XS-ZY-250A 塑料注塑成型机比例控制液压系统设计含9张CAD图
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塑料注塑成型机比例控制液压系统设计含9张CAD图
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外文出处： Polymer Testing 30 (2011) 5435471外文资料翻译译文（约 3000 汉字）：开发注塑塑料零件变形分析的测试方法J.G. Iovacs*, B. SilcloDepartment of Polymer Engineering, Budapest University of Technology and Economics,H-1111 Budapest, Mhegyetem rkp. 3, Hungary摘要：描述注塑塑料零件的弯曲不是一定的，而且由于弯曲的过程其本质是很复杂的， 所以这是很严重的问题。本文提出一种分析和测量注塑塑料零件变形的新方法。在弯曲方面特别介绍了一个特定的部分用一个特殊的模具设计，用以描述不同的工艺参数和模具的影响元素设计。通过实验的使用证明了系统的适用性。通过调查模具温度的影响, 模具温度的差异,保持压力和玻璃纤维材料研究使用不同的模具浇口类型。此外,评估弯曲的新的软件正在开发。根据结果,得出的结论是,沿着边缘角的变形长度可以由曲线进行描述。关键词: 注塑模具；注塑变形；弯曲角效果1.介绍注塑热塑性塑料部件的质量很大程度上取决于所使用的工艺参数和模具设计。注塑塑料零件的一个主要问题是弯曲引起的不均匀收缩。冷却不均匀,收缩不均匀和取向严重影响了这种变形。几个研究人员研究了弯曲的形成和特点而且使用各种方法,特别是多种类型的标本几何图形。许多研究调查使用矩形板收缩标本,并且这个几何的应用程序扩展到翘曲测量。唐家璇等用变形的部分确定刻度盘介绍 two-cavity,two-plate 注塑模具生产丙烯腈丁二烯苯乙烯(ABS)板材弯曲测试,。作者得出结论,弯曲主要是受熔体温度的影响, 其次是包装时间和包装压力。热分析是进行检查模具的热残余应力的影响。相关调查表明弯曲增强热塑性塑料圆盘和显示不同的取向引起的各种变形，也就是说,他们观察了杯和构象马鞍的构造。Kikuchi 和 Koyam 还分析了磁盘标本和盘子,他们引入了一个弯曲指数作为一种记录注塑零件的特征。郑等人也承认由于其简单的几何形状，无法测量弯曲的标本注塑零件，并提出应该使用更复杂的形状。他们继续执行测量肋板与注塑仿真模型, 但是他们只能想象肋的影响,而不是整个形变。詹森不仅在模具里研究了非晶态材料的弯曲还在 l 型标本不同圆角半径和尖角。平板产品的翘曲被定位在三个支持评估针和测量长度的垂直位移上作为协调长度的函数。实验表明, 模具在使用非晶聚合物的温度之间的差异下形变线性增加。结果还表明,在低压力下塑料朝热端的方向弯曲, 而在高压力下弯向冷端。半径较大的角落比半径较小的标本对模具温度差异更敏感。比例角度偏转的长度径向部分是对结果的解释。Akay 等人还分析了弯曲和温度之间的关系差异的两半模具。测量了变形的平板和 l 型标本并且用有限元软件和坐标测试机进行了计算。然后,分析了使用统一的冷却和温度两个下模之间的区别。观察到一个更高的模具腔端的温度导致增加的角角落的部分。一些调查使用框几何分析翘曲 16。Kabanemi et al。17 用箱形部分分析翘曲。提出了不同情况下显示的在变形和残余应力下影响的几何形状的复杂性。得出结论,不对称热剖面是负责弯曲引起的弯矩。得出结论,不对称热剖面是负责弯曲引起的弯矩。Mlekusch18 分 析 了 翘 曲 与 各 种 类 型 的 专 门 设 计 的 部 分 角 落 。 对 于short-fibre-reinforcement 的影响进行了研究,认为是材料的各向异性。多层模型用来计算圆柱段的冷却。模型预测与实验测量比较显示,附加弯曲观察材料可以归因于材料的各向异性。里奇- et al。19使用一个有四个角不同的半径的标本。他们得出结论,造成弯曲有两种现象: 第一个是不对称冷却，第二个是春天的远期效果。由于厚度方向的热膨胀系数的增大，增强了春天的远期效应生成纤维材料。变形转角和最初的变形平面是杰出的。相同的模具温度诱导两个模具的显著角变形为 30 - 50。两模之间的部分有 40 0 的不同引起约 1.50 的角度的变化。本研究的目的是不仅是创建标本,而且是描述弯曲的一个复杂的方法。主要目标是设计和创建一个特定的样品和模具,它允许以不同的方式获得变形。2方法和测量设备描述弯曲的注塑零件的角落，设计了一个特殊的部分。主要目标是衡量不同技术参数在弯曲模具的模具设计或材料属性的影响。生产所谓的 V-top 标准，一个特殊的模具设计和多变的变量插入（图 1），构造的嵌件注塑滑进可快速调换的框架，并且一个插线孔有两个可变的浇到体系。模具的固定的侧面仅仅包含了唯一的可变的型腔嵌件；改变这些嵌件允许将部分的壁厚变化，用这些方法，可以选为壁厚 1mm 或 2mm。顶端的门锁装置完美的使两个模具两等分，保证厚度均匀的部分。图 1 插入移动和固定的模具 3 十 1 门在变形中，材料的方向和注射位置的定位有显著的效果，因此，三个不同的闸口类型在之前的模型中被用作门插入（如图 2）。一个标准的闸口前面的边缘，一个标准的门的边缘，或者沿着整个边缘的电影门。图 2 门的设计:a)标准门在前面的边缘,b)标准门的中间,c)膜状浇口沿着整个边缘V-top 本近 900 年一个角度，造成的变形技术或其他参数可以通过改变这几个角度来量化。除了单向的窝洞填充外，双向的填充可以实现可旋转的插入的应用（如图 3）。在角落，这些特点允许调查焊线20的影响。图 3插入可旋转的 V-top 标本变形受冷却的高度影响，在角落里是非常重要的。模具的核心的散热速度必须比腔快， 否则，内部区域的角落凝固速度较慢，导致它自身被磨角。面对高要求的变形测试，高效的冷却系统是必须的（如图 4）。对于最高的控制精确度，温度传感器将被安装进模具的核心和腔。不仅是温度，而且压力控制也很重要。由于这个原因，两个压力传感器将会被安装；一个距离闸门 5mm，一个在年底前流路径的 5mm 处。在这些传感器的帮助下，转换点会被精确的控制，这是基本稳定和一致的重要性。图 4 模具的冷却系统V-top 样本的变形评估，特殊的图像分析软件被开发。软件的扫描图像分析的标本和关闭角沿着边缘的长度计算拐角点的步骤（如图 5）。图 5 计算关闭角理论的图像3实验在这项研究中，实验的进行证明了测量技术的效率。整洁的聚丙烯与玻璃纤维和聚丙烯增强不同重量的内容为(10、20、30 wt )，在一个广泛的变形部分检查全面评估的新方法。矩阵(北欧化工、HD120M0)和玻璃纤维混合在 Brabender 塑度计双螺杆挤出机,和一个 Brabender 制粒机是用于生产挤出物的颗粒。V-top 标本是注塑的 Arburg 全能球员3200 c 600 - 250 注塑成型机。标本被塑造的厚度为 2 毫米使用所有 3 门的类型。对玻璃纤维含量的影响,温度移动一侧的模具(30、50、70 0 c)和压力的保持(100、300、500 条) 进行分析。所有其他工艺参数保持不变。熔体温度是 230 0 c,固定的模具的温度保持时间是 5 s,注入率为 50 15 秒冷却时间。切换压力传感器达到 25 条。4. 结果与讨论所述空腔之间的区别被控制体重的测量，显示出从不同的腔中的样本的权重之间的相关系数为 0.994。因此，可以得出结论，试件的重量是独立的腔体，和变形在上模腔中产生的试样的外边缘进行分析。该实验的典型结果示于图 6，具有关闭角为相对边缘长度的函数。可以看出，该测量是准确的，标准偏差是比较小的在每个测量点。栅型的影响进行了分析，其结果表明， 熔体入口点和类型，因为它们穿过材料（图 6）的定向性的影响，结果不能被忽略。图 6 影响关闭位置角沿着边缘的相对位置的函数(模具温度:70 0,纤维内容:20%,持有压力:300)下面，一些成果将提交给验证了该方法的广泛适用性。实验结果表明，在保持压力对纯 PP（图 7）的变形有很大影响。靠近拐角的保持压力有较小影响，而进一步远离拐角的角度的增加而增加保持压力。图 7 在 5%和 85%位置拐角角度保压压力（图 8）的纤维含量分别降低翘曲。然而，两个半模之间的温度差对翘曲的影响最大。当用于较高的模具温度对可动模具侧，试件的表面之间的闭合角减小为一个较大的变形的结果。正在分析变形为沿着边缘的相对位置的函数，它被观察到，在截止角单调减少，与角度的依赖于移动模侧的（图 9）的温度的斜率。图 8 持有关闭压力角的影响作为相对位置的功能纤维内容(模具沿边缘:50%)图 9 动模侧的温度的影响在关闭角的函数沿边缘的相对位置(持有压力:100)5、总结在本论文中，介绍了一种新的测量方法，来分析注塑塑料零件。就是最新引进的 V-top 样本，允许调查不同变形工艺的参数和材料性能的影响。另外一种新的可变形的注塑模具设计和建造 V-top 标本的生产。这个新方法是经过测试的，并且经过了实验的研究， 门类型和位置的影响，材料的玻璃纤维含量，模具温度不同，限档压力也会被研究。基于实验数据，得出结论，翘曲强烈依赖于纤维内容和模具温度，但是当使用聚丙烯和玻璃纤维时，这几乎不依赖于限档压力。这些实验强有力的支持了新的翘曲分析技术，相对于以前的翘曲测量方法有一个很大的优势。参考文献1J.M.Fischer,HandbookofMouldedPartShrinkageandWarpagefirsted.Plastics Design Library/William Andrew Inc, Norwich, 2003.2M. Altan, Reducing shrinkage in injection mouldings via the Taguchi AIVOVA and neural network methods, Mater. Design 31 (1) (2010) 599.3K.M.B. Jansen, D.J.v. Dijk, E.V. Burgers, Experimental validation of shrinkage predictions for injection moulded products, Int. Polym.Proc. 13 (1) (1998 ) 99.4X. Chen, F. Gao, A study of packing profile on injection moulded part quality, Mater. Sci. Eng. 358 (1-2) (2003) 205.5K.M.B. Jansen, R. Pantani, G. Titomanlio, As-moulded shrinkage measurements on polystyrene injection moulded products, Polym. Eng. Sci. 38 (2) (1998) 254.6P. Postawa, J. Koszkul, Change in injection moulded parts shrinkage and weight as a function of processing conditions, J. Mater. Process Tech. 162-163 (2005) 109.7A. Demirer, Y. Soydan, A.O. Kapti, An experimental investigation of the effects of hot runner system on injection moulding process in comparison with conventional runner system, Mater. Design 28 (5) (2007) 1467.8K.M.B.Jansen, D.J. van Dijk, K.P. Keizer, Warpage of injection moulded plates and corner products, Int. Polym. Proc. 13 (4) (1998) 417.9M. Akay, S. Ozden, T. Tansey, Prediction of process-induced warpage in injection moulded thermoplastics, Polym. Eng. Sci. 1996 (13) (1839) 36.10S.H. Tang, Y.J. Tan, S.M. Sapuan, S. Sulaiman, IV. Ismail, R. Samin, The use of Taguchi method in the design of plastic injection mould for reducing warpage, J. Mater. Process Tech. 182 (1-3) (2007) 418.11S.H. Tang, Y.M. Kong, S.M. Sapuan, R. Samin, S. Sulaiman, Design and thermal analysis of plastic injection mould, J. Mater. Process Tech. 171 (2) (2006) 259.12E.J. Fahy, Modeling warpage in reinforced polymer disks, Polym.Eng. Sci. 38 (7) (1998) 1072.13H. Kikuchi, K. Koyama, Generalized warpage parameter, Polym. Eng.Sci. 36 (10) (1996) 1309.14H. Kikuchi, K. Koyama, The relation between thickness and warpage in a disk injection moulded from fibre reinforced PA66, Polym. Eng.Sci. 36 (10) (1996) 1317.15R. Zheng, P. Kennedy, IV. Phan-Thien, X.J. Fan, Thermoviscoelastic simulation of thermally and pressure-induced stresses in injection moulding for the prediction of shrinkage and warpage for fibre reinforced thermoplastics, J. IVon-Newton Fluid 84 (2-3) (1999) 159. 16K. Prashantha, J. Soulestin, M.F. Lacrampe, E. Lafranche, P. Krawczak G. Dupin, M. Claes,Taguchianalysisofshrinkageandwarpageofinjection-moulded polypropylene/multiwallcarbonnanotubes nanocomposites, Express Polym. Lett. 3 (10) (2009) 630.17K.K. Kabanemi, H. Vaillancourt, H. Wang, G. Salloum, Residual stresses, shrinkage, and warpage of complex injection moulded products: Numerical simulation and experimental validation Polym. Eng. Sci. 38 (1) (1998) 21.18B. Mlekusch, The warpage of corners in the injection moulding of short-fibre-reinforced thermoplastics, Compos Sci. Technol. 1999 (12)(1923)59.19A. Ammar, V. Leo, G. Regnier, Corner deformation of injected thermoplastic parts, Int. J. Form Proc. 6 (1) (2003) 53.20J.G.Kovacs, B. Siklb, Experimental validation of simulated weld line formation in injection moulded parts, Polym. Test. 29 (7) (2010) 910.21B. Solymossy, J.G. Kovacs, The examination of weld line properties in injection moulded PP composites, Mater. Sci. Forum 589 (2008) 263.2外文资料原文（与课题相关，至少 1 万印刷符号以上）：Test method development for deformation analysis of injection moulded plastic partsJ.G. Kovcs*, B. SiklDepartment of Polymer Engineering, Budapest University of Technology and Economics, H-1111 Budapest, Mhegyetem rkp. 3, HungaryAbstract ： The characterisation of warpage of injection moulded plastic parts is notstandardised and is extremely problematic due to the complex nature of the warping process. This paper presents a novel method for the analysis and measurement of the deformation of injection moulded plastic parts. A specic part with a special mould design was introduced for the characterisation of the effect of different technological parameters and different mould element design on warpage. The applicability of the system was demonstrated via its experimental use. The effects of mould temperature, mould temperature difference, holding pressure and the glass bre content of the material were investigated using different gate types in the mould. Additionally, new software was developed to evaluate warpage. Based on the results, it was concluded that the deformation of the corner along the edge length can be described by a curve.Keywords：Warpage Corner effect；Injection moulding； Deformation Injection mould1、IntroductionThe quality of injection moulded thermoplastic parts is largely determined by the process parameters and the mould design used. One of the main problems with injec- tion moulded plastic parts is warpage caused by non-uniform shrinkage. This deformation is strongly inuenced by non-uniform cooling, differential shrinkage and orientation effects 1.Several researchers have investigated the formation and characteristics of warpage using various methods, partic- ularly multiple types of specimen geometries. Many studies have investigated shrinkage using rectangular plate speci- mens 2,3, and the application of this geometry was extended to warpage measurements 49.Tang et al. 10,11 introduced a two-cavity, two-plate injection mould producing acrylonitrile butadiene styrene (ABS) plates for warpage testing, with deformation of the parts being determined with a dial gauge. The authors concluded that warpage was mostly inuenced by melt temperature, followed by packing time and packing pres- sure. Thermal analysis was performed to check the effect of any thermal residual stress in the mould.Fahy 12 investigated the warpage of reinforced ther- moplastics on a circular disk and showed that different orientation caused various deformations; namely, they observed cup- and saddle-shaped conformations. Kikuchi and Koyama 13,14 also analysed disk specimens and plates, and they introduced a warpage index as a means of recording the characteristics of injection moulded parts.Zheng et al. 15 acknowledged that plate-like speci- mens were incapable of measuring warpage of injection moulded parts because of their simple geometry, and proposed that a more complex shape should be used. They continued to perform measurements with the injection moulding simulation on a ribbed plate model, but they were only able to visualise the effect of the rib and not the entire deformation 15.Jansen 8 studied the warpage of amorphous materials not only on plates but also on L-shaped specimens with different corner radii and sharp corners. The warpage of at plate products was assessed by positioning the plate onthree supporting pins and measuring the vertical displacement as a function of the length coordinate. The experiments showed that deformation linearly increased with the difference between the temperatures of the mould halves when using amorphous polymers. The results also showed that at low holding pressure the plates curved towards the hot side, whereas at high holding pressure the plates curved towards the cold side. The corners with larger radii were more sensitive to mould temperature differences than were specimens with smaller radii. The result was explained by the proportionality of the angle deection to the length of the radial section.Akay et al. 9 also analysed the relationship between warpage and the temperature difference of the two halves of the mould. The deformation of both the at plate and the L-shaped specimens was measured and calculated with nite element software and a coordinate-measuring machine. Then, it was analysed using uniform cooling and also withtemperature difference between the two mould halves. It was observed that a higher mould temperature on the cavity side resulted in increase of the angle in the corner of the part.Some investigations used box geometry for warpage analysis 16,17. Kabanemi et al.17 analysed warpage on box-like parts. Different cases were presented to show the inuence of the geometrical complexity of the shape on the deformations and residual stresses. It was concluded that the asymmetrical thermal prole was responsible for the bending moment that caused warpage.Mlekusch 18 analysed the warpage on a specically designed part with various types of corners. The effect of short-bre-reinforcement was studied and attributed to the anisotropy of the material. A multi-layer model was used to calculate the cooling of a cylindrical segment. The model predictions were compared with experimental measurements showing that the additional warpage observed for short-bre-reinforced materials could be attributed to the anisotropy of the material.Ammar et al. 19 used a specimen with four corners with different radii. They concluded that two phenomena caused warpage: the rst was asymmetrical cooling and the second was the spring forward effect. The spring forward effect was generated in bre-reinforced materials due to the higher thermal expansion coefcient in the thickness direction. The deformation around the corner and the deformation of the initially at surfaces were distinguished. Using polypropylene (PP) in their experi- ments, equal mould temperatures in both mould halves induced a signicant angle deformation of 3oand 5o. A difference of 40 oC between the two mould halves caused an angle variation of about 1.5.The aim of this research was to create not only a spec- imen but also a complex method for warpage character- isation. The main goal was to design and create a specic sample and mould, which allows deformation measure- ments to be obtained in different manners.2、Methodology and measuring equipmentTo characterise the warpage at the corners of injection moulded parts, a special part was designed. The main goal was to measure the effect of varying technological param- eters, mould design or material properties on warpage.To produce the so called V-top specimens, a special mould was designed with changeableand variable inserts (Fig. 1.). The constructed insert mould slides into a quick- change frame and has two cavities with a variable runner system. The stationary side of the mould contains only the changeable cavity inserts; changing these inserts allows the parts wall thickness to be varied. In this way, the wall thickness can be chosen as either 1 mm or 2 mm. Top locks guarantee the perfect closing of the two mould halves assuring a uniform part thickness.The orientation of the material and the positioning of the injection location have signicant effects on the deformation. Therefore, three different gate types can be used by changing the gate inserts in the mould (Fig. 2.): a standard gate at the front of the edge, a standard gate at the middle of the edge or a lm gate along the whole edge. The sides of the V-top specimen close an angle of 90o, and the deformation caused by the technological or other parameters can be quantied by changing this angle. In addition to unidirectional cavity lling, bidirectional lling can be achieved with the application of rotatable inserts (Fig. 3.). This feature allows investigation of the inuence ofthe weld lines 20,21 at the corners.Warpage is highly inuenced by cooling and is very signicant at corners. The core of the mould has to dissipate heat faster than the cavity; otherwise the internal area of the parts corner solidies slower and causes a sharpening of the corner itself. To meet the high requirements of warpage tests, an efcient cooling system is required (Fig. 4.). For the highest control precision, temperature sensors were installed into both the core and the cavity of the mould. Not only the temperature but also the pressure control is important. For this reason, two pressure sensors were mounted; one at a distance of 5 mm from the gate (PGS; post-gate-sensor) and one at a distance of 5 mm before the end of the ow path (EOC; end-of-cavity sensor). With the help of these sensors, the switchover point can be controlled precisely, which is of fundamental importance for a stable and consistent cycle.To evaluate the warpage of the V-top specimen, special image analysis software was developed. The software analysed scanned images of the side of the specimens and calculated the closing angle along the edge length from the corner point (Fig. 5.) in 5% steps.3、ExperimentalIn this study, experiments were carried out to prove the efciency of the novel measuring technique. Neat poly- propylene and polypropylene reinforced with glass bre of different weight contents (10, 20, 30 wt%) were examined to comprehensively evaluate the new method in a wide range of deformed parts. The matrix (Borealis, HD120MO) and the glass bres were mixed on a Brabender Plasticorder twin-screw extruder, and a Brabender pelletizer was used to produce pellets from the extrudate. From these mate- rials, V-top specimens were injection moulded on an Arburg Allrounder 320oC 600250 injection moulding machine. The specimens were moulded with a thickness of 2 mm using all 3 gate types. The effects of glass bre content, temperature of the moving side of the mould (30, 50, 70 oC) and holding pressure (100, 300,500 bar) were analysed. All other technological parameters were kept constant. The melt temperature was 230 oC, the tempera- ture of the stationary side of the mould was 50 oC, the holding time was 5 s, the injection rate was 50 cm3/s and the cooling time was 15 s. The switchover took place when the end-of-cavity pressure sensor reached 25 bar.4、Results and discussionThe difference between the cavities was controlled with weight measurements, showing that the correlation between the weights of the samples from the different cavities was 0.994. Therefore, it was concluded that spec- imen weight is independent of the cavity, and deformation was analysed on the outer edge of the specimens produced in the upper cavity.A typical result of the experiments is shown in Fig. 6, with the closing angle as a function of the relative edge length. It can be seen that the measurement is accurate and the standard deviation is relatively small at each measurement point. The inuence of gate type was ana- lysed, and it was shown that the melt entrance point and type cannot be neglected because they inuenced the results through the orientation of the material (Fig. 6).Below, some results will be presented to demonstrate the wide applicability of the method. The experimental results showed that the holding pressure had a consider- able effect on the deformation of neat PP (Fig. 7.). Close to the corner the holding pressure had a minor effect, whereas further away from the corner the angle increased with increase in holding pressure.Fibre content decreased warpage independently of holding pressure (Fig. 8.). However, the temperature difference between the two mould halves had the biggest effect on warpage. When higher mould temperatures on the movable mould side were used, the closing angle between the faces of the specimen was decreased as a result of a larger deformation. Analysing the deformation as a function of relative position along the edge, it was observed that the closing angle decreased monotonically, with the slope of the angle depending on the temperature of the moving mould side (Fig. 9.).5、ConclusionsIn this paper, a new measurement method was intro- duced for the deformation analysis of injection moulded plastic parts. The newly introduced V-top specimen allows investigation of the effects of different technological parameters and material properties on its deformation. Moreover a novel transformable injection mould was designed and built for the V-top specimens production. The new method was tested and analysed with experi- mental research, in which the effects of gate type and location, glass bre content of the material, mould temperature difference and holding pressure were inves- tigated. Based on the experimental data, it was concluded that warpage strongly depended on the bre content and on mould temperatures, but that it was nearly independent of the holding pressure when using PP with glass bre. These experiments strongly support the new warpage analysis technique in having a signicant advantage over previously used warpage measuring methods.References1J.M.Fischer,HandbookofMouldedPartShrinkageandWarpagefirsted. Plastics Design Library/William Andrew Inc, Norwich, 2003.2M. Altan, Reducing shrinkage in injection mouldings via the Taguchi AIVOVAand neural network methods, Mater. Design 31 (1) (2010) 599.3K.M.B.Jansen,D.J.v. Dijk,E.V. Burgers,Experimentalvalidationofshrinkage predictions for injection moulded products, Int. Polym.Proc. 13 (1) (1998 ) 99.4X. Chen, F. Gao, A study of packing profile on injection moulded part quality,Mater. Sci. Eng. 358 (1-2) (2003) 205.5K.M.B. Jansen, R. Pantani, G. Titomanlio, As-moulded shrinkage measurements on polystyrene injection moulded products, Polym. Eng. Sci. 38 (2) (1998) 254.6P. Postawa, J. Koszkul, Change in injection moulded parts shrinkage and weight as a function of processing conditions, J. Mater. Process Tech. 162-163 (2005) 109.7A. Demirer, Y. Soydan, A.O. Kapti, An experimental investigation of the effects of hot runner system on injection moulding process in comparison with conv
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