培训课程 2 工艺参数的优化

培训课程2工艺参数的优化培训课程2工艺参数的优化受训者手册德马格注塑机工艺参数优化的步骤指导页面周期分析3注塑工艺参数优化6步骤1找出转压点7步骤1结果8步骤2找出保压时间浇口冷凝时间9步骤2结果10步骤3优化注射速度11步骤3结果12步骤4采用正确的螺杆转速13步骤4结果14步骤5优化多级螺杆转速和背压曲线15步骤5结果16步骤6优化松退17步骤6结果18步骤7优化保压曲线19步骤7结果20TABULATEDRESULTS21步骤8优化锁模力22步骤8结果22步骤9设定注射压力23步骤9结果23典型工艺参数公差设定24成型周期分析采用下面表格估计注塑过程中的每一阶段对周期的影响然后去机床看正在运行的模具,写下实际的时间并计算出百分比哪一阶段在整个周期中占最多的时间那里可以是最有效的缩短成型周期模具1估计实际实际评价合模射台前进和后退注射时间保压时间冷却时间开模顶出整个成型周期100SECONDS100模具2估计实际实际评价合模射台前进和后退注射时间保压时间冷却时间开模顶出整个成型周期100SECONDS100工艺参数优化目标一步步改进工艺过程稳定性评估各个参数的更改对工艺过程稳定性的影响TODEMONSTRATETHECUMULATIVEIMPROVEMNTINTHEPROCESSANDPRODUCTCONSISTENCY方法ATEACHSTAGE,AFTERTHEPROCESSHASBEENGIVENSUFFICIENTTIMETOSTABILISE,ARUNOFSIXTEENCONSECUTIVEMOULDINGSISTOBEMADETHESEMOULDINGSWILLBEASSESSEDFORCONSISTENCYBYWEIGHTADIMENSION,APHYSICALPROPERTYORSOMEOTHERATTRIBUTECOULDEQUALLYWELLBEUSED,WEIGHTISSIMPLYTHEMOSTWIDELYAPPLICABLE稳定性通过计算重量的标准偏差来衡量同时打印出机床IBED上的过程统计数据找出转压点找出浇口冷却时间优化注射速度采用正确的螺杆转速优化多级预塑曲线优化松推优化多级保压曲线优化锁模力设定注射压力限定步骤1找出转压点在没有保压压力和保压时间的基础上填满产品9598,然后设定一定的保压和保压时间生产16模初始设置时的指导1采用行程切换2设定切换位置为1012MM逐步增加预塑量直到产品打满9598的位置3设置注射压力为最大值4设定保压压力和保压时间均为05设定注射速度60MMS16设定松推速度为最大值7设定锁模力为最大值8选择适当的螺杆转速9根据材料物性表,设定料桶温度10配置过程统计控制11设定保压压力和保压时间生产完整的产品称12模产品的重量,计算标准偏差打印页面20工艺参数优化页面50工艺过程统计步骤1结果输入实际值平均值范围最小最大没保压时的重量有保压后的重量填充的百分比标准偏差16模G料垫平均值和范围预塑时间平均值和范围螺杆停止位置平均值和范围注射时间平均值和范围注射压力峰值,PINJMAX转压压力,PNPRESS转压位置步骤2找出浇口冷凝时间设定保压压力为步骤1上找出的注射压力峰值的50左右设定保压时间为1S生产数模产品使过程稳定后连续取5模产品称出每模重量和平均值增加保压时间至2S,生产数模产品使过程稳定后连续取5模产品称出每模重量在保压时间3S,4S5S时重复上述过程直到产品重量不再增加作出产品重量和保压时间的关系图记录RECORDTHETCUSETTINGANDTHEACTUALMOULDTEMPERATURE打印页面30温度XLSPREADSHEETGRAPH为什么记录模具温度很重要还有什么因素会影响浇口冷凝时间步骤2结果输入实际值TCUSETTINGFHTEMPERATUREMHTEMPERATURECCC重量1重量2重量3重量4重量5平均重量时间保压重量1重量2重量3重量4重量5平均重量时间保压所需的保压时间S步骤3优化注射速度采用多级注射曲线,使注射行程最后的1020采用逐步降低的注射速度每次更改注射速度,必须重新建立转压点注意每次保压和保压时间都设定为0连续取16模,计算出标准偏差打印页面24MWE使用和没使用多级保压时的曲线页面26多级注射页面50工艺过程统计为什么转压点要更改注射压力发生了什么为什么在数社的末端采用逐步降低的注射速度是有用的步骤3结果输入实际值平均值范围最小最大没有保压时的重量采用保压的重量填充百分比标准偏差16模G料垫平均值和范围预塑时间平均值和范围螺杆停止位置平均值和范围注射时间平均值和范围注射压力峰值,PINJMAX转压压力,PNPRESS转换位置步骤4采用正确的螺杆转速SELECTTHECORRECT,OPTIMUMSCREWSPEEDFORTHEMATERIALBEINGPROCESSEDSEET01NOTES,SECTION5USETHISSINGLESPEEDFORTHEWHOLEPLASTICISINGSTROKESETABACKPRESSUREOF5TO10BARHYDRAULICREADJUSTDOSINGSTROKETOACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE50PROCESSSTATISTICSWHYISITIMPORTANTTOUSETHEMANUFACTURERSRECOMMENDEDSCREWSPEEDSTEPFOURRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPFIVEOPTIMISESCREWSPEEDANDBACKPRESSUREPROFILEUSETHEDOSINGPROFILEPAGETOSLOWDOWNTHESCREWROTATIONSPEEDFORTHELAST10OFTHEMETERINGSTROKEREADJUSTDOSINGSTROKETOACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE21DOSINGPROFILESPAGE50PROCESSSTATISTICSWHATHASHAPPENEDTOTHEDOSINGSTOPPOSITIONSTEPFIVERESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPSIXOPTIMISEDECOMPRESSIONFINDTHEDECOMPRESSIONSPEEDWHICHGIVESBESTSCREWSTROKEANDMELTCUSHIONCONSISTENCYSETADECOMPRESSIONSTROKEOF5MMCHECKTHATYOUSTILLACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE21DOSINGPROFILESPAGE50PROCESSSTATISTICSWHATHASHAPPENEDTOTHESCREWSTOPPOSITIONWHATISHAPPENINGTOTHECHECKRINGSTEPSIXRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPSEVENOPTIMISEHOLDINGPRESSUREPROFILEUSETHEHOLDINGPROFILEPAGETOSETAHOLDINGPRESSUREPROFILEWHICHENSURESASMOOTHTRANSITIONFROMINJECTIONTOTHEHOLDINGPRESSUREPHASEANDUSEAHIGHENOUGHPRESSURETOPACKTHEPARTPROPERLYADDASTEPWHICHREDUCESHOLDINGPRESSUREGRADUALLYTOZEROTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE24MWEPAGE27HOLDINGPROFILEPAGE50PROCESSSTATISTICSWHYDOYOUNEEDASMOOTHTRANSITIONFROMINJECTIONTOHOLDINGPRESSUREWHYBOTHERTOREDUCETHEPRESSUREGRADUALLYIFTHEGATEHASALREADYFROZENSTEPSEVENRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKETABULATEDRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESTHERANGEVALUE,R,ISTHEMAXIMUMMINUSTHEMI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