《塑胶设计原理.ppt》由会员分享，可在线阅读，更多相关《塑胶设计原理.ppt（154页珍藏版）》请在taowenge.com淘文阁网|工程机械CAD图纸|机械工程制图|CAD装配图下载|SolidWorks_CaTia_CAD_UG_PROE_设计图分享下载上搜索。
1、OLE Technology Corporation塑胶设计原理 Still waters run deep.流静水深流静水深,人静心深人静心深 Where there is life,there is hope。有生命必有希望。有生命必有希望OLE Technology Corporation澆注系統設計澆注系統設計Filling System DesignOLE Technology Corporation模具設計的優先順序模具設計的優先順序Priorities of Mold Design澆注系統設計(Filling System Design)排氣系統設計(Venting System
2、 Design)冷卻系統設計(Cooling System Design)脫模系統設計(Ejecting System Design)OLE Technology Corporation澆注系統設計的優先順序澆注系統設計的優先順序Priorities of Filling System Design產品設計(Part Design)型腔設計(Cavity Design)澆口設計(Gate Design)流道設計(Runner Design)豎澆道設計(Sprue Design)噴嘴設計(Nozzle Design)OLE Technology Corporation豎澆道Sprue主流道Mai
3、n Runner成品Part澆口Gate冷料井Cold Slug Well支流道Branch Runner典型的澆注系統典型的澆注系統Typical Filling SystemOLE Technology Corporation壁厚不均是注塑成形中最大的麻煩製造者。這對薄壁零件尤然。這些麻煩包括了遲滯現象、短射、凹陷、發赤、噴流、翹曲及長冷卻時間等；目前都可用CAE以直接或間接的方式預測。Non-uniform wall thickness is the biggest trouble maker in plastic injection molding.This is especially
4、 true to thin-wall part.The troubles,including hesitation,short shot,sink mark,blush,jetting,warpage and long cooling time etc.,can be predicted,directly or indirectly,by using CAE.壁厚不均壁厚不均Non-uniform Wall ThicknessOLE Technology Corporation壁厚設計壁厚設計Wall Thickness Design差 Poor較好 Better最好 BestOLE Tech
5、nology Corporation掏空設計掏空設計(1)Coring Out Design(1)改進設計 Improved原設計 OriginalOLE Technology Corporation差 Poor改進 Improved掏空設計掏空設計(2)Coring Out Design(2)OLE Technology Corporation氣泡或氣泡或/和凹陷的形成和凹陷的形成Void or/and Sink Mark Forming氣泡氣泡(Void)凹陷凹陷(Sink Mark)OLE Technology Corporation肋厚和內圓角半徑的影響肋厚和內圓角半徑的影響The E
6、ffect of Rib Thickness&Fillet RadiusOLE Technology Corporation肋的底部厚度肋的底部厚度Bottom Thickness of RibW0.5W2.5WW1.2WD1.5WD(A)(B)OLE Technology Corporation肋的設計肋的設計(一一)Rib Design(1)t=wall thichnessB=0.5tC=3 tAAD=2 BE=0.13 mm(radius)F=1.5-2 deg假如需要更大的強度假如需要更大的強度,可增加肋的數目可增加肋的數目If more strength is required,ad
7、d additional ribs.FBDECtOLE Technology Corporation 肋的設計肋的設計(二二)Rib Design(2)OLE Technology Corporation肋的設計肋的設計(三三)Rib Design(3)OLE Technology Corporation與側壁相連之凸轂與側壁相連之凸轂(熱塑性塑膠熱塑性塑膠)Boss at Wall(Thermoplastics)A=凸轂附著處壁厚凸轂附著處壁厚 wall thicknessB=凸轂外環直徑凸轂外環直徑 dia.of boss over radiiC=0.5 AD=2 BE=1 2 degF=
8、0.13 mm(radius)G=DH=0.8 AI=A/4J=2 BK=0.3 1 JL=0.5 A LHAAKEIGJDAFCBSection A-AOLE Technology Corporation遠離側壁之凸轂遠離側壁之凸轂(熱塑性塑膠熱塑性塑膠)Boss Away From Wall(Thermoplastics)A=凸轂附著處壁厚凸轂附著處壁厚 wall thicknessB=凸轂外環直徑凸轂外環直徑 (含底部修整圓弧半徑含底部修整圓弧半徑)dia.of boss over radiiC=0.5 AD=2 BE=1-2 degF=0.13 mm(radius)G=0.95 DH=
9、0.3 G min.to G max.I=0.5 AHEFDFGCBAIOLE Technology Corporation外側凸轂外側凸轂Outside Boss AAA(DIA)BB=AB=2A(max.)Section A-AOLE Technology CorporationWhere 1/r:樑的曲率 curvature of the beamM:彎曲力矩 bending momentE :彈性模數 modulus of elasticityI :斷面積對中立軸的慣性矩 moment of inertia of the cross-sectional area with respec
10、t to the neutral axisEI :撓曲剛性 flexural rigidity撓曲剛性撓曲剛性Flexural RigidityOLE Technology CorporationW樑樑 BeamLOLE Technology CorporationWhere :最大偏移 maximum deflection W :負荷 load L :樑長 length of beam E:彈性模數 modulus of elasticity I :斷面積對中立軸的慣性矩 moment of inertia of the cross-sectional area with respect t
11、o the neutral axis EI:撓曲剛性 flexural rigidity:最大應力 maximum stress:中立軸到到其斷面離其最遠的點的距離 distance from the extreme point of a cross section to the neutral axis of this cross section OLE Technology CorporationOLE Technology CorporationNeutral AxisOLE Technology Corporation?10.8OLE Technology Corporation平板和
12、肋板的比較平板和肋板的比較Comparison between Plain&Ribbed PlatesOLE Technology Corporation和平板比，若基於相同的慣性矩(剛性)，肋板需料少了43%，I/A卻增加了1.79倍。肋板的最大厚度減為平板的1/4，使得冷卻時間驟降15/16(94%)。Based on the same moment of inertia(stiffness),ribbed plate needs 43%less material but boost I/A by 1.79 times comparing with plane plate.The maxi
13、mum thickness of ribbed plate is only 1/4 of plain plates;showing a dramatic cooling time reduction of 94%(15/16).平板和肋板的比較平板和肋板的比較Comparison between Plain&Ribbed PlatesOLE Technology CorporationA variety of molded-ininterlocks can add stiffness to thin-wall housing designs.各種一體成形的內鎖件能增加薄殼的剛性。OLE Tec
14、hnology Corporation結構設計是薄殼成形零件的基礎。Structural design is the base of thin-wall molding parts.薄殼成形零件不僅僅是一趨勢，而且也是降低成本和提高競爭力的有效途徑。Thin-wall molding part is not only a trend but also an effective way to achieve cost reduction and competitiveness increase.結構設計和薄殼成形零件Structural Design&Thin-wall Molding Part
15、sOLE Technology Corporation每增加一個澆口，至少增加一條熔接線，同時增加一個澆口痕跡、增加流道的體積以及增加較多的積風。Every time one gate is added,one weld line,at least,one gate mark,more runner volume and more air traps will be added.在型腔能夠完滿充填的前提下，澆口數目是愈少愈好。As long as the cavity is able to be filled appropriately,gates are the less the bette
16、r.為了減少澆口數目，每一澆口應就塑流力所能及的流長/壁厚比之內，找出可以涵蓋最大零件面積的進澆位置。In order to reduce the number of gates,each gate shall be located at where the melt is able to cover maximum part area based on the largest melt flow length/thickness ratio.澆口數目The Number of Gates OLE Technology Corporation熔膠波前推進熔膠波前推進Melt-Front Adv
17、ancementMelt-Front Advancement充填模式,積風和熔接線Filling Patterns,Air-Traps and Weld Lines LocationOLE Technology Corporation熔接線熔接線Weld LinesWeld LinesOLE Technology Corporation材料 Material:PC-GF50原設計 Original更改設計 Revised更改澆口位置以重新定位熔接線更改澆口位置以重新定位熔接線Weld Lines Can Be Relocated Weld Lines Can Be Relocated By C
18、hanging Gate LocationBy Changing Gate LocationOLE Technology Corporation典型對頭熔接線伸張強度保留值典型對頭熔接線伸張強度保留值Typical Butt Weld Tensile Strength Retention ValuesTypical Butt Weld Tensile Strength Retention ValuesOLE Technology Corporation熔接線冷料井熔接線冷料井Weld Slug WellWeld Slug Well對頭熔接線 Butt weld熔接線冷料井Weld slug w
19、ellOLE Technology Corporation積風積風Air TrapsAir TrapsOLE Technology Corporation排氣排氣VentVent大部份熱塑性塑膠Most ThermoplasticsA 0.08 mmB 3.18 mmC 12.7 mmD 0.25 mm耐隆和聚縮醛(POM)Nylon and Acetal(POM)A 0.04 mmB 3.18 mmC 12.7 mmD 0.25 mm進料流道Feed Runner塑膠成品Plastic PartAD排氣孔VentBSEC.A-ACAAOLE Technology Corporation充填均
20、衡Flow Balance熔膠波前於同一時間抵達型腔各末端。Melt front reaches the ends of cavity at the same time.OLE Technology Corporation洗衣機圈板洗衣機圈板OLE Technology Corporation洗衣機圈板洗衣機圈板OLE Technology Corporation冷氣通風飾罩冷氣通風飾罩-原始設計原始設計Air-conditioner Grille-Original18 gatespressure:76 MPaOLE Technology Corporation冷氣通風飾罩冷氣通風飾罩-修正設
21、計修正設計Air-conditioner Grille-Revised8 gatespressure:75 MPaOLE Technology Corporation分析結果比較表分析結果比較表Comparison of Analysis ResultsOLE Technology Corporation原始設計Original Design十二澆口設計十二澆口設計12 Gate Design電子零件置物箱材料 Material：ABSOLE Technology Corporation四澆口設計四澆口設計4 Gate Design修正設計Revised Design電子零件置物箱材料 Mat
22、erial：ABSOLE Technology Corporation電子零件置物箱四澆口電子零件置物箱四澆口和十二澆口設計比較表和十二澆口設計比較表OLE Technology Corporation 論語論語 季氏第十六季氏第十六 不患寡而患不均，不患寡而患不均，不患貧而患不安。不患貧而患不安。-孔子孔子-OLE Technology Corporation如何快速平衡眾多模穴之流道如何快速平衡眾多模穴之流道How to Balance Flow In A Multi-cavity Mold首先調整一排支流道內之次支流道尺寸，使此支流道內之各模穴可平衡充填。First,adjust run
23、ner size in one branch to make flow balanced in this branch.再調整各支流道前段之尺寸，使各支流道可平衡充填。Then,adjust the first sections runner size in each branch to make flow balanced in all branches.OLE Technology Corporation一排支流道之不平衡充填一排支流道之不平衡充填Unbalanced Flow In A Branch OLE Technology Corporation一排支流道平衡後之充填一排支流道平衡
24、後之充填Balanced Flow In A BranchOLE Technology Corporation全模具全模具(128模穴模穴)之不平衡充填之不平衡充填Unbalanced Flow In A MoldOLE Technology Corporation全模具全模具(128模穴模穴)平衡後之充填平衡後之充填Balanced Flow In A MoldOLE Technology CorporationThe melt fills the inside cavities before filling the outside cavities.OLE Technology Corpo
25、rationThe runner system shows that warmer,low-viscosity material(yellow and red)follows the inside wall when the melt splits at an intersection.OLE Technology Corporation剪切速率剪切速率Shear RateOLE Technology Corporation剪剪 切切 應應 力力shear Stress黏黏 度度viscosity剪剪 切切 速速 率率shear rate剪切應力剪切應力Shear StressOLE Tech
26、nology CorporationOLE Technology CorporationOLE Technology CorporationOLE Technology CorporationOLE Technology Corporation澆口種類澆口種類Gate Types針點澆口Pin Gate扇型澆口Fan Gate潛伏澆口Submarine Gate邊緣(薄膜)澆口Edge(Film)Gate凸片澆口Tab Gate閥澆口Valve Gate環狀澆口Ring GateOLE Technology Corporation導致平直零件的澆口設計導致平直零件的澆口設計Gate Desig
27、n for Flat Part中心澆口Center Gate扇形澆口Fan Gate最壞的Worst壞的Worse較好的Better最好的Best側澆口Edge Gate薄模澆口Film GateOLE Technology Corporation澆口設計澆口設計(減少滯流效應減少滯流效應)Gate Design to Avoid Hesitation澆口gate薄thin厚thick差的設計Poor好的設計Good薄thin厚thick澆口gateOLE Technology Corporation0.94秒時，遲滯現象在1.2mm厚凸片處發生公稱厚度3.2mm幫浦零件(Part,Pump)
28、塑料(Polymer):POMOLE Technology Corporation沒有遲滯現象幫浦零件(Part,Pump)塑料(Polymer):POMOLE Technology Corporation澆口設計澆口設計(避免凹陷和氣泡避免凹陷和氣泡)Gate Design to Avoid Sink Mark&Void澆口gate澆口gate差的Poor好的GoodOLE Technology Corporation使用重疊澆口以避免噴流使用重疊澆口以避免噴流Avoid Jetting by Using Overlap Gate差的Poor好的GoodOLE Technology Corp
29、oration正確的澆口位置以避免噴流正確的澆口位置以避免噴流Avoid Jetting by Locating Gate Correctly差的Poor好的GoodOLE Technology Corporation使用凸片澆口以避免噴流使用凸片澆口以避免噴流Avoid Jetting by Using Tab GateOLE Technology Corporation使用適當的澆口形狀以避免噴流使用適當的澆口形狀以避免噴流Avoid Jetting by Profiling Gate Properly差的Poor好的GoodOLE Technology Corporation幫浦零件(P
30、art,Pump)塑料(Polymer):POM進澆處(Polymer entrance)：澆口厚(Gate thickness)1.2mm，模穴厚(Cavity thickness)3.2mm問題(Problem)：噴流(Jetting)OLE Technology CorporationPoor Design Causing JettingGatePart :Handle,RefrigeratorMaterial:ABSProblem:Jetting Mark Gas PinOLE Technology Corporation氣輔成型冰箱把手氣輔成型冰箱把手澆口及氣針入口澆口太小,導致噴流
31、痕產生厚度差異過大,導致二次噴流痕產生R角過小,氣體通路接近把手內側,外側則因體積收縮造成凹陷痕跡OLE Technology Corporation閥澆口閥澆口Valve Gate1.閥澆口梢 Valve-Gate Pin2.加熱管 Heater3.O型環#610 0 Ring4.流道歧管模板 Manifold Plate5.軸封環 Seal Retainer6.套筒軸封 Sleeve Seal7.枕塊 Support Pillar8.油壓缸 Hydraulic CylinderOLE Technology Corporation閥澆口閥澆口(一一)Valve Gate(1)全部閥澆口同時打
32、開時之充填狀況Mold filling with all the valve gates(shut-off gates)opened at the same time.OLE Technology Corporation閥澆口閥澆口(二二)Valve Gate(2)部份閥澆口延遲打開，改變充填模式Mold filling with delayed valve gate opening;filling pattern,weld lines and air traps are changed.OLE Technology Corporation多澆口設計多澆口設計 Multi-Gate Desig
33、nOLE Technology Corporation閥式澆口閥式澆口Valve GateOLE Technology Corporation矩形邊緣澆口設計矩形邊緣澆口設計Rectangular Edge Gate DesignL=0.5 0.75 mmW=澆口寬度(mm)gate width in mmA=型腔表面積(mm2)surface area of cavity in mm2n =材料常數 material constant 0.6 for PE,PS 0.7 for POM,PC,PP 0.8 for CA,PMMA,PA 0.9 for PVCh=n th=澆口厚度(gate
34、thick.in mm)t =零件壁厚(wall thick.in mm)WtLhOLE Technology Corporation扇形澆口設計扇形澆口設計Fan Gate DesignL=1.3mmW=w=澆口寬度 mm gate width in mmA=型腔表面積 mm2 surface area of cavity in mm2n=材料常數 material constant 0.6 for PE,PS 0.7 for POM,PC,PP 0.8 for CA,PMMA,PA 0.9 for PVC澆口厚度 gate thick.in mmt=零件壁厚 wall thick.in m
35、m h1 =n t h2=wh1/DOLE Technology Corporation重疊式澆口設計重疊式澆口設計Overlap Gate DesignW=w=澆口寬度 mm gate width in mmA=型腔表面積 mm surface area of cavity in mmn=材料常數 material constant 0.6 for PE,PS 0.7 for POM,PC,PP 0.8 for CA,PMMA,PA 0.9 for PVC澆口厚度 gate thick.in mm=nt澆口長度 land length in mm t=零件壁厚 wall thick.in m
36、m 2 2 L1=0.50.75L2=h+(w/2)OLE Technology Corporation凸耳澆口設計凸耳澆口設計Tab Gate DesignL=0.50.75mmW=w=澆口寬度 mm gate width in mmA=型腔表面積 mm2 surface area of cavity in mm2n=材料常數 material constant 0.6 for PE,PS 0.7 for POM,PC,PP 0.8 for CA,PMMA,PA 0.9 for PVC澆口厚度 gate thick.in mm t=零件壁厚 wall thick.in mm h1 =n th
37、2 =0.9 tOLE Technology CorporationL=0.5 0.75 mmd=澆口直徑(mm)gate diameter in mmt =零件壁厚(mm)wall thick.in mmA=型腔表面積(mm)surface area of cavity in mmn=材料常數 material constant 0.6 for PE,PS 0.7 for POM,PC,PP 0.8 for CA,PMMA,PA 0.9 for PVC針點澆口設計針點澆口設計Pin Gate DesigndLtOLE Technology Corporation潛伏式澆口設計潛伏式澆口設計S
38、ubgate DesignW=w=澆口寬度 mm gate width in mmA=型腔表面積 mm2 surface area of cavity in mm2n=材料常數 material constant 0.6 for PE,PS 0.7 for POM,PC,PP 0.8 for CA,PMMA,PA 0.9 for PVC澆口厚度 gate thick.in mm=ntt=零件壁厚 wall thick.in mm 30 15 25OLE Technology Corporation水力直徑水力直徑 Hydraulic DiameterWhere is the hydraulic
39、 diameter 水力直徑 A is the cross-sectional area of the flow 流路斷面積 P is the wetted perimeter 濕周長OLE Technology Corporation水力直徑水力直徑 Hydraulic Diameter在不同剖面形狀，相同斷面積下之變化Various runner profiles,based on the same cross-sectional areaOLE Technology Corporation流道尺寸設計流道尺寸設計(1)Runner Sizing(1)D:流道直徑(mm)runner di
40、ameter in mmW:下游塑膠重量(g)downstream plastic weight L:流道長度(mm)runner length in mmOLE Technology Corporation流道尺寸設計流道尺寸設計(2)Runner Sizing(2)OLE Technology Corporation流道尺寸設計流道尺寸設計(3)Runner Sizing(3)OLE Technology Corporation流道尺寸設計流道尺寸設計(4)Runner Sizing(4)OLE Technology Corporation流道尺寸設計流道尺寸設計(A1)Runner Si
41、zing(A1)G:重量 weightS :零件厚度 thicknessD :參考直徑 reference diameterG(g)D(mm)for PS,ABS,SAN,CABOLE Technology Corporation流道尺寸設計流道尺寸設計(A2)Runner Sizing(A2)G(g)D(mm)for PE,PP,PA,POMG:重量 weightS :零件厚度 thicknessD :參考直徑 reference diameterOLE Technology Corporation流道尺寸設計流道尺寸設計(B)Runner Sizing(B)D:參考直徑 reference
42、 diameterL:長度 lengthfL:長度係數 Length coefficientD:流道直徑 runner diameterfLL(mm)D=D fLOLE Technology Corporation冷料井設計冷料井設計Cold Slug Well Design2d次流道Secondary runnerd主流道Primary runner澆口Gate型腔CavityOLE Technology Corporation倒椎度冷料井豎澆道拉料桿Reverse taper cold slug-well sprue pullerZ型冷料井豎澆道拉料桿 Z-taper cold slug-
43、well sprue puller溝型冷料井豎澆道拉料桿Grooved cold slug-well sprue puller冷料井設計冷料井設計Cold Slug Well DesignOLE Technology Corporation澆道襯套尺寸澆道襯套尺寸Sprue Bushing SizingOLE Technology Corporation熱澆道設計熱澆道設計Hot Runner DesignOLE Technology Corporation熱澆道的問題似乎發生在三處:1.澆口直徑 2.澆口長度 3.噴嘴孔徑Problems with hot runner seems to b
44、e in three places:1.Gate diameter 2.Gate land 3.Nozzle orifice diameter熱澆道的問題所在熱澆道的問題所在Where Causes Problems with of RunnerOLE Technology Corporation任何發生在澆口處的發赤或噴流，表示澆口太小。變褐則表示材料過熱而劣解。Any blush or jetting at the gate means the gate is too small,and brown discolorations mean the material is being deg
45、raded by too much heat.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology CorporationBROWN STREAKWITH FLOW LINESA brown streak on thepart molded from easy-flow polycarbonate withthe flow lines.OLE Technology Corporation為了保持澆口暢通而格外加熱塑料，加上塑料在射出時通過長澆口時承受的剪切力，有可能造成褐線。It was probably a combination of shear
46、 through the long land of the gate during injection and the extra heat needed to keep the gates open that are causing the brown streak.褐線褐線Brown Streak OLE Technology Corporation只以噴嘴口徑去配合熱澆道口徑是不對的。首先要將澆道口徑加大，以配合下游塑流通道口徑，然後再加大噴嘴口徑以配合澆道口徑。It isnt just sizing the nozzle orifice to match the hole in the
47、 hot sprue bushing.First you might have to increase the hole size of the sprue bushing to match the flow channel diameter,then drill the nozzle out to match the sprue diameter.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology Corporation理想的澆道襯套設計理想的澆道襯套設計Optimized Sprue Bushing DesignOLE Technology C
48、orporation當塑流通道受限於小或長的澆口，成型技術員常將設定溫度調高，以確保型腔充填、保壓無虞。When the flow path is restricted by a small gate diameter or a long land length,you will usually see higher heat settings being used by the molding technicians to get the parts to fill and pack out.這樣的作法產生的問題有製品的翹曲，澆口的外觀缺陷和長的成型時間。The problem with t
49、his approach is that it usually causes warpage of the parts,cosmetic defects around the gate area,and long molding cycles.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology Corporation如果歧管溫度設定得比料管前區為高，澆口尺寸或許有問題。如果必須將噴嘴溫度設定得特別高，噴嘴口徑或許沒配合上熱澆道口徑。If you find you have to run the manifold heats higher than
50、the front zone of the barrel,you probably have gate sizing problems.If you have to run the heats up on the nozzle,the nozzle orifice probably hasnt been drilled out to match the hot sprue bushing diameter.受限的塑流通道受限的塑流通道Restricted Flow PathOLE Technology Corporation如果塑流通道的尺寸正確，料管的前區、噴嘴和加熱歧管的溫度可以設定得一樣