MoldTria注塑成型工艺优化美国的资料总结.xls
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MoldTria注塑成型工艺优化美国的资料总结.xls
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InfoSheet资资料料表表Customer/客客户户MOLD#:
/模模号号MaterialType/材材料料类类别别Project/项项目目NumberofCavities/模模腔腔号号MaterialShrinkage/材材料料收收缩缩率率PartName/产产品品名名称称MoldMaker/制制模模商商MachineTons/机机器器吨吨位位PartNo./产产品品编编号号MachineShotCap机机器器最最大大射射胶胶量量MachineBrand/机机器器商商标标ProjectManager/项项目目经经理理Shotweight/产产品品啤啤重重ProjectEngineer/项项目目工工程程师师ProcessEng./工工艺艺工工程程师师QuotedCycle/报报价价周周期期Screwsize/螺螺杆杆尺尺寸寸DateofTesting/测测试试日日期期Cycletime/优优化化周周期期PreparedBy/制制作作Conclusion/结结论论:
*Cavitiesarebalancedornot:
*Optimisedholdtime:
Second*OptimisedClampingForce:
Ton*OptimisedCoolingtime:
SecondProductphoto*Partweightstudyresult-pleasemarkBox.01to.10%PrecisionMolding注塑:
优.10to.32%FairtoGood注塑:
良.32to1.0%PoorOperatingZone注塑:
差1%Unacceptable注塑:
不可接受MoldingStatus:
PrecisionGoodAcceptableUnacceptableRemark/备备注注:
NSZ-SMSHEET-1ScientificMoldingInjectionMoldProcessSet-UpChecklist成成型型工工艺艺参参数数设设置置表表checkcomplete1Verifymoldingmaterialisdry,ifrequired,permanufacturerspec,usingamoistureanalyzer,orbydryingpermanufacturerspecinadessicantdryer.检查成型料是否干燥,如果需要,就得查阅原料制造商说明书,用水蒸汽测试仪测量水蒸汽含量或干燥漏斗干燥.2CheckBarrelandWaterTemperaturesManifoldandSprueHeatersifavailableUsedateprocessingsheetfromMaterialManufactureformidrangesettings.根据说明书来检查炮筒温度,冷却水温。
3Purgebarreltocheckmeltandflowmaterialshouldbemeltedandflowunrestricted.orificeneedstobesmallerthanspruebutaslargeaspossibleformostresins净化炮筒确保成型料熔化,流动畅通无阻,喷嘴浇口小,但足以使大多数材料能喷入。
4TurnoffHoldPressureandTimeranyholdpressureatallwhenstartingcouldcausedamagetotool关掉保压开关和计时器(模具启动开始时,如保压会损坏模具)。
5SetInjectiontimerfor1second(thiswillbeadjustedwhenfilltimeisestablished-donotsettimeranymorethan.2secondslongerthanactualfill).设注塑时间为1秒(当填充时间已设定时,调注射时间,但不得长于填充时间2秒以上。
6SetcoolingtimerpartdependantInormallystartwith20secondslettheprocessstabilizeandthenworkitdown2secondsatatimeuntilpartandrunneraresetup设定冷确时间(开始设为20秒,让整个过程稳定,直到零件成型)。
7Settheshotsizesothatyouareassuredofshortshots(toensurenotooldamage,makesurethisisconsiderablybelowtheestimatedshotsize).设定注射量,尽量略少一点(太多会损坏模具).8SetBackPressureto50psi.Makesuretheshotisstillataproximately95%offillaftersettingbackpressure.BackPressureshouldgenerallybesettomatchscrewrecovery,foroptimumcycletime,andshouldnotexceed150psi.背压力设为50PSI,确保射胶量射满型腔的95%,在一个周期里,背压设置的压力应该与螺杆缩回相应配,不能超过150PSI.9SetinjectionSpeedtoMaximumifpartisburningandthefilltimeisover1secondyouneedtohavemoreventing设定注射速度最大值,如果零件烧焦和充满整个型腔时间超过1秒,你必须设计更多气槽.10TurnontheHoldTime,andperformaHoldTimeStudy,pertheHold-TimeStudydocument.Startwith3secondsholdtimeandincreasein1secondincrements,weighingthepartswitheachshot.SetHoldTime1/2secondbeyondweightstabilization.参考说明资料,了解保压情况,保压时间开始设为3秒,然后依次增加1秒,每次称产品重量,直至把保压时间设为比产品重量稳定时的时间多0.5秒.11Cushionshouldbesetat5MMorlesstomuchcushioncouldcasemajordamagetothetoolifatimerfailsduringtheprocess残余量设为5mm左右.(如在工作过程中定时器失败,残余量太大会损坏模具.)12MeasurecavityandcoresurfacesteeltemperatureswithapyrometerandrecordinthePre-ShipProcessSet-Updocument.用高温计测量型腔型芯温度,并记录在运载前模具设置的文档中.13DocumentoverallcycleparametersandcycletimetothePre-ShipProcessSet-Updocument.在运载之前模具设置文档中记录相关参数和整个周期时间.Materialdrytemperature原料干燥温度Materialdrytime原料干燥时间Moldtemperature实际模具温度Nozzleorifice喷嘴口尺寸NSZ-SMSHEET-2ScientificMoldingCAVITYBALANCEVERIFICATION型型腔腔平平衡衡性性的的研研究究FullPartWeights/产产品品重重量量CavityBalanceVerificationProcedure/模模腔腔平平衡衡论论证证程程序序CavityNOShot#1PartWeight(g)Shot#2PartWeight(g)Shot#3PartWeight(g)Shot#4PartWeight(g)Shot#5PartWeight(g)AveragePartWeight(g)1.Entermaximumacceptablecavityvariationinthe0%shadedcell.把可接受的产品重量变化最大差值填在0%的那个框里.2.Mold5consecutivevisuallyfullshots.连续依次啤5啤.3.Weigheachpartandrecordthepartweights.记录每啤中每个产品的重量.4.Reducetheshotsizetoproducepartswhicharevisually50%full.减少注塑量,啤产品,产品充满50%.5.Mold5consecutiveshotsthatarevisually50%full.连续啤5次,使产品只充满50%.GrandAverage/总平均值=#DIV/0!
6.Weigheachpartandrecordthepartweights.记录上述每个产品的重量.50%FullPartWeights7.Ifthedifference(betweentheMaximumandMinimumaverage50%fullweights)islessthantheacceptablecavityvariation%thecavitiesarebalanced.Ifthedifferenceisgreaterthantheacceptablecavityvariation%CavityNOShot#1PartWeight(g)Shot#2PartWeight(g)Shot#3PartWeight(g)Shot#4PartWeight(g)Shot#5PartWeight(g)AveragePartWeight(g)thecavitiesarenotbalanced.如果产品最大与最小差异小于产品可接受指标,则表明型腔平衡,否则就不平衡.8.Ifcavitiesarenotbalancedthemoldrequirescavitybalancing.A.Balancethemoldcavities.B.Repeatthecavitybalancestudy.如型腔未平衡,则需平衡型腔.A:
平衡型腔B:
重复进行平衡性论证,直至符合要求.MinimumAverage/最最小小平平均均值值=NOTES/NOTES/备备注注:
MaximumAverage/最最大大平平均均值值=1)Ifthereisonlycavity,thecavitybalancestudynoneedtodo.如果只有一个模穴,则不用做型腔平衡性研究。
DifferencebetweenMaximumandMinimumAverages最最大大最最小小平平均均值值之之差差=#VALUE!
2)CalculationsarecompletedautomaticallyuponenteringdatainshadedcellsPercentDifferencebetweenMaxandMinAverages/最最大大最最小小平平均均值值所所比比之之差差=#VALUE!
数据记录在表格里,计算自动完成.IfthedifferencebetweenMaxandMinisequaltoorgreaterthan5%cavitybalancingwillberequired如果最大与最小值等于或大于XX则需按平衡模腔Conclusion/结结论论:
#VALUE!
#VALUE!
NSZ-SMSHEET-3ScientificMoldingMoldedPartWeight&HoldTimeStudy保保压压时时间间研研究究&产产品品重重量量研研究究DataSheetforHoldTimeAnalysis保保压压时时间间分分析析表表MoldedPartWeightStudy产产品品重重量量研研究究HoldTimesetting(s)Shot#1PartWeight(g)Shot#2PartWeight(g)Shot#3PartWeight(g)AveragePartWeight(g)Weightmustrepresentthetotalshotweight,entirerunnersystemplusallcavitiesthatarebeingmolded重量是一啤产品总重量加上包括水口重量.0.001#2#3#4#5#6#7#8#9#10#0.40Sample#0.8011#12#13#14#15#16#17#18#19#20#1.201.6021#22#23#24#25#26#27#28#29#30#2.002.402.80HighlightAreabelowonCavCVchart3.20GrossAverage/平均重量CavCVCavStdDev/偏差.01to.10%PrecisionMolding/注塑:
优CavCV.10to.32%FairtoGood/注塑:
良.32to1.0%PoorOperatingZone/注塑:
差1%Unacceptable/注塑:
不可接受HoldTimeStudyProcedure/保保压压时时间间研研究究程程序序1.SettheHoldtimeto1secondandmold3shots.保压时间设定为1秒时,啤3啤.Conclusion/结结论论:
2.Weigh3partsfromcavityoneandrecordtheweightsofeachoftheparts,usinga.01gramscale.用刻度为0.1的秤分别秤出用型腔1中取出零件重量,并记录在表格里.3.IncrementallyincreaseHoldTimeasspecifiedintheHoldTimeSettingcolumnanddecreasethecoolingtimethesameincrement,tomaintainthetotalcycletime.如表格所示,依次增加保压时间,减少冷却时间,使整个循环周期不变.4.AftereachincrementalincreaseofHoldTimemold3shots,weigh3partsfromcavityoneandrecordtheweightsofeachofthe3parts.如上图所示设置多个保压时间,在每个保压时间里啤3啤产品,称型腔1产品的重量,把数据依次记录在表格里.Molding:
PrecisionGoodAcceptableUnacceptable5.SetthemachineHoldTimetotheoptimumvaluedeterminedbythechart.据图表设定最佳保压时间.Conclusion/结结论论:
HoldTime&PartWeight保压时间和产品重量关系表3.22.82.42.01.61.20.80.40.014.0014.2014.4014.6014.8015.0015.20HoldTime保压时间PartWeightNSZ-SMSHEET-4ScientificMoldingOptimisedCoolingTimeandClampingForce冷冷却却时时间间和和锁锁模模力力的的优优化化OptimisedClampingForceProcedure程程序序Procedure程程序序1Withsettingsoptimisedpreviously,andmachinesettomaximumclampingforcecollect3shotsofsamples1Withoptimisedinjectionspeed,holdpressureandholdtime,measuredimensionsofthepartwitha15second(enoughlarge)coolWeighthesamplesandrecordinchartbelowtimefor3shots.注射速度.保压压力,保压时间俱佳情况下,冷却时间设为15秒(使产品足够冷却),啤3啤产品,测量其尺寸.螺杆回料时间,注射速度,保压压力,保压时间为最佳时,注塑机锁模力设为足够大,啤啤,2Recordthepartdimensionsinthetablefollowingandnoteanycommentsregardingpartcosmeticintablefollowing记录每啤产品的重量在下表中,记录好产品尺寸.外观情况.2Reduceclampingforceinincrementsof5tonsandweigh3shotsofpartsandrecorddata,33Reducecoolingtimein1secondincrementsandrecordpartdimensionsandcommentsoncosmeticintablefor3shotsStopreducingclampingforcewhenthepartweightdramaticallyincrease产品冷却时间逐依减少1秒,啤3啤锁模力依次减少5Ton,每次啤啤,记录每啤产品重量,直到产品重量突然变大时为止4Reducecoolingtimeuntilthepartcosmeticiseffectedie.减少冷却时间直到产品外观受到影响时止.5Partsproducedatdifferentcoolingtimesshouldbemeasured24hoursaftermouldingtoestablishdimensionalstabilityClampforce(ton)shot1partweight(g)shot2partweight(g)shot3partweight(g)Averagepartweight(g)PartCosmeticOKorNO每个冷却时间所啤的产品应充分冷却(从模具取出小时后)才测量其尺寸66SetthecoolingTimetotheoptimumvalue(finalselectionofcoolingtimeshouldconsiderdimensionalstabilityofpart).决定最佳冷却时间(冷却时间的选择应考虑产品尺寸稳定性)Coolingtime(s)Partdimensionsafter24hoursPartCosmeticOKorNOCavity1(Lengthorwide)MeasureAveragesShot1Shot2Shot3109876543Conclusion/结结论论:
Conclusion/结结论论:
OptimisedClampingForceTon(Insertoptimisedvalue)最佳锁模力OptimisedCoolingtimeSecond(Insertoptimisedvalue)最佳冷却时间OptimisedClampingforce1.210.80.60.40.2015.0015.2015.4015.6015.8016.00Clampingforce(ton)Partweight(g)Partdimension1110987654101.20101.28101.36101.44101.52101.60PartdimensionCoolingtimeNSZ-SMSHEET-5ScientificMoldingNSZ-SMSHEET-5ScientificMoldingMeasurementPosition:
CPKCP#DIV/0!
AVERAGE=XCavity1-1#DIV/0!
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STANDEV=Cavity1-2#DIV/0!
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Date:
CheckBy:
MoldTestingLotNo.DimProduct:
Upper0.000Note:
Part:
Lower0.000(unit:
Millimeter)MEASURINGINSTRUMENT:
Hour123456789101112131415161718192021222324252627282930AverageUpper0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000Lower0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000X+3#DIV/0!
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