e GE Plastics Engineering Plastic Injection Molding e

  • Slides: 125
Download presentation
e GE Plastics Engineering Plastic Injection Molding

e GE Plastics Engineering Plastic Injection Molding

e GE Plastics Korea 曺 武 植 부장 / 기술 써비스 한국GE(U. S. A)프라스틱스(주)

e GE Plastics Korea 曺 武 植 부장 / 기술 써비스 한국GE(U. S. A)프라스틱스(주) 서울 강남구 논현동 231 -8 (우)135 -010 Tel: 02 -510 -6212 Fax: 02 -510 -6420 E-mail: Moo-Sik. Cho @gep. ge. com

Injection Molding Introduction 리브, 보스, 홀 등이 있는 복잡한 제품

Injection Molding Introduction 리브, 보스, 홀 등이 있는 복잡한 제품

Injection Molding Introduction 대형 제품 : 자동차 Bumper / Fender

Injection Molding Introduction 대형 제품 : 자동차 Bumper / Fender

Extrusion 압출 Pellets Heating Coils Part Screw Continuous Process Die

Extrusion 압출 Pellets Heating Coils Part Screw Continuous Process Die

Extrusion The Profile Extrusion Die Continuous Flow Uniform Cross-Section

Extrusion The Profile Extrusion Die Continuous Flow Uniform Cross-Section

Extrusion Roll Stack Rigid Sheet Extrusion Die Extrusion Cutaway View • Extruded Through Die

Extrusion Roll Stack Rigid Sheet Extrusion Die Extrusion Cutaway View • Extruded Through Die • Supported and Cooled by a Stack of Polishing Rolls • Cut and Trimmed Once Below Glass Transition Temperature • Sheet May be Used in Thermoforming and Compression Molding

압축 성형(Compression Molding) Softened sheet is placed in a mold then pressed into shape

압축 성형(Compression Molding) Softened sheet is placed in a mold then pressed into shape by compressive force.

Compression Molding Compressive Force 1 2 Part Trimming Soft Sheet 3

Compression Molding Compressive Force 1 2 Part Trimming Soft Sheet 3

Thermoforming 진공 성형(Vacuum Forming) Softened Sheet Atmospheric Pressure(14. 7 psi) Part Mold Vacuum

Thermoforming 진공 성형(Vacuum Forming) Softened Sheet Atmospheric Pressure(14. 7 psi) Part Mold Vacuum

중공 성형(Blow Molding)

중공 성형(Blow Molding)

중공 성형(Blow Molding) 1 Parison Drop 2 Pre Blow 3 Full Pressure 4 5

중공 성형(Blow Molding) 1 Parison Drop 2 Pre Blow 3 Full Pressure 4 5 Release Pinch Bar Mold Part

Injection Molding 발포 성형 SKIN CORE SKIN • Increases the attainable wall thickness •

Injection Molding 발포 성형 SKIN CORE SKIN • Increases the attainable wall thickness • Gas expands inside plasticized material to create foam core

Injection Molding 발포성형(Structural Foam Part) LEXAN FOAMABLE RESIN Business Machine Chassis High Strength and

Injection Molding 발포성형(Structural Foam Part) LEXAN FOAMABLE RESIN Business Machine Chassis High Strength and Rigidity in Larger Parts

Injection Molding 발포 성형 Blowing Agent with Resin Advantages • 대형 제품 가능 •

Injection Molding 발포 성형 Blowing Agent with Resin Advantages • 대형 제품 가능 • 저압 성형 가능 • High Stiffness to Weight Ratio Disadvantages • 사이클 타임 길다 • 외관 • 발포제 blending 필요

Injection Molding Gas Assist Molded Rib Injection Molded Rib Sink Gas Created Cavity

Injection Molding Gas Assist Molded Rib Injection Molded Rib Sink Gas Created Cavity

ICM Process (사출 압축 성형) Sequential ICM Go Preset Gap Injection f =0 Compression

ICM Process (사출 압축 성형) Sequential ICM Go Preset Gap Injection f =0 Compression

ICM Process Selective ICM or Coining G Go Preset Gap Injection Advantages 잔류응력 감소

ICM Process Selective ICM or Coining G Go Preset Gap Injection Advantages 잔류응력 감소 충격강도 우수 Low warpage, 치수 안정성 Thinner wall, 중량 감소 Gf = 0 Compression

Injection Molding Introduction 원료 금 형 GOOD PART 성형 공정 제품의 디자인

Injection Molding Introduction 원료 금 형 GOOD PART 성형 공정 제품의 디자인

Injection Molding

Injection Molding

Injection Molding 사출 성형 공정

Injection Molding 사출 성형 공정

Injection Molding Process 건조가 불충분한 경우 :

Injection Molding Process 건조가 불충분한 경우 :

Injection Molding Process 건조 후 적정 수분 함량 Lexan / Xenoy /Cycoloy 0. 02

Injection Molding Process 건조 후 적정 수분 함량 Lexan / Xenoy /Cycoloy 0. 02 %이하 Valox 0. 02 %이하 Ultem 0. 05 %이하

Injection Molding Process 건조기 Hopper 용량 • 1회 사출중량 / Cycle Time • 예:

Injection Molding Process 건조기 Hopper 용량 • 1회 사출중량 / Cycle Time • 예: 1 kg(제품+S/R) 30 초 Cycle • 시간당 사출중량 x 건조시간 예: 120 kg/시간 x 4 시간 시간당 사출중량 = 2 kg/분 = 120 kg/시간 =최소 호파 용량 = 480 kg 이상 용량의 Hopper 1회 사출중량(kg) X 3600 X 건조시간 싸이클타임(초) The Hopper should be sized large enough to provide adequate resin residence time.

Drying Polymers Moisture Content 상대 습도 @ 23 o C 20% 50% 100% Relative

Drying Polymers Moisture Content 상대 습도 @ 23 o C 20% 50% 100% Relative Humidity describes the percent of moisture present in the air relative to the greatest amount that could be held at a given temperature.

Drying Polymers Moisture Content 상대 습도 @ 32 o. C 20% Relative Humidity @

Drying Polymers Moisture Content 상대 습도 @ 32 o. C 20% Relative Humidity @ 23 o. C 50% Relative Humidity @ 10 o. C 100% Relative Humidity

Drying Polymers Moisture Content 이슬점(Dew Point) Condenses at 1 o C Condenses at 12

Drying Polymers Moisture Content 이슬점(Dew Point) Condenses at 1 o C Condenses at 12 o C Condenses at 23 o C 공기중의 수분이 응축되기 시작할 때의 온도

Drying Polymers Moisture Content Pellet Moisture Absorption The Higher the Dew Point, the More

Drying Polymers Moisture Content Pellet Moisture Absorption The Higher the Dew Point, the More Moisture in the Air Dew Point of 1 o Dew Point of 12 o Dew Point of 23 o The More Moisture in the Air, the More Water Absorbed by the Pellets

Drying Polymers Moisture Content There are several test methods to verify moisture content such

Drying Polymers Moisture Content There are several test methods to verify moisture content such as the Karl Fischer Titration Test and the Tomasetti Volatile Indicator (TVI)

Drying Polymers Drying Rates Drying to OK Level Dry Air -29 o. C Dew

Drying Polymers Drying Rates Drying to OK Level Dry Air -29 o. C Dew Point 건조 효율을 극대화하기 위해서는 제습건조기의 이슬점 은 적어도 -29 o. C가 되어야 한다.

Drying Polymers Dryer Efficiencies 건조 방법 Oven Dryer with Trays Effective for Small Batches

Drying Polymers Dryer Efficiencies 건조 방법 Oven Dryer with Trays Effective for Small Batches Hopper Dryer Preferable for Longer Runs

Drying Polymers Dryer Efficiencies 열풍 건조기(Hot Air Dryers) Exhaust Ambient Air Pump Heater Hopper

Drying Polymers Dryer Efficiencies 열풍 건조기(Hot Air Dryers) Exhaust Ambient Air Pump Heater Hopper Dew point는 변하지 않고 상대습도만 낮 추어 준다.

Dry Air Drying Polymers Dryer Efficiencies 제습 건조기 Blower Reactivating Desiccant Bed Processing Desiccant

Dry Air Drying Polymers Dryer Efficiencies 제습 건조기 Blower Reactivating Desiccant Bed Processing Desiccant Bed Hopper Wet Air Processing Air Heater A blower forces air through the desiccant bed to lower its dew point, through the heater to raise its temperature, and into the hopper to dry the pellets.

Drying Polymers Dryer Efficiencies Blower Processing Desiccant Bed Heater Blower Reactivating Desiccant Bed Hopper

Drying Polymers Dryer Efficiencies Blower Processing Desiccant Bed Heater Blower Reactivating Desiccant Bed Hopper Filter Processing Air Heater Just as pellets can become saturated, the desiccant beads can become saturated and therefore have to be periodically reactivated.

Drying Polymers Dryer Efficiencies Desiccant Beads 15 o. C Dew Point Desiccant Beads -29

Drying Polymers Dryer Efficiencies Desiccant Beads 15 o. C Dew Point Desiccant Beads -29 o. C Dew Point The ceramic desiccant beads have such a strong affinity to water that they will absorb enough moisture from the air to achieve a dew point of at least -29 o. C.

Drying Polymers Dryer Efficiencies Preferred Hopper Design Slow Moving Pellets Constant Pellet Movement Dryer

Drying Polymers Dryer Efficiencies Preferred Hopper Design Slow Moving Pellets Constant Pellet Movement Dryer Air Fast Moving Pellets Dryer Air Spreader • Hoppers that are twice as high as they are wide (aspect ratio of 2: 1) improve dryer efficiency. • A spreader will prevent channeling and air flow

Injection Molding Process Model of Amorphous Polymers Locked Entanglements TG Stiff Flow Easier Flow

Injection Molding Process Model of Amorphous Polymers Locked Entanglements TG Stiff Flow Easier Flow Raise Temperature ofof Polymer Adding Heat Increases Space Between Molecular Chains

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process Injection Flow

Injection Molding Process 사출 압력 H y d r a u l i c

Injection Molding Process 사출 압력 H y d r a u l i c P r e s s u r e 배 압 충진시간 계량 시간 Time

Injection Molding Variables 용융 온도 35 M e l t F l o w

Injection Molding Variables 용융 온도 35 M e l t F l o w 30 101 @ 315 deg. C 25 20 LEXAN? 101 288 deg C. 15 (in. ) 10 5 0 . 030 . 060 . 090 . 120 . 150 . 180 . 210 . 240 Wall Thickness in Inches 용융온도를 올리면 흐름길이는 늘어 난다. 그러나 용융온도를 과도하게 올리면 물성이 떨어지므로 주의 해야 한다.

Injection Molding Variables 수지의 실린더내 정체 시간 용융수지가 스크루 내에서 머무르는 시간. Lexan :

Injection Molding Variables 수지의 실린더내 정체 시간 용융수지가 스크루 내에서 머무르는 시간. Lexan : Max. 8분 Xenoy: Max. 5분 Valox : Max. 6분 Ultem : Max. 15분 실린더용량(g) X 2. 5 X 사이클타임 제품중량(g) To measure this, colored pellets are dropped into the base of the hopper. Time is measured until the point when colored extrudant is purged from the nozzle.

Injection Molding 사출 장비

Injection Molding 사출 장비

Injection Molding Equipment 형체부 스크루 배럴 사출부

Injection Molding Equipment 형체부 스크루 배럴 사출부

Injection Molding Equipment Hydraulic Injection Cylinders

Injection Molding Equipment Hydraulic Injection Cylinders

Injection Molding Equipment The Screw Barrel • 수지를 용융 • 용융수지를 금형의 캐비티로 사출

Injection Molding Equipment The Screw Barrel • 수지를 용융 • 용융수지를 금형의 캐비티로 사출

Injection Molding Equipment Barrel Unit The Reciprocating Screw Hopper (Filling) Throat Heating Coils Force,

Injection Molding Equipment Barrel Unit The Reciprocating Screw Hopper (Filling) Throat Heating Coils Force, Torque From Injection Unit Nozzle Barrel Screw

Injection Molding Equipment Barrel Unit The Reciprocating Screw Shot 스크루가 회전하면서 뒤로 후퇴함에 따라

Injection Molding Equipment Barrel Unit The Reciprocating Screw Shot 스크루가 회전하면서 뒤로 후퇴함에 따라 수지가 용융되면서 배럴의 앞 쪽으로 모이게 된다. Rotation and Back Pressure

Injection Molding Equipment Barrel Unit The Reciprocating Screw Shot Injection Pressure 사출 직전 용융수지가

Injection Molding Equipment Barrel Unit The Reciprocating Screw Shot Injection Pressure 사출 직전 용융수지가 스크루의 앞 쪽에 모인 상 태

Injection Molding Equipment Barrel Unit The Reciprocating Screw Cushion Packing Pressure Screw Pushes Forward:

Injection Molding Equipment Barrel Unit The Reciprocating Screw Cushion Packing Pressure Screw Pushes Forward: Inject

Injection Molding Equipment - Screw hm Metering D Transition hf Feed L Screw and

Injection Molding Equipment - Screw hm Metering D Transition hf Feed L Screw and Cylinder Design • L/D = 20: 1 • 압축비 = hf / hm = 2. 5: 1 • 스크루 산 수 : 공급부 5 , 압축부 11 , 계량부 4 • Cylinder bi-metallic for Abrasion Resistance

Injection Molding Equipment Screw Tip Assemblies Ball Type 역류 방지 밸브 Open Closed for

Injection Molding Equipment Screw Tip Assemblies Ball Type 역류 방지 밸브 Open Closed for Injection

Injection Molding Equipment 실린더 노즐 Heating Band To Mold Cylinder Bore 최소 치수 :

Injection Molding Equipment 실린더 노즐 Heating Band To Mold Cylinder Bore 최소 치수 : • 노즐 경 ; Min. 5. 0 mm (금형 스프루보다 0. 5 - 1. 0 mm 작게) • 랜드 길이 ; Min. 5. 0 mm • 노즐 Bore ; Min. 13 mm

Injection Molding Tooling 금 형

Injection Molding Tooling 금 형

Injection Molding Tooling Top Clamping Plate "A" Plate PARTING LINE "B" Plate Return Pin

Injection Molding Tooling Top Clamping Plate "A" Plate PARTING LINE "B" Plate Return Pin Ejector Housing 2단 금 형 Exploded View Leader Pin Support Plate Elector Retainer Plate Ejector Plate

Injection Molding Tooling 2단 금 형

Injection Molding Tooling 2단 금 형

Injection Molding Tooling 1 3 2 4

Injection Molding Tooling 1 3 2 4

Injection Molding Tooling Top Clamping Plate "A" Plate 3단 금 형 PARTING LINE "X"

Injection Molding Tooling Top Clamping Plate "A" Plate 3단 금 형 PARTING LINE "X" Plate PARTING LINE "B" Plate Ejector Housing Support Plate Ejector Retainer Plate Ejector Plate

Injection Molding Tooling 3단 금형 1 2 4 3 5

Injection Molding Tooling 3단 금형 1 2 4 3 5

Injection Molding Tooling Radius Orifice Nozzle Sprue Bushing

Injection Molding Tooling Radius Orifice Nozzle Sprue Bushing

Injection Molding Tooling Sprue Puller REVERSE TAPER BEST Z PULLER GOOD GROOVE TROUBLESOME SUCKER

Injection Molding Tooling Sprue Puller REVERSE TAPER BEST Z PULLER GOOD GROOVE TROUBLESOME SUCKER PIN NOT RECOMMENDED

Injection Molding Tooling Runner Systems 런너는 스프루에서 게이트로 용융수지를 이동시킨다.

Injection Molding Tooling Runner Systems 런너는 스프루에서 게이트로 용융수지를 이동시킨다.

Runners Flow Material Flows Only Through Molten Portion of Runner Outer Skin Chills on

Runners Flow Material Flows Only Through Molten Portion of Runner Outer Skin Chills on Contact with mold Surface

Injection Molding Tooling Direct Sprue Gating Tab Fan Disk Edge Pin Point

Injection Molding Tooling Direct Sprue Gating Tab Fan Disk Edge Pin Point

Injection Molding Tooling Manifold Recommendations • Passages Externally Heated (4 Heaters) • Bore Size

Injection Molding Tooling Manifold Recommendations • Passages Externally Heated (4 Heaters) • Bore Size 12. 7 mm or Larger • 50 Watts/in 3 Minimum

Injection Molding Tooling Hot Runner Systems Manifold = 2600 Cavity Plate = 500 핫런너의

Injection Molding Tooling Hot Runner Systems Manifold = 2600 Cavity Plate = 500 핫런너의 장점 • 사이클 단축 - 15 -20% • 원료 절감 - No Sprues or Runners • 제품 품질 향상 - 스트레스 감소

Tooling Venting Ejector Pin 0. 04 mm Clearance Around Knockout

Tooling Venting Ejector Pin 0. 04 mm Clearance Around Knockout

Injection Molding Material Considerations

Injection Molding Material Considerations

Injection Molding Material Thermoplastics and Degradation 온 과열구역 도 시간

Injection Molding Material Thermoplastics and Degradation 온 과열구역 도 시간

Injection Molding Material 플라스틱의 수축율 Vmold Vpart lmold Sl = lmold - lpart lmold

Injection Molding Material 플라스틱의 수축율 Vmold Vpart lmold Sl = lmold - lpart lmold or Sv = vmold - vpart vmold

Injection Molding Material Shrinkage and Injection Molding Simplified Pressure History - Injection Molding P

Injection Molding Material Shrinkage and Injection Molding Simplified Pressure History - Injection Molding P r e s s u r e Filling A Material Packing B Cooling C Ejection D E

Injection Molding Material 원료의 수축율 비결정성 수지 LEXAN(PC) NORYL(M-PPO) CYCOLAC(ABS) Typical Shrinkage 5 -7

Injection Molding Material 원료의 수축율 비결정성 수지 LEXAN(PC) NORYL(M-PPO) CYCOLAC(ABS) Typical Shrinkage 5 -7 mm/m 결정성 수지 VALOX(PET/PBT) 5 -25 Blends XENOY(PBT/PC) NORYL GTX (PPO/Nylon) CYCOLOY(PC/ABS) 5 -10

Injection Molding Material Amorphous Materials(비결정성 수지) ABS , PC , PVC , PS ,

Injection Molding Material Amorphous Materials(비결정성 수지) ABS , PC , PVC , PS , PMMA , . . . 인장강도는 낮고, 충격강도는 높다. 낮은 수축율

Injection Molding Material TG Degradation Processing Temperature Range Raise Temperature of Polymer

Injection Molding Material TG Degradation Processing Temperature Range Raise Temperature of Polymer

Injection Molding Material 결정성 수지 PA , PE , PP , PBT , PET

Injection Molding Material 결정성 수지 PA , PE , PP , PBT , PET , POM , ---- 사출되는 동안은 비결정성 인장강도는 높고, 충격강도는 낮 다 수축율은 높다 Regulating Crystallinity: Mold Temperature, Cycle Time, Injection and Holding Temperature, Cooling Method After Removal From Mold

Injection Molding Material TG TM Degradation Processing Temperature Range Raise Temperature of Polymer

Injection Molding Material TG TM Degradation Processing Temperature Range Raise Temperature of Polymer

Injection Molding Design Moldability 제품 디자인 관련

Injection Molding Design Moldability 제품 디자인 관련

Injection Molding Design Moldability 불균일한 압력 Runner Gate 1 x Sprue 2 x Flow

Injection Molding Design Moldability 불균일한 압력 Runner Gate 1 x Sprue 2 x Flow Part x 3 P r e s s u r e 1 2 3 Time

Injection Molding Design Moldability Warpage Due to Uneven Pressure 게이트 주위: 고압, 저수축 Gate

Injection Molding Design Moldability Warpage Due to Uneven Pressure 게이트 주위: 고압, 저수축 Gate 흐름 끝단 : 저압, 고수축 휨 발생

Injection Molding Design Moldability Wall Design

Injection Molding Design Moldability Wall Design

Injection Molding Design Moldability Holes Gate - Melt Entry Point Slot Hole이 용융수지의 흐름을

Injection Molding Design Moldability Holes Gate - Melt Entry Point Slot Hole이 용융수지의 흐름을 방해

Injection Molding Design Moldability Holes Gate - Melt Entry Point 흐름성 양호

Injection Molding Design Moldability Holes Gate - Melt Entry Point 흐름성 양호

Injection Molding Design Moldability Ejecting the Part Difficult Ejection Easier Ejection No Draft Angle

Injection Molding Design Moldability Ejecting the Part Difficult Ejection Easier Ejection No Draft Angle 적정한 빼기 구배 : 1 - 2 도 (유리섬유 보강 그래이드 및 깊고 복잡한 형상의 제품은 빼기구배를 더 주어야 한다. )

Injection Molding Design Moldability 빼기 구배 Textured Sidewall 부식 깊이 0. 025 mm 당

Injection Molding Design Moldability 빼기 구배 Textured Sidewall 부식 깊이 0. 025 mm 당 구배 1도 추가

Injection Molding Closing Ten Do's for Molding Engineering Resins • • • Know Your

Injection Molding Closing Ten Do's for Molding Engineering Resins • • • Know Your Material Dry Properly Use Recommended Processing Conditions Use Properly Sized Equipment Use Properly Designed Tooling Use Adequate Runners Use Proper Venting Use Nozzles with Proper Heat Controls Use Proper Screw Design Schedule Annual or Bi-Annual Equipment Maintenance

e GE Plastics 질 문

e GE Plastics 질 문