保洁Mold检验

1、present by supply windows incp&g mold validation procedure for plastic injection molds宝洁公司塑胶模具验证程序宝洁公司塑胶模具验证程序present by supply windows incpurpose目的目的 the purpose of the injection mold validation procedure is to: qidentify a capable mold-process which will achieve key part dimensions and toleran

2、ces. 依据基本的注塑参数測试模具, 是否达到运作要求, 和重要尺寸公差的稳定性.qestablish a mold processing-window for the injection mold. 确定模具生产的稳定性参数.present by supply windows incc q vccommissioning 试运行qvqualification 验收verification 验证present by supply windows incmold certificationdry cycle moldprocess stability testinjection mold va

3、lidation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined by experienced mol

4、d builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in g (

5、m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old, runn

6、er system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn omold certification模具验证模具验证dry cycle mold模具空运行模具空运行process stability test稳定性测试稳定性测试gage r&r test量具的可重复

7、性与重复能力测试量具的可重复性与重复能力测试mold viscosity test粘度测试粘度测试balance of fill test流道平衡测试流道平衡测试gate freeze test浇口冻结测试浇口冻结测试multi cavity analysis多型腔分析多型腔分析dox试验测试设计试验测试设计qualification run验收运行验收运行validation run验证测试验证测试mold validated模具与验证present by supply windows incmold certificationdry cycle moldprocess stability

8、testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examin

9、ed by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t es

10、tc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c p

11、k.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn omold certification模具验证present by supply windows inccommissioning 试运行before the commi

12、ssioning run “c”之前应提供的资料 mold critical dimension report 模具重要尺寸的测量报告 molding process parameter 注塑参数include runner size, gate size.包含流道和浇口尺寸make sure have enough venting.确保有足够的排气槽 mold trial report 试模报告 fai report 产品尺寸报告present by supply windows incmold certificationdry cycle moldprocess stability tes

13、tinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined

14、by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc

15、om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.i

16、nspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn odry cycle mold模具空运行present by supply windows inc1. dry cycle 空运行空运行 validate the mold f

17、unctioning. 验证模具的动作 measure cooling pressure and flow rate. 测量冷却水/油的压力与流量commissioning 试运行run mold without injecting plastic 空运行一段时间fill out the mold functioning form 填表using pressure gauge and flow meter to measure使用压力表与流量表进行测量fill out the flow check form把测量出的数据填入表中present by supply windows incmeas

18、ure cooling pressure and flow rate. 测量冷却水/油的压力与流量pressure gauge 压力表flow meter 流量表present by supply windows incmold certificationdry cycle moldprocess stability testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlypro

19、cess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of

20、tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n a

21、lyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t

22、if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn oprocess stability test稳定性测试present by supply windows incprepare 0.01grams scale before the following test在进行以下测试前，先准备好精度为0.01克的电子称commissioning 试运行present by supply windows inc2. process stability test 稳定性测试稳定性测试 procedure 程

23、序:adjust parameter until no short shot, flash, scratches weight 1 shot of sample and record the part weight.after you feel the condition is stable, run 100 shots, take 1 shot every 10 shots.3 shots for critical dimension check.10 shots for cosmetic check.fill in the form运行稳定后，取1啤称重并记录。打100啤，每10啤取1啤.

24、 总共10啤给外观评估其中3啤作为重要尺寸的读数。commissioning 试运行present by supply windows incmold certificationdry cycle moldprocess stability testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short sh

25、ots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprato

26、rs or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t

27、 m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n

28、a n d e lim in a t ep a s s ?y e sn ogage r&r test量具的可重复性与重复能力测试量具的可重复性与重复能力测试present by supply windows inc3. gage r&r 量具的可重复性与重复能力测试量具的可重复性与重复能力测试procedure:3 ipqc measure 10 parts 3 times each.fill out the gage r&r form.取10个样品，3份空表格分别分给三个制程品管员。每人对每个样品的同一尺寸测量三次，把测量结果填入表中。commissioning 试运

29、行present by supply windows incr and r 10.xlsgage r & r data & calculation - long formmeasuremento.d.gage guage o.d.date10/1/1998location l.s.operators3(2 or 3)trials per oper3(2 or 3)operator aoperator boperator csample trial 1trial 2trial 3rangetrial 1trial 2trial 3rangetrial 1trial 2trial

30、3range14.0214.024.020.001004.0184.0194.0180.00104.024.024.0190.001024.0184.0184.0180.000004.0174.0174.0170.00004.0184.0184.0190.001034.0184.0184.0180.000004.0174.0174.0170.00004.0184.0184.0180.000044.0184.0184.0180.00004.0174.0174.0170.00004.0194.0194.0190.000054.0184.0184.0180.00004.0184.0174.0170.

31、00104.0194.0194.0190.000064.0184.0184.0180.00004.0184.0174.0170.00104.0184.0194.0190.001074.024.024.0190.00104.0184.0184.0170.00104.024.0194.020.001084.0184.0184.0180.00004.0164.0174.0170.00104.0194.0184.0190.001094.0184.0184.0180.000004.0184.0184.0170.00104.0194.0194.0190.0000104.0184.0194.0190.001

32、004.0174.0184.0170.00104.0194.0184.0190.0010averages4.01854.01854.01840.00034.01744.01754.01710.00074.01894.01874.01900.0006grand avg x bar = 4.0185rbar= 0.0003 x bar = 4.0173rbar= 0.0007 x bar = 4.019rbar= 0.0006 r-dbar0.0005max x-bar = 4.0188667xdiff= 0.0015333ucl (r)0.0014 (d4*rbar)min x-bar = 4.

33、0173333rp=0.0018repeatabilityreproducibilityequipment variation (ev)= 0.0016267(k1*rbar) appraiser variation (av)= 0.0041293k1=3.05k2=2.7repeatability & reproducibilityr & r = 0.0044382tolerance analysispart variation (pv)=0.00288 specification max4.027tolerance0.014total variation (true + r

34、&r)0.0053 specification min4.013% tv% specdont put anything here. cell in use.% ev =30.75%11.62%enter information or data% av =78.05%29.50% r & r =83.89%31.70%not oknot okneed = 20%gage r&r 表格present by supply windows incmold certificationdry cycle moldprocess stability testinjection mol

35、d validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined by experienced

36、 mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in

37、 g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old,

38、runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn omold viscosity test粘度测试粘度测试present by supply windows inc4. mold viscosity test 粘度测试粘度测试射出保压枕压位90 填满填满

39、90% filledf p: position保压转换：位置保压转换：位置commissioning 试运行present by supply windows inc4. mold viscosity test 粘度测试粘度测试intensification factorhydraulic pressure 1 (psi)fill time 1 (sec)hydraulic pressure 2 (psi)fill time 2 (sec)hydraulic pressure 3 (psi)fill time 3 (sec)average hydraulic pressure (psi)ave

40、rage fill time (sec)shear rate (1/sec)relative viscosity remarks10011.2never try9011.26700.286750.286770.286740.283.572114burn mark8011.26620.316620.326640.306630.313.2323017011.26380.376390.366370.376380.372.7326206011.26260.406250.406270.406260.402.5028045011.26220.496200.486210.486210.482.0733624

41、011.26150.656150.656140.656150.651.5444753011.26091.016101.016101.016101.010.9968972011.25952.515942.505952.485952.500.40166241011.25873.255853.355863.375863.320.3021812injection rate (in/sec) % viscosity test05000100001500020000250000.000.501.001.502.002.503.003.504.00shear rate (1/sec)relative vis

42、cosity (bar/sec)series1commissioning 试运行present by supply windows incmold certificationdry cycle moldprocess stability testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shot

43、s, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators

44、 or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m

45、 old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a

46、n d e lim in a t ep a s s ?y e sn obalance of fill test流道平衡测试流道平衡测试present by supply windows inc5. balance of fill test 流道平衡测试流道平衡测试commissioning 试运行present by supply windows inc5. balance of fill test 流道平衡测试流道平衡测试cavity idsample 1 (g) sample 2 (g) sample 3 (g) average (g)% imbalancecavity 11.351.35

47、1.351.351.34%cavity 21.351.351.361.350.98%cavity 31.361.361.371.360.24%cavity 41.371.371.361.370.00%5%commissioning 试运行present by supply windows incmold certificationdry cycle moldprocess stability testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to to

48、ol, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is examined by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysism

49、easurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)

50、r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r

51、 u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn ogate freeze test浇口冻结测试浇口冻结测试present by supply windows inc6. gate freeze test 浇口冻结测试浇口冻结测试hold time (sec) shot 1 (g) shot 2 (g) shot 3 (g) average shot (g)0.55.605.625.605.6115.655.665.65

52、5.651.55.705.705.695.7025.735.745.745.742.55.775.785.785.7835.785.785.785.783.55.785.785.785.78gate freeze test5.585.605.625.645.665.685.705.725.745.765.785.8000.511.522.533.54hold time (sec)shot weight (g)commissioning 试运行present by supply windows incmold certificationdry cycle moldprocess stabilit

53、y testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold is examined by experienced mold builder. ok?mold is exam

54、ined by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v iscosity t estb alan ce of f ill a n alysisg ate f reeze t

55、estc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een cavities?p ass?p rocess c apable? m eets c r, t z, and c

56、 pk.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn omulti cavity analysis 多腔模分析多腔模分析present by supply windows incpresent by supply win

57、dows incmold certificationdry cycle moldprocess stability testinjection mold validation flow chartrework mold or repair pressmodify mold or manifolddamage to tool, or press not operating properlyprocess stability established. no short shots, flash, scratches, blemishes, water leakage, or voids.mold

58、is examined by experienced mold builder. ok?mold is examined by experienced mold builder. ok?yesnonoyesnonoyesgage reproducability & repeatability analysismeasurement variation less than 20% of tolerances?provide training for oeprators or use alternative measurement system.noyesyesyesm old v isc

59、osity t estb alan ce of f ill a n alysisg ate f reeze t estc om m ission in g (m u lti-c avity a n alysis)d o xq u alification (p rocess c ap ab ility s tu d y)r ew ork m old , ru n n er systema n alyze p rocess (r ew ork m old )r e-cu t m old m etal to cen ter th e averagef low s balanced betw een

60、cavities?p ass?p rocess c apable? m eets c r, t z, and c pk.inspect m old, runner system . o k ?y esn on on oy esn oy esy esv e r if ic a t io n ( 3 0 - d a y r u n )m o ld v a lid a t e di d e n t if y s o u r c e s o f v a r ia t io n a n d e lim in a t ep a s s ?y e sn odox试验测试设计试验测试设计present by supply windows inc7. dox design of experiments 试验测试设计试验测试设计commissioning 试运行present by supply wind