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1、精细注塑技术精细注塑技术 Aspects for Precise Aspects for Precise Injection MoldingInjection Molding2 Copyright by ARBURG / Nov. 2019内容提要内容提要 Overview Overview 精细注塑的定义 Definition Precise Injection Molding 锁模系统 Clamping Unit 锁模力 Clamping Force选择注射安装的准那么Criteria to Select the Injection Unit SELOGICA 控制器 SELOGICA C
2、ontroller模具设计Mold Design 模具温度控制Mold Temperature Control3 Copyright by ARBURG / Nov. 2019精细注塑的定义精细注塑的定义 Definition Precise Definition Precise Injection Molding Injection Molding 小的尺寸和公差 轻的部件分量 为特定产品配备注塑设备 灵敏的机器配备一台机器可适用于多种模具) 稳定的质量，高的反复性 Small part dimension and tolerance Low weightAdaptation of mach
3、ine performance to the partsFlexible machine configuration (many molds suitable for one machine)Stable quality, reproducibility 4 Copyright by ARBURG / Nov. 2019锁模系统锁模系统 Clamping Unit Clamping Unit合模系统起重要的作用动模板是稳定而经过证明的箱型构造长而准确的导向模板平行度的调理 50 吨范围内 0.05 mm极高的刚度For precise injection molding, the clampi
4、ng take over a very important part. movable platen as stable and proven box-type platen long and precise guiding of the movable platen adjustable parallelism up to 50 to. Machines 0.05 mm high rigidity5 Copyright by ARBURG / Nov. 2019锁模力锁模力 Clamping Force Clamping Force精细注塑的另一个重要要素是锁模力。缘由是：模腔更好的排气 9
5、0%的空气从分型面排出减少机器和模具的磨损节省能源One other important aspect for precise injection molding is the clamping force.Reasons for that are: Much better venting of the cavities during injection. (ca. 90% of the air inside the cavity escape over the parting line) To prevent machine and mold from unnecessary wear. S
6、aving energy6 Copyright by ARBURG / Nov. 2019锁模力锁模力 Clamping Force Clamping Force怎样计算锁模力锁模力 = 单位锁模力 X (产品投影面积 + 流道投影面积假设有滑块，需求将滑块投影面积的 30% 参与产品投影面积How to calculate the clamping force ?If the mold contains sliders! You have to add 30% of the projected slider area to the projected area of molded part.
7、7 Copyright by ARBURG / Nov. 2019锁模力锁模力 Clamping Force Clamping Force单位锁模力确实定可运用以以下图表To define the necessary specific clamping force, use one of the pictures below. For standard partsfor thin walled parts with long flow paths8 Copyright by ARBURG / Nov. 2019锁模力锁模力 Clamping Force Clamping Force举例Exam
8、ple: 接插件 Connector PA6长度 Length: 6 cm宽度 Width: 1.5 cm浇道投影面积 Proj. area sprue: 8 cm2 单位锁模力 Spec. clamping force: 6 kN/cm2 模穴数 8 cavities9 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection UnitShot weightCycle timeMaterialInjec
9、tion pressure10 Copyright by ARBURG / Nov. 2019每一机器尺寸Each machine size三个注射单元3 injection units三个料筒规格3 cylinder sizes选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection Unit模块化 Modularity11 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Sel
10、ect the Injection UnitCriteria to Select the Injection Unit注射单元的欧洲橡塑机械协会(EUROMAP)规格表示注射单元的最大注射功。计算方法最大注射压力 X 最大行程容量 / 1000举例按注塑机 320 C 600-250 规格表最大注射压力(35 mm 螺杆： 1820 bar最大行程容量 144 ccm1820 bar X 144 ccm /1000 250The size of the injection unit is according to EUROMAP and indicates the working perfor
11、mance of the injection unit. The working performance is calculatemax. spec. injection pressure x max. stroke volume / 1000Example:According to the technical data of 320 C 600-250Max. Injection pressure (screw diameter 35mm) = 1820 barMax. Stroke volume = 144 cm31820 bar x 144 cm3 / 1000 25012 Copyri
12、ght by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection Unit注射功Working performance! 一样螺杆直径，但不同注射压力! Same screw diameter but different max. injection pressure13 Copyright by ARBURG / Nov. 2019选择注射量的准那么Selection criteria shot volume最大计量容量m
13、ax. dosage volume20 80 %最佳工作范围 opt. working range10 20 % bzw. 80 90 %可接受的范围 conditional suited 90%不推荐的范围 not recommended选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection Unit14 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the I
14、njection UnitCriteria to Select the Injection UnitExample: Connector (PA6), 8 cavities, 26.5 g shot weight Results according the list below: (1) The injection volume must be on average 25% greater than the volume of the injected part (incl. sprue) due to shrinkage during solidifying and due to the c
15、ompression of the melt during injection.Injection unitInjection unit100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mmMax. injection volumeMax. injection volume31 cm31 cm3 349 cm49 cm3 3106 cm106 cm3 3188 cm188 cm3 3Percentage of capacity Percentage of capac
16、ity 95%95%60%60%28%28%16%16%15 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection UnitExample: Connector (PA6), 8 cavities, 26.5 g shot weight 2nd example, calculation with shot weight Results according the list below: Injecti
17、on unitInjection unit100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mmMolded part weightMolded part weight26 g26 g41 g41 g89 g89 g158g158gPercentage of capacity Percentage of capacity 100%100%64%64%30%30%17%17%16 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选
18、择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection Unit滞留时间准那么滞留时间 = 塑胶进入料筒到分开喷嘴的时间PE,PP,PS: 最少 30 秒 (大于 40 秒为好)PA, POM, PBT: 最少 60 秒 (75 秒为好)Selection criteria dwell time dwell time = from the entree of material into the cylinder until the exit out of the nozzles e.g.
19、PE, PP, PS : min. 30 s (better 40 s)e.g. PA, POM, PBT : min. 60 s (better 75 s)17 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection UnitExample: Connector (PA6), 8 cavities, 26.5 g shot weight (29.31 cm3) Result according to
20、the list below, dwell time for PA6 min. 60 sec.Injection unitInjection unit100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm40 mm40 mmScrew channel volumeScrew channel volume60 cm60 cm3 385 cm85 cm3 3185 cm185 cm3 3265 cm265 cm3 3Cycle time 15s / dwell timeCycle time
21、 15s / dwell time25 sec.25 sec.35 sec.35 sec.75 sec.75 sec.109 sec.109 sec.Cycle time 25s / dwell timeCycle time 25s / dwell time41 sec.41 sec.58 sec.58 sec.126 sec.126 sec.181 sec.181 sec.Remarks: an extended screw and cylinder can increase the dwell time!18 Copyright by ARBURG / Nov. 2019选择注射单元规格的
22、准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection UnitSelection criteria material throughput Example: Connector (PA6), 8 cavities, 26.5 g shot weightInjection unitInjection unit100100100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm
23、30 mm30 mm40 mm40 mmMax. Throughput/h (PA-GF30)Max. Throughput/h (PA-GF30)3.5 kg/h3.5 kg/h5 kg/h5 kg/h6 kg/h6 kg/h11 kg/h11 kg/h15,5 kg/h15,5 kg/hThroughput (cycle time 15s) Throughput (cycle time 15s) 6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/hThroughput (cycle
24、time 25s)Throughput (cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/hMax. Throughput/h (PS)Max. Throughput/h (PS)5.5 kg/h5.5 kg/h8 kg/h8 kg/h9.5 kg/h9.5 kg/h17 kg/h17 kg/h24.5 kg/h24.5 kg/hThroughput (cycle time 15s) Throughput (cycle time 15s) 6.4 kg/h
25、6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/h6.4 kg/hThroughput (cycle time 25s)Throughput (cycle time 25s)3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h3.8 kg/h19 Copyright by ARBURG / Nov. 2019错误的选择会呵斥Mistakes in selection causes e.g. to - 不完全熔化的粒料- Unm
26、elted granulate - 混色不均- Color steaks- 烧焦- Burnt streaks选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitCriteria to Select the Injection Unit20 Copyright by ARBURG / Nov. 2019其他准那么包括所用资料的加工温度有些工程资料如 PEEK,PEI,LCP 等需求接近 450 摄氏度的加工温度 料筒加热圈应运用陶瓷绝缘加热圈Further criteria for the injection unit is
27、 the temperature range of material to be used.Some high technology plastics (e.g. PEEK, PEI, LCP, etc) requires a temperature release of the machine up to 450 (500) deg. C. Therefore the plasticizing cylinder has to be equipped with ceramic isolated heaterbands.选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Se
28、lect the Injection UnitsCriteria to Select the Injection Units21 Copyright by ARBURG / Nov. 2019选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection Units Criteria to Select the Injection Units - 注射控制的方式 -conceptions of injection regulation-规范方式：注射闭环控制basic configurationinjection regulation 扩展方式
29、可选件：螺杆准确定位 extension stage (option)position regulation screw (PRS)22 Copyright by ARBURG / Nov. 2019注射闭环控制的原理Function principle of the injection regulation选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection Units Criteria to Select the Injection Units 螺杆准确定位 Position regulated screw23 Copyright
30、 by ARBURG / Nov. 2019螺杆准确定位的原理Function principle of the position regulated screw选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection Units Criteria to Select the Injection Units Injection control 注射控制Position regulated screw 螺杆准确定位24 Copyright by ARBURG / Nov. 2019螺杆准确定位效果举例 微型齿轮Example for the
31、 efficiency of the position regulated screw with a micro gear wheel 选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitsCriteria to Select the Injection Units25 Copyright by ARBURG / Nov. 20190,005 ccm0,025 ccm0,010 ccm0,040 ccm0,035 ccm0,015 ccm效果举例 改动进料量Example for the efficiency (variat
32、ion dosage volume):选择注射单元规格的准那么选择注射单元规格的准那么Criteria to Select the Injection UnitsCriteria to Select the Injection Units26 Copyright by ARBURG / Nov. 2019注射闭环控制与螺杆准确定位比较注射闭环控制与螺杆准确定位比较Injection regulation in comparison with Injection regulation in comparison with position regulationposition regulatio
33、nInjection speed curvepressure curveinjection speedscrew positionpressure curve position regulationpressure curve injection regulation27 Copyright by ARBURG / Nov. 2019SELOGICASELOGICA 控制器控制器清楚显示动作顺序Transparent display of the sequence28 Copyright by ARBURG / Nov. 2019运用曲线图像优化工艺过程，发现错误Process optimiz
34、ation through graphic display and identification of errors 设定压力过低机器不能调理注射速度Nominal injection pressuresetting too low machine no able to regulate injection speed设定压力过高假设产品没有顶出或浇口冷却，有损坏模具的危险Nominal injection pressuresetting too high risk of damage mold if one partsticking inside the mold, or in caseof
35、 cold slugsSELOGICASELOGICA控制器控制器29 Copyright by ARBURG / Nov. 2019运用曲线图像优化工艺过程，发现错误Process optimization through graphic display andidentification of errors此例中转压切换点 1 太早。此时模腔只需 60 70% 满而不是95% 满。以后是由保压充模工艺不稳定，产质量量不稳定In this example, the set point (1) of switch over into holding pressure is too early.
36、 With injection the part is only 60-70% full, instead of 95%. The rest will be filled by holding pressure. unstable process and unstable part quality 1SELOGICASELOGICA控制器控制器30 Copyright by ARBURG / Nov. 2019运用曲线图像优化工艺过程，发现错误Process optimization through graphic display andidentification of errorsSELO
37、GICASELOGICA控制器控制器正确的设定Good settings31 Copyright by ARBURG / Nov. 2019SELOGICASELOGICA控制器控制器模具内压精细注塑的另一方面是模具内压。保压时模具内压的变化对产质量量，如尺寸，分量，内应力，有直接影响。Mold cavity pressureAs a further aspect for precision molding is the mold cavity pressure. The progress of the pressure during holding has a direct influenc
38、e of the part quality e.g. dimensions, part weight and stresses. 1 injection start2 melt reach sensor3 cavity is volumetric filled (95-98%)3 4 compression phase4 highest cavity pressure5 gate seal off point 6 pressure releasedMold cavity pressureTime 1 - 注射开场2 熔体到达感应器3 模腔充溢 95-98%3 4 紧缩段4 高压段5 浇口凝固点
39、6 压力解除32 Copyright by ARBURG / Nov. 2019模腔压力 Mold cavity pressure两种压力曲线类型 two different pressure curvesSELOGICASELOGICA控制器控制器无规型塑料amorphous plastics e.g. PS, ABS, PC, PMMA, PEI, PSU半结晶型塑料partially crystalline plastics e.g. PP, POM, PA, PEEK, PBT, PETCavity pressureCavity pressureTimeTime33 Copyright
40、 by ARBURG / Nov. 2019内压丈量原理压电式系统，Kistler, Priamus, 应变片式系统，Dynisco, Cavity pressure measuring principles Piezo-electric system Kistler, Priamus, DMS (Strain Gauge system) Dynisco直接丈量 direct measurement 间接丈量 indirect measurementSELOGICASELOGICA控制器控制器1 mold cavity2 transmission element3 force transduc
41、er (measuring tongue)1 mold cavity2 pressure transducer34 Copyright by ARBURG / Nov. 2019内压丈量 Cavity pressure measuring直接丈量感应器安装位置 Sensor locations for direct measuring SELOGICASELOGICA控制器控制器35 Copyright by ARBURG / Nov. 2019机器控制器可显示模具内压力cavity pressure in machine displaySELOGICASELOGICA控制器控制器36 Cop
42、yright by ARBURG / Nov. 2019切换到保压的不同方法Switch over possibilities into holding pressure 按照模腔内压 via cavity pressure 运用温度感应器 安装在模腔内最后填充点 via temperature sensor (placed at flow path end in the mold)SELOGICASELOGICA控制器控制器37 Copyright by ARBURG / Nov. 2019图像显示过程参数graphical display of the process parameters
43、根据实践丈量值监视产质量量quality monitoring based on actual parameter valuespeak value monitoringmonitoring windowpeak value Integral calculationSELOGICASELOGICA 控制器控制器38 Copyright by ARBURG / Nov. 2019工艺参数和图像的监视Monitoring of process parameters and graphical displaySELOGICASELOGICA 控制器控制器39 Copyright by ARBURG
44、/ Nov. 2019曲线监视 curve monitoringSELOGICASELOGICA 控制器控制器40 Copyright by ARBURG / Nov. 2019产质量量记录 Quality documentationSELOGICASELOGICA 控制器控制器41 Copyright by ARBURG / Nov. 2019用图像记录工艺参数丈量值Graphic display of process actual valuesSELOGICASELOGICA 控制器控制器42 Copyright by ARBURG / Nov. 2019模具设计方面模具设计方面Aspec
45、t of Mould Design Aspect of Mould Design 流道设计流道设计( (特别是小产品特别是小产品) )用冷流道用冷流道流道长度取决于模具刚性和复杂程度流道长度取决于模具刚性和复杂程度必需选择足够的横截面积必需选择足够的横截面积用热流道用热流道加热的流道添加资料滞留时间加热的流道添加资料滞留时间热流道需求足够的空间热流道需求足够的空间延伸的喷嘴延伸的喷嘴需求本卷须知与热流道一样需求本卷须知与热流道一样需求附加的加热圈需求附加的加热圈Sprue Design (especially small parts)Sprue Design (especially small
46、 parts)Via cold-runner systemVia cold-runner systemSprue length is the result from mold Sprue length is the result from mold stability and mold complexity stability and mold complexity The sprue section must be selected big The sprue section must be selected big enough enough Via hot-runner systemsV
47、ia hot-runner systemsHeated sprue channel increases the dwell Heated sprue channel increases the dwell timetimeProblems with spaceProblems with spaceVia extended nozzle tipVia extended nozzle tipSame problem like with hot-runner systemsSame problem like with hot-runner systemsAdditional heaterband n
48、ecessary!Additional heaterband necessary!43 Copyright by ARBURG / Nov. 2019模具设计方面模具设计方面Aspect of Mould DesignAspect of Mould Design排气 Venting为防止飞边，排气间隙应不大于 0.02 0.03 mmTo prevent flash formation gap max. 0.02 -0.03 mm44 Copyright by ARBURG / Nov. 2019模具设计方面模具设计方面Aspect of Mould DesignAspect of Mould
49、 Design研磨方向相互交叉 排气容易,90% 空气从分型面排出 Easy venting. approx. 90% of air escapes over parting line 空气可从整个模腔接触面排出 The air can escape over the complete cavity area 本钱低 Low costs1 分型面光洁度 0.007 0.009 mm1 parting line roughness 0.007 0.009 mm2 模芯光洁度 0.003 0.004 mm2 cavity insert roughness 0.003 0.004 mm 45 Cop
50、yright by ARBURG / Nov. 2019排气槽 Venting channel 在流道终点或熔体相交处 At the end of the flow path or where the melt fronts meets together 可随时开出 Afterwards creation possible 会积累脏物，需定时清理 Problems of dirt deposition thus often cleaning 模具设计方面模具设计方面Aspect of Mould DesignAspect of Mould Design1 venting channel (0.
51、01 0.02 mm) 46 Copyright by ARBURG / Nov. 2019溢流槽排气 Overspill venting 在流道终点或熔体相交处 At the end of the flow path or where the melt fronts meet together 排气效果好 Good venting 防止熔合线 Prevention from weld lines in that area 需切掉余料 Afterwards removal of overspill channel模具设计方面模具设计方面Aspect of Mould DesignAspect
52、of Mould Design1 meet point with enclosed air 2 injection point 3 overspill channel (venting through meltfront meet point shifting into overspill channel47 Copyright by ARBURG / Nov. 2019模具设计方面模具设计方面Aspect of Mould DesignAspect of Mould Design对中系统 centering system对中系统 centering system48 Copyright by
53、 ARBURG / Nov. 2019模具设计方面模具设计方面Aspect of Mould DesignAspect of Mould Design对中系统 centering system49 Copyright by ARBURG / Nov. 2019模温控制模温控制Mold Temperature ControlMold Temperature Control模具温度直接影响产质量量的稳定性The mold temperature has a direct influence of the reproducible quality of the molded parts.50 Cop
54、yright by ARBURG / Nov. 2019 温度感应器安装于模具内利于优化控制 模温机与机器通讯 如模温机缺点，机器停机 整个系统内存水量少 3 升，传热好，调理稳定 模腔温度公差 1 流量监视 Optimal mold temperature control via external sensor placed in the mold Communication from temperature control unit to machine in case of malfunction production stop! Best temperature regulation
55、through reduction of heat transfer medium to approx. 3 liter in the complete unit system (no tank). Cavity temperature tolerance 1 deg. C. Flow controlMold Temperature ControlMold Temperature ControlExternal sensorControl connectionsMachine controlMouldTemperature control unit51 Copyright by ARBURG
56、/ Nov. 2019冷却道布置方式 Connection Form of Cooling Channels平行衔接平行衔接压力降小压力降小温度差小温度差小不易检查通道断路不易检查通道断路Parallel connectionSmall pressure dropSmall temperature differenceDifficult monitoring of blockage串联衔接串联衔接 一切通道流量一样一切通道流量一样 断路能够性小断路能够性小 任务可靠性高任务可靠性高 检查容易温度，流量检查容易温度，流量Serial connection same conditions for all channels small risk of blockage high process security simple monitoring (flow rate, mould temperature) simple connections模具温度控制模具温度控制Mold Temperature ControlMold Temperature Control
