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1 The introdution of the Injection Mold 1 Mold basic knowledge 1 1 Introduction There is a close relationship with all kinds of mold which are refered to our daily production and life in the use of the various tools and products the large base of the machine tool the body shell the first embryo to a small screws buttons as well as various home appliances shell Mold s shape determine the shape of these products mold s precision and machining quality determine the quality of these products too Because of a variety of products appearance specifications and the different uses mold devide into Die Casting into the mould die forging die casting mould Die and so on other non plastic molds as well as plastic mold In recent years with the rapid development of the plastics industry and GM and engineering plastics in areas such as strength and accuracy of the continuous enhancement the scope of the application of plastic products have also constantly expanded such as household appliances instrumentation construction equipment automotive daily hardware and many other fields the proportion of plastic products is rapidly increasing A rational design of plastic parts often can replace much more traditional metal pieces The trend of industrial products and daily products plasticed is rising day after day 1 2 Mold general definition In the industrial production with the various press and the special instruments which installed in the press it produces the required shape parts or products through pressure on the metal or non metallic materials this special instruments collectively call as the mold 1 3 Mold general classification Mold can be divided into plastic and non plastic mould 1 Non plastic mould Die Casting forging Die Die die casting mould and so on A Die Casting taps pig iron platformB Forging Die car body C Die computer panel D Die Casting Die superalloy cylinder body 2 For the production technology and production the plastic mold are divided into different products A Injection molding die TV casing keyboard button 2 the most common application B Inflatable module drink bottles C Compression molding die bakelite switches scientific Ciwan dish D Transfer molding die IC products E Extrusion die of glue plastic bags F Hot forming die transparent shell molding packaging G Rotomoulding mode Flexible toy doll Injection Molding is the most popurlar method in plastics producing process The method can be applied to all parts of thermoplastic and some of thermosetting plastics the quantity of plastic production is much more than any other forming method Injection mold as one of the main toolsof injection molding processing whosh production efficiency is low or high in the quality of precision manufacturing cycle and the process of injection molding and so on directly affect the quality of products production cost and product updates at the same time it also determines the competitiveness of enterprises in the market s response capacity and speed Injection Mold consists of a number of plate which mass with the various component parts It divided into A molding device Die punch B positioning system I column I sets C fixtures the word board code pit D cooling system carrying water hole E thermostat system heating tubes the hotline F Road System jack Tsui hole flow slot streaming Road Hole G ejection system Dingzhen top stick 1 4 Type of mold It can be divided into three categories according to gating system with the different type of mold 1 intake die Runner and gate at the partig line it will strip together with products when in the open mode it is the most simple of design easy processing and lower costing So more people operations by using large intake system 2 small inlet die It general stay in the products directly but runner and gate are not at the partig line Therefore it should be design a multi outlet parting line And then it is more complex in the designing more difficult in processing generally chosing the small inlet die is depending on the product s requirements 3 hot runner die It consists of heat gate heat runner plate temperature control box Hot runner molds are two plate molds with a heated runner system inside one half of the mold A hot runner system is divided into two parts the manifold and the drops The manifold has channels that convey the plastic on a single plane parallel to the parting line to a point above the cavity The drops situated perpendicular to the manifold convey 3 the plastic from the manifold to the part The advantages of hot runner system 1 No outlet expected no need processing the whole process fully automated save time and enhance the efficiency of the work 2 small pressure loss 2 Injection Mold There are many rules for designing molds These rules and standard practices are based on logic past experience convenience and economy For designing mold making and molding it is usually of advantage to follow the rules But occasionally it may work out better if a rule is ignored and an alternative way is selected In some texts the most common rules are noted but the designer will learn only from experience which way to go The designer must ever be open to new ideas and methods to new molding and mold material that may affect these rules The process consists of feeding a plastic compound in powdered or granular form from a hopper through metering and melting stages and then injecting it into a mold Injection molding process Mold is a production of plastic tool It consists of several parts and this group contains forming cavities When it injects molding mold clamping in the injection molding machine melting plastic is Injected forming cavities and cooling stereotypes in it then it separate upper and lower die it will push the production from the cavity in order to leave the mold through ejection system finally mold close again and prepared the next injection The entire process of injection is carried out of the cycle An injection mold consists of at least two halves that are fastened to the two platens of the injection molding machine so that can be opened and closed In the closed position the product forming surfaces of the two mold halves define the mold cavity into which the plastic melt is injected via the runner system and the gate Cooling provisions in the mold provide for cooling and solidification of the molded product so that it can be subsequently ejected For product ejection to occur the mold must open The shape of the molded product determines whether it can be ejected simply by opening the two mold halves or whether undercuts must be present The design of a mold is dictated primarily by the shape of the product to be molded and the provisions necessary for product ejection Injection molded products can be 4 classified as 1 Products without undercuts 2 products with external undercuts of lateral openings 3 products with internal undercuts 4 products with external and internal undercuts 3 The composition of injection mold 3 1 Mold Cavity Space The mold cavity space is a shape inside the mold when the molding material is forced into this space it will take on the shape of the cavity space In injection molding the plastic is injected into the cavity space with high pressure so the mold must be strong enough to resist the injection pressure without deforming 3 2 Number of Cavities Many molds particularly molds for larger products ate built for only 1 cavity space but many molds especially large production molds are built with 2 or more cavities The reason for this is purely economical It takes only little more time to inject several cavities than to inject one Today most multicavity molds are built with a preferred number of cavities 2 4 6 8 12 16 24 32 48 64 96 128 These numbers are selected because the cavities can be easily arranged in a rectangular pattern which is easier for designing and dimensioning for manufacturing and for symmetry around the center of the machine which is highly desirable to ensure equal clamping force for each cavity 3 3 Cavity and Core By convention the hollow portion of the cavity space is called the cavity The matching often raised portion of the cavity space is called the core Most plastic products are cup shaped This does not mean that they look like a cup but they do have an inside and an outside The outside of the product is formed by the cavity the inside by the core Usually the cavities are placed in the mold half that is mounted on the injection side while the cores are placed in the moving half of the mold The reason for this is that all injection molding machines provide an ejection mechanism on the moving platen and the products tend to shrink onto and 5 cling to the core from where they are then ejected Most injection molding machines do not provide ejection mechanisms on the injection side For moulds containing intricate impressions and for multi impression moulds it is not satisfactory to attempt to machine the cavity and core plates from single blocks of steel as with integer moulds The cavity and core give the molding its external and internal shapes respectively the impression imparting the whole of the form to the molding 3 4 The Parting Line To be able to produce a mold we must have ta least two separate mold halves with the cavity in one side and the core in the other The separation between these plates is called the parting line and designated P L Actually this is a parting area or plane but by cinvention in this intext it is referred to as a line The parting surfaces of a mould are those portion of both mould plates adjacent to the impressions which butt together to form a seal and prevent the loss of plastic material from the impression The parting line can have any shape many moldings are required which have a parting line which lies on a non planar or curved surface but for ease of mold manufacturing it is preferable to have it in one plane The parting line is always at the widest circumference of the product to make ejection of the product from the mold possible With some shapes it may be necessary to offset the P L or to have it at an angle but in any event it is best to have is so that itan be easily machined and often ground to ensure that it shuts off tightly when the mold is clamped during injection If the parting line is poorly finished the plastic will escape which shows up on the product as an unsightly sharp projection which must then be removed otherwise the product could be unusable There is even a danger that the plastic could squirt out of the mold and do personal danger 3 5 Runners and Gates Now we must add provisions for bringing the plastic into these cavity spaces This must be done with enough pressure so that the cavity spaces are filled completely before the plastic freezes that is cools so much that the plastic cannot flow anymore The flow passages are the sprue from wherethe machine nozzle contactss the mold the runners which distribute the 6 plastic to the individual cavities the wall of the runner channel must be smooth to prevent any restriction to flow Also as the runner has to be removed with the molding there must be no machine marks left which would tend to retain the runner in the mould plate And the gates which are small openings leading from the runner into the cavity space The gate is a channel or orifice connecting the runner with the impression It has a small cross sectional area when compared with the rest of the feed system The gate freezes soon after the impression is filled so that the injection plunger can be withdrawn without the probability of void being created in the molding by suck back 4 The injection molding machine process Injection Mold is installed in the injection molding machine and its injection molding process is completed by the injection molding machine Following is the injection molding machine process The molding machine uses a vacuum to move the plastic from the dryer to it s initial holding chamber This chamber is actually a small hopper on the back of the barrel of the machine The barrel is where all the real work is done and it s essentially a large screw housed in a heater which moves the plastic closer to the mold As the screw turns the plastic traverses the barrel and reaches a molten state Only when it s molten can it be injected into the mold with a rapid turn of the screw As the chamber in front of the screw becomes filled it forces the screw back tripping a limit switch that activates a hydraulic cylinder that forces the screw forward and injects the fluid plastic into the closed mold The gate freezes soon after the impression is filled so that the injection plunger can be withdrawn without the probability of void being created in the molding by suck back The tip of the barrel is called the nozzle and from this point to the cavity in the mold the material is not heated and is constantly cooling The runner is the cooled set plastic that extends from the nozzle to the cavity and is process scrap Actually the cooled material from the nozzle to the mold is the sprue but it s connected to the runner There are ways around having sprues and runners but it s beyond the scope of what we re talking about here Most people have probably seen runners before and not realized it The most likely place to see them are in model airplane car kits as the individual components are left attached to the runner system Typically the 7 runners are ejected into a chute below the mold or else they will be picked out of the mold by a robotic arm and dumped into a regrinder The regrinder chops the runners into bits and prepares them to be moved back into the dryer Though once plastic has been heated it degrades a bit and some molding processes will not allow for regrind to be mixed back in with virgin material as it can cause problems with the final part In cases like this the regrind is used elsewhere or it is discarded completely Shrinkage plays a crucial role in molding and most plastic shrinks 20 as it cools In order to combat this phenomenon in critical plastic pieces not really toys it is up the mold designer to build this factor into his design so that the finished parts will meet the original product design specifications Ejector pins are part of the mold itself and are used to push the molded parts from the cavity once the mold is opened This ejecting process is controlled by the molding machine The molding cycle is basically close shoot open eject The mold is clamped into the machine with the front half remaining stationary on the barrel side of the machine and the back half being the movable half Also on this movable half are the ejector pins that push the molded parts from the cavity The parting surfaces of a mould are those portion of both mould plates adjacent to the impressions which butt together to form a seal and prevent the loss of plastic material from the impression When all molds open up the parts are stuck to the back half of the mold so that they can be ejected with the built in pins These are related to the introduction of the injection mold 注射模具的介紹 1 模具基本知識 1 1引言 我們?nèi)粘Ｉa(chǎn) 生活中所使用到的各種工具和產(chǎn)品 大到機床的底座 機身外殼 小到一個胚頭螺絲 紐扣以及各種家用電器的外殼 無不與模具有著密切的關(guān)系 模具 的形狀決定著這些產(chǎn)品的外形 模具的加工質(zhì)量與精度也就決定著這些產(chǎn)品的質(zhì)量 因 為各種產(chǎn)品的材質(zhì) 外觀 規(guī)格及用途的不同 模具分為了鑄造模 鍛造模 壓鑄模 沖壓模等非射膠模具 以及射膠模具 近年來 隨著射料工業(yè)的飛速發(fā)展和通用與工程 射料在強度和精度等方面的不斷提高 射料制品的應(yīng)用范圍也在不斷擴大 如 家用電 8 器 儀器儀表 建筑器材 汽車工業(yè) 日用五金等眾多領(lǐng)域 射料制品所占的比例正迅 猛增加 一個設(shè)計合理的射料件往往能代替多個傳統(tǒng)金屬件 工業(yè)產(chǎn)品和日用產(chǎn)品射料 化的趨勢不斷上升 1 2 模具的一般定義 在工業(yè)生產(chǎn)中 用各種壓力機和裝在壓力機上的專用工具 通過壓力把金屬或非 金屬材料制出所需形狀的零件或制品 這種專用工具統(tǒng)稱為模具 1 3 模具的一般分類 可分為射膠模具及非射膠模具 1 非射膠模具有 鑄造模 鍛造模 沖壓模 壓鑄模等 A 鑄造模 水龍頭 生鐵平臺 B 鍛造模 汽車身 C 沖壓模 計算機面板 D 壓鑄模 超合金 汽缸體 2 射膠模具根據(jù)生產(chǎn)工藝和 生產(chǎn)產(chǎn)品的不同又分為 A 注射成型模 電視機外殼 鍵盤按鈕 應(yīng)用最普遍 B 吹氣模 飲料瓶 C 壓縮成型模 電木開關(guān) 科學(xué)瓷碗碟 D 轉(zhuǎn)移成型模 集成電路制品 E 擠壓成型模 膠水管 射膠袋 F 熱成型模 透明成型 包裝外殼 G 旋轉(zhuǎn)成型模 軟膠洋娃娃玩具 注射成型是射料加工中最普遍采用的方法 該方法適用于全部熱射性射料和部分 熱固性射料 制得的射料制品數(shù)量之大是其它成型方法望塵莫及的 作為注射成型加 工的主要工具之一的注射模具 在質(zhì)量精度 制造周期以及注射成型過程中的生產(chǎn)效 率等方面水平高低 直接影響產(chǎn)品的質(zhì)量 產(chǎn)量 成本及產(chǎn)品的更新 同時也決定著 企業(yè)在市場競爭中的反應(yīng)能力和速度 注射模具是由若干塊鋼板配合各種零件組成 的 基本分為 A 成型裝置 凹模 凸模 B 定位裝置 導(dǎo)柱 導(dǎo)套 C 固定裝 置 工字板 碼?？?D 冷卻系統(tǒng) 運水孔 E 恒溫系統(tǒng) 加熱管 發(fā)熱線 F 流道系統(tǒng) 唧咀孔 流道槽 流道孔 G 頂出系統(tǒng) 頂針 頂棍 1 4 模具的類型 根據(jù)澆注系統(tǒng)型制的不同可將模具分為三類 1 大水口模具 流道及澆口在分 模線上 與產(chǎn)品在開模時一起脫模 設(shè)計最簡單 容易加工 成本較低 所以較多人 采用大水口系統(tǒng)作業(yè) 2 細水口模具 流道及澆口不在分模線上 一般直接在產(chǎn)品 上 所以要設(shè)計多一組水口分模線 設(shè)計較為復(fù)雜 加工較困難 一般要視產(chǎn)品要求 而選用細水口系統(tǒng) 3 熱流道模具 主要由熱澆口套 熱澆道板 溫控電箱構(gòu)成 熱流道模具是在一個半模有流道加熱系統(tǒng)的兩板式模具 熱流道系統(tǒng)分成兩個部分 分流板和噴嘴 分流板的通道將射料傳送到一個和分型線平行平面 這個平面在型腔 的上面 噴嘴垂直于分流板安裝 把射料從分流板送進行腔 熱流道系統(tǒng)的優(yōu)勢 1 無水口料 不需要后加工 使整個成型過程完全自動化 節(jié)省工作時間 提高工 作效率 2 壓力損耗小 9 2 注射模 設(shè)計模具有很多的規(guī)則 這些規(guī)則和標準的做法 都是基于邏輯 過往的經(jīng)驗 方便性 經(jīng)濟性 設(shè)計 模具制造 和成型 它通常的優(yōu)勢就是遵循規(guī)則 但有時候 它可能會做出更好的 如果一項方法是被忽視和另一種方法被選擇 在一些書中 最普 通的規(guī)則都會一一列出 而設(shè)計者設(shè)計的東西也僅僅是跟著以往的經(jīng)驗走而已 設(shè)計者 應(yīng)該研究出新的想法和方法 來進行新的成型和選擇模具材料 注射工藝過程就是從給料斗送進粉狀或粒狀的射料混合物 經(jīng)過定量區(qū)和熔化區(qū) 然后將其注射到模具型腔中 注射過程說明 模具是一種生產(chǎn)射料制品的工具 它由 幾組零件部分構(gòu)成 這個組合內(nèi)有成型模腔 注射時 模具裝夾在注射機上 熔融射 料被注入成型模腔內(nèi) 并在腔內(nèi)冷卻定型 然后上下模分開 經(jīng)由頂出系統(tǒng)將制品從 模腔頂出離開模具 最后模具再閉合進行下一次注射 整個注射過程是循環(huán)進行的 注射模至少是由裝在注射機的兩個壓板上的兩部分組成 以便可以開模和合模 在合模的時候 模具的兩半部分形成的產(chǎn)品成型表面是由射料熔體通過澆口和熱流道系 統(tǒng)注入模具型腔形成的 模具中冷卻的原則是產(chǎn)品要在模具中冷卻和凝固 以便隨后可 以脫模 隨著產(chǎn)品注射的完成 模具就必須開模 產(chǎn)品的形狀決定著它是否由模具兩部份簡 單地開?；蛴捎袀?cè)向分型來開模 模具的設(shè)計是由產(chǎn)品的形狀和產(chǎn)品開模的方式?jīng)Q定 的 注射成型的產(chǎn)品可以分為以下幾類 無側(cè)抽芯的產(chǎn)品 有側(cè)向開口的外側(cè)抽芯的產(chǎn)品 有內(nèi)側(cè)抽芯的產(chǎn)品 有外側(cè)抽芯和內(nèi)側(cè)抽芯的產(chǎn)品 3 注射模具的組成 3 1 型腔空間 型腔空間是在模具中的一個形狀 當(dāng)注射的材料充滿這個空間的時候 它就會呈現(xiàn) 出和型腔空間一樣的形狀 在注射成型時 射料是通過很高的壓力注射入型腔空間的 所以模具必須要足夠的堅固來抵抗注射的壓力 以防變形 3 2 型腔的數(shù)量 許多的模具 特別是較大產(chǎn)品的模具 僅僅只有一個模具型腔 但是也有許多的 模具 特別是比較大型的模具 都會有 2個或更多的型 究其原因就是它純粹的經(jīng)濟 性 它僅僅是注入多個型腔比注入一個型腔多花了一點的時間 今天 大多數(shù)的模具型 腔數(shù)量都是以這些數(shù)字為參考的 2 4 6 8 12 16 24 32 48 64 96 128 選擇這些數(shù) 字 偶數(shù) 的原因是為了在長方形區(qū)域內(nèi)布置型腔方便 這樣就有利于設(shè)計 定尺寸 10 加工制造和圍繞機器中心對稱 這種對稱分布對于保證每個型腔分配到相同的鎖模力 非常重要 3 3 型腔和型芯 按照習(xí)慣 腔空間的中空部分稱為型腔 與型腔空間所匹配的部分稱為型芯 大 部分射膠制品是杯形的 但這并不意味著它們看起來就像是一個杯 只是它們有一個 內(nèi)部和外部 產(chǎn)品的外部是由型腔形成的 而內(nèi)部是有由型芯形成的 通常情況下 型 腔是位于注射一邊的那半模具上 而型芯是位于可以移動的那半模具上的 這樣安排的 原因是注射機上的移動板有一個彈射裝置 而產(chǎn)品是收縮和包緊在型芯上的 然后產(chǎn)品 就可以通過此來彈射出來 大部分的注射機在注射的一邊都不會安裝彈射裝置 對于模具包含復(fù)雜型腔和多型腔模具 試圖象整體模具那樣在一塊鋼板加工型腔 和型芯是不讓人滿意的 型腔和型芯分別決定著成型的外部和內(nèi)部的形狀 而它們的整 體決定著整個成型的方式 3 4 分模線 為了能夠生產(chǎn)出一個模具 我們必需具備有兩個分半的模具 一半裝型腔一半裝型 芯 這兩個板分離時的部分叫做分模線 簡稱 P L 其實 這是一個分離的區(qū)域或面 但 是為了方便 我們習(xí)慣叫它成一條線 模具的分型面是兩模板接近型腔的那些部分 它們對接一起形成油封并且避免型腔里射性材料的損失 分模線可以是任何形狀的 許多的注射成型都是要求分模線是不在同一平面或是曲面的 但是為了便于模具制造 最好設(shè)計在同一個平面上 為了能夠在模具上脫出產(chǎn)品 分模線總是在分布在產(chǎn)品最寬 的圓周區(qū)域 對一些形狀來說 設(shè)置分模線或其角度是非常有必要的 但是在任何情 況下 都要有目的地讓它容易加工 以確保當(dāng)注射的時候模具能夠緊緊地合在一起 如果分模線設(shè)計不好 射料將會溢出來 那樣產(chǎn)品就會有一個非常大的凹陷 那樣的產(chǎn)品 肯定會被拆除 否則那樣的產(chǎn)品是不能夠使用的 甚至更危險的是 射料噴射進模具的 時候 它會飛濺出傷害到人本身 3 5 流道和澆口 現(xiàn)在 增加介紹的是把射料從外面帶到型腔空間的裝置 在射料冷卻之前 也就是 射料冷卻后不能在流動之前 它必需有足夠的壓力以便使射料能夠充滿型腔 流動的 通道就是流道 它把注射機的噴嘴和模具連接了起來 流道是一個獨立的型腔 流道本 身要光滑 以便可以阻止射料自由流動 同時 型腔被充滿后 澆口處先凝固 注射機 螺桿抽回時可防止成型中的回流 澆口是一個小型的開口 它引導(dǎo)著流道到型腔空間 澆口是一個渠道 是連接與流道相通的小口 與其他的進料系統(tǒng)相比 它有一個很小的 橫截面積 在射料充滿型腔后 澆口很快就會冷卻 注射的噴嘴往后退 在模具退后的時 候射料還是留有在噴嘴中的 11 4 注射機的工作過程 注射模具是安裝在注射機上的 它的注射成型過程是由注射機來完成的 以下是 注射機的工作過程 注射成型機通過抽真空把射料原料從干燥機吸到料斗里面 料斗 實際上是一個小的漏斗 它被安裝在機臺料筒的后面 開始起實際作用的地方是料筒 料筒實質(zhì)上是四周都是加熱器的一個很大的螺桿安放室 它把原料送向模具 隨著螺 桿的旋轉(zhuǎn) 原料在料筒里前進并成為熔融狀態(tài) 只有完全熔融后 原料才會在螺桿高 速旋轉(zhuǎn)產(chǎn)生的擠壓力下射進模腔 當(dāng)螺桿前端壓室注滿射料時 螺桿被迫后退 斷開 限位開關(guān)而開動液壓缸 從而向前推動螺桿 將熔融射料注射到閉合的模具型腔中 型腔被充滿后 澆口處先凝固 注射機螺桿抽回時可防止成型中的回流 螺桿端部稱 為噴嘴 從這里開始直到模具型腔這段空間內(nèi) 熔融材料沒有被加熱 并且一直處于 被冷卻的狀態(tài) 流道水口料就是在噴嘴到模腔之間冷卻固化的射料 屬于工藝廢料 實際上 在噴嘴到模腔之間的冷卻射料是 主流道 但它和流道是連在一塊的 有 一些關(guān)于處理水口料的方法 但這不是我們這里要討論的 大多數(shù)人以前都見過流道 但卻沒有認出 最容易見到他們的地方是由單獨零件構(gòu)成的飛機和汽車模型上 在這 些零件上面一般都附著著流道系統(tǒng) 一般地 水口料被頂出 落進安放在模具下面的 落料裝置 通過一個斜坡傳送通道 或者被機械手取出 然后投入粉料機 粉料機 把水口料絞成碎料并送回干燥機 盡管塑料一旦被加熱就會發(fā)生降解 而且有些成型工藝不允許碎材混入原材料里 面 因為這樣會導(dǎo)致成品的缺陷 這種情況下水口料可以用到其他地方或者干脆不用 收縮在成型中影響深遠 大部分塑料冷卻后會收縮 20 為了在重點 關(guān)鍵 塑料零件 上 當(dāng)然不只是玩具 克服這種現(xiàn)象 模具設(shè)計者必須把這個要素考慮到設(shè)計里面去 那樣成型出來的產(chǎn)品才能滿足設(shè)計規(guī)格 頂針是模具本身的零件 用來在模具打開的 時候頂出產(chǎn)品 整個過程都有注射成型機控制 一個成型周期實際上就是合模 注射 開模 頂出 模具被鎖緊在機臺上 前模固定不動 在機臺的料筒側(cè) 后模則可以 移動 上面說的頂針就是后模側(cè) 當(dāng)模具打開 產(chǎn)品吸附在后模側(cè)以被頂出 以上就是關(guān)于注射模具的相關(guān)介紹