工程塑胶专业技术培训教材.pptx

按一下以編輯母片標題樣式,#,按一下以編輯母片,第二層,第三層,第四層,第五層,维熹科技股份有限公司,维尔斯电子,(,昆山,),有限公司,工程部 制作,原料,塑料,(,聚合物,),热固性塑料,(,尿素 电木,),热可塑性塑料,工程塑料,泛用塑料,结晶性,非结晶性,热敏感性,复合材料,-,热可塑性,热固,/,硬性,化学性变化,*初期塑料成本较低,*较高耐热和抗潜变性,*耐电弧性,*不可回收,物理性变化,*较低塑件成本,*较宽广设计自由度,*稳定电气特性,*可回收,非结晶性,化学性敏感,.,适度耐热温度,.,冲击强度,.,较低模收缩率,.,均匀物性,.,结晶性,抗化学性,.,较高耐热性,.,缺口效应敏感,.,模收缩率较大,.,耐疲劳性,.,耐磨耗性,.,热可塑性,塑料四大要素,成品,原料,模具,注塑,设计,工作执行中要知道的事项,:,材料,成型,干燥,设备,CYCOLAC,ABS,非结晶性,无填充材,添加物,低比重,优异的成形性,韧性,低成本,耐热性,(up to 85),外观性,缺点,:,抗化学性,户外耐候性,特性,:,T,AM,EX120/121,GPM4700,GPM5600,GPM6300,X11,X17,X37,SEA2,KJ-T/B/W/U,-,-,-,CYCOLOY,PC/ABS,合金材料,非结晶性,无填充材,添加物,物性较为均衡性,.,成形性,.,优异冲击强度,.,低温韧性,.,耐热性,(up to 120),UV,特性,.,缺点,:,抗化学性,.,特性,:,C1100,C1100HF,C1200,C1200HF,C2800,C2950,C2950HF,C6200,C6600,CU6800,C7210A,NORYL,改良式,PPO,塑料,非結晶性,填充材 和 無填充材,添加物,尺寸安定性,.,成形性,.,優異電氣性質,.,耐熱性,(up to 150),低比重,.,低吸水性,.,缺點,:,抗化學性,.,UV,顏色特性,.,特性,:,NORYL,儀表座,-,電氣特性,&,尺寸安定性,731,SE100X,SE1X,N190,N225X,N300X,N1052P,PX1005X,PX1007,GFN1/2/3,SE1GFN1,HM3020,FN215X,LEXAN,聚碳酸酯,(PC),非結晶性,填充材 和 無填充材,添加物,優異衝擊強度,.,透明性,/,顏色穩定性,.,尺寸安定性,.,自熄性,.,抗潛變性,.,耐熱性,(150,PPC 165),缺點,:,抗化學性,.,缺口效應,水解性,應力敏感,特性,:,LEXAN,磁碟片,:,純淨度,透明性,高流動性,141/241/R,121/221/R,101/R,HF1130,3412/3/4,500R,LGN5030,920/940/A,LC,LS1/2/3,LF1000,FL900,PPC4701,SP7602/4,JK1000,OQ1020,NORYL,GTX,PPX,CRX,Resin,PPO/PA,PPO/PP,合金材料,非結晶性,/,結晶性,填充材和 無填充材,抗化學性,.,衝擊強度,.,尺寸安定性,成形性,耐熱性,(up to 235),噴漆後加工性,缺點,:,吸水率,模收縮率,特性,:,GTX600,GTX6203,GTX6801(30%),GTX830,GTX870(20%),GTX880(30%),VALOX,PBT,熱可塑性聚酯,結晶性,填充材,無填充材,添加物,抗化學性,耐熱性,(up to 255),電氣特性,耐摩擦性,/,磨耗性,耐疲勞性,缺點,:,缺口敏感性,收縮率,/,撓曲,特性,:,VALOX,熱熔槍,:,耐熱性,310,310SEO,325,DR51,DR48,420,420SEO,507,553,830,PDR4910(15%),-,-,-,ULTEM,PEI,聚亞醚,非結晶材料,填充材,無填充材,添加物,抗化學性,高溫功能特性,.,耐熱性,(up to 225),完美自熄性,電氣特性,透明性,缺點,:,缺口敏感性,顏色限制,特性,:,ULTEM,醫療用接頭,:,抗化學性,1000,2100,2200,2300,2400,JD7902,JD7101,SUPEC,PPS,金屬樹脂,結晶性,填充材,添加物,高耐熱性,(up to 260),抗化學性傑出自熄性,抗水解性,疲勞特性,高流動性,缺點,:,缺口效應敏感,特性,:,G401,G402,料管的撰用的合理性,料管的介紹,(,工程塑膠,),計量段 混鍊,/,壓縮,供給段,供給段,:,進料供給作用,.,混鍊,/,壓縮 段,:,利用牙深產生剪熱壓縮混鍊材料,.,計量段,:,最後塑化材料,.,成品投影面積,模腔內壓力,模具長寬尺寸,最小模具厚度尺寸,最大開模行程,射出比率,(40 60%),最大射出壓力,流動距離,成品厚度,周邊設備,-,塑料預備乾燥,WELL SHIN,Resin,Resin,Resin,熱可塑性工程塑膠,工程塑膠原料會因,;,製造,運輸,存放過程而增加含水率,.,H,2O,H,2,O,H,2,O,塑料含水率,水份吸收均衡性,H,2,O,H,2,O,H,2,O,乾燥過程,利用乾燥空氣帶走水份,.,吸收,移轉,.8,.02,吸,濕,比,率,-30-200204060,Dew Point,露點,均勢,適合程度,吸收,/,移轉,烘料筒,乾燥珠,乾燥空氣,熱空氣,利用乾燥劑將空氣乾燥再除濕烘料,.,乾燥系統,烘料筒,回收空氣,乾,燥,系,統,二次乾燥系統,加熱系統,将空气送进低于露点之干燥筒中,再加热进入烘料筒循环充分干燥塑料,.,干燥机,烘料筒,鼓風機,乾,燥,系,統,乾,燥,系,統,加熱系統,密闭式循环系统,-,利用过滤器将回收空气去除污染再循环充分干燥塑料,.过滤器,熱空氣,流量較快,慢速流量,擴散器,均勻流量,熱空氣,烘料筒設備,料筒應用造成不同循環流動,(2:1),對乾燥效果亦所有不同,.,使用擴散器具對原料乾燥效果較為均勻,.,乾燥塑料注意事項,:,確認露點溫度,.,確認回收空氣溫度,.,確認循環空氣流量,至少,1 CFM/(lbs/hour).,若使用直接回收料,必須延長乾燥時間,1-2,小時,確認乾燥劑功能使用,.,烘料筒選用,成品重量,x,射出循環時間,=,數值,例如,:500 g,成品重,x 30,秒循環時間,=1Kg/,分,或,60 Kg/,時,數值,x,乾燥時間,=,建議烘料筒尺寸,例如,:60Kg/,時,x 4,小時,=240 Kg,烘料筒,烘料筒選用必須大於足夠乾燥時間,干燥条件,原料 烘料温度 烘料时间 露点空气,PPO 991-2 Hours-30,ABS 822-4 Hours-30,PC1203-4 Hours-30,Polyetherimide1203-4 Hours-30,PBT1202-4 Hours-30,NYLON 66 80 3-4 Hours -20,NYLON 6 80 3-4 Hours -20,NOTE:,回收料使用因粉碎颗粒较大,必须增长烘干时间,每一规格塑料之烘干条件请参照物性表建议事项,.,成型製程,製程,初始,:,使用正確塑料清洗料管,.,使用正確製程條件,.,建議各種清洗料管使用原料,規格 清洗用塑料,CYCOLAC/CYCOLOY Acrylic,Polystyrene,SAN,NORYL Polystyrene,Acrylic,LEXAN Acrylic,HD Polyethylene,VALOX Polystyrene,HD Polyethylene,ULTEM LEXAN 101,141,HD Polyethylene,(Extrusion Grade),SUPEC HD Polyethylene,塑化溫度設定,電氣性加熱,:,加熱片,(Heater Bands),機械性加熱,:,螺桿轉速,(RPM),背壓,射出壓力,/,速度,塑料溫度設定過高,噴射痕,銀條紋,顏色變更,較長冷卻時間,材料劣解,射出成形加工考慮要點,模具成形溫度,塑料溫度,螺桿回轉速度,背壓設定,射出成形壓力,射出成形速度,塑膠成形要項,參照塑料物性,/,製程條件建議,原料差異性,塑料規格差異性,GE,材料商品名 成形溫度,(),CYCOLAC?218-260,LEXAN?266-310,NORYL?PREVEX?218-327,VALOX?236-277,ULTEM?338-450,CYCOLOY?235-285,XENOY?240-280,SUPEC?300-332,GELOY?195-220,模具溫度,成品冷卻和固化過程,熔融原料,模具冷卻,固化成品,模具溫度必須低於,TG,達到冷卻成品作用,T,G,成形溫度範圍,劣解,冷卻作用,:,非結晶性材料,劣解,T,M,T,G,成形溫度範圍,Mold Temperature Determines Cooling Time and Therefore Degree of Crystallinity,Cooling Through the Crystallinization Range Too Quickly Will Result in Reduced Crystallinity(Quenching),冷卻作用,:,結晶性材料,120,125,125,135,135,145,130,140,140,130,150,145,O,O,O,O,O,O,O,O,O,O,O,O,IN,OUT,模溫控制,P,L,模溫控制,範例,相關配備,計量段 混鍊,/,壓縮,供給段,供給段,:,進料供給作用,.,混鍊,/,壓縮 段,:,利用牙深產生剪熱壓縮混鍊材料,.,計量段,:,最後塑化材料,.,計量段,供給段,螺桿設計,h,f,h,m,L/D=20:1,壓縮比,=2:1,雙金屬設計,磨耗性,熱傳導性,h,m,h,f,壓縮,/,混鍊,L,D,(,供給段牙深,),球形逆流閥,Open,Closed,射出動作,球形逆料閥,耐久性,阻礙流動,滯流塑料和黑點發生,不回流閥,計量供給時動作,高壓射出時動作,Check Ring Valves are Suggested,不回流閥,對塑料剪切影響較低,.,耐久性較差,.,逆流閥流量功能與螺桿較接近,.,噴嘴,(Nozzle),加熱片,注料管,注射方向,噴嘴設計,段道長度,0.0-4.75.,口徑尺寸,4.76-9.5.,豎焦道口徑小於,0.5-0.8,噴嘴尺寸,儘可能使用較短尺寸之噴嘴設計,.,射出成型,射出流動,射出成形,射出流動,射出成形,射出流動,射出成形,射出流動,射出成形,射出流動,射出成形,射出成形,射出壓力,射,出,壓,力,Time,充填時間,回料時間,背壓,射出成形條件,射出成形條件變化因素,塑料溫度,模具溫度,溫度變化,滯留時間,射出速度,射出壓力,背壓,閉模力,殘量,射出成形條件,塑料溫度,35,30,25,20,15,10,5,0,.030.060.090.120.150.180.210.240,成形厚度,(in),流,動,長,度,(in.),LEXAN,101,550 deg F.,101 600 deg.F,增加塑料溫度亦增加流動性,.,然而,過高塑料溫度將引起劣解現象,.,射出成形條件,背壓,Gate,不均勻壓力分佈,均勻壓力分佈,H,y,d,r,a,u,l,i,c,P,r,e,s,s,u,r,e,Time,Fill Time,Screw Run Time,Back Pressure,過分充填,適當充填和均勻壓力分佈可避免收縮和翹曲問題發生,亦降低充填所產生內應力,成形模具,二板模,Exploded View,移動側模板,固定側模板,固定側定位板,間隔塊,背板,上頂板,下頂板,導柱,回位銷,分模面,成形模具,1,2,3,4,成形模具,背板,上頂板,下頂板,Ejector Housing,B Plate,X Plate,固定側模板,固定側定位板,三板模,分模面,分模面,成形模具,三板模,1,2,3,4,5,射出成形模具,內部壓力,豎澆道,流道,澆口,1 2 3,x x x,成品,Flow,壓,力,時間,3,2,1,豎澆道勾梢,倒斜度設計,優,“Z”,型,好,倒環型,普通,崁入型,較差,流道設計,流道,射出成形模具設計,進料點選定不均平衡系統設計,A,A,A,A,B,B,B,B,流道設計,平均分佈設計,A,A,A,A,A,A,A,A,流道設計,容許最大材料流動,塑料冷凝影響最少,流道,流動,流道設計,流道設計,全圓型,優,梯型,好,半圓型,較差,P,L,建議之流道尺寸,:,流動均衡,主流道,-,全圓形 或 梯形設計,9.5 250,以上,8.0 75-250,6.5 75,或 以下,次流道,6.5,最少,流道,梯型側圖,R,D,R,D,RD W D,1/83/161/8,3/161/43/16,1/45/161/4,5/167/165/16,3/81/23/8,對等設計之一,設計之二,流道設計,阻礙流動,較佳設計,流道設計,流動方向,冷料井,冷料井尺寸設計與流道相同或大於,1.5,倍,冷料井,流道設計,熱流道系統,:,主流道岐管直徑最小應為,12,大型件時為,16,或更大,.,分岐塊末端務必製作圓形設計,.,使用,4,支加熱棒,均勻分佈,.,分岐塊,(Manifold),所需的熱量,每立方吋之鋼材最少應有,50,瓦特的加熱能力,.,緊密配合,固定螺絲,無澆道設計,熱流道系統,固定側模板,=50,Manifold=260,優點,快速循環時間,-15-20%,時間減少,節省材料,-,沒有澆道和流道,較好成品品質,-,減少應力殘留,-,較佳外觀,母模板,=50,分歧塊,=260,金屬熱膨脹系數,:0.00000633 in/C,6 in.=.017 In.,12 in.=.034 In.,18 in.=.051 In.,無澆道設計,進澆口,澆口設計,直接豎澆道,成形製品,豎澆道,澆口設計,邊緣料口,段道長度,0.76 mm(Max),澆口設計,碟形澆口,流道,成品,流道,豎澆道,澆口設計,Single Tab Gate,Multiple Tab Gate,Gate,Tab,Sprue,6 in.Max,12 in.Max,Tab,Sprue,Gate,Gate,Tab,成形品,豎澆道,分模線,潛道,料口,無段道長度,頂出梢,料口側打光平順,Min.2,0,潛道式料口,澆口設計,冷料井,R,角,改良式扇形料口,澆口設計,成品,流道,澆口,段道,扇形料口,澆口設計,澆口設計,料口,成品,碟型流道,料口,環型料口,潛道,成品,豎澆道,分模線,澆口,澆口,冷料區,潛道設計之冷料區,R,R,料口,腰果式料口,(,牛角式,),澆口設計,L,0.5mm,段道長度,1.27mm,90,0,澆口設計,針點式料口,排氣系統,模具排氣,加工空隙,0.05mm,頂出梢部份,模具排氣,分模面部份,深度,0.03-0.06mm,料口,排風孔,1.5mm Min.,Note Step,12.7mm,1.3mmMin.,模具排氣,頂出機構,Blade at,Deep Ribs,Rounds Pins,Sleeve,Ejector,Boss,Eject,Mold Pin,Stationary,Parts,Stripper,Plate,Stationary Force,Knock Out,Bars,GOOD KNOCK OUT,FOR ROUND PARTS,USED AROUND,PINS&BOSSES,頂出機構,頂出影響因素,:,離模角度,離模面積,離模面粗糙度,/,蝕刻處理,頂出角度,模具溫度,模具附著,頂出機構原則,:,儘可能使用較大尺寸之頂針,.,儘可能增加頂針數量,均勻地將成品頂出,.,離模角度設計 和 蝕刻面,射出成形模具,成品頂出,無脫模角,頂出困難,頂出容易,離模角度設計,脫模角,1/2?Min.,脫模角,離模角度設計,蝕刻脫模角,每增加,0.025,深度,則加大,1,度脫模角,射出成形模具,不均勻收縮效應,氣泡,外部固化但內部持續收縮,下陷,外部持續收縮,不均勻肉厚設計,模具設計,不均勻內應力分佈,撓曲變型,Gate,高應力,低收縮,低應力,高收縮,撓曲,模具設計,厚度設計,模具設計,補強厚度設計,肋部厚度必須小於肉厚,過分肋部厚度設計將引起下陷和氣泡問題發生,模具設計,轉角設計,Sharp Corners Concentrate Stresses,A Rounded Outside Corner/Sharp Inside,Corner Creates Uneven Shrinkage:Warpage,A Rounded Inside Corner/Sharp Outside Corner Creates,Uneven Shrinkage:Sink Marks and Voids,模具設計,靠破孔,Not Recommended,Poor Flow!,進料點,模具設計,靠破孔,進料位置,Recommended,Better Flow,變形,燒焦,光澤,氣泡,短射,收縮不均,毛邊,噴痕,黏模,壓力過高,指印,生產中問題發生時候,?,認定,.,塑料有問題,!,基本原則,一些基本步驟可有效率地處理成形所發生之問題,.,計劃性思考對策,一次處理一種問題,耐心地,觀其變化,使其規律化,記錄其變化,射出成形中之,問題對策,收縮,/,下陷,Caused by Internal,Stresses within Thicker,Sections of the Part,as a Result of,Insufficient Polymer,Molecules.,收縮,/,下陷,Ways to Minimize Sink Marks,Check the Part Design,Check Feed Rate,Increase Injection Speed,Increase Injection Pressure,Increase Mold Temperature,Increase Injection Hold Time,Check Melt Temperature,Increase Back Pressure,Maintain Sufficient Venting,Increase Runner/Gate Dimensions,氣泡,Voids Are Cause by Too,Few Molecules within the,Mold.As Opposed to Sink,Marks,Part Wall Strength,is Sufficient to Withstand,the Internal Stress Caused,by the Melt Cooling,Process.,氣泡,Ways to Minimize Voids,Check the Part Design,Check Feed Rate,Increase Injection Hold Time,Increase Injection Speed,Increase Mold Temperature,Check Melt Temperature,Increase Back Pressure,Maintain Sufficient Venting,Increase Runner/Gate Dimensions,Increase Injection Pressure,變型,Warping is Caused by Non-Uniform Orientation and Uneven Stress Levels on Different Sides of the Part.,變型,Check the Piece Part Design,Check Feed Rate,Decrease Injection Pressure,Decrease Injection Speed,Decrease Mold Temperature,Increase Injection Hold Time,Check Melt Temperature,Check Cooling Passages,毛邊,Flash Will Occur When,Injection Pressure,Exceeds Clamp Force,or Shut-Off is Damaged.,毛邊,Loose Clamp,Injection Pressure Too High,Injection High Pressure on Too Long,Injection Speed Too Fast,Melt Temperature Too High,Improper Feed Rate,Damaged or Overheated Mold,短射,/,缺料,Short Shot is,the Inability to,Completely Fill,a Part.,短射,/,缺料,Ways to Minimize Short Shots,Check for Nozzle Damage,Increase Injection Pressure,Increase Stock Temperature,Increase Shot Size,Increase Mold Temperature,Check Non-Return Valve and Barrel for Excessive Wear or Damage,成品表面焦化,/,黃紋,Surface Burning of Parts Can,Be Caused by Too High a Stock,Temperature.Excessive Shear,Heating Caused by Too High a,Back Pressure is Also a Possible,Cause.Check to Make Sure,that the Venting of the Mold is,Adequate.When a High Injection,Speed is Used to Overcome Flow,Restrictions,Frictional Burning,Can Result.,成品表面焦化,/,黃紋,Ways to Minimize Surface Burning,Decrease the Stock Temperature,Decrease Injection Speed,Check Venting of the Mold,Enlarge Gates,Check Sprue for Burning and/or Purge Shot,Check Clamp Pressure,Check Venting,Decrease Injection Speed,Decrease Injection Pressure,Check Stock and Mold Temperatures,結合線,/,熔合線,Weld lines Occur When Two,or More Melt Fronts Merge.,Typically,These Will Be Melt,Fronts from Different Gates,or a Single Melt Front Forced,to Split Around an Obstruction,Such as a Core pin.,澆口焦紋,Gas Burn is a Degradation,of the Part Caused by,the Compression and,Ignition of Trapped Air,or Gasses in the Mold.,澆口焦紋,Improper Clamp Tonnage,Clogged Air Vents,Lack of Adequate Venting,Injection Speed Too High,Injection Pressure Too High,Melt Temperature Too High,Mold Temperature Too High,剝離,The Separation by Layer,Caused by Contamination,of a Dissimilar Polymer.,工程塑料成形必須注意十點事項,瞭解塑料規格,正確乾燥條件,使用建議之成形條件,使用正確周邊設備,使用適當模具設計,使用適當流道設計,使用適當排氣系統,設定正確噴嘴溫度控制,選用適當螺桿設計,確實做好設備保養工作,謝謝收看,學完後要好好的利用,維爾斯工程部 制,