注塑模具准则中英文对照版Word下载.docx
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注塑模具准则中英文对照版Word下载.docx
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brandonourtoolplan
c.Alltheplasticmaterialsformoldingmustbesameasthematerialsduringdevelopmentstage.
d.Incaseofmaterialshortageorcostissue,thenewsourcedmaterialshallbetestedandconfirmedacceptableprioruse.
2.Colorant
a.AllthecolorantmustbeconformedtoheavyelementsdirectivesforbothASTMF963&
EN71.
b.Mostofthedrypigmentsarehygroscopic;
theymustbeproperlysealedafteruse.
c.Forthecomponentswithhighcolorconsistence,themasterbatchesorpre-colorplasticmaterialsarerequired.
3.RegrindMaterialRatio
a.Forplasticmaterialonstructuralcomponents,noregrindisallowed
b.Forgeneralpurposematerialonnonstructuralcomponents,20%maximumrunnerregrindcanbeblendedwithvirginmaterial.
c.Forthosetranslucentortruewhitecolorcomponents,noregrindisallowed.
d.Forshortglassfilledmaterials,15%maximumregrindcanbeblendedwithvirginmaterial
e.Forlongglassfilledmaterials,noregrindisallowed.
f.Themaximumnumberofregrindpassesforgeneralpurposematerialsshallbe3.
g.Only1timeofregrindpassisallowedforshortglassreinforcedmaterials
h.Theregrindratioshallbeshowninourupdatedtoolplantofollow.
i.Theregrindratioandno.ofregrindpasseshastobevalidatedandconfirmedduringdevelopmentstage.Ifnot,noregrindwillbeallowed.
j.
Burnedordiscoloredspruesorpartsmustnotbeusedasregrind.
k.Hotnozzle&
hotrunnerisourpreferencetoeliminaterunnerscrap.
4.MaterialDrying
a.Mostplasticresinsrequirethoroughdryingpriorinjectionmoldingtoassuremaximumpropertiesinthemoldedparts.Belowtablepleasefindtherecommendeddryingtemperature&
durationforreference:
b.Forthosehygroscopicmaterials,thedehumidifyinghopperdryerwithclosed-loopaircirculatingsystemisrequiredtoensureacceptablemoisturecontenttobeachievedduringmolding.
c.Forthosenon-hygroscopicmaterials,theregrindhavetobedriedas80º
Cfor2hourstopreventsurfaceblemishesduetovolatiles,suchasPE,PP,POM,HIPS.
Material
DryingTemperature
Timerequired(Hour)
DehumidifyingDryerrequired
ABS/C-ABS
80º
C
2
No
Nylon6/PPO/PC+ABS
100º
Nylon66
120º
PU
110º
2–3
Yes
PC
2-3
PET
RegrindblenchforPE/PP/HIPS/POM
5.ScrewDesign
a.Formostofun-filledplastic,standardscrewwithL/Dratio22:
1isrecommended
b.Forglassreinforcedplastic,screwwithlowerL/Dratio20:
c.Bi-metallicscrewandbarrelarerequiredforglassreinforcedplastictohavehigherwearassistance
6.MoldingMachine&
AccessoriesSelection
a.Thedistancebetweentwocolumns(Horizontal)shallbe10mmminimumlongerthanthemoldwidth
b.Fornonengineeringorunfilledplasticresin,upto90%ratedbarrelcapacityshallbeutilized.
c.Forengineeringandallglassfilledplasticresin,upto70%ratedbarrelcapacityshallbeutilized.
d.Forclampingtonnageconsideration,themultipleofprojectileareaandfillpressureshouldbeupto90%ofratedclampingtonnageofmachine.However,theactualrequirementwillbedependeduponthewallthickness,partsgeometryandgatedesign.Belowtablepleasethefillpressurefactorforcommonuseplasticforreference.
PlasticMaterials
FillPressure(Ton/SqInch)
PE/PP/EVA
1.8
HIPS/ABS/C-ABS
TPU/PC/PC+ABS
4
GlassFilledPlastic
5andUp
e.TheminimumtonnageformoldsizeshallbeputtoMachineSizecolumnonToolPlan
f.Forhighprecisionparts&
opticallens,electricmoldingmachineispreferred.
g.Automaticparts/sprueremovalsystemshouldbeinstalledfor220tonorabovemoldingmachines
h.Hopperloadershouldbeinstalledfor220tonsorabovemachines
i.Proportionaltypehopperloadershouldbeusedforthemoldingwithinstantrunnerscraprecycling.
j.Hoppermagnetshallbeequippedforallmaterialhoppers.
7.MoldClamping
a.Formachinecapacityupto130tons,allmoldscanbeclampedontomachineplatensbyeitherclampingslotsormountingholes.
b.Formachinecapacitymorethan130tons,allmoldscanonlybeclampedontomachineplatensbyclampingslots.
c.Alwaysuseappropriateclampingtonnageforclamping,10%higherthanthetheoreticalclampingtonnageassection6d).Excessiveclampingpressurewillruinthemolds,especiallyonweakpartinglineareas.
d.Jiffytypeplugsandconnectorsarepreferredtospeedupset-uptime.
e.AllEyeboltsmustberemovedbeforemoldingstartinordernottointerfereanymechanicalmovement
f.TheHoistRingtypeispreferredtopreventaccidentscausedbytraditionaleyeboltfailure
8.MoldCooling
a.Allcoolinglinesmustbeconnectedtowatermanifoldofmachinesasperindicationofmolddrawing
b.Thewatertemperaturedifferencebetweeninletandoutletshallbelessthan5º
C.
c.Correctmoldtemperatureshallbemaintainedfordifferentmaterialstoobtaingoodaestheticandmechanicalproperties
d.Appropriatemoldtemperatureshouldbedependeduponthewallthickness,aestheticrequirementandflowlengthtothicknessratio(L/T).Belowtablepleasefindrecommendedmoldtemperatureformostcommonmaterials:
MoldTemperature
PE/PP/HIPS
Chillwaterto40º
ABS/C-ABS
20º
Cto50º
POM/UnfilledNylon/UnfilledPET
40º
Cto70º
PC+ABS/PC
50º
Cto80º
FilledNylon/FilledPET
60º
Cto100º
9.MoldingProcessParameter
a.Setbarrelheaterstorampprofile,loweratthefeedthroatandhigheratfrontzone.Belowtablepleasefindtherecommendedtemperaturerangeforreference:
CylinderTemperatureº
PE/PP
190–220
HIPS/GPPS
180–220
190–240
Polyacetal
170–210
260–300
260-290
b.Settheinjectiontolowerlimitandaddgraduallytoobtaingoodparts
c.Settheinjectionspeedtohighforcrystallinematerialandmediumforamorphousmaterials.
d.Setholdingpressureandtimetozero.
e.Startmakingshortshotswithoutanycushion,theincrementallyincreaseshotvolumeuntilthepartisapproximately95%full.Thisbecomesthetransferpoint(time).Beginweighingparts.
f.Setthepackingpressure30%to40%belowfirststagepressureandcontinueweighingparts(normallyusesonly1–3secondspacktime).Increaseshotvolumeuntilacushionisdeveloped.Incrementallyincreasepacktimeuntilpartweightdoesnotincrease.Atthispoint,gatefreeze-offhasbeenreached.
g.Setthebackpressurelowbutensuretodisplacetrappedairinthescrewfeedsectionandgoodmelthomogeneity.Forglassfilledplastic,therecommendedpackpressureshouldbe20–50PSItopreventglassbreakage.
h.Setthecoolingtimetopermitthepartstobeejectedwithouttheejectorpinsmarksorpushingintotheparts.
i.Themoldingset-upsheetforeverymoldmustbewelldocumentedandattachedtomoldingmachineforreviewduringmolding.
10.CycleTime
a.Belowtablepleasefindourexpectedquotingcycletimefordifferentpartscategoryandmachinesize:
PartsDescription
Example
MachineSize
ExpectedCycleTime(S)
Smallsizepartswith1.5mmwallthicknessorbelow
ButtonorPOMcomponents
70tonorbelow
26
Mediumsizepartswith1.5mmwallthicknessorbelow
BatteryDoor&
4upCartridgemold
70to120ton
30
SmallsizeHousingwith2.0mmwallthicknessorbelow,ormulticavitiescomponents
LTLPCountingHouse&
FridgeDJHousing
Over120to200ton
34
MediumsizeHousingwith2.5mmwallthicknessorbelow
LeapPad&
MFLPHousing
Over200–280ton
38
AroundtheBlockHousing
Over280ton–350ton
42
LargeHousingwith3.0mmwallthicknessorbelow
BabyDVDBaseHousing
Over350–450ton
48
ExtremelylargeHousingwith3.0mmwallthicknessorbelow
Top&
BottomHousingforLearningTable
450–600ton
55
b.ThecycletimeforalltoolingwillbefinalizedafterverificationbyourtoolingengineerduringFEPstage.
c.Thelimitedconditionthatkeepsthemoldsfrombeingrunatalowercycletimehastobespecifiedinquotationandmolddrawingapprovalstage,suchaswallthickness,aesthetics,dimensionaltoleranceorcomponentsdesign.
11.MoldReleasingAgent
a.DuringfirstshotandEPstages,themoldreleasingagentcanbeappliedwhenparts’stickingoccurs.
b.DuringFEPandPPstagesonwards,nomoldreleasingagentisallowed.
c.Allmoldreleasingagentmustbenon-toxicandCFC-freeaerosols
12.SecondOperation
a.ThefixturematerialsshallbemadeofPhenolic,Aluminum,coatedsteelorthosematerialswithhighresistancetoworn-outandcorrosiveness.
b.Allthefixturesmustbecalibrateddailyandoncemoldingstart.
c.Nobreakableknifeortoolsareallowedfordegatingandflashingtrimming
13.ProcessControl
a.Thesignedshotsampleandcomponents’specificationshallbeattachedtomachineforroutinequalitycheckbyqualityinspectorormoldingsupervisorpriormoldingstart.
b.Themoldedcolor,aestheticsandcriticaldimensionsshallbeinspectedandconfirmedacceptablebyqualityinspectorpriormoldingstart.
c.Bi-hourlyprocessinspectionshallbeconductedtoverifyaestheticsandfunctionalrequirements
d.Criticaldimensionalcheckhastobeperformedforevery4hours
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