injection molding guideline——注塑成型指南【中英文對照】

1、<p>　　Injection Molding Guideline——注塑成型指南【中英文對照】</p><p>　　Injection Molding Guideline</p><p>　　1. Plastic Material</p><p>　　Assume the general purpose grade plastic materials t

2、o be used for our molding</p><p>　　In case of special grade materials, please list the material grade & brand on our tool plan</p><p>　　All the plastic materials for molding must be same as

3、the materials during development stage. </p><p>　　In case of material shortage or cost issue, the new sourced material shall be tested and confirmed acceptable prior use.</p><p>　　2. Colorant<

4、;/p><p>　　All the colorant must be conformed to heavy elements directives for both ASTM F963 & EN71.</p><p>　　Most of the dry pigments are hygroscopic; they must be properly sealed after use. &

5、lt;/p><p>　　For the components with high color consistence, the masterbatches or pre-color plastic materials are required.</p><p>　　3. Regrind Material Ratio</p><p>　　For plastic mater

6、ial on structural components, no regrind is allowed</p><p>　　For general purpose material on non structural components, 20% maximum runner regrind can be blended with virgin material.</p><p>　　F

7、or those translucent or true white color components, no regrind is allowed.</p><p>　　For short glass filled materials, 15% maximum regrind can be blended with virgin material</p><p>　　For long g

8、lass filled materials, no regrind is allowed. </p><p>　　The maximum number of regrind passes for general purpose materials shall be 3.</p><p>　　Only 1 time of regrind pass is allowed for short g

9、lass reinforced materials</p><p>　　The regrind ratio shall be shown in our updated tool plan to follow.</p><p>　　The regrind ratio and no. of regrind passes has to be validated and confirmed dur

10、ing development stage. If not, no regrind will be allowed.</p><p>　　Burned or discolored sprues or parts must not be used as regrind.</p><p>　　Hot nozzle & hot runner is our preference to el

11、iminate runner scrap.</p><p>　　4. Material Drying</p><p>　　Most plastic resins require thorough drying prior injection molding to assure maximum properties in the molded parts. Below table pleas

12、e find the recommended drying temperature & duration for reference:</p><p>　　For those hygroscopic materials, the dehumidifying hopper dryer with closed-loop air circulating system is required to ensure

13、acceptable moisture content to be achieved during molding.</p><p>　　For those non-hygroscopic materials, the regrind have to be dried as 80ºC for 2 hours to prevent surface blemishes due to volatiles, s

14、uch as PE, PP, POM, HIPS.</p><p>　　5. Screw Design</p><p>　　For most of un-filled plastic, standard screw with L / D ratio 22:1 is recommended</p><p>　　For glass reinforced plastic,

15、 screw with lower L / D ratio 20:1 is recommended</p><p>　　Bi-metallic screw and barrel are required for glass reinforced plastic to have higher wear assistance</p><p>　　6. Molding Machin </p

16、><p>　　e & Accessories Selection </p><p>　　The distance between two columns (Horizontal) shall be 10mm minimum longer than the mold width</p><p>　　For non engineering or unfilled p

17、lastic resin, up to 90% rated barrel capacity shall be utilized.</p><p>　　For engineering and all glass filled plastic resin, up to 70% rated barrel capacity shall be utilized.</p><p>　　For clam

18、ping tonnage consideration, the multiple of projectile area and fill pressure should be up to 90% of rated clamping tonnage of machine. However, the actual requirement will be depended upon the wall thickness, parts geom

19、etry and gate design. Below table please the fill pressure factor for common use plastic for reference.</p><p>　　The minimum tonnage for mold size shall be put to Machine Size column on Tool Plan</p>

20、<p>　　For high precision parts & optical lens, electric molding machine is preferred.</p><p>　　Automatic parts / sprue removal system should be installed for 220 ton or above molding machines</p&

21、gt;<p>　　Hopper loader should be installed for 220 tons or above machines</p><p>　　Proportional type hopper loader should be used for the molding with instant runner scrap recycling.</p><p&

22、gt;　　Hopper magnet shall be equipped for all material hoppers.</p><p>　　7. Mold Clamping </p><p>　　For machine capacity up to130 tons, all molds can be clamped onto machine platens by either cla

23、mping slots or mounting holes.</p><p>　　For machine capacity more than130 tons, all molds can only be clamped onto machine platens by clamping slots. </p><p>　　Always use appropriate clamping to

24、nnage for clamping, 10% higher than the theoretical clamping tonnage as section 6d). Excessive clamping pressure will ruin the molds, especially on weak parting line areas.</p><p>　　Jiffy type plugs and conn

25、ectors are preferred to speed up set-up time.</p><p>　　All Eyebolts must be removed before molding start in order not to interfere any mechanical movement</p><p>　　The Hoist Ring type is preferr

26、ed to prevent accidents caused by traditional eyebolt failure</p><p>　　8. Mold Cooling </p><p>　　All cooling lines must be connected to water manifold of machines as per indication of mold drawi

27、ng</p><p>　　The water temperature difference between inlet and outlet shall be less than 5º C.</p><p>　　Correct mold temperature shall be maintained for different materials to obtain good a

28、esthetic and mechanical properties</p><p>　　Appropriate mold temperature should be depended upon the wall thickness, aesthetic requirement and flow length to thickness ratio (L/T). Below table please find re

29、commended mold temperature for most common materials:</p><p>　　9. Molding Process Parameter </p><p>　　Set barrel heaters to ramp profile, lower at the </p><p>　　feed throat and high

30、er at front zone. Below table please find the recommended temperature range for reference: </p><p>　　Set the injection to lower limit and add gradually to obtain good parts</p><p>　　Set the inje

31、ction speed to high for crystalline material and medium for amorphous materials.</p><p>　　Set holding pressure and time to zero.</p><p>　　Start making short shots without any cushion, the increm

32、entally increase shot volume until the part is approximately 95% full. This becomes the transfer point (time). Begin weighing parts.</p><p>　　Set the packing pressure 30% to 40% below first stage pressure an

33、d continue weighing parts (normally uses only 1 – 3 seconds pack time). Increase shot volume until a cushion is developed. Incrementally increase pack time until part weight does not increase. At this point, gate freeze-

34、off has been reached.</p><p>　　Set the back pressure low but ensure to displace trapped air in the screw feed section and good melt homogeneity. For glass filled plastic, the recommended pack pressure should

35、 be 20 – 50 PSI to prevent glass breakage.</p><p>　　Set the cooling time to permit the parts to be ejected without the ejector pins marks or pushing into the parts.</p><p>　　The molding set-up s

36、heet for every mold must be well documented and attached to molding machine for review during molding.</p><p>　　10. Cycle Time </p><p>　　Below table please find our expected quoting cycle time f

37、or different parts category and machine size:</p><p>　　The cycle time for all tooling will be finalized after verification by our tooling engineer during FEP stage. </p><p>　　The limited conditi

38、on that keeps the molds from being run at a lower cycle time has to be specified in quotation and mold drawing approval stage, such as wall thickness, aesthetics, dimensional tolerance or components design.</p>&l

39、t;p>　　11. Mold Releasing Agent </p><p>　　During first shot and EP stages, the mold rel </p><p>　　easing agent can be applied when parts’ sticking occurs. </p><p>　　During FEP and

40、 PP stages onwards, no mold releasing agent is allowed.</p><p>　　All mold releasing agent must be non-toxic and CFC - free aerosols</p><p>　　12. Second Operation </p><p>　　The fixtu

41、re materials shall be made of Phenolic, Aluminum, coated steel or those materials with high resistance to worn-out and corrosiveness.</p><p>　　All the fixtures must be calibrated daily and once molding start

42、.</p><p>　　No breakable knife or tools are allowed for degating and flashing trimming</p><p>　　13. Process Control </p><p>　　The signed shot sample and components’ specification sha

43、ll be attached to machine for routine quality check by quality inspector or molding supervisor prior molding start.</p><p>　　The molded color, aesthetics and critical dimensions shall be inspected and confir

44、med acceptable by quality inspector prior molding start.</p><p>　　Bi-hourly process inspection shall be conducted to verify aesthetics and functional requirements</p><p>　　Critical dimensional c

45、heck has to be performed for every 4 hours or first and last shot for every shift. </p><p>　　The shot sample should be stored in an air-conditioned environment for at least 1 hour before dimensional check.&l

46、t;/p><p>　　Final inspection check shall be performed for every shift prior dispatch to further manufacturing process or storage.</p><p>　　Date code label shall be adhered to every outgoing lot for

47、quality tracking.</p><p>　　14. Mold Maintenance</p><p>　　The mold surface and vents shall be routinely cleaned to eliminate the air trapped & worn-out problems, once for every shift molding.

48、 For the volatile materials, such as Polyacetal or PVC, the mold surface or vents shall be cleaned for every 4 hours molding. </p><p>　　The molds, which are in continuous molding, should be dismantled for pr

49、eventive maintenance, proper cleaning and lubricating on ejector pins, slides, and bushings, etc., once for every week.</p><p>　　For those tailor made spare parts & hot runner consumable components, the

50、safety inventory should be maintained to cover 2 times of lead-time for replenishing.</p><p>　　In case the actual number of shot exceeds our committed tool life as per our Tool Standard, LeapFrog will be res

51、ponsible for expense for normal mold repair, except the carelessness from operator or poor molding practice. Moreover, the quotation must be approved prior mold repair start.</p><p>　　After any mold is repai

52、red as section 14d, the tool life should be increased at least by 20% of committed tool life, 100K shots for injection mold and 60K shots for blow & die casting molds. </p><p>　　Appropriate mold repair m

53、achineries & facilities is required for daily repair & maintenance.</p><p>　　The Copper electrodes for all molds shall be identified and properly storage </p><p>　　15. Shutdown Procedure

54、s </p><p>　　When any molds becomes necessary to halt molding for a period of time, the barrel temperature shall be lower down or the cylinder should be purged at regular intervals to prevent material degrada

55、tion, especially for Polyacetal, PVC, flame retardant or temperature sensitive materials.</p><p>　　And, the water sh </p><p>　　all also be turned off prior to last 30 shots such that the steel w

56、arms up to prevent condensation forming on mold inserts. </p><p>　　The completion of molding run, all traces of compound should be thoroughly purged from barrel with HDPE, PP, Acrylic, Polycarbonate, General

57、 Purpose Styrene or commercially available purging compounds.</p><p>　　And, the mold shall be thoroughly cleaned and then coated with rust preventive spray or grease.</p><p>　　16. Tool Plan Upda

58、ting </p><p>　　The actual number of shots for all active items shall be updated on Tool Plan for every 3 months</p><p>　　The actual number of shots for all inactive items shall be updated on Too

59、l Plan for every year </p><p>　　17. Injection Molding Trouble – Shooting</p><p><b>　　注塑成型指南</b></p><p>　　(中文版僅供參考, 以英文版為準)</p><p><b>　　1. 塑膠原料</b&g

60、t;</p><p>　　我們的注塑生產(chǎn)一般使用通用等級的塑膠料</p><p>　　如果需要用到特殊等級的塑料, 請在我們的tool plan中列出該膠料的資料</p><p>　　所有生產(chǎn)中使用的膠料必須與開發(fā)階段所用的膠料一致</p><p>　　如果遇到原料短缺或成本問題, 新找到的原料在使用前應(yīng)該通過測試并確認它是可接受的</

61、p><p><b>　　2. 色粉</b></p><p>　　所有的色粉應(yīng)該符合ASTM963 和EN71中關(guān)于重金屬的指示</p><p>　　大多數(shù)的干色粉是吸水的(易受潮), 使用后必須適當?shù)孛芊?lt;/p><p>　　對于顏色的一致性要求高的零件, 要求使用色母料或者預(yù)先混色的膠料</p><p&

62、gt;<b>　　3.再生料的比率</b></p><p>　　用于結(jié)構(gòu)件的膠料, 不允許使用再生料(翻打料)</p><p>　　用于非結(jié)構(gòu)件的一般用途的膠料, 允許最多20%的水口再生料(翻打料)與原料混合, 用于注塑生產(chǎn)</p><p>　　透明件或者純白色零件不允許用再生料</p><p>　　短玻璃纖維填充膠料

63、, 允許最多15%的再生料與原料混合</p><p>　　長玻璃纖維填充膠料, 不允許用再生料</p><p>　　通用膠料最多允許翻打3次 </p><p>　　所有的玻璃纖維填充膠料只能翻打1次</p><p>　　再生料的使用比率應(yīng)該在更新的tool plan 中顯示出來</p><p>　　再生料的使用比率和翻

64、打次數(shù)必須在開發(fā)階段得到驗證和確認, 否則將不允許使用再生料</p><p>　　燒焦或污染的水口或零件一定不能用作再生料</p><p>　　熱唧咀或熱流道是我們的優(yōu)先選擇用于消除水口廢料</p><p><b>　　4. 材料烘干</b></p><p>　　大多數(shù)塑膠樹脂要求徹底烘干以保證零件有最好的性能. 下表是

65、推薦的干燥溫度和時間</p><p>　　對于那些吸濕性的塑料, 要求帶閉環(huán)式循環(huán)空氣系統(tǒng)的除濕料斗干燥器, 以保證注塑期間膠料中的水分是可接受的</p><p>　　對于非吸濕性的塑料,比如PE, PP, POM和HIPS, 再生料必須在80ºC干燥2小時以消除由于揮發(fā)性物質(zhì)造成的表面瑕疵</p><p><b>　　5. 螺桿設(shè)計</b

66、></p><p>　　對于大多數(shù)非填充塑料, 推薦用L/D 比率為22:1的標準螺桿</p><p>　　對于玻纖增強塑料, 推薦用20:1的更低的L/D比率的螺桿</p><p>　　對于玻纖增強塑料, 為了更好的防止磨損, 要求用雙合金螺桿和料筒</p><p><b>　　6. 注塑機的選擇</b><

67、/p><p>　　兩條水平導(dǎo)柱之間的距離(tie bar)應(yīng)該比模具的寬度最少寬10mm</p><p>　　對于非工程或非填充塑料, 應(yīng)該使用額定料筒容量的90%以內(nèi)</p><p>　　對于工程或玻纖填充塑料, 應(yīng)該使用額定料筒容量的70%以內(nèi)</p><p>　　對于鎖模噸數(shù)的考慮, 零件的投影面積與填充壓力的乘積應(yīng)該在機器額定鎖模噸數(shù)的9

68、0%以內(nèi), 然而, 實際的要求將取決于零件壁厚, 幾何形狀和入水的設(shè)計. 下表列出了一些通用塑料的填充壓力系數(shù)供參考</p><p>　　在Tool Plan的機器大小一欄中應(yīng)填入模具可用的最小注塑機的噸數(shù)</p><p>　　對于高精密的零件和光學(xué)鏡片, 更好地選擇電動注塑機</p><p>　　對于220噸或以上的注塑機, 應(yīng)該使用機械手, 自動從模具移出零件和

69、水口</p><p>　　對于220噸或以上的注塑機, 應(yīng)該配備供料器</p><p>　　對于配有實時水口料再生裝置的注塑機, 應(yīng)該使用比例式供料器</p><p>　　料斗磁石應(yīng)該被裝備于所有材料的料斗</p><p><b>　　7. 模具鎖模方法</b></p><p>　　對于130噸以

70、內(nèi)的注塑機, 模具可以通過碼?？踊蛘咄ㄟ^安裝孔鎖緊在注塑機的模板上</p><p>　　對于130噸以上的注塑機, 模具只能通過碼模坑鎖緊在注塑機的模板上</p><p>　　總是用適當?shù)逆i模力來鎖緊模具, 比第6節(jié)d中所要求的理論鎖模力高10%. 過大的鎖模力將損壞模具, 特別是較弱 </p><p><b>　　的分型面區(qū)域 </b><

71、;/p><p>　　為了縮短模具裝上機器的時間, 應(yīng)優(yōu)先選擇帶快插的冷卻水管</p><p>　　為了避免與任何機械運動相干涉, 在開始注塑前應(yīng)取下所有的吊環(huán)螺栓</p><p>　　起重環(huán)是更好的選擇用于防止由于傳統(tǒng)的吊環(huán)螺栓失靈造成的事故</p><p><b>　　8. 模具的冷卻</b></p><

72、;p>　　所有的冷卻通道應(yīng)該根據(jù)模圖的指示連接到提供冷卻水的分水器上</p><p>　　入口和出口的溫差應(yīng)少于5º C</p><p>　　為了提供好的外觀和機械性能, 不同的塑料應(yīng)保持正確的模溫</p><p>　　合適的模溫應(yīng)該取決于零件的壁厚, 外觀要求和流動長度與厚度的比率. 下表是最常用材料所推薦的模溫</p><p&

73、gt;<b>　　9. 注塑加工參數(shù)</b></p><p>　　設(shè)置料筒發(fā)熱器的溫度逐級遞升, 在入口段低而在料筒的前段高. 下表是推薦的料筒溫度范圍供參考.</p><p>　　設(shè)置較低限度的射膠壓力, 然后逐漸增加以提供好的零件</p><p>　　對于結(jié)晶型材料應(yīng)設(shè)置較高的射膠速度, 對于非結(jié)晶型材料應(yīng)設(shè)置中等的射膠速度</p&g

74、t;<p>　　設(shè)置保壓壓力和時間為零</p><p>　　開始不用任何儲料池(cushion)做短射, 然后逐漸增加射膠量直到充滿零件的約95%, 設(shè)置轉(zhuǎn)換點(時間), 開始零件的稱重</p><p>　　設(shè)置保壓壓力低于第一階段壓力的30%-40%, 繼續(xù)零件的稱重(通常只用1-3秒的保壓時間). 增加射膠量直到形成儲料池(cushion), 逐漸增加保壓時間直到零件的重

75、量不再增加, 此時,入水口已經(jīng)凍結(jié)</p><p>　　設(shè)置低的背壓, 但確保排除在進料段內(nèi)的空氣以及有好的熔融均勻性. 對于玻纖填充塑料, 推薦用20-50PSI的背壓防止玻纖破壞</p><p>　　設(shè)置冷卻時間, 允許零件在沒有頂白或頂穿零件的條件下被頂出</p><p>　　每副模具的設(shè)置參數(shù)表應(yīng)該被很好做成文件并附帶在注塑機旁供啤塑期間查看</p&g

76、t;<p><b>　　10. 注塑周期</b></p><p>　　下表請找到對于不同的零件和機器大小, 我們所期望提供的注塑周期</p><p>　　所有模具的注塑周期經(jīng)過LeapFrog的模具工程師在FEP階段確認后將被最后定下來</p><p>　　保持模具運行在較低注塑周期的一些限制條件必須在報價和模圖批準階段被指定下來

77、, 比如零件的壁厚, 外觀, 尺寸公差或者零件的設(shè)計</p><p>　　11. 脫模劑的使用</p><p>　　在first shot 和EP階段, 發(fā)生粘模問題時可使用脫模劑, 但脫模劑必須是無毒的, 不含氯氟烴(一種破壞臭氧層的物質(zhì))</p><p>　　在FEP和PP階段以后, 不允許使用脫模劑</p><p><b>　

78、　12. 二次工序</b></p><p>　　夾具應(yīng)該用酚醛樹脂, 鋁, 鍍層鋼板, 高防磨性或防腐蝕性的材料</p><p><b>　　每天以 </b></p><p>　　及開始注塑生產(chǎn)前, 所有的夾具必須被校準 </p><p>　　不允許易斷的刀片或工具用于剪水口和批鋒</p>&l

79、t;p><b>　　13. 過程控制</b></p><p>　　在開始注塑生產(chǎn)前, 簽辦和零件規(guī)格應(yīng)該附帶在機器旁供質(zhì)量檢查員或注塑主管日常的質(zhì)量檢查</p><p>　　在開始注塑生產(chǎn)前, 零件的顏色, 外觀和關(guān)鍵尺寸由質(zhì)檢員檢測并確認可接受的</p><p>　　每兩小時一次的檢測應(yīng)該被執(zhí)行, 用于核實外觀和功能要求</p&g

80、t;<p>　　關(guān)鍵尺寸必須每四小時檢查一次或者檢查每次換班的頭尾的膠件</p><p>　　啤塑的零件在做尺寸檢查前應(yīng)該在空調(diào)環(huán)境中最少存放一小時</p><p>　　在發(fā)出到其它的制造工序之前, 每個班都應(yīng)該做最后的檢測</p><p>　　為了質(zhì)量追蹤, 日期代碼貼紙應(yīng)該貼在每個發(fā)出的批次上</p><p><b&g

81、t;　　14. 模具保養(yǎng)</b></p><p>　　模具表面和排氣應(yīng)該作例行清潔以消除困氣和磨損問題. 每班一次. 對于不穩(wěn)定的材料, 比如Polyacetal 或者 PVC, 模具表面和排氣應(yīng)該每四小時清潔一次</p><p>　　對于連續(xù)啤塑的模具, 應(yīng)該拆下進行預(yù)防性保養(yǎng), 每周一次對頂針, 行位以及導(dǎo)邊等進行清潔和潤滑</p><p>　　對于

82、那些自制的模具配件以及熱流道的消耗件, 應(yīng)該保持足夠的安全庫存以維持在配件交貨期兩倍長的時間內(nèi)的生產(chǎn)</p><p>　　如果實際的啤件數(shù)量超過我們的模具標準所要求的模具壽命, LeapFrog將負責正常的模具維修費用, 但不包括工人的疏忽以及不良注塑習(xí)慣造成的模具損壞, 而且, 在模具維修前, 報價必須得到批準.</p><p>　　任何模具如第14d節(jié)維修之后, 模具壽命應(yīng)該增加最少2

83、0%(塑膠模100K啤, 吹塑模與壓鑄模60K啤), 最終增加的模具壽命應(yīng)該經(jīng)過LeapFrog的模具工程師核實并確認</p><p>　　適當?shù)哪＞呔S修工具和設(shè)備是要求的, 用于日常的模具維修和保養(yǎng)</p><p>　　所有模具的銅公應(yīng)該被標識并適當?shù)谋４?lt;/p><p><b>　　15. 停工程序</b></p><p

84、>　　當任何模具必須終止啤塑一段時間時, 料筒的溫度應(yīng)該降下來或者每隔一段時間清除一次, 特別對Polyacetal, PVC, 含阻燃劑或?qū)囟让舾械牟牧?lt;/p><p>　　冷卻水應(yīng)該在最后30啤前被關(guān)閉, 以便模具有足夠熱量來防止內(nèi)模上凝結(jié)水珠</p><p>　　注塑完成后, 所有的殘留物應(yīng)該用HDPE, PP, Acrylic, Polycarbonate, 通用的苯乙烯或

85、市面上出售的清洗劑徹底從料筒清除</p><p>　　模具應(yīng)該徹底清潔, 然后涂上防銹劑或防銹油</p><p>　　16. 更新Tool Plan</p><p>　　每三個月應(yīng)該在Tool Plan中更新所有活動項目的實際啤塑次數(shù)</p><p>　　每年應(yīng)該在Tool Plan中更新所有非活動項目的實際啤塑次數(shù)</p>&