Plastic Injection Mold: Txoj caij dab neeg koj yuav tsum paub ua ntej khi koj sau pov thawj

Paub txog Lub Ntaub Laj Chaw Tso Tshuab Tso Lub Ntaub Laj

Lub Ntaub Laj Chaw Tso Tshuab Yog Li Cas Thiab Nws Yog Li Cas Nws Txhawj

Rau tshuab ntxuag plastic yuav ua raws li kev pab cuam meej meej los ntxuag thermoplastics kuab rau hauv qhov chaw tsim khoom zoo ib yam, siv kev txhiab ntau. Kev tsim kho rov qab pib thaum cov kab ntxuag plastic tau ntsia rau hauv qhov chaw ntxuag uas muaj qhov rooj kheej kheej, hauv no muaj lub screw twirling los ua rau cov kab ntxuag tau melting tag nrho los ua rau nws tuaj yeem ntxuag tau. Nrog qhov txhiab ntawm 10,000 mus rau 30,000 pounds per square inch, cov plastic melted no tau ntxuag rau hauv qhov chaw ntxuag uas raug zam tseg. Thaum lawm hauv, cov cooling channels pab harden rau lub thawj plastic, tom qab ntawd lub tshuab yuav nqaws tawm tus khoom tiav. Qhov uas tsim qhov kev cyclem no zoo heev yog nws qhov tswj hais tsim cov khoom me me thiab muaj qhov sib txawv me me, feem ntau txog plus lossis minus 0.001 inches per inch measurement. Cov tshuab tsim kho siv zog tuaj yeem tsim tau 10,000 khoom los sis ntau dua txhua hnub, yog li qhov kev no yog qhov tseemceeb rau kev tsim kho loj rau hauv ntau qhov chaw tsim khoom.

Qhov Muaj Ntau ntawm Chav Tshuab Thermoplastic Injection Molding

Txhua chav tshuab injection molding muaj sib txuas rau plaub qhov kev sib txuas ntawm chav tshuab:

1. Chav Nruab Tseg : Siv tshuab hydraulic lossis tshuab electric los nruab tseg ob lub nruab tseg ntawm lub mold nyob rau hauv lub zog txog 8,000 tons
2. Chav Injection : Muaj qhov chaw ntxuav thiab lub screw auger los ua rau yav tshuab sov thiab ntau yam ntxuav nrog kev sib piv ±0.5% nyob rau hauv kev ntau ntawm yav tshuab
3. Chav Tshuab Mold : Lub tshuab mold siv los ntawm steel lossis aluminum uas tau tsim los nrog kev sib piv meej, muaj qhov tseem ceeb, qhov ntxuav sov, lub nruab tseg, thiab qhov tso tawm
4. Tsav Duab Lag Muag : Lub tshuab Programmable logic controllers (PLC) los saib xyuas txheej sov, ntau zog, injection speed (±0.05 mm/sec nyob rau hauv kev sib piv meej), thiab qhov sib txuas ntawm kev tsim

Thiab thaum cov qhov muaj no tau txuas nrog zoo, lawv tuaj yeem txuas nrog rau qhov sib txuas tsawg dua 15 seconds rau cov ntaub ntawv leeg, los txhim kho kev tsim khoom zoo tshaj

Kev Txhim Kho Lub Tshuab Tso Ntawv Thiab Kev Siv Tshuab: Ntawm Qhov Kev Xav Mus Rau Kev Pab Cuam Tshuab

Kev Ntxig Mus Rau Kev Pab Cuam Tshuab Los ntawm CAD kev txhim kho mus rau lub tshuab pab cuam muaj ib feem ntawm 5 qhov feem tseem ceeb uas muab faib los ntawm kev pab cuam tshuab khoos tseem ceeb:

Kev ua haujlwm no txo kev hloov pauv thiab tiv thaiv cov nqaij ntsoog xws li cov npe tseg lossis qho chaw nqus, kom meej meej tias cov ntsiab lus tsis muaj kev hloov pauv rau hauv qhov tseem ceeb.

Kev xaiv Vajtxwv rau kev pab lub tshuab ntaus tsis zoo txaus

Cov vajtxwv thermoplastics feem ntau siv hauv kev ntaus

Hauv kev ntaus, cov vajtxwv plastics feem ntau siv yog polypropylene (PP), ABS, thiab polyethylene (PE) vim lawv muaj kev nyob ib ncig zoo li ntawm kev ceev, kev ua kom so, thiab kev tsawg nqi. Thaum chaw tsim khoom tau ob ob, nylon thiab polycarbonate tuaj yeem pab tau los ntawm lawv qhov yooj yim tshaib rau cov khoom tsim nyog. Thiab tom qab ntawd muaj PEEK, uas hu ua polyether ether ketone, uas yog tus xaiv tseem ceeb thaum kub txog qhov chaw uas lom tiam tau lwm hom resins. Txhua hom vajtxwv hlais sib txawv hauv molds, thiab no muaj tseeb heev thaum tsim tshuab. Qhov viscosity ntawm vajtxwv txiav txim siab seb yuav tsum siv ntau npaum li cas hauv kev ntaus, uas tsuas yog txiav txim siab seb yuav tso gates nyob qhov twg thiab tshuab yuav tsum muaj kev sib txawv npaum li cas rau kev ntaus tiav.

Sib phim kev xaiv vajtxwv rau kev ua haujlwm thiab hauv qab chaw

Kev xaiv lub vajtim thiab qhov chaw siv yog kev tshuaj xyuas seb lub ntsiab lus xav tau li cas thiab nws yuav tsum tau ua rau li cas nyob hauv keev cai. Rau cov khoom siv rau lub rooj tshuab uas sib hlo tshuaj, kev tiv thaiv tsis pub muaj keev cai yog yam tseem ceeb heev. Cov khoom siv nyob ntawm ntuj kib tau kev tiv thaiv los ntawm kev siv cov duab ntsuab uas muaj keev cai tiv thaiv ntawm dej tshuaj, vim tias dej tshuaj tuaj yeem tsau cov duab ntsuab tsha tsha. Thaum hais txog cov khoom siv rau kev kho mob, peb yuav tsum xaiv cov duab ntsuab tshiab uas tsis txhob muaj keev cai tshwm sim hauv lub cev thiab tshwm tau txais cov keev cai tshwm sim. Ib qho kev xam pom los ntawm qhov chaw Polymer Processing Society tau pom ib yam tseem ceeb – nyob rau hauv 42% ntawm cov khoom siv uas tsis txaus siab nyob rau hauv qhov sijhawm txaus siab yog vim xaiv tsis yog lub vajtim uas yuav tsum tau siv rau qhov chaw nws yuav tsum tau ua haujlwm. Piv txwv li cov khoom siv rau kev sib cuag. Cov no feem ntau yuav tsum tau siv cov vajtim uas tiv thaiv dej thiab muaj keev cai tshwm sim. Qhov no txhais tau tias kev xaiv vajtim muaj feem ntau npaum li cas nyob rau hauv kev tsim khoom siv rau kev tsim khoom los ntawm kev siv cov duab ntsuab thermoplastic.

Txeej Siv Lub Hom Thawj Ntawm Lub Hom Thiab Sijhawm Tshuab

Siv ntau tias ntawm kev saib xyuas los ntawm cheebtsheev hlo rau 2023, cov duably composite uas muaj phiaj cim tau los ntawm kev siv phiaj yuav tuag lub hom txog 60% ntau dua li cov duably tsis muaj phiaj. Txawm li cas los xwb, tus neeg tsim khoom feem ntau yuav tsum sau nyiaj xaiv cov hom siv hluv uas muaj zog dua, tab sis lawv muaj leejtwg ntau dua. Rau cov duably crystalline zoo li nylon, cov no yuav tsum tau siv sijhawm ntxov los sov tseg tas li ntawm qhov chaw uas lawv tsim crystals nyob rau hauv kev tsim kho. Yog li ntawd, sijhawm tsim kho yuav ntev ntxov ntawm 15% mus rau 25%. Tom qab no, cov duably amorphous feem ntau yuav tso tawm ntxiv siab dua thaum tso pov tseg rau ib qho sijhawm tshwm sim. Rau cov khoom tsim los ntawm injection molding uas siv cov duably feem ntau zoo li ABS lossis polypropylene, qhov shrinkage feem ntau nyob rau hauv qhov chaw ntawm 0.5% mus rau 3%. Cov neeg tsim khoom yuav tsum pom tiam qhov shrinkage no thaum tsim cov cavities kom cov khoom tiav tuaj yeem nyob rau hauv qhov tolerance tseem ceeb, feem ntau tsis ntau dua plus lossis minus 0.05 millimeters.

Kev Txhim Kev Tshaj Tawv (DFM) thiab Kev Ntuag Ntawm Qhov Loj

Thiab tias yuav tsum muaj kev txhim kho nrog kev tshaj tawv nyob hauv siab, cov neeg ua haujlwm tau kev pab los ntawm kev tshaj tawv. Yog tau daws tej qhov teeb meem ntawm kev tshaj tawv nyob rau hauv qab chaw, ces pheej hmong tau ntau rau kev lag luam tom ntej thiab tshaj tawv khoom ntau dua. Raws li ib tug neeg sau tseg hais tias, tseem ceeb tshaj plaws yog kev tshaj tawv khoom tshiab hais tias, yuav tsum muaj kev txhim kho kom tsim nyog rau kev tshaj tawv, uas tuaj yeem cuam tshuam txog 30% ntawm kev tshaj tawv. Cov teeb meem tseem ceeb tshaj plaws uas cov neeg tshaj tawv xav tau? Yuav tsum kom meej meej txog qhov chaw nyiag siab thiab tswj kom cov khoom muaj feem txwv raws li feem txwv tseem ceeb. Qhov kev xav no tsis yog yog ib txwm pab kom cov formwork nyob ntev dua, tab sis kuj pab kom muaj kev sib xws zoo tagnrho rau tag nrho cov khoom tshaj tawv. Ntau lub chaw tshaj tawv tau pom tias, yog xav txog kev tshaj tawv thaum yuav tshaj tawv, ces yuav tsum muaj kev txhim kho kom tsim nyog rau kev tshaj tawv.

Cov Ntsiab Lus Tseem Ceeb ntawm Kev Txhim Kev Tshaj Tawv (DFM)

Kev tsim kho tshuab yooj yim kom sai hauv kev lag luam tau muab faus los ntawm kev suav xyuas sib pab nrog ntawm qhov chaw tsim tshuab thiab qhov chaw tsim kho tshuab ua phau ntawv thawj. Nws txhais tias yooj yim kev sau tshuab, xaiv cov khoom siv uas tuaj nrog lub tshuab ntau, thiab tso tsis tau cov cogs npeem uas tso cai rau kev sib tham. Hauv kev tsim kho tshuab thermoplastic, cov raj yog qhov zoo dua li cov kab ntsug thick kom txhaum nyob ib si thiab kom sov tsha paug thiab kom siv khoom me me.

Daim ntawv xwall Thickness, Draft Angles, thiab Ejection: Tso tsis tau cov nqaij kev phom sij

Keev tshaj tshwv ntawm kev txhim kho cov kab tuab hauv qhov chaw sib xws ntawm 1.5 thiab 4 millimeters pab tiv thaiv cov teeb meem kev ntxoov ntxoom thiab cov duab ntxoov uas tsis muaj leej twg xav tau. Txog thaum mob thiab kawg rau hauv qab, thiaj li muaj qhov nqes ntawm 1 thiab 3 degrees saum ib sab kom cov khoom yuav rov qab los sai sai hauv qhov tshav kub. Yog tias cov ntsiab lus sib txawv ntau heev hauv qhov nyeej, peb feem ntau pom cov chaw tsis muaj los yog tseem tshaiv dua, cov teeb meem ntawm pob ntawd tom qab tsim kho. Qhov chaw tshaj tshwv ntawm cov npu tshaj tshwv yog ib qho tseem ceeb ntxiv. Sib xyaw tshaj tshwv ntawm kab tuab, txhua 4 los 8 npu saum ib square foot zoo tagnrho hauv tib txoj kev, uas tiv thaiv cov khoom los ntawm kev poob khi tes thaum lawv raug tshaj tshwv. Rau kev nyob ntev, hlau txwm thoob yog tus thawj lej lej rau cov npu no vim tias lawv feem ntau nyob tau txog ob hlis txog ob hlis ntawm kev siv ua ke ua ntej yuav tsum tau ua haujlwm.

Daws Txoj Cai, Kev Kawm, thiab Kev Tshwm Sim ntawm Qhov Chaw Nyob Nyob Nyob Nyob

Xuas nrog kev kawm ntawm vaj khoom nyob hauv kev tsim kho tsev hauv ntej—tsim tsev ntau dua raws li xws. Qhov chaw nyob tseemceeb yuav tsum txhawj xws li ISO 20457 (±0.05–0.15 mm), uas tau txhob los ntawm kev tswj xyuas saub hluv hluv hauv ±5°C. Txo kev tshwm sim los ntawm kev tswj xyuas lub tsev sov, nrog 70% ntau dua hauv qhov chaw ntau dua kom txuag kev sib piv.

Qhov Sib Sau, Kev Tswj Txoj Cai, thiab Kev Txhim Kho Daim Duab Tsev

Kev xaiv qhov sib sau yooj yim tshwj tsis tshwm sim thiab tsis muaj kev tshwm sim. Lub teb nruab nruab nrog tsawg dua 0.02 mm yuav tshwm sim tsis tshwm sim, thaum lub rooj nruab nruab (0.015–0.03 mm ntev) yuav tshem tawm dej nyob hauv. Kev txhim kho daim duab xws li daim duab ntsuab yuav pab yooj yim dua thiab txo sijhawm tsim kho los ntawm 18% ( 2022 Tooling Efficiency Report ).

Kev Xaiv Lub Tsev thiab Kev Txhim Kho Kev Tsis Nyob Hauv Lub Tsev

Hom Lub Tsev thiab Nws Kev Tshwm Sim ntawm Kev Nyob thiab Kev Nyob

Kev xaiv lub tsev muaj kev tshwm sim ntawm kev nyob thiab kev nyob hauv tawj ntsuam plastic injection cov kev tshwm sim. Lub tshuab feem ntau muaj:

• Edge/tab gates : Siv tau zoo rau cov khoom muaj dej du, tab sis tso caij ntawm lub voj voog
• Submarine/cashew gates : Pab siv tshuab ceev kom kho tawm qhov kho, tsis muaj qhov tso caij
• Pinpoint gates : Tso caij me me, yooj yim rau qhov chaw yuav tsum zoo
  Fan gates pab tiv thaiv kev nyuaj siab nyob rau hauv qhov loj, thaum pinpoint gates me dua yuav tiv thaiv kev sib thaus. Nyob rau hauv lub xov xwm Plastic International (2023) pom tias submarine gates tau txo qhov tsis zoo los ntawm 47% dhau hlo li gates uas tau kho los ntawm tus neeg nyob rau hauv khoom siv hauv tsev.

Siv kev xaiv qhov chaw xa tshuab kom txo qhov tshwm sim ntawm weld lines thiab air traps

Kev txiav txim siab lub ntim thiab kev tswj xyuas kev sib dhau los ntawm kev sau kom meej meej tuaj yeem pab kom pom zoo dua. Ntau tus neeg tsim mold paub tag nrho tias single end gates feem ntau tsim weld lines nyob rau hauv 8 ntawm 10 hnub, raws li cov kev suav hais tseg los ntawm Moldflow. Yog li no, ntau yam chaw tsim kho mus rau dual gates uas pab txawj xaiv qhov weld line ntawm qhov chaw tseem ceeb uas yuav ua rau muaj teeb meem. Thaum txiav txim siab tias yuav tso gate sa ib cheeb tsam, yuav tsum tso lawv nyob deb ntawm qhov muaj duab ntau kom dej nkhiab hauv av tso tseg tau zoo rau hauv qhov tsho. Rau cov khoom muaj kab rooj ntev, kev tso gate nyob rau sab nraud yog qhov zoo tshaj plaws vim nws tso kom dej nkhiab tau sib npaug txog tag nrho lub khoom thiab tsis txawj ua rau muaj kev cuam tshuam ntawm kev nkhiab.

Sib cuam tshuam ntawm kev sib ntxiv thiab kev faib ntau

Kev sib ntxiv sib xws yog ib qhov tseem ceeb kom kev faib ntau sib xws thiab kom tsis muaj kev cuam tshuam hauv siab. Kev sib dhau tsis sib xws yuav ua rau:

Txog li ntau dua 60% ntawm qhov sib txawv hauv qhov ntev yog los ntawm cov kev tswj hwm tsis nyob qhov chaw. Qhov kev pib sib npaug tuaj yeem txo qhov ntxhais hauv plua pluaj los ntawm 34% thiab txo qhov sib txawv los ntawm 19%.

Cov kev tshaj lij ntau dua hauv kev tsim tshuab thiab cov kev tshwm sim tseem ceeb tshaj plua pluaj hauv tshuab tsim tshuab tsim tshuab

CNC Machining vs. EDM: Cov kev tshaj lij hauv kev tsim tshuab tsim tshuab

Kev siv neeg tsim kompiuter kho tshuab yuav tig nrog qhov muaj zog hauv 0.005 mm los ntawm kev siv tshuab pheej ywg uas peb paub tag nrho. Qhov no ua rau CNC zoo tshaj plaws rau daim npoo tsis tas li thiab pab pib tau ntev dua thaum siv rau daim ntawv kho tshuab nyiaj. Tom qab ntawd yog Electrical Discharge Machining, lossis EDM li cov neeg hu. Txawv ntawm kev tig tshuab tshaiv, EDM tsim cov duab le le tshwj tsis ntawm ib cheeb tsam tig tshuab uas tig tshuab tshaiv tshwj tsis. Kev tig tshuab no tuaj yeem tig tshuab ntau yam tshwj tsis uas yuav tig tshuab tshaiv tshwj tsis. Rau cov neeg tsim kho tshuab uas tab tom tsim daim npoo zoo tshaj plaws lossis cov duab me me, EDM pab ruaj ntev vim lawv tsis tas tig tshuab ntev tom qab tig tshuab. Ntau chaw tsim kho tshuab thiaj li hla mus rau EDM thaum lawv xav tau qhov muaj zog hauv microns hauv kev tsim kho tshuab.

Npoo, kev tsim kab, thiab kev xaiv rau kev muaj yam ntxwv

Thaum pib tsim cov ntawv sau uas muaj lub npe tiv tauj nyob rau hauv khoom, cov neeg tsim khoom feem ntau sau ua ke nrog kev kho kom zoo li siv tshuaj ntxhiab lossis kev sau nrog laser. Cov txoj kev no pab rau cov duv tsim tau txhua yam ntawm cov ntawv sau yooj yim mus rau cov ntawv sau tseem ceeb uas muaj feem ntau. Cov kev kho kom smooth feem ntau kuj sib txawv ntau—mus rau hauv cov kev kho kom smooth tshaj plaws SPI-C1 uas tseem ceeb rau cov khoom zoo li lenses thiab mirrors txhua yam mus rau hauv cov ntawv sau tseem ceeb uas muaj feem ntau uas xyaum zoo li cov khoom nyob rau hauv yam khoom. Ntau chaw tsim khoom tam sim no siv software sib cuag sib txawv kom pom lub ntsiab lus ntawm cov ntawv sau no yuav tsum nyob qhov twg kom tsis txhob muaj teeb meem nyob rau hauv kev tsim khoom. Kev xaiv qhov chaw tseem ceeb kom tsis txhob muaj teeb meem nrog kev sib luag ntawm yam khoom thaum kuj tseem pab kom cov khoom tsim tau zoo thiab txhawis tau cov ntsiab lus hauv lub hauv paus txhua zaus.

Thaum sib piv cov hlau nyob rau hauv qhov chaw ntxhiab nrog cov hlau uas tau ntxhiab ua ntej: kev nyob dav thiab kev sib piv ntau ntxiv

Thaj chaw ua dej npuas sib ntxur H13 (~50 HRC) tuaj yeem tiv thaiv tau dhau li 500,000 lub sijhawm nyob rau hauv kev siv khoom siv los ntawm dej npuas sib ntxur, tab sis muaj 30–40% ntau dua rau kev tsim kho. Thaj chaw ua dej npuas sib ntxur P20 (~32 HRC) yuav txo qhov lag luam thawj zaug los ntawm 25%, yog li ntawd nws zoo tshaj rau kev tsim kho tshiab lossis kev siv me ntsawv. Qhov kev xaiv no nyob ntawm qhov ntau thiab me ntawm kev tsim kho, qhov tshem theem ntawm khoom siv, thiab tus nqi.

Daim Duab Sma, Cov Chav Sua Hauv Daim Duab, thiab Kev Tso Daim Duab Txoj kev Tshwm Kab

Cov daim duab muaj hauv nrog cov chav suav siab thiab suav tog zog tuaj yeem suav kom pom feem xwm thaum kawg, tsim kev kho mob tswj hwm kom tshem tawm kev phom sij li ntawm kev tso tseg lossis kev sib tshuam tsawg. Cov daim duab no tseem muaj cov kab ntsug kho tshav ntuj tsim los los ntawm kev tsim txuj ci, uas ua haujlwm zoo dua hauv cheeb kam thiab sau nyiaj txhua lub lim 15 mus rau 20% ntawm ntau yam ntxiv. Koj kuj muaj cov khoom siv tshiab rau kev tsim kho tshiab uas yuav ploj tsaus tom qhov siv. Lawv khaws cov kabon tshwm txog li 30% ntau dua li cov khoom siv hlau theej theem, yog li cov neeg tsim khoom uas xav tsim cov khoom me me kuj muaj txoj haujlwm tsim khoom nyom tshaub ntau dua rau lawv cov kev tsim khoom ntaus.

FAQ

Qhov ncaj ncees ntawm cov daim duab ntaus plastik yog dab tsi?

Cov daim duab ntaus plastik twb raug tsim los ntaus cov khoom thermoplastics kub los ua rau ib qho chaw tshwj xeeb thiab tshwj xeeb, nrog qhov ncaj ncees yog kom paub meej tias kev tsim khoom tau zoo thiab meej ntes.

Cov duab ntawv twg yog qhov feem ntau siv hauv kev tsim kho rau ntim plastic?

Zoo tshaj plaws cov duab ntawv muaj polypropylene (PP), ABS, polyethylene (PE), thiab cov duab ntawv nyeej dua xws li nylon, polycarbonate, thiab PEEK uas siv rau cov kev siv ntau txaus siab.

Kev xaiv duab ntawv li cas txhawb rau kev puav tsoob thiab kev tsim kho?

Cov duab ntawv xws li glass-filled composites tuaj yeem tso kom ntau dua thiab nce ntau nqi, thaum crystalline polymers rov qab lub sijhawm sov tsheb, txhawb rau kev tsim kho. Cov duab ntawv amorphous feem ntau sov ntev dua.

Cov cuab yeej twg tau raug xav nrog hauv Kev Sau Ntaub NTawv Rau Kev Tsav Tsheb (DFM)?

DFM zoo yuav pab simplify kev sau ntaub, xaiv cov duab ntawv uas pab sux ntau, thiab kho kev sau ntaub xws li qhov thickness tseem ceeb kom txhob muaj kev phom sij thiab pab tau rau kev tsim kho.

Qhov kev pab tshaj plaws ntawm kev siv smart molds thiab in-mold sensors yog dab tsi?

Smart molds uas muaj in-mold sensors tuaj yeem pab kom kev tsim kho zoo dua los ntawm kev soj ntsuam thiab kho nyob zej zog, kom txhob muaj kev phom sij thiab kom nqi hluav taws khib zo tsoo.