注塑问题及解决方法最终

1、注注塑塑问问题题及及解解决决方方法法问题可能成因解决方法小黑点熔胶筒内壁烧焦，胶块脱落1.清洗炮筒内壁（拆螺杆清小洗）2.用较硬胶料进入，以擦净炮筒内壁（小船坞机，如用清洗剂及亚加力等）3.避免胶料长时间受高温（料温不宜太高，储料不能太多，黑点空气带来肮脏物或模腔腔内有空气引至1.封盖料斗2.胶料封闭好，保持干净3.增加或减低熔胶筒和模具温度，以改变胶料进入模腔的速度4.减低注塑压力或速度黑色条纹1.料筒或螺杆不干净，原料不干净1.清理料筒及螺杆并小心处理胶料不受污染2.料筒能胶料局部过热2.使炮筒之每段受热圴匀3.冷胶料互相磨擦或与炮筒壁磨擦时烧焦 3.A加入有外润滑剂的胶料B胶料加小许白矿

2、油C增加炮筒后段温度4.射嘴过热烧焦胶料4.减低射嘴温度5.射嘴温度变化大5.采用恒温控制器控制电热黄点黄线棕色条纹变色1.溶胶筒全面或局部过热1.A 减低温度B减低螺杆转速C减低回料背压2.胶料黏住炮筒内壁或射嘴以至烧2.清理射嘴或炮筒螺杆3.胶料在炮筒内停留时间过长3.缩短注塑周期4.炮筒内存有死角4.更换螺杆产品哑白原料潮湿烘干原料再生产气泡模腔填料不足，原因：1.A制品切面厚，模腔壁上有突起线1.A 再设计模具B 注塑压力太低B 加大注塑压力C注塑时间太长C 增加注塑时间D入料不足D 增加注塑速度及增加入水口阔度2.胶料潮湿2.模塑前胶粒避免受过大的温度变化及要干燥胶粒3.模具温度不均

3、匀3.重新排列运水信道，使模具温度一致破裂或龟裂 1.填模太实1.A减低速度；B减低压国 C 缩短注射时间2.模温太低2.提高模温3.不适当的脱模设计如角度斜位及倒扣位 3.修改工模4.顶针或环定不当4.再按放顶针让制品能顺利顶出工模5.再用料过多(拉粒水口)5.少用或不用拉粒或水口产品尺寸性改变1.模塑情况不稳定1.A 调节操作情况，直至得到最大平稳操作B 视乎啤塑工人的操作情况而决定啤塑时间长短2.注塑条件与正常时不一致2.A 更正跟平常时不用的注塑条件B 检查注塑温度，压力 ，工模温度，模塑时间，入料，电压，3.在检查塑件时周围空气温度不固定3.A 保持周围空气温度固定B 在同一条件下测

4、量及检查制品漏胶1.胶料太热1.A 降低胶料温度B 减少螺杆转速和背压2.注塑压力过高2.A 降低压力B 减少枕压时间3.模具或射咀凸凹两面接触不良3.再次打磨模具唧嘴4.射台增压不够4.检查机台射台射增压系统开模时射咀滴胶1.胶料过热1.A 降低炉咀温度 B 降低料筒温度2.注塑料料不够干燥2.干燥胶料流纹和塑面起波纹1.胶料不够热1.增加胶料温度2.模温不够热2.增加工模温度3.注射压力太低3.提高注射现象4.注射速度太低4.提高注塑速度5.浇口太小引致胶料在模腔内有喷射现象 5.扩大浇口和降低注射压力6.塑品切面厚薄不均匀6.A设计塑件俾切面厚薄均一 B去除制品上凸起的线条7.排气不足7

5、.增加排气塑料在浇口成层状1.模温太低1.升高电热、升高模温2.射速太慢2.提高注射速度3.注射压力不足3.提高注塑速度4.射胶时间过长4.缩短射胶时间5.胶料有杂质5.A清洁熔胶筒 B避免混入其它塑料6.工模润滑剂过多6.清洁模面，用小量润滑剂(脱模剂)7.水口小7.调节水口大小，使其得到良好的压力控制水口四周有条纹料温过高，流速太快降低温度及注射速度啤塑周期需时过长1.料温度高易缩水1.A 降低温度B 减少螺杆旋转速度或背压2.工模温度过高2.降低模温3.模塑时间不稳定(工人问题)3.用计时表及加强管制工人的操作速度4.塑料融化的温度和所需时间不够4.增加温度和延长时间5.塑件较厚处冷却不

6、足5.A 改变模内冷却水道位置B 用冷水机产品变形1.注射压力太大1.减低注射压力2.保压时间过长2.减少保压时间3.前后模差太大3.使前且模温一致4.入水位设计不常4.再设计入水位置5.塑件切面厚度不均匀5.尽可能保持切面厚度均匀6.工模温度过低6.增高模温7.料温过低7.升高料温C注6和7即变相减压8.螺杆背压过高8.减少螺杆背压塑件粘模1.注射压力或熔胶筒温度过高1.A 减低注射压力或机筒温度B 降低螺杆的旋转速度或螺杆背压2.过多入料2.减少入料3.注射时间过长3.减少注射时间4.工模冷却不足(塑件热膨胀)4.延长工模冷却时间漏胶5.塑件因收缩而粘在阳模上5.减少冷却时间，使前后模有不

7、同温度6.模内塑件未冷硬6.延长保压并加强工模冷却7.工模内有倒扣位7.却除倒扣位，打磨抛光，增加脱兔 模部份的斜度8.模腔内深入部份空气压力小(真空状态) 8.设立适宜的排气道9.工模内壁光洁度不够9.模腔壁再次抛光夹纹1.料温太低1.升高料温2.模面有脱模剂等油渍2.抹干净工模壁，不喷脱模剂或少脱模剂3.熔溶位离入水位太远3.再设定入水位或再加几个对称的入水4.排气不良4.增设足够排气5.塑品切面厚薄转化大5.再设计塑件及设定适当的入水位置6.模温太低6.提高模温7.注塑压力低及速度慢7.升高注射压力或速度塑件表面粗糙1.模温低1.提高模温2.注射压力低2.增加注射压力3.注射速度慢3.增

8、加注射速度4.模壁有水份4.清洁和修理漏水裂痕或防止水汽在模壁凝洁5.用脱模剂过多5.不用或少用脱模剂6.使用过多的内或外润滑剂6.检查材料是适合和混料时减少矿油用量7.模表面粗糙7.再次抛光模壁射胶不足1.熔胶管各段不够1.增加熔胶筒各段2.模温不够2.温度增加模温3.压力不足3.增加压力4.刚开机时射咀太冷4.多啤几啤或用火焰加热射咀5.模温不均一5.不用或少用脱模剂6.空气不能排出模腔(困气)6.增加排气道数目及尺码7.注射时间不够7.增加注射时间8.流入多模腔工模的熔胶流态不能适当平行8.修正平行情形9.浇口小9.扩大浇口10.模腔熔胶量比注塑机大10.用较大的注塑机塑件表面光亮条纹1

9、.料温不够1.提高熔胶筒温度2.模温低2.升高模温3.模内有水气3.加热干燥工模4.工模有污渍4.清洁工模5.转压转速位置不当5.调整适当的转压转速位置6.料内有湿气6.烘干胶料油温机利用热传导原理，将热传导油加热至适当温度，输送至成型机模具之管道内，加热模具至要求温度，并控制油温在要求温度范围内。适合模温要求高的成型。改善塑料制品的质量，亦可提高生产效益。常见塑料之模温要求PS 10-70HLPS 10-75ABS 10-80SAN 10-80LDPE 20-60HDPE 20-60PP 10-80PVC 20-60PC 70-115PMMA 30-70PA 50-80POM 60-90塑件

10、粘模停停机机操操作作注注意意PS，SAN因为硬胶的热稳定性好，在啤塑温度下长期受热也不会分解因此停机前只需把热并闭即可ABS此胶料的热稳定性也较好，停机时无需把机筒内的剩余胶料推出和清理PE此胶料的热稳定性很好，在料筒内长期受热不会分解，故停机时不需推出料筒内的剩余胶料PP和PE相似，但热稳定性比PE稍差PC由于生产暂时停顿(如夜班不开工)需使料筒一直保持在160度C，以免胶料受潮，如需换料，则需用PE清理料筒，并从热料筒中取出螺杆，用铜丝刷清理螺杆PVC此为热敏性胶料，停机前，首先关闭电热，然把PVC推出，直至料筒温度降到150度C后，再用另一热稳定性较好的胶料把料筒内的胶料全部推出PMMA

11、虽然胶料在较高的温度下易热分解，但在正常温度下，热稳定性尚好，故停机时只需关闭电热PA胶料热稳定性尚好，停机时不需清洗料筒或把料推干净，但需立刻关闭电热，否则15分钟后胶料会度坏PE为热敏性，停机时，于关闭电热前十分钟把压力调零，然后连续注射，把料筒内胶料推出，再用PE清机ProblemsProblems ofof injectioninjection andand solutionssolutionsProblemfactorsSolutions small blackdotsthe inside wall of barrel was burned andthe burned rubber

12、block fall down intothe product1.to Clean the barrel(unload the screw )2.load hard rubber inside the barrel to clean the burned wall(smallcamber machine,to clean with detergent and PMMA )3.Invoid the rubber long time under high temperature (the material cannot heated at too high temprature,material

13、storing can not be toomuch,cycle time can not be too long and do not stop the machine toooften. black dotthe dirty stuff comes with the air orthere are air in the mould cavity.1.assemble the lodder with sealing cover.2.to keep the rubber cleaning and seal it in a good tank.3.add or reduce the tempre

14、ture of barrel and mould to adjust thespeed of the rubber into the mould cavity.4.reducing the inject pressure or speedblackstreak 1.charging barrel，screw and rawmaterial are not cleam1.when clean up charging barrel and screw shoould be careful, makesure the sizing material clean 2.barrel to rubber

15、is overheating 2.let each gun barrel well-heated3.friction against the cold glue size orfriction against gun barrel then burned 3.A) add some sizing materail with lubricant B)add a little WhiteParaffin Oil in sizing materical C) increase the tempreture atposterior segment of gun barral4.the Nozzle i

16、s overheated that scorchthe plastic4.decrease the temperature of nozzle 5.have a big change of nozzle 5.Using electric temperature controlleryellow spotyellow linebrownstripe,discolour,Dark whiteof product1 barrel soloverall or local overheating1.A reduce the temperature B reduce the speed of screw

17、C reduceback pressure of reclaim2 Plastic material stick barrel wall ornozzle so that it burns.2.clean the nozzle or barrel screw3 Rubber material stays long time inbarrel.3.shorten the injection cycle4 Barrel has corner.4.change the screwDark white ofproductraw material is moistdrying raw material

18、and then reproduceBlisterlack of filling materials,reasons: 1.The thickness of product isthick,there is an extrude line in thecavity surface.1.A Make new designBThe injection pressure is too low B Increase the injection pressureCThe injection time is too longC Increase the injection timeDshort shotD

19、 Increase the injection speed and water gap width2.Material is moist2.Avoid large scale temperature difference,keep the material dry3.The temperature of mould is notuniformity,3.Rearrange the water line,make the mould temperature conformity.fracture orchecking 1.Mold filling is too real1.A,lower spe

20、ed；B,reduce injection pressure C,Shorten the injectiontime2.Too low mould temperature2.Increase mold temperature3.Stripping inappropriate design,such asthe oblique angle and upside downposition3.Modify corn4.Thimble or ring unsuitable4.put the ejectorpin,let the product come out smooth from the corn

21、5.Too much recyclematerial(longs.water gat)5.No or little use the longs and water ductsdimensionchanged 1.moulding parameter unstable1.A adjust the operation parameter to stable.B different operater cost different operate time2.moulding parameter inconformity tothe normal2.A correct inject pa

22、rameter which is uselessB checking all parameter such as injection tempreture、 pressure、mould tempreture、 cycle time、feeding、voltage、tempreture adjustmeter、pressure system and material dry tempreture etc. to seewhether it is ok or not3.checking the product at unstabledtempreture3.A keep the surround

23、ing air at stable tempreture B checking and measuring the product under same conditionrubberleakage 1. rubber is too hot1.A reducing the rubble tempretureB reducing the screw speed and backpressure2.injection pressure is too high2.A reducing the pressureB reducing booster time3.mould or shoot nozzle

24、 have badconnect at convex-concave surface3.repolishing the mould sprue bushing4.Shoot a pressurization not enough4.checking booster systemNozzle gulewhen openthe mould 1.The material overheating1.A Reduce the nozzle temperature B Reduce the barrel2.The material for injection not dryenough2.Dry the

25、materialflow line andPlastic surfaceripples1.sizing material not hot enough1.increase the temperature of sizing material2.mould temperature is not hot enough2.increase the temperature of core 3.Injection pressure is too low3.increase the injection 4.injection speed is to slow 4.increas the injection

26、 speed 5.gating is so small that sizing materialhave jet phenomenon in mold form5.enlarge the gate and decrease the injection pressure6.the thickness of plastic products planis not same 6.A)the thinckness of plan are not same B) wipe off the raised lines in the product7.exhaust is not good 7.increas

27、e exhaustThe materialshowslamellararound thegate1.The mould termperature is too low1.Increase the electric heating、mould temperature2.The speed of injection too slow2.Increase the injection speed3.Injection pressure not enough3.Improve the injection speed4.Injection time too long4.Shorten the inject

28、ion time5.Material is impurity5.A clean the machine barrel B Avoid other material mix in6.Lubricant on core too much6. Clean the surface,use less lubricant (release agent)7.Water gap small7.Adjust the size of water gap,to make it under pressure better.stripe arroundthe water gaprubber tempreture is

29、to high,flow rate tofastreduce the tempreture and injection speed.MoldingCycle taketoo long1.Materials with High temperature easyto shrink1.A, Lower the temperatureB, Reduce screw rotation speed or reduce backpressure2.the corns temperature is too high2.reduce mould temperature3. Instability of the

30、Injection time(workers problem)3.use the stopwatch tp comtrol the workersoperation speed4.Plastic melt temperature notenough,and time is not enough.4.increase the temperature and go into overtime5.Thick plastic parts lack of cooling5.A ,Change the seat of the cooling water inside the mouldB ,Use the

31、 chillerproductvarients1.injection pressure is too big1. reduce injection pressure2.hold up time is too long2.reduce hold up time3.tempreture range is too big betweenmould front and mould back 3.keep mould front and back at same tempreture4.cooling water inlet place designirregular4.redesigning the

32、cooling water inlet place5.thickness of product sectionnonuniform5.keep the product section uniform as far as possible6.mould tempreture too low6.increasing the mould tempreture7.feed material too low7.rising the feeding tempreture at C mark 6 and 7, in disguised form toreduce the pressure8.back pre

33、ssure of screw is too high8. reducing the screw back pressurePlastic partstik mould1.Injection pressure or machine barreltemperature too high1.A Reduce the injection pressure or machine barrel temperatureB Reduce the rotate speed of screw or backpressure of screw2.Material enters too much2.reduce th

34、e material enter3.The injection time too long3.Reduce the injection time4.Core undercooling (plastic partexpansion)4.Lengthen the cooling time of corerubberleakage 5.plastic part stick to the core becauseof shrink5.Reduce the cooling time,make the temperature between fron andback different6.Material

35、 in mould not chill6.Lengthen pressure maintaining and strengthen the cooling of core 7.There is undercut position in core7.Remove the undercut,polish,increase the inclination of demould part 8.The pressure in deep cavity is small(vacuum state)8.Set up reasonable exhaust passage9.The gloss finish of

36、 the mould innersurface is not enough9.The surface of mould polish againWeld Line1.the temperature of material is too low. 1.rise the temperature2.Die surface have grease stains such asrelease agents2.clean the core wall,not spary release agents3.pyrosol is too far away from waterinlet3.setting agai

37、n the water inlet or add several balanced water inlet4.inadequate venting4.increase enough venting5.Plastic products cut thicknesschanges big 5.redesign plastic part and set suitable water inlet.6.mould temperauter is too low6.increase the mould temperature7.Injection pressure and speed is low7.rise

38、 injection pressure or speedthe surface ofplasticproduct iscrude1.the mould temperature is too low 1.increase the mould temperature 2.injection pressure is too low 2.increase the injection pressure 3.injectionspeed is too slow3.increase the injection speed 4.Die wall have some water 4.clean and repa

39、ir chasm of making water or avoid water vaporcondense 5.too much parting agent 5.dont use or less use parting agent 6 to much ubricant used inside andoutside6.confirm the material is suitable or not and decrease the dosage whemmix the material 7.mould surface is crude 7.polish the die wall againshor

40、t shot 1.every welding hose is not enough1.increase the welding hose2.the moulds temperature is too high2.increase the mold temperature3.pressure is not enough3.increase the pressure4.Just machines start to work, thenozzle is too cold4.inject more shot or heating the shot nozzle with fire5.The mould

41、 temperature is not average 5.No or little use release agent6.the air in the cavity can not bedischarged(Trapped gas)6.Increase the exhausts number and size 7.Injection time is not enough7.increase inject time8.Multi-cavity mold into the melt flowpattern is not appropriate parallel8.amend the flow r

42、ate to balance9.Small gate9.increase inject time10.Cavity melt volume bigger duce on bigger injection machinebrightnessstripe onproductsurface1.feeding tempreture is not enough1. rising the barrel tempreture2.mould tempreture is too low2. rising the mould tempreture3.moisture exi

43、st in the mould cavity3.heating and drying the mould cavity4.mould cavity blotted4. cleaning the mould cavity5.turn pressure and speed improper5.adjust the location to turn pressure and speed 6.moisture feeding material6.dry the feeding materialOil machinemake use of heat transfer theory, let the he

44、at transfer oil is heated to a suitable temperature,then transported tothe pipe forming machine mold, heating the mold to the required temperature, and control the oil temperature atthe required temperature range. Suitable for high temperature molding mold. Improve the quality of plasticproducts and

45、 also improve production efficiencyMouldtemparaturerequirementof commonmateialPS 10-70HLPS 10-75ABS 10-80SAN 10-80LDPE 20-60HDPE 20-60PP 10-80PVC 20-60PC 70-115PMMA 30-70PA 50-80POM 60-90Plastic partstik mouldAttention for stop operationPS，SANBecause PS thermal stability, during the molding temperat

46、ure will not decompose if its heated forlong time,you just need to close the machine and keep heating.ABSABS have good thermal stalility, when the machine stop working you neednt push out the barreland clean up the remaining plastic material in the barrel.PEPE have very good thermal stalility，it wil

47、l not decompose althouth its heated for long time, so itsalso neednt push out the barrel and neednt clean up the remaining material.在料筒内长期受热不会分解，故停机时不需推出料筒内的剩余胶料PPPE is almost same as PE, but the thermal stality is no that good.PCAs a temporary halt of production (do not work at night), the barrel h

48、as to be maintained at 160degrees, in order to avoid damp the material. If need to change the material, you need to use PE toclean the barrel, and remove the screw from the hot barrel, with copper wire brush clean-up thescrewPVCPVC is kind of heat sensitivity material，before you close the machine, y

49、ou should turn off theelectric heating first, than puch out the PVC material, after the temperature drop to 150 degrees,you should use another good thermal stability material to push out all PVC material from the barrel.PMMAAlthough the PMMA is easy to decompose base on high temperature, but base on

50、 the normaltemperature, it has good thermal stability, so when the machine stop working you just need to closethe eelectric heating.PA thermal stability of material is good,when machine shuts down,it doesnt need to clean barrel orpuch materil cleanly. but we need to close electric heat immediately,

51、otherwisePEThermal sensitivity,when machine close down,mix the presssure to zero,ten minutes before closingelectric heating,then continuous injector,push the material in machine barrel，then purging with PEProblemsProblems ofof injectioninjection andand solutionssolutionsSolutions1.to Clean the barre

52、l(unload the screw )2.load hard rubber inside the barrel to clean the burned wall(smallcamber machine,to clean with detergent and PMMA )3.Invoid the rubber long time under high temperature (the material cannot heated at too high temprature,material storing can not be toomuch,cycle time can not be to

53、o long and do not stop the machine toooften.1.assemble the lodder with sealing cover.2.to keep the rubber cleaning and seal it in a good tank.3.add or reduce the tempreture of barrel and mould to adjust thespeed of the rubber into the mould cavity.4.reducing the inject pressure or speed1.when clean

54、up charging barrel and screw shoould be careful, makesure the sizing material clean 2.let each gun barrel well-heated3.A) add some sizing materail with lubricant B)add a little WhiteParaffin Oil in sizing materical C) increase the tempreture atposterior segment of gun barral4.decrease the temperatur

55、e of nozzle 5.Using electric temperature controller1.A reduce the temperature B reduce the speed of screw C reduceback pressure of reclaim2.clean the nozzle or barrel screw3.shorten the injection cycle4.change the screwdrying raw material and then reproduce1.A Make new designB Increase the injection

56、 pressureC Increase the injection timeD Increase the injection speed and water gap width2.Avoid large scale temperature difference,keep the material dry3.Rearrange the water line,make the mould temperature conformity.1.A,lower speed；B,reduce injection pressure C,Shorten the injectiontime2.Increase m

57、old temperature3.Modify corn4.put the ejectorpin,let the product come out smooth from the corn5.No or little use the longs and water gat.1.A adjust the operation parameter to stable.B different operater cost different operate time2.A correct inject parameter which is uselessB checking all parameter

58、such as injection tempreture、 pressure、mould tempreture、 cycle time、feeding、voltage、tempreture adjustmeter、pressure system and material dry tempreture etc. to seewhether it is ok or not3.A keep the surrounding air at stable tempreture B checking and measuring the product under same condition1.A redu

59、cing the rubble tempretureB reducing the screw speed and backpressure2.A reducing the pressureB reducing booster time3.repolishing the mould sprue bushing4.checking booster system1.A Reduce the nozzle temperature B Reduce the barrel2.Dry the material1.increase the temperature of sizing material2.inc

60、rease the temperature of core 3.increase the injection 4.increas the injection speed 5.enlarge the gate and decrease the injection pressure6.A)the thinckness of plan are not same B) wipe off the raised lines in the product7.increase exhaust1.Increase the electric heating、mould temperature2.Increase