精密注塑技术Aspects for Precise Injection Molding

1、精密注塑技术精密注塑技术 aspects for precise aspects for precise injection moldinginjection molding 2 copyright by arburg / nov. 2006 内容提要内容提要 overviewoverview 精密注塑的定义 definition precise injection molding 锁模系统 clamping unit 锁模力 clamping force 选择注射装置的准则 criteria to select the injection unit selogica 控制器 selogica

2、 controller 模具设计 mold design 模具温度控制 mold temperature control 3 copyright by arburg / nov. 2006 精密注塑的定义精密注塑的定义 definition precise definition precise injection molding injection molding 小的尺寸和公差 轻的部件重量 为特定产品配备注塑设备 灵活的机器配备（一台机器可适用于 多种模具) 稳定的质量，高的重复性 small part dimension and tolerance low weight adaptati

3、on of machine performance to the parts flexible machine configuration (many molds suitable for one machine) stable quality, reproducibility 4 copyright by arburg / nov. 2006 锁模系统锁模系统 clamping unitclamping unit 合模系统起重要的作用 动模板是稳定而经过证实的箱 型结构 长而精确的导向 模板平行度的调节 50 吨 范围内 0.05 mm 极高的刚度 for precise injection

4、 molding, the clamping take over a very important part. movable platen as stable and proven box- type platen long and precise guiding of the movable platen adjustable parallelism up to 50 to. machines 0.05 mm high rigidity 5 copyright by arburg / nov. 2006 锁模力锁模力 clamping forceclamping force 精密注塑的另一

5、个重要因素是锁模力。 原因是： 模腔更好的排气 （90%的空气从分型面排出） 减少机器和模具的磨损 节省能源 one other important aspect for precise injection molding is the clamping force. reasons for that are: much better venting of the cavities during injection. (ca. 90% of the air inside the cavity escape over the parting line) to prevent machine an

6、d mold from unnecessary wear. saving energy 6 copyright by arburg / nov. 2006 锁模力锁模力 clamping forceclamping force 怎样计算锁模力 锁模力 = 单位锁模力 x (产品投影面积 + 流道投影面积） 如果有滑块，需要将滑块投影面积的 30% 加入产品投影面积 how to calculate the clamping force ? if the mold contains sliders! you have to add 30% of the projected slider area

7、 to the projected area of molded part. sprue) area proj. part molded all of area (projected force clampingspecific force clamping 7 copyright by arburg / nov. 2006 锁模力锁模力 c clamping forcelamping force 单位锁模力的确定可使用以下图表 to define the necessary specific clamping force, use one of the pictures below. for

8、 standard partsfor thin walled parts with long flow paths 8 copyright by arburg / nov. 2006 锁模力锁模力 clampingclamping force force 举例 example: 接插件接插件 connector pa6connector pa6 长度 length: 6 cm 宽度 width: 1.5 cm 浇道投影面积 proj. area sprue: 8 cm2 单位锁模力 spec. clamping force: 6 kn/cm2 模穴数 8 cavities to.48or kn

9、 480 cm 80 kn/cm 6 force clamping ) sprue .8 cavities 8 cm 6 cm (1.5 kn/cm 6 force clamping 22 22 forceclamping areaprojcm 9 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit shot weight cycle time material injection pre

10、ssure 10 copyright by arburg / nov. 2006 每一机器尺寸 each machine size 三个注射单元 3 injection units 三个料筒规格 3 cylinder sizes 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit 模块化 modularity 11 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to se

11、lect the injection unitcriteria to select the injection unit 注射单元的欧洲橡塑机械协会 (euromap)规格表示注射单元的最大注 射功。 计算方法 最大注射压力 x 最大行程容量 / 1000 举例 按注塑机 320 c 600-250 规格表 最大注射压力(35 mm 螺杆）： 1820 bar 最大行程容量 144 ccm 1820 bar x 144 ccm /1000 250 the size of the injection unit is according to euromap and indicates the w

12、orking performance of the injection unit. the working performance is calculate max. spec. injection pressure x max. stroke volume / 1000 example: according to the technical data of 320 c 600-250 max. injection pressure (screw diameter 35mm) = 1820 bar max. stroke volume = 144 cm3 1820 bar x 144 cm3

13、/ 1000 250 12 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit 注射功 working performance ! 相同螺杆直径，但不同注射压力 ! same screw diameter but different max. injection pressure 13 copyright by arburg / nov. 2006 选择注射量的准则 selection c

14、riteria shot volume 最大计量容量max. dosage volume 20 80 %最佳工作范围 opt. working range 10 20 % bzw. 80 90 % 可接受的范围 conditional suited 90%不推荐的范围 not recommended 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit 14 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单

15、元规格的准则 criteria to select the injection unitcriteria to select the injection unit example: connector (pa6), 8 cavities, 26.5 g shot weight results according the list below: (1) the injection volume must be on average 25% greater than the volume of the injected part (incl. sprue) due to shrinkage dur

16、ing solidifying and due to the compression of the melt during injection. 3 3 cm 23.45 g/cm 1.13 g 26.5 eightspecific w weightshot volume shot 33(1) cm 29.31 cm 23.45 1.25 volume shot 1.25 volume injection injection unitinjection unit100100100100250250250250 screw diameterscrew diameter20 mm20 mm25 m

17、m25 mm30 mm30 mm40 mm40 mm max. injection volumemax. injection volume31 cm31 cm3 349 cm49 cm3 3106 cm106 cm3 3188 cm188 cm3 3 percentage of capacity percentage of capacity 95%95%60%60%28%28%16%16% 15 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria

18、 to select the injection unit example: connector (pa6), 8 cavities, 26.5 g shot weight 2nd example, calculation with shot weight results according the list below: injection unitinjection unit100100100100250250250250 screw diameterscrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mm molded part wei

19、ghtmolded part weight26 g26 g41 g41 g89 g89 g158g158g percentage of capacity percentage of capacity 100%100%64%64%30%30%17%17% 16 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit 滞留时间准则 滞留时间 = 塑胶进入料筒到离开喷 嘴的时间 pe,pp,ps:

20、最少 30 秒 (大于 40 秒 为好) pa, pom, pbt: 最少 60 秒 (75 秒为好) selection criteria dwell time dwell time = from the entree of material into the cylinder until the exit out of the nozzles e.g. pe, pp, ps : min. 30 s (better 40 s) e.g. pa, pom, pbt : min. 60 s (better 75 s) 17 copyright by arburg / nov. 2006 选择注射

21、单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit example: connector (pa6), 8 cavities, 26.5 g shot weight (29.31 cm3) result according to the list below, dwell time for pa6 min. 60 sec. injection unitinjection unit100100100100250250250250 screw diametersc

22、rew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mm screw channel volumescrew channel volume60 cm60 cm3 385 cm85 cm3 3185 cm185 cm3 3265 cm265 cm3 3 cycle time 15s / dwell cycle time 15s / dwell timetime 25 sec.25 sec.35 sec.35 sec.75 sec.75 sec.109 sec.109 sec. cycle time 25s / dwell cycle time 25

23、s / dwell timetime 41 sec.41 sec.58 sec.58 sec.126 sec.126 sec.181 sec.181 sec. time cycle volume injection volume channelscrew max. 0.8 time dwell remarks: an extended screw and cylinder can increase the dwell time! 18 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the in

24、jection unitcriteria to select the injection unit selection criteria material throughput example: connector (pa6), 8 cavities, 26.5 g shot weight time cycle weightshot 3.6 throughput material injection unitinjection unit100100100100100100250250250250 screw diameterscrew diameter20 mm20 mm25 mm25 mm3

25、0 mm30 mm30 mm30 mm40 mm40 mm max. throughput/h (pa-gf30)max. throughput/h (pa-gf30)3.5 kg/h3.5 kg/h5 kg/h5 kg/h6 kg/h6 kg/h11 kg/h11 kg/h15,5 kg/h15,5 kg/h throughput (cycle time 15s) throughput (cycle time 15s) 6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h throug

26、hput (cycle time 25s)throughput (cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h max. throughput/h (ps)max. throughput/h (ps)5.5 kg/h5.5 kg/h8 kg/h8 kg/h9.5 kg/h9.5 kg/h17 kg/h17 kg/h24.5 kg/h24.5 kg/h throughput (cycle time 15s) throughput (cycle time

27、 15s) 6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h throughput (cycle time 25s)throughput (cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h 19 copyright by arburg / nov. 2006 错误的选择会造成 mistakes in selection causes e.g.

28、to - 不完全熔化的粒料 - unmelted granulate - 混色不均 - color steaks - 烧焦 - burnt streaks 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitcriteria to select the injection unit 20 copyright by arburg / nov. 2006 其他准则包括所用材料的加工温度 有些工程材料（如 peek,pei,lcp 等）需要接近 450 摄氏度 的加工温度 料筒加热圈应使用陶瓷绝缘加热圈 further criter

29、ia for the injection unit is the temperature range of material to be used. some high technology plastics (e.g. peek, pei, lcp, etc) requires a temperature release of the machine up to 450 (500) deg. c. therefore the plasticizing cylinder has to be equipped with ceramic isolated heaterbands. 选择注射单元规格

30、的准则选择注射单元规格的准则 criteria to select the injection unitscriteria to select the injection units 21 copyright by arburg / nov. 2006 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitscriteria to select the injection units - 注射控制的方式 - -conceptions of injection regulation- 标准方式：注射闭环控制 basic confi

31、guration injection regulation 扩展方式（可选件）：螺杆精确定位 extension stage (option) position regulation screw (prs) 22 copyright by arburg / nov. 2006 注射闭环控制的原理 function principle of the injection regulation 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitscriteria to select the injection units 螺杆精确

32、定位 position regulated screw 23 copyright by arburg / nov. 2006 螺杆精确定位的原理 function principle of the position regulated screw 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitscriteria to select the injection units injection control 注射控制 position regulated screw 螺杆精确定位 24 copyright by arbur

33、g / nov. 2006 螺杆精确定位效果举例 微型齿轮 example for the efficiency of the position regulated screw with a micro gear wheel 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitscriteria to select the injection units 25 copyright by arburg / nov. 2006 0,005 ccm 0,025 ccm 0,010 ccm 0,040 ccm0,035 ccm 0,0

34、15 ccm 效果举例 （改变进料量） example for the efficiency (variation dosage volume): 选择注射单元规格的准则选择注射单元规格的准则 criteria to select the injection unitscriteria to select the injection units 26 copyright by arburg / nov. 2006 注射闭环控制与螺杆精确定位比较注射闭环控制与螺杆精确定位比较 injection regulation in comparison with injection regulation

35、 in comparison with position regulationposition regulation injection speed curve pressure curve injection speed screw position pressure curve position regulation pressure curve injection regulation 27 copyright by arburg / nov. 2006 selogicaselogica 控制器控制器 清楚显示动作顺序 transparent display of the sequenc

36、e 28 copyright by arburg / nov. 2006 selogicaselogica控制器控制器 29 copyright by arburg / nov. 2006 使用曲线图像优化工艺过程，发现错误 process optimization through graphic display and identification of errors 此例中转压切换点 1 太早。此时 模腔只有 60 70% 满而不是 95% 满。以后是由保压充模 工艺不稳定，产品质量不稳定 in this example, the set point (1) of switch over

37、into holding pressure is too early. with injection the part is only 60-70% full, instead of 95%. the rest will be filled by holding pressure. unstable process and unstable part quality 1 selogicaselogica控制器控制器 30 copyright by arburg / nov. 2006 使用曲线图像优化工艺过程，发现错误 process optimization through graphic

38、display and identification of errors selogicaselogica控制器控制器 正确的设定 good settings 31 copyright by arburg / nov. 2006 selogicaselogica控制器控制器 模具内压 精密注塑的另一方面是模具内压。保压 时模具内压的变化对产品质量，如尺寸， 重量，内应力，有直接影响。 mold cavity pressure as a further aspect for precision molding is the mold cavity pressure. the progress o

39、f the pressure during holding has a direct influence of the part quality e.g. dimensions, part weight and stresses. 1 injection start 2 melt reach sensor 3 cavity is volumetric filled (95-98%) 3 4 compression phase 4 highest cavity pressure 5 gate seal off point 6 pressure released mold cavity press

40、ure time 1 - 注射开始 2 熔体达到感应器 3 模腔充满 （95-98%） 3 4 压缩段 4 高压段 5 浇口凝固点 6 压力解除 32 copyright by arburg / nov. 2006 模腔压力 mold cavity pressure 两种压力曲线类型 two different pressure curves selogicaselogica控制器控制器 无规型塑料 amorphous plastics e.g. ps, abs, pc, pmma, pei, psu 半结晶型塑料 partially crystalline plastics e.g. pp,

41、 pom, pa, peek, pbt, pet cavity pressure cavity pressure timetime 33 copyright by arburg / nov. 2006 内压测量原理 压电式系统，kistler, priamus, 应变片式系统，dynisco, cavity pressure measuring principles piezo-electric system kistler, priamus, dms (strain gauge system) dynisco 直接测量 direct measurement 间接测量 indirect mea

42、surement selogicaselogica控制器控制器 1 mold cavity 2 transmission element 3 force transducer (measuring tongue) 1 mold cavity 2 pressure transducer 34 copyright by arburg / nov. 2006 内压测量 cavity pressure measuring 直接测量感应器安装位置 sensor locations for direct measuring selogicaselogica控制器控制器 35 copyright by ar

43、burg / nov. 2006 机器控制器可显示模具内压力 cavity pressure in machine display selogicaselogica控制器控制器 36 copyright by arburg / nov. 2006 切换到保压的不同方法 switch over possibilities into holding pressure 按照模腔内压 via cavity pressure 使用温度感应器 （安装在模腔内最后填充点） via temperature sensor (placed at flow path end in the mold) selogic

44、aselogica控制器控制器 37 copyright by arburg / nov. 2006 图像显示过程参数 graphical display of the process parameters 根据实际测量值监视产品质量 quality monitoring based on actual parameter values peak value monitoring monitoring window peak value integral calculation selogicaselogica 控制器控制器 38 copyright by arburg / nov. 2006

45、 工艺参数和图像的监视 monitoring of process parameters and graphical display selogicaselogica 控制器控制器 39 copyright by arburg / nov. 2006 曲线监视 curve monitoring selogicaselogica 控制器控制器 40 copyright by arburg / nov. 2006 产品质量记录 quality documentation selogicaselogica 控制器控制器 41 copyright by arburg / nov. 2006 用图像记录

46、工艺参数测量值 graphic display of process actual values selogicaselogica 控制器控制器 42 copyright by arburg / nov. 2006 模具设计方面模具设计方面 aspect of mould designaspect of mould design 流道设计流道设计( (特别是小产品特别是小产品) ) 用冷流道 流道长度取决于模具刚性和复杂程度 必须选择足够的横截面积 用热流道 加热的流道增加材料滞留时间 热流道需要足够的空间 延长的喷嘴 需要注意事项与热流道相同 需要附加的加热圈 sprue design (e

47、specially small parts)sprue design (especially small parts) via cold-runner systemvia cold-runner system sprue length is the result from mold stability and mold complexity the sprue section must be selected big enough via hot-runner systemsvia hot-runner systems heated sprue channel increases the dw

48、ell time problems with space via extended nozzle tipvia extended nozzle tip same problem like with hot-runner systems additional heaterband necessary! 43 copyright by arburg / nov. 2006 模具设计方面模具设计方面 aspect of mould designaspect of mould design 排气 venting 为避免飞边，排气间隙应不大于 0.02 0.03 mm to prevent flash

49、formation gap max. 0.02 -0.03 mm 44 copyright by arburg / nov. 2006 模具设计方面模具设计方面 aspect of mould designaspect of mould design 研磨方向互相交叉 排气容易,90% 空气从分型面排出 easy venting. approx. 90% of air escapes over parting line 空气可从整个模腔接触面排出 the air can escape over the complete cavity area 成本低 low costs 1 分型面光洁度 0.

50、007 0.009 mm 1 parting line roughness 0.007 0.009 mm 2 模芯光洁度 0.003 0.004 mm 2 cavity insert roughness 0.003 0.004 mm 45 copyright by arburg / nov. 2006 排气槽 venting channel 在流道终点或熔体相交处 at the end of the flow path or where the melt fronts meets together 可随时开出 afterwards creation possible 会积累脏物，需定时清理 p

51、roblems of dirt deposition thus often cleaning 模具设计方面模具设计方面 aspect of mould designaspect of mould design 1 venting channel (0.01 0.02 mm) 46 copyright by arburg / nov. 2006 溢流槽排气 overspill venting 在流道终点或熔体相交处 at the end of the flow path or where the melt fronts meet together 排气效果好 good venting 防止熔合线

52、 prevention from weld lines in that area 需切掉余料 afterwards removal of overspill channel 模具设计方面模具设计方面 aspect of mouldaspect of mould design design 1 meet point with enclosed air 2 injection point 3 overspill channel (venting through meltfront meet point shifting into overspill channel 47 copyright by arburg / nov. 2006 模具设计方