注塑工艺参数优化

1、注塑工艺参数优化注塑工艺参数优化注塑工艺参数优化培训课程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:采纳正确的螺杆转速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成型周期分析采纳下边表格预计

2、注塑过程中的每一阶段对周期的影响.此后去机床看正在运转的模具,写下实质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能够是最有效的缩短成型周期模具1预计%实质实质%谈论合模射台行进和退后注射时间保压时间冷却时间开模顶出整个成型周期100%seconds100%模具2预计%实质实质%谈论合模射台行进和退后注射时间保压时间冷却时间开模顶出整个成型周期100%seconds100%工艺参数优化目标:一步步改良工艺过程坚固性.评估各个参数的改正对工艺过程坚固性的影响todemonstratethecumulativeimprovemntintheprocessandproductconsi

3、stency方法:Ateachstage,aftertheprocesshasbeengivensufficienttimetostabilise,arunofsixteenconsecutivemouldingsistobemade.Thesemouldingswillbeassessedforconsistencybyweight(adimension,aphysicalpropertyorsomeotherattributecouldequallywellbeused,weightissimplythemostwidelyapplicable).坚固性经过计算重量的标准误差来权衡.同时打

4、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纳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制步骤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95%-98%,此后设定必然的保压和保压时间生产16模.初始设置时的指导采纳行程切换设定切换地点为10-12mm(逐渐增添预塑量直到产品打满95%-98%的地点)设置注射压力为最大值设定保压压力和保压时间均为0设定注射速度60mms-1设定松推速度为最大值设定锁模力为最大值选择适合的螺杆转速依据资料物性表,设定料桶温度配置过程统计控制设定保压压力和保压时间生产圆满的产品称12模产品的重

5、量,计算标准误差打印:页面20工艺参数优化页面50工艺过程统计步骤1结果输入实质值没保压时的重量有保压后的重量填补的百分比标准误差(16模)料垫(均匀值和范围)预塑时间(均匀值和范围)螺杆停止地点(均匀值和范围)注射时间(均匀值和范围)注射压力峰值,Pinj.max转压压力,PNpress.均匀值范围最小最大%g转压地点步骤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坚固后连续取5模产品称出每模重量和均匀值增添保压时间至2s,生产数模产品使过程坚固后连续取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

6、不再增添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为何记录模具温度很重要还有什么要素会影响浇口冷凝时间步骤2结果输入实质值TCUsettingFHtemperatureMHtemperatureCCC重量1重量2重量3重量4重量5均匀重量时间保压重量1重量2重量3重量4重量5均匀重量时间保压所需的保压时间s步骤3优化注射速度采纳多级注射曲线,使注射行程最后的10-20%采纳逐渐降低的注射速度.每次改正注射速度,必然从头成立转压点.(注意每次保压和保压时

7、间都设定为0.)连续取16模,计算出标准误差.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工艺过程统计为何转压点要改正注射压力发生了什么为何在数社的尾端采纳逐渐降低的注射速度是合用的步骤3结果输入实质值没有保压时的重量采纳保压的重量填补百分比标准误差(16模)料垫(均匀值和范围)预塑时间(均匀值和范围)螺杆停止地点(均匀值和范围)注射时间(均匀值和范围)注射压力峰值,Pinj.max转压压力,PNpress.变换地点均匀值范围最小最大%g步骤4采纳正确的螺杆转速Selectthecorrect,optimumscrewspeedforthematerialbeing

8、processed(seenotes,Section5).UsethissinglespeedforthewholeplasticisingstrokeSetabackpressureof5to10bar(hydraulic).Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page50ProcessStatisticsWhyisitimportanttousethemanufacturersr

9、ecommendedscrewspeedSTEPFOURRESULTSInsertactualvaluesintherelevantboxesMeanRangevalueminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinj

10、ectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPFIVEOptimisescrewspeedandback-pressureprofileUsetheDosingProfilepagetoslowdownthescrewrotationspeedforthelast10%ofthemeteringstroke.Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethes

11、tandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtotheDosingStoppositionSTEPFIVERESULTSInsertactualvaluesintherelevantboxesMeanRangevalueminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(mea

12、nandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPSIXOptimisedecompressionFindthedecompressionspeedwhichgivesbestscrewstrokeandmeltcushionconsistency.Setadecompressionstr

13、okeof5mm.Checkthatyoustillachieve95-98%fill.Takesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtothescrewstoppositionWhatishappeningtothecheckringSTEPSIXRESULTSInsertactualvaluesintherelevantboxesMeanRangeva

14、lueminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPS

15、EVENOptimiseholdingpressureprofileUsetheHoldingProfilepagetosetaholdingpressureprofilewhichensuresasmoothtransitionfrominjectiontotheholdingpressurephaseanduseahighenoughpressuretopackthepartproperly.Addastepwhichreducesholdingpressuregraduallytozero.Takesixteeenconsecutivemouldingsanddeterminethest

16、andarddeviationoftheweights.Printout:Page24MWEPage27HoldingProfilePage50ProcessStatisticsWhydoyouneedasmoothtransitionfrominjectiontoholdingpressureWhybothertoreducethepressuregraduallyifthegatehasalreadyfrozenSTEPSEVENRESULTSInsertactualvaluesintherelevantboxesMeanRangevalueminmaxWeightwithoutholdi

17、ngpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeTABULATEDRESULTSInsertactualvalu

18、esintherelevantboxesTherangevalue,R,isthemaximumminustheminumum,takenfromthesevensteps.1234567meanRmeanRmeanRmeanRmeanRmeanRmeanRMeltcushionDosingtimeScrewendpositionInjectiontimeInjectionpressurePhydmaxInectionpressurePNhydraulicChangeoverstrokeStandarddeviation(16shots)CanyouseeatrendWhichstephadt

19、hegreatesteffectontheconsistencyofthemouldingSTEPEIGHTOptimisingtheclampforceReducetheclampforcebystepsof50kN(100kNformachinesover100tonnes)usingthesettingsfaroptimisedinthesevenstepsabove.Allowtheprocesstostabiliseeachtimeandthenweighfivemouldings.Tabulateyourresultsbelowandplotagraphoftonnageagain

20、stpartweight.DoesthemouldrequiretheexpectedclampforceWhataretheadvantagesofrunningatreducedtonnageSTEPEIGHTRESULTSInsertactualvaluesintherelevantboxesEnterresultsinXLspreadsheet.Printoutgraph.Weight1Weight2Weight3Weight4Weight5MeanweightClampforceRequiredclampforcekNSTEPNINESetinjectionpressureUntil

21、nowtheinjectionpressurehasbeensettothemachinesmaximumvalue.FromtheProcessStatistcspageitcanbeseenthatthemachinedoesnotneedallthatpressuretofillthemould.Graduallydecreasethesetinjectionpressureuntiltheinjectiontimestartstoincrease.Increasethepressureagainuntilthepreviousinjectiontimeisestablishedwith

22、aconsistencyofsorbetterpreferablytosvariation.WhatisthepurposeoflimitingtheinjectionpressureSTEPNINERESULTSActualpeakinjectionpressureSetinjectionpressurebarbarAppendix1TYPICALPROCESSTOLERANCESShot-weightdeviation%PlasticisingtimeInjectiontimeCycletime%1%1%Screwposition,dosingstopMeltcushionMelttemp

23、erature2C2C3C5CMouldtemperature1C1C2C4CBarreltemperature1C1C2C4CFeedzonetemperature1C2C3C4CHotrunnertemperature1C2C3C4CHydraulicoiltemperature1C1C2C2CRoomtemperature2C2C3C4CMouldcavitypressure3bar4bar6bar8barPressureintegral200300600900Injectionfillingpressure1bar2bar3bar4barHoldingpressure1bar1barb

24、ar2barBackpressurebarbar1bar1barFillingdifferences(Balanceof1%fillforeachcavity)onmulti-cavitytoolsMouldbreatheChangeoverpressure(PnValue)1barScrewsurfacespeed10mms-1MelttemperaturepeakvalueoCMelttemperaturevalueatoCchangeover1%2%5%2bar3bar4bar-1-1-115mms20mms30mmsoCoCoCoCoCoCTheachievablepartqualityismuchinfluencedbytheconditionofthematerialprocessed.Itisimportantthatmoisturecontent,proportionofregrindandproportionofcolour(masterbatch)areconstant