塑胶产品与模具设计.pdf

塑膠產品與模具設計塑膠產品與模具設計塑膠產品與模具設計塑膠產品與模具設計 plastic part and mold designplastic part and mold designplastic part and mold designplastic part and mold design 澆注系統設計澆注系統設計澆注系統設計澆注系統設計 filling system designfilling system designfilling system designfilling system design 模具設計的優先順序模具設計的優先順序模具設計的優先順序模具設計的優先順序 priorities of mold designpriorities of mold designpriorities of mold designpriorities of mold design 澆注系統設計 (filling system design) 排氣系統設計 (venting system design) 冷卻系統設計 (cooling system design) 脫模系統設計 (ejecting system design) 澆注系統設計的優先順序澆注系統設計的優先順序澆注系統設計的優先順序澆注系統設計的優先順序 priorities of filling system designpriorities of filling system designpriorities of filling system designpriorities of filling system design 產品設計 (part design) 型腔設計 (cavity design) 澆口設計 (gate design) 流道設計 (runner design) 豎澆道設計 (sprue design) 噴嘴設計 (nozzle design) 豎澆道 sprue 主流道 main runner 成品 part 澆口 gate 冷料井 cold slug well 支流道 branch runner 典型的澆注系統典型的澆注系統典型的澆注系統典型的澆注系統 typical filling systemtypical filling systemtypical filling systemtypical filling system 壁厚不均是注塑成形中最大的麻煩製造者。 這對薄壁零 件尤然。 這些麻煩包括了遲滯現象、短射、凹陷、發赤 、噴流、翹曲及長冷卻時間等；目前都可用cae以直接 或間接的方式預測。 non-uniform wall thickness is the biggest trouble maker in plastic injection molding. this is especially true to thin-wall part. the troubles, including hesitation, short shot, sink mark, blush, jetting, warpage and long cooling time etc., can be predicted, directly or indirectly, by using cae. 壁厚不均壁厚不均壁厚不均壁厚不均 non-uniform wall thicknessnon-uniform wall thicknessnon-uniform wall thicknessnon-uniform wall thickness 壁厚設計壁厚設計壁厚設計壁厚設計 wall thickness designwall thickness designwall thickness designwall thickness design 差 poor 較好 better 最好 best 掏空設計掏空設計掏空設計掏空設計( ( ( (1 1 1 1) ) ) ) coring out design (1)coring out design (1)coring out design (1)coring out design (1) 改進設計 improved原設計 original 差 poor 改進 improved 掏空設計掏空設計掏空設計掏空設計( ( ( (2 2 2 2) ) ) ) coring out design (2)coring out design (2)coring out design (2)coring out design (2) 氣泡或氣泡或氣泡或氣泡或/ / / /和凹陷的形成和凹陷的形成和凹陷的形成和凹陷的形成 void or/and sink mark formingvoid or/and sink mark formingvoid or/and sink mark formingvoid or/and sink mark forming 氣泡氣泡氣泡氣泡 ( void )凹陷凹陷凹陷凹陷 ( sink mark ) 肋厚和內圓角半徑的影響肋厚和內圓角半徑的影響肋厚和內圓角半徑的影響肋厚和內圓角半徑的影響 the effect of rib thickness the effect of rib thickness the effect of rib thickness the effect of rib thickness showing a dramatic cooling time reduction of 94% (15/16) . 平板和肋板的比較平板和肋板的比較平板和肋板的比較平板和肋板的比較 comparison between plain filling pattern, weld lines and air traps are changed. 多澆口設計多澆口設計多澆口設計多澆口設計 multi-gate designmulti-gate designmulti-gate designmulti-gate design 閥式澆口閥式澆口閥式澆口閥式澆口 valve gatevalve gatevalve gatevalve gate 矩形邊緣澆口設計矩形邊緣澆口設計矩形邊緣澆口設計矩形邊緣澆口設計 rectangular edge gate designrectangular edge gate designrectangular edge gate designrectangular edge gate design l = 0.5 0.75 mm w = 澆口寬度 ( mm ) gate width in mm a = 型腔表面積 ( mm ) surface area of cavity in mm n = 材料常數 material constant 0.6 for pe, ps 0.7 for pom, pc, pp 0.8 for ca, pmma, pa 0.9 for pvc 2 2 2 2 2 2 2 2 h = n th = n th = n th = n t h = 澆口厚度( gate thick. in mm ) t = 零件壁厚( wall thick. in mm ) wwww t t t tl l l l h h h h 30 an w = 扇形澆口設計扇形澆口設計扇形澆口設計扇形澆口設計 fan gate designfan gate designfan gate designfan gate design l= 1.3mm w= w= 澆口寬度 mm gate width in mm a= 型腔表面積 mm surface area of cavity in mm n= 材料常數 material constant 0.6 for pe, ps 0.7 for pom, pc, pp 0.8 for ca, pmma, pa 0.9 for pvc 澆口厚度 gate thick. in mm t= 零件壁厚 wall thick. in mm 2 2 30 n h1 = n t h2 = wh1/d 重疊式澆口設計重疊式澆口設計重疊式澆口設計重疊式澆口設計 overlap gate designoverlap gate designoverlap gate designoverlap gate design w= w= 澆口寬度 mm gate width in mm a= 型腔表面積 mm surface area of cavity in mm n= 材料常數 material constant 0.6 for pe, ps 0.7 for pom, pc, pp 0.8 for ca, pmma, pa 0.9 for pvc 澆口厚度 gate thick. in mm = nt 澆口長度 land length in mm t= 零件壁厚 wall thick. in mm 2 2 30 n l1 = 0.50.75l2 = h+( w/2 ) 凸耳澆口設計凸耳澆口設計凸耳澆口設計凸耳澆口設計 tab gate designtab gate designtab gate designtab gate design l= 0.50.75mm w= w= 澆口寬度 mm gate width in mm a= 型腔表面積 mm surface area of cavity in mm n= 材料常數 material constant 0.6 for pe, ps 0.7 for pom, pc, pp 0.8 for ca, pmma, pa 0.9 for pvc 澆口厚度 gate thick. in mm t= 零件壁厚 wall thick. in mm 2 2 30 n h1 = n th2 = 0.9 t l = 0.5 0.75 mm d = 澆口直徑( mm ) gate diameter in mm t = 零件壁厚( mm ) wall thick. in mm a = 型腔表面積 ( mm ) surface area of cavity in mm n = 材料常數 material constant 0.6 for pe, ps 0.7 for pom, pc, pp 0.8 for ca, pmma, pa 0.9 for pvc 針點澆口設計針點澆口設計針點澆口設計針點澆口設計 pin gate designpin gate designpin gate designpin gate design d l t d0.206n ta 4 = 潛伏式澆口設計潛伏式澆口設計潛伏式澆口設計潛伏式澆口設計 subgatesubgatesubgatesubgate design design design design w= w= 澆口寬度 mm gate width in mm a= 型腔表面積 mm surface area of cavity in mm n= 材料常數 material constant 0.6 for pe, ps 0.7 for pom, pc, pp 0.8 for ca, pmma, pa 0.9 for pvc 澆口厚度 gate thick. in mm = nt t= 零件壁厚 wall thick. in mm 30 n 2 30303030 15151515 25 25 25 25 2 水力直徑水力直徑水力直徑水力直徑 hydraulic diameterhydraulic diameterhydraulic diameterhydraulic diameter p a dh 4 = where is the hydraulic diameter 水力直徑 a is the cross-sectional area of the flow 流路斷面積 p is the wetted perimeter 濕周長 h d 水力直徑水力直徑水力直徑水力直徑 hydraulic diameterhydraulic diameterhydraulic diameterhydraulic diameter 在不同剖面形狀，相同斷面積下之變化 various runner profiles, based on the same cross-sectional area 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計 (1) (1) (1) (1) runner sizing (1)runner sizing (1)runner sizing (1)runner sizing (1) d : 流道直徑 ( mm ) runner diameter in mm w: 下游塑膠重量 ( g ) downstream plastic weight l : 流道長度 ( mm ) runner length in mm d wl 3.7 4 = 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計( ( ( (2)2)2)2) runner sizing (2)runner sizing (2)runner sizing (2)runner sizing (2) 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計( ( ( (3)3)3)3) runner sizing (3)runner sizing (3)runner sizing (3)runner sizing (3) mmd g cmcmcmgw mml lw d 338 . 2 14.14 4 10 2 . 0/9 . 0 30 7 . 3 1 2 2 3 1 1 4 11 1 = = = = = 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計( ( ( (4)4)4)4) runner sizing (4)runner sizing (4)runner sizing (4)runner sizing (4) mmd g gg cmcmcmgww mml lw d 533. 4 66.28 219. 014.14 2 4 3 . 0 3/9 . 0 80 7 . 3 2 2 2 3 12 2 4 22 2 = = += += = = 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計( ( ( (a1)a1)a1)a1) runner sizing (a1)runner sizing (a1)runner sizing (a1)runner sizing (a1) g : 重量 weight s : 零件厚度 thickness d : 參考直徑 reference diameter g( g ) d ( mm ) for ps, abs, san, cab 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計( ( ( (a2)a2)a2)a2) runner sizing (a2)runner sizing (a2)runner sizing (a2)runner sizing (a2) g( g ) d ( mm ) for pe, pp, pa, pom g : 重量 weight s : 零件厚度 thickness d : 參考直徑 reference diameter 流道尺寸設計流道尺寸設計流道尺寸設計流道尺寸設計( ( ( (b)b)b)b) runner sizing (b)runner sizing (b)runner sizing (b)runner sizing (b) d : 參考直徑 reference diameter l : 長度 length fl l l l :長度係數 length coefficient d : 流道直徑 runner diameter fl l l l l (mm) d = d fl l l l 冷料井設計冷料井設計冷料井設計冷料井設計 cold slug well designcold slug well designcold slug well designcold slug well design 2d 次流道 secondary runner d 主流道 primary runner 澆口 gate 型腔 cavity 倒椎度冷料井 豎澆道拉料桿 reverse taper cold slug-well sprue puller z型冷料井 豎澆道拉料桿 “ z “- taper cold slug-well sprue puller 溝型冷料井 豎澆道拉料桿 grooved cold slug-well sprue puller 冷料井設計冷料井設計冷料井設計冷料井設計 cold slug well designcold slug well designcold slug well designcold slug well design 澆道襯套尺寸澆道襯套尺寸澆道襯套尺寸澆道襯套尺寸 spruespruespruesprue bushing sizing bushing sizing bushing sizing bushing sizing 排氣系統設計排氣系統設計排氣系統設計排氣系統設計 venting system designventing system designventing system designventing system design 徐昌煜 charles hsucharles hsucharles hsucharles hsu 為何排氣仍然還是一個問題？ why venting is still a problem ? 因為降低射速，讓積風有較多的時間逃氣，是一 件太容易的事。但是 because it is too easy to slow down the injection speed and give the trapped air more time to escape. but . 排氣排氣排氣排氣 ventventventvent 射速一降，熔膠溫度很快降低，射壓必須提高，殘餘應 力隨之提高，翹曲的可能性增加。 如果想藉提高料溫， 以降低射壓，料溫必須升得很高，這樣又會引起塑料裂 解。 when injection speed is lower, melt temperature goes down very fast, injection pressure has to be increased, residual stress is increased and the possibility getting warppage becomes higher. if one would like to increase barrel temperature to reduce the required injection pressure, the barrel temperature has to be increased to a quite high level and polymer degradation would be induced. 排氣排氣排氣排氣 ventventventvent 高料溫和高射壓都說明充填系統有了流動的問題 both high barrel temperature and high injection pressure are indications of flow problem in the filling system. 排氣排氣排氣排氣 ventventventvent 我們常發現: 射速提高時，塑料表現得更為出色。 it is quite common that material performs better when it is injected faster. 最適化螺桿速度充分運用摩擦熱，將塑流保持在最佳狀 態。許多充填和翹曲的問題也就迎刃而解。 an optimized ram speed profile fully uses the friction heat to keep the best flow characteristics, which corrects many of the fill and warpage problems. 排氣排氣排氣排氣 ventventventvent 有了適當的排氣，射速可以提高，充填和保壓可 達良好狀態，不須過度增加料管和噴嘴的溫度。 with proper venting, the injection speed could be increased to achieve good fill and pack conditions, without having to raise the barrel and nozzle heats, improperly. 排氣排氣排氣排氣 ventventventvent 深度(depth) : 1. 0.075 mm易流塑料(easy-flow mat.) 2. 0.125 mm難流塑料(stiffer-flow mat.) 3. 深度深到流道末端見毛邊為準 (deep enough to feel flash at runner end) 寬度(width) : 和流道同寬(as wide as runner dia.) 排氣唇部(vent lip): 1.5mm a1拋光(finish) 排氣通道通大氣(vent channel to atmosphere): 1mm深(deep) 流道排氣流道排氣流道排氣流道排氣 runner ventsrunner ventsrunner ventsrunner vents 深度(depth) : 參照廠商建議 (refer to manufacturers recommendation) 寬度(width) : 全圓周長(whole perimeter) or 5mm 長度(length) : 1.5mm a1拋光(finish) 排氣通道通大氣(vent channel to atmosphere): 1mm深(deep) 分模面排氣分模面排氣分模面排氣分模面排氣 parting line ventsparting line ventsparting line ventsparting line vents 深度(depth) : 參照廠商建議 (refer to manufacturers recommendation) 寬度(width) : 全圓周長(whole perimeter) 長度(length) : 1.5mm 排氣溝(vent groove): 1mm深(deep) 頂出銷或心型銷排氣頂出銷或心型銷排氣頂出銷或心型銷排氣頂出銷或心型銷排氣 ejector and core pin ventsejector and core pin ventsejector and core pin ventsejector and core pin vents 冷卻系統設計冷卻系統設計冷卻系統設計冷卻系統設計 cooling system designcooling system designcooling system designcooling system design 徐昌煜 charles hsucharles hsucharles hsucharles hsu 模具冷卻設計的目的模具冷卻設計的目的模具冷卻設計的目的模具冷卻設計的目的 purposes of mold cooling designpurposes of mold cooling designpurposes of mold cooling designpurposes of mold cooling design 1. 均衡冷卻(改良產品品質) even cooling (improve part quality) 2.有效冷卻(提高生產力) efficient cooling (increase productivity) 薄殼產品不像傳統壁厚者一般可以承受較大的因熱傳不 均而產生的殘餘應力。 為了將收縮彎翹控制在可以接受 的程度，均衡的冷卻設計變得非常重要。 thin-wall part can not afford as much thermal induced residual stress as the conventional one does. an even cooling design becomes very important to control the shrinkage and warpage at an acceptable level. 冷卻設計冷卻設計冷卻設計冷卻設計 cooling designcooling designcooling designcooling design 射出成型週期時間射出成型週期時間射出成型週期時間射出成型週期時間 injection molding cycle timeinjection molding cycle timeinjection molding cycle timeinjection molding cycle time 充填時間 fill time 開模時間 open time 後充填時間 post-fill time 對冰箱蔬果盤之類的大零件而言，材料往往佔成本50% 以上。 對小而薄的零件而言， 成形機費用可佔成本的 90% ，材料6% ，而模具只佔4%。 小而薄的產品較之 厚者更能從冷卻的改善而獲得效益。 for larger molded parts, material typically represents more than 50% of the part cost for a refrigerator crisper tray. in the case of a thin-wall small part, the press cost could be 90% of the cost of the part; material constitutes 6% and the mold only 4% of the cost of each part. small thin-wall parts typically benefit from improved cooling more than thick parts. 冷卻設計冷卻設計冷卻設計冷卻設計 cooling designcooling designcooling designcooling design 典型的冷卻系統典型的冷卻系統典型的冷卻系統典型的冷卻系統 typical cooling systemtypical cooling systemtypical cooling systemtypical cooling system 模溫調節機 temperature controlling unit 軟管 hoses 冷卻迴路 2 cooling circuit 2 冷卻迴路 1 cooling circuit 1 泵 pump 收集歧管 collection manifold 供給歧管 supply manifold 模具冷卻管路模具冷卻管路模具冷卻管路模具冷卻管路 mold schematicmold schematicmold schematicmold schematic 冷卻孔道冷卻孔道冷卻孔道冷卻孔道 cooling channelscooling channelscooling channelscooling channels 入口 inlet 出口 outlet 入口 inlet 出口 outlet 噴泉管噴泉管噴泉管噴泉管 bubblerbubblerbubblerbubbler 障板管障板管障板管障板管 bafflebafflebafflebaffle 熱管熱管熱管熱管 heat pipeheat pipeheat pipeheat pipe 蒸發部位熱輸入 heat in 凝結部位熱輸出 heat out 液體 liquid 蒸汽 vapor 燈心 ( 毛細管 ) wick ( capillary ) 熱管的應用熱管的應用熱管的應用熱管的應用 the application of heat pipethe application of heat pipethe application of heat pipethe application of heat pipe 理論上最短冷卻時間理論上最短冷卻時間理論上最短冷卻時間理論上最短冷卻時間 min. possible cooling timemin. possible cooling timemin. possible cooling timemin. possible cooling time 理論上最短冷卻時間 the min. possible cooling time 產品最大厚度 the max. part thickness 熔膠的熱擴散度 thermal diffusivity of the melt 射出溫度 injection temp. 冷卻液溫度 coolant temp. 頂出溫度 ejection temp. 冷卻時間和厚度分佈冷卻時間和厚度分佈冷卻時間和厚度分佈冷卻時間和厚度分佈 cooling time and thickness profilecooling time and thickness profilecooling time and thickness profilecooling time and thickness profile 差的設計 bad design 好的設計 good design 冷卻孔道直徑、深度和節距建議值冷卻孔道直徑、深度和節距建議值冷卻孔道直徑、深度和節距建議值冷卻孔道直徑、深度和節距建議值 recommended diameter, depth & pitchrecommended diameter, depth & pitchrecommended diameter, depth & pitchrecommended diameter, depth & pitch d : 直徑為10至14mm diameter of cooling channel, 10 to 14 mm d : 深度為d至3d depth, d, to 3d p : 節距為3d至5d pitch, 3d to 5d 原始設計原始設計原始設計原始設計 original designoriginal designoriginal designoriginal design 修正設計修正設計修正設計修正設計 revised designrevised designrevised designrevised design aa sec. a-a 原始設計原始設計原始設計原始設計 original designoriginal designoriginal designoriginal design 母模板 cavity plate 澆道襯套 sprue bushing 母模嵌塊 cavity insert 公模嵌塊 core insert 公模板 core plate 承板 support plate 修正設計修正設計修正設計修正設計 revised designrevised designrevised designrevised design 母模板 cavity plate 澆道襯套 sprue bushing 母模嵌塊 cavity insert 公模嵌塊 core insert 公模板 core plate 承板 support plate 原始設計原始設計原始設計原始設計 original designoriginal designoriginal designoriginal design 公模嵌塊 core insert o型環 o-ring 空氣囊 air pocket 修正設計修正設計修正設計修正設計 ( ( ( (一一一一) ) ) ) revised design ( 1 )revised design ( 1 )revised design ( 1 )revised design ( 1 ) 公模嵌塊 core insert o型環 o-ring 修正設計修正設計修正設計修正設計( ( ( (二二二二) ) ) ) revised design ( 2 )revised design ( 2 )revised design ( 2 )revised design ( 2 ) 公模嵌塊 core insert o型環 o-ring 不平衡的設計不平衡的設計不平衡的設計不平衡的設計 unbalanced designunbalanced designunbalanced designunbalanced design 平衡的設計平衡的設計平衡的設計平衡的設計 balanced designbalanced designbalanced designbalanced design 不用限流孔梢的內歧管設計不用限流孔梢的內歧管設計不用限流孔梢的內歧管設計不用限流孔梢的內歧管設計 internal manifold design without internal manifold design without internal manifold design without internal manifold design without fropfropfropfrops s s s 使用限流孔梢的內歧管設計使用限流孔梢的內歧管設計使用限流孔梢的內歧管設計使用限流孔梢的內歧管設計 internal manifold design utilizinginternal manifold design utilizingin