ARBURG精密注塑技術

1、精密注塑技術精密注塑技術 Aspects for Precise Aspects for Precise Injection MoldingInjection Molding2 Copyright by ARBURG / Nov. 2006內容提要內容提要 OverviewOverview 精密注塑的定義 Definition Precise Injection Molding 鎖模系統(tǒng) Clamping Unit 鎖模力 Clamping Force選擇注射裝置的準則Criteria to Select the Injection Unit SELOGICA 控制器 SELOGICA Con

2、troller模具設計Mold Design 模具溫度控制Mold Temperature Control3 Copyright by ARBURG / Nov. 2006精密注塑的定義精密注塑的定義 Definition Precise Definition Precise Injection Molding Injection Molding 小的尺寸和公差 輕的部件重量 為特定產(chǎn)品配備注塑設備 靈活的機器配備（一臺機器可適用于多種模具) 穩(wěn)定的質量，高的重復性 Small part dimension and tolerance Low weightAdaptation of machi

3、ne performance to the partsFlexible machine configuration (many molds suitable for one machine)Stable quality, reproducibility 4 Copyright by ARBURG / Nov. 2006鎖模系統(tǒng)鎖模系統(tǒng) Clamping UnitClamping Unit合模系統(tǒng)起重要的作用 動模板是穩(wěn)定而經(jīng)過證實的箱型結構 長而精確的導向 模板平行度的調節(jié) 50 噸范圍內 0.05 mm 極高的剛度For precise injection molding, the clam

4、ping 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. 2006鎖模力鎖模力 Clamping ForceClamping Force精密注塑的另一個重要因素是鎖模力。原因是：模腔更好的排氣

5、（90%的空氣從分型面排出）減少機器和模具的磨損節(jié)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

6、. Saving energy6 Copyright by ARBURG / Nov. 2006鎖模力鎖模力 Clamping ForceClamping Force怎樣計算鎖模力鎖模力 = 單位鎖模力 X (產(chǎn)品投影面積 + 流道投影面積）如果有滑塊，需要將滑塊投影面積的 30% 加入產(chǎn)品投影面積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 pa

7、rt.sprue) area proj. part molded all of area (projected force clampingspecific force clamping7 Copyright by ARBURG / Nov. 2006鎖模力鎖模力 Clamping ForceClamping Force單位鎖模力的確定可使用以下圖表To define the necessary specific clamping force, use one of the pictures below. For standard partsfor thin walled parts with

8、 long flow paths8 Copyright by ARBURG / Nov. 2006鎖模力鎖模力 Clamping ForceClamping Force舉例Example: 接插件接插件 Connector Connector PA6 PA6長度 Length: 6 cm寬度 Width: 1.5 cm澆道投影面積 Proj. area sprue: 8 cm2 單位鎖模力 Spec. clamping force: 6 kN/cm2 模穴數(shù) 8 cavities to.48or kN 480 cm 80 kN/cm 6 force clamping ) sprue .8 ca

9、vities 8 cm 6 cm (1.5 kN/cm 6 force clamping22 22forceclampingareaprojcm9 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the InjectionCriteria to Select the Injection Unit UnitShot weightCycle timeMaterialInjection pressure10 Copyright by ARBURG / Nov. 2006每一機器尺寸Each machine

10、 size三個注射單元3 injection units三個料筒規(guī)格3 cylinder sizes選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UnitCriteria to Select the Injection Unit模塊化 Modularity11 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UnitCriteria to Select the Injection Unit注射單元的歐洲橡塑機

11、械協(xié)會(EUROMAP)規(guī)格表示注射單元的最大注射功。計算方法最大注射壓力 X 最大行程容量 / 1000舉例按注塑機 320 C 600-250 規(guī)格表最大注射壓力(35 mm 螺桿）： 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 performance of the injection unit. The working performance is calculatemax

12、. 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 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select th

13、e Injection UnitCriteria to Select the Injection Unit注射功Working performance! 相同螺桿直徑，但不同注射壓力! Same screw diameter but different max. injection pressure13 Copyright by ARBURG / Nov. 2006選擇注射量的準則Selection criteria shot volume最大計量容量max. dosage volume20 80 %最佳工作范圍 opt. working range10 20 % bzw. 80 90 %可接

14、受的范圍 conditional suited 90%不推薦的范圍 not recommended選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the InjectionCriteria to Select the Injection Unit Unit14 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the InjectionCriteria to Select the Injection Unit UnitExample: Connector (PA6),

15、 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 compression of the melt during injection.33cm 23.45 g/cm 1.13g 26.5 eightspe

16、cific w weightShot volume Shot33(1)cm 29.31 cm 23.45 1.25 volume shot 1.25 volume InjectionInjection 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 cm

17、188 cm3 3Percentage of capacity Percentage of capacity 95%95%60%60%28%28%16%16%15 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則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

18、 weight Results according the list below: Injection 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%1

19、7%16 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UnitCriteria to Select the Injection Unit滯留時間準則滯留時間 = 塑膠進入料筒到離開噴嘴的時間PE,PP,PS: 最少 30 秒 (大于 40 秒為好)PA, POM, PBT: 最少 60 秒 (75 秒為好)Selection criteria dwell time dwell time = from the entree of material into the cy

20、linder until the exit out of the nozzles e.g. 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. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UnitCriteria to Select the Injection UnitExample: Connector (PA6), 8 cavities, 26.5 g

21、shot weight (29.31 cm3) Result according to 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 cm26

22、5 cm3 3Cycle time 15s / dwell Cycle time 15s / dwell timetime25 sec.25 sec.35 sec.35 sec.75 sec.75 sec.109 sec.109 sec.Cycle time 25s / dwell Cycle time 25s / dwell timetime41 sec.41 sec.58 sec.58 sec.126 sec.126 sec.181 sec.181 sec.time cycle volume injectionvolume channelscrew max. 0.8 time dwellR

23、emarks: an extended screw and cylinder can increase the dwell time!18 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the InjectionCriteria to Select the Injection Unit UnitSelection criteria material throughput Example: Connector (PA6), 8 cavities, 26.5 g shot weighttime cyc

24、le weightshot 3.6 throughput materialInjection unitInjection unit100100100100100100250250250250Screw diameterScrew diameter20 mm20 mm25 mm25 mm30 mm30 mm30 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/hT

25、hroughput (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 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. Thro

26、ughput/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/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 time 25s)Throughput (cycle time 25s)3.8 kg/h3.8 kg/h3.8 k

27、g/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. 2006錯誤的選擇會造成Mistakes in selection causes e.g. to - 不完全熔化的粒料- Unmelted granulate - 混色不均- Color steaks- 燒焦- Burnt streaks選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the InjectionCriteria to Select the Injection Unit

28、Unit20 Copyright by ARBURG / Nov. 2006其他準則包括所用材料的加工溫度有些工程材料（如 PEEK,PEI,LCP 等）需要接近 450 攝氏度的加工溫度 料筒加熱圈應使用陶瓷絕緣加熱圈Further criteria for the injection unit is 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

29、 up to 450 (500) deg. C. Therefore the plasticizing cylinder has to be equipped with ceramic isolated heaterbands.選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UniCriteria to Select the Injection Unitsts21 Copyright by ARBURG / Nov. 2006選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection

30、 UniCriteria to Select the Injection Unitsts - 注射控制的方式 -conceptions of injection regulation-標準方式：注射閉環(huán)控制basic configuration injection regulation 擴展方式（可選件）：螺桿精確定位 extension stage (option) position regulation screw (PRS)22 Copyright by ARBURG / Nov. 2006注射閉環(huán)控制的原理Function principle of the injection regu

31、lation選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UniCriteria to Select the Injection Unitsts 螺桿精確定位 Position regulated screw23 Copyright by ARBURG / Nov. 2006螺桿精確定位的原理Function principle of the position regulated screw選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UniCriteria to S

32、elect the Injection Unitsts Injection control 注射控制 Position regulated screw 螺桿精確定位24 Copyright by ARBURG / Nov. 2006螺桿精確定位效果舉例 微型齒輪Example for the efficiency of the position regulated screw with a micro gear wheel 選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UniCriteria to Select the Injec

33、tion Unitsts25 Copyright by ARBURG / Nov. 20060,005 ccm0,025 ccm0,010 ccm0,040 ccm0,035 ccm0,015 ccm效果舉例 （改變進料量）Example for the efficiency (variation dosage volume):選擇注射單元規(guī)格的準則選擇注射單元規(guī)格的準則Criteria to Select the Injection UniCriteria to Select the Injection Unitsts26 Copyright by ARBURG / Nov. 2006注射閉

34、環(huán)控制與螺桿精確定位比較注射閉環(huán)控制與螺桿精確定位比較Injection regulation in comparison with Injection regulation in comparison with position regulationposition regulationInjection speed curvepressure curveinjection speedscrew positionpressure curve position regulationpressure curve injection regulation27 Copyright by ARBURG

35、 / Nov. 2006SELOGICASELOGICA 控制器控制器清楚顯示動作順序Transparent display of the sequence28 Copyright by ARBURG / Nov. 2006SELOGICASELOGICA控制器控制器29 Copyright by ARBURG / Nov. 2006使用曲線圖像優(yōu)化工藝過程，發(fā)現(xiàn)錯誤Process optimization through graphic display andidentification of errors此例中轉壓切換點 1 太早。此時模腔只有 60 70% 滿而不是95% 滿。以后是由保

36、壓充模工藝不穩(wěn)定，產(chǎn)品質量不穩(wěn)定In this example, the set point (1) of switch over into holding pressure is too early. 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 / N

37、ov. 2006使用曲線圖像優(yōu)化工藝過程，發(fā)現(xiàn)錯誤Process optimization through graphic display andidentification of errorsSELOGICASELOGICA控制器控制器正確的設定Good settings31 Copyright by ARBURG / Nov. 2006SELOGICASELOGICA控制器控制器模具內壓精密注塑的另一方面是模具內壓。保壓時模具內壓的變化對產(chǎn)品質量，如尺寸，重量，內應力，有直接影響。Mold cavity pressureAs a further aspect for precision m

38、olding is the mold cavity pressure. The progress of the pressure during holding has a direct influence 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 of

39、f point 6 pressure releasedMold cavity pressureTime 1 - 注射開始2 熔體達到感應器3 模腔充滿 （95-98%）3 4 壓縮段4 高壓段5 澆口凝固點6 壓力解除32 Copyright by ARBURG / Nov. 2006模腔壓力 Mold cavity pressure兩種壓力曲線類型 two different pressure curvesSELOGICASELOGICA控制器控制器無規(guī)型塑料amorphous plastics e.g. PS, ABS, PC, PMMA, PEI, PSU半結晶型塑料partially

40、crystalline plastics e.g. PP, POM, PA, PEEK, PBT, PETCavity pressureCavity pressureTimeTime33 Copyright by ARBURG / Nov. 2006內壓測量原理 壓電式系統(tǒng)，Kistler, Priamus, 應變片式系統(tǒng)，Dynisco, Cavity pressure measuring principles Piezo-electric system Kistler, Priamus, DMS (Strain Gauge system) Dynisco直接測量 direct measur

41、ement 間接測量 indirect measurementSELOGICASELOGICA控制器控制器1 mold cavity2 transmission element3 force transducer (measuring tongue)1 mold cavity2 pressure transducer34 Copyright by ARBURG / Nov. 2006內壓測量 Cavity pressure measuring直接測量感應器安裝位置 Sensor locations for direct measuring SELOGICASELOGICA控制器控制器35 Co

42、pyright by ARBURG / Nov. 2006機器控制器可顯示模具內壓力cavity pressure in machine displaySELOGICASELOGICA控制器控制器36 Copyright by ARBURG / Nov. 2006切換到保壓的不同方法Switch over possibilities into holding pressure 按照模腔內壓 via cavity pressure 使用溫度感應器 （安裝在模腔內最后填充點） via temperature sensor (placed at flow path end in the mold)S

43、ELOGICASELOGICA控制器控制器37 Copyright by ARBURG / Nov. 2006 圖像顯示過程參數(shù) graphical display of the process parameters 根據(jù)實際測量值監(jiān)視產(chǎn)品質量 quality monitoring based on actual parameter valuespeak value monitoringmonitoring windowpeak value Integral calculationSELOGICASELOGICA 控制器控制器38 Copyright by ARBURG / Nov. 2006

44、工藝參數(shù)和圖像的監(jiān)視Monitoring of process parameters and graphical displaySELOGICASELOGICA 控制器控制器39 Copyright by ARBURG / Nov. 2006曲線監(jiān)視 curve monitoringSELOGICASELOGICA 控制器控制器40 Copyright by ARBURG / Nov. 2006產(chǎn)品質量記錄 Quality documentationSELOGICASELOGICA 控制器控制器41 Copyright by ARBURG / Nov. 2006用圖像記錄工藝參數(shù)測量值Grap

45、hic display of process actual valuesSELOGICASELOGICA 控制器控制器42 Copyright by ARBURG / Nov. 2006模具設計方面模具設計方面Aspect of Mould Design Aspect of Mould Design 流道設計流道設計( (特別是小產(chǎn)品特別是小產(chǎn)品) )用冷流道流道長度取決于模具剛性和復雜程度必須選擇足夠的橫截面積用熱流道加熱的流道增加材料滯留時間熱流道需要足夠的空間延長的噴嘴需要注意事項與熱流道相同需要附加的加熱圈Sprue Design (especially small parts)Spr

46、ue Design (especially small parts)Via cold-runner systemVia cold-runner systemSprue length is the result from mold stability and mold complexity The sprue section must be selected big enough Via hot-runner systemsVia hot-runner systemsHeated sprue channel increases the dwell timeProblems with spaceV

47、ia extended nozzle tipVia extended nozzle tipSame problem like with hot-runner systemsAdditional heaterband necessary!43 Copyright by ARBURG / Nov. 2006模具設計方面模具設計方面Aspect of Mould DesignAspect of Mould Design排氣 Venting為避免飛邊，排氣間隙應不大于 0.02 0.03 mmTo prevent flash formation gap max. 0.02 -0.03 mm44 Cop

48、yright by ARBURG / Nov. 2006模具設計方面模具設計方面Aspect of Mould DesignAspect of Mould Design研磨方向互相交叉 排氣容易,90% 空氣從分型面排出 Easy venting. approx. 90% of air escapes over parting line 空氣可從整個模腔接觸面排出 The air can escape over the complete cavity area 成本低 Low costs1 分型面光潔度 0.007 0.009 mm1 parting line roughness 0.007

49、0.009 mm2 模芯光潔度 0.003 0.004 mm2 cavity insert roughness 0.003 0.004 mm 45 Copyright by ARBURG / Nov. 2006排氣槽 Venting channel 在流道終點或熔體相交處 At the end of the flow path or where the melt fronts meets together 可隨時開出 Afterwards creation possible 會積累臟物，需定時清理 Problems of dirt deposition thus often cleaning

50、模具設計方面模具設計方面Aspect of Mould DesignAspect of Mould Design1 venting channel (0.01 0.02 mm) 46 Copyright by ARBURG / Nov. 2006溢流槽排氣 Overspill venting 在流道終點或熔體相交處 At the end of the flow path or where the melt fronts meet together 排氣效果好 Good venting 防止熔合線 Prevention from weld lines in that area 需切掉余料 Afterwards removal of overspill channel模具設計方面模具設計方面Aspect of Mould DesignAspect 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