德馬格注塑機工藝參數(shù)優(yōu)化的步驟指導

1、培訓課程 2 工藝參數(shù)的優(yōu)化受訓者手冊德馬格注塑機工藝參數(shù)優(yōu)化的步驟指導頁面周期分析3注塑工藝參數(shù)優(yōu)化6步驟 1: 找出轉(zhuǎn)壓點7步驟 1結果8步驟 2: 找出保壓時間(澆口冷凝時間)9步驟 2 結果10步驟 3: 優(yōu)化注射速度11步驟 3 結果12步驟 4: 采用正確的螺桿轉(zhuǎn)速13步驟 4 結果14步驟 5: 優(yōu)化多級螺桿轉(zhuǎn)速和背壓曲線15步驟 5 結果16步驟 6: 優(yōu)化松退17步驟 6 結果18步驟 7: 優(yōu)化保壓曲線19步驟 7 結果20tabulated results21步驟 8: 優(yōu)化鎖模力22步驟 8 結果22步驟 9: 設定注射壓力23步驟 9 結果23典型工藝參數(shù)公差設定24

2、成型周期分析采用下面表格估計注塑過程中的每一階段對周期的影響. 然后去機床看正在運行的模具, 寫下實際的時間并計算出百分比.哪一階段在整個周期中占最多的時間? 那里可以是最有效的縮短成型周期? 模具 1估計 %實際實際%評價 合模射臺前進和后退注射時間保壓時間冷卻時間開模頂出整個成型周期100%seconds100%模具 2估計 %實際實際%評價合模射臺前進和后退 注射時間保壓時間冷卻時間開模頂出整個成型周期100%seconds100%工藝參數(shù)優(yōu)化目標:· 一步步改進工藝過程穩(wěn)定性.· 評估各個參數(shù)的更改對工藝過程穩(wěn)定性的影響· to demonstrate t

3、he cumulative improvemnt in the process and product consistency 方法:at each stage, after the process has been given sufficient time to stabilise, a run of sixteen consecutive mouldings is to be made. these mouldings will be assessed for consistency by weight (a dimension, a physical property or some

4、other attribute could equally well be used, weight is simply the most widely applicable).穩(wěn)定性通過計算重量的標準偏差來衡量. 同時打印出機床ibed上的過程統(tǒng)計數(shù)據(jù). 1. 找出轉(zhuǎn)壓點2. 找出澆口冷卻時間3. 優(yōu)化注射速度4. 采用正確的螺桿轉(zhuǎn)速5. 優(yōu)化多級預塑曲線6. 優(yōu)化松推7. 優(yōu)化多級保壓曲線8. 優(yōu)化鎖模力9. 設定注射壓力限定 步驟 1 找出轉(zhuǎn)壓點在沒有保壓壓力和保壓時間的基礎上填滿產(chǎn)品95% -98%, 然后設定一定的保壓和保壓時間生產(chǎn)16模. 初始設置時的指導1采用行程切換2設定切換位

5、置為10-12mm (逐步增加預塑量直到產(chǎn)品打滿95% - 98% 的位置) 3設置注射壓力為最大值4設定保壓壓力和保壓時間均為05設定注射速度 60 mm s-1 6設定松推速度為最大值7設定鎖模力為最大值8選擇適當?shù)穆輻U轉(zhuǎn)速9根據(jù)材料物性表, 設定料桶溫度10配置過程統(tǒng)計控制11設定保壓壓力和保壓時間生產(chǎn)完整的產(chǎn)品稱12 模產(chǎn)品的重量, 計算標準偏差打印:頁面 20 工藝參數(shù)優(yōu)化頁面 50 工藝過程統(tǒng)計步驟 1 結果輸入實際值平均值范圍最小最大沒保壓時的重量有保壓后的重量填充的百分比%標準偏差 (16 模)g料墊 (平均值和范圍)預塑時間 (平均值和范圍)螺桿停止位置 (平均值和范圍)注射

6、時間 (平均值和范圍)注射壓力峰值, p inj. max轉(zhuǎn)壓壓力, pn press.轉(zhuǎn)壓位置 步驟 2 找出澆口冷凝時間設定保壓壓力為步驟1 上找出的注射壓力峰值的50% 左右. 設定保壓時間為 1 s .生產(chǎn)數(shù)模產(chǎn)品使過程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量和平均值 增加保壓時間至2 s, 生產(chǎn)數(shù)模產(chǎn)品使過程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量.在保壓時間3s, 4s 5s . . . 時重復上述過程直到產(chǎn)品重量不再增加 作出產(chǎn)品重量和保壓時間的關系圖. 記錄record the tcu setting and the actual mould temperature.打印:頁面 30 溫度xl

7、 spreadsheet graph為什么記錄模具溫度很重要?還有什么因素會影響澆口冷凝時間?步驟 2 結果輸入實際值tcu settingfh temperaturemh temperature°c°c°c重量 1重量2重量3重量4重量5平均重量時間保壓重量1重量2重量3重量4重量5平均重量時間保壓所需的保壓時間s 步驟 3 優(yōu)化注射速度采用多級注射曲線, 使注射行程最后的10-20% 采用逐步降低的注射速度. 每次更改注射速度, 必須重新建立轉(zhuǎn)壓點. (注意每次保壓和保壓時間都設定為0.)連續(xù)取16模, 計算出標準偏差. 打印:頁面 24 mwe 使用和沒使用

8、多級保壓時的曲線頁面 26 多級注射頁面50 工藝過程統(tǒng)計為什么轉(zhuǎn)壓點要更改?注射壓力發(fā)生了什么?為什么在數(shù)社的末端采用逐步降低的注射速度是有用的?步驟 3 結果輸入實際值平均值范圍最小最大沒有保壓時的重量采用保壓的重量填充百分比%標準偏差 (16 模)g料墊 (平均值和范圍)預塑時間 (平均值和范圍)螺桿停止位置(平均值和范圍)注射時間 (平均值和范圍)注射壓力峰值, p inj. max轉(zhuǎn)壓壓力, pn press.轉(zhuǎn)換位置 步驟 4 采用正確的螺桿轉(zhuǎn)速select the correct, optimum screw speed for the material being proces

9、sed (see t.01 notes, section 5 ). use this single speed for the whole plasticising strokeset a back pressure of 5 to 10 bar (hydraulic).readjust dosing stroke to achieve 95-98% filltake sixteeen consecutive mouldings and determine the standard deviation of the weights.print out:page 50 process stati

10、sticswhy is it important to use the manufacturers recommended screw speed?step four resultsinsert actual values in the relevant boxesmean valuerangeminmaxweight without holding pressureweight with holding pressurepercentage fill%standard deviation (16 shots)gmelt cushion (mean and range)dosing time

11、(mean and range)screw stop position (mean and range)injection time (mean and range)peak injection pressure, p inj. maxinjection pressure at changeover, pn press.changeover stroke step fiveoptimise screw speed and back-pressure profileuse the dosing profile page to slow down the screw rotation speed

12、for the last 10% of the metering stroke.readjust dosing stroke to achieve 95-98% filltake sixteeen consecutive mouldings and determine the standard deviation of the weights.print out:page 21 dosing profilespage 50 process statisticswhat has happened to the dosing stop position?step five resultsinser

13、t actual values in the relevant boxesmean valuerangeminmaxweight without holding pressureweight with holding pressurepercentage fill%standard deviation (16 shots)gmelt cushion (mean and range)dosing time (mean and range)screw stop position (mean and range)injection time (mean and range)peak injectio

14、n pressure, p inj. maxinjection pressure at changeover, pn press.changeover stroke step sixoptimise decompressionfind the decompression speed which gives best screw stroke and melt cushion consistency. set a decompression stroke of 5mm.check that you still achieve 95-98% fill.take sixteeen consecuti

15、ve mouldings and determine the standard deviation of the weights.print out:page 21 dosing profilespage 50 process statisticswhat has happened to the screw stop position?what is happening to the check ring? step six resultsinsert actual values in the relevant boxesmean valuerangeminmaxweight without

16、holding pressureweight with holding pressurepercentage fill%standard deviation (16 shots)gmelt cushion (mean and range)dosing time (mean and range)screw stop position (mean and range)injection time (mean and range)peak injection pressure, p inj. maxinjection pressure at changeover, pn press.changeov

17、er stroke step sevenoptimise holding pressure profileuse the holding profile page to set a holding pressure profile which ensures a smooth transition from injection to the holding pressure phase and use a high enough pressure to pack the part properly.add a step which reduces holding pressure gradua

18、lly to zero.take sixteeen consecutive mouldings and determine the standard deviation of the weights.print out:page 24 mwepage 27 holding profilepage 50 process statisticswhy do you need a smooth transition from injection to holding pressure?why bother to reduce the pressure gradually if the gate has

19、 already frozen? step seven resultsinsert actual values in the relevant boxesmean valuerangeminmaxweight without holding pressureweight with holding pressurepercentage fill%standard deviation (16 shots)gmelt cushion (mean and range)dosing time (mean and range)screw stop position (mean and range)inje

20、ction time (mean and range)peak injection pressure, p inj. maxinjection pressure at changeover, pn press.changeover stroke tabulated results insert actual values in the relevant boxesthe range value, r, is the maximum minus the minumum, taken from the seven steps.1234567meanrmeanrmeanrmeanrmeanrmean

21、rmeanrmelt cushiondosing timescrew end positioninjection timeinjection pressure p hyd maxinection pressure pn hydraulicchangeover strokestandard deviation (16 shots)can you see a trend?which step had the greatest effect on the consistency of the moulding?step eightoptimising the clamp forcereduce th

22、e clamp force by steps of 50 kn (100 kn for machines over 100 tonnes) using the settings far optimised in the seven steps above.allow the process to stabilise each time and then weigh five mouldings.tabulate your results below and plot a graph of tonnage against part weight.does the mould require th

23、e expected clamp force?what are the advantages of running at reduced tonnage?step eight resultsinsert actual values in the relevant boxesenter results in xl spreadsheet. print out graph.weight 1weight 2weight 3weight 4weight 5mean weightclamp forcerequired clamp forceknstep nineset injection pressur

24、euntil now the injection pressure has been set to the machines maximum value. from the process statistcs page it can be seen that the machine does not need all that pressure to fill the mould.gradually decrease the set injection pressure until the injection time starts to increase. increase the pres

25、sure again until the previous injection time is established with a consistency of 0.08 s or better preferably 0.02 to 0.03 s variation.what is the purpose of limiting the injection pressure?step nine resultsactual peak injection pressurebarset injection pressurebarappendix 1typical process tolerance

26、sshot-weight deviation0.05%0.1%0.2%0.4%plasticising time± 0.04s± 0.06s0.08s0.13sinjection time± 0.02s± 0.02s± 0.04s± 0.06scycle time± 0.5%± 0.5%± 1%± 1%screw position, dosing stop± 0.1mm± 0.1mm± 0.2mm± 0.3mmmelt cushion± 0.1m

27、m± 0.1mm± 0.2mm± 0.3mmmelt temperature± 2°c± 2°c± 3°c± 5°cmould temperature± 1°c± 1°c± 2°c± 4°cbarrel temperature± 1°c ± 1°c± 2°c± 4°cfeed zone temperature± 1&#

28、176;c± 2°c± 3°c± 4°chot runner temperature± 1°c± 2°c± 3°c± 4°chydraulic oil temperature± 1°c± 1°c± 2°c± 2°croom temperature± 2°c± 2°c± 3°c± 4°cmould c

29、avity pressure± 3 bar± 4 bar± 6 bar± 8 barpressure integral± 200± 300± 600± 900injection filling pressure± 1 bar± 2 bar± 3 bar± 4 barholding pressure± 1 bar± 1 bar± 1.5 bar± 2 barback pressure± 0.5 bar± 0.5 bar

30、± 1 bar± 1 barfilling differences (balance of fill for each cavity) on multi-cavity tools± 1%± 1%± 2%± 5%mould breathe0.01mm0.01mm0.02mm0.04mmchange over pressure (pn value)± 1 bar± 2 bar± 3 bar± 4 barscrew surface speed ± 10mms-1± 15mms-1&

31、#177; 20mms-1± 30mms-1melt temperature peak value± 0.3ºc± 0.4ºc± 0.5ºc± 0.6ºcmelt temperature value at changeover± 0.3ºc± 0.4ºc± 0.5ºc± 0.6ºcthe achievable part quality is much influenced by the condition of the mater