1、精密注塑技术 Aspects for Precise Injection Molding,2, Copyright by ARBURG / Nov. 2006,内容提要 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 UnitSELOGICA 控制器SELOGICA Controller模具设计 Mold Design模具温度控制 Mold Temperature Control,3,
2、Copyright by ARBURG / Nov. 2006,精密注塑的定义 Definition Precise 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 weight Adaptation of machine performance to the parts Flexible machine configuration (many molds suitable for one machine) Sta
3、ble quality, reproducibility,4, Copyright by ARBURG / Nov. 2006,锁模系统 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 platenlong and precise guidin
4、g of the movable platenadjustable parallelism up to 50 to. Machines 0.05 mmhigh rigidity,5, Copyright by ARBURG / Nov. 2006,锁模力 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
5、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 energy,6, Copyright by ARBURG / Nov. 2006,锁模力 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 3
6、0% 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.,7, Copyright by ARBURG / Nov. 2006,锁模力 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 p
7、ictures below.,For standard parts for thin walled parts with long flow paths,8, Copyright by ARBURG / Nov. 2006,锁模力 Clamping Force,举例 Example: 接插件 Connector 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 cavities,9, Copyright by ARBURG
8、/ Nov. 2006,选择注射单元规格的准则 Criteria to Select the Injection Unit,10, Copyright by ARBURG / Nov. 2006,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 Unit,模块化 Modularity,11, Copyright by ARBURG / Nov. 2006,选择注射单元规格的准则 Criteria to Sel
9、ect 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 250,The size of the injection unit is according to EUROMAP and indicates the working performance of the injection unit. The
10、working performance is calculatemax. spec. injection pressure x max. stroke volume / 1000Example: According to the technical data of 320 C 600-250 Max. Injection pressure (screw diameter 35mm) = 1820 bar Max. Stroke volume = 144 cm31820 bar x 144 cm3 / 1000 250,12, Copyright by ARBURG / Nov. 2006,选择
11、注射单元规格的准则 Criteria 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 pressure,13, Copyright by ARBURG / Nov. 2006,选择注射量的准则 Selection criteria shot volume,选择注射单元规格的准则 Criteria to Select the Injection Unit,14, Copyright by ARBURG /
12、 Nov. 2006,选择注射单元规格的准则 Criteria to Select the Injection Unit,Example: 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 d
13、ue to the compression of the melt during injection.,15, Copyright by ARBURG / Nov. 2006,选择注射单元规格的准则 Criteria to Select the Injection Unit,Example: Connector (PA6), 8 cavities, 26.5 g shot weight 2nd example, calculation with shot weightResults according the list below:,16, Copyright by ARBURG / Nov.
14、 2006,选择注射单元规格的准则 Criteria 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 (bett
15、er 40 s) e.g. PA, POM, PBT : min. 60 s (better 75 s),17, Copyright by ARBURG / Nov. 2006,选择注射单元规格的准则 Criteria to Select the Injection Unit,Example: 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.,Remarks: an extended scre
16、w and cylinder can increase the dwell time!,18, Copyright by ARBURG / Nov. 2006,选择注射单元规格的准则 Criteria to Select the Injection Unit,Selection criteria material throughput Example: Connector (PA6), 8 cavities, 26.5 g shot weight,19, Copyright by ARBURG / Nov. 2006,错误的选择会造成 Mistakes in selection causes
17、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 Injection Unit,20, Copyright by ARBURG / Nov. 2006,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 ran
18、ge 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 Units,21, C
19、opyright by ARBURG / Nov. 2006,选择注射单元规格的准则 Criteria to Select the Injection Units,- 注射控制的方式 - -conceptions of injection regulation-标准方式：注射闭环控制 basic configuration injection regulation 扩展方式（可选件）：螺杆精确定位extension stage (option) position regulation screw (PRS),22, Copyright by ARBURG / Nov. 2006,注射闭环控制的
20、原理 Function principle of the injection regulation,选择注射单元规格的准则 Criteria to Select the Injection Units,螺杆精确定位 Position regulated screw,23, Copyright by ARBURG / Nov. 2006,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 Units,Injection control注射
21、控制,Position regulated screw螺杆精确定位,24, Copyright by ARBURG / Nov. 2006,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 Units,25, Copyright by ARBURG / Nov. 2006,效果举例 （改变进料量） Example for the efficiency (var
22、iation dosage volume):,选择注射单元规格的准则 Criteria to Select the Injection Units,26, Copyright by ARBURG / Nov. 2006,注射闭环控制与螺杆精确定位比较 Injection regulation in comparison with position regulation,Injection speed curve,pressure curve,injection speed,screw position,27, Copyright by ARBURG / Nov. 2006,SELOGICA 控
23、制器,清楚显示动作顺序 Transparent display of the sequence,28, Copyright by ARBURG / Nov. 2006,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 pressure setting 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
24、， 有损坏模具的危险 Nominal injection pressure setting too high risk of damage mold if one part sticking inside the mold, or in case of cold slugs,SELOGICA控制器,29, Copyright by ARBURG / Nov. 2006,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,此例中转压切换点 1 太早。此时模腔只有 6
25、0 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,SELOGICA控制器,30, Copyright b
26、y ARBURG / Nov. 2006,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,SELOGICA控制器,正确的设定 Good settings,31, Copyright by ARBURG / Nov. 2006,SELOGICA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 pressure As a further aspect for precisio
27、n 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.,32, Copyright by ARBURG / Nov. 2006,模腔压力 Mold cavity pressure 两种压力曲线类型 two different pressure curves,SELOGICA控制器,无规型塑料 amorphous pl
28、astics e.g. PS, ABS, PC, PMMA, PEI, PSU,半结晶型塑料 partially crystalline plastics e.g. PP, POM, PA, PEEK, PBT, PET,Cavity pressure,Cavity pressure,Time,Time,33, Copyright by ARBURG / Nov. 2006,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 Kistl
29、er, Priamus, DMS (Strain Gauge system) Dynisco直接测量 direct measurement 间接测量 indirect measurement,SELOGICA控制器,1 mold cavity 2 transmission element 3 force transducer (measuring tongue),1 mold cavity 2 pressure transducer,34, Copyright by ARBURG / Nov. 2006,内压测量 Cavity pressure measuring直接测量感应器安装位置 Sen
30、sor locations for direct measuring,SELOGICA控制器,35, Copyright by ARBURG / Nov. 2006,机器控制器可显示模具内压力 cavity pressure in machine display,SELOGICA控制器,36, Copyright by ARBURG / Nov. 2006,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
31、sensor (placed at flow path end in the mold),SELOGICA控制器,37, Copyright by ARBURG / Nov. 2006,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 values,SELOGICA 控制器,38, Copyright by ARBURG / Nov. 2006,工艺参数和图像的监视 Monitoring of process parame
32、ters and graphical display,SELOGICA 控制器,39, Copyright by ARBURG / Nov. 2006,曲线监视 curve monitoring,SELOGICA 控制器,40, Copyright by ARBURG / Nov. 2006,产品质量记录 Quality documentation,SELOGICA 控制器,41, Copyright by ARBURG / Nov. 2006,用图像记录工艺参数测量值 Graphic display of process actual values,SELOGICA 控制器,42, Copy
33、right by ARBURG / Nov. 2006,模具设计方面 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)Via cold-runner system Sprue length is the result from mold stability and mold complexity The sprue sec
34、tion must be selected big enough Via hot-runner systems Heated sprue channel increases the dwell time Problems with space Via extended nozzle tip Same problem like with hot-runner systems Additional heaterband necessary!,43, Copyright by ARBURG / Nov. 2006,模具设计方面 Aspect of Mould Design,排气 Venting,44
35、, Copyright by ARBURG / Nov. 2006,模具设计方面 Aspect 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 costs,1 分型面光洁度 0.007 0.009 mm 1 parting line roughness 0.007 0.009 mm 2 模芯光洁度 0.003 0
36、.004 mm 2 cavity insert roughness 0.003 0.004 mm,45, Copyright by ARBURG / Nov. 2006,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 De
37、sign,1 venting channel (0.01 0.02 mm),46, Copyright by ARBURG / Nov. 2006,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
38、Mould Design,1 meet point with enclosed air 2 injection point 3 overspill channel (venting through meltfront meet point shifting into overspill channel,47, Copyright by ARBURG / Nov. 2006,模具设计方面 Aspect of Mould Design,对中系统 centering system,对中系统 centering system,48, Copyright by ARBURG / Nov. 2006,模具
39、设计方面 Aspect of Mould Design,对中系统 centering system,49, Copyright by ARBURG / Nov. 2006,模温控制 Mold 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.,50, Copyright by ARBURG / Nov. 2006,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
40、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 moldCommunication 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 com
41、plete unit system (no tank).Cavity temperature tolerance 1 deg. C.Flow control,Mold Temperature Control,51, Copyright by ARBURG / Nov. 2006,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 connection Small pressure drop Small temperature difference Difficult 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 connectionsame conditions for all channelssmall risk of blockagehigh process securitysimple monitoring (flow rate, mould temperature)simple connections,模具温度控制 Mold Temperature Control,
