科学成型手册.doc

FMTS SCIENTIFIC MOLDING HANDBOOK 科学成型手册Customer(客户) _ Mold No.（模号）_Project name(项目名称)_ Part name(产品名)_Mold manufactured date(模具制造日)_Mold manufacturer(模具制造商)_Tooling engineer(跟模工程师)_ FMTS series mold No._Molding Engineer(成型工程师)_Manufacture Engineer(制造工程师)_Part pictureMold pictureContents(目录)l 4M engineering change record(4M 工程变更记录)l Mold basic information (模具基本信息)l DFMEA data collection(设计失效评估资料收集)l Mold specification checklist（模具规范表）l Working steps of first trial ( 第一次试模准备工作)l Verifying checklist before mold set up to machine（上模前模具确认检查表） l Injection machine specification information checklist（注塑机规格检查表）l Resin ready verifying sheet（原料准备确认表）l New mold trial run working instruction(新模试产作业指导书)l Dry cycle-running checklist.（空转试跑检查表）l Molding parameter record sheet（注塑参数记录表）l Mold trial report sheet（试模报告）l PPAP report data(PPAP 报告)l Molding yields report data(注塑成型良率报告)l Manufacture working instruction(制造过程作业指导书)l Surface finish relevant technical data(表面处理相关技术资料) l Second process yield report（二次加工良率报告）l Mold transferred procedure from NPI to mass production(NPI 转模流程)l Commitment data of mold transferred from NPI to production(转模同意报告)Notice: In order to eliminate failure as best as possible, all the relate engineer will be showing out every potential risk items during tool design FMEA phase. Plastic New Mold Transferred Procedure Flow-chartFMTS 新模导入生产流程Scientific molding handbook transfer to production by NPI teamPPAP runTool trial in FMTS molding siteTool checking by FMTS tooling shopScientific molding handbook transfer to production NPI team by global NPI teamTooling transfer checkingT final and ship the part to customer for approval evaluationCommitment document from Customer for the tool transfer approval.Mold 3D data and any other documentation for the steel qualificationMore times for tool trial if necessaryT3 Trial and DocumentationPart FAI report documentationTooling improvement documentationPart evaluation and result documentT2 Trial and Documentation PreparationTooling Repair and ImprovementParameter optimizationF O T (First Trial) and DocumentationTool Manufacture Processing StudyResin property StudySteel Selection StudyMold Flow StudyTooling Design ReviewNeed to provide support data during every step for NEXT step!Tool information模具基本信息Customer/客户Tool manufacture factoryTool run productionProject Manager general /项目经理MOLD#:/模号Material Type/原料名称Project/项目Tool Class/模级Material Shrinkage/原料收缩率Part Name/产品名称Number of Cavities/模穴数Recommendation Machine Size (Tons)/吨位Part No./产品编号Mold Maker/模具供应商Actual machine tonnage used(实际吨位)Shot Size (grams)/每啤重（克）Tool dimension模具尺寸Machine Brand/机器品牌Date of Testing/试模日期Part Revision Number/产品版本号Barrel Capacity(Grams)/炮筒料量（克）Process Eng./成型工程师Quoted Cycle/周期Screw Compression Ratio/螺杆压缩比Tooling Eng./模具工程师Process Set Sheet/成型设定表完成日Screw and Barrel size(mm)/螺杆及炮筒大小（mm)Transfer Check complete/转模完成日期Setup Check List/建立检查表日Material melt point(C)Deliverables /交付信息Tool Design Notes/模具设计通知日Mold Spec Sheet Complete/模具规格完成日Tool Design Special Actions/模具设计中特别处理Project Engineer/项目工程师Short Term CPK Complete/CPK测定完成日Tool Design Check Heat/Cool/模具设计加热及运水完成日期Residence Time Study/滞料时间评定日Tool Design Check Hot Runner/热流道检查日期Process Test Date/工艺测试日期:Hold Time Study Complete/保压确定日Cavity Balance Complete/模穴进胶平衡确定日Dry Cycle test Date/试模日期Part Weight Study Complete/产品重量确定日Dry Cycle Checklist Complete/空料试啤周期检查表完成日期Mold specification(模具规范检查表)Mold flow analysis data(模流分析结果)HERE need to paste mold flow analysis result data summit by simulation engineerNew mold trial procedure(新模试模流程)New mold set up working checklist新模上模工作检查表#Check point(确认点检单元）YESNO1Is mold set up guy already got qualification from Flextronics training?上模者是否取得伟创力培训部门的资格认证Pre-works2Is corrected mold will be set up?是否正确就是要上的模具？ 3Is eye ring fit to eye bolt and enough?是否准备匹配和足够数量的吊环？4Is Crane is ready?天车是否准备好？5Are set up tools ready?上模工具是否准备好？6How many KO hole for KO rod or pull back rod?顶杆或拉杆孔的数量?7If enough KO rods or pull back rods are prepared?是否准备足够数量的顶杆或拉杆？ 8If all the KO rods or pull back rods are same size?是否所有顶杆或拉杆都是同样规格？9Have any warp, bent or thread damage KO rod or pull back rod?是否发现有弯曲变形或者螺纹损坏的顶杆或拉杆？ 10If the mold core side and cavity side is locked by mold-lock?前后模是否锁上？11If enough nibs，hoses and connectors are prepared?是否准备足够的水嘴,水管和接头？ 12If the mold will run by hot water or hot oil?本套模具是否需要跑热水或热油？13If the mold will run by steam-assisted?本套模具是否需要跑蒸汽辅助？14If this mold need to prepare high temperature and high pressure water hose?本套模具需要准备高温高压水管吗？15If this mold need to prepare special connectors or nibs?本套模具是否需要特制的接头或水嘴？16Need to prepare 2 sets of mold temperature controller for this mold or not?本套模具是否需要2台模温机？17Need to prepare chiller for this mold or not?本套模具是否需要准备冷水机？18Need to prepare hot-runner controller for this mold or not?本套模具是否需要准备热流道控制器？19Need to prepare core pull out system for this mold or not? 本套模具是否需要提供抽芯功能？20Need to prepare EXTRA core pull out device for this mold or not? 本套模具是否需要提供额外的抽芯设备？21Need to prepare air-valve or air resource for this mold or not?本套模具是否需要气阀或汽源？22How many safety limit switches in the mold?本套模具的安全限位开关的数量？23If this mold fit to set up on the injection machine according to the mold size?根据模具的尺寸大小是否可以上机？24If this mold fit to set up on the injection machine according to machine functionalities?根据注塑机的功能是否可以匹配模具的需要？25If CRANE 100% safety for this mold?天车是否绝对安全？26If safety cap is ready?是否准备好了安全帽？New mold set up working instruction(新模上模作业指导)Mold set up working27Make sure the horizontal level moving by CRANE on the topside of the injection machine.确保模具保持水平状态使用天车移到注塑机的上方。YESNO28HAVE to remember: need to option” mold setting mode for mold loading and unloading working.必须记住：在上下模作业时，必须选择“低压装模”模式。29Make sure location ring of the mold and injection machine is matched.确认模具的定位环与机器的定位全匹配。 30Dont forget fitting the mold to front clamp-plate first everytime.Then close mold in low pressure and mold height adjusting，some machine has automatic mold height adjustment function).不要忘记每次上模必须先贴往前模板，在低压关模调整模厚(有些机器有自动模厚调整功能）。31Mold height adjustment finished, then tie up clamping grippers on fit side first，need to avoid conflicted water line. Dont forget: grippers quantity defined is:400t below 4pcs for each side; exceed 400t to 600t 6pcs for each side, need to add more grippers if the machine is exceed 600t. 模厚调整完成后，先打紧前模码仔,不要与水路冲突。码仔数量的定义：一般400吨以下注塑机前后模各打4个；大于400吨到600吨的机器应该前后模个上6个码仔；如果机器大于600吨的记住多加码仔更安全。32Tighten up fix side clamp grippers, then started to hook up KO pin or pull back rods, HAVE to remember NEVER use bent, warp or de-thread pull back pin or bolt and nut for ejector-plate. All the KO pin, pull back pin bolt and nuts need consistency size. 打紧前模码仔后，就开始连接顶杆或拉杆，千万要记住：绝对不能使用弯曲的，变形的，滑牙的顶杆，拉杆，螺丝和螺母，所有顶杆，拉杆，螺丝和螺母规格要一致。33Every mold without early-return HAVE to hook up pull back rods.所有没有早回装置的模具都必须连接拉杆。34Tie up rear clamp grippers without conflict to water line. 打紧后模码仔记得不要与水路冲突。35When tighten up rear clamp grippers ,HAVE to remember unlock the mold-lock; Open the mold in low pressure ready for water hose or hot water(hot oil) hook up. HAVE to remember: mold loading and unloading job need to be done under mold setting打紧后模码仔后，必须记得松开锁模块，然后低压开模准备接水管（热水管或者热油管），必须记住：在上下模作业中，从开始到结束都必须在“模具安装”模式下进行的。36Water line connection HAVE to keep in mind:1INOUTmark and channel mark need to clearly understand;2need to blowing up and checking and make sure is no jammed inside water line before hook up the water hose;3 NEVER allowed looping connection water line;4Every cavity need to make sure same water flowing direction;5Make sure same length of water hose for every cavity;6Need to separately control cavity side and core side by two mold controller.7Need to separately controll block insert and mold base./接水路时必须牢牢记住：认清“进”“出”和渠道号；接水管前用气枪吹吹看看水路有否堵住；各个模穴绝对不允许搭管连接；每个模穴号确保一样的水流方向；确保每个模穴的水管长度一致；前后模必须分开控制温度；模腔与模胚要分开控制温度。37Safety limit switch connection: need to hook up every safety limit switch if the mold with. Normally every plastic mold sure be have at least one or two limit switch for ejector plate return. If found without any limit switch or early-return device for ejector-plate please report to supervisor. Notice: normally for safety limit switch connection, need to paper formally ask for facilitys support.安全限位开关连接：只要是模具上配有的安全限位开关都必须连接，通常塑胶模具都会配有至少个或者个安全限位开关给顶针板复位.如果发现没有限位开关又没有早回装置的必须向主管汇报。注意：对于安全限位开关，通常应该正式的书面要求设备部协助。38Hot runner controller connection:1Need to clearly to know how many heat zones with the mold;2Need to option matching hot runner controller and cable;3Need to correctly to hook up male and female connector between mold and hot runner controller;4If connector in the mold not match to the linking cable, need to paper formally ask for facility replace of correct standard connector，no allowed to replace the connector of the cable. 热流道控制器连接：1必须很清楚地了解模具需要多少段热源；2必须选配合适的控制器和电源连接线；3模具与热控制器之间的母座与公座要连接正确；4如果没有合适的接头匹配模具，应该书面要求设备部更换模具那端的母座与公座使其统一化标准化，而不是更换电源连接线那头的接头。39Air valve for valve pin connection,HAVE to keep in mind:1for the mold with valve-pin, NEVER hook up air source for valve-pin before hot runner heating up;2At least 3min after hot runner heating up reach to process temperature, hook up air-source to the valve-pin switch but no need immediately switch on the motion option. 3 Molding technician will later turn on the motion option and adjust the air-pressure.封胶针气阀连接，必须牢牢记住：1对于带有封胶针的模具，在热流道温度升温到加工温度时绝对不能连接汽源；2在热流道升温到加工温度至少3分钟后可以连接汽源但不必要马上打开动作功能;3注塑技术员将会打开气阀功能和调节气压。40Mold surface cleaning Dont forget to clean the mold surface with virgin cotton or cleaner, never cleaning the mold surface with dirty rag or dirty cotton. ( 模面清洗时必须使用新的棉花或者洗模水，决不使用脏的碎布或者脏的棉花) New mold trial run working steps(新模试产作业程序)StepsCheckpoint 确认点YNStep1Checking IF mold set up guy working under guideline instruction?/确认上模者是否遵循作业指导书工作？Step 2Check IF melt temperature is setting accordance with datasheet provided by resin supplier.确认熔胶温度设定是否遵照原料供应商的推荐值 Step 3Check IF mold temperature is setting accordance with datasheet provided by resin supplier.确认模温温度设定是否遵照原料供应商的推荐值 ？Step 4Check IF mold temperature is separated controlled ?/前后模温是否分开控制？Step 5Check IF KO rod or pull back rod corrected connection?/顶杆或拉杆是否安装正确？Step 6Check IF water-line is corrected connection?确认水路连接方法是否正确？Step 7If all the limited switch is corrected hook up?/所有该连接的限位保护开关都正确连接？ Step 8If ejector forward and return smoothly?/顶针活动是否顺畅？Step 9There is adequate clearance in the 3 plate mold to eject the runner system (Not Applicable-NA)/3板模顶出空间是否够/NAStep 10The mold open stroke is adequate to allow parts to fall freely./开模距离是否足够Step 11The temperature control lines are connected as intended by the mold designer. /温控线是否安装正确,是否按开模设计要求进行连接Step 12Check coolant flow to ensure no blockages, minimum 5-7 pounds pressure drop. /运水是否顺畅,水压是否达5-7磅Step 13Check IF water hose leak or not? Ensure water hose resist to high pressure and high temperature./确认水管漏水与否，保证水管能经得起高温高压。 Step 14Check water, oil, electrical lines and fittings are secured with adequate clearance./ 水管,油管及电线是否布置安全,留有足够的空间.Step 15Check the mold low pressure close protection has been set，HAVE to remember: every mold need to set low pressure and mold protection travel, NEVER allowed low pressure setting exceed 5% of the actual clamping force./是否有低压锁模设定,必须记住：所有模具都要设定低压保护模具和保护的行程,绝对不能设定大于实际锁模力的Step 16Check the mold close speed transition occurs just prior to the leader pins entering the leader pin bushings./检查合模速度(先于导柱进入导向套)Step 17Verify molding material is dry, if required, per manufacturer spec, using a dew point meter and moisture analyzer, or by drying per manufacturer spec in a desiccant dryer. /检查料是否烘干,如需要可使用露点仪和湿度计测量,或按生产需要用带干燥剂（除湿系统）的干燥炉Step 18Check the actual mold temperature and actual melted temperature with thermometer/使用高度计测量实际的模温和料温。 Step 19Check Barrel and Water Temperatures Manifold and Sprue Heaters if available Use date processing sheet from Material Manufacture for mid range settings./检查料温及运水温度,参照原料供应商提供的原料规格表进行设定Step 20Molding parameter HAVE to obey previous data. Never allowed to change anything without any approval from molding engineer./成型条件设定必须根据上一次数据来参考，没有成型工程师允许绝对不能更改任何条件。Step 21HAVE to purge barrel to check melt and flow all material should be melted and flow unrestricted. Nozzle orifice needs to be smaller than sprue but as large as possible for most resins/进行清料,检查熔溶料的流动情况所有原料需熔解并能顺利流动,射嘴孔径需小于进胶套直径,但一定要足够大让料能顺畅流动Step 22Turn off Hold Pressure and Timer any hold pressure at all when starting could cause damage to tool保压压力及保压时间是否关闭(开机时使用保压可能会损坏模具)Step 23Set the shot size so that you are assured of short shots (to ensure no tool damage, make sure this is considerably below the estimated shot size)/.设定料量(料量设定需保证达啤重,为保证模具安全,料量设定稍低于评估啤重)Step 24Set Back Pressure to 50 psi. Make sure the shot is still at approximately 95% of fill after setting back pressure. Back Pressure should generally be set to match screw recovery, for optimum cycle time, and should not exceed 150 psi./将背压设为50Psi.确保设定背压后料量为啤重的95%.背压设定需与计量相配,为优化周期,不可超过150psiStep 25Set Injection timer for 1 second (this will be adjusted when fill time is established - do not set timer any more than .2 seconds longer than actual fill)./设定射胶时间(先将射胶时间定为1秒,当填充时间建立后再调整,射胶时间不能长于填充时间0.2秒Step 26HAVE to remember doing short-shot study when starting to run the mold, the part little by little from 20% to 95%, when the part got to 95% of the part weight started to add packing pressure and packing time./记得要做走水板(短射学习)，从20%到95%，当产品填充到总重量95%时可以施加保压压力和保压时间。Step 27Cooling time setting: normally start with 20 seconds let the process stabilize and then work it down or up 2 seconds at a time until part and runner are set up/设定冷却时间(通常开机时将冷却时间定为20秒,等周期稳定后按2秒为单位进行减少或增加,直达稳定状态Step 28Pack & hold setting, per the Hold-Time Study document. Start with 3 seconds hold time and increase in 1 second increments, weighing the parts with each shot. Set Hold Time 1/2 second beyond weight stabilization. Normally packing pressure is lower than last stage of fill pressure，And holding pressure is lower than packing pressure./保压与保持设定，根据保压分析,开始设定3秒保压,增加一秒进胶,称每啤产品重.直到产品重稳定后现加0.5秒保压,通常保压压力都会比最后一段射胶压力小，然而，保持压力也会小于保压压力。Step 29For bigger part, Set initial Hold pressure at 500lbs Try to stay at 500 psi depending on gate and runner system If part weight does not stabilize by 22 sec. Of Hold time, increase pressure by 100 psi and repeat study./对于大塑胶件，设定初始保压500lbs根据进浇口大小,设定500psi保压,如果22秒内产品重量还不稳定,每次增加100psi进行分析,测量,直到重量稳定.Step 30When the is full and pack is stable, need to check the cushion, Cushion should be set at 3-5mm ,too much cushion could case major damage to the tool if a timer fails during the process/,当产品啤满时记得要确认余料量，残余料量应该在3-5mm之间如果设定太多的残余料量可能导致啤货过程中模具严重损坏Step 31Need to remember first 10 shots part is unsuitable for first sample evaluation,记住：十啤以内的产品不宜做为首件评估。Step 32Run 20 to 30 shots prior to initial dimension checks. Parts should not be warm to the touch when measured. If dimensions are OK this process should not c