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江西理工大學應(yīng)用科學學院 附錄 A Fundament Of Injection Molding Injection molding appearance can have a complex size precise or with metal embedded parts of the texture MiZhi of plastic products have been widely applied in defence electrical automotive transportation building materials packaging agriculture culture education health and People s Daily life field For all kinds of plastic injection molding process has good adaptability and high production capacity and is easy to realize the automation With the rapid development of industry in plastic injection today in quantity or species are occupies an important position thus become the fastest growth in plastic machinery one of the most number of production cost Our plastic processing enterprise star ROM the cloth throughout the country the technology of equipment most processing enterprise in different levels of equipment are needed This machinery industry in China in recent years the technology progress especially significant injection technology level and foreign famous brand products the smaller gap in the control level product quality and appearance shape etc Has achieved remarkable difference Choose domestically manufactured equipment with less investment also can produce and the quality of the product is imported equipment These for enterprise s technological transformation Must have good products must have good equipment The equipment corrosion and abrasion is a kind of natural laws they have the rule can prevent or reduce wear and corrosion of the equipment prolong the use of equipment to ensure that equipment s readiness cycle In order to strengthen the use of plastic machinery maintenance and management China has made relevant departments of the detailed rules for the implementation of the related standards and requirements the equipment management and production enterprise for equipment management and use it correctly scientific management reasonable use lubrication maintenance repair and maintenance the plan regularly to improve equipment equipment often pipe is in good condition Plastic injection molding technology is based on die casting principle from the 19th century at the beginning of the 20th century is the most widely used in plastics processing method This applies to all thermoplastics thermosetting plastic parts and plastic volume 1 3 The working principle of injection molding 1 1 The working principle and injection of syringe injection with similar it is with screw or plunger will have the thrust plasticizing good melting state i e sticky flow of plastic injection into the mold cavity closed good after obtaining the curing finalize the design process of products The injection molding process is a cycle of each cycle mainly includes quantitative charging molten plastic injection molding pressure and take mold cooling Remove molded parts again after closing for the next cycle The injection of 1 2 structure According to the way into the plastic injection machine and piston type machine screw The transmission way according to the machine can be divided into the hydraulic mechanical and hydraulic machinery link According to the operation mode into automatic and 常姍姍 汽車電源插孔板注射模具設(shè)計 semiautomatic manual machines 1 the horizontal injection this is the most common types The injection mould parts and parts in the same horizontal center and mould is online along horizontal open Its features are fuselage short easy operation and maintenance Machine low gravity installation is more stable The products can be dropped after the gravity easy to realize automatic operation At present the market with this form Injection 2 vertical injection mould parts and its injection parts in the vertical center and mould is along the line perpendicular direction of open Therefore the area is lesser easy loading and unloading mould was embedded into more convenient since the material can be a hopper evenly on plastic But after the products to be taken with the hand must fall under the realization of automatic operation easy Vertical injection molding machine for small anger is in commonly below 60 grams of injection molding machine large and medium sized machine unfavorable use 3 injection mould and the direction in the same surface boundary it is particularly suitable for machining center parts are not allowed to leave the plane sprinkle trace It covers an area smaller than horizontal injection mould but in the embedded easy Tilt This type of injection molding machine for small anger 4 multimode plate drilling machine it is a kind of special multistage operation its characteristic is injection mould device adopts the rotor disc structure mould around This type of machine was full of plastic injection unit can shorten the cycle of production capacity improve the production ability thus machine suitable for a long time or finalizes the design was embedded parts and need for more auxiliary time of mass production of plastic products but for large and complicated mould system mould device of force the less often in plastic injection products production application soles General injection mould device including injection unit hydraulic system and electric control system The basic requirements of injection molding plastic injection and is forming Plasticizing is realized and ensure the quality of products molding and to meet the requirements of injection molding must ensure sufficient pressure and speed At the same time because of high pressure injection correspondingly in the cavity of a high pressure mold cavity pressure in general average 20 45MPa between see table 1 so there must be large enough to close Thus injection mould device is injection unit niv key components The machine operation 1 4 1 4 1 injection program Forward injection nozzle and pressure keeping plastic shrinkage gets down cooling and nozzle backward and open the door closed and back needle mould and nozzle 1 4 2 injection machines operate project project including operating keyboard operate electric control cabinet operation and hydraulic system operation Separately feeding movement injected process action injection pressure and injection velocity the type selection each of the current voltage and temperature injection pressure and monitor back pressure adjustment etc 1 4 2 1 injection process action Can manual machine commonly also can with fullautomatic operation Manual operation is in a production cycle each movement by the operator is the operation switch clicked Generally in commissioning moulding adjustment only choose Semi automatic machine can automatically when operating cycle of a job but each production cycle must be opened after the completion of the operator the security the workpiece again to close the security machine can continue to the next cycle of production Full automatic operation in a cycle of injection molding machine automatic action after entering the next working cycle In the process of continuous work normally without downtime control and adjustment But must pay attention to automatic work such as 1 do not open the exit otherwise midway through the automatic interrupt 2 shall timely charging 3 if choose electric induction should pay attention to not hide the exploding close In fact in the automatic operation is usually need midway through the temporary shutdown such as injection mould for machine as softening agent The normal production general selection semi automatic or automatic operation Operation began when should according to production needs operating mode manual semiautomatic or automatic and the corresponding clicked manual semiautomatic or automatic switch Semi automatic and automatic working procedure has itself by lines in electrical counter operators on speed and pressure change the size length of time and frequency of thimble not by operators systematic and make wrong tuning procedures chaos When a period of adjustment before the appropriate action should be to choose the manual confirm every action then choose normal semi automatic or automatic operation 1 4 2 2 piasticising action According to the plastic injection advance before feeding whether the seat back mould injection nozzle is left general has three choices 1 former model fixed feeding and after always stick into the mold nozzle seat will not move note 2 before feeding nozzle with plastic mould for plastic feeding gets back seat note mould Leave nozzle Choose this option purpose is when using plastic mould injection advance against nozzle aperture avoid grant melting in high pressure from the nozzle flow plastic mould and nozzle can avoid after long time contact and heat transfer the influence of the temperature of their relative stability 3 after charging after the completion of the injection nozzle seat back left and plastic mould plastic finished gets more seats The action applies to processing molding temperature due to the narrow special plastic mould contact with short time of nozzle avoid the loss of heat also avoid the melting of the hole in the nozzle Injection timing cooling end timer plastic action after the start Screw rotation and squeezing plastic melting to screw head ahead Due to the front of the screw check out of the loop molten plastic fitting in front of the barrel screw back forced out When the screw back into a predetermined location this position by travel switch control screw back the distance realize quantitative charging plastic stop stop screw Then shrinks pour down shrinkage screw for traces of axial back this movement can make gathered in the melting of nozzle overcome the pressure of the pressure cylinder due to internal and external imbalances caused leave saliary phenomenon If you don t need to pour should put down to stop switch shrinkage piasticising make appropriate location on the pressure switch was stopped at the same time stop switch is also shrinks When the screw for fall back into action on shrinkage pressure switch to stop stop shrinkage Then start back seat note When the note on the back seat to the pressure switch to stop stop back seat If you use fixed way of feeding should pay attention to adjusting the position of switch trips well General production adopts fixed way of feeding back seat to save time of operation injection accelerate production cycle 1 4 2 3 injection pressure selection 常姍姍 汽車電源插孔板注射模具設(shè)計 The injection pressure injection by pressure regulating valve regulated set in stressful situation through the high and low voltage control the fuel injection pressure of late before Ordinary medium above machine Settings have three choices namely high pressure low pressure and low pressure after the first By injection pressure injection is the high pressure oil cylinder pressure oil Due to the high pressure from the start plastics in high pressure high condition into the cavity When the mould plastic injection pressure injection pressure cylinder rapidly rising fast reading By injection pressure injection is the low pressure cylinder oil injection process gauge reading rises slow plastic at low speed enter the cavity After the first high voltage is according to the types of plastic mould and actual requirements from the control of the cylinder pressure oil pressure to achieve In order to meet different requirements of various plastic injection pressure also can be used to replace the diameter of piston rod or screw this method can not only meet the injection pressure and give full play to the machine production capacity In large injection with more often for injection pressure and multistage speed control functions such injection can ensure the quality of products and precision 1 4 2 4 injection speed selection General control injection are fast slow knob to meet requirements of injection velocity In the hydraulic system in a large flow pump and a small flow pump running supply When the fuel injection big flow through quickly when opening rapid injection when the hydraulic oil provide only small flow injection molding machine various action is slow 1 4 2 5 top form The machine has the form of mechanical and hydraulic out two kinds some are also equipped with pneumatic ejector systems with a number of single and multiple two kinds The movement can be manually also can be automatically The action is open to stop by the limit switches to start The operator may according to need through adjusting control cabinet out time to achieve the button The speed and the pressure on the switch cabinet can through to control the movement of distance thimble determined by travel switch 1 4 2 6 temperature control In temperature measurement thermocouple temperature sensor for temperature changes with temperature control device plan as a nitrogen treated barrel and mould electric conductor the current ring selectively fixed nitrogen treated barrel temperature and each mould temperature 5 lists some plastic molding process temperature range available for reference A nitrogen treated barrel are generally classified into 2 electrothermal circle three or four control Electric cabinet of the ammeter respectively show the size of electric current each circle The readings are fixed if in reading ammeter is found in the running for a long time could the low heating circle faults occur or poor contact wires or resistanse wire or a fine oxidation heating circle all these will make burnt circuit of resistance increases in parallel to the current decline In the ammeter have readings can also simply use the plastic one heating circle in the wall see the material with judge a molten or electric circle is energized or burned to the ground 1 4 2 7 mould control Mould is huge mechanical thrust will die to molten plastic injection molding process to withstand the pressure injection mold and die filling and great ZhangKaiLi Close the switch each completed exit signals are given action immediately began First is to slow start moving template after a short pressure switch control rod slow pressure plate block out by rapid activity forward In advance to near the end of the mould the other end of the control lever lever and pressure on the slow switch activity board and turning to slow and with low In the process of low pressure mould if any between the mold can be successfully closed obstacles to the high voltage switch turn to unbend machine high pressure is close to completion action This distance extremely short generally only 0 3 1 0 mm just turn high pressure immediately terminated mould was touched when action to stop limit switches mould process is over The injection mould structure has full hydraulic and mechanical connecting rod type Whether it is a kind of structure finally is by connecting to the implementation of the full extension of mould The process of connecting rod straight board and end plate is propped process also is the tension stress were four pillars of the process The size of the mould can force from close tightly mode of hydraulic table rises high moments mould hydraulic power high peak and the form of low conversely A small injection mould with oil is at the table according to the situation of mould to judge whether the straight fits tight Really If a injection mould easily when connecting rod and poor little straight to unbend or a few connecting a deputy vice in incomplete unbend injection mould will appear bulge compactions will appear flash or other problems 1 4 2 8 open mode control When molten plastic injection into the mold cavity when after the completion of cooling is open mode with action remove products Open mode process is divided into three stages The first stage of slow prevent parts in the mold cavity The second stage of rapid to shorten the time of mould The third stage slowly open mold cavity to reduce the impact of inertia and vibration 1 4 3 injection molding process conditions At present the injection molding machine factory developed a variety of process control mode roughly injection speed control injection pressure control injection mold cavity plastic filling quantity control screw back pressure and speed control of the state of refining etc Realizing process control of product quality the purpose of which is to improve the efficiency of machines to get maximum play 1 4 3 1 injection speed program control The program control injection velocity of the screw is injected into 3 4 stroke stage at each stage of the use of appropriate injection velocity Example in the molten plastic started by runner injection velocity slows down when in the process of filling mold filling injection adopting high speed in slow at the end of the mould Using this method can prevent overflow eliminating flow mark and reduce the residual stresses of the products When filling mold flow speed smooth stable product size low stress wave smaller products and products to stress the uniformity such as a polycarbonate parts with high carbon tetrachloride immersion of injection molding stamping have craze of low cracking In the relatively slow filling mold conditions material flow of temperature especially after the gate can help to avoid the temperature shrinkage and depression But because of filling mold for a long time to continue to make parts appear statified and combining the weld 1ine adverse effect not only and mechanical strength appearance is reduced greatly High speed injection material flow speed when high speed filling mould smoothly 常姍姍 汽車電源插孔板注射模具設(shè)計 melting with cavity temperature soon fall down too little viscosity can use lower injection pressure is a hot filling mold High speed filling mold can improve the smoothness and gloss and eliminate the phenomenon and the joint line statified phenomenon shrinkage sag color uniform most of the product can ensure plump But easy to produce products fat bubbles or parts even burn zoom yellow or cause difficulty or demoulding filling mold uneven phenomenon For high viscosity plastic may lead to melt rupture make product surface Cloud The following conditions may consider using high pressure injection 1 plastic viscosity cooling speed long parts by low slow cannot completely filled every corner of the cavity 2 wall thickness is too thin expect the parts of thin walled place easily condensation and retention must adopt a high speed injection melting into energy consume immediately before the cavity 3 using glass fiber reinforced plastic or contains a large plastic filling materials because of poor liquidity in order to get the smooth and even parts must adopt high pressure injection For high precision products stamping thick wall thickness variation of large and thick tu margin and reinforcement of workpieces had better use multilevel injection such as secondary tertiary cet 4 or 5 1 4 3 2 injection pressure control program Usually the injection pressure control into an injection pressure the second injection pressure pressure or above 3 times of the injection pressure control Pressure switch time whether appropriate to prevent the high pressure and prevent overflow or lack of material is very important Mold pressure keeping stage of hematocrit depends on the closed gate when melting temperature and pressure If every time pressure switch to the products from the pressure and temperature of cooling stage the products of hematocrit won t change At constant temperature the molding the most important decision goods size parameter is the pressure the influence of dimensional tolerance of products is the most important variable is holding pressure and temperature Example in the end the mould filling immediately reduce pressure when the surface forms certain thickness the pressure can rise to the low thick wall molding mould force of large products eliminate collapse pit and flash The pressure and the speed of filling mold cavity is usually plastic pressure and speed when the highest 50 65 namely the pressure lower than the injection pressure about 0 6 0 8 MPa Due to the low pressure injection pressure than in considerable pressure within the time the oil