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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 (Nozzle Design)豎
2、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 is especially true t
3、o 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) Coring Out Design (1)改進設計
4、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針點澆口 Pin Gate扇型澆口 Fan Gate潛伏澆口 Subm
5、arine 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 DesignL = 0.5 0.75 mmW = 澆口寬度 ( mm )gate width in mm A = 型腔表面積 ( mm2 )surface area of cavity in mm2n = 材料常數 material constant0.6 for PE, PS0.7 for POM, PC, PP0.8 for CA, PMMA,
6、PA0.9 for PVCh = n th = 澆口厚度( gate thick. in mm ) t = 零件壁厚( wall thick. in mm )WtLh扇形澆口設計 Fan Gate DesignL= 1.3mmW= w= 澆口寬度 mmgate 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, PS0.7 for POM, PC, PP0.8 for CA, PMMA, PA0.9 for PVC 澆口厚度 gate thick. in mmt
7、= 零件壁厚 wall thick. in mm h1 = n t h2 = wh1/D重疊式澆口設計 Overlap Gate DesignW= w= 澆口寬度 mmgate 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, PS0.7 for POM, PC, PP0.8 for CA, PMMA, PA0.9 for PVC 澆口厚度 gate thick. in mm = nt 澆口長度 land length in mm t= 零件壁厚 wall t
8、hick. in mm L1 = 0.50.75L2 = h+( w/2 )凸耳澆口設計 Tab Gate DesignL= 0.50.75mmW= w= 澆口寬度 mmgate 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, PS0.7 for POM, PC, PP0.8 for CA, PMMA, PA0.9 for PVC 澆口厚度 gate thick. in mm t= 零件壁厚 wall thick. in mm h1 = n th2 = 0.
9、9 t針點澆口設計 Pin Gate DesignL = 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 constant0.6 for PE, PS0.7 for POM, PC, PP0.8 for CA, PMMA, PA0.9 for PVCdLt潛伏式澆口設計 Subgate DesignW= w= 澆口寬度 mmgate width in mm A=
10、 型腔表面積 mm2 surface area of cavity in mm2 n= 材料常數 material constant 0.6 for PE, PS0.7 for POM, PC, PP0.8 for CA, PMMA, PA0.9 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 Shear 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 DiameterW
11、here 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 same 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 )downstre
12、am 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 S : 零件厚度thickness D : 參考直徑reference diameterG( g )D ( mm )for PS, ABS, SAN, CAB流道尺寸設計(A2)Runner Sizing (A2)G( g )D ( mm )for P
13、E, PP, PA, POMG : 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 coefficient D : 流道直徑runner diameterfLL (mm)D = D fL冷料井設計 Cold Slug Well Design2d次流道 Secondary runnerd 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 pullerZ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
