ARBURG精密注塑技术PPT课件.ppt

精密注塑技术 Aspects for Precise Aspects for Precise Injection MoldingInjection Molding内容提要 Overview Overview 精密注塑的定义 Definition Precise Injection Molding 锁模系统 Clamping Unit 锁模力 Clamping Force选择注射装置的准则Criteria to Select the Injection Unit SELOGICA 控制器 SELOGICA Controller模具设计Mold Design 模具温度控制Mold Temperature Control2.精密注塑的定义 Definition Precise Definition Precise Injection Molding Injection Molding 小的尺寸和公差 轻的部件重量 为特定产品配备注塑设备 灵活的机器配备（一台机器可适用于多种模具)稳定的质量，高的重复性 Small part dimension and tolerance Low weightAdaptation of machine performance to the partsFlexible machine configuration(many molds suitable for one machine)Stable quality,reproducibility 3.锁模系统 Clamping Unit Clamping Unit合模系统起重要的作用动模板是稳定而经过证实的箱型结构长而精确的导向模板平行度的调节 50 吨范围内 0.05 mm极高的刚度For precise injection molding,the clamping take over a very important part.movable platen as stable and proven box-type platen long and precise guiding of the movable platen adjustable parallelism up to 50 to.Machines 0.05 mm high rigidity4.锁模力 Clamping Force Clamping Force精密注塑的另一个重要因素是锁模力。原因是：模腔更好的排气（90%的空气从分型面排出）减少机器和模具的磨损节省能源One other important aspect for precise injection molding is the clamping force.Reasons for that are:Much better venting of the cavities during injection.(ca.90%of the air inside the cavity escape over the parting line)To prevent machine and mold from unnecessary wear.Saving energy5.锁模力 Clamping Force Clamping Force怎样计算锁模力锁模力=单位锁模力 X(产品投影面积+流道投影面积）如果有滑块，需要将滑块投影面积的 30%加入产品投影面积How to calculate the clamping force?If the mold contains sliders!You have to add 30%of the projected slider area to the projected area of molded part.6.锁模力 Clamping Force Clamping Force单位锁模力的确定可使用以下图表To define the necessary specific clamping force,use one of the pictures below.For standard partsfor thin walled parts with long flow paths7.锁模力 Clamping Force Clamping Force举例Example:接插件 Connector Connector PA6 PA6长度 Length:6 cm宽度 Width:1.5 cm浇道投影面积 Proj.area sprue:8 cm2 单位锁模力 Spec.clamping force:6 kN/cm2 模穴数 8 cavities8.选择注射单元规格的准则Criteria to Select the InjectionCriteria to Select the Injection Unit UnitShot weightCycle timeMaterialInjection pressure9.每一机器尺寸Each machine size三个注射单元3 injection units三个料筒规格3 cylinder sizes选择注射单元规格的准则Criteria to Select the Injection UnitCriteria to Select the Injection Unit模块化 Modularity10.选择注射单元规格的准则Criteria to Select the Injection UnitCriteria to Select the Injection Unit注射单元的欧洲橡塑机械协会(EUROMAP)规格表示注射单元的最大注射功。计算方法最大注射压力 X 最大行程容量/1000举例按注塑机 320 C 600-250 规格表最大注射压力(35 mm 螺杆）：1820 bar最大行程容量 144 ccm1820 bar X 144 ccm/1000 250The size of the injection unit is according to EUROMAP and indicates the working performance of the injection unit.The working performance is calculatemax.spec.injection pressure x max.stroke volume/1000Example:According to the technical data of 320 C 600-250Max.Injection pressure(screw diameter 35mm)=1820 barMax.Stroke volume=144 cm31820 bar x 144 cm3/1000 25011.选择注射单元规格的准则Criteria to Select the Injection UnitCriteria to Select the Injection Unit注射功Working performance!相同螺杆直径，但不同注射压力!Same screw diameter but different max.injection pressure12.选择注射量的准则Selection criteria shot volume最大计量容量max.dosage volume20 80%最佳工作范围 opt.working range10 20%bzw.80 90%可接受的范围 conditional suited 90%不推荐的范围 not recommended选择注射单元规格的准则Criteria to Select the InjectionCriteria to Select the Injection Unit Unit13.选择注射单元规格的准则Criteria to Select the InjectionCriteria to Select the Injection Unit UnitExample:Connector(PA6),8 cavities,26.5 g shot weight Results according the list below:(1)The injection volume must be on average 25%greater than the volume of the injected part(incl.sprue)due to shrinkage during solidifying and due to the compression of the melt during injection.Injection unitInjection unit100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mmMax.injection volumeMax.injection volume31 cm31 cm3 349 cm49 cm3 3106 cm106 cm3 3188 cm188 cm3 3Percentage of capacity Percentage of capacity 95%95%60%60%28%28%16%16%14.选择注射单元规格的准则Criteria to Select the Injection UnitCriteria to Select the Injection UnitExample:Connector(PA6),8 cavities,26.5 g shot weight 2nd example,calculation with shot weight Results according the list below:Injection unitInjection unit100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mmMolded part weightMolded part weight26 g26 g41 g41 g89 g89 g158g158gPercentage of capacity Percentage of capacity 100%100%64%64%30%30%17%17%15.选择注射单元规格的准则Criteria to Select the Injection UnitCriteria to Select the Injection Unit滞留时间准则滞留时间=塑胶进入料筒到离开喷嘴的时间PE,PP,PS:最少 30 秒(大于 40 秒为好)PA,POM,PBT:最少 60 秒(75 秒为好)Selection criteria dwell time dwell time=from the entree of material into the cylinder until the exit out of the nozzles e.g.PE,PP,PS:min.30 s(better 40 s)e.g.PA,POM,PBT:min.60 s(better 75 s)16.选择注射单元规格的准则Criteria to Select the Injection UnitCriteria to Select the Injection UnitExample:Connector(PA6),8 cavities,26.5 g shot weight(29.31 cm3)Result according to the list below,dwell time for PA6 min.60 sec.Injection unitInjection unit100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mmScrew channel volumeScrew channel volume60 cm60 cm3 385 cm85 cm3 3185 cm185 cm3 3265 cm265 cm3 3Cycle time 15s/dwell Cycle time 15s/dwell timetime25 sec.25 sec.35 sec.35 sec.75 sec.75 sec.109 sec.109 sec.Cycle time 25s/dwell Cycle time 25s/dwell timetime41 sec.41 sec.58 sec.58 sec.126 sec.126 sec.181 sec.181 sec.Remarks:an extended screw and cylinder can increase the dwell time!17.选择注射单元规格的准则Criteria to Select the InjectionCriteria to Select the Injection Unit UnitSelection criteria material throughput Example:Connector(PA6),8 cavities,26.5 g shot weightInjection unitInjection unit100100100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm30 mm30 mm40 mm40 mmMax.Throughput/h(PA-GF30)Max.Throughput/h(PA-GF30)3.5 kg/h3.5 kg/h5 kg/h5 kg/h6 kg/h6 kg/h11 kg/h11 kg/h15,5 kg/h15,5 kg/hThroughput(cycle time 15s)Throughput(cycle time 15s)6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/hThroughput(cycle time 25s)Throughput(cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/hMax.Throughput/h(PS)Max.Throughput/h(PS)5.5 kg/h5.5 kg/h8 kg/h8 kg/h9.5 kg/h9.5 kg/h17 kg/h17 kg/h24.5 kg/h24.5 kg/hThroughput(cycle time 15s)Throughput(cycle time 15s)6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/hThroughput(cycle time 25s)Throughput(cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h18.错误的选择会造成Mistakes in selection causes e.g.to-不完全熔化的粒料-Unmelted granulate-混色不均-Color steaks-烧焦-Burnt streaks选择注射单元规格的准则Criteria to Select the InjectionCriteria to Select the Injection Unit Unit19.其他准则包括所用材料的加工温度有些工程材料（如 PEEK,PEI,LCP 等）需要接近 450 摄氏度的加工温度 料筒加热圈应使用陶瓷绝缘加热圈Further criteria for the injection unit is the temperature range of material to be used.Some high technology plastics(e.g.PEEK,PEI,LCP,etc)requires a temperature release of the machine up to 450(500)deg.C.Therefore the plasticizing cylinder has to be equipped with ceramic isolated heaterbands.选择注射单元规格的准则Criteria to Select the Injection UniCriteria to Select the Injection Unitsts20.选择注射单元规格的准则Criteria to Select the Injection UniCriteria to Select the Injection Unitsts -注射控制的方式-conceptions of injection regulation-标准方式：注射闭环控制basic configurationinjection regulation 扩展方式（可选件）：螺杆精确定位 extension stage(option)position regulation screw(PRS)21.注射闭环控制的原理Function principle of the injection regulation选择注射单元规格的准则Criteria to Select the Injection UniCriteria to Select the Injection Unitsts 螺杆精确定位 Position regulated screw22.螺杆精确定位的原理Function principle of the position regulated screw选择注射单元规格的准则Criteria to Select the Injection UniCriteria to Select the Injection Unitsts Injection control 注射控制Position regulated screw 螺杆精确定位23.螺杆精确定位效果举例 微型齿轮Example for the efficiency of the position regulated screw with a micro gear wheel 选择注射单元规格的准则Criteria to Select the Injection UniCriteria to Select the Injection Unitsts24.0,005 ccm0,025 ccm0,010 ccm0,040 ccm0035 ccm0,015 ccm效果举例（改变进料量）Example for the efficiency(variation dosage volume):选择注射单元规格的准则Criteria to Select the Injection UniCriteria to Select the Injection Unitsts25.注射闭环控制与螺杆精确定位比较Injection regulation in comparison with Injection regulation in comparison with position regulationposition regulationInjection speed curvepressure curveinjection speedscrew positionpressure curve position regulationpressure curve injection regulation26.SELOGICASELOGICA 控制器清楚显示动作顺序Transparent display of the sequence27.使用曲线图像优化工艺过程，发现错误Process optimization through graphic display and identification of errors 设定压力过低机器不能调节注射速度Nominal injection pressuresetting too low machine no able to regulate injection speed设定压力过高如果产品没有顶出或浇口冷却，有损坏模具的危险Nominal injection pressuresetting too high risk of damage mold if one partsticking inside the mold,or in caseof cold slugsSELOGICASELOGICA控制器28.使用曲线图像优化工艺过程，发现错误Process optimization through graphic display andidentification of errors此例中转压切换点 1 太早。此时模腔只有 60 70%满而不是95%满。以后是由保压充模工艺不稳定，产品质量不稳定In this example,the set point(1)of switch over into holding pressure is too early.With injection the part is only 60-70%full,instead of 95%.The rest will be filled by holding pressure.unstable process and unstable part quality 1SELOGICASELOGICA控制器29.使用曲线图像优化工艺过程，发现错误Process optimization through graphic display andidentification of errorsSELOGICASELOGICA控制器正确的设定Good settings30.SELOGICASELOGICA控制器模具内压精密注塑的另一方面是模具内压。保压时模具内压的变化对产品质量，如尺寸，重量，内应力，有直接影响。Mold cavity pressureAs a further aspect for precision molding is the mold cavity pressure.The progress of the pressure during holding has a direct influence of the part quality e.g.dimensions,part weight and stresses.1 injection start2 melt reach sensor3 cavity is volumetric filled(95-98%)3 4 compression phase4 highest cavity pressure5 gate seal off point 6 pressure releasedMold cavity pressureTime 1-注射开始2 熔体达到感应器3 模腔充满（95-98%）3 4 压缩段4 高压段5 浇口凝固点6 压力解除31.模腔压力 Mold cavity pressure两种压力曲线类型 two different pressure curvesSELOGICASELOGICA控制器无规型塑料amorphous plastics e.g.PS,ABS,PC,PMMA,PEI,PSU半结晶型塑料partially crystalline plastics e.g.PP,POM,PA,PEEK,PBT,PETCavity pressureCavity pressureTimeTime32.内压测量原理压电式系统，Kistler,Priamus,应变片式系统，Dynisco,Cavity pressure measuring principles Piezo-electric system Kistler,Priamus,DMS(Strain Gauge system)Dynisco直接测量 direct measurement 间接测量 indirect measurementSELOGICASELOGICA控制器1 mold cavity2 transmission element3 force transducer (measuring tongue)1 mold cavity2 pressure transducer33.内压测量 Cavity pressure measuring直接测量感应器安装位置 Sensor locations for direct measuring SELOGICASELOGICA控制器34.机器控制器可显示模具内压力cavity pressure in machine displaySELOGICASELOGICA控制器35.切换到保压的不同方法Switch over possibilities into holding pressure 按照模腔内压 via cavity pressure 使用温度感应器（安装在模腔内最后填充点）via temperature sensor(placed at flow path end in the mold)SELOGICASELOGICA控制器36.图像显示过程参数graphical display of the process parameters根据实际测量值监视产品质量quality monitoring based on actual parameter valuespeak value monitoringmonitoring windowpeak value Integral calculationSELOGICASELOGICA 控制器37.工艺参数和图像的监视Monitoring of process parameters and graphical displaySELOGICASELOGICA 控制器38.曲线监视 curve monitoringSELOGICASELOGICA 控制器39.产品质量记录 Quality documentationSELOGICASELOGICA 控制器40.用图像记录工艺参数测量值Graphic display of process actual valuesSELOGICASELOGICA 控制器41.模具设计方面Aspect of Mould Design Aspect of Mould Design 流道设计(特别是小产品)用冷流道流道长度取决于模具刚性和复杂程度必须选择足够的横截面积用热流道加热的流道增加材料滞留时间热流道需要足够的空间延长的喷嘴需要注意事项与热流道相同需要附加的加热圈Sprue Design(especially small parts)Sprue Design(especially small parts)Via cold-runner systemVia cold-runner systemSprue length is the result from mold stability and mold complexity The sprue section must be selected big enough Via hot-runner systemsVia hot-runner systemsHeated sprue channel increases the dwell timeProblems with spaceVia extended nozzle tipVia extended nozzle tipSame problem like with hot-runner systemsAdditional heaterband necessary!42.模具设计方面Aspect of Mould DesignAspect of Mould Design排气 Venting为避免飞边，排气间隙应不大于 0.02 0.03 mmTo prevent flash formation gap max.0.02-0.03 mm43.模具设计方面Aspect of Mould DesignAspect of Mould Design研磨方向互相交叉 排气容易,90%空气从分型面排出 Easy venting.approx.90%of air escapes over parting line 空气可从整个模腔接触面排出 The air can escape over the complete cavity area 成本低 Low costs1 分型面光洁度 0.007 0.009 mm1 parting line roughness 0.007 0.009 mm2 模芯光洁度 0.003 0.004 mm2 cavity insert roughness 0.003 0.004 mm 44.排气槽 Venting channel 在流道终点或熔体相交处 At the end of the flow path or where the melt fronts meets together 可随时开出 Afterwards creation possible 会积累脏物，需定时清理 Problems of dirt deposition thus often cleaning 模具设计方面Aspect of Mould DesignAspect of Mould Design1 venting channel(0.01 0.02 mm)45.溢流槽排气 Overspill venting 在流道终点或熔体相交处 At the end of the flow path or where the melt fronts meet together 排气效果好 Good venting 防止熔合线 Prevention from weld lines in that area 需切掉余料 Afterwards removal of overspill channel模具设计方面Aspect of Mould DesignAspect of Mould Design1 meet point with enclosed air 2 injection point 3 overspill channel(venting through meltfront meet point shifting into overspill channel46.模具设计方面Aspect of Mould DesignAspect of Mould Design对中系统 centering system对中系统 centering system47.模具设计方面Aspect of Mould DesignAspect of Mould Design对中系统 centering system48.模温控制Mold Temperature ControlMold Temperature Control模具温度直接影响产品质量的稳定性The mold temperature has a direct influence of the reproducible quality of the molded parts.49.温度感应器安装于模具内利于优化控制 模温机与机器通讯 如模温机故障，机器停机 整个系统内存水量少（3 升），传热好，调节稳定 模腔温度公差 1 流量监视 Optimal mold temperature control via external sensor placed in the mold Communication from temperature control unit to machine in case of malfunction production stop!Best temperature regulation through reduction of heat transfer medium to approx.3 liter in the complete unit system(no tank).Cavity temperature tolerance 1 deg.C.Flow controlMold Temperature ControlMold Temperature ControlExternal sensorControl connectionsMachine controlMouldTemperature control unit50.冷却道布置方式 Connection Form of Cooling Channels平行连接压力降小温度差小不易检查通道断路Parallel connectionSmall pressure dropSmall temperature differenceDifficult monitoring of blockage串联连接 所有通道流量相同 断路可能性小 工作可靠性高 检查容易（温度，流量）Serial connection same conditions for all channels small risk of blockage high process security simple monitoring(flow rate,mould temperature)simple connections模具温度控制Mold Temperature ControlMold Temperature Control51.阿博格机械贸易(上海）有限公司沪青平公路58号201105 上海Tel.:021 6268 2211Fax:[phone] ARBURG(Shanghai)Co.,Ltd.No.58 Huqinping Highway201105 ShanghaiTel.:021 6268 2211Fax:[phone]