科学化射出成型_1

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1、SymbolTechnologiesScientificInjectionMolding科学化射出成型(ProcessOptimization)(过程最优化)JohnnySingh2CONTENTS内容Introduction简介PlasticFlowRate塑料的流动率PlasticPressurel塑料的压力CoolingRateandTime冷却的速率和时间PlasticTemperature塑料的温度CharacteristicstoMonitor塑料特性之监控MoldingWindowoptimizatio

2、nl成型窗口最优化Appendix附注31.IntroductionScientificInjectionMoldingEnsuresthatidenticalpartsareproducedconsistentlyindependentofthenormalmachinetomachine,daytodayandlottolotvariations保证相同部件生产的一致性,不受一般的不同机器,生产批号,日期之变异所影响Scientificapproachtoestablishallmoldingvariables以

3、科学的方法来建立所有成型的变异数Providesabilitytodetectanddocumentproblemsbasedondata-notpersonalopinions能够用数据化的方式来侦测和纪录问题点,而不是靠个人观点Canincreaseprofitmarginby20to50%能够提高利润20%到50%41.IntroductionProfitpercentage(利潤百分比)5EffectofCycleTimeonProfit(成型周期对利润的影响)PartWeight(gm)(部件重量)Mate

4、rial(材料)ApproxCostperlb(1b的大约成本)MaterialCost–Cents(物料成本—分)CycleTime(周期)MachineRate$/hr(机械速率)CycleTimeCost–Cents(周期成本—分)ActualPlasticCost(实际塑料成本)OverheadsandLabor(管销和人力)Profitat5%-Cents(利润5%)分PercentofQuotedPriceProfit(报价利润率)50PC/ABS$3.0033.320.0$30.0016.750.060

5、.55.5210050PC/ABS$3.0033.322.5$30.0018.852.163.03.4462.350PC/ABS$3.0033.325.0$30.0020.854.265.51.3624.61.Introduction61.IntroductionFourCriticalcomponentstomakeagoodpart做出好成品的四大重要成分PartDesign(成品设计)Materialselectionandhandling(材料选择和处理方式)Tooldesignandconstruction

6、(模具设计和结构)Processing(加工制程)InProcessing,thefourmainplasticvariables(加工中的四大塑料变异因素)PlasticFlowRate(塑料流动率)PlasticPressure塑料压力CoolingRate&Time冷却速率和时间PlasticTemperature塑料温度72.PlasticFlowRateFundamentals基本性Itsflowpatternislikefountainflow塑料流动模式类似于喷泉流动模式Chainendssticks&

7、freezetowall,thusformingfrozenlayers.流体末端会附着、凝固在侧壁,形成凝固层Directlyproportionaltoshearrate;highertheshear,fastertheflow与剪切率比例成正比:剪切率越高,流动率越快Inverselyproportionaltoviscosity;lowertheviscosity,fastertheflow与黏度比例成反比:黏度越低,流动率越快BigmisunderstandingaboutMFR,itdoesNOTcorr

8、elatetoprocessability对MFR的误解,它与加工能力无关Whatdoesitaffect?它的影响82.PlasticFlowRateTypicalPlasticFlow典型的塑膠流動率StiffEasySlowFast92.PlasticFlowRateTypicalPlasticFlow典型的塑膠流動StiffEasySl