Shanghai Daoqin Plastics Co., Ltd.

molding process process/workflow and conditions introduction Molding technique procedure and parameter introduction第一節 molding process Section 1 molding technique.1. molding process parameters type type Sorts of molding parameter.(1). injection molding parts parameters ※※※※ction parameter.a. injection amount ※※※※ction rate.b.计 amount 行程Screw back positionc.余 material amount Cushiond. anti amount Sucking back ratee. screw speed Screw speedf.塑化 amount Plastic0 rateg.预塑 back pressure Screw back pressureh. injection pressure and holding pressure pressure ※※※※ction pressure and holding pressurei. injection speed degree ※※※※ction speed(2) clamping parameters Clamping parametera. clamping force Clamping forceb. clamping speed degree Clamping speedc. clamping 行程.Clamping stroked. mold opening force Opening forcee. mold opening speed degree Opening speedf. mold opening 行程Opening positiong. ejection pressure Ejector advance pressureh. ejection speed degree Ejector advance speedi. ejection 行程Ejector advance position2. temperature parameters Temperature parametera.烘 material temperature degree Dry resin material temperatureb. material toward and nozzle temperature degree Cylinder temperature and nozzle temperaturec. injection molding parts mold temperature degree Mold temperatured.油 temperature Oil temperature3. molding cycle Molding cyclea.循 ring cycle Cycle timeb. cooling time Cool timec. injection time ※※※※ction timed. holding pressure time Holding pressure timee.塑化 time Plant timef. ejection and time Knocking out and delay timeg. low pressure time Mold protect time molding process parameters setting must according to product different 设置.Molding technique parameter setting differs depending on type of product第二节 molding conditions setting Section 2 Molding parameter Setting按 molding steps: can separation is 开锁模, add hot, injection shot, ejection process.Molding steps: mold opening/closing, heating ※※※※ction and knocking out.开锁模 conditions:Mold opening parameter: fast speed in speed degree low pressure high pressure speed degree High-speedmid-speedLow pressure high pressure speed锁模 conditions setting:Mold closing parameter setting1锁模 generally separation: fast speed → in speed → low pressure → high pressure Mold closing: high-speed →low-speed →low pressure→high pressure2. fast generally injection molding parts mold separation, if is 平面二 sheet/plate injection molding parts mold, fast speed 锁模段 can use relatively fast speed degree,甚至于 use to fast,当 use to generally fast speed 时, speed degree to 55-75%,完 full 平面模 can setting to 80-90%, if use to fast can setting in 45-55%, pressure can setting 于50-75%,位置段视 product deep shallow (or long short) different, generally is mold opening wide degree 1/3.In high-speed section, Mold closing speed depends on type of mold. For two –plate mold it can set quick and even especially quick usually, it set speed within 55-75%. For full-plate mold it set speed within80-90% while using especially high speed it set speed within 45-55% and pressure within 50-75% position distance setting differs depending on the volume of product and usually it can be set 1/3 of mold opening position.3. in speed 段, in fast speed 段结束 rear 即转换 formed in speed, in speed generally is to sheet/plate (包括三 sheet/plate 模,二 sheet/plate 模) combined in block is 止, specific long degree 应视模 sheet/plate sheet/plate 间隔, speed degree generally in 30%-50%间, pressure is 20%-45%间.In mid-speed section: Mold closing speed changes into mid-speed after high-speed section finish. Mid-speed start position is where two plates meet (include three-plate mold and two-plate mold) Distance of mid-speed is up to distance of two plates plate it speed within 30-50% and pressure 20-45%.4. low pressure setting, low speed setting generally is in sheet/plate 接触 一瞬间, specific 位置就设 in machine 台显示屏显示 一瞬间 数字 is 准, this generally is this is standards,,即于此点则起不 high pressure, high 于此点则 large, light easy high pressure. setting speed degree generally is 15%-25%,视乎 different machine types 而定, pressure generally setting 于1-2%, has machine can 设于5-15%,也 is different machine types different.Low-pressure section: Mold closing sets low-pressure when plates meeting. This position is set to the data of machine screen on this time. This point is the gage of the data. Data lower the point there is no high-pressure. Data higher the point there is high-pressure easily. It set speed within 15-25% and pressure within 1-2% depending on type within 1-2% depending on type of ※※※※ction molding machine.5. high pressure setting,按 generally machine 台而言, high pressure machine in injection molding parts processing already as setting, versus for 讲, is can more 改, ratio 如震雄 machine in 50P. speed degree versus for low pressure high, large in 30-35% left right,而 pressure 则视乎 injection molding parts mold 而定, can in 55-85% in 取, ratio full 平面之 new 模, injection molding parts mold gas good,甚至于设 in 55%即 can, if is slip block relatively more,原 production flash/burrs relatively more,甚至于 can in 90% also 略显不足.High-pressure section: To normal ※※※※ction molding machine, high-pressure position had been set before they were sent to customer. It can not be modified. For example high-pressure position of CHENHSONG machine is 50P.The speed of high-pressure section is about 30-35% and higher than that of low-pressure. The pressure is up to mold, it can set within 55-85% For full-plate mold, it’s eject air well, it can set pressure 55%.If mold has a lot of slides and flash rate high in production, pressure can set 90%. add hot process conditions setting Heating technique parameter setting1. add hot temperature degree setting must according to product use raw materials different different,但却必 must 遵循一 this 样 规则,即由射口筒 to 进科段 temperature degree is 逐步递 decrease.且递 decrease temperature degree is 以10. degree is mono 位.The proper temperature setting differs depending on type of resin material, but it must be abide by a rule that temperature setting should diminish in step 10.C from nozzle to feeding resin material position.2特殊情况 lower.如 material filament,则射口筒 temperature degree reduce, if is comparison raw materials cold comparison fast.则射口筒 temperature degree 则不止 ratio 第二节 method temperature degree high 10 degree. ratio 如PPS. nylon and other.Nozzle temperature setting should low if product line. If resin material such asPPS, PA, cool very soon, Nozzle temperature should higher more 10.C than the second cylinder temperature.3. machine 台马达启动 temperature degree machine different different, generally for machine 台油路 in 油封保护 need,油 temperature most good can control in 40 degree -60 degree,以免油封 long high pressure 而变化, shrink short use lifespan,造 formed molding unstable.Pump turning on temperature is different depending on type of ※※※※ction molding machine. To protect oil seal of machine it set oil temperature within 40.C-60.C, If oil seal work on condition that high pressure and damaged It’s work time will be shorter, it can cause molding stable. 第三节 injection and 熔胶(add material) process conditions setting ※※※※ction and plastic Technique parameter setting一. injection ※※※※ction第四节 Common plastics raw materials has temperature degree value. raw materials Resin名称Name melting point ℃Melt’s molding temperature degree ℃Molding Temperature(’c) separation understanding temperature degree ℃Decomposing Temperature(‘C) injection molding parts mold temperature degree ℃Mold Temperature(‘c) drying temperature degree ℃Resin dry temperature(‘c) injection is plastics raw materials add hot rear mold cavity process, it generally can separation is grade,第二 grade,第三 grade,第四 grade and holding pressure 几段:※※※※ction is a step which ※※※※ct melt resin material into mold. It consists of stepl,step2,step3,step4 and holding pressure step:1.第一 grade injection generally is injection material 头段. tool injection amount generally can according to material light heavy its 行程,当然也 can based on 公式 计算,如公式:Step l ※※※※cts usually tunnel material, ※※※※ction Volume can be estimated according to the weight of course it can be calculated by formula:L=Si=Vi/0.785Ds2L: injection 行程; Si: injection 行程;L: ※※※※ction stroke Si: ※※※※ction strokeVi:理论 injection 容积; Ds: screw 直径;Vi: ※※※※ction volume of theoretical Ds: diameter of screw0.785: is Ω/4 value.0. 785: value ofΩ/4.当然, if in molding setting parameters need one-time, need molding product need several small can formed.But it cost a lot of time to produce one product if every time molding parameter is setting by calculation.2.第二 grade is injection molding parts product 约2/3 stage/phase,当然, according to product need,也允许 molding to 2/3 stage/phase, ratio 如避免结 combined issues, this stage/phase molding speed degree and pressure generally is molding most large value 段, if product and machine basic is versus combined. injection molding parts mold structure combined 理,排 gas good, this pressure generally 也不会 ultra- 80%. speed degree product 需变, can can large to 95%也 can,自然 generally is in 55%-80%间.Step 2 ※※※※ct 2/3 of product. It can lower 2/3 of product according to requirement of product. For example to prevent weld line. Molding speed and pressure on this step is the maximum of whole molding section. If Mold suit the ※※※※ction molding machine and mold structure reasonable and eject air well, pressure of this step should lower 80%. Molding speed setting within 55-80% but it may setting 95% for especial product.3.第三段 is injection lower 1/3段, its speed degree and pressure according to product need, generally is small 于第二段, speed degree and pressure in 于一 往 decline process. main/primary is is anti product flash/burrs generate,但 meanwhile also must product saturated 满.Step3 ※※※※ct remain 1/3 of product. According to product molding speed and pressure lower than that of step2 To prevent flash speed and pressure should decrease but it can’t shot short.4.第四段: generally has machine also has 第五,第六段, this molding speed degree and pressure same front,都存 in 两段一 递 decrease process. its function is to again 次充满 function.Step4 section: Some ※※※※ction machines have step5,step6 which are same as former molding speed and pressure this step should diminish and ※※※※ct once more.5. holding pressure 段:不论 molding what product,都存 in holding pressure process.任何 product different degree in thick thin issues, positive 常情况 lower, relatively thick separation can can in shrinkage phenomenon, is solution this type of phenomenon,就应 application to holding pressure, holding pressure generally application relatively slow speed,而 pressure 设置则应看 sink marks how to, small to 25%, large to 80%都 has can can.Holding pressure step: No matter what product there is a holding pressure step. Any product can’t molding a same thickness. Usually the deeper section may sink mark. To prevent this defect it should set holding pressure, The ※※※※ction speed of holding pressure step is slow but holding pressure setting within 25-80% depending on sink mark.二.熔胶段 process Plastic Technique1. again complex 熔胶旋转 process most more ultra- 三段,因 is 熔胶本身就 is in 于 胶熔进 material process, if raw materials viscosity large,熔胶 pressure large,但 speed degree 则应取决于 raw materials separation understanding temperature degree,熔胶 speed degree fast, raw materials in force 则会越 large, material tube/pipe temperature degree high, local raw materials generate separation understanding can can property 则会越 large,故 generally 熔胶会 using/adopting in speed is 宜,如45%-75%,熔胶 meanwhile to comparison important step/link, that is back pressure use, product degree requirements large, back pressure use more large, back pressure can make raw materials separation structure more 紧密, molding product dimensions more stability, appearance good.当然, back pressure large,则会 generate 流涎, therefore back pressure use also 应考虙 to its it causes.Plastic should lower 3 steps, because plastic is a step to add melt resin material to cyclinder, Higher stick of resin material,higher screw back pressure. Screw speed differs depending on decomposing temperature of resin material,Higher screw speed,Higher trim force of resin, higher cyclinder temperature. Some resin material may decomposes so it set screw speed in mid-speed such as 45-75%, In plastic step setting screw back pressure is very important, Higher screw back pressure,higher quality of product screw back pressure make resin structure order, Molding product is beautiful and volume stable. But,it maybe flow if screw back pressure too high. So all factors should be considered when using screw back pressure.2.熔胶 process also has comparison important step/link, that is 松退,松退 separation front and rear 松退, its function generally is is anti 止流涎 and filament, setting value speed degree and pressure in 20%-50%间, setting generally in 2-5cm间,太 long can can make material 筒里面贮存空 gas,导致 lower 一模出现不期望 bubbles.In plastic step sucking back is very important too. Sucking back include front sucking back and back sucking back It setting sucking back to prevent flow and line. It sets sucking back speed and pressure within 20-50% and distance within 2-5cm. TOO long distance make cyclinder reserve air and cause bubble at next molding. ejection process setting knocking out technique setting product cooling type rear has mold opening process, mold opening basic upper is clamping process. mold opening 未段则 has slow speed 设置, mold opening formed rear, product must ejection process.There is a mold opening step after product cooling taking shape. Mold opening is a reverse step of mold closing. The last step of mold opening speed set slow. Product should be knocked out after mold opened.一.顶 front:Knocking out顶 front most good separation 两 阶 grade,第一阶 can separation is in pressure slow speed,即 is product light light ejection separation,然 rear is in pressure in speed 顶, in pressure in speed generally is 35%-55%,而 low speed has can can low to 5%, this product different 而言, ejection setting is ejection long degree ratio product deep degree large 1-2cm即 can.Knocking out includes two steps, Step1 section setting mid-speed, knocks product out partly step2 section setting mid-pressure and mid-speed. Depending on different product, mid-pressure and mid-speed sets within 35-55% but low-speed can set 5%. Distance of knocking out longer 1-2cm than the vertical thickness of product.二.退针Back顶退包括两 process and process basic 一致,顶退 终点应预留1-3cm 空间,以保护顶针油 tube/pipe by bad.The same as knocking out, ejector back includes 2 steps. To protect the ejector oil jar, it should make a 1-3mm distance in the ending point of ejector back.三.顶针 methods also 包括一 more 次顶, mono and 顶针停留 selection, machine 械手取 product, demolding 顺利 情况都采取 more 项, is 顶针油缸 lifespan long, more 次顶就以不 ultra- 三次 is 宜,顶针停留 generally use in belt/tape product has can can for increase product generate loss injection molding parts mold, meanwhile is combined machine use, has need relatively short 顶针停留.The way of knocking out includes knocking out once, Knocking out repeat and ejector delay. Take product by manipulator or take product easy, it should select knocking out once. To longer the work time of ejector oiljar, times of knocking out lower 3 times. Ejector delay used when product will be damaged if ejector back or suit manipulator. molding time setting Molding time setting in ensure product quality front lower, cycle time is short good, cycle time also 包括如 lower 几项:射胶 time, holding pressure time,熔胶 time, cooling time, ejection time,锁模 low pressure time,甚至乎关系 to time factors also has also mold opening and 锁模, and ejection fast slow.Cycle time should shorter on condition that product quality well. Cycle time includes: ※※※※ction time, holding pressure time, plastic time, cure time, knocking out time and mold protect time. Even mold opening closing sopeed and knocking out speed affect cycle.1.射胶 time holding pressure time, generally 看起,射胶 time long, product saturated and,但我们 in quality 时, meanwhile must production capacity, more 何况,射胶 time long, has can can formed product saturated 满而寻致 mold sticking deformation 呎寸偏 large and other series issues,故我们 in 设置射胶 time comprehensive 考虑,尽 amount in combined quality requirements shrink short time.※※※※ction time consists holding pressure time. Longer ※※※※ction time, fuller product, we should consider production quantity when we suit for quality. If ※※※※ction time too long, it may cause a series of defects suck as flash strain. So all sorts of factors should be considered, ※※※※ction time should be shout if quality suit for requirement.2.熔胶 time long short 取决于熔胶 speed degree setting fast slow, back pressure setting large small,但 has 一点,熔胶 time control long short need ratio cooling time short.Plastic time depends on plastic speed and screw back pressure, but plastic time must shorter than cure time.3. cooling time: cooling time long short effect/influence to molding cycle, cooling time long, molding time long,造 formed production capacity low,故我们 in setting high pressure cooling time 时, need can ensure to product molding 顺利,不会直接 effect/influence to deformation and other issues, setting time is short good.Cure time: Cure time affects molding cycle. Longer cure time, longer molding cycle, lower production quantity. So it sets cure time short on condition that product molding succed and can’t deformation..4. in a large amount of use machine plastics company,我们 ejection time generally is and machine 械手配 combined is 宜, full use machine 械手时 ejection time generally maintain 1.5-2秒, semi production,如因顶针退回会导致 product or 卡紧,而取不 lower product,停留 time maintain 5秒 left right.In PCE company, for using manipulator in abundence, knocking out time suits manipulator, Knocking out delay keeps 1.5-2 second when using manipulator full-manipulator, knocking out delay keeps about 5 second when using manipulator semi-manipulator and product will fall or can’t be taken off if ejector back.5. low pressure time for 保护我们人身 safety, injection molding parts mold safety very large function,配 combined good injection molding parts mold low pressure and low pressure pressure adjustment, low pressure time 应取1-3秒,保护 time short, can can formed 危害则越 small.Low-pressure protect is very important for safety and protect mold, Mold protect time should adjust within 1-3 second suit low pressure and position of mold protect, shorter protect time, make damaged