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1、射出成型塑膠產品與模具設計 Injection Molding Plastic Part & Mold Design,澆注系統設計 Filling System Design,模具設計的優先順序 Priorities of Mold Design,澆注系統設計 (Filling System Design) 排氣系統設計 (Venting System Design) 冷卻系統設計 (Cooling System Design) 脫模系統設計 (Ejecting System Design),澆注系統設計的優先順序 Priorities of Filling System Design,產品設
2、計 (Part Design) 型腔設計 (Cavity Design) 澆口設計 (Gate Design) 流道設計 (Runner Design) 豎澆道設計 (Sprue Design) 噴嘴設計 (Nozzle Design),典型的澆注系統 Typical Filling System,壁厚不均是注塑成形中最大的麻煩製造者。 這對薄壁零件尤然。 這些麻煩包括了遲滯現象、短射、凹陷、發赤、噴流、翹曲及長冷卻時間等；目前都可用CAE以直接或間接的方式預測。 Non-uniform wall thickness is the biggest trouble maker in plasti
3、c injection molding. This is especially true to thin-wall part. The troubles, including hesitation, short shot, sink mark, blush, jetting, warpage and long cooling time etc., can be predicted, directly or indirectly, by using CAE.,壁厚不均 Non-uniform Wall Thickness,壁厚設計 Wall Thickness Design,掏空設計(1) Co
4、ring Out Design (1),掏空設計(2) Coring Out Design (2),氣泡或/和凹陷的形成 Void or/and Sink Mark Forming,肋厚和內圓角半徑的影響 The Effect of Rib Thickness & Fillet Radius,肋的底部厚度 Bottom Thickness of Rib,肋的設計 (一 ) Rib Design ( 1 ),肋的設計 (二 ) Rib Design ( 2 ),肋的設計 (三 ) Rib Design ( 3 ),與側壁相連之凸轂(熱塑性塑膠) Boss at Wall ( Thermoplas
5、tics ),遠離側壁之凸轂(熱塑性塑膠) Boss Away From Wall( Thermoplastics ),外側凸轂 Outside Boss,Where 1/r : 樑的曲率 curvature of the beam M : 彎曲力矩 bending moment E : 彈性模數 modulus of elasticity I : 斷面積對中立軸的慣性矩 moment of inertia of the cross- sectional area with respect to the neutral axis EI : 撓曲剛性 flexural rigidity,撓曲剛性
6、 Flexural Rigidity,平板和肋板的比較 Comparison between Plain & Ribbed Plates,和平板比，若基於相同的慣性矩(剛性)，肋板需料少了43%，I/A卻增加了1.79倍。肋板的最大厚度減為平板的1/4 ，使得冷卻時間驟降15/16 (94%)。 Based on the same moment of inertia (stiffness), ribbed plate needs 43% less material but boost I/A by 1.79 times comparing with plane plate. The maxim
7、um thickness of ribbed plate is only 1/4 of plain plates; showing a dramatic cooling time reduction of 94% (15/16) .,平板和肋板的比較 Comparison between Plain & Ribbed Plates,結構設計是薄殼成形零件的基礎。 Structural design is the base of thin-wall molding parts. 薄殼成形零件不僅僅是一趨勢，而且也是降低成本和提高競爭力的有效途徑。 Thin-wall molding part i
8、s not only a trend but also an effective way to achieve cost reduction and competitiveness increase.,結構設計和薄殼成形零件 Structural Design & Thin-wall Molding Parts,每增加一個澆口，至少增加一條熔接線，同時增加一個澆口痕跡、增加流道的體積以及增加較多的積風。 Every time one gate is added, one weld line, at least, one gate mark, more runner volume and mor
9、e air traps will be added. 在型腔能夠完滿充填的前提下，澆口數目是愈少愈好。 As long as the cavity is able to be filled appropriately, gates are the less the better. 為了減少澆口數目，每一澆口應就塑流力所能及的流長/壁厚比之內，找出可以涵蓋最大零件面積的進澆位置。 In order to reduce the number of gates, each gate shall be located at where the melt is able to cover maximum
10、 part area based on the largest melt flow length/thickness ratio .,澆口數目 The Number of Gates,熔膠波前推進 Melt-Front Advancement,充填模式,積風和熔接線 Filling Patterns, Air-Traps and Weld Lines Location,熔接線 Weld Lines,材料 Material : PC-GF50,原設計 Original,更改設計 Revised,更改澆口位置以重新定位熔接線 Weld Lines Can Be Relocated By Chang
11、ing Gate Location,典型對頭熔接線伸張強度保留值 Typical Butt Weld Tensile Strength Retention Values,熔接線冷料井 Weld Slug Well,對頭熔接線 Butt weld,熔接線冷料井 Weld slug well,積風 Air Traps,排氣 Vent,大部份熱塑性塑膠 Most Thermoplastics A 0.08 mm B 3.18 mm C 12.7 mm D 0.25 mm,耐隆和聚縮醛 ( POM ) Nylon and Acetal ( POM ) A 0.04 mm B 3.18 mm C 12.
12、7 mm D 0.25 mm,進料流道 Feed Runner,塑膠成品 Plastic Part,A,D,排氣孔 Vent,B,SEC. A-A,C,A,A,充填均衡 Flow Balance,熔膠波前於同一時間抵達型腔各末端。 Melt front reaches the ends of cavity at the same time.,洗衣機圈板,洗衣機圈板,冷氣通風飾罩-原始設計 Air-conditioner Grille - Original,18 gates pressure: 76 MPa,冷氣通風飾罩-修正設計 Air-conditioner Grille - Revised
13、,8 gates pressure: 75 MPa,分析結果比較表 Comparison of Analysis Results,原始設計 Original Design,十二澆口設計 12 Gate Design,電子零件置物箱 材料 Material：ABS,四澆口設計 4 Gate Design,修正設計 Revised Design,電子零件置物箱 材料 Material：ABS,電子零件置物箱四澆口 和十二澆口設計比較表,論語季氏第十六 不患寡而患不均， 不患貧而患不安。 - 孔子 -,如何快速平衡眾多模穴之流道 How to Balance Flow In A Multi-cavi
14、ty Mold,一排支流道之不平衡充填 Unbalanced Flow In A Branch,一排支流道平衡後之充填 Balanced Flow In A Branch,全模具(128模穴)之不平衡充填 Unbalanced Flow In A Mold,全模具(128模穴)平衡後之充填 Balanced Flow In A Mold,The melt fills the inside cavities before filling the outside cavities.,The runner system shows that warmer, low-viscosity materia
15、l (yellow and red) follows the inside wall when the melt splits at an intersection.,剪切速率 Shear Rate,剪 切 應 力 shear Stress 黏 度 viscosity 剪 切 速 率 shear rate,剪切應力 Shear Stress,澆口種類 Gate Types,導致平直零件的澆口設計 Gate Design for Flat Part,澆口設計(減少滯流效應) Gate Design to Avoid Hesitation,沒有遲滯現象,幫浦零件(Part, Pump) 塑料(Po
16、lymer): POM,澆口設計(避免凹陷和氣泡) Gate Design to Avoid Sink Mark & Void,使用重疊澆口以避免噴流 Avoid Jetting by Using Overlap Gate,正確的澆口位置以避免噴流 Avoid Jetting by Locating Gate Correctly,使用凸片澆口以避免噴流 Avoid Jetting by Using Tab Gate,使用適當的澆口形狀以避免噴流 Avoid Jetting by Profiling Gate Properly,幫浦零件(Part, Pump) 塑料(Polymer): POM
17、進澆處(Polymer entrance)： 澆口厚(Gate thickness) 1.2mm，模穴厚(Cavity thickness) 3.2mm 問題 (Problem)： 噴流(Jetting),Poor Design Causing Jetting,Gate,氣輔成型冰箱把手,閥澆口 Valve Gate,1. 閥澆口梢 Valve-Gate Pin 2. 加熱管 Heater 3. O型環 #610 “0“ Ring 4. 流道歧管模板 Manifold Plate 5. 軸封環 Seal Retainer 6. 套筒軸封 Sleeve Seal 7. 枕塊 Support Pi
18、llar 8. 油壓缸 Hydraulic Cylinder,閥澆口 (一) Valve Gate ( 1 ),全部閥澆口同時打開時之充填狀況 Mold filling with all the valve gates ( shut-off gates ) opened at the same time.,閥澆口 (二) Valve Gate ( 2 ),部份閥澆口延遲打開，改變充填模式 Mold filling with delayed valve gate opening; filling pattern, weld lines and air traps are changed.,多澆口
19、設計 Multi-Gate Design,閥式澆口 Valve Gate,矩形邊緣澆口設計 Rectangular Edge Gate Design,扇形澆口設計 Fan Gate Design,重疊式澆口設計 Overlap Gate Design,凸耳澆口設計 Tab Gate Design,L = 0.5 0.75 mm d = 澆口直徑( mm ) gate diameter in mm t = 零件壁厚( mm ) wall thick. in mm A = 型腔表面積 ( mm ) surface area of cavity in mm n = 材料常數 material con
20、stant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC,針點澆口設計 Pin Gate Design,d,L,t,潛伏式澆口設計 Subgate Design,W= w= 澆口寬度 mm gate width in mm A= 型腔表面積 mm2 surface area of cavity in mm2 n= 材料常數 material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC 澆口厚度 g
21、ate thick. in mm = nt t= 零件壁厚 wall thick. in mm ,水力直徑 Hydraulic Diameter,Where is the hydraulic diameter 水力直徑 A is the cross-sectional area of the flow 流路斷面積 P is the wetted perimeter 濕周長,水力直徑 Hydraulic Diameter,在不同剖面形狀，相同斷面積下之變化 Various runner profiles, based on the same cross-sectional area,流道尺寸設計
22、 (1) Runner Sizing (1),D : 流道直徑 ( mm ) runner diameter in mm W : 下游塑膠重量 ( g ) downstream plastic weight L : 流道長度 ( mm ) runner length in mm,流道尺寸設計(2) Runner Sizing (2),流道尺寸設計(3) Runner Sizing (3),流道尺寸設計(4) Runner Sizing (4),流道尺寸設計(A1) Runner Sizing (A1),G : 重量 weight S : 零件厚度 thickness D : 參考直徑 refe
23、rence diameter,流道尺寸設計(A2) Runner Sizing (A2),G : 重量 weight S : 零件厚度 thickness D : 參考直徑 reference diameter,流道尺寸設計(B) Runner Sizing (B),D : 參考直徑 reference diameter L : 長度 length fL :長度係數 Length coefficient D : 流道直徑 runner diameter,冷料井設計 Cold Slug Well Design,冷料井設計 Cold Slug Well Design,澆道襯套尺寸 Sprue Bu
24、shing Sizing,熱澆道設計 Hot Runner Design,熱澆道的問題似乎發生在三處: 1. 澆口直徑 2. 澆口長度 3. 噴嘴孔徑 Problems with hot runner seems to be in three places: 1. Gate diameter 2. Gate land 3. Nozzle orifice diameter,熱澆道的問題所在 Where Causes Problems with of Runner,任何發生在澆口處的發赤或噴流，表示澆口太小。 變褐則表示材料過熱而劣解。,Any blush or jetting at the ga
25、te means the gate is too small, and brown discolorations mean the material is being degraded by too much heat.,受限的塑流通道 Restricted Flow Path,BROWN STREAK WITH FLOW LINES A brown streak on the part molded from easy- flow polycarbonate with the flow lines.,為了保持澆口暢通而格外加熱塑料，加上塑料在射出時通過長澆口時承受的剪切力，有可能造成褐線。,
26、It was probably a combination of shear through the long land of the gate during injection and the extra heat needed to keep the gates open that are causing the brown streak.,褐線 Brown Streak,只以噴嘴口徑去配合熱澆道口徑是不對的。 首先要將澆道口徑加大，以配合下游塑流通道口徑，然後再加大噴嘴口徑以配合澆道口徑。,It isnt just sizing the nozzle orifice to match t
27、he hole in the hot sprue bushing . First you might have to increase the hole size of the sprue bushing to match the flow channel diameter, then drill the nozzle out to match the sprue diameter.,受限的塑流通道 Restricted Flow Path,理想的澆道襯套設計 Optimized Sprue Bushing Design,當塑流通道受限於小或長的澆口，成型技術員常將設定溫度調高，以確保型腔充填
28、、保壓無虞。,When the flow path is restricted by a small gate diameter or a long land length, you will usually see higher heat settings being used by the molding technicians to get the parts to fill and pack out. 這樣的作法產生的問題有製品的翹曲，澆口的外觀缺陷和長的成型時間。 The problem with this approach is that it usually causes war
29、page of the parts, cosmetic defects around the gate area, and long molding cycles.,受限的塑流通道 Restricted Flow Path,如果歧管溫度設定得比料管前區為高，澆口尺寸或許有問題。 如果必須將噴嘴溫度設定得特別高，噴嘴口徑或許沒配合上熱澆道口徑。,If you find you have to run the manifold heats higher than the front zone of the barrel, you probably have gate sizing problems
30、. If you have to run the heats up on the nozzle, the nozzle orifice probably hasnt been drilled out to match the hot sprue bushing diameter.,受限的塑流通道 Restricted Flow Path,如果塑流通道的尺寸正確，料管的前區、噴嘴和加熱歧管的溫度可以設定得一樣； ABS：232 C、易流PC：274 C。,If the flow path is sized correctly, you will be able to set the heat s
31、ettings on the front zone of the barrel, the nozzle, and the heated manifold, such as 232C across the board for ABS or 274C for easy-flow PC.,受限的塑流通道 Restricted Flow Path,易流的PE和PP : 壁厚的50% 50% of wall thickness for easy-flow PE and PP ABS, SAN和壓克力: 壁厚的75% 75% of wall thickness for ABS, SAN, and acry
32、lics PC/acetal/PVC/加玻纖材料和PPO : 壁厚的90% 90% of wall thickness for PC/acetal/PVC/glass-filled materials and PPOs,熱澆道模具的澆口直徑 Gate Diameter for Hot Runner Molds,澆口長度應小於0.125mm。 Land should be no longer than 0.125mm. 諮詢熱澆道製造廠，以獲得正確的澆口長度。 Consult with your hot runner manufacturer for correct land length.,熱
33、澆道模具的澆口長度 Gate Land Length for Hot Runner Molds,排氣系統設計 Venting System Design,徐鑫 XUXIN,為何排氣仍然還是一個問題？ Why venting is still a problem ? 因為降低射速，讓積風有較多的時間逃氣，是一件太容易的事。但是 Because it is too easy to slow down the injection speed and give the trapped air more time to escape. But .,排氣 Vent,射速一降，熔膠溫度很快降低，射壓必須提高
34、，殘餘應力隨之提高，翹曲的可能性增加。 如果想藉提高料溫，以降低射壓，料溫必須升得很高，這樣又會引起塑料裂解。 When injection speed is lower, melt temperature goes down very fast, injection pressure has to be increased, residual stress is increased and the possibility getting warppage becomes higher. If one would like to increase barrel temperature to r
35、educe the required injection pressure, the barrel temperature has to be increased to a quite high level and polymer degradation would be induced.,排氣 Vent,高料溫和高射壓都說明充填系統有了流動的問題,Both high barrel temperature and high injection pressure are indications of flow problem in the filling system.,排氣 Vent,我們常發
36、現: 射速提高時，塑料表現得更為出色。 It is quite common that material performs better when it is injected faster. 最適化螺桿速度充分運用摩擦熱，將塑流保持在最佳狀態。許多充填和翹曲的問題也就迎刃而解。 An optimized ram speed profile fully uses the friction heat to keep the best flow characteristics, which corrects many of the fill and warpage problems.,排氣 Ven
37、t,有了適當的排氣，射速可以提高，充填和保壓可達良好狀態，不須過度增加料管和噴嘴的溫度。,With proper venting, the injection speed could be increased to achieve good fill and pack conditions, without having to raise the barrel and nozzle heats, improperly.,排氣 Vent,深度(depth) : 1. 0.075 mm易流塑料(easy-flow mat.) 2. 0.125 mm難流塑料(stiffer-flow mat.) 3
38、. 深度深到流道末端見毛邊為準 (deep enough to feel flash at runner end) 寬度(width) : 和流道同寬(as wide as runner dia.) 排氣唇部(vent lip): 1.5mm A1拋光(finish) 排氣通道通大氣(vent channel to atmosphere): 1mm深(deep),流道排氣 Runner Vents,深度(depth) : 參照廠商建議 (refer to manufacturers recommendation) 寬度(width) : 全圓周長(whole perimeter) or 5mm
39、 長度(length) : 1.5mm A1拋光(finish) 排氣通道通大氣(vent channel to atmosphere): 1mm深(deep),分模面排氣 Parting Line Vents,分模面排氣 Parting Line Vents,深度(depth) : 參照廠商建議 (refer to manufacturers recommendation) 寬度(width) : 全圓周長(whole perimeter) 長度(length) : 1.5mm 排氣溝(vent groove): 1mm深(deep),頂出銷或心型銷排氣 Ejector and Core P
40、in Vents,冷卻系統設計 Cooling System Design,徐昌煜 Charles Hsu,模具冷卻設計的目的 Purposes of Mold Cooling Design,1. 均衡冷卻(改良產品品質) Even Cooling (Improve Part Quality) 2.有效冷卻 (提高生產力) Efficient Cooling (Increase Productivity),薄殼產品不像傳統壁厚者一般可以承受較大的因熱傳不均而產生的殘餘應力。 為了將收縮彎翹控制在可以接受的程度，均衡的冷卻設計變得非常重要。 Thin-wall part can not affo
41、rd as much thermal induced residual stress as the conventional one does. An even cooling design becomes very important to control the shrinkage and warpage at an acceptable level.,冷卻設計 Cooling Design,射出成型週期時間 Injection Molding Cycle Time,充填時間 Fill Time,開模時間 Open Time,後充填時間 Post-fill Time,對冰箱蔬果盤之類的大零
42、件而言，材料往往佔成本50%以上。 對小而薄的零件而言， 成形機費用可佔成本的90% ，材料6% ，而模具只佔4%。 小而薄的產品較之厚者更能從冷卻的改善而獲得效益。 For larger molded parts, material typically represents more than 50% of the part cost for a refrigerator crisper tray. In the case of a thin-wall small part, the press cost could be 90% of the cost of the part; mater
43、ial constitutes 6% and the mold only 4% of the cost of each part. Small thin-wall parts typically benefit from improved cooling more than thick parts.,冷卻設計 Cooling Design,典型的冷卻系統 Typical Cooling System,模具冷卻管路 Mold Schematic,冷卻孔道 Cooling Channels,噴泉管 Bubbler,障板管 Baffle,熱管 Heat Pipe,熱管的應用 The Applicat
44、ion Of Heat Pipe,理論上最短冷卻時間 Min. Possible Cooling Time,冷卻時間和厚度分佈 Cooling Time and Thickness Profile,冷卻孔道直徑、深度和節距建議值 Recommended Diameter, Depth & Pitch,D : 直徑為10至14mm Diameter of Cooling Channel, 10 to 14 mm d : 深度為D至3D Depth, D, to 3D P : 節距為3D至5D Pitch, 3D to 5D,原始設計 Original Design,修正設計 Revised De
45、sign,原始設計 Original Design,修正設計 Revised Design,原始設計 Original Design,修正設計 (一) Revised Design ( 1 ),修正設計(二) Revised Design ( 2 ),不平衡的設計 Unbalanced Design,平衡的設計 Balanced Design,不用限流孔梢的內歧管設計 Internal Manifold Design without Frops,使用限流孔梢的內歧管設計 Internal Manifold Design Utilizing Frops,限流孔梢 Flow Resistance
46、Orifice Pin,紊流和層流 Turbulent and Laminar Flows,紊流 Turbulent Flow,層流 Laminar Flow,雷諾數 Reynolds Number,Nu對雷諾數(Re) Nusselt Number Vs. Reynolds Number,差的設計 Poor Design,好的設計 Better Design,差的設計 Poor Design,好的設計 Better Design,差的設計 Poor Design,好的設計 Better Design,冷卻設計原則 Cooling Design Principles,選擇熱擴散係數大的塑料。
47、Select Plastic Material with large thermal diffusivity. 採用薄而均一的製件厚度。 Use a thin and uniform part thickness. 在型腔周圍均衡的配置冷卻孔道。 Layout cooling channels around cavities evenly. 在熱傳的道路上移除空氣間隙和空氣囊。 Remove air gaps and pockets from heat transfer path. 平衡冷卻液流動。 Balance coolant flow. 檢查冷卻效率。 Check cooling efficiency. 促使冷卻勻稱。 Make cooling evenly. 選擇適當設備。 Select appropriate equipment.,