塑料模科学试模法

1810.91880223.861.111111169202721.041730223.490.961538179923631.171666222.820.85470119492.24541.351570220.70.740741211955451.581475218.350.632911233056352.011332216.140.49751226773.27242.91142213.130.344828331188154.55975212.50.2197844362.59101112ShearRate剪切率(1/FT)Viscosity粘度(hpsixFTx10)In-MoldRheologytoDetermineFillRateGeneralinformation:通用信息ToolTemp(°C):模温Machineinformation:设备信息Melttemp(°C):熔融温度Sumitomo350T288mm63mm*PressManufacture/Tonnage:注塑机/吨位205C115-80C214.42Maxinjectionpressure(psi):最高注塑压力Barrelsize(stroke,mm):炮筒尺寸（冲程）Barrelsize(diameter,mm):炮筒尺寸（直径）Maxinjectionspeed(mm/sec):最高注塑速度Pressure@TransferPlastic(ppsi)切换压力Screwlength(mm):螺杆长度*Screwdesign:螺杆设计InjectionSpeed注塑速度PartWeight零件重量(g)Fillonlypartweight(g):零件重量（刚填充满）288mmcommon,L/D=288/6390mm/sec150barhydr.FillTime填充时间(FT)BreakPoint:2.01169201799219492.2211952330526773.23311844362.50500010000150002000025000300003500040000450005000000.20.40.60.811.2BreakPoint:拐点2.01Procedure:1.)Loadthetool上模12.)Plottheviscosityvs.shearrate绘制粘度V剪切率曲线13.)Onceacurvehasbeencreated,pickalocationatwhichthecurvebeginstobreak(flatten)找出曲线的拐点（趋于平缓部分）14.)Markthislocationinthecelltitled'breakpoint'标注此位置为拐点并填入breakpoint表格7.)Recordthe'FillTime','PeakTransferPressure'andpartweightinspreadsheetalongwiththecorrespondinginjectionspeed记录各个注塑速度对应下的填充时间、峰值切换压力、零件重量；8.)Onsuccessiveshotsdecreasetheinjectionspeedinnominalincrements按预定的步长逐步减小注塑速度9.)Recordthefilltime,pressureattransferandweightaftereveryadjustment记录每一步的填充时间、切换压力和重量10.)Repeatthisprocedureuntiltheinjectionspeedistooslowtofillthepart重复上述步骤，直到注塑速度慢到无法充满产品11.)Calculateviscosityandshearrate(calculationsareinthespreadsheet)计算粘度和剪切率（计算方式见左表）2.)Establishaprocesstheyieldsacompletepartandruntooluntilitreachesequilibriumtemperature热机直到温度稳定3.)Verifymelttemperaturebutmeasuringthetemperatureofanairshotincycle通过空射确认熔融温度4.)Beginbysettingpackandholdtimesto0andtheinjectionspeedtothemachinemaximum设定保压压力和保压时间为0；注塑速度设为机台最高速；5.)Nextestablishthetransferpoint(1ststagecut-off)thatyieldsa95%-98%fullpart(s)设置转换点为产品饱和度95~98%（一段射较）6.)Set1ststageandtotalinjectiontimerto10sec设置总注射时间计时器为10s；15.)Thisvalueshouldbeusedastheoptimuminjectionvelocity这个值将作为最优的注塑速度1.2系列1取点举例：12.)Plottheviscosityvs.shearrate绘制粘度V剪切率曲线13.)Onceacurvehasbeencreated,pickalocationatwhichthecurvebeginstobreak(flatten)找出曲线的拐点（趋于平缓部分）14.)Markthislocationinthecelltitled'breakpoint'标注此位置为拐点并填入breakpoint表格7.)Recordthe'FillTime','PeakTransferPressure'andpartweightinspreadsheetalongwiththecorrespondinginjectionspeed记录各个注塑速度对应下的填充时间、峰值切换压力、零件重量；8.)Onsuccessiveshotsdecreasetheinjectionspeedinnominalincrements按预定的步长逐步减小注塑速度9.)Recordthefilltime,pressureattransferandweightaftereveryadjustment记录每一步的填充时间、切换压力和重量10.)Repeatthisprocedureuntiltheinjectionspeedistooslowtofillthepart重复上述步骤，直到注塑速度慢到无法充满产品11.)Calculateviscosityandshearrate(calculationsareinthespreadsheet)计算粘度和剪切率（计算方式见左表）2.)Establishaprocesstheyieldsacompletepartandruntooluntilitreachesequilibriumtemperature热机直到温度稳定3.)Verifymelttemperaturebutmeasuringthetemperatureofanairshotincycle通过空射确认熔融温度4.)Beginbysettingpackandholdtimesto0andtheinjectionspeedtothemachinemaximum设定保压压力和保压时间为0；注塑速度设为机台最高速；5.)Nextestablishthetransferpoint(1ststagecut-off)thatyieldsa95%-98%fullpart(s)设置转换点为产品饱和度95~98%（一段射较）6.)Set1ststageandtotalinjectiontimerto10sec设置总注射时间计时器为10s；15.)Thisvalueshouldbeusedastheoptimuminjectionvelocity这个值将作为最优的注塑速度Cavity1Cavity2Cavity3Cavity4RunnerShot#114833bar116.2116.27232.47Shot#214833bar116.11116.24232.35Shot#314833bar116.05116.21232.26Shot#116833bar116.87116.91233.78Shot#216833bar116.93116.98233.91Shot#316833bar116.92116.95233.87Shot#118833bar117.68117.68235.36Shot#218833bar117.65117.69235.34Shot#318833bar117.65117.7235.35Shot#120833bar118.18118.28236.46Shot#220833bar118.18118.21236.39Shot#320833bar118.27118.41236.68Shot#122833bar118.43118.51236.94Shot#222833bar118.41118.44236.85Shot#322833bar118.53118.52237.05Shot#124833bar118.56118.58237.14Shot#224833bar118.62118.57237.19Shot#324833bar118.55118.56237.11Cavity1Cavity2Cavity3Cavity4RunnerShot#122714bar118.83118.87237.7Shot#222714bar118.81118.86237.67Shot#322714bar118.77118.83237.6Shot#122761bar119.12119.11238.23Shot#222761bar119.15119.14238.29Shot#322761bar119.17119.09238.26Shot#122809bar119.21119.26238.47Shot#222809bar119.27119.27238.54Shot#322809bar119.27119.29238.56Shot#122856bar119.42119.52238.94Shot#222856bar119.45119.54238.99Shot#322856bar119.43119.51238.94GateFreezeStudy浇口封闭时间研究PackingWeightStudy保压压力研究PartWeight产品重量Pack/HoldTime保压时间PackingPressure保压压力Totalw/oRunnerPack/HoldTime保压时间PackingPressure保压压力PartWeight产品重量Totalw/oRunnerexample:8sec99.28-10=.90%10sec100.110-12=.10%12sec100.210-12.25%souse10secexample:650psi99.28-10=.90%750psi100.110-12=.10%850psi100.2750-850.25%souse750psiGateFreezeStudy浇口封闭时间研究Continueincreasingtimeuntilweightgainislessthen0.25%.逐步增加保压时间直到重量增加小于0.25%Usetimefromgatefreezestudy(10-12.25%souse10sec)保压时间采用浇口封闭时间研究得出的时间Continueincreasingpressureby100-150psiincremants(dependingonpartsize)untilweightgainislessthen0.25%.逐步增加保压压力100~150psi（取决于产品大小）直到产品重量增加小于0.25%2