注塑成型流程及常用模具结构

Injection Molding Process (注塑成型的工藝)
Loading of pellets through the Hopper (在料桶裝入膠珠)
Injection Molding Process (注塑成型的工藝)
Drying the Pellets(膠珠的烘干)
Engineering Thermoplastic Pellets Absorb Moisture During Manufacturing, Transportation, and Storage. 工程熱塑性膠珠在制造,運輸,儲存的過程中會吸收濕氣
• 加熱圈的熱量通過桶傳入到塑料里
Injection Molding Process (注塑成型的工藝) Injection Flow (注塑流程)
Injection Molding Process (注塑成型的工藝) Injection Flow (注塑流程)
Injection Molding Process (注塑成型的工藝) Injection Flow (注塑流程)
Screw Drives
Characteristics(特征) Efficiency
(效率) Screw Safety
Hydraulic(油機) Low 60-75% 低 Relief Valve
(螺杆保險裝置)
(安全)
Size
Small, Light, Good
Shot Weight Control
• Conversion of Mechanical Energy by Shearing the Plastic
• (注塑機螺杆在旋轉過程中和塑 料剪切產生的能量)
• Conduction of Heat From the Heater Bands Through the Barrel and Into The Resin
P r
Filling
Packing Cooling Ejection
e
s
s
u
r
e
Time
Injection Molding Process (注塑成型的工藝)
Important Process Variables
(重要的工藝變量)
Melt Temperature(塑化溫度) Mold Temperature(模具溫度) Temperature Profiles(溫度曲線圖) Resident Time(占用時間) Injection Speed(注塑速度) Injection Pressure(注塑壓力) Pack Pressure(保壓壓力) Clamp Tonnage(鎖模力) Cushion(緩沖量)
Pellets Not Dried May:(不需要烘干的膠珠:)
• Produce Substandard Parts in Terms of Surface Appearance and Property Performance
• (生產的產品外觀要求在條款之下和有特殊性能的)
• Cause Series Inconsistency During Processing • 烘干工藝會導致一系列變化的
Tooling Costs are High(高的模具費用) High Machinery and Auxiliary Costs (高的機器和輔助設備的費用) High Pressure Process(高壓工藝) Limited Large Part Capability(能生產的產品,大是有限的)
Injection Molding Parts(注塑成型的產品)
Detailed Parts Including Ribs, Holes, and Bosses (詳細的部件包括加強筋,孔和突起)
Injection Molding Parts (注塑成型的產品)
Smபைடு நூலகம்ll Parts with Tight Tolerances (較小公差的小尺寸產品)
(大地的生產能力)
(能維持很小地公差)
Low Labor Cost(低的人工)
Molded-in Inserts Available
Easily Automated(容易實行自動化操作) (工模內可以利用鑲件)
Minimum Secondary Operations
Glass, Carbon, etc. Fillers
(少的二次加工)
Complex Part Capability(有生產復雜產品的能力)
Permits Very Small Parts
Good Decoration Possible(優良的裝鈽能力)
(允許生產很小的產品)
Injection Molding Disadvantages
(注塑成型的缺點)
(尺寸)
(小量,輕便,很容易
控制射出量)
Torque
Highly Adjustable
(扭矩力)
(非常好調的)
Speed
Step less Control
(速度)
控制步驟少
Melt Quality(塑化質量) Best(很好)
Electrical(電機) High 95% 高 Overload Protection Difficult (超負載保護困難) Heavy, Poorer Shot Weight Control (重的,不容易控制
Injection Molding Process (注塑成型的工藝) Injection Flow (注塑流程)
Injection Molding Process (注塑成型的工藝) Injection Flow (注塑流程)
Injection Molding Process (注塑成型的工藝)
The Screw Barrel (螺杆桶)
•Melting and Homogenizing the Resin •(塑化和攪均勻塑料) •Injection of the Plastic Into the Mold •(將塑料射入工模內)
Injection Molding Equipment (注塑成型的設備)
Injection Molding (注塑成型)
The Equipment (設備)
Injection Molding Equipment (注塑成型的設備)
Clamp Unit (鎖模部分)
Screw Barrel (螺杆桶)
Injection Unit (注塑部分)
Injection Molding Equipment (注塑成型的設備)
The Barrel Unit(料筒部分) (Plunger Machine)活塞式注塑機
Heating Coils(加熱圈)
Plastic Pellets(膠珠)
Pellet Input Stopped Plunger（活塞） （膠珠停止進入)
Torpedo (魚雷梭)
To Mold
Passing Through Heated Channels Around the Torpedo, The Pellets Melt 膠珠在通過魚雷梭周圍的加熱通道時被塑化
2
Knock-out pins eject the part
3
from the mold.
(頂針將產品從工模中頂出)
Injection Molding Process (注塑成型的工藝)
Simplified Pressure History - Injection Molding
簡化的注塑成型壓力歷史記錄
Part Cooling and Solidification (產品的冷卻和凝固)
Hot Melt 受熱塑化
Cooled Mold(冷的工模)
Solid Part 堅實的產品
Injection Molding Process (注塑成型的工藝) 1 Part Ejection(產品被頂出)
2 plate mold example(盤子模塑實例)
Injection Molding (注塑成型)
The Process (工藝)
Injection Molding Process(注塑成型工藝)
Injection Molding Steps:(注塑成型的步驟:)
•Drying the Pellets(膠珠的烘干)
•Loading Into Molding Machine(將膠珠 裝入注塑機內)
•Heating and Shearing Material Into a Melt •(加熱和剪切原料至其塑化) •Injecting the Melt Into the Mold Cavity(將塑化的膠料射入模腔內) •Part Cooling, Solidification(產品冷卻,凝固) •Ejecting the Finished Part From the Mold(將完成的產品從工模內頂出)
Injection Molding Process (注塑成型的工藝)
Model of Amorphous Polymers
(無定形聚合物的成型)
Locked
Entanglements (相互糾纏)
Stiff Flow(流動困難)
TG
Easier Flow(流動容易)
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Injection Molding Process (注塑成型的工藝)
Drying Removes Moisture (烘干除濕氣)
H2O
H2O
Moisture
Migrates
out of Pellet
When Exposed to Dry Air.
H2O
(當暴露在干燥地空氣中時濕氣就會從膠珠中移除)
Injection Molding Parts (注塑成型的產品)
Larger Parts: Car Fender (長的產品:汽車的擋泥板)
Injection Molding (注塑成型)
Material(原料)
Tooling(工模)
GOOD PART (好的產品)
Processing(工藝)
The Injection Unit (注塑部分)
•Provides Injection and Packing Pressure •提供注塑壓力和保壓壓力 •Provides Torque to Turn the Screw •螺杆的旋轉提供扭矩力
Injection Molding Equipment (注塑成型的設備)
Injection Molding(注塑成型)
Injection Molding Introduction
(注塑機的介紹)
Injection molding makes possible mass production of intricate, high performance, tight tolerance parts with very little secondary labor and minimal waste. (注塑機能在占次要地位的人的工作下大批量的生產復雜的,高性能的,公差 小的產品,而且壞品少)
Design(設計)
Injection Molding Advantages(注塑機的優勢)
High Production Rates(高的生產效率) Minimal Scrap Loss(很小的壞品損失)
Large Volume Production Possible Tight Tolerances Can Be Maintained
射出量) Varies with Speed (隨著速度的變化而變化) Limited Number 少數 Acceptable(可接受)
Injection Molding Equipment (注塑成型的設備)
Hydraulic Injection Cylinders (油機的注塑料筒)
Injection Molding Equipment (注塑成型的設備)
(提高聚合物的溫度)
Adding Heat Increases Space Between Molecular Chains(升高溫度增大分子鏈之間的空間)
Injection Molding Process (注塑成型的工藝) Heating and Melting the Material
Heater Coils on the Screw Barrel (在螺杆桶上的加熱圈)