塑膠射出成型問題診斷與產(chǎn)品模具設(shè)計(jì)

模具設(shè)計(jì)的優(yōu)先順序PrioritiesofMoldDesign澆注系統(tǒng)設(shè)計(jì)

(FillingSystemDesign)排氣系統(tǒng)設(shè)計(jì)

(VentingSystemDesign)冷卻系統(tǒng)設(shè)計(jì)

(CoolingSystemDesign)脫模系統(tǒng)設(shè)計(jì)

(EjectingSystemDesign)澆注系統(tǒng)設(shè)計(jì)的優(yōu)先順序PrioritiesofFillingSystemDesign產(chǎn)品設(shè)計(jì)(PartDesign)型腔設(shè)計(jì)(CavityDesign)澆口設(shè)計(jì)(GateDesign)流道設(shè)計(jì)(RunnerDesign)噴嘴設(shè)計(jì)(NozzleDesign)豎澆道Sprue主流道MainRunner成品Part澆口Gate冷料井ColdSlugWell支流道BranchRunner典型的澆注系統(tǒng)TypicalFillingSystem壁厚不均是注塑成型中最大的麻煩製造者。這對(duì)薄壁產(chǎn)品尤然。這些麻煩包括了遲滯現(xiàn)象、短射、凹陷、發(fā)赤、噴流、翹曲及長(zhǎng)冷卻時(shí)間等；目前都可用CAE以直接或間接的方式預(yù)測(cè)。Non-uniformwallthicknessisthebiggesttroublemakerinplasticinjectionmolding.Thisisespeciallytruetothin-wallpart.Thetroubles,includinghesitation,shortshot,sinkmark,blush,jetting,warpageandlongcoolingtimeetc.,canbepredicted,directlyorindirectly,byusingCAE.壁厚不均

Non-uniformWallThickness壁厚設(shè)計(jì)WallThicknessDesign差[Poor]較好[Better]最好[Best]掏空設(shè)計(jì)(1)CoringOutDesign(1)改進(jìn)設(shè)計(jì)[Improved]原設(shè)計(jì)[Original]差[Poor]改進(jìn)[Improved]掏空設(shè)計(jì)(2)CoringOutDesign(2)氣泡或/和凹陷的形成Voidor/andSinkMarkForming氣泡(Void)凹陷(SinkMark)肋厚和內(nèi)圓角半徑的影響TheEffectofRibThickness&FilletRadius肋的底部厚度BottomThicknessofRibW0.5W2.5WW1.2WD1.5WD(A)(B)肋的設(shè)計(jì)(1)RibDesign(1)t =wallthichnessB=0.5tC =3tAAD=2BE=0.13mm(radius)F=1.5-2deg假如需要更大的強(qiáng)度,可增加肋的數(shù)目Ifmorestrengthisrequired,addadditionalribs.FBDECt

肋的設(shè)計(jì)(2)RibDesign(2)肋的設(shè)計(jì)(3)RibDesign(3)與側(cè)壁相連之凸轂(熱塑性塑膠)BossatWall(Thermoplastics)A =凸轂附著處壁厚 wallthicknessB =凸轂外環(huán)直徑 dia.ofbossoverradiiC =0.5AD =2BE =1~2degF =0.13mm(radius)G =DH =0.8AI =A/4J =2BK =0.3~1JL =0.5ALHA'A'KEIGJDAFCBSectionA'-A'遠(yuǎn)離側(cè)壁之凸轂(熱塑性塑膠)BossAwayFromWall(Thermoplastics)A =凸轂附著處壁厚 wallthicknessB =凸轂外環(huán)直徑

(含底部修整圓弧半徑) dia.ofbossoverradiiC=0.5AD=2BE =1-2degF =0.13mm(radius)G=0.95DH=0.3Gmin.toGmax.I =0.5AHEFDFGCBAI外側(cè)凸轂OutsideBossA'A'A(DIA)BB=AB=2A(max.)SectionA'-A'Where1/r :樑的曲率

curvatureofthebeamM :彎曲力矩

bendingmomentE :彈性模數(shù)

modulusofelasticityI :斷面積對(duì)中立軸的慣性矩

momentofinertiaofthecross-sectionalareawithrespecttotheneutralaxisEI :撓曲剛性flexuralrigidity撓曲剛性

FlexuralRigidityAvarietyofmolded-ininterlockscanaddstiffnesstothin-wallhousingdesigns.各種一體成型的內(nèi)鎖件能增加薄殼的剛性。結(jié)構(gòu)設(shè)計(jì)是薄殼成型零件的基礎(chǔ)。Structuraldesignisthebaseofthin-wallmoldingparts.薄殼成型產(chǎn)品不僅僅是一趨勢(shì)，而且也是降低成本和提高競(jìng)爭(zhēng)力的有效途徑。Thin-wallmoldingpartisnotonlyatrendbutalsoaneffectivewaytoachievecostreductionandcompetitivenessincrease.結(jié)構(gòu)設(shè)計(jì)和薄殼成型產(chǎn)品StructuralDesign&Thin-wallMoldingParts熔膠波前推進(jìn)Melt-FrontAdvancement充填模式,積風(fēng)和熔接線FillingPatterns,Air-TrapsandWeldLinesLocation熔接線Wel維dL遭ine麻s材料[Mat鋸eria捷l]:箏PC-占GF50原設(shè)計(jì)[Ori煙gina梢l]更改設(shè)計(jì)[Re招vis怕ed]更改澆口夫位置以重波新定位熔熱接線Weld灶Lin墾esC恒anB握eRe甚loca宜tedBy婆Cha耐ngi幅ng魯Gat御eL似oca扒tio巨n典型對(duì)頭榮熔接線伸策張強(qiáng)度保革留值Typi螺cal御Butt厘Wel貪dTe嘗nsil淹eSt斃reng布thR薄eten螞tion葡Val捉ues熔接線宿冷料井Wel搞dS粗lug界We損ll對(duì)頭熔接值線[But杠twe肚ld]熔接線妨冷料井[Wel蘆dsl賄ugw俘ell]積風(fēng)Air且Trap伸s排氣Vent大部份熱塑性塑膠MostThermoplastics A0.08mm B3.18mm C12.7mm D0.25mm耐隆和聚縮醛

(POM)NylonandAcetal(POM) A0.04mm B3.18mm C12.7mm D0.25mm進(jìn)料流道FeedRunner塑膠成品PlasticPartAD排氣孔VentBSEC.A'-A'CA'A'每增加一巧個(gè)澆口，畢至少增加廟一條熔接置線，同時(shí)偉增加一個(gè)壘澆口痕跡隙、增加流瀉道的體積冶以及增加鬼較多的積目風(fēng)。Ever鳴yti披meo壓neg況ate惑isa幫dded辟,on寸ewe瞇ldl抽ine,階at捕leas捉t,o粘neg父ate軌mark警,mo困rer霧unne夢(mèng)rvo塔lume緒and千mor拳eai懼rtr央aps逮will祖be靜adde逢d.在型腔慶能夠完市滿充填害的前提開下，澆宮口數(shù)目浙是愈少寶愈好。Asl儀ong考ast燈hec虧avit文yis杜abl卵eto旨be些fill欄eda項(xiàng)ppro訓(xùn)pria旅tely番,ga跳tes婆are枯the亭less霉the蚊bet踩ter.為了減聯(lián)少澆口燃數(shù)目，胞每一澆轉(zhuǎn)口應(yīng)就關(guān)塑流力出所能及煤的流長(zhǎng)備/壁厚破比之內(nèi)慣，找出薦可以涵跪蓋最大澆產(chǎn)品面樸積的進(jìn)蕩澆位置扔。Ino鳴rder邀to吸redu辟cet煮hen糞umbe醉rof論gat磁es,墻each推gat艙esh舒all覽bel閣ocat丈eda糾twh憲ere匹the殲melt漏is刷able巧to遷cove鵲rma巾ximu侄mpa喝rta積rea嘗base絲式don慈the唯lar消gest洞mel凍tfl痛owl炭engt瓦h(yuǎn)/th拘ickn遭ess搭rati月o.澆口數(shù)塔目The腥Numb荒ero吧fGa宰tes充填均衡Flo窩wB除ala霜nce熔膠波朱前於同瓦一時(shí)間溜抵達(dá)型兄腔各末忘端。Melt陷fro押ntr燭each煙est缺hee副nds桑ofc惠avit溫yat脊the紛sam悉eti褲me.洗衣機(jī)圈蠶板洗衣機(jī)扔圈板冷氣通垃風(fēng)飾罩半-原始營(yíng)設(shè)計(jì)Air峰-co淋ndi爺tio垃ner慢Gr錘ill焦e-平Or甲igi蘿nal18gatespressure:76MPa冷氣通軋風(fēng)飾罩盜-修正婚設(shè)計(jì)Air-班cond弊itio篇ner舒Gril巾le-弦Rev縣ised8gatespressure:75MPa分析結(jié)韻果比較鹽表Comp伯a(chǎn)ris其ono毅fAn跌alys糊isR笨esul螞ts十二澆罵口設(shè)計(jì)12難Gat播eD流esi戴gn原始設(shè)計(jì)OriginalDesign電子零件置物箱材料Material：ABS四澆口設(shè)發(fā)計(jì)4G逼ate架De母sig址n修正設(shè)計(jì)RevisedDesign電子零件置物箱材料Material：ABS電子零件響置物箱四歷澆口和十二公澆口設(shè)冊(cè)計(jì)比較攻表如何快乖速平衡陽(yáng)眾多模簽穴之流朱道How卻to住Ba牽lan防ce網(wǎng)Flo史wI胖nAMult塵i-ca撫vity挖Mol索d首先調(diào)整一排支流道內(nèi)之次支流道尺寸，使此支流道內(nèi)之各模穴可平衡充填。 First,adjustrunnersizeinonebranchtomakeflowbalancedinthisbranch.再調(diào)整各支流道前段之尺寸，使各支流道可平衡充填。 Then,adjustthefirstsection’srunnersizeineachbranchtomakeflowbalancedinallbranches.一排支流峽道之不平采衡充填Unb蝕ala糊nce遼dFlo都wI吐nA畜Br輕anc累h一排支帖流道平劇衡後之郊充填Bal恨anc求ed鉤Flo變wI授nA集Br便anc禽h全模具(慶128模廣穴)之不鈴平衡充填Unba翅lanc設(shè)edF胞low忠InA感Mol隙d全模具的(12榆8模穴帖)平衡坊後之充蜂填Bal嘴anc顫ed乎Flo翼wI撲nA鍬Mo由ldThe唱me該lt汽fil捆ls渣the度in爺sid粉ec童avi偉tie暴sb姥efo驚re敲fil憂lin臣gt調(diào)he間out睬sid社ec初avi噴tie浙s.The廁ru床nne餐rs門yst誓em趁sho遮ws泄tha跳tw掉arm判er,睜lo辛w-v持isc臨osi篇ty弦mat恭eri累al趙(ye男l(wèi)lo云wa育nd刻red已)f竊oll掏ows封th蘭ei皺nsi狂de寺wal埋lw甘hen側(cè)th遠(yuǎn)em借elt青sp撓lit剩sa宿ta子ni爸nte裂rse租cti哲on.Mel軌t”彼Fl某ipp擋er嬸”導(dǎo)致平直廚產(chǎn)品的澆架口設(shè)計(jì)Gat陳eD紫esi甘gn爺for細(xì)Fl度at待Par蘇t中心澆口CenterGate扇形澆口FanGate最壞的Worst壞的Worse較好的Better最好的Best側(cè)澆口EdgeGate薄模澆口FilmGate澆口設(shè)告計(jì)(減頸少滯流腸效應(yīng))Gat散eD繁esi銹gn峽to名Avo仁id帶Hes盈ita糠tio克n澆口gate薄thin厚thick差的設(shè)計(jì)Poor好的設(shè)計(jì)Good薄thin厚thick澆口gate0.94秒時(shí)，遲滯現(xiàn)象在1.2mm厚凸片處發(fā)生公稱厚度3.2mm幫浦零件(Part,Pump)塑料(Polymer):POM沒有遲滯暗現(xiàn)象幫浦零件(Pa級(jí)rt,序Pu逝mp)塑料(Pol西ymer依):P君OM澆口設(shè)衛(wèi)計(jì)(避療免凹陷貼和氣泡迅)Gat詳eD危esi昏gn辨to教Avo證id殘Sin融kM謹(jǐn)ark瞞&奮Voi萄d澆口gate澆口gate差的Poor好的Good使用重疊咱澆口以避諸免噴流Avo差id廉Jet濫tin灰gb蛙yU紅sin虛gO桑ver爬lap褲Ga熟te差的Poor好的Good正確的澆撤口位置以纖避免噴流Avoi銳dJe漂ttin汁gby懲Loc海atin孩gGa毛teC覺orre苦ctly差的Poor好的Good使用凸片桃澆口以避倘免噴流Avo拍id覽Jet可tin蜓gb盛yU蝦sin俱gT柔ab翻Gat臺(tái)e使用適當(dāng)閥的澆口形命狀以避免擇噴流Avo頁(yè)id慕Jet礎(chǔ)tin盾gb籠yP吉rof暴ili狐ng遵Gat糧eP倡rop篇erl脹y差的Poor好的Good幫浦零件(Par穩(wěn)t,P副ump)塑料(Po碰lym特er)駁:并POM進(jìn)澆處(Pol殺ymer炊ent歇ranc振e)：澆口厚(Ga物te綠thi剩ckn龜ess盤)1.2醒mm，遞模穴厚(Cav論ity芹thic兔knes仆s)3.2m脅m問題(Pro兔blem冷)：噴流(Jet顧ting秋)Poor傍Des壁ign妨Caus虛ing品Jett綱ingPart :Handle,RefrigeratorMaterial :ABSProblem :JettingMarkGasPinGate氣輔成抽型冰箱夜把手澆口及氣針入口澆口太小,導(dǎo)致噴流痕產(chǎn)生厚度差異過大,導(dǎo)致二次噴流痕產(chǎn)生R角過小,氣體通路接近把手內(nèi)側(cè),外側(cè)則因體積收縮造成凹陷痕跡閥澆口Valv熔eGa考te1.閥拼澆口梢Valv跪e-Ga憐teP壤in2.雞加熱站管Hea蛾ter3.晶O型環(huán)#61寺0"臉0"散Rin法g4.蝕流道歧管簽?zāi)０錗an北ifo廁ld衛(wèi)Pla毒te5.尊軸封隨環(huán)Sea凡lR率eta葵ine拋r6.經(jīng)套筒脅軸封Slee債veS慘eal7.轟枕塊Supp拋ort持Pill乎ar8.膊油壓示缸Hyd恐rau攜lic糠Cy牢lin嗓der閥澆口宰(1笑)Valv屠eGa踢te(蹈1)全部閥澆挽口同時(shí)打勞開時(shí)之充第填狀況Mol以df俱ill糖ing浪wi橋th裂a(bǔ)ll互th梁ev雞alv離eg躺ate擴(kuò)s(瞎sh游ut-想off咳ga壩tes策)康ope嶄ned謝at帳th霧es粉ame出ti子me.閥澆口林(2)Val角ve滴Gat市e(屆2慮)部份閥澆姨口延遲打扣開，改變章充填模式Mold淘fil尊ling舅wit辭hde固laye攝dva伙lve沉gate峰ope第ning忙;愉fil膝ling坡pat橡tern洗,we汽ldl交ines債and依air昆tra僵psa臭rec浴hang撐ed.多澆口棋設(shè)計(jì)Mul召ti-漲Gat狀eD座esi五gn閥式澆口Valv影eGa磚te針點(diǎn)澆口PinGate扇型澆口FanGate潛伏澆口SubmarineGate邊緣(薄膜)澆口Edge(Film)Gate凸片澆口TabGate閥澆口ValveGate環(huán)狀澆口RingGate澆口種類Gat袋eT星ype箏s矩形邊寒緣澆口宅設(shè)計(jì)Rec嘆tan貧gul象ar謎Edg幻玉eG庭ate線De隆sig廚nL=0.5~0.75mmW=澆口寬度(mm)gatewidthinmmA=型腔表面積(mm2

)surfaceareaofcavityinmm2n=材料常數(shù)materialconstant0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVCh=nth=澆口厚度(gatethick.inmm)t=零件壁厚(wallthick.inmm)WtLh扇形澆口刪設(shè)計(jì)Fan拳Ga涉te與Des趙ignL=1.3mmW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]t=零件壁厚[wallthick.inmm]h1=nth2=wh1/D重疊式澆廟口設(shè)計(jì)Over稅lap炒Gate撿Des天ignW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]=nt澆口長(zhǎng)度[landlengthinmm]t=零件壁厚[wallthick.inmm]

L1=0.5~0.75L2=h+(w/2)凸耳澆應(yīng)口設(shè)計(jì)Tab紅Gate濃Des窯ignL=0.5~0.75mmW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]t=零件壁厚[wallthick.inmm]h1=nth2=0.9t針點(diǎn)澆口嚴(yán)設(shè)計(jì)Pin吊Ga企te體Des吉ignL =0.5~0.75mmd =澆口直徑(mm)gatediameterinmmt =零件壁厚(mm)wallthick.inmmA =型腔表面積(mm2)surfaceareaofcavityinmm2n =材料常數(shù)materialconstant0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVCdLt潛伏式娃澆口設(shè)尊計(jì)Sub乒gat宅eD尺esi勝gnW=w=澆口寬度[mm]gatewidthinmmA=型腔表面積[mm2]surfaceareaofcavityinmm2n=材料常數(shù)[materialconstant]0.6forPE,PS0.7forPOM,PC,PP0.8forCA,PMMA,PA0.9forPVC澆口厚度[gatethick.inmm]=ntt=零件壁厚[wallthick.inmm]30~15o~25o剪切速旋率Shea齒rRa芝te剪切應(yīng)力shearStress黏度viscosity剪切速率shearrate剪切應(yīng)力Shea伙rSt足ress水力直徑Hydr娃auli鑰cDi休amet桂erWhereisthehydraulicdiameter水力直徑Aisthecross-sectionalareaoftheflow

流路斷面積Pisthewettedperimeter濕周長(zhǎng)水力直徑Hyd遠(yuǎn)rau涼lic自Di既ame綠ter在不同雜剖面形呼狀，相騎同斷面躺積下之哪變化Var應(yīng)iou將sr誕unn稻er挺pro緞fil懷es,水ba乓sed疤on輔th以es化ame隸cr衫oss殲-se沈cti草ona秧la棚rea流道尺寸推設(shè)計(jì)(犬1)Run偉ner淘Si榨zin止g(電1)D :流道直徑(m矛m)runn殺erd還iame里ter捐inm異mW :下游塑定膠重量(g德)dow耀nst吵rea拳mp勇las陳tic艱we乞igh堅(jiān)tL :流道長(zhǎng)被度(m麻m)runn暖erl壯engt蹦hin宗mm流道尺寸肺設(shè)計(jì)(五2)Run終ner絞Si線zin悔g(附2)流道尺件寸設(shè)計(jì)新(3滅)