注塑模具准则中英文对照版.doc

Injection Molding GuidelineDocument No.: DOC-186Revision: ADocument Owner: Lawrence ChungMaintained by: HK PDMREVISIONDESCRIPTION OF CHANGECHANGE NO.DATE RELEASED1Initial Release26222May 2006 (See Agile)APPROVALS OBTAINED IN AGILEInjection Molding Guideline1. Plastic Materiala. Assume the general purpose grade plastic materials to be used for our moldingb. In case of special grade materials, please list the material grade & brand on our tool planc. All the plastic materials for molding must be same as the materials during development stage. d. In case of material shortage or cost issue, the new sourced material shall be tested and confirmed acceptable prior use.2. Coloranta. All the colorant must be conformed to heavy elements directives for both ASTM F963 & EN71.b. Most of the dry pigments are hygroscopic; they must be properly sealed after use. c. For the components with high color consistence, the masterbatches or pre-color plastic materials are required.3. Regrind Material Ratioa. For plastic material on structural components, no regrind is allowedb. For general purpose material on non structural components, 20% maximum runner regrind can be blended with virgin material.c. For those translucent or true white color components, no regrind is allowed.d. For short glass filled materials, 15% maximum regrind can be blended with virgin materiale. For long glass filled materials, no regrind is allowed. f. The maximum number of regrind passes for general purpose materials shall be 3.g. Only 1 time of regrind pass is allowed for short glass reinforced materialsh. The regrind ratio shall be shown in our updated tool plan to follow.i. The regrind ratio and no. of regrind passes has to be validated and confirmed during development stage. If not, no regrind will be allowed.j. Burned or discolored sprues or parts must not be used as regrind.k. Hot nozzle & hot runner is our preference to eliminate runner scrap.4. Material Dryinga. Most plastic resins require thorough drying prior injection molding to assure maximum properties in the molded parts. Below table please find the recommended drying temperature & duration for reference:b. For those hygroscopic materials, the dehumidifying hopper dryer with closed-loop air circulating system is required to ensure acceptable moisture content to be achieved during molding.c. For those non-hygroscopic materials, the regrind have to be dried as 80C for 2 hours to prevent surface blemishes due to volatiles, such as PE, PP, POM, HIPS.MaterialDrying TemperatureTime required (Hour)Dehumidifying Dryer requiredABS / C-ABS80C2NoNylon 6 / PPO / PC+ABS100C2NoNylon 66120C2NoPU110C2 3YesPC120C2 - 3NoPET120C2 - 3YesRegrind blench for PE / PP / HIPS / POM80C2No5. Screw Designa. For most of un-filled plastic, standard screw with L / D ratio 22:1 is recommendedb. For glass reinforced plastic, screw with lower L / D ratio 20:1 is recommendedc. Bi-metallic screw and barrel are required for glass reinforced plastic to have higher wear assistance6. Molding Machine & Accessories Selectiona. The distance between two columns (Horizontal) shall be 10mm minimum longer than the mold widthb. For non engineering or unfilled plastic resin, up to 90% rated barrel capacity shall be utilized.c. For engineering and all glass filled plastic resin, up to 70% rated barrel capacity shall be utilized.d. For clamping tonnage consideration, the multiple of projectile area and fill pressure should be up to 90% of rated clamping tonnage of machine. However, the actual requirement will be depended upon the wall thickness, parts geometry and gate design. Below table please the fill pressure factor for common use plastic for reference.Plastic MaterialsFill Pressure (Ton/Sq Inch)PE / PP / EVA1.8HIPS / ABS / C-ABS2TPU / PC / PC+ABS4Glass Filled Plastic5 and Upe. The minimum tonnage for mold size shall be put to Machine Size column on Tool Planf. For high precision parts & optical lens, electric molding machine is preferred.g. Automatic parts / sprue removal system should be installed for 220 ton or above molding machinesh. Hopper loader should be installed for 220 tons or above machinesi. Proportional type hopper loader should be used for the molding with instant runner scrap recycling.j. Hopper magnet shall be equipped for all material hoppers.7. Mold Clamping a. For machine capacity up to130 tons, all molds can be clamped onto machine platens by either clamping slots or mounting holes.b. For machine capacity more than130 tons, all molds can only be clamped onto machine platens by clamping slots. c. Always use appropriate clamping tonnage for clamping, 10% higher than the theoretical clamping tonnage as section 6d). Excessive clamping pressure will ruin the molds, especially on weak parting line areas.d. Jiffy type plugs and connectors are preferred to speed up set-up time.e. All Eyebolts must be removed before molding start in order not to interfere any mechanical movementf. The Hoist Ring type is preferred to prevent accidents caused by traditional eyebolt failure8. Mold Cooling a. All cooling lines must be connected to water manifold of machines as per indication of mold drawingb. The water temperature difference between inlet and outlet shall be less than 5 C.c. Correct mold temperature shall be maintained for different materials to obtain good aesthetic and mechanical propertiesd. Appropriate mold temperature should be depended upon the wall thickness, aesthetic requirement and flow length to thickness ratio (L/T). Below table please find recommended mold temperature for most common materials:Plastic MaterialsMold TemperaturePE / PP / HIPSChill water to 40CABS / C-ABS 20C to 50CPOM / Unfilled Nylon / Unfilled PET40C to 70CPC+ABS / PC50C to 80CFilled Nylon / Filled PET60C to 100C9. Molding Process Parameter a. Set barrel heaters to ramp profile, lower at the feed throat and higher at front zone. Below table please find the recommended temperature range for reference:Plastic MaterialsCylinder Temperature CPE / PP190 220HIPS / GPPS180 220ABS / C-ABS 190 240Polyacetal170 210PC260 300Nylon 66260 - 290b. Set the injection to lower limit and add gradually to obtain good partsc. Set the injection speed to high for crystalline material and medium for amorphous materials.d. Set holding pressure and time to zero.e. Start making short shots without any cushion, the incrementally increase shot volume until the part is approximately 95% full. This becomes the transfer point (time). Begin weighing parts.f. Set the packing pressure 30% to 40% below first stage pressure and continue weighing parts (normally uses only 1 3 seconds pack time). Increase shot volume until a cushion is developed. Incrementally increase pack time until part weight does not increase. At this point, gate freeze-off has been reached.g. Set the back pressure low but ensure to displace trapped air in the screw feed section and good melt homogeneity. For glass filled plastic, the recommended pack pressure should be 20 50 PSI to prevent glass breakage.h. Set the cooling time to permit the parts to be ejected without the ejector pins marks or pushing into the parts.i. The molding set-up sheet for every mold must be well documented and attached to molding machine for review during molding.10. Cycle Time a. Below table please find our expected quoting cycle time for different parts category and machine size:Parts DescriptionExampleMachine SizeExpected Cycle Time (S)Small size parts with 1.5mm wall thickness or belowButton or POM components70 ton or below26Medium size parts with 1.5mm wall thickness or belowBattery Door & 4 up Cartridge mold70 to 120 ton30Small size Housing with 2.0mm wall thickness or below, or multi cavities componentsLTLP Counting House & Fridge DJ HousingOver 120 to 200 ton34Medium size Housing with 2.5mm wall thickness or belowLeapPad & MFLP HousingOver 200 280 ton38Medium size Housing with 2.5mm wall thickness or belowAround the Block HousingOver 280 ton 350 ton42Large Housing with 3.0mm wall thickness or belowBaby DVD Base HousingOver 350 450 ton48Extremely large Housing with 3.0mm wall thickness or belowTop & Bottom Housing for Learning Table450 600 ton55b. The cycle time for all tooling will be finalized after verification by our tooling engineer during FEP stage. c. The limited condition that keeps the molds from being run at a lower cycle time has to be specified in quotation and mold drawing approval stage, such as wall thickness, aesthetics, dimensional tolerance or components design.11. Mold Releasing Agent a. During first shot and EP stages, the mold releasing agent can be applied when parts sticking occurs. b. During FEP and PP stages onwards, no mold releasing agent is allowed.c. All mold releasing agent must be non-toxic and CFC - free aerosols12. Second Operation a. The fixture materials shall be made of Phenolic, Aluminum, coated steel or those materials with high resistance to worn-out and corrosiveness.b. All the fixtures must be calibrated daily and once molding start.c. No breakable knife or tools are allowed for degating and flashing trimming13. Process Control a. The signed shot sample and components specification shall be attached to machine for routine quality check by quality inspector or molding supervisor prior molding start.b. The molded color, aesthetics and critical dimensions shall be inspected and confirmed acceptable by quality inspector prior molding start.c. Bi-hourly process inspection shall be conducted to verify aesthetics and functional requirementsd. Critical dimensional check has to be performed for every 4 hours or first and last shot for every shift. e. The shot sample should be stored in an air-conditioned environment for at least 1 hour before dimensional check.f. Final inspection check shall be performed for every shift prior dispatch to further manufacturing process or storage.g. Date code label shall be adhered to every outgoing lot for quality tracking.14. Mold Maintenancea. The mold surface and vents shall be routinely cleaned to eliminate the air trapped & worn-out problems, once for every shift molding. For the volatile materials, such as Polyacetal or PVC, the mold surface or vents shall be cleaned for every 4 hours molding. b. The molds, which are in continuous molding, should be dismantled for preventive maintenance, proper cleaning and lubricating on ejector pins, slides, and bushings, etc., once for every week.c. For those tailor made spare parts & hot runner consumable components, the safety inventory should be maintained to cover 2 times of lead-time for replenishing.d. In case the actual number of shot exceeds our committed tool life as per our Tool Standard, LeapFrog will be responsible for expense for normal mold repair, except the carelessness from operator or poor molding practice. Moreover, the quotation must be approved prior mold repair start.e. After any mold is repaired as section 14d, the tool life should be increased at least by 20% of committed tool life, 100K shots for injection mold and 60K shots for blow & die casting molds. f. Appropriate mold repair machineries & facilities is required for daily repair & maintenance.g. The Copper electrodes for all molds shall be identified and properly storage 15. Shutdown Procedures a. When any molds becomes necessary to halt molding for a period of time, the barrel temperature shall be lower down or the cylinder should be purged at regular intervals to prevent material degradation, especially for Polyacetal, PVC, flame retardant or temperature sensitive materials.b. And, the water shall also be turned off prior to last 30 shots such that the steel warms up to prevent condensation forming on mold inserts.c. The completion of molding run, all traces of compound should be thoroughly purged from barrel with HDPE, PP, Acrylic, Polycarbonate, General Purpose Styrene or commercially available purging compounds.d. And, the mold shall be thoroughly cleaned and then coated with rust preventive spray or grease.16. Tool Plan Updating a. The actual number of shots for all active items shall be updated on Tool Plan for every 3 monthsb. The actual number of shots for all inactive items shall be updated on Tool Plan for every year 17. Injection Molding Trouble ShootingProblemCauseRemedyBrittlenessWet Material- Review drying procedureOverheating- Reduce barrel / nozzle temperatureMolded-in-Stresses- Increase barrel / nozzle temperatureWeld Lines- Increase injection pressure- Increase melt temperatureWarped PartsPart temperature differential- Check mold cooling systemExcessive shrinkage- Increase part packingOrientation on material- Change gate locationEjection problem- Increase cooling time- Reduce mold temperature- Increase ejector pin areaFlashingInadequate Clamp Tonnage- Use a larger machineHigh Injection Pressure- Reduce injection pressureExcessive Vent Depth- Review mold ventingBurn MarksAir Trapped in Cavity- Improve mold ventingBarrel or Nozzle Overheating- Check heater controlShear Heat- Reduce injection speedContamination- Purge barrel- Clean hopper dryerWeak Weld-linesInsufficient venting- Improve cavity ventingInjection speed too low- Increase injection rateMold temperature too low- Increase mold temperatureIncorrect gate location- Relocate gate or add overflow tabSticking in MoldOver packing- Reduce injection pressure- Reduce injection speedMold design - Check for undercuts- Inspect ejector system- Increase draft in toolSurface ImperfectionsInjection speed too slow- Increase injection speedCold melt - increase barrel temperatureCold mold- Increase mold temperatureWet material- Review drying procedureSinks or VoidsHolding pressure or time too low- Increase holding pressure or timeInsufficient feed- Increase shot sizeGate freezing off or located improperly- Check gate dimension and locationGate BlushCold material- Add cold slug well in runner- Increase melt temperatureMelt fracture- Reduce injection speed- Increase gate size- Add radius to gateDimensional InconsistencyShot to shot variation- Maintain adequate cushion- Check for worn check ringMelt temperature variation- Check heater bands / controllersInadequate packing- Increase hold time- Enlarge gate to prevent premature freeze-off- END -注塑成型指南(中文版仅供参考, 以英文版为准)1. 塑胶原料a. 我们的注塑生产一般使用通用等级的塑胶料b. 如果需要用到特殊等级的塑料, 请在我们的tool plan中列出该胶料的资料c. 所有生产中使用的胶料必须与开发阶段所用的胶料一致d. 如果遇到原料短缺或成本问题, 新找到的原料在使用前应该通过测试并确认它是可接受的2. 色粉a. 所有的色粉应该符合ASTM963 和EN71中关于重金属的指示b. 大多数的干色粉是吸水的(易受潮), 使用后必须适当地密封c. 对于颜色的一致性要求高的零件, 要求使用色母料或者预先混色的胶料3.再生料的比率a. 用于结构件的胶料, 不允许使用再生料(翻打料)b. 用于非结构件的一般用途的胶料, 允许最多20%的水口再生料(翻打料)与原料混合, 用于注塑生产c. 透明件或者纯白色零件不允许用再生料d. 短玻璃纤维填充胶料, 允许最多15%的再生料与原料混合e. 长玻璃纤维填充胶料, 不允许用再生料f. 通用胶料最多允许翻打3次 g. 所有的玻璃纤维填充胶料只能翻打1次h. 再生料的使用比率应该在更新的tool plan 中显示出来i. 再生料的使用比率和翻打次数必须在开发阶段得到验证和确认, 否则将不允许使用再生料j. 烧焦或污染的水口或零件一定不能用作再生料k. 热唧咀或热流道是我们的优先选择用于消除水口废料4. 材料烘干a. 大多数塑胶树脂要求彻底烘干以保证零件有最好的性能. 下表是推荐的干燥温度和时间b. 对于那些吸湿性的塑料, 要求带闭环式循环空气系统的除湿料斗干燥器, 以保证注塑期间胶料中的水分是可接受的c. 对于非吸湿性的塑料,比如PE, PP, POM和HIPS, 再生料必须在80C干燥2小时以消除由于挥发性物质造成的表面瑕疵胶料烘干温度要求时间 (小时)是否要求除湿的料斗干燥机ABS / C-ABS80C2NoNylon 6 / PPO / PC+ABS100C2NoNylon 66120C2NoPU110C2 3YesPC120C2 - 3NoPET120C2 - 3YesRegrind blench for PE / PP / HIPS / POM80C2No5. 螺杆设计a. 对于大多数非填充塑料, 推荐用L/D 比率为22:1的标准螺杆b. 对于玻纤增强塑料, 推荐用20:1的更低的L/D比率的螺杆c. 对于玻纤增强塑料, 为了更好的防止磨损, 要求用双合金螺杆和料筒6. 注塑机的选择a. 两条水平导柱之间的距离(tie bar)应该比模具的宽度最少宽10mmb. 对于非工程或非填充塑料, 应该使用额定料筒容量的90%以内c. 对于工程或玻纤填充塑料, 应该使用额定料筒容量的70%以内d. 对于锁模吨数的考虑, 零件的投影面积与填充压力的乘积应该在机器额定锁模吨数的90%以内, 然而, 实际的要求将取决于零件壁厚, 几何形状和入水的设计. 下表列出了一些通用塑料的填充压力系数供参考e. 在Tool Plan的机器大小一栏中应填入模具可用的最小注塑机的吨数塑料填充压力 (吨/平方英寸)PE / PP / EVA1.8HIPS / ABS / C-ABS2TPU / PC / PC+ABS4Glass Filled Plastic5 and Upf. 对于高精密的零件和光学镜片, 更好地选择电动注塑机g. 对于220吨或以上的注塑机, 应该使用机械手, 自动从模具移出零件和水口h. 对于220吨或以上的注塑机, 应该配备供料器i. 对于配有实时水口料再生装置的注塑机, 应该使用比例式供料器j. 料斗磁石应该被装备于所有材料的料斗7. 模具锁模方法a. 对于130吨以内的注塑机, 模具可以通过码模坑或者通过安装孔锁紧在注塑机的模板上b. 对于130吨以上的注塑机, 模具只能通过码模坑锁紧在注塑机的模板上c. 总是用适当的锁模力来锁紧模具, 比第6节d中所要求的理论锁模力高10%. 过大的锁模力将损坏模具, 特别是较弱的分型面区域d. 为了缩短模具装上机器的时间, 应优先选择带快插的冷却水管e. 为了避免与任何机械运动相干涉, 在开始注塑前应取下所有的吊环螺栓f. 起重环是更好的选择用于防止由于传统的吊环螺栓失灵造成的事故8. 模具的冷却a. 所有的冷却通道应该根据模图的指示连接到提供冷却水的分水器上b. 入口和出口的温差应少于5 Cc. 为了提供好的外观和机械性能, 不同的塑料应保持正确的模温d. 合适的模温应该取决于零件的壁厚, 外观要求和流动长度与厚度的比率. 下表是最常用材料所推荐的模温塑料模温PE / PP / HIPSChill water to 40CABS / C-ABS 20C to 50CPOM / Unfilled Nylon / Unfilled PET40C to 70CPC+ABS / PC50C to 80CFilled Nylon / Filled PET60C to 100C9. 注塑加工参数a. 设置料筒发热器的温度逐级递升, 在入口段低而在料筒的前段高. 下表是推荐的料筒温度范围供参考.塑胶材料料筒温度 (C)PE / PP190 220HIPS / GPPS180 220ABS / C-ABS 190 240Polyacetal170 210PC260 300Nylon 66260 - 290b. 设置较低限度的射胶压力, 然后逐渐增加以提供好的零件c. 对于结晶型材料应设置较高的射胶速度, 对于非结晶型材料应设置中等的射胶速度d. 设置保压压力和时间为零e. 开始不用任何储料池(cushion)做短射, 然后逐渐增加射胶量直到充满零件的约95%, 设置转换点(时间), 开始零件的称重f. 设置保压压力低于第一阶段压力的30%-40%, 继续零件的称重(通常只用1-3秒的保压时间). 增加射胶量直到形成储料池(cushion), 逐渐增加保压时间直到零件的重量不再增加, 此时,入水口已经冻结g. 设置低的