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1、1 / 20 工艺注塑手册 Injection process handbook 一. 基本理念： Basic opinion: 1. 什么是最佳的流动状态： What is the best flow state: 流体流动状态应该是喷泉状的，最佳的流动状态是流体前端的流动速度在型腔 内处处相等。由于流动方向上截面积的不同，在其变化的位置应进行注射速度 的调节 b5E2RGbCAP DXDiTa9E3d 2. 什么是最佳的压力 ,温度分布 状态： What is the best pressure and temperature state: 最佳的压力和温度分布状态 是压力和温度分布在型腔
2、内 部处处相等，并且随着熔体 地逐步冷却而下降并使最终 产品的内应力为零。 RTCrpUDGiT The best pressure and temperature state should be like this that the pressure and temperature everywhere in cavities are the same, and make the force of the part inside be zero finally as the melt solidified.5PCzVD7HxA 实际压力分布状况是浇口附 近最大并随着距离的增加而 降低。 xH
3、AQX74J0X 2 / 20 所以,综合来讲 ,参数设定的一般准则 : (1) 尽量选用高的注射速度 (螺杆前进速度 (2) 尽量选用高的料筒温度 (3) 尽量选用高的模具温度 So the general principles when setting parameters are: LDAYtRyKfE (1) As fast injection speed as possible (Screw forward speedZzz6ZB2Ltk (2) As high cylinder temperature as possible (3) As high mold temperature
4、 as possible 二. 基本概念： Basic conception: 1. 收缩： Shrinkage: .c.分子取向； EmxvxOtOco c. Molecule orientation。 (For non-strengthen material, the shrinkage in the flowing direction is more than that, which is vertical with the flowing direction。 and for the strengthen material, the result is just reverse, Si
5、xE2yXPq5 d. Form changing 不均匀 Inhomogeneous cooling b. 壁厚不均匀 Different wall thickness c.压力分布不均匀 Not average location of pressure location d. 分子取向 Molecule orientation e. 脱模受力不均 Inhomogeneous forces when demolding 2. 结晶 Crystallization: 在高速注射的情况下，剪切速度起主导作用(所以,对于薄壁 产品或含薄壁部分的产品宜采用高速注射。 In high injectio
6、n speed situation, the shear rate is the main factor. (So use high injection speed for thin wall thickness partsGMsIasNXkA 4. 止回阀 : Non-return valve: a. 止回阀的功能是什么 : Function of non-return valve: 在注射，保压时防止熔体倒流，从而给予熔体我们所需的压力和速 度。 To prevent the melt flowing back when injection and packing.TIrRGchYzg b
7、. 怎么判断止回阀或料筒损坏 How to recognize the non-return valve is broken: 初步判断：经常性的出现料垫不稳，或无料垫。 Recognize presumedly: Melt cushion is not stable usually or no cushion.7EqZcWLZNX 准确判断：延长保压时间，如果出现零料垫则说明止回阀损坏或料筒 损坏。 Recognize precisely: Prolong the holding time, if there is no melt cushion, the non-return valve
8、is broken or the cylinder is broken. lzq7IGf02E 5 / 20 c.怎么区别止回阀损坏还是料筒损坏 How to recognize the non-return valve is broken or the cylinder is broken:zvpgeqJ1hk 方法一：换上新的止回阀，延长保压时间依然没有料垫，则说明料筒 损坏。 Method 1: Change into a new non-return valve 。 prolong the holding time, if there is still no melt cushion,
9、 it means the cylinder is broken. NrpoJac3v1 方法二：放大料垫，延长保压时间依然没有料垫，则说明止回阀损 坏；反之则说明料筒损坏。 Method 2: Make the melt cushion big enough 。 prolong the holding time. If there is still no melt cushion, it means the non-return valve is broken 。 if there is melt cushion, it means the cylinder is broken. 1nowf
10、TG4KI 三.基本参数： Basic parameters: 1. 注射速度： Injection speed: 注射时间 Injection Time (s 低粘度 Low Viscosity 中粘度 Mid Viscosity 高粘度 High Viscosity 1-8 0.2-0.4 0.25-0.5 0.3-0.6 8-15 0.4-0.5 0.5-0.6 0.6-0.75 15-30 0.5-0.6 0.6-0.75 0.75-0.9 30-50 0.6-0.8 0.75-1.0 0.9-1.2 50-80 0.8-1.2 1.0-1.5 1.2-1.8 80-120 1.2-1
11、.8 1.5-2.2 1.8-2.7 120-180 1.8-2.6 2.2-3.2 2.7-4.0 180-250 2.6-3.5 3.2-4.4 4.0-5.4 250-350 3.5-4.6 4.4-6.0 5.4-7.2 350-550 4.6-6.5 6.0-8.0 7.2-9.5 塑料 Plastic PE, PP, PA6, PA66, POM, PET, PBT, PPS PE, PP, PA12, ABS, PS PC, PMMA 2. 转压点： Switch point: : Up to 98% of their uEh0U1Yfmh volume. 对于非平衡流道：一般为
12、70-80，应视具体情况而定。并建议采 用慢-快-慢多级注射。 To non-balance runners: Normally its up to 70% to 80%. It should be IAg9qLsgBX determined by the reality. We suggest using step injection speed (Slow- Fast- Slow.WwghWvVhPE v4bdyGious , material decomposed (which cause burns, different color, broken etc4B7a9QFw9h 螺杆转速
13、太慢：影响周期 Too slow rotation speed: Waste time. 6. 冷却时间： Cooling time: 作为原则，冷却时间的设定应越短越好，以产品不变形，不粘模，无过深的 顶出痕为基本要求。 并且：螺杆转速： PA, not packed enough (Which cause air bubbles, burns etc.xS0DOYWHLP 8. 回吸量： Retract： （1） 如何确定回吸量： How to decide retract: 回吸量的确定 dGY2mcoKtT 9. 锁模力： Clamping force: , mold deformat
14、ion.FyXjoFlMWh 锁模力太小：飞边 Too low clamping force: flash 10. 熔体温度： Melt temperature: 7qWAq9jPqE 11 / 20 熔体温度太低：材料塑化不均，熔体内含冷料 11. 模具温度： Mold temperature: 。 need more cooling timefuNsDv23Kh 模温低：流动性差 四. 常见产品缺陷及其原因： Normal defects and the reason: 太快 Dosing speed is too fast. c. 喷嘴温度太高 The nozzle temperatur
15、e is too high. d. 不好的回料 (粉状 Too much powder in regrinds. e. 回吸量不够 Not enough retract f. 喷嘴接触力不足 Not enough force between the nozzle and the mold bush.HmMJFY05dE g. 喷嘴与模具浇口套尺寸不匹配 The dimension of the nozzle and the mold bush is not correct.ViLRaIt6sk h. 喷嘴接触表面脏 (造成表面不平 Dirty interface of the nozzle 9
16、eK0GsX7H1 13 / 20 Wrong setting parameters (Too low switch point, too high naK8ccr8VI holding pressure, too fast injection speed, too high temperature B6JgIVV9ao etc b. 模具脏 Mold is dirty c. 锁模力不足 Locking force is not enough d. 模具问题 f. 喷嘴温度过低 Too low nozzle temperature g. 塑化不均 Wrong setting parameter
17、s (Too low switch point, too high 3YIxKpScDM holding pressure, too fast injection speed, too high temperature gUHFg9mdSs etc b. 模具脏 Mold is dirty c. 喷嘴温度过低 , 结构不合理 Low temperature in the tip of nozzle, and wrong structure uQHOMTQe79 d. 止回阀或料筒损坏 Non-return valve or cylinder is broken e. 浇口, 流道尺寸太小 To
18、o small gate, runners f. 不干净的回料 (含杂料 Other material in the regrind g. 材料受潮 Wet material h.设备问题 (压力不足 Machine problem (Not enough pressure I. 射台没对准 The nozzle is not in the centre of the runner. 14 / 20 h. 回吸太小造成止回阀关闭不稳定 Too little retract to cause the non-return valve closing unstablyIMGWiDkflP b. 对
19、大产品，熔体温度不够 Melt temperature is too low c. 塑化不均 WHF4OmOgAw d. 喷嘴温度不够 Nozzle temperature is too low e. 止回阀或料筒损坏 Non-return valve or cylinder is broken f. 杂质 Other materials inside g. 模具脏 Mold is dirty h. 材料烘干不彻底或材料受潮 Material is wet I. 射台没对准 The nozzle is not in the centre of the runner. h. 回吸太小造成止回阀关
20、闭不稳定 Too little retract to cause the non-return valve closing unstablyaDFdk6hhPd Not correct setting parameter (Too fast injection speed ozElQQLi4T c. 材料烘干不彻底或材料受潮 Material is wet d. 锁模力太大 Locking force is too big e. 模具问题 (排气不畅 Mold problem (Bad air vent f. 回吸量太大 Retract is too mach g. 料筒与二接头处不密封 Th
21、e adapter is not connected well with cylinder 15 / 20 d. 塑化不均 e. 对大产品，熔体温度不够 Melt temperature is not enough d. 止回阀或料筒损坏 Non-return valve or cylinder is broken e. 射台没对准 The nozzle is not in the centre of the runner. 16 / 20 Parameter control not is precise (mold temperature, melt ijCSTNGm0E temperatu
22、re, cooling time b. 回料比不合理或不稳定 Regrind rate is unreasonable or unstable c. 止回阀或料筒损坏 Non-return valve or cylinder is broken d. 回吸太小造成止回阀关闭不稳定 Too little retract to cause the non-return valve closing unstablyvfB1pxanfk Not correct setting parameter (mold temperature, melt temperature, JbA9VhEou1 cooli
23、ng time b. 喷嘴温度太低 Nozzle temperature is too low c. 保压时间太短 Holding time is too low d. 止回阀或料筒损坏 Non-return valve or cylinder is broken e. 回料比不稳定 Unstable regrind rate f. 回吸太小造成止回阀关闭不稳定 Too little retract to cause the non-return valve closing unstablyX7Ahr18pJI h. 模具锐边 Mold sharp place i. 不稳定回料比 Unstab
24、le regrind rate pZyytu5rc5 d. 回料比添加合理吗，过程控制准确吗 The regrind ratio is reasonable and stable or not, xEve2buwnw 19 / 20 ( 保压时间 0.3 t ( 剩余冷却时间 0.7 t 六. 试模的基本步骤： Basic steps for mold test: 1 st Step: Find the parameter to fill the part (90-95% with the injection pressure. KAvmyVYxCd 第一步 ：找出充满产品的工艺 and dr
25、aw the graph. The holding time will be the time when the part weight start to be stable. We add 0.5 s at this time.Ywuu4FszRT 第二步：找出保压时间。每次取2 模。然后称重 . When the parts start to be incomplete add holding pressure to get the complete parts. This pressure will be Plh.qotL69pBkh 第四步： 找出比较低的保压压力. When the
26、parts start to have a burr. This pressure will be Phh.Sgs28CnDOE 第五步： 找出比较高的保压压力 Plh P1 P2 Phh P2 Cooling time 冷却 时间 (s Tc Tc Tc Tc Tc + sup Cycle time 周期 (s CT CT CT CT CT + sup 1 2 3 4 5 Holding pressure 保压压力 (bar Plh P1 P2 Phh P2 Cooling time 冷却 时间 (s Tc Tc Tc Tc Tc + sup Cycle time 周期 (s CT CT C
27、T CT CT + sup 1 2 3 4 5 Holding pressure 保压压力 (bar Cooling time 冷却时间 (s Cycle time 周期 (s The 5 th try is to check the 3rd try.第五步就是检查第三步。 20 / 20 Take 2 shots per try (At least 8 parts per try. 每种方法取两模每次至少8 个产品）。 y3qrGQOGwI We will study them later. 我们后面将研究他们。 7 th Step:When the injection machine an
28、d the mold are running 10 minutes with the good parameters we take 50 shots to check the stability process. MZpzcAiHKo We weight the parts to check if it s stable. 第七步：注塑机和模具在好的工艺条件下工作10 分钟后，我们取50 模来检查过程稳定 性。我们通过称重来检查是否稳定。0VoHIjMIZ5 七. 如何判断材料降解程度： 材料降解可通过材料在使用后的MFR 测试值占使用前的MFR 测试值的百分比后再减 去 100来衡量。其值越大说明降解程度越大。dRoQe3gJeM 例如： 使用前使用后 MFR 值10 12 降解程度 12/10-1=20% 申明： 所有资料为本人收集整理，仅限个人学习使用，勿做商业用途。