注塑模具-模具篇

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塑膠射出成型模具PlasticsInjectionMold綱要1.模具結構(MoldStructure)2.流道系統（RunnerSystem）3.冷卻系統（CoolingSystem）4.頂出系統（EjectionSystem）5.模具種類(TypeofMold)1 模具的構造MoldStructure模具的構造主要可分為下列五部分：1.模座（MoldBase)2.型腔（Cavity）3.流道系統（RunnerSystem）4.冷卻系統（CoolingSystem）5.頂出系統（EjectionSystem）型腔Cavity射出成型模是由一組部件組成的總成。部件中有一稱為型腔者，熔體注入其中，繼之以冷卻定型。型腔是由兩部分組成：1.母模；給予成型零件的外部造型，2.公模；給予成型零件的內部造型。Theinjectionmoldisanassemblyofpartscontainingwithinita‘cavity’intowhichmeltisinjected,cooledandformed.Thecavityisformedbytwomoldmembers:1.Thecavity,whichisthefemaleportionofthemold,givesthepartitsexternalform,2.Thecore,whichisthemaleportionofthemold,formstheinternalshapeofthepart.2 公和母模板CoreandCavityMoldPlate公模仁和母模仁CoreandCavityMoldInserts3 分模面PartingSurface模具的分模面是模板和模穴鄰接的部分，這部分面對面接觸，以形成密封，以防熔體自腔型溢出。分模面可分為平面或非平面，後者又可分為階梯狀、輪廓狀或斜角狀。Thepartingsurfacesofamoldarethoseportionsofbothmoldplates,adjacenttothecavities,whichbutttogethertoformasealandpreventthelossofmeltfromthecavity.Thepartingsurfacecanbeclassifiedaseitherflatornon-flat.Thelateronecanbefurtherclassifiedaseitherstepped,profiledandangled.澆注系統RunnerSystem在射出成型模中以流路將(射出成型機的)噴嘴和型腔連接起來。此一流路稱為澆注系統，一般包含了豎澆道、流道和澆口。Aflow-wayisprovidedintheinjectionmoldtoconnectthenozzle(oftheinjectionmachine)toeachcavity.Thisflow-wayistermedthefeedsystem.Normallythefeedsystemcomprisesasprue,runnerandgate.4 澆注系統RunnerSystem豎澆道Sprue澆口成品GatePart主流道MainRunner冷料井ColdSlugWell支流道BranchRunner冷流道和熱流道ColdRunnerandHotRunner冷流道和成型零件一塊兒冷卻、固化、成型和頂出。熱流道連接噴嘴與型腔(或冷豎澆道或冷流道)，維持在熔融狀態下，可以間歇性的注入型腔。Coldrunneriscooled,solidified,formedandejected,withparts.Hotrunner,connectingnozzleandcavities(orcoldspruesorcoldrunners),ismaintainedatameltandcanbefedintermittentlyintothecavities.5 流道設計考慮(1)•單模穴或多模穴•冷流道系統或熱流道系統•自然平衡或人工平衡流道(多模穴模具)•澆口數目•澆口位置•澆口形狀•澆口尺寸•流道配置(多模穴模具)•流道截面形狀•流道尺寸流道設計考慮(2)•流道系統與成品重量比例•流道系統對成品品質的影響•熔膠在模穴流動充填的方式•射出壓力、保壓壓力•熔膠溫度•縫合線的控制•空氣包陷的形成•排氣孔道位置•美觀•避免短射充填不足•避免不均衡擠壓•流道系統與頂出機構的配合•節省塑料6 排氣系統VentingSystem當熔體進入型腔，空氣被置換。為了使空氣得以逃逸，一條淺的排氣口可以加工在模面上。排氣道也可穿過模板，比如說，在必要的位置加頂出銷，頂出銷和模板孔之間的小間隙就足以讓空氣逃逸。Whenmeltentersacavity,airisdisplaced.Inordertoletairescape,thesurfacevent,ashallowslot,canbemachinedintothemoldplate.Theventcanalsobeprovidedthroughthemoldplate,e.g.incorporatinganejectorpinintherequiredposition.Theminutegapbetweentheejectorpinandthemoldplateholeissufficienttoallowtheairtoescape.冷卻系統CoolingSystem熱的熔體在型腔內冷卻、固化和定型。為了維持模具和熔體間的溫度差，冷卻液在模具內的孔道循環。連接整個軟管和孔道的系統叫作迴路。Hotmeltiscooled,solidifiedandformedinthecavity.Tomaintaintherequiredtemperaturedifferencebetweenthemoldandthemelt,coolantiscirculatedthroughholesorchannelswithinthemold.Thecompletesystemofconnectingholesandchannelsiscalledcircuit.7 冷卻系統（含模溫控制器）示意圖CoolingSystem冷卻系統的組成ConstructionofCoolingSystem•模溫控制機(TemperatureControllingUnit)•幫浦(Pump)•配管(Piping)•供水岐管(SupplyManifold)•連接軟管(ConnectionHose)•模具內之冷卻管路(CoolingChannel)•集水岐管(CollectionManifold)8 冷卻系統CoolingSystem冷卻製程相關參數RelevantProcessingParameters五大類別•熔膠與成型品幾何特性•塑膠熱物性質(密度、比熱和熱傳導係數)•成品厚度及幾何•模具材質•模座材料與熱物性質•模穴崁塊材料與熱物性質•冷卻管路設計-冷卻管路佈置、種類與尺寸•冷卻液性質-冷卻液熱物性質與流變性質•冷卻操作條件-冷卻液溫度、頂出溫度(冷卻時間)•其它-接觸熱阻(ContactThermalResistance)整體影響效益-模具溫度與分佈9 紊流和層流TurbulentandLaminarFlows紊流TurbulentFlow層流LaminarFlow雷諾數ReynoldsNumber雷諾數(無因次)Reynoldsnumber(dimensionless)密度density(g/cm3)直徑diameter(cm)速度velocity(cm/sec)黏度viscosity(poiseordyne-sec/cm2org/cm-sec)10 理論上最短冷卻時間Min.PossibleCoolingTime理論上最短冷卻時間themin.possiblecoolingtime產品最大厚度themax.partthickness熔膠的熱擴散度thermaldiffusivityofthemelt射出溫度injectiontemp.冷卻液溫度coolanttemp.頂出溫度ejectiontemp.冷卻裝置CoolingDevices直線式圓管直線式方管環型圓管11 冷卻裝置CoolingDevices檔板(Baffle)噴流管(Bubbler)吸熱管(HeatPipe)冷卻管道佈置CoolingChannelLayout入口出口InletOutlet出口入口OutletInlet12 冷卻孔道直徑、深度和節距建議值RecommendedDiameter,DepthandPitchD:直徑為10至14mmDiameterofCoolingChannel,10to14mmd:深度為D至3DDepth,D,to3DP:節距為3D至5DPitch,3Dto5D冷卻時間和厚度分佈CoolingTimeandThicknessProfile差的設計BadDesign好的設計GoodDesign13 頂出系統EjectorSystem材料固化時會收縮，這意味著零件會收縮在(形成零件的)公模仁上。射出成型機上的一些設備是用來自動啟動頂出系統的，這些設備置於可動模板之後。成型後的零件可以此一頂出系統自公模仁頂出。Materialcontractsasitsolidify,whichmeansthatthepartwillshrinkontothecorewhichformsit.Facilitiesareprovidedontheinjectionmachineforautomaticactuationofanejectorsystem,andthisissituatedbehindthemovingplaten.Themoldedpartcanbeejectedfromthecorebytheejectorsystem.標準模座StandardMoldBase標準模座定義為標準模具零件的套裝總成，這些零件採用一些標準的型式，以便大量生產和降低成本。這種模座可以裝配好的模具單元形式購得，這種模具單元中的模板是不含型腔的，型腔則是留給專業模具廠去加工。Astandardmoldbaseisdefinedasanassemblageofstandardmoldparts,adoptingsomeformofstandardisationinordertomanufacturetheminquantityatareducedcost.Themoldbasecanbepurchasedasanassembledmoldunit.Theplatesinthismoldunitdonotcontaincavityform,asthisaspectofmoldmanufactureislefttothespecialistmoldmaker.14 標準模座StandardMoldBase模具種類TypeofMold•兩板模(TwoPlateMold)•三板模(ThreePlateMold)•螺旋模具(UnscrewingMold)15 兩板模TwoPlateMold兩板模-母模側視圖“A”HalfPlanView(1)1.LeaderPins/Bushings4.Spure2.MoldBaseScrews5.EyeBolts3.JiffyConnectors16 兩板模-母模側視圖“A”HalfPlanView(2)6.LocatingRing7.Cavity8.ClampingSlots兩板模-公模側視圖“B”SidePlanView(1)1.SupportPillars3.ReturnPins2.GreaseFittings4.LeaderPinbushings17 兩板模-公模側視圖“B”SidePlanView(2)5.GuidedEjection7.JiffyConnectors6.HollowDowel8.SpurePuller兩板模-公模側視圖“B”SidePlanView(3)9.EjectorPins10.Core18 兩板模TopView(1)1.TopClampPlate4.SupportPlate2.”A”Plate5.EjectorRails3.”B”Plate6.-7.EjectorPlate兩板模TopView(2)8.MoldBaseScrews12.BottomClampPlate9.WaterLines13.MoldBaseScrews10.HollowDowel14.EjectorHousing11.CampingSlots19 兩板模TopView(3)15.SupportPillars18.MKOStuds16.-17.GuidedEjection滑塊系統（1）TwoPlateMold-Slide(1)1.HornPin3.Slide2.HeelBlocks20 滑塊系統（2）TwoPlateMold-Slide（2）4.WearPlate5.SpringBallPlunger兩板模作動順序(1st)TwoPlateMold’sSequencing(1st)21 兩板模作動順序(2nd)TwoPlateMold’sSequencing(2nd)頂出機構（1）StripperPlateMold(1)1.StripperPlate2.StripperPlateBushing3.LeaderPinandBushing22 頂出機構（2）StripperPlateMold(2)4.SpruePullerPin7.DowelPin5.SpruePullerBushing8.Spirolox6.Stripper兩板模-頂出機構作動順序(1st)StripperPlateMold’sSequencing(1ST)23 兩板模-頂出機構作動順序(2nd)StripperPlateMold’sSequencing(1st)三板模ThreePlateMold24 三板模(1)ThreePlateMold(1)1.StripperBolt4.ExtensionNozzleSprueWearBushing2.UrethaneSpring5.ExtensionNozzleSprueBushing3.StripperBolt6.GateDropPullerPin三板模（2）ThreePlateMold(2)7.GateDropPullerPinBushing11.RunnerPlate8.LeaderPin12.CavityPlateLeaderPinBushing9.LeaderPinBushing13.HollowDowel10.RunnerStripperPlate25 三板模作動順序(1st)ThreePlateMold’sSequencing(1st)三板模作動順序(2nd)ThreePlateMold’sSequencing(2nd)26 三板模作動順序(3rd)ThreePlateMold’sSequencing(3rd)三板模作動順序(4th)ThreePlateMold’sSequencing(4th)27 螺旋模具UnscrewingMold螺旋模具（1）UnscrewingMold(1)1.CamFollowers2.Stripper-(Grabber)-Rings3.CamBars28 螺旋模具(2)UnscrewingMold(2)1.Racks4.Thrust-NeedleBearings2.RackWearPlates5.RollerBearings3.ThreadedCore螺旋模具-上視圖(1)UnscrewingMold1.ThreadedCore3.CamBarWearPlates2.BubblerTube4.CamBars29 螺旋模具-上視圖（2）UnscrewingMold5.CamFollowers8.HotManifold6.COOLEDGATEINSERT9.ManifoldSprueBushing7.HotDrops螺旋模具作動順序(1st)UnscrewingMold’sSequencing(1st)30 螺旋模具作動順序（2nd)UnscrewingMold’sSequencing(2nd)31