e GE Plastics ProcessingTroubleshooting Seminar GE Plastics Southwest
e GE Plastics Processing/Troubleshooting Seminar GE Plastics Southwest Region
長華塑膠股份有限公司 奇異 程塑膠( G. E-Engineering plastics ) 技術開發 - 黃濂榕 黃再添 E-mail : willis@nwp. com. tw terry@nwp. com. tw
Great example of how presentations in the library may be combined through cutting and pasting to create hybrid pitches. . . This presentation took only 2 hours to create (over 100 slides), thanks to GESlides !
Impact Modification Glass (High Modulus) Reinforcement Increased Impact Resistance Increased Strength Increased Elongation Decreased Stiffness Decreased Thermal Expansion Decreased Strength Potential Warpage
吸收 / 移轉 P e r c e n t . 8 均勢 M o i s t u r e C o n t e n t 吸收 移轉. 02 適合程度 -20 -10 0 20 Dew Point露點 40 60
鼓風機 乾 燥 系 統 加熱器 鼓風機 乾 燥 系 統 烘料筒 過濾器 加熱系統 Just as pellets can become saturated, the desiccant beads can become saturated and therefore have to be periodically reactivated.
建議各種清洗料管使用原料 Polymer Purge Material CYCOLAC / CYCOLOY Acrylic, Polystyrene, SAN NORYL Polystyrene, Acrylic LEXAN Acrylic, HD Polyethylene VALOX Polystyrene, HD Polyethylene ULTEM LEXAN 101, 141, HD Polyethylene (Extrusion Grade) SUPEC HD Polyethylene
商品名 CYCOLAC? LEXAN? NORYL? PREVEX? VALOX? ULTEM? CYCOLOY? XENOY? SUPEC? GELOY? 成形溫度 (℃) 218 -260 266 -310 218 -327 236 -277 338 -450 235 -285 240 -280 300 -332 195 -220
模溫控制 IN 120 O 130 140 OUT 150 O O O 125 O 135 O 145
冷卻作用 : 結晶性材料 TG TM 劣解 成形溫度範圍 • • Mold Temperature Determines Cooling Time and Therefore Degree of Crystallinity Cooling Through the Crystallinization Range Too Quickly Will Result in Reduced Crystallinity (Quenching)
噴嘴 ( Nozzle ) 加熱片 注射方向 Cylinder Bore
Single Tab Gate 6 in. Max Multiple Tab Gate 12 in. Max Tab Gate Sprue Gate Tab Gate Sprue
Three Plate Design Closed
進料點選定 Gate Location is Strongly Influenced by Glass Content. End Gating is Preferred in Glass Filled Materials to Minimize Warpage.
Sleeve Ejector Blade at Deep Ribs Rounds Pins USED AROUND PINS & BOSSES Stationary Force Knock Out Bars Boss Eject Parts Stripper Plate Mold Pin Stationary GOOD KNOCK OUT FOR ROUND PARTS
射出成型問題 Injection molding problems
Voids Warpage Streaking Fingerprinting Splay Burning Flash Gloss Overpacking Shrinkage Shorts
製程中問題發生時, 第一件要想到的事情 What is the first thing you do to your process when a problem occurs? 合理假設 可能是原料問題
基本原則 BASIC ROULES Some Basic Rules to Follow in Effectively Solving Molding Problems. . . • 擬定計畫 Have your plan ready • 一次改變一個參數 Make Only One Change at a Time • 耐心找出影響 Be Patient, Let Them Take Effect • 保持機器運轉狀態 Keep Machine on Cycle • 記錄改變結果 Keep Records of Changes
縮水 Sinks 產品肉厚部, 因內應力 影響, 致使聚合物分子 量不足的結果. Caused by Internal Stresses within Thicker Sections of the Part as a Result of Insufficient Polymer Molecules.
縮水 Sinks 減少縮水的方法 Ways to Minimize Sink Marks 確認部品設計 增加保壓時間 Check the Part Design Increase Injection Hold Time 確認入料速率 確認熔融溫度 Check Feed Rate Check Melt Temperature 增加射出速度 增加背壓 Increase Injection Speed Increase Back Pressure 增加射出壓力 維持有效排氣 Increase Injection Pressure Maintain Sufficient Venting 增加模溫 增加流道/澆口直徑 Increase Mold Temperature Increase Runner/Gate Dimensions
空穴 Void s 空穴是因模腔內聚合物分 子量少. 但與縮水相反的是 在冷卻過程中, 表皮層的強 度足以對抗內應力的作用. Voids Are Cause by Too Few Molecules within the Mold. As Opposed to Sink Marks, Part Wall Strength is Sufficient to Withstand the Internal Stress Caused by the Melt Cooling Process.
空穴 Voids 減少空穴的方法 Ways to Minimize Voids 確認產品設計 確認熔融溫度 Check the Part Design Check Melt Temperature 確認入料速率 增加背壓 Check Feed Rate Increase Back Pressure 增加保壓時間 維持有效排氣 Increase Injection Hold Time Maintain Sufficient Venting 增加射出速度 增加流道/膠口直徑 Increase Injection Speed Increase Runner/Gate Dimensions 增加模溫 Increase Mold Temperature 增加射出壓力 Increase Injection Pressure
彎曲 Warpin g 彎曲是因部品的兩側承受 不平均的配向與應力 Warping is Caused by Non-Uniform Orientation and Uneven Stress Levels on Different Sides of the Part.
彎曲 Warping • 確認片狀部品的設計 Check the Piece Part Design • 確認入料速率 Check Feed Rate • 降低射出壓力 Decrease Injection Pressure • 降低射出速度 Decrease Injection Speed • 降低模溫 Decrease Mold Temperature • 增加保壓時間 Increase Injection Hold Time • 確認熔融溫度 Check Melt Temperature • 確認冷卻過程 Check Cooling Passages
毛邊 Flash 當射出壓力超過合模力 或遮斷閥損壞時, 毛邊就 產生. Flash Will Occur When Injection Pressure Exceeds Clamp Force or Shut-Off is Damaged.
毛邊 Flash • 合模力不足 Loose Clamp • 射出壓力過大 Injection Pressure Too High • 射出高壓時間過長 Injection High Pressure on Too Long • 射出速度過快 Injection Speed Too Fast • 料溫過高 Melt Temperature Too High • 不適當的入料速率 Improper Feed Rate • 模具損壞或過熱 Damaged or Overheated Mold
短射 Short Shots 短射是無法完 全填滿部品 Short Shot is the Inability to Completely Fill a Part.
短射 Short Shots 減少短射的方法 Ways to Minimize Short Shots • 確認噴嘴是否損壞 Check for Nozzle Damage • 增加射出壓力 Increase Injection Pressure • 增加儲料溫度 Increase Stock Temperature • 增加射膠量 Increase Shot Size • 增加模溫 Increase Mold Temperature • 確認阻逆閥與料管是否過度磨損或損壞 Check Non-Return Valve and Barrel for Excessive Wear or Damage
部品表面燒焦 Surface Burning of Parts 部品表面燒焦發生可能原因由於 過高儲料溫度, 過高剪切熱, 過高背 壓. 確認排氣適當. 為克服流動限制, 採高速射出時, 摩擦燒焦亦會發生. Surface Burning of Parts Can Be Caused by Too High a Stock Temperature. Excessive Shear Heating Caused by Too High a Back Pressure is Also a Possible Cause. Check to Make Sure that the Venting of the Mold is Adequate. When a High Injection Speed is Used to Overcome Flow Restrictions, Frictional Burning Can Result.
部品表面燒焦 Surface Burning of Parts 減少表面燒焦的方法 Ways to Minimize Surface Burning • 降低儲料溫度 • 確認合模力 • Decrease the Stock Temperature • Check Clamp Pressure • 降低射出速度 • 確認排氣 • Decrease Injection Speed • Check Venting • 確認模具排氣 • 降低射出速度 • Check Venting of the Mold • Decrease Injection Speed • 加大澆口 • 降低射出壓力 • Enlarge Gates • Decrease Injection Pressure • 確認澆道與空射狀況 • 確認儲料與模 • Check Sprue for Burning and/or Purge Shot • Check Stock and Mold Temperatures
結合線 Weld Lines 來自不同澆口或同一澆口的分 流, 當多股熔料前端融合在一起 時, 結合線由此產生. Weld lines Occur When Two or More Melt Fronts Merge. Typically, These Will Be Melt Fronts from Different Gates, or a Single Melt Front Forced to Split Around an Obstruction Such as a Core pin.
氣体燒焦 Gas Burn 氣体燒焦是部品劣解的一 種, 發生原因在於空氣或瓦 斯氣於模具內受到絕熱壓縮 燃燒. Gas Burn is a Degradation of the Part Caused by the Compression and Ignition of Trapped Air or Gasses in the Mold.
氣体燃燒 Gas Burn • 不適當的合模 Tonnage Improper Clamp • 排氣阻塞 Clogged Air Vents • 缺乏適當的排氣 Venting Lack of Adequate • 射出速度過快 High Injection Speed Too • 射出壓力過高 High Injection Pressure Too • 料溫過高 High Melt Temperature Too
剝離 Delamination 層剝離發生的原因在於 混入不相同的聚合物. The Separation by Layer Caused by Contamination of a Dissimilar Polymer.
成型 程塑膠 10項法則 Ten Do�for Molding Engineering Resins • 熟識成型的原料 Know Your Material • 適當的乾燥 Dry Properly • 按照推薦的成型條件 Use Recommended Processing Conditions • 選用合適的設備 Use Properly Sized Equipment • 適當設計模具 Use Properly Designed Tooling • 流道適當 Use Adequate Runners • 排氣要充分 Use Proper Venting • 選用合適的噴嘴 Use Nozzles with Proper Heat Controls • 採用合適的螺桿設計 Use Proper Screw Design • 一年一次或兩次的設備保養計畫 Schedule Annual or Bi-Annual Equipment Maintenance
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