1、精密注塑技术 Aspects for Precise Injection Molding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 Unit SELOGICA 控制器 SELOGICA Controller模具设计Mold Design 模具温度控制Mold Temperature Control2 Copyright by ARBURG / Nov. 2006精密
2、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) Stable quality, reproducibility 3
3、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 platen long and precise guiding of the movable platen adjustabl
4、e parallelism up to 50 to. Machines 0.05 mm high rigidity4 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 are: Much better venting of the cavitie
5、s 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 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 30% 加入产品投影面积How to calculate the clamping
6、force ?If the mold contains sliders! You have to add 30% of the projected slider area to the projected area of molded part.6 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 pictures below. For standard partsfor thin wall
7、ed parts with long flow paths7 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 cavities8 Copyright by ARBURG / Nov. 2006选择注射单元规格的准则Criteria to Select the Injection Un
8、itShot weightCycle timeMaterialInjection pressure9 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 Modularity10 Copyright by ARBURG / Nov. 2006选择注射单元规格的准则Criteria to Select the Injection Unit注射单元的欧
9、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 calculat
10、emax. 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 Copyright by ARBURG / Nov. 2006选择注射单元规格的准则Criteria to Select the Injec
11、tion 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 Copyright by ARBURG / Nov. 2006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 opt. working range10 20 % bzw. 80 90 %可接受的范 conditional suited 90%不推荐的范 not recommend
12、ed选择注射单元规格的准则Criteria to Select the Injection Unit13 Copyright by ARBURG / Nov. 2006选择注射单元规格的准则Criteria to Select the Injection 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 th
13、e injected part (incl. sprue) due to shrinkage during solidifying and due to the compression of the melt during injection.Injection unit100100250250Screw diameter20 mm25 mm30 mm40 mmMax. injection volume31 cm349 cm3106 cm3188 cm3Percentage of capacity 95%60%28%16%14 Copyright by ARBURG / Nov. 2006选择
14、注射单元规格的准则Criteria 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 unit100100250250Screw diameter20 mm25 mm30 mm40 mmMolded part weight26 g41 g89 g158gPercentage of capacity 100%
15、64%30%17%15 Copyright by ARBURG / Nov. 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
16、e.g. PE, PP, PS : min. 30 s (better 40 s)e.g. PA, POM, PBT : min. 60 s (better 75 s)16 Copyright by ARBURG / Nov. 2006选择注射单元规格的准则Criteria 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 se
17、c.Injection unit100100250250Screw diameter20 mm25 mm30 mm40 mmScrew channel volume60 cm385 cm3185 cm3265 cm3Cycle time 15s / dwell time25 sec.35 sec.75 sec.109 sec.Cycle time 25s / dwell time41 sec.58 sec.126 sec.181 sec.Remarks: an extended screw and cylinder can increase the dwell time!17 Copyrigh
18、t by ARBURG / Nov. 2006选择注射单元规格的准则Criteria to Select the Injection UnitSelection criteria material throughput Example: Connector (PA6), 8 cavities, 26.5 g shot weightInjection unit100100100250250Screw diameter20 mm25 mm30 mm30 mm40 mmMax. Throughput/h (PA-GF30)3.5 kg/h5 kg/h6 kg/h11 kg/h15,5 kg/hThr
19、oughput (cycle time 15s) 6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/hThroughput (cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/hMax. Throughput/h (PS)5.5 kg/h8 kg/h9.5 kg/h17 kg/h24.5 kg/hThroughput (cycle time 15s) 6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/hThroughput (cycle time 25s)3.8 kg/h3.8 k
20、g/h3.8 kg/h3.8 kg/h3.8 kg/h18 Copyright by ARBURG / Nov. 2006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 Injection Unit19 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
21、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
22、with ceramic isolated heaterbands.选择注射单元规格的准则Criteria to Select the Injection Units20 Copyright 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 (
23、option) position regulation screw (PRS)21 Copyright by ARBURG / Nov. 2006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 Units 螺杆精确定位 Position regulated screw22 Copyright by ARBURG / Nov. 2006螺杆精确定位的原理Function principle of the position regulated scr
24、ew选择注射单元规格的准则Criteria to Select the Injection Units Injection control 注射控制 Position regulated screw 螺杆精确定位23 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 Units24 Copyright
25、by ARBURG / Nov. 20060,005 ccm0,025 ccm0,010 ccm0,040 ccm0,035 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 Units25 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 regulationInj
26、ection speed curvepressure curveinjection speedscrew positionpressure curve position regulationpressure curve injection regulation26 Copyright by ARBURG / Nov. 2006SELOGICA 控制器清楚显示动作顺序Transparent display of the sequence27 Copyright by ARBURG / Nov. 2006使用曲线图像优化工艺过程，发现错误Process optimization through g
27、raphic 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 slugsSELO
28、GICA控制器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 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 i
29、s only 60-70% full, instead of 95%. The rest will be filled by holding pressure. unstable process and unstable part quality 1SELOGICA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 andidentification of errorsSELOGICA控制器正确的设定Good settings30 Copyright
30、 by ARBURG / Nov. 2006SELOGICA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 stre
31、sses. 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 Copyright by ARBURG / Nov. 2006模腔压力 Mold cavity
32、pressure两种压力曲线类型 two different pressure curvesSELOGICA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 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,
33、 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 measurementSELOGICA控制器1 mold cavity2 transmission element3 force transducer (measuring tongue)1 mold cavity2 pressure transducer33 Copyright by ARBURG
34、/ Nov. 2006内压测量 Cavity pressure measuring直接测量感应器安装位置 Sensor locations for direct measuring SELOGICA控制器34 Copyright by ARBURG / Nov. 2006机器控制器可显示模具内压力cavity pressure in machine displaySELOGICA控制器35 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 cav
35、ity 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)SELOGICA控制器36 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 valuespeak value monitoringmonitoring windowpea
36、k value Integral calculationSELOGICA 控制器37 Copyright by ARBURG / Nov. 2006工艺参数和图像的监视Monitoring of process parameters and graphical displaySELOGICA 控制器38 Copyright by ARBURG / Nov. 2006曲线监视 curve monitoringSELOGICA 控制器39 Copyright by ARBURG / Nov. 2006产品质量记录 Quality documentationSELOGICA 控制器40 Copyri
37、ght by ARBURG / Nov. 2006用图像记录工艺参数测量值Graphic display of process actual valuesSELOGICA 控制器41 Copyright 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
38、 system Sprue length is the result from mold stability and mold complexity The sprue section 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 ne
39、cessary!42 Copyright by ARBURG / Nov. 2006模具设计方面Aspect 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 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 l
40、ine 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 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 o
41、r 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 Design1 venting channel (0.01 0.02 mm) 45 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 wher
42、e 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 Design1 meet point with enclosed air 2 injection point 3 overspill channel (venting through meltfront meet point shifting into overspill
43、 channel46 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 system47 Copyright by ARBURG / Nov. 2006模具设计方面Aspect of Mould Design对中系统 centering system48 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
44、direct influence of the reproducible quality of the molded parts.49 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 mac
45、hine 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 ControlExternal sensorControl connectionsMachine controlMou
46、ldTemperature control unit50 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 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 al
47、l channels small risk of blockage high process security simple monitoring (flow rate, mould temperature) simple connections模具温度控制Mold Temperature Control51 Copyright by ARBURG / Nov. 2006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: 021 6268 ARBURG (Shanghai) Co., Ltd.No. 58 Huqinping Highway201105 ShanghaiTel.: 021 6268 2211Fax: 021 6268
