注塑模具简介.ppt

,GEPlastics,InjectionMoldTooling射出成型模具,e,GOODPART,ToolingConsiderations模具相關事項,好產品,RESINSUPPLIER膠粒供應商,ENDUSER最終用戶,MOLDER製模師父,MOLDMAKER模具加工商,ToolingConsiderations模具相關事項,TOOLINGDEVELOPMENT塑膠模具發展,Tooling模具,ProcessingProblems製程上所遇之問題,BlackSpecks黑點Gloss光澤度Jetting噴射現象Delamination分層Fingerprinting手紋Plate-Out電鍍,ToolingDevelopment模具發展,WeldLines結合線BurnMarks燒痕DimensionalControl尺寸控制Streaking流痕Sticking黏模Brittleness脆性,ProcessingProblems製程上所遇之問題,ToolingDevelopment模具發展,ProcessingProblems製程上所遇之問題,ToolingDevelopment模具發展,InconsistentCycle周期不一致,THEWORSTPROBLEM最嚴重的問題,ProcessingProblems製程上所遇之問題,ToolingDevelopment模具發展,-Anonymous佚名,TheCHEAPESTToolisTheOneThatWORKS左圖為最便宜之模具只有一個模板,ToolingDevelopment模具發展,CustomsandPracticesoftheMoldmakingIndustry,ClassificationsofInjectionMoldsforThermoplasticMaterialsAGuideforthePurchaserorManufacturerofThermo-plasticInjectionMoldsUpto400Tonsand400tonsandover.,SI,P,ToolingDevelopment模具發展,熱塑性模具分類400到400噸以上熱塑性模具購買指南,模具行業海關分類標準,MOLDTYPES模具種類,Tooling模具,TypesofMolds模具型式(Tools)(Dies),SeriesSeriesSeriesSeriesClassAClassBCollapsibleCoreTwoPlate二板模ThreePlate三板模,AccelerationKO?SideInjectionLifterCAMRunnerless-InternallyHeated-ExternallyHeatedPrototypeMUDEtc.,ToolingMoldTypes模具型式,ToolingMoldTypes模具型式,TwoPlateDesign二板模設計ExplodedView爆炸圖,SupportPlate承板,EjectorPlate上頂出板,LeaderPin導柱,ReturnPin回位銷,ToolingMoldTypes模具型式,TwoPlateDesign二板模設計,ToolingMoldTypes模具成型型式,StandardTwoPlateMold標準二板模,SprueBushing射嘴,Plate母模,ClampingPlate夾模板,Plate公模,SupportPlate承板,EjectorPlate頂出板,ToolingMoldTypes模具成型型式,PartingLine分模面,ToolingMoldTypes模具成型型式,TwoPlateMoldEjection二板模分模情形,1.開模(公母模分開),ToolingMoldTypes模具成型型式,TwoPlateMoldEjection二板模分模情形,EjectedPart頂出成品,2.頂針將成品頂出落下,InjectionMoldingTooling射出成型模具,3.頂針退回，準備合模,InjectionMoldingTooling射出成型模具,4.公模藉導柱與母模導銷確實閉合,ToolingMoldTypes成型模具種類,SupportPlate承板,EjectorRetainerPlate下頂出板,EjectorPlate上頂出板,EjectorHousing下夾模板模座,BPlate母模板,XPlate公模板,APlate脫料板,ThreePlateDesign三板模設計,ToolingMoldTypes模具成型型式,ThreePlateDesign三板模設計,Closed合模狀態,ToolingMoldTypes模具成型型式,MainLeaderPin主要導柱,PartingLine1第一合模面,1.脫料板分開，將水口與成品分開,三板模分模情形,ToolingMoldTypes模具成型型式,PartingLine1第一分模面,PartingLine2第二分模面,三板模分模情形,2.公母模分開,ToolingMoldTypes模具成型型式,PartingLine1第一分模面,PartingLine2第二分模面,三板模分模情形,3.公模頂出板將成品頂出,ToolingMoldTypes模具成型型式,PartingLine1第一分模面,PartingLine2第二分模面,PartingLine3第三分模面,Part成品,Runner澆道,三板模分模情形,4.脫料板將料頭頂出脫落,SPRUEBUSHINGS射嘴,ToolingSprueBushings模具射嘴,HeatedSprue加熱式射嘴-HelicalHeaters螺旋電熱片式加熱-GasPipe瓦斯管加熱Non-heatedSprue無熱式射嘴,SPRUEBUSHINGS射嘴,ToolingSprueBushings模具射嘴,COLDSPRUEBUSHING冷式射嘴,ToolingSprueBushings模具射嘴,SPRUEBUSHING射嘴,GasPipe瓦斯管,ToolingSprueBushings模具射嘴,HotSprueBushing熱射嘴,ToolingSprueBushings模具射嘴,RUNNERS澆道,ToolingRunners模具澆道,MaterialFlowsOnlyThroughMoltenPortionofRunner,OuterSkinChillsonContactwithmoldSurface,RunnersFlow膠粒於澆道流動狀態,ToolingRunners模具澆道,2.後續膠粒藉著澆道內部未固化之部份進行填充模腔。,1.一開始膠粒接觸模腔表面部份將冷卻形成固化層。,RunnersDesign澆道設計,1.FullRoundMostEfficient澆道剖面為圓形者，為最佳流動狀態,2.TrapezoidalGood澆道剖面為梯形流動性良好,3.HalfRoundNotGood澆道部面為半圓形流動性不佳,P.L分模線,ToolingRunners模具澆道,r,d,r,d,r/dWD1/83/161/83/161/43/161/45/161/45/167/165/163/81/23/8,EquivalentRoundRunner同效果之圓形與梯形剖面,DesignAlternative設計上可選擇二種其中之一,ToolingRunners模具澆道,W,D,SpruePuller料頭倒扣,1.REVERSETAPERBEST倒錐形倒扣效果最佳,2.ZPULLERGOODz型倒扣效果良好,3.GROOVETROUBLESOME環狀倒扣不易脫模,4.SUCKERPINNOTRECOMMENDED無設計倒扣不建議使用,ToolingRunners模具澆道,RESTRICTIVE限制性,PREFERRED首選,ToolingRunners模具澆道,Asmallincreaseinradiusdramaticallyincreasestheflowthroughtherunner.少量增加澆道半徑，Q值流動速率會大幅增加,R=Radius半徑,Q=VolumetricFlowRate單位體積流動速率,Q=,8nL,QProportionaltoR2Q與R2成正比,nRP,2,ToolingRunners模具澆道,FlowDirection膠粒流動方向,ColdSlugWell冷料井效果良好,RoundCrossSection(3/16to3/8Dia.)冷料井末端為環狀直徑3/16英吋到3/8英吋ShortLengthColdSlugWells短距離之冷料井效果良好,ColdSlugWell冷料井效果良好,ToolingRunners模具澆道,UnbalancedSystem非平衡式澆道設計,A,A,A,A,B,B,B,B,ToolingRunners模具澆道,ArtificiallyBalanced人工設計平衡澆道,1/8,1/4,3/8,1/2,1/2英吋Dia直徑,ToolingRunners模具澆道,BalancedSystem平衡的澆道系統,ToolingRunners模具澆道,RUNNERLESSMOLDING無澆道系統,ToolingRunnerlessMolding模具無澆道系統,HotRunnerBenefits熱澆道的優點FasterCycles成型周期減少1520%-15-20%FasterEliminatesMaterialWaste排除材料浪費-NoSpruesorRunners無注口或澆道ImprovesPartQuality改進成形品品質-LessStress較低殘留內應力-BetterAppearance較佳之外觀,ToolingRunnerlessMolding模具無澆道系統,RUNNERLESSMOLDINGSYSTEMS:無澆道系統,INCOEKONAD-M-EPLASTHINGHotOneRAMACoolOneHUSKYMOLDMASTERFASTHEATSPEAREUROPE&ASIA,SPRUELESS,HOMEMADE,CompressionSeal高壓密封,Plug插銷MoldmakersChoice模具製造商自行選擇,DiameterFitSeal直徑合適密封,ToolingRunnerlessMolding模具無澆道成型,CavityPlate=500,Manifold=5000,ThermalExpansionofSteel.00000633PerInchPerDegree,6in.=.017In.12in.=.034In.18in.=.051In.,ToolingRunnerlessMolding模具無澆道成型,GATING進澆口,ToolingGating模具進膠,DirectSprueGate直接進膠EdgeGate側邊進膠FanGate扇形進膠TunnelGate潛入進膠Single單點進膠MultipleTabGates多點進膠DiskGateRingGate環形進膠,lashGateiaphragmGateodified?GateinGateumpGatealveGateEtc.,TypesofGating進膠口之種類,ToolingGating模具進膠,DirectSprueGate直接進膠式,MoldedPart成形品,Sprue進膠口,ToolingGating模具進膠,PART成形品,RUNNER澆道,GATE進膠,LAND進膠緩沖帶,FanGate扇形進膠,ToolingGating模具進膠,COLDSLUGWELL較佳之冷料井,RADIUS半徑,FanGate扇形進膠,ToolingGating模具進膠,EdgeGate側面進膠,ToolingGating模具進膠,SingleTabGate單點進膠,MultipleTabGate多點進膠,Gate澆道,Tab,Sprue注口,6in.Max,12in.Max,Tab,Sprue注口,Gate澆道,Gate澆道,Tab,ToolingGating模具進澆,MultipleTabGate多點進膠,ToolingGating模具進膠,DiskorDiaphragmGate,Runner,Part,Runner,Sprue,ToolingGating模具進膠,ToolingGating,Gate,Part,RunnerDisk,Gate,RingGate,Runner,ParallelRunner,Gate,FlashGate,ParallelRunner,ToolingGating,0.020LandLength,0.050,900,ToolingGating,PinPointGating,MoldedPart,Sprue,PartingLine,Tunnel,Gate,ZeroLandLength,KnockOutPin,GrindFlatonGateSide,Min.20,FastenPinHeadToPreventTurning,TunnelGate,ToolingGating,Tunnel,KnockOutPin,TunnelGate,ToolingGating,R,R,Gate,CashewGate,ToolingGating,KnitLine,GateArea,ToolingGating,KnitLineandGateArea,InjectionMoldingTooling,ValveGateShutOffSystem,BushingsareOpenedforInjection,InjectionMoldingTooling,ValveGateShutOffSystem,AFills,BushingACloses,InjectionMoldingTooling,ValveGateShutOffSystem,BFills,BushingBCloses,VENTING,ToolingVenting,PartingLine,.001-.0025Depth,Gate,Vent,.060Min.,NoteStep,.500,.050Min.,ToolingVenting,ClearanceAroundKnockout,.0025,EjectorPin,ToolingVenting,TEMPERATURECONTROL,ToolingTemperatureControl,TheMostEfficientCoolingSystemsAreThoseWhichOperateSuchThatTheInletandOutletCoolantTemperaturesAreWithin100OfEachOther,FluidVelocityFt./Sec.,TurbulentFlow,TransitionArea,HeatTransferEfficiencyWaterCoolant,0.5,1.0,1.5,2.0,Laminar,Flow,ToolingTemperatureControl,120,125,125,135,135,145,130,140,140,130,150,145,O,O,O,O,O,O,O,O,O,O,O,O,IN,OUT,ToolingTemperatureControl,BalancedCoolingUniformCoolingMaximumTemperatureDifferentialof10oF,ToolingTemperatureControl,InjectionMoldingTooling,MoldCoolingSeriesBubbler,IN,OUT,POOR,Pin,Blade,InjectionMoldingTooling,MoldCoolingParallelBubbler,IN,Correct,OUT,Pin,Tube,EJECTORMECHANISMS,ToolingEjectorMechanisms,PinDiameterisasLargeasPossiblePinsAreasNumerousasPossiblePinsExertaUniformForceonMoldedParts,ToolingEjectorMechanisms,FactorsEffectingEjectionForce,SidewallDraftSidewallContactAreaSidewallPolish/TexturingDegreeofPackingMoldTemperatureMoldRelease,ToolingEjectorMechanisms,TEXTURINGANDDRAFTANGLE,ToolingTextureandDraftAngle,DRAFTANGLE,DRAFTANGLE,1/2oMIN,ToolingTextureandDraftAngle,Additional1DegreeperMilinDepthofTexture,DraftAngleforTexturedSidewall,ToolingTextureandDraftAngle,QualityofTextureVarieswithTypeofSteelIdenticalGradesofSteelCanEtchDifferently,TexturingGuidelines,ToolingTextureandDraftAngle,EnhancesStylingandAestheticsReducesRejects,TexturingMoldFinishes,ToolingTextureandDraftAngle,COREPULLS,ToolingCorePulls,HydraulicCorePulls,ToolingCorePulls,ToolingCorePulls,ToolingCorePulls,ToolingCorePulls,PROTOTYPING,ToolingPrototyping,PrototypeToolMaterialsAluminumBerylliumAlloysMildSteelP20Steel,ThermalConductivity(BTU/hrftoF)956526219.4,2,AluminumThermalConductivityIs4.5TimesThatofP20Steel,ToolingPrototyping,PartsCoolMoreQuicklyinAluminumToolingPartsShrinkLessinAluminumTooling,ShrinkIsDifferentinSteelandAluminum,ToolingPrototyping,ChoosePrototypeToolMaterialsAfterConsiderationof:,DimensionalCriteriaofPart,SurfaceFinishRequired,WearResistance,ToolingPrototyping,PartDesignDictatesPerformancePerformanceDictatesMaterial,ToolingSummary,PlasticPartProduction,MaterialDictatesTooling,ToolingSummary,MoldDesign,GOODPART,ToolingConsiderations,GEPlastics,EJECTORMECHANISMSDESIGN,80to100InSidewallContactPINDIAMETER1/81/43/8?,REQUIRESPINBEARINGSURFACE1in21in21in2,1InPinBearingSurfaceNUMBEROFPINS82209,2,2,ToolingEjectorMechanisms,INTERNALTHREAD,SNAPLID,COMMONUNDERCUTS,ToolingEjectorMechanisms,DetailonSide,ExternalThread,COMMONUNDERCUTS,ToolingEjectorMechanisms,LatchorHook,BobbinorSpool,COMMONUNDERCUTS,ToolingEjectorMechanisms,BladeatDeepRibs,RoundsPins,SleeveEjector,Boss,Eject,MoldPinStationary,Parts,StripperPlate,StationaryForce,KnockOutBars,G