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1、OLE Technology Corporation射出成型塑膠產品與模具設計 Injection Molding Plastic Part & Mold DesignOLE Technology Corporation澆注系統設計Filling System DesignOLE Technology Corporation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 (Eject
2、ing System Design)OLE Technology Corporation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)豎澆道設計 (Sprue Design)噴嘴設計 (Nozzle Design)OLE Technology Corporation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
3、型的澆注系統Typical Filling SystemOLE Technology Corporation壁厚不均是注塑成形中最大的麻煩製造者。 這對薄壁零件尤然。 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 to thin-wall part. The troubles, including hesitatio
4、n, 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 ThicknessOLE Technology Corporation壁厚設計Wall Thickness Design差 Poor較好 Better最好 BestOLE Technology Corporation掏空設計(1) Coring Out Design (1)改進設計 Imp
5、roved原設計 OriginalOLE Technology Corporation差 Poor改進 Improved掏空設計(2) Coring Out Design (2)OLE Technology Corporation氣泡或/和凹陷的形成Void or/and Sink Mark Forming氣泡 ( Void )凹陷 ( Sink Mark )OLE Technology Corporation肋厚和內圓角半徑的影響The Effect of Rib Thickness & Fillet RadiusOLE Technology Corporation肋的底部厚度Bottom
6、Thickness of RibW0.5W2.5WW1.2WD1.5WD(A)(B)OLE Technology Corporation肋的設計 (一 )Rib Design ( 1 )t = wall thichnessB = 0.5tC = 3 tAAD = 2 BE = 0.13 mm(radius)F = 1.5 - 2 deg假如需要更大的強度,可增加肋的數目If more strength is required, add additional ribs.FBDECtOLE Technology Corporation 肋的設計 (二 )Rib Design ( 2 )OLE Te
7、chnology Corporation肋的設計 (三 )Rib Design ( 3 )OLE Technology Corporation與側壁相連之凸轂(熱塑性塑膠)Boss at Wall ( Thermoplastics )A =凸轂附著處壁厚 wall thicknessB =凸轂外環直徑 dia. of boss over radiiC = 0.5 AD = 2 BE = 1 2 degF = 0.13 mm ( radius )G = DH = 0.8 AI = A / 4J = 2 BK = 0.3 1 JL = 0.5 A LHAAKEIGJDAFCBSection A-A
8、OLE Technology Corporation遠離側壁之凸轂(熱塑性塑膠)Boss Away From Wall( Thermoplastics ) A =凸轂附著處壁厚 wall thicknessB =凸轂外環直徑 (含底部修整圓弧半徑) dia. of boss over radiiC = 0.5 AD = 2 BE = 1 - 2 degF = 0.13 mm ( radius )G = 0.95 DH = 0.3 G min. to G max.I = 0.5 AHEFDFGCBAIOLE Technology Corporation外側凸轂Outside Boss AAA (
9、 DIA )BB = AB= 2A ( max. )Section A-AOLE Technology CorporationWhere 1/r : 樑的曲率 curvature of the beamM: 彎曲力矩 bending momentE : 彈性模數 modulus of elasticityI : 斷面積對中立軸的慣性矩 moment of inertia of the cross- sectional area with respect to the neutral axisEI : 撓曲剛性 flexural rigidity撓曲剛性Flexural RigidityOLE
10、Technology CorporationW樑 BeamLOLE Technology CorporationWhere : 最大偏移 maximum deflection W : 負荷 load L : 樑長 length of beam E : 彈性模數 modulus of elasticity I : 斷面積對中立軸的慣性矩 moment of inertia of the cross- sectional area with respect to the neutral axis EI : 撓曲剛性 flexural rigidity: 最大應力 maximum stress: 中
11、立軸到到其斷面離其最遠的點的距離 distance from the extreme point of a cross section to the neutral axis of this cross section OLE Technology CorporationOLE Technology CorporationNeutral AxisOLE Technology Corporation?10.8OLE Technology Corporation平板和肋板的比較Comparison between Plain & Ribbed PlatesOLE Technology Corpor
12、ation和平板比，若基於相同的慣性矩(剛性)，肋板需料少了43%，I/A卻增加了1.79倍。肋板的最大厚度減為平板的1/4 ，使得冷卻時間驟降15/16 (94%)。Based on the same moment of inertia (stiffness), ribbed plate needs 43% less material but boost I/A by 1.79 times comparing with plane plate. The maximum thickness of ribbed plate is only 1/4 of plain plates; showing
13、 a dramatic cooling time reduction of 94% (15/16) .平板和肋板的比較Comparison between Plain & Ribbed PlatesOLE Technology CorporationA variety of molded-ininterlocks can add stiffness to thin-wall housing designs.各種一體成形的內鎖件能增加薄殼的剛性。OLE Technology Corporation結構設計是薄殼成形零件的基礎。Structural design is the base of th
14、in-wall molding parts.薄殼成形零件不僅僅是一趨勢，而且也是降低成本和提高競爭力的有效途徑。Thin-wall molding part is not only a trend but also an effective way to achieve cost reduction and competitiveness increase.結構設計和薄殼成形零件Structural Design & Thin-wall Molding PartsOLE Technology Corporation每增加一個澆口，至少增加一條熔接線，同時增加一個澆口痕跡、增加流道的體積以及增加
15、較多的積風。Every time one gate is added, one weld line, at least, one gate mark, more runner volume and more air traps will be added.在型腔能夠完滿充填的前提下，澆口數目是愈少愈好。As long as the cavity is able to be filled appropriately, gates are the less the better.為了減少澆口數目，每一澆口應就塑流力所能及的流長/壁厚比之內，找出可以涵蓋最大零件面積的進澆位置。In order to
16、 reduce the number of gates, each gate shall be located at where the melt is able to cover maximum part area based on the largest melt flow length/thickness ratio .澆口數目The Number of Gates OLE Technology Corporation熔膠波前推進Melt-Front AdvancementMelt-Front Advancement充填模式,積風和熔接線Filling Patterns, Air-Tra
17、ps and Weld Lines LocationOLE Technology Corporation熔接線Weld LinesWeld LinesOLE Technology Corporation材料 Material : PC-GF50原設計 Original更改設計 Revised更改澆口位置以重新定位熔接線Weld Lines Can Be Relocated Weld Lines Can Be Relocated By Changing Gate LocationBy Changing Gate LocationOLE Technology Corporation典型對頭熔接線伸
18、張強度保留值Typical Butt Weld Tensile Strength Retention ValuesTypical Butt Weld Tensile Strength Retention ValuesOLE Technology Corporation熔接線冷料井Weld Slug WellWeld Slug Well對頭熔接線 Butt weld熔接線冷料井Weld slug wellOLE Technology Corporation積風Air TrapsAir TrapsOLE Technology Corporation排氣VentVent大部份熱塑性塑膠Most Th
19、ermoplasticsA 0.08 mmB 3.18 mmC 12.7 mmD 0.25 mm耐隆和聚縮醛 ( POM )Nylon and Acetal ( POM ) A 0.04 mmB 3.18 mmC 12.7 mmD 0.25 mm進料流道Feed Runner塑膠成品Plastic PartAD排氣孔VentBSEC. A-ACAAOLE Technology Corporation充填均衡Flow Balance熔膠波前於同一時間抵達型腔各末端。Melt front reaches the ends of cavity at the same time.OLE Technol
20、ogy Corporation洗衣機圈板OLE Technology Corporation洗衣機圈板OLE Technology Corporation冷氣通風飾罩-原始設計Air-conditioner Grille - Original18 gatespressure: 76 MPaOLE Technology Corporation冷氣通風飾罩-修正設計Air-conditioner Grille - Revised8 gatespressure: 75 MPaOLE Technology Corporation分析結果比較表Comparison of Analysis Results
21、OLE Technology Corporation原始設計Original Design十二澆口設計12 Gate Design電子零件置物箱材料 Material：ABSOLE Technology Corporation四澆口設計4 Gate Design修正設計Revised Design電子零件置物箱材料 Material：ABSOLE Technology Corporation電子零件置物箱四澆口和十二澆口設計比較表OLE Technology Corporation 論語 季氏第十六 不患寡而患不均， 不患貧而患不安。 - - 孔子 - -OLE Technology Corp
22、oration如何快速平衡眾多模穴之流道How to Balance Flow In A Multi-cavity Mold首先調整一排支流道內之次支流道尺寸，使此支流道內之各模穴可平衡充填。First, adjust runner size in one branch to make flow balanced in this branch.再調整各支流道前段之尺寸，使各支流道可平衡充填。Then, adjust the first sections runner size in each branch to make flow balanced in all branches.OLE Te
23、chnology Corporation一排支流道之不平衡充填Unbalanced Flow In A Branch OLE Technology Corporation一排支流道平衡後之充填Balanced Flow In A BranchOLE Technology Corporation全模具(128模穴)之不平衡充填Unbalanced Flow In A MoldOLE Technology Corporation全模具(128模穴)平衡後之充填Balanced Flow In A MoldOLE Technology CorporationThe melt fills the in
24、side cavities before filling the outside cavities.OLE Technology CorporationThe runner system shows that warmer, low-viscosity material (yellow and red) follows the inside wall when the melt splits at an intersection.OLE Technology Corporation剪切速率Shear RateOLE Technology Corporation剪 切 應 力shear Stre
25、ss黏 度viscosity剪 切 速 率shear rate剪切應力Shear StressOLE Technology CorporationOLE Technology CorporationOLE Technology CorporationOLE Technology CorporationOLE Technology Corporation澆口種類Gate Types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 GateOLE
26、 Technology Corporation導致平直零件的澆口設計Gate Design for Flat Part中心澆口Center Gate扇形澆口Fan Gate最壞的Worst壞的Worse較好的Better最好的Best側澆口Edge Gate薄模澆口Film GateOLE Technology Corporation澆口設計(減少滯流效應)Gate Design to Avoid Hesitation澆口gate薄thin厚thick差的設計Poor好的設計Good薄thin厚thick澆口gateOLE Technology Corporation0.94秒時，遲滯現象在1
27、.2mm厚凸片處發生公稱厚度3.2mm幫浦零件(Part, Pump)塑料(Polymer): POMOLE Technology Corporation沒有遲滯現象幫浦零件(Part, Pump)塑料(Polymer): POMOLE Technology Corporation澆口設計(避免凹陷和氣泡)Gate Design to Avoid Sink Mark & Void澆口gate澆口gate差的Poor好的GoodOLE Technology Corporation使用重疊澆口以避免噴流Avoid Jetting by Using Overlap Gate差的Poor好的GoodO
28、LE Technology Corporation正確的澆口位置以避免噴流Avoid Jetting by Locating Gate Correctly差的Poor好的GoodOLE Technology Corporation使用凸片澆口以避免噴流Avoid Jetting by Using Tab GateOLE Technology Corporation使用適當的澆口形狀以避免噴流Avoid Jetting by Profiling Gate Properly差的Poor好的GoodOLE Technology Corporation幫浦零件(Part, Pump)塑料(Polyme
29、r): POM進澆處(Polymer entrance)： 澆口厚(Gate thickness) 1.2mm，模穴厚(Cavity thickness) 3.2mm問題 (Problem)： 噴流(Jetting)OLE Technology CorporationPoor Design Causing JettingGatePart : Handle, RefrigeratorMaterial : ABSProblem : Jetting Mark Gas PinOLE Technology Corporation氣輔成型冰箱把手澆口及氣針入口澆口太小,導致噴流痕產生厚度差異過大,導致二次
30、噴流痕產生R角過小,氣體通路接近把手內側,外側則因體積收縮造成凹陷痕跡OLE Technology Corporation閥澆口Valve Gate1. 閥澆口梢 Valve-Gate Pin2. 加熱管 Heater3. O型環 #610 0 Ring4. 流道歧管模板 Manifold Plate5. 軸封環 Seal Retainer6. 套筒軸封 Sleeve Seal7. 枕塊 Support Pillar8. 油壓缸 Hydraulic CylinderOLE Technology Corporation閥澆口 (一)Valve Gate ( 1 )全部閥澆口同時打開時之充填狀況M
31、old filling with all the valve gates ( shut-off gates ) opened at the same time.OLE Technology Corporation閥澆口 (二)Valve Gate ( 2 )部份閥澆口延遲打開，改變充填模式Mold filling with delayed valve gate opening; filling pattern, weld lines and air traps are changed.OLE Technology Corporation多澆口設計 Multi-Gate DesignOLE Te
32、chnology Corporation閥式澆口Valve GateOLE Technology Corporation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 mmA = 型腔表面積 ( mm2 ) surface area of cavity in mm2n = 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 PVCh = n th = 澆口厚度(
33、 gate thick. in mm )t = 零件壁厚( wall thick. in mm )WtLhOLE Technology Corporation扇形澆口設計Fan Gate DesignL= 1.3mmW= w= 澆口寬度 mm gate width in mmA= 型腔表面積 mm2 surface area of cavity in mm2n= 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 mmt= 零件
34、壁厚 wall thick. in mm h1 = n t h2 = wh1/DOLE Technology Corporation重疊式澆口設計Overlap Gate DesignW= w= 澆口寬度 mm gate width in mmA= 型腔表面積 mm surface area of cavity in mmn= 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澆口長度 land length i
35、n mm t= 零件壁厚 wall thick. in mm 2 2 L1 = 0.50.75L2 = h+( w/2 )OLE Technology Corporation凸耳澆口設計Tab Gate DesignL= 0.50.75mmW= w= 澆口寬度 mm gate width in mmA= 型腔表面積 mm2 surface area of cavity in mm2n= 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
36、. in mm t= 零件壁厚 wall thick. in mm h1 = n th2 = 0.9 tOLE Technology CorporationL = 0.5 0.75 mmd = 澆口直徑( mm ) gate diameter in mmt = 零件壁厚( mm ) wall thick. in mmA = 型腔表面積 ( mm ) surface area of cavity in mmn = 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針點
37、澆口設計Pin Gate DesigndLtOLE Technology Corporation潛伏式澆口設計Subgate DesignW= w= 澆口寬度 mm gate width in mmA= 型腔表面積 mm2 surface area of cavity in mm2n= 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 = ntt= 零件壁厚 wall thick. in mm 30 15 25OLE T
38、echnology Corporation水力直徑 Hydraulic DiameterWhere 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OLE Technology Corporation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 areaOLE Technolog
39、y Corporation流道尺寸設計 (1) Runner Sizing (1)D : 流道直徑 ( mm ) runner diameter in mmW: 下游塑膠重量 ( g ) downstream plastic weight L : 流道長度 ( mm ) runner length in mmOLE Technology Corporation流道尺寸設計(2) Runner Sizing (2)OLE Technology Corporation流道尺寸設計(3) Runner Sizing (3)OLE Technology Corporation流道尺寸設計(4) Run
40、ner Sizing (4)OLE Technology Corporation流道尺寸設計(A1) Runner Sizing (A1)G : 重量 weightS : 零件厚度 thicknessD : 參考直徑 reference diameterG( g ) D ( mm )for PS, ABS, SAN, CABOLE Technology Corporation流道尺寸設計(A2) Runner Sizing (A2) G( g ) D ( mm )for PE, PP, PA, POMG : 重量 weightS : 零件厚度 thicknessD : 參考直徑 referen
41、ce diameterOLE Technology Corporation流道尺寸設計(B) Runner Sizing (B)D : 參考直徑 reference diameterL : 長度 lengthfL :長度係數 Length coefficientD : 流道直徑 runner diameterfLL (mm)D = D fLOLE Technology Corporation冷料井設計Cold Slug Well Design2d次流道Secondary runnerd主流道Primary runner澆口Gate型腔CavityOLE Technology Corporati
42、on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 DesignOLE Technology Corporation澆道襯套尺寸Sprue Bushing SizingOLE Technology Corporation熱澆道設計Hot Runner DesignOLE Technology Corporati
43、on熱澆道的問題似乎發生在三處: 1. 澆口直徑 2. 澆口長度 3. 噴嘴孔徑Problems with hot runner seems to be in three places: 1. Gate diameter 2. Gate land 3. Nozzle orifice diameter熱澆道的問題所在Where Causes Problems with of RunnerOLE Technology Corporation任何發生在澆口處的發赤或噴流，表示澆口太小。 變褐則表示材料過熱而劣解。Any blush or jetting at the gate means the g
44、ate is too small, and brown discolorations mean the material is being degraded by too much heat.受限的塑流通道Restricted Flow PathOLE Technology CorporationBROWN STREAKWITH FLOW LINESA brown streak on thepart molded from easy-flow polycarbonate withthe flow lines.OLE Technology Corporation為了保持澆口暢通而格外加熱塑料，加
45、上塑料在射出時通過長澆口時承受的剪切力，有可能造成褐線。It was probably a combination of shear through the long land of the gate during injection and the extra heat needed to keep the gates open that are causing the brown streak.褐線Brown Streak OLE Technology Corporation只以噴嘴口徑去配合熱澆道口徑是不對的。 首先要將澆道口徑加大，以配合下游塑流通道口徑，然後再加大噴嘴口徑以配合澆道口
46、徑。It isnt just sizing the nozzle orifice to match the hole in the hot sprue bushing . First you might have to increase the hole size of the sprue bushing to match the flow channel diameter, then drill the nozzle out to match the sprue diameter.受限的塑流通道Restricted Flow PathOLE Technology Corporation理想的
47、澆道襯套設計Optimized Sprue Bushing DesignOLE Technology Corporation當塑流通道受限於小或長的澆口，成型技術員常將設定溫度調高，以確保型腔充填、保壓無虞。When the flow path is restricted by a small gate diameter or a long land length, you will usually see higher heat settings being used by the molding technicians to get the parts to fill and pack o
48、ut.這樣的作法產生的問題有製品的翹曲，澆口的外觀缺陷和長的成型時間。The problem with this approach is that it usually causes warpage of the parts, cosmetic defects around the gate area, and long molding cycles.受限的塑流通道Restricted Flow PathOLE Technology Corporation如果歧管溫度設定得比料管前區為高，澆口尺寸或許有問題。 如果必須將噴嘴溫度設定得特別高，噴嘴口徑或許沒配合上熱澆道口徑。If you fin
49、d you have to run the manifold heats higher than the front zone of the barrel, you probably have gate sizing problems. If you have to run the heats up on the nozzle, the nozzle orifice probably hasnt been drilled out to match the hot sprue bushing diameter.受限的塑流通道Restricted Flow PathOLE Technology C
50、orporation如果塑流通道的尺寸正確，料管的前區、噴嘴和加熱歧管的溫度可以設定得一樣；ABS：232 C、易流PC：274 C。If the flow path is sized correctly, you will be able to set the heat settings on the front zone of the barrel, the nozzle, and the heated manifold, such as 232C across the board for ABS or 274C for easy-flow PC.受限的塑流通道Restricted Flo
51、w PathOLE Technology Corporation易流的PE和PP : 壁厚的50%50% of wall thickness for easy-flow PE and PPABS, SAN和壓克力: 壁厚的75%75% of wall thickness for ABS, SAN, and acrylicsPC/acetal/PVC/加玻纖材料和PPO : 壁厚的90%90% of wall thickness for PC/acetal/PVC/glass-filled materials and PPOs熱澆道模具的澆口直徑Gate Diameter for Hot Run
52、ner MoldsOLE Technology Corporation澆口長度應小於0.125mm。 Land should be no longer than 0.125mm.諮詢熱澆道製造廠，以獲得正確的澆口長度。Consult with your hot runner manufacturer for correct land length.熱澆道模具的澆口長度Gate Land Length for Hot Runner MoldsOLE Technology Corporation排氣系統設計Venting System Design徐鑫XUXINOLE Technology Cor
53、poration為何排氣仍然還是一個問題？Why venting is still a problem ?因為降低射速，讓積風有較多的時間逃氣，是一件太容易的事。但是Because it is too easy to slow down the injection speed and give the trapped air more time to escape. But .排氣VentOLE Technology Corporation射速一降，熔膠溫度很快降低，射壓必須提高，殘餘應力隨之提高，翹曲的可能性增加。 如果想藉提高料溫，以降低射壓，料溫必須升得很高，這樣又會引起塑料裂解。Whe
54、n injection speed is lower, melt temperature goes down very fast, injection pressure has to be increased, residual stress is increased and the possibility getting warppage becomes higher. If one would like to increase barrel temperature to reduce the required injection pressure, the barrel temperatu
55、re has to be increased to a quite high level and polymer degradation would be induced. 排氣VentOLE Technology Corporation高料溫和高射壓都說明充填系統有了流動的問題Both high barrel temperature and high injection pressure are indications of flow problem in the filling system.排氣VentOLE Technology Corporation我們常發現: 射速提高時，塑料表現
56、得更為出色。It is quite common that material performs better when it is injected faster.最適化螺桿速度充分運用摩擦熱，將塑流保持在最佳狀態。許多充填和翹曲的問題也就迎刃而解。An optimized ram speed profile fully uses the friction heat to keep the best flow characteristics, which corrects many of the fill and warpage problems.排氣VentOLE Technology Co
57、rporation有了適當的排氣，射速可以提高，充填和保壓可達良好狀態，不須過度增加料管和噴嘴的溫度。With proper venting, the injection speed could be increased to achieve good fill and pack conditions, without having to raise the barrel and nozzle heats, improperly.排氣VentOLE Technology Corporation深度(depth) : 1. 0.075 mm易流塑料(easy-flow mat.) 2. 0.12
58、5 mm難流塑料(stiffer-flow mat.)3. 深度深到流道末端見毛邊為準 (deep enough to feel flash at runner end)寬度(width) : 和流道同寬(as wide as runner dia.)排氣唇部(vent lip): 1.5mm A1拋光(finish)排氣通道通大氣(vent channel to atmosphere): 1mm深(deep)流道排氣Runner VentsOLE Technology Corporation深度(depth) : 參照廠商建議 (refer to manufacturers recommen
59、dation)寬度(width) : 全圓周長(whole perimeter) or 5mm長度(length) : 1.5mm A1拋光(finish)排氣通道通大氣(vent channel to atmosphere): 1mm深(deep)分模面排氣Parting Line VentsOLE Technology Corporation分模面排氣Parting Line VentsOLE Technology Corporation深度(depth) : 參照廠商建議 (refer to manufacturers recommendation)寬度(width) : 全圓周長(wh
60、ole perimeter)長度(length) : 1.5mm排氣溝(vent groove): 1mm深(deep)頂出銷或心型銷排氣Ejector and Core Pin VentsOLE Technology Corporation冷卻系統設計Cooling System Design徐昌煜Charles HsuOLE Technology Corporation模具冷卻設計的目的Purposes of Mold Cooling Design1. 均衡冷卻(改良產品品質)Even Cooling (Improve Part Quality)2.有效冷卻 (提高生產力)Efficien
61、t Cooling (Increase Productivity)OLE Technology Corporation薄殼產品不像傳統壁厚者一般可以承受較大的因熱傳不均而產生的殘餘應力。 為了將收縮彎翹控制在可以接受的程度，均衡的冷卻設計變得非常重要。Thin-wall part can not afford as much thermal induced residual stress as the conventional one does. An even cooling design becomes very important to control the shrinkage and
62、 warpage at an acceptable level.冷卻設計Cooling DesignOLE Technology Corporation射出成型週期時間Injection Molding Cycle Time充填時間Fill Time開模時間Open Time後充填時間Post-fill TimeOLE Technology Corporation對冰箱蔬果盤之類的大零件而言，材料往往佔成本50%以上。 對小而薄的零件而言， 成形機費用可佔成本的90% ，材料6% ，而模具只佔4%。 小而薄的產品較之厚者更能從冷卻的改善而獲得效益。For larger molded parts
63、, material typically represents more than 50% of the part cost for a refrigerator crisper tray. In the case of a thin-wall small part, the press cost could be 90% of the cost of the part; material constitutes 6% and the mold only 4% of the cost of each part. Small thin-wall parts typically benefit f
64、rom improved cooling more than thick parts.冷卻設計Cooling DesignOLE Technology Corporation典型的冷卻系統Typical Cooling System模溫調節機Temperature controlling unit軟管Hoses冷卻迴路 2Cooling Circuit 2冷卻迴路 1Cooling Circuit 1泵Pump收集歧管Collection manifold供給歧管Supply manifoldOLE Technology Corporation模具冷卻管路 Mold SchematicOLE
65、Technology Corporation冷卻孔道Cooling Channels入口Inlet出口Outlet入口Inlet出口OutletOLE Technology Corporation噴泉管BubblerOLE Technology Corporation障板管BaffleOLE Technology Corporation熱管Heat Pipe蒸發部位熱輸入Heat In凝結部位熱輸出Heat Out液體Liquid蒸汽Vapor燈心 ( 毛細管 )Wick ( Capillary )OLE Technology Corporation熱管的應用The Application O
66、f Heat PipeOLE Technology Corporation理論上最短冷卻時間Min. Possible Cooling Time理論上最短冷卻時間the min. possible cooling time產品最大厚度the max. part thickness熔膠的熱擴散度thermal diffusivity of the melt射出溫度injection temp.冷卻液溫度coolant temp.頂出溫度ejection temp.OLE Technology Corporation冷卻時間和厚度分佈Cooling Time and Thickness Profi
67、le差的設計Bad Design好的設計Good DesignOLE Technology Corporation冷卻孔道直徑、深度和節距建議值Recommended Diameter, Depth & PitchD : 直徑為10至14mm Diameter of Cooling Channel, 10 to 14 mmd : 深度為D至3D Depth, D, to 3D P : 節距為3D至5D Pitch, 3D to 5DOLE Technology Corporation原始設計Original DesignOLE Technology Corporation修正設計Revised
68、 DesignAASEC. A-AOLE Technology Corporation原始設計Original Design母模板Cavity Plate澆道襯套Sprue Bushing母模嵌塊Cavity Insert公模嵌塊Core Insert公模板Core Plate承板Support PlateOLE Technology Corporation修正設計Revised Design母模板Cavity Plate澆道襯套Sprue Bushing母模嵌塊Cavity Insert公模嵌塊Core Insert公模板Core Plate承板Support PlateOLE Techno
69、logy Corporation原始設計Original Design公模嵌塊core insertO型環O-ring空氣囊air pocketOLE Technology Corporation 修正設計 (一)Revised Design ( 1 )公模嵌塊core insertO型環O-ringOLE Technology Corporation修正設計(二)Revised Design ( 2 )公模嵌塊core insertO型環O-ringOLE Technology Corporation不平衡的設計Unbalanced DesignOLE Technology Corporat
70、ion平衡的設計Balanced DesignOLE Technology Corporation不用限流孔梢的內歧管設計Internal Manifold Design without FropsOLE Technology Corporation使用限流孔梢的內歧管設計Internal Manifold Design Utilizing FropsOLE Technology Corporation限流孔梢Flow Resistance Orifice PinOLE Technology Corporation紊流和層流Turbulent and Laminar Flows紊流Turbul
71、ent Flow層流Laminar FlowOLE Technology Corporation雷諾數Reynolds Number雷諾數(無因次)Reynolds number (dimensionless)密度density (g/cm3)直徑diameter (cm)速度velocity (cm/sec)黏度viscosity (poise or dyne-sec/cm2 or g/cm-sec)OLE Technology CorporationNu對雷諾數(Re)Nusselt Number Vs. Reynolds Number層流Laminar紊流TurbulentOLE Tec
72、hnology Corporation差的設計Poor DesignOLE Technology Corporation好的設計Better DesignOLE Technology Corporation差的設計Poor DesignOLE Technology Corporation好的設計Better DesignOLE Technology Corporation差的設計Poor DesignOLE Technology Corporation好的設計Better DesignOLE Technology Corporation冷卻設計原則Cooling Design Principl
73、es選擇熱擴散係數大的塑料。Select Plastic Material with large thermal diffusivity.採用薄而均一的製件厚度。Use a thin and uniform part thickness.在型腔周圍均衡的配置冷卻孔道。Layout cooling channels around cavities evenly.在熱傳的道路上移除空氣間隙和空氣囊。Remove air gaps and pockets from heat transfer path.平衡冷卻液流動。Balance coolant flow.檢查冷卻效率。Check cooling efficiency.促使冷卻勻稱。Make cooling evenly.選擇適當設備。Select appropriate equipment.
