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1、模具設計的優先順序 Priorities of Mold Design 澆注系統設計 (Filling System Design) 排氣系統設計 (Venting System Design) 冷卻系統設計 (Cooling System Design) 脫模系統設計 (Ejecting System Design) 澆注系統設計的優先順序 Priorities of Filling System Design 產品設計 (Part Design) 型腔設計 (Cavity Design) 澆口設計 (Gate Design) 流道設計 (Runner Design) 噴嘴設計 (Nozzl
2、e Design) 豎澆道 Sprue 主流道 Main Runner 成品 Part 澆口 Gate 冷料井 Cold Slug Well 支流道 Branch Runner 典型的澆注系統 Typical Filling System 壁厚不均是注塑成型中最大的麻煩製造者。 這對薄壁 產品尤然。 這些麻煩包括了遲滯現象、短射、凹陷、 發赤、噴流、翹曲及長冷卻時間等；目前都可用CAE 以直接或間接的方式預測。 Non-uniform wall thickness is the biggest trouble maker in plastic injection molding. This i
3、s especially true to thin- wall part. The troubles, including hesitation, short shot, sink mark, blush, jetting, warpage and long cooling time etc., can be predicted, directly or indirectly, by using CAE. 壁厚不均 Non-uniform Wall Thickness 壁厚設計 Wall Thickness Design 差 Poor 較好 Better 最好 Best 掏空設計 (1) Co
4、ring Out Design (1) 改進設計 Improved原設計 Original 差 Poor 改進 Improved 掏空設計 (2) Coring Out Design (2) 氣泡或/和凹陷的形成 Void or/and Sink Mark Forming 氣泡 ( Void )凹陷 ( Sink Mark ) 肋厚和內圓角半徑的影響 The Effect of Rib Thickness filling pattern, weld lines and air traps are changed. 多澆口設計 Multi-Gate Design 閥式澆口 Valve Gate
5、針點澆口 Pin Gate 扇型澆口 Fan Gate 潛伏澆口 Submarine Gate 邊緣(薄膜)澆口 Edge ( Film ) Gate 凸片澆口 Tab Gate 閥澆口 Valve Gate 環狀澆口 Ring Gate 澆口種類 Gate Types 矩形邊緣澆口設計 Rectangular Edge Gate Design L = 0.5 0.75 mm W = 澆口寬度 ( mm ) gate width in mm A = 型腔表面積 ( mm2 ) surface area of cavity in mm2 n = 材料常數 material constant 0.
6、6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC h = n t h = 澆口厚度( gate thick. in mm ) t = 零件壁厚( wall thick. in mm ) W tL h 扇形澆口設計 Fan Gate Design L= 1.3mm W= w= 澆口寬度 mm gate width in mm A= 型腔表面積 mm2 surface area of cavity in mm2 n= 材料常數 material constant 0.6 for PE, PS 0.7 for POM,
7、 PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC 澆口厚度 gate thick. in mm t= 零件壁厚 wall thick. in mm h1 = n t h2 = wh1/D 重疊式澆口設計 Overlap Gate Design W= w= 澆口寬度 mm gate width in mm A= 型腔表面積 mm2 surface area of cavity in mm2 n= 材料常數 material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 fo
8、r PVC 澆口厚度 gate thick. in mm = nt 澆口長度 land length in mm t= 零件壁厚 wall thick. in mm L1 = 0.50.75L2 = h+( w/2 ) 凸耳澆口設計 Tab Gate Design L= 0.50.75mm W= w= 澆口寬度 mm gate width in mm A= 型腔表面積 mm2 surface area of cavity in mm2 n= 材料常數 material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, P
9、A 0.9 for PVC 澆口厚度 gate thick. in mm t= 零件壁厚 wall thick. in mm h1 = n th2 = 0.9 t 針點澆口設計 Pin Gate Design L = 0.5 0.75 mm d = 澆口直徑( mm ) gate diameter in mm t = 零件壁厚( mm ) wall thick. in mm A = 型腔表面積 ( mm2 ) surface area of cavity in mm2 n = 材料常數 material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0
10、.8 for CA, PMMA, PA 0.9 for PVC d L t 潛伏式澆口設計 Subgate Design W= w= 澆口寬度 mm gate width in mm A= 型腔表面積 mm2 surface area of cavity in mm2 n= 材料常數 material constant 0.6 for PE, PS 0.7 for POM, PC, PP 0.8 for CA, PMMA, PA 0.9 for PVC 澆口厚度 gate thick. in mm = nt t= 零件壁厚 wall thick. in mm 30 15 25 剪切速率 She
11、ar Rate 剪 切 應 力 shear Stress 黏 度 viscosity 剪 切 速 率 shear rate 剪切應力 Shear Stress 水力直徑 Hydraulic Diameter Where is the hydraulic diameter 水力直徑 A is the cross-sectional area of the flow 流路斷面積 P is the wetted perimeter 濕周長 水力直徑 Hydraulic Diameter 在不同剖面形狀，相同斷面積下之變化 Various runner profiles, based on the s
12、ame cross-sectional area 流道尺寸設計 (1) Runner Sizing (1) D : 流道直徑 ( mm ) runner diameter in mm W: 下游塑膠重量 ( g ) downstream plastic weight L : 流道長度 ( mm ) runner length in mm 流道尺寸設計 (2) Runner Sizing (2) 流道尺寸設計 (3) Runner Sizing (3) 流道尺寸設計 (4) Runner Sizing (4) 流道尺寸設計(A1) Runner Sizing (A1) G : 重量 weight
13、 S : 零件厚度 thickness D : 參考直徑 reference diameter G( g ) D ( mm ) for PS, ABS, SAN, CAB 流道尺寸設計(A2) Runner Sizing (A2) G( g ) D ( mm ) for PE, PP, PA, POM G : 重量 weight S : 零件厚度 thickness D : 參考直徑 reference diameter 流道尺寸設計(B) Runner Sizing (B) D : 參考直徑 reference diameter L : 長度 length fL : 長度係數 Length
14、coefficient D : 流道直徑 runner diameter fL L (mm) D = D fL 冷料井設計 Cold Slug Well Design 2d 次流道 Secondary runner d 主流道 Primary runner 澆口 Gate 型腔 Cavity 倒椎度冷料井 豎澆道拉料桿 Reverse taper cold slug-well sprue puller Z型冷料井 豎澆道拉料桿 Z - taper cold slug-well sprue puller 溝型冷料井 豎澆道拉料桿 Grooved cold slug-well sprue puller 冷料井設計 Cold Slug Well Design 澆道襯套尺寸 Sprue Bushing Sizing
