注塑模具原理与基本方法外文文献翻译、中英文翻译
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外文资料翻译资料来源：文章名：Tribological assessment of the interface injection mold/plastic part书刊名：tribology international作 者：crossmark出版社：journal homepage文 章 译 名： 注塑模具原理及基本方法 姓 名： 学 号： 指导教师(职称)： 专 业： 班 级： 所 在 学 院： 外文原文:The sector of plastics processing is relatively young compared to cast iron, steel or glass industry. So it still has a very strong development potential. One of the current challenges of the plastic injection process is linked to the importance given to product design that enables a strong differentiation 1. Plastic parts with an increased technical level of surface accuracy are required in the areas of luxury, packaging, automotive, including the medical and optics. Their development involves the improvement of the fabrication process, and one of the keys lies in the mastery of the surface conditions of the molds.Injection molding is a cyclic process, characterized by 5 phases: dosing, injection, packing, cooling and ejection . The raw material that is dosed in the machine must be pure and conserved before use at an adequate temperature in order to be as dried as possible. This is necessary to avoid condensation inside the mold. The injection phase is characterized by high flow rates and hence high shear rate (tangential effect). As the molten material enters the mold, two heat transfer mechanisms occur: convection (between the melted material and mold surface) and viscous dissipation (due to the effect of injection speed on the injected material viscosity). As the filling is complete, the mold is uphold at a predetermined pressure and so the packing phase is initiated. During this phase, the molten polymer continues to be introduced into the mold to compensate for the shrinkage of the already injected material as it cools down. After a specific time, the cooling phase (contrary to the cooling state which begins during injection and packing phase) of the entire assembly starts and so also the solidification process of the plastic part. As the material solidifies and shrinks in the mold, the dominant heat transfer mechanism is conduction. When the part is sufficient solidified, it is ejected from the mold. During this last phase, a normal effect can be attributed to the ejection force and adhesion phenomena can occur between the mold surface and the plastic part 2.Despite the undeniable diversity of configurations available (in terms of combination: mold material, surface finish and processed materials), the producers are faced with similar difficulties. Thus, the key shortcomings that stand out, more or less combined, can be summarize as follows: the fouling phenomena which require frequent stops for cleaning; corrosion phenomena that can greatly limit the lifetime of the mold cavity as a function of the type of injected polymer; problems of sticking and releasing in function of the injected materials and surface quality; problems in keeping the polishing quality; scratches or shocks during use or storage.The available literature approaches experimental and/or numerical, various aspects regarding the plastic injection molding process. One of them is the filling and flow behavior of molten polymers. 3Bociaga and Jaruga studied the formation of flow, weld and meld lines by developing a new method of flow visualization, which can prove helpful in the identification of weakareas on injected parts. Also the effect of pressure and cavity thickness were assessed. Same topic was treated by Ozdemir etal. 4, comparing the behavior of molten HDPE (high density poly-ethylene) and PE experimentally and numerically.During molding, friction forces act first between the mold surface and the molten polymer and second when the plastic part is ejected from the mold. Bull etal. 5 adapted the ASTM rubber wheel abrasion test to simulate the conditions of wear produced by the glass filled polymers on the barrel surface of an injection molding machine. Various coatings were tested, but unfortunately they tended to have a weak performance on account of the test conditions. 6 developed a prototype apparatus to study the friction properties of molding thermoplastics during ejection phase. The measured friction coefficient had a tendency to increase with the roughness. But when the roughness was reduced the friction coefficient increase due to the rising adhesion forces effect. The scanning electron microscopy images of the mold surface and the ones for the polycarbonate (PC) and polypropylene (PP) plastic parts, revealed a clear replication of the mold surface on the parts.Transient in nature, injection molding process involves not only several heat transfer mechanisms, phase change and time varying boundary conditions, but goes further in adding the effect of material properties and geometry of the injected part. 7 Bendada etal performed a study to evaluate the nature of thermal contact between polymer and mold through the different phases of a typical injection cycle. Their findings concluded that the thermal contact resistance was not negligible, not constant with time and was strongly linked with the process conditions.The existing number of studies concerning the phenomena present at the interface mold surface/polymer is relatively low to other related topics. Besides, they dont focus on studying the current limitations of the plastic injection process at a microscopic scale, taking into account various macroscopic influences. To overcome plastic injection molding shortcomings, the contact conditions at the interface between mold surface and plastic part have to be identified. This work focus on the effect of the polishing quality, the mold geometry and the injected material on that interface, by studying the corrosion-mechanical attack and the mechanical -physical- chemical one.2. Method and materials2.1. MaterialsFour polymers were chosen to be injected: ionomer resin (E-MMA Surlyns PC 2 000), styrene-acrylonitrile resin (SAN Tyril 790), polyamide with 25% glass fibers (PA66GF25) and poly-carbonate (PC Makrolon LQ 2647). Surlyn is a copolymer of ethylene and methacrylic acid where some of the acid groups are neutralized to form the sodium salt. The acid in the polymer gives polarity and reduces crystallinity. The ionic bonding between the polymer chains gives outstanding melt strength, toughness and clarity. The reason of choosing Surlyn was based on the experience of our industrial partners, which find it particularly corrosive despite its good properties. Surlyn is also a copolymer, optically transparent and brittle in mechanical behavior. Its considered in this study a reference material, usually used in cosmetics, luxury and automobile domains. PA66GF25 is an aliphatic-polyamide, reinforced with 25% glass fibers. PA66 has an excellent balance of strength, ductility and heat resistance. The glass fibers exert an abrasive effect and thus affect the mechanical protection of the polishing. PC is composed by carbonate groups. It has a high impact-resistance, low scratch-resistance and is highly transparent to visible light. It is usually used for the production of eyewear lenses and exterior automotive components.2.2. MoldsTwo molds, made of hardened steel (52 HRC) containing 13% to 15% of Chromium, with different geometries were used, one with a mirror polished surface (complex geometry) and another with an optical polished surface (simple geometry) . The mold has two parts: the stamp and the matrix. For the mold with complex geometry the stamp is of 149 119 80 mm in size and the matrix of 149 119 50 mm. In case of the one with a simple geometry, the stamp is of 50 70 mm in size and the matrix has a cylinder form with a diameter of 70 mm. The surface finish of the mirror and optical polished molds involved a polishing cloth and diamond paste. Further details on the polishing process are confidential.The mirror polished mold was specially designed for this study by Technimold (a mold maker) to highlight the role of angles and obstacles in the formation of defaults. Also the mold design did not include a special feature that can evacuate the air. This was done intentionally in order to submit the polished surfaces to aggressive conditions. The molding process was performed at “Center Technique dela Plasturgie et des Composites” (IPC, France) on a 50 T Engel machine. The injection parameters, listed in Table 2, were chosen in accordance with standard specifications for the injected polymers. Based on a numerical simulation they were adapted to respond in conformity with the mold design. Two injection campaigns were conducted on this type of mold. After the first campaign, on the plane part of the mold stamp, an insert with a diameter of 12 mm and a height of 8 mm, was mounted to facilitate the morphology assessment.For the Surlyn injection, 3000 parts were injected in the first campaign. After surface analysis, the mold was submitted to the industrial cleaning operation. The second campaign consisted in the injection of 3700 more parts. SAN and PA66GF25 were injected on the same mold. During the first campaign, only 8000 SAN parts were injected. Before starting a second campaign, the mold was polished entirely. The second campaign consisted in the injection of 300 parts of SAN. The insert was changed before starting the injection of 12 200 PA66GF25 parts.2.3. MethodThe surface expertize consisted in two main steps: the microscopy analysis and the inter ferometry measurements before and after injection process. Due to their large dimensions and elevated mass, the surface analysis of the mirror polished molds was per-formed using a classic optical microscope. For the optical polished one, thanks to smaller dimensions, the microscope analysis could be carried out using a numerical optical microscope (Keyence) and a high resolution environmental scanning electron microscope (FEI XL30 ESEM). Although two injection campaigns have been performed, the results presented in this paper, refer only to the surface expertize performed at the end of the second campaign. For the injected plastic parts, only the interface between mold matrix plane part and plastic part is discussed in this paper.In order to identify the chemical composition of different deposits found on the mirror polished mold surfaces, a Fourier Transform Infrared (FTIR) spectrometer was used for the analysis.3. Results and discussions3.1. Mirror polished mold3.1.1. Injection SurlynsAll along the stamp plane part, deposits different in texture and consistence can be observed (Fig. 5). Their location and morphologyseem to indicate the flow direction of the molten polymer. Also it can be noticed, towards the end of the flow, the deposits grow in terms of thickness and occupied surface.The type of deposit observed in Fig. 5e and f is also observed after the first injection campaign (3000 injected parts), and appeared that the cleaning operation has been able to remove it, but formed again during the second injection campaign (3700 injected parts). This particular deposit is located between the extremity of the oval bump and the hole where one of the ejection pins acts. Also in this location the flow changes direction, more precisely makes a left turn; fact also revealed by the deposit morphology. Its existence can be explained starting with the effect of the injection speed on the molten polymer viscosity, which is considered to be a heat transfer mechanism that occurs during the injection process. Due to the geometry factor, the viscous dissipation creates a temperature gradient which sensitizes this area. During the packing phase, as the mold continues to be filled, the location identified is one of the last to be reached by the molten polymer. As the holding phase begins and with it the solidification, the temperature gradient that appears in the injection phase continues to act and by doing so it delays the solidification in this area. When the established time for the holding phase expires, the mechanism of ejection is set in motion. The ejection pin is close to the identified location and as it was affected by the temperature gradient and has not yet been entirely solidifies, it will also be the first area to be separated from the mold surface. All these can explain the appearance of the adhesion phenomenon.In the deposit appears like a thin film and is also located in an area where the flow changes direction. It could also be justified by the temperature gradient, but its aspect and composition suggest that may another phenomena can occur. The infrared analysis performed on this area suggest that only some of the wave numbers match with the ones from the spectrum registered for the injected part It is possible that the gases released from the contact of the molten polymer with the mold surface reacted with the additives from the raw material composition and facilitated the separation of the thin layer that stick on the mold surface. Also the “scraped” aspect of this deposit indicates that is more likely that this type of deposit has formed during the injection phase.Holes (form 14.6nm to 404nm deep) are observed before injection probably due to polishing.Their morphology evolves during injection process:the holes expand in occupation area and depth(39.7nm to 877nm).the pointing red arrows indicate the presence of the evolved holes.They exhibit two types of morphology.The first type illustrated shows very small holes focused altogether in smaller or larger spots and the second type illustrated presents a hole surrounded by a “cloud” of small holes. Due to the inclusions in the bulk material,grains dislocation could occur causing the formation of holes during polishing process.Those holes are modified in term of depth and area during injection process.As reported,stress corrosion cracking can affect the molds,starting at a microscopic level and revealing itself at crack.The primary causal elements are the metallurgy of steel,the presence of chlorine in the water used in the cooling lines of the mold and the stresses on the tool during molding.It is known that Chromium gives the steel corrosion resistance,by providing a protective oxide layer.Thus it is possible that due to the polishing defects(holes),the thickness of the layer is compromised and thus when a high viscous corrosive polymer,like Surlyn,is injected,the areas affected by holes,are submitted to corrosion nature of Surlyn(based on the experience of industrial project partners),can create an aggressive environment at the mold/molten polymer interface due to the gases release.The high viscosity of Surlyn and its capability to stick onto the mold surface also plays a role in terms of exerting a mechanical-physico-chemical attack on the area where the defaults are located.All these statements allow to catalog this default as corrosion pit.4. ConclusionsThis study has allowed the identification and evaluation of defaults that occur during plastic injection process,at microscopic scale.The results obtained highlight the different damage mechanisms sustained by the mold surface,as a function of polishing,geometry and injected material.It can be also observed that for each material injected there is a difference of level of wear and damage mechanism between the stamp and the matrix.Surlyn injection exhibited considerable amount of deposits on the mold stamp.It seems that the physico-chemical conditions,created during the injection by this type polymer,favored the adhesion.Also in the case ,the coupling effects of polishing quality,the injected material,adhesion and the lack of the mold feature that evacuates air,tend to form corrosion pits on a mirror polished surface. SAN and PA66GF25 polymers were injected successively on the same mold.The mold surface presented polishing defaults(holes)before injection.The holes were enlarged in the direction perpendicular to the injection flow due to abrasive effect of glass fibers. A critical characterization of the mold surface topography was performed in order to identify the location and the type of defaults that occur when more or less aggressive material were injected in molds with different geometries.All the results provided can be taken into consideration for the design of a “chameleon” coating that can overcome present drawback.注塑模具原理与基本方法译文：与铸铁、钢铁或玻璃工业相比，塑料加工行业相对年轻。因此，它仍有很强的发展潜力。塑料注射工艺目前面临的挑战之一是与产品设计的重要性有关，从而使产品具有很强的差异性。 y与 zh铸 ti铁 、 gng钢 ti铁 hu或 b玻 li璃 gng工 y业 xing相 b比 ， s塑 lio料 ji加 gng工 hng行 y业 xing相 du对 nin年 qng轻 。 yn因 c此 ， t它 rng仍 yu有 hn很 qing强 de的 f发 zhn展 qin潜 l力 。 s塑 lio料 zh注 sh射 gng工 y艺 m目 qin前 min面 ln临 de的 tio挑 zhn战 zh之 y一 sh是 y与 chn产 pn品 sh设 j计 de的 zhng重 yo要 xng性 yu有 gun关 ， cng从 r而 sh使 chn产 pn品 j具 yu有 hn很 qing强 de的 ch差 y异 xng性 。 1. Plastic parts with an increased technical level of surface accuracy are required in the areas of luxury, packaging, automotive, including the medical and optics. Their development involves the improvement of the fabrication process, and one of the keys lies in the mastery of the surface conditions of the molds. 1 在豪华、包装、汽车等医疗和光学领域，要求提高表面精度的塑料件。它们的发展涉及到制造工艺的改进，关键之一是掌握模具的表面条件。 注射成型是一个循环过程，其特征为5个阶段：注射、注射、包装、冷却和脱模，在适当的温度下使用前，机器中所含的原材料必须是纯的和保守的，以便尽可能干燥。这是必要的，以避免在模具内冷凝。注入阶段的特点是高流速，因此高剪切速率（切向效应）。当熔融材料进入模具时，会出现两种传热机理：对流（熔化的材料和模具表面）和粘性耗散（由于注射速度对注入材料粘度的影响）。当填充完成时，模具处于预定压力下，从而开始填充阶段。在这个阶段，熔融的聚合物继续被引入模具，以补偿已经注入的材料在冷却过程中的收缩。在特定的时间之后，整个装配过程中的冷却阶段（与注射和包装阶段开始的冷却状态相反）开始，也就是塑件的凝固过程。当材料固化收缩时在模具，主要是传导传热机理。当零件充分凝固时，就会从模具中排出。在这最后一个阶段，一个正常的效果可以归因于脱模力和模具表面和塑件之间可能发生粘着现象。 2 尽管配置的多样性不可否认，但在组合方面：模具材料、表面光洁度和加工材料，生产商也面临类似的困难。因此，突出的关键缺点，或多或少地结合起来，可以总结如下： jn尽 gun管 pi配 zh置 de的 du多 yng样 xng性 b不 k可 fu否 rn认 （ zi在 z组 h合 fng方 min面 ： m模 j具 ci材 lio料 、 bio表 min面 gung光 ji洁 d度 h和 ji加 gng工 ci材 lio料 ） ， shng生 chn产 shng商 y也 min面 ln临 li类 s似 de的 kn困 nan难 。 yn因 c此 ， t突 ch出 de的 gun关 jin键 qu缺 din点 ， hu或 du多 hu或 sho少 de地 ji结 h合 q起 li来 ， k可 y以 zng总 ji结 r如 xi下 ： 结垢现象需要频繁启停的清洁； ji结 gu垢 xin现 xing象 x需 yo要 pn频 fn繁 q启 tng停 de的 qng清 ji洁 ； 腐蚀现象，极大地限制了模具型腔的寿命作为一种注入聚合物型函数； f腐 sh蚀 xin现 xing象 ， j极 d大 d地 xin限 zh制 le了 m模 j具 xng型 qing腔 de的 shu寿 mng命 zu作 wi为 y一 zhng种 zh注 r入 j聚 h合 w物 xng型 hn函 sh数 ； 问题贴和释放功能的注射材料和表面质量； wn问 t题 ti贴 h和 sh释 fng放 gng功 nng能 de的 zh注 sh射 ci材 lio料 h和 bio表 min面 zh质 ling量 ； 保持抛光质量问题； 划痕或冲击使用或贮存过程中。 3 现有文献接近实验和/或数值，关于塑料注射成型过程的各个方面。其中之一是熔融聚合物的填充和流动行为。Bociaga和Jaruga 研究了流的形成，焊缝和焊线通过流动可视化的新方法，它可以在弱的鉴定证明是有益的注射部位。此外，压力和空腔厚度的影响进行了评估。同一主题采用Ozdemir etal。 4 实验比较了熔融HDPE（高密度聚乙烯）和聚乙烯的行为。 在成型过程中，摩擦力首先作用于模具表面和熔融聚合物之间，其次是塑料部分从模具中排出。牛等。 5 调整了ASTM橡胶轮磨损试验，模拟注塑机桶面上玻璃填充聚合物的磨损情况。各种涂层进行了测试，但不幸的是，他们往往有一个弱的性能，由于测试条件。 6 开发了一个原型装置来研究成型热塑性塑料在喷射阶段的摩擦性能。测量的摩擦系数随粗糙度增大而增大。但当粗糙度降低时，由于粘着力的增加，摩擦系数增加。对模具表面和聚碳酸酯（PC）和聚丙烯（PP）塑料件的扫描电子显微镜图像，揭示了模具表面上的部件清楚地复制。 在瞬态过程中，注塑过程不仅涉及到多种传热机理、相变和时变边界条件，而且还涉及到注入部分材料性能和几何形状的影响。zi在 shn瞬 ti态 gu过 chng程 zhng中 ， zh注 s塑 gu过 chng程 b不 jn仅 sh涉 j及 do到 du多 zhng种 chun传 r热 j机 l理 、 xing相 bin变 h和 sh时 bin变 bin边 ji界 tio条 jin件 ， r而 qi且 hi还 sh涉 j及 do到 zh注 r入 b部 fen分 ci材 lio料 xng性 nng能 h和 j几 h何 xng形 zhung状 de的 yng影 xing响 。 B e n d a d a e t a l 。 7 performed a study to evaluate the nature of thermal contact between polymer and mold through the different phases of a typical injection cycle. Their findings concluded that the thermal contact resistance was not negligible, not constant with time and was strongly linked with the process conditions. 7 Bendada etal行了一项研究，以评估通过一个典型的注塑周期的不同阶段的聚合物和模具之间的热接触的性质。他们的结论是，热接触电阻是不可忽略的，不随时间而定，并与工艺条件密切相关。1 方法和材料 2 。 fng方 f法 h和 ci材 lio料 1.1 材料 四聚合物进行注射：离子树脂（e-mma surlyns PC 2 000）、苯乙烯-丙烯腈（SAN tyril 790），25%玻璃纤维的聚酰胺（pa66gf25）和聚碳酸酯（PC聚碳酸酯LQ 2647）。沙林是一种乙烯共聚物和甲基丙烯酸中的酸基团中和成钠盐。聚合物中的酸具有极性，降低了结晶度。聚合物链之间的离子键具有优异的熔体强度、韧性和透明度。选择沙林的原因是基于我们的工业合作伙伴的经验，发现尽管特别腐蚀性能良好。SAN也是一种共聚物，在机械性能上是透明的和脆性的。在这项研究中，它被认为是一种参考材料，通常用于化妆品、奢侈品和汽车领域。pa66gf25是脂肪族聚酰胺，25%玻璃纤维增强。PA66具有优良的平衡强度，韧性和耐热性。玻璃纤维产生研磨作用，从而影响抛光的机械保护。PC由碳酸盐族组成。它具有高的抗冲击性、低的抗划伤性和对可见光的高度透明性。它通常用于生产眼镜镜片和外部汽车部件。 1.2 模具 两个模具，由硬化钢（52 HRC）含有13%到15%的铬，具有不同的几何形状，有镜面抛光表面（复杂几何）和一个光学表面抛光（简单的几何图形）模具有两部分：图章和模板。对于复杂几何形状的模具，特征是149 119 80毫米的大小和模板的149 119 50毫米。在一个简单的几何形状的情况下，特征是50 70毫米的大小和模板的圆筒形，直径为70毫米。镜面和光学抛光模具的表面处理涉及抛光布和金刚石浆料。抛光过程的进一步细节是保密的。镜面抛光的模具是专门为这项研究的technimold（模具制造商）突出的角度和障碍在违约的形成中的作用。此外，模具设计没有包括一个特殊的功能，可以疏散空气。这是故意做的，以便提交抛光表面侵略性条件。成型过程进行在“中心技术德拉plasturgie et des复合材料”（IPC，法国）在50 T恩格尔机。表2列出的注射参数是根据注射聚合物的标准规范选择的。在数值模拟的基础上，他们根据模具设计进行了相应的响应。对这种类型的模具进行了两次注射运动。在第一次战役之后，在模具特征的平面部分上，安装了直径为12毫米和高度为8毫米的插入物，以便于进行形态学评估。 对于沙林注射，3000部分是在第一次注射。经过表面分析，将模具提交工业清洗作业。第二场运动是注射3700个以上的部件。三、pa66gf25注射在同一模具。在第一次战役中，只注射了8000个沙林部件。在开始第二次战役之前，模具全部抛光了。第二场战役是由300部分的圣注组成。插入前12 200 pa66gf25件注塑开始改变。1.3 方法 表面的专业包括两个主要步骤：和干涉测量的测量之前和之后的注射过程的显微分析。由于镜面尺寸大、质量高，采用经典光学显微镜对镜面抛光模具进行了表面分析。对于光学抛光，由于小尺寸、显微镜分析可以用光学显微镜进行数值（KEYENCE）和一个高分辨率的环境扫描电子显微镜（FEI型扫描电子显微镜）。虽然两注入活动已进行，本文的结果，仅指表面的专业在第二战役结束后进行。对于注塑件，本文只讨论了模具基体平面部分与塑件之间的界面。 为了识别镜面抛光模具表面不同镀层的化学成分，采用傅立叶变换红外光谱仪（FTIR）进行分析。 wi为 le了 sh识 bi别 jng镜 min面 po抛 gung光 m模 j具 bio表 min面 b不 tng同 d镀 cng层 de的 hu化 xu学 chng成 fn分 ， ci采 yng用 f傅 l立 y叶 bin变 hun换 hng红 wi外 gung光 p谱 y仪 （ F T I R ） jn进 xng行 fn分 x析 。 2 结果与讨论 sn三 . ji结 gu果 y与 to讨 ln论 2.1 镜面抛光模具 注射surlyns 沿着特征平面部分，可以观察到纹理和一致性不同的沉积物（图5）。它们的位置和形态 似乎表示熔融聚合物的流动方向。也可以注意到，在流动的末端，沉积物以厚度和占据的表面生长。 矿床类型观察图5e和F也是第一次注射后观察运动（3000注射部位），和出现的清洁操作已经能够消除它，但又形成第二注射活动期间（3700注射部位）。这种特殊的沉淀物位于椭圆形凸起的末端和一个弹射销的孔之间。也在这个位置，流动方向改变，更准确地说左转；事实也揭示了沉淀物形态。它的存在可以从注入速度对熔体粘度的影响开始解释，这被认为是在注射过程中发生的传热机理。由于几何因素，粘性耗散产生温度梯度，促进这一地区。在包装阶段，当模具继续填充时，所确定的位置是熔融聚合物最后到达的位置之一。随着保温阶段的开始，随着凝固的进行，在注射阶段出现的温度梯度继续起作用，从而延缓了这个区域的凝固。当保持阶段的建立时间结束时，弹射机构开始运动。顶出销接近确定的位置，因为它是由温度梯度的影响，尚未完全固化时，它也将被从模具表面分离的第一区。这些都可以解释粘连现象的出现。在沉积物中看起来像一个薄膜，也位于流动方向改变的区域。它也可以通过温度梯度来证明，但是它的外形和组成表明可能会出现另一种现象。红外分析表明在这个地区只有一些波数的光谱匹配的注册注入的部分可能是从与模具表面接触反应的聚合物熔体从原料成分的添加剂和便利的薄层分离，在模具表面坚持释放气体。此外，该矿床的“擦伤”方面表明，这种类型的沉积物更可能是在注入阶段形成的。 孔（形式14.6nm到404nm深）观察注射前可能由于抛光。其形态的演变过程：在注射孔扩大占地面积和深度（39.7nm到877nm）。指向红色箭头指示的是孔的存在。他们表现出两种形态。第一类说明很小孔集中
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