科學(xué)化射出成型課件

SymbolTechnologiesScientificInjectionMolding科學(xué)化射出成型

(ProcessOptimization)(過程最優(yōu)化)JohnnySinghSymbolTechnologiesScientific2CONTENTS內(nèi)容

Introduction簡介

PlasticFlowRate塑料的流動(dòng)率

PlasticPressurel

塑料的壓力CoolingRateandTime冷卻的速率和時(shí)間

PlasticTemperature塑料的溫度

CharacteristicstoMonitor塑料特性之監(jiān)控

MoldingWindowoptimizationl

成型窗口最優(yōu)化Appendix附注2CONTENTS內(nèi)容Introduction簡介31.IntroductionScientificInjectionMoldingEnsuresthatidenticalpartsareproducedconsistentlyindependentofthenormalmachinetomachine,daytodayandlottolotvariations保證相同部件生產(chǎn)的一致性,不受一般的不同機(jī)器,生產(chǎn)批號(hào),日期之變異所影響Scientificapproachtoestablishallmoldingvariables以科學(xué)的方法來建立所有成型的變異數(shù)Providesabilitytodetectanddocumentproblemsbasedondata-notpersonalopinions能夠用數(shù)據(jù)化的方式來偵測和紀(jì)錄問題點(diǎn),而不是靠個(gè)人觀點(diǎn)Canincreaseprofitmarginby20to50%能夠提高利潤20%到50%31.IntroductionScientificInj41.IntroductionProfitpercentage(利潤百分比)41.IntroductionProfitpercent5EffectofCycleTimeonProfit(成型周期對(duì)利潤的影響)PartWeight(gm)(部件重量)Material(材料)ApproxCostperlb(1b的大約成本)MaterialCost–Cents(物料成本—分)CycleTime(周期)MachineRate$/hr(機(jī)械速率)CycleTimeCost–Cents(周期成本—分)ActualPlasticCost(實(shí)際塑料成本)OverheadsandLabor(管銷和人力)Profitat5%-Cents(利潤5%)分PercentofQuotedPriceProfit(報(bào)價(jià)利潤率)50PC/ABS

$3.0033.320.0

$30.0016.750.060.55.5210050PC/ABS

$3.0033.322.5

$30.0018.852.163.03.4462.350PC/ABS

$3.0033.325.0

$30.0020.854.265.51.3624.61.Introduction5EffectofCycleTimeonProfi61.IntroductionFourCriticalcomponentstomakeagoodpart做出好成品的四大重要成分PartDesign(成品設(shè)計(jì))Materialselectionandhandling(材料選擇和處理方式)Tooldesignandconstruction(模具設(shè)計(jì)和結(jié)構(gòu))Processing(加工制程)InProcessing,thefourmainplasticvariables(加工中的四大塑料變異因素)PlasticFlowRate(塑料流動(dòng)率)PlasticPressure塑料壓力CoolingRate&Time冷卻速率和時(shí)間PlasticTemperature塑料溫度61.IntroductionFourCritical72.PlasticFlowRateFundamentals基本性Itsflowpatternislikefountainflow塑料流動(dòng)模式類似于噴泉流動(dòng)模式Chainendssticks&freezetowall,thusformingfrozenlayers.流體末端會(huì)附著、凝固在側(cè)壁,形成凝固層Directlyproportionaltoshearrate;highertheshear,fastertheflow與剪切率比例成正比:剪切率越高,流動(dòng)率越快Inverselyproportionaltoviscosity;lowertheviscosity,fastertheflow與黏度比例成反比:黏度越低,流動(dòng)率越快BigmisunderstandingaboutMFR,itdoesNOTcorrelatetoprocessability

對(duì)MFR的誤解,它與加工能力無關(guān)Whatdoesitaffect?它的影響72.PlasticFlowRateFundament82.PlasticFlowRateTypicalPlasticFlow典型的塑膠流動(dòng)率StiffEasySlowFast82.PlasticFlowRateTypicalP92.PlasticFlowRateTypicalPlasticFlow典型的塑膠流動(dòng)StiffEasySlowFastNonNewtonianMixedNewtonian92.PlasticFlowRateTypicalP102.PlasticFlowRateNewtonianfluidscanbedefinedasthoseforwhichviscosityisaconstantregardlessofshearstressorrateofshear.牛頓流體可被定義為黏度是一個(gè)常數(shù),不隨著剪切應(yīng)力或剪切率變化的流體。Non-Newtonianfluidsarethoseforwhichviscosityisnotaconstant,butvariesbasedupontherateofshearortheshearstress.非牛頓流體是那些黏度不是一個(gè)常數(shù),而是隨著剪切應(yīng)力或剪切率變化的流體102.PlasticFlowRate112.PlasticFlowRateMomentumEffect慣性作用StiffEasySlowFastElectric電力Hydraulic水力112.PlasticFlowRateMomentum122.PlasticFlowRateMFREffectMFR效應(yīng)StiffEasySlowFast11.5MFR6MFRMFR10gm/10minutes.ShearRate1/10/60=.007Machineflowrate30gmin.5sec=3/.05=60122.PlasticFlowRateMFREffe132.PlasticFlowRateMeltTempEffect融熔溫度效應(yīng)StiffEasySlowFast525degF425degF132.PlasticFlowRateMeltTem142.PlasticFlowRatePlasticViscosityVaries塑料黏度的變化與以下有關(guān)Withinjectionspeed與射出速度Lotchanges,temperature生產(chǎn)批號(hào)變化,溫度%regrind,colorants再生料%,抽料制程Screwrotatetime螺桿旋轉(zhuǎn)速度-Butthesecanbeminimizedbyvelocitycontrol但這些可經(jīng)速度控制減到最小Whatelsechangestheviscosity?其他改變黏度的因素:Inordertohavecruisecontrolonvelocity,weneedtohaveconstantfilltime(samefilltimeonanypress).為了在速度上的穩(wěn)定性,我們需要有穩(wěn)定的注料時(shí)間(在任何射出循環(huán)有穩(wěn)定的注料時(shí)間)Inordertohavecontrolonconstantfilltime,weneedtouseabundantpressuredifferencebetweenpressureattransferandavailablemachinepressure-DeltaP.為了對(duì)穩(wěn)定的注料時(shí)間進(jìn)行控制,我們需要在移轉(zhuǎn)的壓力和可利用的機(jī)器壓力之間使用大量的壓力差-DeltaP142.PlasticFlowRatePlastic152.PlasticFlowRateTwoStageMolding成型二階段Fillto95-99%on1ststage第一步注料95%-99%Packandholdon2ndStage第二步射飽和保壓Velocitycontrol,deltaP速度控制,deltaPSwitchoverbyposition位置交換(V-P切換位置)Wewilldeterminethefollowingperimeters:我們將決定以下參數(shù)Cutoffposition,cushion,velocityandplasticpressureattransfer.切換位置,緩沖,速度和切換時(shí)之塑料壓力FilltimeanddeltaP充填時(shí)間和deltaPPackingpressureandtime(Gatesealed&unsealed)保壓壓力和時(shí)間(澆口被密封或未封)Backpressureandscrewdelay背壓和螺桿延遲時(shí)間Coolingandcycletime.冷卻時(shí)間和成型周期152.PlasticFlowRateTwoStag162.PlasticFlowRateTwoStageMolding成型二階段162.PlasticFlowRateTwoStag173.PlasticPressureFundamentals基本原理ItisveryimportanttodetermineplasticpressureattransferandDeltaP.在轉(zhuǎn)換和DeltaP時(shí)決定正確的塑料壓力是很重要的Alsodeterminethepressurelossoftheflowpath(Nozzle-Sprue-Runner-Gate-Part)也要決定流道的壓力流失(噴嘴,注道-流道-澆口-成品)Machinecontrollersmustuseplasticpressure機(jī)器控制器必須使用塑料壓力IntensificationRatio:強(qiáng)化比率:-Ratioofeffectivehydraulicramareatoscrewarea

-有效的液壓缸區(qū)域與螺桿區(qū)域的比率-Ratioofmax.injectionpressuretomax.hyd.Pressure-最大的射入壓力與最大液壓比。-Usemachinegraph-使用機(jī)器圖表173.PlasticPressureFundament184.CoolingRate&TimeCoolingTimeistheprofitkillinggiant冷卻時(shí)間--是利潤的最大殺手Injectioncyclecomponents;注射循環(huán)之組成:184.CoolingRate&TimeCoolin194.CoolingRate&TimeBasicsofCooling冷卻的基本知識(shí)Radiation輻射--Moldradiatesenergyinalldirection模具在所有方向放熱能量-Notusuallyvisible-通常不可視-Infraredwavescanbemonitored-紅外線可被監(jiān)測Convection對(duì)流-Energyisemittedthroughaircurrents-能量通過氣流散發(fā)-Hotairrises,lessdense-熱空氣上升,較輕-Moldfacesseesanupdraft-模具正面有上升氣流Conduction傳導(dǎo)-Energyistransferredthroughcontact;likethroughcoolinglines-能量通過接觸轉(zhuǎn)移;如通過冷卻管路-Themosteffectiveandtheonewecancontrol–是最有效的和我們能控制的-----It’sasciencebutoftendonepoorly

--是科學(xué)但經(jīng)常很少有效的去執(zhí)行194.CoolingRate&TimeBasics204.CoolingRate&TimeConductionCooling傳導(dǎo)冷卻:Dependson:依靠

-Turbulentflow;Reynolds#-亂流;雷諾號(hào)碼-CoolingLineLocation冷卻管路的位置-CleanChannels-干凈的管道-Time-時(shí)間-Temperaturedifference-溫度區(qū)別ReynoldsEquation(Nr):Reynolds公式(雷諾號(hào)碼)

Nr=3160xQQ=GPMofcoolant冷卻劑的GPM

DxnD=ChannelDiameter(in)管道直(吋)

n=KinematicViscosity動(dòng)態(tài)黏度(cs)204.CoolingRate&TimeConduc214.CoolingRate&TimeReynolds’#for1/8”&5/16”IDMinimumNr32F50F80F100F140F214.CoolingRate&TimeReynol224.CoolingRate&TimeCoolingLineConnection冷卻管路連接ParallelFlow平行流動(dòng)

-Blockageinmulti-cavity-多洞穴之阻塞-UnevenflowthruChannels-通過管路時(shí)流量不均-MaximumCooling--最大值冷卻-LargestGPMdemand最大的GPM需求-Leastdeltas:T&P-最少變數(shù):時(shí)間&壓力SeriesFlow串聯(lián)流動(dòng)

-Blockagefoundquickly-阻塞可迅速找到-EvenflowthruChannels-通過流道流量均勻-AverageCooling?DeltaT-平均冷卻值-MinimumGPMdemand–最小值GPM需求-Maximumdeltas:T&P-最大變數(shù):時(shí)間&壓力224.CoolingRate&TimeCoolin234.CoolingRate&TimeCoolingIssues有關(guān)冷卻的議題Uniformforeachcavity每穴位需均勻SameGPMforeachline各管路同樣的GPMDeltaTshouldbemaximum4F最大DeltaT應(yīng)該是4FLargerHosesthanmoldchannels水喉要比模子管路更大Useparallel/seriescombo使用并聯(lián)與串聯(lián)組合方式CoolingTimeisaffectedby:冷卻時(shí)間受影響于:Howthickisthethickestsection最厚部分的厚度DeltaTbetweenplasticandmoldsteel在塑料和模金屬之間的DeltaTStiffness&Thermalpropertiesoftheplastic塑料之硬度和熱力特性ReleaseCharacteristics&Draftangles脫模特性和脫模角度Amountofejectionsurfacearea頂出面積的大小Coolantflowrate冷卻劑的流動(dòng)率

234.CoolingRate&TimeCoolin245.PlasticTemperatureHopper料斗Massflow大流量Uniformtemp;insulated一致溫度,需作絕緣Cleanitwithvacuum以真空清洗MaterialDryingusingdehumidifierat-40F.物料使用除濕乾燥機(jī)在-40F干燥。

245.PlasticTemperatureHopper255.PlasticTemperatureInjectionScrewshoulddelivermeltedplasticuniformly.螺桿必須均勻的把熔融射出L/Dratio:L/D比率-16:1isshort,poormeltquality!-16:1是很短的,很差的熔融質(zhì)量!-24:1islong,bettermeltquality…..Critical24:1是長的,更好的熔融質(zhì)量.....非常重要

-20:1minimum20:1最少值Compressionratio:壓縮比-Flightdepthratio;feedtometeringsection進(jìn)入深度比;進(jìn)料到測量部分-Range:1.5:1to8:1范圍:1.5:1到8:1-Highratiostendtoworktheplasticmore;highertemp高比率會(huì)使塑料工作更快;更高的溫度255.PlasticTemperatureInject265.PlasticTemperatureTemperatureprofile溫度特征Targetmidrangeofmfg.recommendations目標(biāo)為使用原料商推薦范圍之中間值Use800–1200psitoturnscrew用800–1200psi轉(zhuǎn)動(dòng)螺桿Mostenergytomeltplasticcomesfromscrewrotation(shearingeffect)多數(shù)熔化塑料的能量來自螺桿的轉(zhuǎn)動(dòng)(剪切熱作用)Frontzoneshouldnotattempttochangemelttemperature前面區(qū)域不應(yīng)該試圖用來改變?nèi)廴跍囟萕atchTemperaturecontrollerduringmolding:成型時(shí)要時(shí)常觀察溫度控制器Ifzoneoverridessetpoints如果區(qū)域超過設(shè)定點(diǎn)

-raiserearorcenterzone–提高后方或中心區(qū)域-slowscrewrpm–減慢螺桿rpm-lowerbackpressure–減低背壓-removebarrelblanket--移除料桶的毯子?

265.PlasticTemperatureTemper276.CharacteristicstoMonitorFactorstoMonitor:主要監(jiān)控因素:Pressureattransfer(V-P)切換時(shí)的壓力Cushion緩沖FillTime充填時(shí)間Recoverytime恢復(fù)時(shí)間276.CharacteristicstoMonito287.MoldingWindowOptimizationProcessWindowStudy加工窗口研究TraditionallyHoldPressureandMeltTemperature(andMoldTempforSCMaterials)傳統(tǒng)上保壓和熔融溫度(和sc物料的模具溫度)AsdiscussedMelttemphasverylittleeffectonprocessability(shearrateisthemaincontroller)如討論所說,熔融溫度對(duì)加工能力很少有影響,剪切率是主要控制因素Dropmelttempfromstudy?放棄熔融溫度的研究?Addhighandlowfillrate?增加高和低的填充率?287.MoldingWindowOptimizati298.AppendixAppendix附錄298.AppendixAppendix附錄30ShearRateFormulaForacircularorifice:對(duì)於圓形的管口WhereQisthevolumetricflowrateAndristheradiusoftheorificeQ是容量流速,r是管口的半徑So,duringthefirststage,shearrateisaffectedbythegeometryofthetoolandthevolumeofmeltenteringthecavityduringtheinjectiontime.因此,在第一階段,剪切率是受在射出期間,模具的幾何形狀和熔融進(jìn)入模穴的容量所影響的4Qpr3剪切率ShearRate=30ShearRateFormulaForacirc31ShearRateforMachineForsimplicity,imaginemeasuringtheshearrateatthenozzleofanoldfashionedplungertypemoldingmachine:衝程Stroke=L灌咀半徑NozzleRadius=r射出時(shí)間InjectionTime=t料管半徑BarrelRadius=R簡單來說,想像在一種老的柱塞類型的成型機(jī)器的噴管上測量剪率31ShearRateforMachineForsi32ShearRateforMachine(cont.)Thenthevolumetricflowrateis:容量流速是:Q=(面積X長度)/時(shí)間Substitutingintotheshearrateformula,weget:代入剪切率公式,我們得到:tpR2LQ=4Qpr3ShearRate=4(pR2L/t)pr3=4R2Lr3t=AreaxLengthTime()32ShearRateforMachine(cont33EffectofStrokeonShearRateSo,ifthetoolandmachinearen’tvaried:所以,如果工具和機(jī)器不變化:Wherekisaconstantequalto4R2/r3k是恆定的等於4R2/r3

Inotherwords:ShearRateisdirectlyproportionaltothestrokeandinverselyproportionaltotheinjectiontime;changeeitherinisolationandtheShearRatechanges.換句話說:剪切率與衝程是成正比與射入時(shí)間成反比;單獨(dú)改變?nèi)魏我环蕉紩?huì)帶來剪切率變動(dòng)Lt剪切率ShearRate=k.33EffectofStrokeonShearRaSymbolTechnologiesScientificInjectionMolding科學(xué)化射出成型

(ProcessOptimization)(過程最優(yōu)化)JohnnySinghSymbolTechnologiesScientific35CONTENTS內(nèi)容

Introduction簡介

PlasticFlowRate塑料的流動(dòng)率

PlasticPressurel

塑料的壓力CoolingRateandTime冷卻的速率和時(shí)間

PlasticTemperature塑料的溫度

CharacteristicstoMonitor塑料特性之監(jiān)控

MoldingWindowoptimizationl

成型窗口最優(yōu)化Appendix附注2CONTENTS內(nèi)容Introduction簡介361.IntroductionScientificInjectionMoldingEnsuresthatidenticalpartsareproducedconsistentlyindependentofthenormalmachinetomachine,daytodayandlottolotvariations保證相同部件生產(chǎn)的一致性,不受一般的不同機(jī)器,生產(chǎn)批號(hào),日期之變異所影響Scientificapproachtoestablishallmoldingvariables以科學(xué)的方法來建立所有成型的變異數(shù)Providesabilitytodetectanddocumentproblemsbasedondata-notpersonalopinions能夠用數(shù)據(jù)化的方式來偵測和紀(jì)錄問題點(diǎn),而不是靠個(gè)人觀點(diǎn)Canincreaseprofitmarginby20to50%能夠提高利潤20%到50%31.IntroductionScientificInj371.IntroductionProfitpercentage(利潤百分比)41.IntroductionProfitpercent38EffectofCycleTimeonProfit(成型周期對(duì)利潤的影響)PartWeight(gm)(部件重量)Material(材料)ApproxCostperlb(1b的大約成本)MaterialCost–Cents(物料成本—分)CycleTime(周期)MachineRate$/hr(機(jī)械速率)CycleTimeCost–Cents(周期成本—分)ActualPlasticCost(實(shí)際塑料成本)OverheadsandLabor(管銷和人力)Profitat5%-Cents(利潤5%)分PercentofQuotedPriceProfit(報(bào)價(jià)利潤率)50PC/ABS

$3.0033.320.0

$30.0016.750.060.55.5210050PC/ABS

$3.0033.322.5

$30.0018.852.163.03.4462.350PC/ABS

$3.0033.325.0

$30.0020.854.265.51.3624.61.Introduction5EffectofCycleTimeonProfi391.IntroductionFourCriticalcomponentstomakeagoodpart做出好成品的四大重要成分PartDesign(成品設(shè)計(jì))Materialselectionandhandling(材料選擇和處理方式)Tooldesignandconstruction(模具設(shè)計(jì)和結(jié)構(gòu))Processing(加工制程)InProcessing,thefourmainplasticvariables(加工中的四大塑料變異因素)PlasticFlowRate(塑料流動(dòng)率)PlasticPressure塑料壓力CoolingRate&Time冷卻速率和時(shí)間PlasticTemperature塑料溫度61.IntroductionFourCritical402.PlasticFlowRateFundamentals基本性Itsflowpatternislikefountainflow塑料流動(dòng)模式類似于噴泉流動(dòng)模式Chainendssticks&freezetowall,thusformingfrozenlayers.流體末端會(huì)附著、凝固在側(cè)壁,形成凝固層Directlyproportionaltoshearrate;highertheshear,fastertheflow與剪切率比例成正比:剪切率越高,流動(dòng)率越快Inverselyproportionaltoviscosity;lowertheviscosity,fastertheflow與黏度比例成反比:黏度越低,流動(dòng)率越快BigmisunderstandingaboutMFR,itdoesNOTcorrelatetoprocessability

對(duì)MFR的誤解,它與加工能力無關(guān)Whatdoesitaffect?它的影響72.PlasticFlowRateFundament412.PlasticFlowRateTypicalPlasticFlow典型的塑膠流動(dòng)率StiffEasySlowFast82.PlasticFlowRateTypicalP422.PlasticFlowRateTypicalPlasticFlow典型的塑膠流動(dòng)StiffEasySlowFastNonNewtonianMixedNewtonian92.PlasticFlowRateTypicalP432.PlasticFlowRateNewtonianfluidscanbedefinedasthoseforwhichviscosityisaconstantregardlessofshearstressorrateofshear.牛頓流體可被定義為黏度是一個(gè)常數(shù),不隨著剪切應(yīng)力或剪切率變化的流體。Non-Newtonianfluidsarethoseforwhichviscosityisnotaconstant,butvariesbasedupontherateofshearortheshearstress.非牛頓流體是那些黏度不是一個(gè)常數(shù),而是隨著剪切應(yīng)力或剪切率變化的流體102.PlasticFlowRate442.PlasticFlowRateMomentumEffect慣性作用StiffEasySlowFastElectric電力Hydraulic水力112.PlasticFlowRateMomentum452.PlasticFlowRateMFREffectMFR效應(yīng)StiffEasySlowFast11.5MFR6MFRMFR10gm/10minutes.ShearRate1/10/60=.007Machineflowrate30gmin.5sec=3/.05=60122.PlasticFlowRateMFREffe462.PlasticFlowRateMeltTempEffect融熔溫度效應(yīng)StiffEasySlowFast525degF425degF132.PlasticFlowRateMeltTem472.PlasticFlowRatePlasticViscosityVaries塑料黏度的變化與以下有關(guān)Withinjectionspeed與射出速度Lotchanges,temperature生產(chǎn)批號(hào)變化,溫度%regrind,colorants再生料%,抽料制程Screwrotatetime螺桿旋轉(zhuǎn)速度-Butthesecanbeminimizedbyvelocitycontrol但這些可經(jīng)速度控制減到最小Whatelsechangestheviscosity?其他改變黏度的因素:Inordertohavecruisecontrolonvelocity,weneedtohaveconstantfilltime(samefilltimeonanypress).為了在速度上的穩(wěn)定性,我們需要有穩(wěn)定的注料時(shí)間(在任何射出循環(huán)有穩(wěn)定的注料時(shí)間)Inordertohavecontrolonconstantfilltime,weneedtouseabundantpressuredifferencebetweenpressureattransferandavailablemachinepressure-DeltaP.為了對(duì)穩(wěn)定的注料時(shí)間進(jìn)行控制,我們需要在移轉(zhuǎn)的壓力和可利用的機(jī)器壓力之間使用大量的壓力差-DeltaP142.PlasticFlowRatePlastic482.PlasticFlowRateTwoStageMolding成型二階段Fillto95-99%on1ststage第一步注料95%-99%Packandholdon2ndStage第二步射飽和保壓Velocitycontrol,deltaP速度控制,deltaPSwitchoverbyposition位置交換(V-P切換位置)Wewilldeterminethefollowingperimeters:我們將決定以下參數(shù)Cutoffposition,cushion,velocityandplasticpressureattransfer.切換位置,緩沖,速度和切換時(shí)之塑料壓力FilltimeanddeltaP充填時(shí)間和deltaPPackingpressureandtime(Gatesealed&unsealed)保壓壓力和時(shí)間(澆口被密封或未封)Backpressureandscrewdelay背壓和螺桿延遲時(shí)間Coolingandcycletime.冷卻時(shí)間和成型周期152.PlasticFlowRateTwoStag492.PlasticFlowRateTwoStageMolding成型二階段162.PlasticFlowRateTwoStag503.PlasticPressureFundamentals基本原理ItisveryimportanttodetermineplasticpressureattransferandDeltaP.在轉(zhuǎn)換和DeltaP時(shí)決定正確的塑料壓力是很重要的Alsodeterminethepressurelossoftheflowpath(Nozzle-Sprue-Runner-Gate-Part)也要決定流道的壓力流失(噴嘴,注道-流道-澆口-成品)Machinecontrollersmustuseplasticpressure機(jī)器控制器必須使用塑料壓力IntensificationRatio:強(qiáng)化比率:-Ratioofeffectivehydraulicramareatoscrewarea

-有效的液壓缸區(qū)域與螺桿區(qū)域的比率-Ratioofmax.injectionpressuretomax.hyd.Pressure-最大的射入壓力與最大液壓比。-Usemachinegraph-使用機(jī)器圖表173.PlasticPressureFundament514.CoolingRate&TimeCoolingTimeistheprofitkillinggiant冷卻時(shí)間--是利潤的最大殺手Injectioncyclecomponents;注射循環(huán)之組成:184.CoolingRate&TimeCoolin524.CoolingRate&TimeBasicsofCooling冷卻的基本知識(shí)Radiation輻射--Moldradiatesenergyinalldirection模具在所有方向放熱能量-Notusuallyvisible-通常不可視-Infraredwavescanbemonitored-紅外線可被監(jiān)測Convection對(duì)流-Energyisemittedthroughaircurrents-能量通過氣流散發(fā)-Hotairrises,lessdense-熱空氣上升,較輕-Moldfacesseesanupdraft-模具正面有上升氣流Conduction傳導(dǎo)-Energyistransferredthroughcontact;likethroughcoolinglines-能量通過接觸轉(zhuǎn)移;如通過冷卻管路-Themosteffectiveandtheonewecancontrol–是最有效的和我們能控制的-----It’sasciencebutoftendonepoorly

--是科學(xué)但經(jīng)常很少有效的去執(zhí)行194.CoolingRate&TimeBasics534.CoolingRate&TimeConductionCooling傳導(dǎo)冷卻:Dependson:依靠

-Turbulentflow;Reynolds#-亂流;雷諾號(hào)碼-CoolingLineLocation冷卻管路的位置-CleanChannels-干凈的管道-Time-時(shí)間-Temperaturedifference-溫度區(qū)別ReynoldsEquation(Nr):Reynolds公式(雷諾號(hào)碼)

Nr=3160xQQ=GPMofcoolant冷卻劑的GPM

DxnD=ChannelDiameter(in)管道直(吋)

n=KinematicViscosity動(dòng)態(tài)黏度(cs)204.CoolingRate&TimeConduc544.CoolingRate&TimeReynolds’#for1/8”&5/16”IDMinimumNr32F50F80F100F140F214.CoolingRate&TimeReynol554.CoolingRate&TimeCoolingLineConnection冷卻管路連接ParallelFlow平行流動(dòng)

-Blockageinmulti-cavity-多洞穴之阻塞-UnevenflowthruChannels-通過管路時(shí)流量不均-MaximumCooling--最大值冷卻-LargestGPMdemand最大的GPM需求-Leastdeltas:T&P-最少變數(shù):時(shí)間&壓力SeriesFlow串聯(lián)流動(dòng)

-Blockagefoundquickly-阻塞可迅速找到-EvenflowthruChannels-通過流道流量均勻-AverageCooling?DeltaT-平均冷卻值-MinimumGPMdemand–最小值GPM需求-Maximumdeltas:T&P-最大變數(shù):時(shí)間&壓力224.CoolingRate&TimeCoolin564.CoolingRate&TimeCoolingIssues有關(guān)冷卻的議題Uniformforeachcavity每穴位需均勻SameGPMforeachline各管路同樣的GPMDeltaTshouldbemaximum4F最大DeltaT應(yīng)該是4FLargerHosesthanmoldchannels水喉要比模子管路更大Useparallel/seriescombo使用并聯(lián)與串聯(lián)組合方式CoolingTimeisaffectedby:冷卻時(shí)間受影響于:Howthickisthethickestsection最厚部分的厚度DeltaTbetweenplasticandmoldsteel在塑料和模金屬之間的DeltaTStiffness&Thermalpropertiesoftheplastic塑料之硬度和熱力特性ReleaseCharacteristics&Draftangles脫模特性和脫模角度Amountofejectionsurfacearea頂出面積的大小Coolantflowrate冷卻劑的流動(dòng)率

234.CoolingRate&TimeCoolin575.PlasticTemperatureHopper料斗Massflow大流量Uniformtemp;insulated一致溫度,需作絕緣Cleanitwithvacuum以真空清洗MaterialDryingusingdehumidifierat-40F.物料使用除濕乾燥機(jī)在-40F干燥。

245.PlasticTemperatureHopper585.PlasticTemperatureInjectionScrewshoulddelivermeltedplasticuniformly.螺桿必須均勻的把熔融射出L/Dratio:L/D比率-16:1isshort,poormeltquality!-16:1是很短的,很差的熔融質(zhì)量!-24:1islong,bettermeltquality…..Critical24:1是長的,更好的熔融質(zhì)量.....非常重要

-20:1minimum20:1最少值Compressionratio:壓縮比-Flightdepthratio;feedtometeringsection進(jìn)入深度比;進(jìn)料到測量部分-Range:1.5:1to8:1范圍:1.5:1到8:1-Highratiostendtoworktheplasticmore;highertemp高比率會(huì)使塑料工作更快;更高的溫度255.PlasticTemperatureInject595.PlasticTemperatureTemperatureprofile溫度特征Targetmidrangeofmfg.recommendations目標(biāo)為使用原料商推薦范圍之中間值Use800–1200psitoturnscrew用800–1200psi轉(zhuǎn)動(dòng)螺桿Mostenergytomeltplasticcomesfromscrewrotation(shearingeffect)多數(shù)熔化塑料的能量來自螺桿的轉(zhuǎn)動(dòng)(剪切熱作用)Frontzoneshouldnotattempttochangemelttemperature前面區(qū)域不應(yīng)該試圖用來改變?nèi)廴跍囟萕atchTemperaturecontroll