多功能充電器外殼注射模具設(shè)計(jì)-注塑模具【三維PROE】【15張CAD圖紙+PDF圖】

喜歡這套資料就充值下載吧。資源目錄里展示的都可在線(xiàn)預(yù)覽哦。下載后都有，請(qǐng)放心下載，文件全都包含在內(nèi)，【有疑問(wèn)咨詢(xún)QQ:1064457796 或 1304139763】 THE PREPARATION AND USE OF PLASTIC MOLDS M. B. Borisov UDC 666.5:666.3.032 Plaster molds are widely used for casting wares in the ceramics industry. Apart from certain ad- vantages, they have a low mechanical strength and short working life due to wear of the work surface under the action of water and electrolytes in the body. Besides this, the temperature in the dryer cannot be higher than 65 as above this temperature the plaster is destroyed. The necessity of finding a substitute for plaster was increased when the porcelain industry began in- stalling semiautomatic machines for molding and drying, with intensified drying conditions. The search for a substitute for plaster began in our factory in 1967, and to this end a group was organized containing the following workers: A. V. Saveleva, P. S. Polyakov, T. A. Pashkova, V. A. Kholkin, A. V. Sarichev, F. I. Lisov, and others. At the start of their work the research group were guided by data from the State Ceramics Research Institute 1. However, this did not answer a number of questions arising from the working of the plant, such as: how to design and make press molds so as to avoid cracking in the plane of intersection of two surfaces, what batch to take per unit volume of mold, what schedule to use for the heat treatment, how to obtain uniform distribution of pores and increase general porosity, and how to avoid adhering by the body, etc. Following on the results of their research, in 1969 the group began developing the preparation of PVC molds, and converting the production line of the factory to their use. At the present time there are in the factory five production lines for plates, three of which are for shallow 200 mm plates and two for deep 200 mm plates, as well as seven lines for cups. Using the plastic molds a totalof24,000 plates and 35-37,000 cups are produced per day (24 h). The provisional annual saving accruing from the introduction of only one production line is 2500 rubles. The working life of the plastic molds in cup production reaches 4000 cycles and can still be increased. The life of the molds in plate production has still not been determined. A section for preparing the molds was organized in the factory in 1969 (Fig. 1). The raw material was domestic polyvinylchloride latex, grade L-5, or emulsified polyvinylchloride, grade E-62. Polyvinyl- chloride is the product of polymerization of vinyl chloride. It is a white finely dispersed (no residue on No. 0056 sieve) powder of density 1.41 g/cm 3. At a tempera- ture of 170-180 and under slight pressure (specific pressure 0.05 kg/cm 2) the polyvinylchloride par- ticles melt and cohere. The first stage in the preparation of the molds is a preliminary vibromolding (on the vibrotable) which ensures uniform porosity. The vibrotable performs 50 oscillations/sec with an amplitude of 0.5 ram. The vibromolding is carried out for 15-20 sec. This preliminary vibromolding is an essential part of the process for making the molds, since, during molding, internal stresses are generated which are concentrated near the points of contact of molec- ular cohesion of the fine particles. This internal stress is especially dangerous during the process of sin- tering. It can be removed by vibration, which almost completely breaks all connections between particles and ensures their uniform distribution. The basic piece of equipment in the preparation of the plastic molds is the metal press-mold (Fig. 2) which is made from grade 45 or St. 3 steel. Its internal surface must be chromium plated. Dulevo Porcelain Factory. Translated from Steklo i Keramika, No. 3, pp. 7-9, March, 1972. 9 1972 Consultants Bureau, a division of Plenum Publishing Corporation, 227 g/est 17th Street, New York, N. Y. 10011. All rights reserved. This article cannot be reproduced for any purpose whatsoever without permission of the publisher. A copy of this article is available from the publisher for $i5.00. 147 ,.- 13 500 l 2 3 45 6 fi IO 9 8 7 Fig. I Fig. 2 Fig. I. i) Hand press; 2) SNOL electrically heated cabinet for heat treatment of the molds; 3) cabinet for cooling the molds; 4) table for assembly and dismantling; 5) stand for prepared molds; 6) storage for the plastics; 7) electrically heated cabinet for drying; 8) stand for finishing the molds; 9) table for packing plastics; i0) table for measuring out plastics; ii) vibrating table. Fig. 2. Press-mold. a) Assembled; b) dismantled. The process of filling the press-mold for making flat ware (plates) plastic molds is shown in Fig. 3. L-5 powder, which has previously been dried in the eleetrodrying cabinet at ll0 and then screened through a No. 05 sieve, is charged into the matrix of the press-mold and leveled with a special tool. The amount of plastic depends on the type (volume) of the mold. For shallow 200 mm plates it is 600 g, for deep 200 mm plates 660 g, for saucers 400 g, and for cups 500-515 g. The press-mold punch is then in- serted into the matrix in such a way that it enters under its own weight until it is in contact with the plastic. To check the correctness of assembly at this point, the punch is rotated relative to the matrix. The assembled press-mold is placed on the vibrotable and compacted for 15-20 sec. After com- pacting, the gap between the matrix flange and the punch flange should be 8-10 ram. The press-mold is next inserted into SNOL electrocabinet for the heat process and a weight is placed on the top so as to give a pressure of 0.05 kg/cm 2. To monitor the temperature, a thermometer is inserted so that it touches the center of the punch. A small amount of the plastic is heaped on the punch flange, and its change in color is used to assess the readiness of the mold. The heat process continues for 2-3 h and at its completion the temperature of the press-mold is 170-175 After the completion of the heat process, the thermometer is removed and the press-mold taken from the cabinet and placed into the ventilated cabinet to cool. The press-mold is then dismantled using an ex- traction screw. The prepared plastic mold is removed, trimmed smooth at the edges, and after inspection is ready for use. The molds for the hollow wares (cups) were prepared according to the following schedule. The cor- rect amount of PVC plastic was put into the matrix Fig. 4) and leveled off. Two 22-24 mm thick spacers were placed on the flange of the matrix 1, and the matrix 2 lowered onto it so that the ring flange was resting on the spacers. The punch 3 was then lowered into the ring so that its flange was level with the ring flange. The assembled press-mold was then turned over and placed flange down on the vibrotable, with the punch flange standing on a 50 x 50 mm block. The spacers were then. removed from under the ring flange, and a weight of 8-10 kg placed on the bottom of the matrix, positioned to that its center lay on the axis of the press-mold. The vibrator was turned on and the ring held behind the flange vibrated the plastic for 15-20 sec. After vibrating the clearance between the flanges of the matrix and punch should be about 5-7 ram, and between the punch flange and the ring about 10 mm. The press-mold was then turned over, and 5-6 mm thick packing laid on the punch flange, and then the weight placed on this which gave the pressure of 0.05 kg/cm 2 for the heat process. The press-mold, with the weight, was placed in the electrodrying cabinet on a fireclay base 6-8 cm thick. The heating process was carried out according to the graph (Fig. 5) for 1.5-2 h up to a temperature of of 180-185 The temperature was monitored by a mercury thermometer. At the end of the heat treatment the load was removed and the press-mold taken from the electrocabinet and pressed on the hand press until 148 Fig. 3 tc 160 _ . =.: .iu/ 0 20 40 60 80 lOO Time, rain Fig. 4 Fig. 5 Fig. 3. 1) Stop washer; 2) ring; 3) punch; 4) die; 5) polyvinylchloride. Fig. 4. 1) Matrix; 2) ring; 3) punch; 4) screw; 5) mold. Fig. 5. Heat treatment graphs for processing plastic molds. 200 mm diameter plates. 1) For cups; 2) for shallow the ring and punch flanges made contact with the matrix flange. After retaining under the press for 10 min the press-mold was removed and placed in the ventilated cabinet to cool down to 40-45 The press-mold was dismantled and the prepared plastic mold extracted. After trimming it was ready for use. Experience in the preparation of these polyvinylchloride molds and in their use in the factory has shown that deviation from the above preparation schedules leads to the appearance of various faults in the molds which show up during the process of forming wares with them: underpressing, porosity of the ma- terial under the shoulders of the hollow mold, ring cracks on the stem of the hollow mold. Constant control of the electrodrying cabinet by means of the thermoregulator ensures a uniform temperature in the chamber during the heat treatment of the pressings, and ensures uniform heating of the plastic for all section thicknesses. The resultant uniformity of sintering prevents the production of a mold with different coefficients of thermal expansion between the edges and center of the plastic. This greatly reduces the occurrence of cracks in the working surface of the mold during use and increases its working life. Accumulated experience in the use of the molds in the factory has shown that it is necessary to pay attention to: careful adjustment of the mold holder under the pedestal of the semiautomatic machine; selec- tion of the molding schedule; avoiding sudden lowering of the roller at the moment of contact with the body; the selection of the correct speed for the molding roller (500-550 rpm for cups and 250-275 rpm for plates) and for the mold holder (750-800 rpm for cups and 300-500 for plates) in order to avoid the production of scrap in the form of humpers and whirlers. Failure to observe these requirements can also lead to damage to the mold (chipping off the shoulder, and digging out the bottom with hollow ware). The molds when produced vary in color from rose to dark brown, according to the duration of the heat treatment at constant pressure and the final temperature in the electrocabinet. The dark brown ones have low porosity, and in practice cannot be used. The rose colored ones have adequate working proper- ties, but their low mechanical strength significantly reduces their working life. Obtaining the normal working porosity of 31-35%, with uniformly distributed pores, and at the same time retaining the necessary mechanical strength, was one of the most difficult problems in the production of the molds. If the heat treatment was forced, this rapidly led to the appearance of a surface crust with a raw interior in the mold. If the final temperature was raised above 210 in order to speed up the heat treatment, this led to decomposition of the plastic with the evolution of gases which destroyed the surface of the mold. After extensive investigation, the optimum heating schedule for the plastic in the press-mold, which gave molds of the desired quality, was found and is shown in Fig. 5. From experience in the preparation and use of the molds, the correct amount of plastic per unit vol- ume of mold was established as 0.9 g/cm 3. This enables, with other factors remaining constant, to main- tain a constant density for the molds. The technical criteria for acceptance of the molds were established in the factory. They must have a smooth dense working surface and a homogeneous color matching the established standard. Dimensional 149 variations must not exceed =0.05%. The molds must have no deformations. Their porosity must fall within the limits 31-35%. Their rate of water absorption is determined by a method developed in the factory. The surface of wares made in these molds requires no further treatment, which is a commercial advantage. The consumption of gypsum by the factory is reduced by 500 tons per year. The labor re- quirement on heavy loading/unloading work is reduced, the work of the laborer/molders is relieved, and transport is released. The factory team continue to work on the introduction of more progressive methods of preparing plastic molds, on speeding the heat treatment process to give increased output of molds per press-mold, and on increasing their mechanical strength whilst preserving a high porosity. 1. LITERATURE CITED S. M. Tsenter et al., Steklo i Keram., No. 1 (1969). 150 畢業(yè)設(shè)計(jì)(論文)外文資料翻譯系 別： 機(jī)電信息系 專(zhuān) 業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 班 級(jí)： 姓 名： 學(xué) 號(hào)： 附 件： 1. 原文； 2. 譯文 2013年03月The introdution of the Injection Mold 1. Mold basic knowledge1.1 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. Molds shape determine the shape of these products, molds 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 definitionIn 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 classificationMold 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 (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 markets 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 moldIt 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 products 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 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 MoldThere 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 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 mold3.1 Mold Cavity SpaceThe 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 CavitiesMany 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 ofcavities: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 CoreBy 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 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 LineTo 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 GatesNow,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 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 processInjection 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 its 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 its 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 its 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 its connected to the runner. There are ways around having sprues and runners, but its beyond the scope of what were 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 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.注射模具的介紹1.模具基本知識(shí)1.1引言 我們?nèi)粘Ｉa(chǎn)、生活中所使用到的各種工具和產(chǎn)品，大到機(jī)床的底座、機(jī)身外殼，小到一個(gè)胚頭螺絲、紐扣以及各種家用電器的外殼，無(wú)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?yàn)楦鞣N產(chǎn)品的材質(zhì)、外觀(guān)、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(lái)，隨著射料工業(yè)的飛速發(fā)展和通用與工程射料在強(qiáng)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(kuò)大，如：家用電器、儀器儀表，建筑器材，汽車(chē)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(gè)設(shè)計(jì)合理的射料件往往能代替多個(gè)傳統(tǒng)金屬件。工業(yè)產(chǎn)品和日用產(chǎn)品射料化的趨勢(shì)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(jī)和裝在壓力機(jī)上的專(zhuān)用工具，通過(guò)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(zhuān)用工具統(tǒng)稱(chēng)為模具。1.3 模具的一般分類(lèi)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(tái) B鍛造模汽車(chē)身 C沖壓模計(jì)算機(jī)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(jī)外殼、鍵盤(pán)按鈕（應(yīng)用最普遍） B吹氣模飲料瓶 C壓縮成型模電木開(kāi)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(guò)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(shí)也決定著企業(yè)在市場(chǎng)競(jìng)爭(zhēng)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?？樱?D 冷卻系統(tǒng)（運(yùn)水孔） E 恒溫系統(tǒng)（加熱管，發(fā)熱線(xiàn)） 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(lèi)型根據(jù)澆注系統(tǒng)型制的不同可將模具分為三類(lèi):（1）大水口模具：流道及澆口在分模線(xiàn)上，與產(chǎn)品在開(kāi)模時(shí)一起脫模，設(shè)計(jì)最簡(jiǎn)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(xì)水口模具：流道及澆口不在分模線(xiàn)上，一般直接在產(chǎn)品上，所以要設(shè)計(jì)多一組水口分模線(xiàn)，設(shè)計(jì)較為復(fù)雜，加工較困難，一般要視產(chǎn)品要求而選用細(xì)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(gè)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(gè)部分：分流板和噴嘴。分流板的通道將射料傳送到一個(gè)和分型線(xiàn)平行平面，這個(gè)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(jìn)行腔。熱流道系統(tǒng)的優(yōu)勢(shì):（1）無(wú)水口料，不需要后加工，使整個(gè)成型過(guò)程完全自動(dòng)化，節(jié)省工作時(shí)間，提高工作效率。（2）壓力損耗小。2注射模設(shè)計(jì)模具有很多的規(guī)則。這些規(guī)則和標(biāo)準(zhǔn)的做法，都是基于邏輯，過(guò)往的經(jīng)驗(yàn)，方便性，經(jīng)濟(jì)性。設(shè)計(jì)，模具制造，和成型，它通常的優(yōu)勢(shì)就是遵循規(guī)則。但有時(shí)候，它可能會(huì)做出更好的，如果一項(xiàng)方法是被忽視和另一種方法被選擇。在一些書(shū)中,最普通的規(guī)則都會(huì)一一列出,而設(shè)計(jì)者設(shè)計(jì)的東西也僅僅是跟著以往的經(jīng)驗(yàn)走而已。設(shè)計(jì)者應(yīng)該研究出新的想法和方法,來(lái)進(jìn)行新的成型和選擇模具材料。注射工藝過(guò)程就是從給料斗送進(jìn)粉狀或粒狀的射料混合物，經(jīng)過(guò)定量區(qū)和熔化區(qū)，然后將其注射到模具型腔中。注射過(guò)程說(shuō)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(gè)組合內(nèi)有成型模腔。注射時(shí)，模具裝夾在注射機(jī)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(kāi)，經(jīng)由頂出系統(tǒng)將制品從模腔頂出離開(kāi)模具，最后模具再閉合進(jìn)行下一次注射，整個(gè)注射過(guò)程是循環(huán)進(jìn)行的。注射模至少是由裝在注射機(jī)的兩個(gè)壓板上的兩部分組成，以便可以開(kāi)模和合模。在合模的時(shí)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(guò)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(kāi)模。產(chǎn)品的形狀決定著它是否由模具兩部份簡(jiǎn)單地開(kāi)模或由有側(cè)向分型來(lái)開(kāi)模。模具的設(shè)計(jì)是由產(chǎn)品的形狀和產(chǎn)品開(kāi)模的方式?jīng)Q定的。注射成型的產(chǎn)品可以分為以下幾類(lèi):無(wú)側(cè)抽芯的產(chǎn)品；有側(cè)向開(kāi)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(gè)形狀,當(dāng)注射的材料充滿(mǎn)這個(gè)空間的時(shí)候,它就會(huì)呈現(xiàn)出和型腔空間一樣的形狀。在注射成型時(shí),射料是通過(guò)很高的壓力注射入型腔空間的,所以模具必須要足夠的堅(jiān)固來(lái)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(gè)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(huì)有2個(gè)或更多的型。究其原因就是它純粹的經(jīng)濟(jì)性。它僅僅是注入多個(gè)型腔比注入一個(gè)型腔多花了一點(diǎn)的時(shí)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(zhǎng)方形區(qū)域內(nèi)布置型腔方便，這樣就有利于設(shè)計(jì)、定尺寸、加工制造和圍繞機(jī)器中心對(duì)稱(chēng)，這種對(duì)稱(chēng)分布對(duì)于保證每個(gè)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(chēng)為型腔。與型腔空間所匹配的部分稱(chēng)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(lái)就像是一個(gè)杯，只是它們有一個(gè)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(dòng)的那半模具上的。這樣安排的原因是注射機(jī)上的移動(dòng)板有一個(gè)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(guò)此來(lái)彈射出來(lái)。大部分的注射機(jī)在注射的一邊都不會(huì)安裝彈射裝置。對(duì)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(mǎn)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(gè)成型的方式。3.4 分模線(xiàn)為了能夠生產(chǎn)出一個(gè)模具,我們必需具備有兩個(gè)分半的模具,一半裝型腔一半裝型芯。這兩個(gè)板分離時(shí)的部分叫做分模線(xiàn),簡(jiǎn)稱(chēng)P/L。其實(shí),這是一個(gè)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(xiàn)。 模具的分型面是兩模板接近型腔的那些部分，它們對(duì)接一起形成油封并且避免型腔里射性材料的損失。分模線(xiàn)可以是任何形狀的, 許多的注射成型都是要求分模線(xiàn)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(jì)在同一個(gè)平面上。為了能夠在模具上脫出產(chǎn)品,分模線(xiàn)總是在分布在產(chǎn)品最寬的圓周區(qū)域。對(duì)一些形狀來(lái)說(shuō)，設(shè)置分模線(xiàn)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(shí)候模具能夠緊緊地合在一起。如果分模線(xiàn)設(shè)計(jì)不好,射料將會(huì)溢出來(lái),那樣產(chǎn)品就會(huì)有一個(gè)非常大的凹陷,那樣的產(chǎn)品肯定會(huì)被拆除,否則那樣的產(chǎn)品是不能夠使用的。甚至更危險(xiǎn)的是,射料噴射進(jìn)模具的時(shí)候,它會(huì)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(dòng)之前),它必需有足夠的壓力以便使射料能夠充滿(mǎn)型腔。流動(dòng)的通道就是流道,它把注射機(jī)的噴嘴和模具連接了起來(lái),流道是一個(gè)獨(dú)立的型腔, 流道本身要光滑,以便可以阻止射料自由流動(dòng)。同時(shí), 型腔被充滿(mǎn)后，澆口處先凝固，注射機(jī)螺桿抽回時(shí)可防止成型中的回流。澆口是一個(gè)小型的開(kāi)口,它引導(dǎo)著流道到型腔空間。澆口是一個(gè)渠道,是連接與流道相通的小口。與其他的進(jìn)料系統(tǒng)相比,它有一個(gè)很小的橫截面積。在射料充滿(mǎn)型腔后,澆口很快就會(huì)冷卻,注射的噴嘴往后退,在模具退后的時(shí)候射料還是留有在噴嘴中的。4. 注射機(jī)的工作過(guò)程注射模具是安裝在注射機(jī)上的，它的注射成型過(guò)程是由注射機(jī)來(lái)完成的。以下是注射機(jī)的工作過(guò)程：注射成型機(jī)通過(guò)抽真空把射料原料從干燥機(jī)吸到料斗里面。料斗實(shí)際上是一個(gè)小的漏斗，它被安裝在機(jī)臺(tái)料筒的后面。開(kāi)始起實(shí)際作用的地方是料筒，料筒實(shí)質(zhì)上是四周都是加熱器的一個(gè)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(jìn)并成為熔融狀態(tài)。只有完全熔融后，原料才會(huì)在螺桿高速旋轉(zhuǎn)產(chǎn)生的擠壓力下射進(jìn)模腔。當(dāng)螺桿前端壓室注滿(mǎn)射料時(shí)，螺桿被迫后退，斷開(kāi)限位開(kāi)關(guān)而開(kāi)動(dòng)液壓缸，從而向前推動(dòng)螺桿，將熔融射料注射到閉合的模具型腔中。型腔被充滿(mǎn)后，澆口處先凝固，注射機(jī)螺桿抽回時(shí)可防止成型中的回流。螺桿端部稱(chēng)為噴嘴，從這里開(kāi)始直到模具型腔這段空間內(nèi)，熔融材料沒(méi)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(shí)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(jiàn)過(guò)流道，但卻沒(méi)有認(rèn)出。最容易見(jiàn)到他們的地方是由單獨(dú)零件構(gòu)成的飛機(jī)和汽車(chē)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(jìn)安放在模具下面的落料裝置（通過(guò)一個(gè)斜坡傳送通道），或者被機(jī)械手取出，然后投入粉料機(jī)。粉料機(jī)把水口料絞成碎料并送回干燥機(jī)。盡管塑料一旦被加熱就會(huì)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?yàn)檫@樣會(huì)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(yuǎn)，大部分塑料冷卻后會(huì)收縮20%。為了在重點(diǎn)（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(jì)者必須把這個(gè)要素考慮到設(shè)計(jì)里面去，那樣成型出來(lái)的產(chǎn)品才能滿(mǎn)足設(shè)計(jì)規(guī)格。 頂針是模具本身的零件，用來(lái)在模具打開(kāi)的時(shí)候頂出產(chǎn)品。整個(gè)過(guò)程都有注射成型機(jī)控制。一個(gè)成型周期實(shí)際上就是合模-注射-開(kāi)模-頂出。模具被鎖緊在機(jī)臺(tái)上，前模固定不動(dòng)（在機(jī)臺(tái)的料筒側(cè)），后模則可以移動(dòng)。上面說(shuō)的頂針就是后模側(cè)。當(dāng)模具打開(kāi)，產(chǎn)品吸附在后模側(cè)以被頂出。- 11 -