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汽车塑件领域注塑工艺的应用与实践
由于汽车复杂零件的塑料件有与众不同的特殊性，所以其注塑成型在设计上需要充分考虑到如下因素，材料的干燥处理、玻纤增强材料对螺杆的新要求、驱动形式及合模结构等。
首先，当汽车保险杠、仪表板等常用的树脂材料为改性PP和改性ABS等改性树脂时，树脂材料有不同的吸湿性，为满足成型时的水份含量要求(一般要求≤0.2%)，树脂原料在进入注塑机螺杆预塑计量之前，都要经过热风干燥或除湿干燥处理。
改性PP(PP EPDM)树脂的吸湿性较小，一般采用热风干燥机在80-100℃的条件下2-3h即可。改性ABS(PC ABS)的吸湿性较强，在成型干燥前，应用除湿干燥机进行除湿干燥处理。我们在设计汽车复杂塑料零件成型系统上充分考虑了除湿干燥系统功能运用。
第二，目前国内汽车用塑料件基本上为无玻璃纤维增强的塑料制品，与使用含有短切玻璃纤维增强的树脂相比，成型无玻璃纤维增强塑料件所用注塑机的螺杆的材质和结构有较大的不同。注塑机在设计时，要注意螺杆料筒的合金材质和特殊的热处理加工工艺，保证它的耐腐性和强度。
第三，由于汽车零部件与常规产品不同，它的型腔面十分复杂，受力不等、应力分布不均，在设计中重点考虑它所需的加工能力。注塑机的加工能力体现在合模力和注塑能力(以最大理论注射容积来表示)两方面。注塑机在成型制品时，合模力必须大于模具型腔压力产生的开模力，否则模具分型面将会分开而成产生溢料。
确定注塑机合模力的公式如下：P合模≥P型腔×F/100。式中：P合模为注塑机的合模力(或称锁模力)KN;P型腔为模腔平均压力，MPa，与制品结构形状、精度要求和每模型腔数等有关，取值范围一般在25-40MPa之间;F为模具型腔，浇道和进料口的水平重叠投影面积CM3。
为保证可靠的锁模、注塑成型时的工艺锁模力必须小于注塑机的额定锁模力。注塑机的最大理论注射容积与注塑机合模力吨位相匹配，是注塑机在出厂前以聚苯乙烯(PS)为基准树脂标称出来的注射容量。
第四，根据汽车复杂塑料零部件特性而对注塑机的驱动形式和合模机构的设计，国内目前使用较多的为液压机械式或者全液压式的液压曲肘，或者是中心部直压合模机构的注塑机。泰瑞机械股份有限公司经过多年努力，突破传统约束，研发出二板合模直压、复合锁模形式机械结构。这种结构的优越性在于它的开模行程远远大于液压曲肘合模结构，至少在2倍以上，满足汽车大型塑件(如保险杠、仪表板等)生产需求。其次，锁模采用4个复合油缸同步锁住，用小流量实现大吨位的平稳锁模，锁模力可以高于同吨位的液压曲肘合模结构。对汽车大型复杂塑料零部件的成型复合面精度给予充分保证。
第五，由于汽车零部件的型腔面十分复杂，注塑机在设计时要考虑其特殊性，配置一些特殊的功能程序：如多组抽芯功能、时序控制功能、注塑机配套换模装置功能、配套取件机械手装置功能等。这些特殊功能在生产汽车塑料零部件中优势十分明显。例如，用这种机型注塑机在保险杠生产过程中，为了缩短生产周期，通过取件机械手自动取出模具开模顶出后的大型塑料制品件，多组抽芯使大型塑料制品平稳整体顶出，不会产生顶白或开裂现象。目前我们在这注塑系统中使用的多为3轴取件机械手，个别使用6轴取件机械手。
车用塑料零部件优势
汽车复杂塑料零部件的优势：
1、塑料可以一次加工成型，加工时间短，精度有保证。
2、塑料制品的弹性变形特性能吸收大量的碰撞能量，对强烈撞击有较大的缓冲作用，对车辆和乘员起到保护作用。现代汽车上都采用塑化仪表板和方向盘，以增强缓冲作用。前后保险杠、车身装饰条都采用塑料材料，以减轻车外物体对车身的冲击力。塑料还具有吸收和衰减振动和噪声的作用，可以提高乘坐的舒适性。
3、塑料耐腐蚀性强，局部受损不会腐蚀。
4、通过添加不同的填料、增塑剂和硬化剂来制出所需性能的塑料，以适应车上不同部件的用途要求。更方便的是塑料颜色可以通过添加剂调出不同颜色，省去喷漆的麻烦。有些塑料件还可以电镀。
另一方面，汽车复杂零部件的注塑件特殊的外观和尺寸要求提高了汽车注塑件的开发门槛和风险。Moldflow三维软件帮助企业在产品设计阶段分析塑件的成型可行性，通过对部品的变形及成型工艺的分析，评估并优化产品设计，同时指导了下游厂商的模具及注塑优化。
部分型号部分物性表
| Physical Properties | Metric | English | Comments |
|---|---|---|---|
| Specific Gravity | 0.960 g/cc | 0.960 g/cc | ASTM D792 and ISO 1183 |
| Mechanical Properties | Metric | English | Comments |
| Hardness, Shore A |
60 @Time 15.0 sec |
60 @Time 0.00417 hour |
2 mm; ISO 868 |
| Tensile Strength at Break | 5.10 MPa | 740 psi | Across Flow; ASTM D412 and ISO 37 |
| Tensile Stress |
1.90 MPa @Strain 100 % |
276 psi @Strain 100 % |
Across Flow; ASTM D412 and ISO 37 |
| Elongation at Break | 450 % | 450 % | Across Flow; ASTM D412 and ISO 37 |
| Compression Set |
16 % @Temperature 23.0 °C, Time 79200 sec |
16 % @Temperature 73.4 °F, Time 22.0 hour |
ASTM D395B Type 1 and ISO 188 Type A |
|
35 % @Temperature 70.0 °C, Time 79200 sec |
35 % @Temperature 158 °F, Time 22.0 hour |
ASTM D395B Type 1 and ISO 188 Type A | |
|
42 % @Temperature 100 °C, Time 79200 sec |
42 % @Temperature 212 °F, Time 22.0 hour |
ASTM D395B Type 1 and ISO 188 Type A | |
|
47 % @Temperature 100 °C, Time 1.08e+6 sec |
47 % @Temperature 212 °F, Time 300 hour |
ASTM D395B Type 1 and ISO 188 Type A | |
PP (polypropylene # folding glue | soft) /PP-141/ Korea Dalin
Uses: other
Important beters: melt flow rate: 25 g/10min density: 0.9 g/cm3 impact strength: 4 tensile strength: 39.2 MPa elongation: 20% flexural modulus: 1666 MPa hardness: 110 VEKA softening point of 157 DEG C heat debation temperature: 115 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-197/ Korea Dalin
Uses: other
Important beters: melt flow rate: 25 g/10min density: 0.9 g/cm3 notched impact strength: 3 tensile strength: 36.26 MPa bending modulus: 1372 MPa hardness: 100 VEKA softening point: 155 degrees of hot debation temperature: 105 DEG C
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-246/ Korea Dalin
Uses: other
Important beters: melt flow rate: 20 g/10min density: 0.9 g/cm3 impact strength: 8 tensile strength: 28.42 MPa elongation: 20% flexural modulus: 1225 MPa hardness: 90 VEKA softening point of 150 DEG C heat debation temperature: 110 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-245/ Korea Dalin
Uses: other
Important beters: melt flow rate: 13 g/10min density: 0.9 g/cm3 impact strength: 8 tensile strength: 28.42 MPa elongation: 20% flexural modulus: 1274 MPa hardness: 90 VEKA softening point of 150 DEG C heat debation temperature: 110 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-172/ Korea Dalin
Uses: other
Important beters: melt flow rate: 14 g/10min density: 0.9 g/cm3 impact strength: 4 tensile strength: 37.24 MPa elongation: 10% flexural modulus: 1470 MPa hardness: 104 VEKA softening point of 156 DEG C heat debation temperature: 105 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-180/ Korea Dalin
Uses: other
Important beters: melt flow rate: 26 g/10min density: 0.9 g/cm3 impact strength: 3 tensile strength: 37.24 MPa elongation: 10% flexural modulus: 1470 MPa hardness: 104 VEKA softening point of 155 DEG C heat debation temperature: 106 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-184/ Korea Dalin
Uses: other
Important beters: melt flow rate: 34 g/10min density: 0.9 g/cm3 impact strength: 3 tensile strength: 37.24 MPa elongation: 10% flexural modulus: 1470 MPa hardness: 98 VEKA softening point of 150 DEG C heat debation temperature: 100 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-124T/ Korea Dalin
Uses: other
Important beters: melt flow rate: 3.2 g/10min density: 0.9 g/cm3 elongation at break: 12% bending modulus: 1569 MPa VEKA softening point: 153 degrees of hot debation temperature: 100 degrees centigrade
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP/g-PP/ glass / fuyuda plasticizing
Uses: other
Characteristic notes: good perbance, stable quality, reasonable price and so on
Important beters: notched impact strength: 9.4 tensile strength: 92.2 MPa bending strength: 100 MPa bending modulus: 5180 MPa, hot debation temperature: 147 DEG C
Manufacturer: Cixi Da Da plasticization Co., Ltd.
PP (polypropylene # folding glue | soft) /PP-101/ Korea Dalin
Application: film grade
Important beters: melt flow rate: 12 g/10min density: 0.9 g/cm3 impact strength: 4 tensile strength: 34.3 MPa elongation: 12% bending strength: 1519 MPa hardness: 101 VEKA softening point of 155 DEG C heat debation temperature: 102 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /P2300/ Hearst of Germany
Uses: other
Characteristic note: include random PP
Important beter: melt flow rate: 15 g/10min density: 0.901 g/cm3
Manufacturer: Germany Hoechst group
PP (polypropylene # folding glue | soft) /PP-164/ Korea Dalin
Uses: other
Important beters: melt flow rate: 3.5 g/10min density: 0.9 g/cm3 impact strength: 5 tensile strength: 36.26 MPa elongation: 12% flexural modulus: 1568 MPa hardness: 100 VEKA softening point of 154 DEG C heat debation temperature: 104 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-186/ Korea Dalin
Uses: other
Important beters: melt flow rate: 60 g/10min density: 0.9 g/cm3 impact strength: 2.5 tensile strength: 37.24 MPa elongation: 10% flexural modulus: 1470 MPa hardness: 98 VEKA softening point of 150 DEG C heat debation temperature: 100 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-N/ Yuyao Manulife
Uses: other
Important beters: melt flow rate: 10 g/10min notched impact strength: 80 tensile strength: 25 MPa, elongation at break: 200% bending strength: 35 MPa bending modulus: 1100 MPa
Manufacturer: Yuyao Hongli Plastics & Chemical Co., Ltd.
PP (polypropylene # folding glue | soft) /PP-M/ Yuyao Manulife
Uses: other
Important beters: melt flow rate: 7 g/10min notched impact strength: 120 tensile strength: 23 MPa, elongation at break: 300% bending strength: 32 MPa bending modulus: 900 MPa
Manufacturer: Yuyao Hongli Plastics & Chemical Co., Ltd.
PP (polypropylene # folding glue | soft) /PP-137/ Korea Dalin
Uses: other
Important beters: melt flow rate: 12.5 g/10min density: 0.9 g/cm3 impact strength: 2 tensile strength: 37.24 MPa elongation: 12% flexural modulus: 1577.8 MPa hardness: 104 VEKA softening point of 155 DEG C heat debation temperature: 107 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP-171/ Korea Dalin
Application: fiber grade
Important beters: melt flow rate: 12 g/10min density: 0.9 g/cm3 notched impact strength: 4 tensile strength: 37.24 MPa, elongation at break: 10% bending modulus: 1470 MPa hardness: 104 VEKA softening point: 156 DEG C
PP (polypropylene # folding glue | soft) /PP-185/ Korea Dalin
Application: fiber grade
Important beters: melt flow rate: 38 g/10min density: 0.9 g/cm3 impact strength: 3 tensile strength: 37.24 MPa elongation: 10% flexural modulus: 1470 MPa hardness: 98 VEKA softening point of 150 DEG C heat debation temperature: 100 degrees
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP10/ Zhejiang toshiji
Uses: other
Important beters: notched impact strength: 11 tensile strength: 60 MPa bending strength: 120 MPa hardness: 110, hot debation temperature: 150 DEG C
Manufacturer: Zhejiang Juner New Material Co Ltd
PP (polypropylene # folding glue | soft) /PP-124M/ Korea Dalin
Uses: other
Important beters: melt flow rate: 3 g/10min density: 0.9 g/cm3 impact strength: 5 tensile strength: 36 MPa elongation: 12% flexural modulus: 1569 MPa hardness: 98 VEKA softening point of 153 DEG C heat debation temperature: 100 degrees
Manufacturer: Korea Dalin Co.
