機台頂杆行程確認:1.機台頂杆行程:查機台參數可得，模具頂針行程在模具LAYOUT上有標注.2.一般要求模具頂針行程小于機台頂杆行程.3.S模具vS機台•Uniform Stock Temperature 均匀储料温度•Streamlined Melt Flow 线性熔融流动•Faster Cycles 更快成型周期作用:•UniformPlasticizing均匀塑化•Less Pressure Loss 低压力损耗Metering Trans ition 计量 过渡LScrew and Cylinder Design螺杆和料筒设计•L/D = 20:l (16 〜24 :1)•Compression Ratio 压缩比=/h m =2 〜2.5:1 (1.5 〜3：DFeed进料150 RPM转速推荐螺杆转速SCREW SPEEDSuggestions100 —m MAXIMUM x OPTIMUM5025 Screw Dia in mm50 75 100 1251螺杆150直径往复式螺杆头结构检查环类型：止回环熔融树脂流过开放检查环检查环关闭，防止在注塑过程中料的回流建议采用止逆阀Standard Cylinder Nozzles标准料筒喷嘴Provides Mechanical and Thermal Connection FromHot Cylinder to Colder Mold提供从热的料筒到相对冷的模具的机械和热连接Heating Band加热环To MoldCylinder 到模具主体Bore 料筒■aInjection Molding Process ■…注塑成型工藝：1.注塑成型流程.2.重要加工參數介紹：溫度:料溫/模溫/烘干溫度.速度:注塑速度/開合模速度/頂出速度. 壓力：注塑壓力/開鎖模壓力/頂岀壓力.3.成型十大原則1 •加料松退螺桿在料管內旋轉，將從料斗來的塑膠卷入, 並逐步將其壓實，排氣，塑化，融化塑膠不斷由螺桿推向前端，並逐漸積存在頂端和噴嘴之間，而螺桿本身受熔體的壓力而緩慢後移，當積存熔體達到一次注射量時，螺桿停止移動.2.射膠當螺桿停止移動,在液壓缸或機械力作用下, 推動螺桿前進使熔体通過噴嘴注入模具.3 •保壓當模具充滿后流動速度減慢，此時塑膠被繼續擠入模腔，熔體密度提高.型流程加壓流動模具充填合模塑膠塑化加料松退 ■射事蘇■ 「凝固及冷卻開模頂出Inj ection Molding Process Important Process Variables重要加工参数Melt Temperature 熔融温度Mold Temperature 模具温度Temperature Profiles 温度曲线Residence Time 停留时间Injection Speed 注射速度Injection Pressure 注射压力Pack Pressure 保压Clamp Tonnage 锁模力Cushion缓冲料垫Model of AmorphousPolymersBetween Molecular Chains 在分子链之间Melt Temperature 熔融温度35F1ow(in.).030 .060 .090 .120 .150 .180 .210 .240Wall Thickness in Inches壁厚(In)Increased M eltTem peratuw yields hcreased Fbw •提高熔融温度导致增加流动H ow ever, Too H feh a M eltTem perature M ay C ause D egradatibn.但、过高熔融温度造成降解How is heat added to the polymer?外热如何作用于高分子材料Electrical Heat: Heater Bands 电加热加热带Mechanical Heat 机械热Screw SpeedBack Pressure 螺杆速度背压Injection Pressure / Speed 注射速度/压力Injection Molding B arrel Unit 料筒组件he Reciprocating Screw 0转式螺杆 片 & 料斗HopperScrew螺杆加料口(Filling) Throat喷嘴来自注塑单 元的力和力 矩Nozzle加热Heating CoilsBarrel料筒Force, TorqueFrom Injection Unit FromInjection UnitDrying• Drying temperature and time are an important key factor for good products in our production 在生产得到好的产品，干燥温度和时间是一重要因素・良品典型PCMoisture Level: Less than 0.02%—-121 o C/3 ~ 4 Hrs水分含量小于0.02 % …… 121 ° C/3 ~ 4 HrsInj ection Molding ProcessPart Cooling and SolidificationSolid Part固化的制件 温度较低的模具制件冷却和固化Hot MeltCooled Mold热熔体Injection Molding CoolingMold Temperature模温Mold Temperature is critical inglossary and residue strain of 模温対制件的光洁度和模塑残余应力等级很重要Uniform mold temperature reducesthe effects ofwarpag e.均匀的模温可以减少翘曲Commonly controlled by watercooling channels・模温通常冷却水孔道来控制Injection Molding Variables Injection Speed 注射速度Inaction Speed affects the viscosity of the m ohen m ate rial注射速度影响熔体粘Injection Molding VariablesInjection Pressure Profile注射压力曲线液压压力Injection Molding•Barrel Unit•The Reciprocating Sere翳召矩Screw Rotation Feeds and Shears MaterialInto a Melt. Melt Collects Into Front ofBarrel, Forcing Screw Back 通过螺杆回转，熔体聚集于料筒前部，反作用力使螺杆后退。

Inj ection Molding EquipmentB arrel UnitThe Reciprocating ScrewMelt Required to Fill Mold Ready for Injection 将要注入模具内的熔体(3〜5mm for PC)Injection Molding VariablesCushion 缓冲垫M aterialwm ahing h bairelwhen ■thee^ctbn phase is com pleted.注过程结束后，残于料筒前端的熔体The h^ctbn m oldhg process should a lbw acushion to provide sufficfentpackhg pressureh 1he m oHCushion注过程必须要有缓冲垫以保证有效的保压Injection Molding Regrind 对材料回收使用的建议REGRIND SUGGESTIONS•Use Only Clean Non-degraded•Uncontaminated Resin for Regrind•Keep It As New Materia 1•Normally 20% of Regrind can be Used•Screen Sizes should be 7 to 9 mm•只使用未降解材料•回收料不能有污染•要象保存新料一样•通常允许添加20%的回收料•过滤网应该在7至9 MM。