最新注塑件成型与设计课件PPT.ppt 65页

'注塑件成型与设计 InjectionMoldingProcessOverviewPartandToolDesignTerminologyCommonMoldingDefectsMoldedPartDesignBestPractices InjectionMoldingProcessOverview InjectionMoldComponentsCavityCoreClampPlatesEjectorPlate&PinsLiftersSlidesWaterLinesGatesandSpruesHotRunnerSystem,etc HotRunnerManifold&MultipleValveGatesThemanifoldinalargemoldheatsanddeliversthehotplasticfromthemoldingmachinetothegatelocationsonthepart. Lifters-FormDie-LockedFeaturesLiftersaremechanismswhichmoveapproximatelyinthedirectionofthemoldopening(dieangle).Theyareusuallyactivatedbylifterrodsoperatedbytheejectorplate.Liftersoftenmoveonanangletothepartduringmoldopeningandejectiontounlockadie-lockedfeature.MoldOpenMoldClosedDieDirection(moldopeningangle)Lifter CoreSlides-FormDie-LockedFeaturesAcoreslideisamechanismonthecorewhichmovesnormal(90°)todieangledirectiontoformdie-lockfeaturesorundercutsinthepartdesign.Theslideisactuatedbypins,cams,orhydraulicorpneumaticcylindersduringandafterthemoldcavityopens. SimpleCoreSlideandEjectionPlasticPartEjectionPinCoreWithSlideCavityWithHornPin*Actually,thecavityisstationary,andthecoresidemovestoopenthetoolwhenmountedinthemoldingmachine.AcceleratingEjectionPinInjectionSprueEjectionwithLifter CavityandCorewithLifterandPinPlasticPartEjectionPinCorewithlifterCavityTravelingAngledLifterFormsribwithflangeInjectionSprueCamOperatedCorePinFormsholeinflange*Actually,thecavityisstationary,andthecoresidemovestoopenthetoolwhenmountedinthemoldingmachine.Cam DesignTerminologyPartandToolDesignTerminology PartandToolDesignTerminology-DieAngles&DraftAngles,拔模角-ASurface,BSurface,etc.A面,B面-PartingLines,LifterLines,分模线-Doghouses,Ribs,Flanges安装支座,加强筋,翻边-TrueHoles,MoldedHoles,注塑孔-ToolingConsiderations,注塑模考虑.... DieAngle&PartingLineDieAngle(DieVector)MoldopeningdirectionPartingLine–wherethecore,cavity,andpartmeettogether.Part(2cavity)CoreCavity DraftAnglesPartsmusthaveopendraftanglesinthepartgeometrydesign.Partdraftangleismeasuredrelativetothedieopeningangle.Ifthereisnodraftangle,thepartwillcoolandshrinkontothetoolandwillbedifficultorimpossibletoremovewithoutdamage.Wegenerallyuseminimum3degreesdraftperside.Moredraftisneededforgrainedsurfaces. Cavity"A"surfacevs.Core"B"surfaceOriginalPart,tooledwrong,core/cavity.Ejectionpinsonshowsurface(Asurface).RevisedPart,eliminatepinsonAsurfaceDoyouknowthedifference?Doesyoursupplierandtoolshop?Didyouindicateitclearlyinyourmathdatafile?Oops! MoldingIssuesandCommonDefectsMoldingIssuesandCommonDefects MoldExpansion/PartShrinkageThermoplasticsshrinkastheycoolandsolidifyduringthemoldingprocessandafterpartejection.Themoldcavityismachinedlargerthanthefinaldesiredpartsizeinordertocompensateforpartshrinkageasthepartcools.Moldshrinkagedataforthespecificplasticmaterialcanbeusedtocalculatetheamountofmoldexpansionneeded.Moldshrinkageunitsareexpressedaslength-perunit-length,orasapercentage,andiscalculatedusingthefollowingformula:(molddimension–partsize)/molddimension=ShrinkFactor MoldingIssuesandCommonDefectsDimensionalSizeErrors(toolong,tooshort,toothin,toothick,etc.)DimensionalWarpage,Distortion,&StressSink&ShrinkMarksLifterLineRead-ThroughFlowLines,Weld(Knit)LinesMetallicFlakeOrientationPorosityNon-isotropicBehavior(differentbehaviorindifferentdirections) FlowLines,MetalFlakeOrientationThissectionofmetallicmolded-in-colorrockermoldingshowappearancedefectscausedbyflowlinesandmetalflakealignmentsformedaroundtheattachingholepins.GateFlowObstructionFlowLine&MetalFlakeOrientation WeldLines(KnitLines)Weld(knit)linesareappearanceandstructuraldefectswhichareformedwhenthemoltenplasticmustdividetogoaroundanobstructionandthenrejoinitself.Weoftenfindthisproblemondoghousesandalsoatattachingholesnearapartedge. SinkMarksSinkMarksformaroundthecenterofthelargermassofmaterialandshrinktowardsthecenterofthemass.Sinkmarksareappearancedefectscausedbypoorpartdesign.Sinksmarksaredifficulttoimprovebytoolingorprocessing. RibsandGussetsRibsandgussetsshouldhaveangledcornerstoavoidtrappingairduringfilling.Squarecornersaremoredifficulttofillcomparedtoangledorradiusedcorners. ChromePlatingConsiderationsChromeplatingisanelectrochemicalprocess,andthedepositionofthemetaltothepartisattractedtosharpoutsideradiiandisrejectedbysharpinsideradii.Non-uniformchromedepositcausessurfaceprofileappearanceproblems.Useradiiandfilletstoeliminatesharpfeaturesandmakethechromedepositionmoreuniform. ChromePlatingConsiderationsStiffenedgesifpossibletoreducedamage.Avoidflatsurfacesduetoriskofnon-uniformchromedepositionandalsoplasticshrinkagesinkmarks.Usecrowned(largeradius,notflat)surfacestomaintainuniformchromethicknessandavoidshrinkmarks. Runner,Gating,FillingMoldingAnalysisDoanalysisbeforeyoudesignandbuildthetool! PartDesignBestPracticesPartDesignBestPractices DesignForSuccess–FollowaPlanAfteryougatherandunderstandthepartrequirements:Selecttheproperpartconstruction,materialsselection,andprocess.(materialtype,stiffness,weatherable,paintable,moldable,etc.)Studyandunderstandthematerialbehavioranddesignrequirements(minimumwallstockthickness,ribsensitivity,holesensitivity,shrinkage,etc.SeekassistancefromMaterialsEngineers,suppliers,LeadEngineers,colleagues,etcfordesignreviewandadvice.ConductPeerReviewsofyourdesignwithmoldersandtoolshopsasitdevelops. InjectionMaterialFamiliesThermoplastic:Categoryofplasticswhichdeformsandre-meltswhenreheated."recyclable“CommonFillers:GlassFiber:Short,Long,Continuous,MatMineral:MicaTalc ThermoplasticMaterialsThermoplasticscommoninautomotive:TPO,PPABS,ABS+PC,ASA,ASA+PCPC,PC+PBT,PMMAPA6,PA66,Nylon,+mineralorglassfiberThermoplasticmaterialsareusuallyhighpressureinjectionmoldedbutsomegradescanalsobeblow-moldedorextrudedorthermoformed. PartMaterialsUsageMatrix UniformWallStock(thickness)PoorDesignGoodDesignDesigningpartsforuniformwallstock(thickness)isprobablythesinglemostimportantthingyoucandotomakeadesignwhichisrobustformoldingandpainting.Uniformwallstockpartsmoldwithbetterfillingandreducedinternalstresses.Uniformwallstockpartscoolandshrinkmoreuniformly,reducingdimensionaldistortionandwarpage. CornerRadiiMaintainconstantpartthicknessincornerradii.Avoid"Thick-thin-thick"or"Thin-thick-thin"sectiontransitions.Non-uniformthicknesscreatesflow,stress,shrinkage,andwarpageconditionsinthepartastheplasticcoolsandshrinksatdifferentratesduetodifferentthicknesses.Good! ThicknessTransitionsAvoidsuddenorsharpchangesinsectionshape.Suddenchangesaffectflowandfillcharacteristics,andalsocreatehighstressconcentrationsinthepart.Usesmoothtransitionsbetweensections. AvoidSolidMassesPoorDesignGoodDesignThickmassesofsolidplastic.Coolsslowly.Someareasarethinner.Shrinksunevenly.Uniformconstantthickness OffsetRibsOffsetribscanhelphidesinkmarksandmakethemlessvisible.Sinkmarksandshrinkageareeasierto"hide"whentheyoccuronsmallradiussurfaces.Sinkmarksaredifficulttohideonlargeradius(flat)surfaces.Itisgenerallygoodpracticetoplaceanyribsbehindpartsurfacefeaturelines,ratherthanbehindflatsurfaces. RibDesignPracticesAvoidthickribfeatureswhichcancausepartwarpageandsurfacesinkmarks.Avoidtallthinribfeatureswhichcanbuckleorbendunderload. RibDesignGuidelinesRibdesignislargelyaffectedbymaterialselection.ConsultwithResinsuppliersandmoldersforassistance.Generally,wedesignaminimumof3degreesdraftpersideforribsandsurfacesforrobustmoldingandejection.Smallerdraftcansometimesbeusedifyouhaveagreementfromyourmolderandtoolshop.However,largeribsincreasethechanceofsurfacesinkmarks.0.3-0.4T RibWarpageItisalwaysbettertogainstructurethroughsurfaceshapechange,ratherthanaddedribsandgussetsonthebackside.Ribsaddstructurebutcancausewarpageduetocoolingofnon-uniformgeometry.Fillershaveavariedeffectoncoolingandwarpage.Itisdifficulttopredict,analyze,orcontrolwarpagefromplasticribstructure.GlassFilledresinUn-Filledresin MultipleRibsSometimesasinglelargeribcanbereplacedbymultiplesmallerribstoavoidsinkmarks,etc. BossDesignsThisshowsatypicalbossdesignforascreworstudforreferenceDetailsvarydependingonmaterialsandfastenerdesign.Consultfastenerandmaterialsassistance.Theimportantideashownistoreducethewallthicknessofthemoldingatthebottomofthebosstoreducethesinkmarkonthesurfaceduetotheexcessmassofmaterial. BossDesigns‘Open’bossdesignmaintainsuniformthicknessinthepartwall,andavoidsathintoolsteelcondition. BossCoreDepthWillformsinkmarkWillformsinkmarkGood,pincouldbealittlelonger.Pinmaybetoolong.Partmaybetoothin. BasicPartDesignPracticesSomeoilsandcoatingsonfastenersattackPCandABS+PC.UseHi-LotypethreadedscrewsfordirectengagementintoTPO,ASA,andNylonplasticbosses.Usemetalthreadedstudsandinsertsforhighloadattachments. BasicPartDesignPracticesAvoiddesigningvariablecrosssectionareasbecauseitallowsmaterialtoflowfasterinsomeareasthaninothers.Ejectorpinssometimesinterferewithcoolingwatercircuits,andpinsapplyforceonlyinsmallareas.Somepartsejectbetterbycontrollingcoolingratherthanexertingmechanicalforce. BasicPartDesignPracticesDraftangleof3degreesisnormallyusedforpaintedexteriorparts.Moreisaddedforgrainedparts.3+1.5/0.001’’graindeepthAvoidsharpcornersandstressconcentrations.Taperthecrosssectionofbeamelementstodistributedeflectionenergyandcreateconstant-straindesigns. BasicPartDesignPracticesAvoidsharpradiioninsidecornerswhenpossible,howeveraddingradiicansometimesleadtonon-uniformwallthicknessandsurfacesinkmarks.Maintainconstantwallthicknessaroundcornersonpartflangesandthroughoutthepartsection.Thisisnecessarytomaintainconstantcoolingandshrinkageandtoavoidwarpage. CrownHeightversusStiffnessSurfaceshapeisanimportantmethodforgainingbothstiffnessandstructure.Itisalmostalwaysbettertoaddstiffnessusingsurfaceshape,ratherthanbyaddingribsandgussets. AddingStiffnessPartscanbemadestifferandalsomoredimensionallystablebythecarefulplacementofflangesandsectionshape.Avoidaddingribstoincreasestiffness.Increasestiffnessbychangingsurfaceshapeandprofile. Core-CavityShutoffToolingactionandcostcanoftenbeavoidedbydesigningfeaturestouseonlythecoreandcavityshutoffforformingthefeature. Core-CavityShutoffMoreexamplesofformingfeatureswithoutslidesorlifters.Thiscanoftenbeusedtoformnon-criticalholesandslotsinplasticpartswithoutmoveablepins. thanks 寿险理念篇之医疗篇 为什麽考虑医疗问题科学的发展生存环境工作的压力 各种疾病让生命越来越脆弱1、生活环境严重污染2、不当的生活习惯3、不良的饮食卫生4、长期缺乏运动5、紧张的工作压力根据医疗卫生部门统计，97年将近130万人死于各类疾病，死亡率从70年代的0.84‰，上涨到90年代的1.08‰，上涨了30%，各类传染病的发病率为203.7/10万——资料来源《中国统计年鉴》 医疗费来源个人储蓄单位报销亲友援助社会募捐社会保险商业保险 社会医疗保险简介关于门诊关于住院 社会医疗保险门诊住院最低起付线最高给付线补充医疗最高给付（大额医疗）（个人帐户支付）（个人+社会医疗） 癌症占城市死亡人口比率22.58%脑中风后遗症占城市死亡人口比率22.33%心脏病占城市死亡人口比率17.28%心脏病、脑中风后遗症、癌症总发病率高达62.19%发病率统计 重大疾病医疗手术费举例别让重大疾病把您的家庭拖得一贫如洗！资料来源：中国卫生部 个人医疗费支付现状分析个人储蓄单位报销社会医疗亲友援助社会募捐商业保险 点燃思考谁能保证不得病？医疗费准备好了吗？谁都不愿得病，谁都不愿没钱。但，当既有病又没钱治时会更惨！怎麽办？ 商业保险带来的帮助减少大额医疗费带来的烦恼医疗费报销补充社会保险减少意外、疾病带来的经济损失这样会更好！ 结论：商业医疗保险给你的是：生存的权利、生命的尊严、对家人的责任和爱心！'