注塑技術(shù)員用英語全攻略

注塑專業(yè)英語全攻略!成型工藝流程及條件介紹Moldingtechniqueprocedureandparameterintroduction第一節(jié)成型工藝Section1moldingtechnique.1.成型工藝參數(shù)類型Sortsofmoldingparameter.(1.注塑參數(shù)Injectionparameter.a.注射量Injectionrate.b.計(jì)量行程Screwbackpositionc.余料量Cushiond.防誕量Suckingbackratee.螺桿轉(zhuǎn)速Screwspeedf.塑化量lasticrateg.預(yù)塑背壓Screwbackpressureh.注射壓力和保壓壓力Injectionpressureandholdingpressurei.注射速度Injectionspeed(2合模參數(shù)Clampingparametera.合模力Clampingforceb.合模速度Clampingspeedc.合模行程.Clampingstroked.開模力Openingforcee.開模速度Openingspeedf.開模行程Openingpositiong.頂出壓力Ejectoradvancepressureh.頂出速度Ejectoradvancespeedi.頂出行程Ejectoradvanceposition2.溫控參數(shù)Temperatureparametera.烘料溫度Dryresinmaterialtemperatureb.料向與噴嘴溫度Cylindertemperatureandnozzletemperaturec.模具溫度Moldtemperatured.油溫Oiltemperature3.成型周期Moldingcyclea.循環(huán)周期Cycletimeb.冷卻時(shí)間Cooltimec.注射時(shí)間Injectiontimed.保壓時(shí)間Holdingpressuretimee.塑化時(shí)間lanttimef.頂出及停留時(shí)間Knockingoutanddelaytimeg.低壓保護(hù)時(shí)間Moldprotecttime成型工藝參數(shù)的設(shè)定須根據(jù)產(chǎn)品的不同設(shè)置.Moldingtechniqueparametersettingdiffersdependingontypeofproduct第二節(jié)成型條件設(shè)定Section2MoldingparameterSetting按成型步驟:可分為開鎖模,加熱,射出,頂出四個(gè)過程.Moldingsteps:moldopening/closing,heatinginjectionandknockingout.開鎖模條件:Moldopeningparameter:快速段中速度低壓高壓速度High-speedmid-speedLowpressurehighpressurespeed鎖模條件設(shè)定:Moldclosingparametersetting1鎖模一般分:快速→中速→低壓→高壓Moldclosing:high-speed→low-speed→lowpressure→highpressure2.快鎖模一般按模具情況分,如果是平面二板模具,快速鎖模段可用較快速度,甚至于用到特快,當(dāng)用到一般快速時(shí),速度設(shè)到55-75%,完全平面?？稍O(shè)定到80-90%,如果用到特快就只能設(shè)定在45-55%,壓力則可設(shè)定于50-75%,位置段視產(chǎn)品的深淺(或長短不同,一般是開模寬度的1/3.Inhigh-speedsection,Moldclosingspeeddependsontypeofmold.Fortwo–platemolditcansetquickandevenespeciallyquickusually,itsetspeedwithin55-75%.Forfull-platemolditsetspeedwithin80-90%whileusingespeciallyhighspeeditsetspeedwithin45-55%andpressurewithin50-75%positiondistancesettingdiffersdependingonthevolumeofproductandusuallyitcanbeset1/3ofmoldopeningposition.3.中速段,在快速段結(jié)束后即轉(zhuǎn)換成中速,中速的位置一般是到模板(包括三板模,二板模合在一塊為止,具體長度應(yīng)視模板板間隔,速度一般設(shè)置在30%-50%間,壓力則是20%-45%間.Inmid-speedsection:Moldclosingspeedchangesintomid-speedafterhigh-speedsectionfinish.Mid-speedstartpositioniswheretwoplatesmeet(includethree-platemoldandtwo-platemoldDistanceofmid-speedisuptodistanceoftwoplatesplateitspeedwithin30-50%andpressure20-45%.4.低壓設(shè)定,低速設(shè)定一般是在模板接觸的一瞬間,具體位置就設(shè)在機(jī)臺顯示屏顯示的一瞬間的數(shù)字為準(zhǔn),這個(gè)數(shù)字一般是以這點(diǎn)為標(biāo)準(zhǔn),,即于此點(diǎn)則起不了高壓,高于此點(diǎn)則大,輕易起高壓.設(shè)定的速度一般是15%-25%,視乎不同機(jī)種而定,壓力一般設(shè)定于1-2%,有些機(jī)則可設(shè)于5-15%,也是視乎不同機(jī)種不同.Low-pressuresection:Moldclosingsetslow-pressurewhenplatesmeeting.Thispositionissettothedataofmachinescreenonthistime.Thispointisthegageofthedata.Datalowerthepointthereisnohigh-pressure.Datahigherthepointthereishigh-pressureeasily.Itsetspeedwithin15-25%andpressurewithin1-2%dependingontypewithin1-2%dependingontypeofinjectionmoldingmachine.5.高壓設(shè)定,按一般機(jī)臺而言,高壓位置機(jī)臺在出廠時(shí)都已作了設(shè)定,相對來講,是不可以隨便更改的,比如震雄機(jī)在50P.速度相對低壓略高,大約在30-35%左右,而壓力則視乎模具而定,可在55-85%中取,比如完全平面之新模,模具排氣良好,甚至于設(shè)在55%即可,如果是滑塊較多,原來生產(chǎn)時(shí)毛邊也較多,甚至于可設(shè)在90%還略顯不足.High-pressuresection:Tonormalinjectionmoldingmachine,high-pressurepositionhadbeensetbeforetheyweresenttocustomer.Itcannotbemodified.Forexamplehigh-pressurepositionofCHENHSONGmachineis50P.Thespeedofhigh-pressuresectionisabout30-35%andhigherthanthatoflow-pressure.Thepressureisuptomold,itcansetwithin55-85%Forfull-platemold,it’sejectairwell,itcansetpressure55%.Ifmoldhasalotofslidesandflashratehighinproduction,pressurecanset90%.加熱工藝條件設(shè)定HeatingtechniqueparametersettingThepropertemperaturesettingdiffersdependingontypeofresinmaterial,butitmustbeabidebyarulethattemperaturesettingshoulddiminishinstep10.Cfromnozzletofeedingresinmaterialposition.Nozzletemperaturesettingshouldlowifproductline.IfresinmaterialsuchasPS,PA,coolverysoon,Nozzletemperatureshouldhighermore10.Cthanthesecondcylindertemperature.3.機(jī)臺馬達(dá)啟動溫度視乎機(jī)臺不同而不同,一般出于對機(jī)臺油路中的油封保護(hù)需要,油溫最好能控制在40度-60度,以免油封長期高壓而變化,縮短使用壽命,造成成型不穩(wěn)定.umpturningontemperatureisdifferentdependingontypeofinjectionmoldingmachine.Toprotectoilsealofmachineitsetoiltemperaturewithin40.C-60.C,IfoilsealworkonconditionthathighpressureanddamagedIt’sworktimewillbeshorter,itcancausemoldingstable.第三節(jié)注射及熔膠(加料工藝條件設(shè)定InjectionandplasticTechniqueparametersetting一.注射Injection第四節(jié)常見塑料原料的有關(guān)溫度值.原料Resin名稱Name熔點(diǎn)℃Melt’s成型溫度℃MoldingTemperature(’c分解溫度℃DecomposingTemperature(‘C模具溫度℃MoldTemperature(‘c干燥溫度℃Resindrytemperature(‘c注射是把塑料原料經(jīng)加熱后射進(jìn)模腔的過程,它一般可分為第一級,第二級,第三級,第四級及保壓幾段:Injectionisastepwhichinjectmeltresinmaterialintomold.Itconsistsofstepl,step2,step3,step4andholdingpressurestep:Steplinjectsusuallytunnelmaterial,InjectionVolumecanbeestimatedaccordingtotheweightofcourseitcanbecalculatedbyformula:L=Si=Vi/0.785Ds2L:注射行程;Si:注射行程;L:injectionstrokeSi:injectionstrokeVi:理論注射容積;Ds:螺桿直徑;Vi:injectionvolumeoftheoreticalDs:diameterofscrew0.785:是Ω/4的值.0.785:valueofΩ/4.當(dāng)然,如果我們在成型時(shí)每設(shè)定一個(gè)參數(shù)都要計(jì)算一次,要成型出一個(gè)產(chǎn)品就要幾個(gè)小時(shí)才能完成了.Butitcostalotoftimetoproduceoneproductifeverytimemoldingparameterissettingbycalculation.2.第二級是注塑產(chǎn)品約2/3的階段,當(dāng)然,根據(jù)產(chǎn)品特殊需要,也允許成型不到2/3階段,比如避免結(jié)合線問題,這一階段的成型速度及壓力一般是整個(gè)成型段的最大值段,如果排的產(chǎn)品與機(jī)臺基本是相吻合的.模具結(jié)構(gòu)合理,排氣良好,這一段的壓力一般也不會超過80%.速度側(cè)視產(chǎn)品需變,可能大到95%也可,自然一般都是在55%-80%間.Step2inject2/3ofproduct.Itcanlower2/3ofproductaccordingtorequirementofproduct.Forexampletopreventweldline.Moldingspeedandpressureonthisstepisthemaximumofwholemoldingsection.IfMoldsuittheinjectionmoldingmachineandmoldstructurereasonableandejectairwell,pressureofthisstepshouldlower80%.Moldingspeedsettingwithin55-80%butitmaysetting95%forespecialproduct.3.第三段是注射余下的1/3段,其速度和壓力根據(jù)產(chǎn)品的需要,一般是小于第二段,速度和壓力存在于一個(gè)往下降的過程.主要是為了防止產(chǎn)品毛邊的產(chǎn)生,但同時(shí)又必須把產(chǎn)品充填飽滿.Step3injectremain1/3ofproduct.Accordingtoproductmoldingspeedandpressurelowerthanthatofstep2Topreventflashspeedandpressureshoulddecreasebutitcan’tshotshort.4.第四段:一般有機(jī)臺還有第五,第六段,這段的成型速度和壓力相同前,都存在兩段一個(gè)遞減過程.其作用都是起到一個(gè)再次充滿的作用.Step4section:Someinjectionmachineshavestep5,step6whicharesameasformermoldingspeedandpressurethisstepshoulddiminishandinjectoncemore.5.保壓段:不論成型什么產(chǎn)品,都存在一個(gè)保壓過程.任何產(chǎn)品都不同程度的存在一個(gè)厚薄不一的問題,正常情況下,較厚的部分都可能存在一個(gè)收縮凹陷的現(xiàn)象,為了解決這種現(xiàn)象,就應(yīng)應(yīng)用到保壓,保壓一般來講都應(yīng)用較慢的射速,而壓力的設(shè)置則應(yīng)看縮水的情況如何,小到25%,大到80%都有可能.Holdingpressurestep:Nomatterwhatproductthereisaholdingpressurestep.Anyproductcan’tmoldingasamethickness.Usuallythedeepersectionmaysinkmark.Topreventthisdefectitshouldsetholdingpressure,Theinjectionspeedofholdingpressurestepisslowbutholdingpressuresettingwithin25-80%dependingonsinkmark.二.熔膠段工藝lasticTechnique1.再復(fù)雜的熔膠旋轉(zhuǎn)過程最多不會超過三段,因?yàn)槿勰z本身就是存在于把膠熔進(jìn)料筒的過程,如果原料粘度大,熔膠壓力則大,但速度則應(yīng)取決于原料的分解溫度,熔膠速度越快,原料中的剪切力則會越大,料管溫度則越高,局部原料產(chǎn)生分解的可能性則會越大,故一般熔膠會采用中速為宜,如45%-75%,熔膠同時(shí)會碰到一個(gè)比較重要的環(huán)節(jié),那就是背壓的使用,產(chǎn)品精度要求越大,背壓的使用則更大,背壓可使原料分子間結(jié)構(gòu)更緊密,成型出的產(chǎn)品則尺寸更穩(wěn)定,外觀越好.當(dāng)然,背壓太大,則會產(chǎn)生流涎,所以背壓的使用又應(yīng)考虙到其它原因.lasticshouldlower3steps,becauseplasticisasteptoaddmeltresinmaterialtocyclinder,Higherstickofresinmaterial,higherscrewbackpressure.Screwspeeddiffersdependingondecomposingtemperatureofresinmaterial,Higherscrewspeed,Highertrimforceofresin,highercyclindertemperature.Someresinmaterialmaydecomposessoitsetscrewspeedinmid-speedsuchas45-75%,Inplasticstepsettingscrewbackpressureisveryimportant,Higherscrewbackpressure,higherqualityofproductscrewbackpressuremakeresinstructureorder,Moldingproductisbeautifulandvolumestable.But,itmaybeflowifscrewbackpressuretoohigh.Soallfactorsshouldbeconsideredwhenusingscrewbackpressure.2.熔膠過程還有一個(gè)比較重要的環(huán)節(jié),那就是松退,松退分前松退和后松退,其作用一般是為了防止流涎和抽絲,設(shè)定值速度和壓力都在20%-50%間,設(shè)定的行程一般在2-5cm間,太長的行程可能會使料筒里面貯存空氣,導(dǎo)致下一模出現(xiàn)不期望的氣泡.Inplasticstepsuckingbackisveryimportanttoo.SuckingbackincludefrontsuckingbackandbacksuckingbackItsettingsuckingbacktopreventflowandline.Itsetssuckingbackspeedandpressurewithin20-50%anddistancewithin2-5cm.TOOlongdistancemakecyclinderreserveairandcausebubbleatnextmolding.頂出的工藝設(shè)定knockingouttechniquesetting產(chǎn)品經(jīng)冷卻定型后則有一個(gè)開模的過程,開?；旧鲜呛夏５姆催^程.開模的未段則有一個(gè)慢速設(shè)置,開模完成后,產(chǎn)品必須頂出的過程.Thereisamoldopeningstepafterproductcoolingtakingshape.Moldopeningisareversestepofmoldclosing.Thelaststepofmoldopeningspeedsetslow.Productshouldbeknockedoutaftermoldopened.一.頂前:Knockingout頂前最好分兩個(gè)階級,第一階可分為中壓慢速,即是把產(chǎn)品輕輕頂出一部分,然后是中壓中速頂,中壓中速一般指的是35%-55%,而低速則有可能低到5%,這需視產(chǎn)品不同而言,頂出行程設(shè)定是頂出長度稍比產(chǎn)品垂直深度大1-2cm即可.Knockingoutincludestwosteps,Step1sectionsettingmid-speed,knocksproductoutpartlystep2sectionsettingmid-pressureandmid-speed.Dependingondifferentproduct,mid-pressureandmid-speedsetswithin35-55%butlow-speedcanset5%.Distanceofknockingoutlonger1-2cmthantheverticalthicknessofproduct.二.退針Back頂退包括兩個(gè)過程與頂落的過程基本一致,頂退的終點(diǎn)應(yīng)預(yù)留1-3cm的空間,以保護(hù)頂針油管不被頂壞.Thesameasknockingout,ejectorbackincludes2steps.Toprotecttheejectoroiljar,itshouldmakea1-3mmdistanceintheendingpointofejectorback.三.頂針方式還包括一個(gè)多次頂,單次頂及頂針停留的選擇,機(jī)械手取產(chǎn)品,脫模順利的情況都采取多項(xiàng),為了頂針油缸壽命的延長,多次頂就以不超過三次為宜,頂針停留一般用在頂針帶著產(chǎn)品退回有可能對增品產(chǎn)生損傷的模具,同時(shí)為配合機(jī)械手使用,有時(shí)也需要較短的頂針停留.Thewayofknockingoutincludesknockingoutonce,Knockingoutrepeatandejectordelay.Takeproductbymanipulatorortakeproducteasy,itshouldselectknockingoutonce.Tolongertheworktimeofejectoroiljar,timesofknockingoutlower3times.Ejectordelayusedwhenproductwillbedamagedifejectorbackorsuitmanipulator.成型時(shí)間的設(shè)定Moldingtimesetting在保證產(chǎn)品質(zhì)量的前提下,周期時(shí)間是越短越好,周期時(shí)間又包括如下幾項(xiàng):射膠時(shí)間,保壓時(shí)間,熔膠時(shí)間,冷卻時(shí)間,頂出時(shí)間,鎖模低壓時(shí)間,甚至乎關(guān)系到時(shí)間因素的還有還開模與鎖模,及頂出的快慢.Cycletimeshouldshorteronconditionthatproductqualitywell.Cycletimeincludes:injectiontime,holdingpressuretime,plastictime,curetime,knockingouttimeandmoldprotecttime.Evenmoldopeningclosingsopeedandknockingoutspeedaffectcycle.1.射膠時(shí)間包含保壓時(shí)間,一般看起來,射膠時(shí)間越長,產(chǎn)品越飽和,但我們在講求質(zhì)量時(shí),同時(shí)也須考慮產(chǎn)能,更何況,射膠時(shí)間過長,有可能會造成產(chǎn)品過于飽滿而尋致粘模頂?shù)淖冃螀沾缙蟮纫幌盗袉栴},故我們在設(shè)置射膠時(shí)間時(shí)應(yīng)綜合考慮,盡量在合乎質(zhì)量要求時(shí)縮短射膠時(shí)間.Injectiontimeconsistsholdingpressuretime.Longerinjectiontime,fullerproduct,weshouldconsiderproductionquantitywhenwesuitforquality.Ifinjectiontimetoolong,itmaycauseaseriesofdefectssuckasflashstrain.Soallsortsoffactorsshouldbeconsidered,injectiontimeshouldbeshoutifqualitysuitforrequirement.2.熔膠時(shí)間的長短取決于熔膠速度設(shè)定的快慢,背壓設(shè)定的大小,但有一點(diǎn),熔膠時(shí)間控制的長短一定要比冷卻時(shí)間短.lastictimedependsonplasticspeedandscrewbackpressure,butplastictimemustshorterthancuretime.3.冷卻時(shí)間:冷卻時(shí)間的長短直接影響到成型的周期,冷卻時(shí)間越長,成型時(shí)間就越長,造成產(chǎn)能就越低,故我們在設(shè)定高壓冷卻時(shí)間時(shí),只要能保證到產(chǎn)品成型順利,不會直接影響到變形等問題,設(shè)定的時(shí)間也是越短越好.Curetime:Curetimeaffectsmoldingcycle.Longercuretime,longermoldingcycle,lowerproductionquantity.Soitsetscuretimeshortonconditionthatproductmoldingsuccedandcan’tdeformation..4.在大量使用機(jī)械手的塑膠公司,我們的頂出時(shí)間一般是與機(jī)械手配合為宜,全自動使用機(jī)械手時(shí)頂出停留時(shí)間一般保持1.5-2秒,半自動生產(chǎn),如因頂針退回會導(dǎo)致產(chǎn)品掉落或卡緊,而取不下產(chǎn)品,停留時(shí)間則應(yīng)保持5秒左右.InPCEcompany,forusingmanipulatorinabundence,knockingouttimesuitsmanipulator,Knockingoutdelaykeeps1.5-2secondwhenusingmanipulatorfull-manipulator,knockingoutdelaykeepsabout5secondwhenusingmanipulatorsemi-manipulatorandproductwillfallorcan’tbetakenoffifejectorback.5.低壓保護(hù)時(shí)間對保護(hù)我們?nèi)松戆踩?模具安全起很大作用,配合好模具低壓位置和低壓壓力的調(diào)整,低壓保護(hù)的時(shí)間應(yīng)取1-3秒,保護(hù)時(shí)間越短,可能造成的危害則越小.Low-pressureprotectisveryimportantforsafetyandprotectmold,Moldprotecttimeshouldadjustwithin1-3secondsuitlowpressureandpositionofmoldprotect,shorterprotecttime,makedamaged.SurfaceAppearance外觀Glossiness/glossfinish光潔度Mattfinish/mattsurface毛面Glassfiberrichsurface/glassemergenceonthesurface玻纖外露Blooming/surfaceblooming表面析出Whitepatchesonsurface表面白斑Silvermarks/silverstreak銀紋Splaymark水紋Flowma