1、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）:機器注塑容量（實際）=機器注塑容量（理論）*PM/PPS機器注塑容量（理論）:查機器參數.PM-使用原料比重.PPS-聚苯乙烯（PS）常溫下的比重（1.06g/cm3）机器塑模力確定机器塑模力確定:（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=Q*S F-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,cm2
2、 3.標准要求:F=Hm+H1+H2+a+510mm.Sk-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）.Hm-模具厚度（mm）.H1-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,為母模板與撥料板分開時的距離 510mm安全距離,當使用機械手時需取3050mm.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.S模具S機台 Uniform Plasticizing 均匀塑化均匀塑化Less Pressure Loss 低压力损耗低压力损耗Fas
3、ter Cycles 更快成型周期更快成型周期Uniform Stock Temperature 均匀储料温度均匀储料温度Streamlined Melt Flow 线性熔融流动线性熔融流动機台螺杆介紹作用:Metering计量计量Feed进料进料Screw and Cylinder Design螺杆和料筒设计螺杆和料筒设计hf hm L/D=20:1（16 24:1）Compression Ratio压缩比压缩比=hf/hm=2 2.5:1（1.5 3:1）Transition过渡过渡LD15010050255075125150100Screw Dia in mmRPMSCREW SPEED
4、 Suggestions推荐螺杆转速推荐螺杆转速螺杆直径转速往复式螺杆头结构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建议采用止逆阀Standard Cylinder Nozzles标准料筒喷嘴标准料筒喷嘴Heating Band加热环加热环CylinderBore料筒料筒主体主体To MoldProvides 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提供从热的料筒到相对冷的模具的机械和热连接到模具到
5、模具Injection 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/頂出壓力.3.成型十大原則注塑成型流程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
6、度提高.加壓流動模具充填加壓流動模具充填加壓流動模具充填加壓流動模具充填射膠保壓射膠保壓射膠保壓射膠保壓凝固及冷卻凝固及冷卻凝固及冷卻凝固及冷卻塑膠塑化塑膠塑化塑膠塑化塑膠塑化加料松退加料松退加料松退加料松退合模合模合模合模開模開模開模開模頂出頂出頂出頂出Injection Molding ProcessImportant Process Variables重要加工参数重要加工参数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In
7、jection Pressure 注射压力Pack Pressure 保压Clamp Tonnage 锁模力Cushion 缓冲料垫Model of Amorphous PolymersAdding Heat Increases Space 外热提供空间Between Molecular Chains 在分子链之间Raise Temperature of Polymer TGLocked 固态固态EntanglementsStiff Flow难于流动难于流动Easier Flow 较易流动较易流动Melt Temperature 熔融温度熔融温度35302520151050.030.060.0
8、90.120.150.180.210.240Wall Thickness in Inches壁厚（In）MeltFlow（in.）LEXAN?101550 deg F.101 600 deg.FIncreased Melt Temperature yields increased Flow.提高熔融温度导致增加流动However,Too High a Melt Temperature May Cause Degradation.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外热如何作用于高分子材料Electrical Heat
9、:电加热电加热Heater Bands 加热带Mechanical Heat 机械热机械热Screw Speed 螺杆速度Back Pressure 背压Injection Pressure/Speed 注射速度/压力Injection MoldingBarrel UnitThe Reciprocating Screw（Filling）ThroatHeating CoilsNozzleHopperScrewBarrelForce,TorqueFrom Injection Unit料筒组件料筒组件回转式螺杆回转式螺杆喷嘴螺杆加热料斗加料口料筒来自注塑单元的力和力矩DryingDrying tem
10、perature and time are an important key factor for good products in our production在生产得到好的产品，在生产得到好的产品，干燥温度和时间是一重干燥温度和时间是一重要因素要因素Good Parts 良品良品 Typical Lexan（PC）:典型典型PCMoisture Level:Less than 0.02%-121 0 C/3 4 Hrs水分含量小于水分含量小于0.02%-121 0 C/3 4 HrsDrying Temperature-烘干溫度Injection Molding ProcessPart C
11、ooling and SolidificationHot MeltCooled MoldSolid Part制件冷却和固化制件冷却和固化热熔体温度较低的模具固化的制件Mold TemperatureMold Temperature is critical in glossary and residue strain of partUniform mold temperature reduces the effects of warpage.均匀的模温可以减少翘曲Commonly controlled by water cooling channels.模温通常冷却水孔道来控制Injection
12、 Molding Cooling模温模温模温对制件的光洁度和模塑残余应力等级很重要Injection Molding VariablesInjection Speed100010010100100010000LEXAN?141 644 deg FLEXAN?141 608 deg FLEXAN?141 572 deg FApparentViscosity（Pa/s）Shear Rate（1/s）Injection Speed affects the viscosity of the molten material.注射速度注射速度表观粘度表观粘度剪切速率剪切速率注射速度影响熔体粘度注射速度影响
13、熔体粘度Injection Molding VariablesInjection Pressure ProfileHydraulicPressureTimeFill TimeScrew Run TimeBack PressurePeak Injection PressurePressure Applied by Injection Ram to Force the Plastic From the Barrel to the Mold.注射压力曲线注射压力曲线注射压力峰值注射压力峰值液液压压压压力力填充时间Injection MoldingBarrel UnitThe Reciprocatin
14、g ScrewScrew Rotation Feeds and ShearsMaterial Into a Melt.Melt Collects Into Front of Barrel,Forcing Screw BackShotRotation and Back Pressure出量通过螺杆回转，熔体聚集于料筒前部，反作用力使螺杆后退。回转力矩和背压Injection Molding EquipmentBarrel UnitThe Reciprocating ScrewMelt Required to Fill Mold Ready for InjectionShotInjection P
15、ressure注射压力注射压力将要注入模具内的熔体将要注入模具内的熔体（3 5mm for PC）Injection Molding VariablesCushionCushionMaterial remaining in barrel whenthe ejection phase is completed.注过程结束后，注过程结束后，残于料筒前残于料筒前端的熔体端的熔体The injection molding process should allow a cushion to provide sufficient packing pressure in the mold缓冲垫缓冲垫注过程必须要有缓冲垫以保证注过程必须要有缓冲垫以保证有效的保压有效的保压REGRIND SUGGESTIONS Use Only Clean Non-degraded Uncontaminated Resin for Regrind Keep It As New Material Normally 20%of Regrind can be Used Screen Sizes should be 7 to 9 mmInjection Molding Regrind对材料
