1、注塑工藝參數優化注塑工藝參數優化注塑工藝參數優化培訓課程2工藝參數的優化受訓者手冊德馬格注塑機工藝參數優化的步驟指導頁面周期分析3注塑工藝參數優化6步驟1:找出轉壓點7步驟1結果8步驟2:找出保壓時間(澆口冷凝時間)9步驟2結果10步驟3:優化注射速度11步驟3結果12步驟4:采納正確的螺桿轉速13步驟4結果14步驟5:優化多級螺桿轉速和背壓曲線15步驟5結果16步驟6:優化松退17步驟6結果18步驟7:優化保壓曲線19步驟7結果20TABULATEDRESULTS21步驟8:優化鎖模力22步驟8結果22步驟9:設定注射壓力23步驟9結果23典型工藝參數公差設定24成型周期分析采納下邊表格預計

2、注塑過程中的每一階段對周期的影響.此后去機床看正在運轉的模具,寫下實質的時間并計算出百分比.哪一階段在整個周期中占最多的時間那里能夠是最有效的縮短成型周期模具1預計%實質實質%談論合模射臺行進和退后注射時間保壓時間冷卻時間開模頂出整個成型周期100%seconds100%模具2預計%實質實質%談論合模射臺行進和退后注射時間保壓時間冷卻時間開模頂出整個成型周期100%seconds100%工藝參數優化目標:一步步改良工藝過程堅固性.評估各個參數的改正對工藝過程堅固性的影響todemonstratethecumulativeimprovemntintheprocessandproductconsi

3、stency方法:Ateachstage,aftertheprocesshasbeengivensufficienttimetostabilise,arunofsixteenconsecutivemouldingsistobemade.Thesemouldingswillbeassessedforconsistencybyweight(adimension,aphysicalpropertyorsomeotherattributecouldequallywellbeused,weightissimplythemostwidelyapplicable).堅固性經過計算重量的標準誤差來權衡.同時打

4、印出機床IBED上的過程統計數據.找出轉壓點找出澆口冷卻時間優化注射速度采納正確的螺桿轉速優化多級預塑曲線優化松推優化多級保壓曲線優化鎖模力設定注射壓力限制步驟1找出轉壓點在沒有保壓壓力和保壓時間的基礎上填滿產品95%-98%,此后設定必然的保壓和保壓時間生產16模.初始設置時的指導采納行程切換設定切換地點為10-12mm(逐漸增添預塑量直到產品打滿95%-98%的地點)設置注射壓力為最大值設定保壓壓力和保壓時間均為0設定注射速度60mms-1設定松推速度為最大值設定鎖模力為最大值選擇適合的螺桿轉速依據資料物性表,設定料桶溫度配置過程統計控制設定保壓壓力和保壓時間生產圓滿的產品稱12模產品的重

5、量,計算標準誤差打印:頁面20工藝參數優化頁面50工藝過程統計步驟1結果輸入實質值沒保壓時的重量有保壓后的重量填補的百分比標準誤差(16模)料墊(均勻值和范圍)預塑時間(均勻值和范圍)螺桿停止地點(均勻值和范圍)注射時間(均勻值和范圍)注射壓力峰值,Pinj.max轉壓壓力,PNpress.均勻值范圍最小最大%g轉壓地點步驟2找出澆口冷凝時間設定保壓壓力為步驟1上找出的注射壓力峰值的50%左右.設定保壓時間為1s.生產數模產品使過程堅固后連續取5模產品稱出每模重量和均勻值增添保壓時間至2s,生產數模產品使過程堅固后連續取5模產品稱出每模重量.在保壓時間3s,4s5s.時重復上述過程直到產品重量

6、不再增添作出產品重量和保壓時間的關系圖.記錄RecordtheTCUsettingandtheactualmouldtemperature.打印:頁面30溫度XLSpreadsheetgraph為何記錄模具溫度很重要還有什么要素會影響澆口冷凝時間步驟2結果輸入實質值TCUsettingFHtemperatureMHtemperatureCCC重量1重量2重量3重量4重量5均勻重量時間保壓重量1重量2重量3重量4重量5均勻重量時間保壓所需的保壓時間s步驟3優化注射速度采納多級注射曲線,使注射行程最后的10-20%采納逐漸降低的注射速度.每次改正注射速度,必然從頭成立轉壓點.(注意每次保壓和保壓時

7、間都設定為0.)連續取16模,計算出標準誤差.打印:頁面24MWE使用和沒使用多級保壓時的曲線頁面26多級注射頁面50工藝過程統計為何轉壓點要改正注射壓力發生了什么為何在數社的尾端采納逐漸降低的注射速度是合用的步驟3結果輸入實質值沒有保壓時的重量采納保壓的重量填補百分比標準誤差(16模)料墊(均勻值和范圍)預塑時間(均勻值和范圍)螺桿停止地點(均勻值和范圍)注射時間(均勻值和范圍)注射壓力峰值,Pinj.max轉壓壓力,PNpress.變換地點均勻值范圍最小最大%g步驟4采納正確的螺桿轉速Selectthecorrect,optimumscrewspeedforthematerialbeing

8、processed(seenotes,Section5).UsethissinglespeedforthewholeplasticisingstrokeSetabackpressureof5to10bar(hydraulic).Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page50ProcessStatisticsWhyisitimportanttousethemanufacturersr

9、ecommendedscrewspeedSTEPFOURRESULTSInsertactualvaluesintherelevantboxesMeanRangevalueminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinj

10、ectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPFIVEOptimisescrewspeedandback-pressureprofileUsetheDosingProfilepagetoslowdownthescrewrotationspeedforthelast10%ofthemeteringstroke.Readjustdosingstroketoachieve95-98%fillTakesixteeenconsecutivemouldingsanddeterminethes

11、tandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtotheDosingStoppositionSTEPFIVERESULTSInsertactualvaluesintherelevantboxesMeanRangevalueminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(mea

12、nandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPSIXOptimisedecompressionFindthedecompressionspeedwhichgivesbestscrewstrokeandmeltcushionconsistency.Setadecompressionstr

13、okeof5mm.Checkthatyoustillachieve95-98%fill.Takesixteeenconsecutivemouldingsanddeterminethestandarddeviationoftheweights.Printout:Page21DosingProfilesPage50ProcessStatisticsWhathashappenedtothescrewstoppositionWhatishappeningtothecheckringSTEPSIXRESULTSInsertactualvaluesintherelevantboxesMeanRangeva

14、lueminmaxWeightwithoutholdingpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeSTEPS

15、EVENOptimiseholdingpressureprofileUsetheHoldingProfilepagetosetaholdingpressureprofilewhichensuresasmoothtransitionfrominjectiontotheholdingpressurephaseanduseahighenoughpressuretopackthepartproperly.Addastepwhichreducesholdingpressuregraduallytozero.Takesixteeenconsecutivemouldingsanddeterminethest

16、andarddeviationoftheweights.Printout:Page24MWEPage27HoldingProfilePage50ProcessStatisticsWhydoyouneedasmoothtransitionfrominjectiontoholdingpressureWhybothertoreducethepressuregraduallyifthegatehasalreadyfrozenSTEPSEVENRESULTSInsertactualvaluesintherelevantboxesMeanRangevalueminmaxWeightwithoutholdi

17、ngpressureWeightwithholdingpressurePercentagefill%Standarddeviation(16shots)gMeltcushion(meanandrange)Dosingtime(meanandrange)Screwstopposition(meanandrange)Injectiontime(meanandrange)Peakinjectionpressure,Pinj.maxInjectionpressureatchangeover,PNpress.ChangeoverstrokeTABULATEDRESULTSInsertactualvalu

18、esintherelevantboxesTherangevalue,R,isthemaximumminustheminumum,takenfromthesevensteps.1234567meanRmeanRmeanRmeanRmeanRmeanRmeanRMeltcushionDosingtimeScrewendpositionInjectiontimeInjectionpressurePhydmaxInectionpressurePNhydraulicChangeoverstrokeStandarddeviation(16shots)CanyouseeatrendWhichstephadt

19、hegreatesteffectontheconsistencyofthemouldingSTEPEIGHTOptimisingtheclampforceReducetheclampforcebystepsof50kN(100kNformachinesover100tonnes)usingthesettingsfaroptimisedinthesevenstepsabove.Allowtheprocesstostabiliseeachtimeandthenweighfivemouldings.Tabulateyourresultsbelowandplotagraphoftonnageagain

20、stpartweight.DoesthemouldrequiretheexpectedclampforceWhataretheadvantagesofrunningatreducedtonnageSTEPEIGHTRESULTSInsertactualvaluesintherelevantboxesEnterresultsinXLspreadsheet.Printoutgraph.Weight1Weight2Weight3Weight4Weight5MeanweightClampforceRequiredclampforcekNSTEPNINESetinjectionpressureUntil

21、nowtheinjectionpressurehasbeensettothemachinesmaximumvalue.FromtheProcessStatistcspageitcanbeseenthatthemachinedoesnotneedallthatpressuretofillthemould.Graduallydecreasethesetinjectionpressureuntiltheinjectiontimestartstoincrease.Increasethepressureagainuntilthepreviousinjectiontimeisestablishedwith

22、aconsistencyofsorbetterpreferablytosvariation.WhatisthepurposeoflimitingtheinjectionpressureSTEPNINERESULTSActualpeakinjectionpressureSetinjectionpressurebarbarAppendix1TYPICALPROCESSTOLERANCESShot-weightdeviation%PlasticisingtimeInjectiontimeCycletime%1%1%Screwposition,dosingstopMeltcushionMelttemp

23、erature2C2C3C5CMouldtemperature1C1C2C4CBarreltemperature1C1C2C4CFeedzonetemperature1C2C3C4CHotrunnertemperature1C2C3C4CHydraulicoiltemperature1C1C2C2CRoomtemperature2C2C3C4CMouldcavitypressure3bar4bar6bar8barPressureintegral200300600900Injectionfillingpressure1bar2bar3bar4barHoldingpressure1bar1barb

24、ar2barBackpressurebarbar1bar1barFillingdifferences(Balanceof1%fillforeachcavity)onmulti-cavitytoolsMouldbreatheChangeoverpressure(PnValue)1barScrewsurfacespeed10mms-1MelttemperaturepeakvalueoCMelttemperaturevalueatoCchangeover1%2%5%2bar3bar4bar-1-1-115mms20mms30mmsoCoCoCoCoCoCTheachievablepartqualityismuchinfluencedbytheconditionofthematerialprocessed.Itisimportantthatmoisturecontent,proportionofregrindandproportionofcolour(masterbatch)areconstant