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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) /PP598/ Taizhou jiaoguang
Uses: other
Remark: flame retardant grade
Important beters: melt flow rate: 6 g/10min density: 0.92 g/cm3 notched impact strength: 11.07 tensile strength: 27 MPa, elongation at break: 25% VEKA softening point: 155.8 DEG C
Manufacturer: Taizhou pepper light Plastic Engineering Ltd
PP (polypropylene # folding glue | soft) /PP01/ Taizhou jiaoguang
Uses: other
Remark: flame retardant grade
Important beters: melt flow rate: 4 g/10min density: 0.93 g/cm3 notched impact strength: 13.36 tensile strength: 30 MPa, elongation at break: 20% VEKA softening point: 156.8 DEG C
Manufacturer: Taizhou pepper light Plastic Engineering Ltd
PP (polypropylene # folding glue | soft) /PP201-M8/ Ningbo tatone
Uses: other
Important beters: melt flow rate: 2.5 g/10min density: 1.25 g/cm3 notched impact strength: 4.5 tensile strength: 29.5 MPa bending strength: 55 MPa hot debation temperature: 132 DEG C
Ningbo high speed Plastics & Chemical Co., Ltd.
PP (polypropylene # folding glue | soft dasailu) /PP-GF50-02/
Uses: other
Important beters: density: 1.33 g/cm3, notch impact strength: 20, elongation at break: 1.7% bending strength: 235 MPa
Manufacturer: polymer Co., Ltd.
PP (polypropylene # folding glue | soft dasailu) /PP-GF40-02/
Uses: other
Important beters: density: 1.22 g/cm3, notch impact strength: 19, elongation at break: 2.1% bending modulus: 230 MPa
Manufacturer: polymer Co., Ltd.
PP (polypropylene # folding glue | soft) /PP-V10/ Guangzhou blonde
Uses: other
Characteristic note: high odour
Important beters: melt flow rate: 13 g/10min molding shrinkage: 0.0145% notched impact strength: 1.11 tensile strength: 30 MPa, elongation at break: 90% bending strength: 36 MPa bending modulus: 1358 MPa hardness: 85
Manufacturer: Guangzhou blond Polytron Technologies Inc
PP (polypropylene # folding glue | soft) /PP-V25/ Guangzhou blonde
Uses: other
Characteristic remark: high rigidity
Important beters: melt flow rate: 13 g/10min molding shrinkage: 0.0115% notched impact strength: 0.993 tensile strength: 28 MPa, elongation at break: 75% bending strength: 40 MPa bending modulus: 1724 MPa hardness: 80
Manufacturer: Guangzhou blond Polytron Technologies Inc
PP (polypropylene # folding glue | soft /PP-320/ selon)
Uses: other
Features: weather resistance, low shrinkage, dimensional stability
Important beters: melt flow rate: 14 g/10min density: 1.1 g/cm3 molding shrinkage rate: 1.3% notched impact strength: 4 tensile strength: 27 MPa elongation: 20% bending strength: 36 MPa flexural modulus: 1600 MPa hardness: 110 thermal debation temperature: 120 degrees
Manufacturer: Super Dragon Engineering Plastics Co. Ltd.
PP (polypropylene # folding glue | soft /PP400/ M.Holland America)
Uses: other
Characteristic note: homopolymer
Important beters: melt flow rate: 12 g/10min density: 0.905 g/cm3 notched impact strength: 26.7 tensile strength: 33.8 MPa, elongation at break: 11% bending modulus: 1450 MPa, hardness: 109
Manufacturer: American M.Holland company
PP (polypropylene # folding glue | soft) /PP8/ Changzhou xingyidi
Uses: other
Characteristic note: heat resistant oxygen aging, light aging perbance, fan
Important beters: density: 1.23 g/cm3 tensile strength: 30 MPa bending strength: 45 MPa, hot debation temperature: 140 DEG C
Changzhou Star Technology Co., Ltd.
PP (polypropylene # folding glue | soft /PP-4364/ Ravago America)
Uses: other
Characteristic note: calcium carbonate packing, 40% processability, good
Important beters: melt flow rate: 10 g/10min density: 1.25 g/cm3 notched impact strength: 32 bending modulus: 2760 MPa, hot debation temperature: 107 DEG C
Manufacturer: Ravago USA
PP (polypropylene # folding glue | soft) /PP-EPDM/ Shanghai China Co
Uses: other
Important beters: density: 0.9 g/cm3 molding shrinkage: 1.5% notched impact strength: 150 tensile strength: 24 MPa, elongation at break: 50% bending strength: 28 MPa bending modulus: 1100 MPa, hot debation temperature: 95 DEG C
Manufacturer: Shanghai Hua Hua composite material Co., Ltd.
PP (polypropylene # folding glue | soft) /SUV-25/ Yuyao Jin Jia
Uses: other
Note: the properties of materials used in anti aging system of light and heat, according to the United States of Florida outdoor sun exposure experiment data, anti aging ability of outdoor daylight aging time with pure PP specimens compared to about 15 times of pure PP. Therefore, this brand modified PP products can be used outdoors for a long time.
Important beters: melt flow rate: 5 g/10min impact strength: 68.8 tensile strength: 33.7 MPa elongation: 63% bending strength: 46.4 MPa flexural modulus: 1209 MPa VEKA softening point: debation temperature of 145 DEG C heat: 102 degrees
Manufacturer: Yuyao Jin Yuan Plastics Research Institute
PP (polypropylene # folding glue | soft) /PP-333/ Korea Dalin
Uses: other
Features: high transparency, super high transparency, excellent gloss
Important beters: melt flow rate: 25 g/10min density: 0.9 g/cm3 notched impact strength: 5 tensile strength: 27.44 MPa bending modulus: 1176 MPa hardness: 90 VEKA softening point: 85 degrees of hot debation temperature: 100 DEG C
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PP401-G4/ Ningbo tatone
Uses: other
Important beters: melt flow rate: 2.5 g/10min density: 1.26 g/cm3 notched impact strength: 15 oxygen index: 27% tensile strength: 67 MPa bending strength: 88 MPa, hot debation temperature: 137 DEG C, filler content: 20%
Ningbo high speed Plastics & Chemical Co., Ltd.
PP (polypropylene # folding glue | soft) /006P/ Nanjing Dellon
Uses: other
Characteristic note: PP/EPDM
Important beters: density: 0.95 g/cm3 molding shrinkage: 0.006% notched impact strength: 30 tensile strength: 27 MPa breaking elongation
Manufacturer: Nanjing Dellon Plastic Alloy Co. Ltd.
PP (polypropylene # folding glue | soft) /PP-R001/ Guangzhou blonde
Uses: other
Characteristic note: flame retardant
Important beters: melt flow rate: 15 g/10min molding shrinkage: 0.011% notched impact strength: 0.955 tensile strength: 28 MPa, elongation at break: 40% bending strength: 30 MPa bending modulus: 1800 MPa hardness: 95
Manufacturer: Guangzhou blond Polytron Technologies Inc
PP (polypropylene # folding glue | soft) /PP-R2/ Guangzhou blonde
Uses: other
Characteristic note: flame retardant
Important beters: melt flow rate: 10 g/10min molding shrinkage: 0.016% notched impact strength: 0.787 tensile strength: 32 MPa, elongation at break: 100% bending strength: 35 MPa bending modulus: 1048 MPa hardness: 85
Manufacturer: Guangzhou blond Polytron Technologies Inc
PP (polypropylene # folding glue | soft) /PP-350/ Guangzhou blonde
Uses: other
Remarks: high resistance, high impact resistance,
Important beters: melt flow rate: 13 g/10min molding shrinkage: 0.0145% notched impact strength: 1.59 tensile strength: 28 MPa, elongation at break: 50% bending strength: 34 MPa bending modulus: 1551 MPa hardness: 86
Manufacturer: Guangzhou blond Polytron Technologies Inc
PP (polypropylene # folding glue | soft taikena) /PP-GF30-02/
Uses: other
Important beters: melt flow rate: 1.12 g/10min notched impact strength: 20 tensile strength: 92 MPa bending strength: 155 MPa bending modulus: 6000 MPa
Manufacturer: America taikena company
