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注塑成型中常见异常因素及解决方法
注塑成型过程中,很容易发生一些异常现象,比如说:裂纹、制品表面有波纹、制品脆性强度下降、脱模难、制品尺寸不稳定、制品尺寸不稳定、制件脱皮分层、熔接痕、注射不满等,这些现象都会影响到成型模具的具体使用效果,因此我们需要找出相关因素以及解决方法。
裂纹
1.模具太冷,调整模具温度。
2.冷却时间太长,降低冷却时间。
3.塑料和金属嵌件收缩不一样,对金属嵌件预热。
4.顶出装置倾斜不平衡,顶出截面积小或分布不当,调整顶出装置或合理安排顶杆数量及其位置。
5.制作斜度不够,脱模难,正确设计脱模斜度。
制品表面有波纹
1.物料温度低,拈度大 提高料温。
2.注射压力,料温高,可减少注射压力,反之则加大注射压力。
3.模具温度低,提高模具温度或增大注射压力。
4.注射速度太慢 提高注射速度。
5.浇口太小,适当扩展浇口。
制品脆性强度下降
1.料温太高,塑料分解,降低料温,控制物料在料筒内滞留时间。
2.塑料和嵌件处内应力过大,对嵌件预热,保证嵌件周围有一定厚度的塑料。
3.塑料回用次数多 控制回料配比。
4.塑料含水,原料预热干燥。
脱模难
1.模具顶出装置结构不良,改进顶出设计。
2.模腔脱模斜度不够,正确设计模具。
3.模腔温度不合适,适当控制模温。
4.模腔有接缝或存料,清理模具。
5.成型周期太短或太长,适当控制注塑周期
6.模芯无进气孔,修改模具。
制品尺寸不稳定
1.机器电路或油路系统不稳,修正电器或油压系统。
2.成型周期不一样,控制成型周期,使一致。
3.温度。时间。压力变化,调节,控制基本一致。
4.塑料颗粒大小不一,使用均一塑料。
5.回收下脚料与新料混合比例不均,控制混合比例,使均匀。
6.加料不均 控制或调节加料均匀。
制件脱皮分层
1.不同塑料混杂,采用单一品种的塑料。
2.同一塑料不同牌号混杂,采用同牌号的塑料。
3.塑化不良,提高成型温度。
4.混入异物,清理原材料,出去杂质。
熔接痕
1.塑料温度太低 提高机筒。喷嘴及模具温度。
2.浇口太多 减少浇口或改变浇口位置。
3.脱模剂过量 采用雾化脱模剂。减少用量。
4.注射速度太慢,提高注射速度。
5.模具温度太低,提高模温。
6.注射压力太小,提高注射压力。
7.模具排气不良,增加模具排气孔。
注射不满
1.机筒及喷嘴温度偏低,提高机筒及喷嘴温度。
2.模具温度偏低,提高模具温度。
3.加料量不够,适当增加下料量。
4.制件超过注射成型机最大注射量,选用注射量更大的注射机。
5.流道及浇口太小,适当增加浇口尺寸。
6.注射压力太低或注射速度太慢,提高注射压力或提高温度,提噶注射速度。
部分型号部分物性表
| Physical Properties | Metric | English | Comments |
|---|---|---|---|
| Specific Gravity | 0.940 g/cc | 0.940 g/cc | 23°C; ASTM D792 |
| Mechanical Properties | Metric | English | Comments |
| Hardness, Shore A | 96 | 96 | 2 mm, 15 sec; ISO 868 |
| 97 | 97 | Air at 302°F, 168 hr; ASTM D573 | |
| Tensile Strength at Break | 13.0 MPa | 1890 psi | Across Flow; ASTM D412 |
| 13.2 MPa | 1910 psi | Air at 302°F, 168 hr; ASTM D573 | |
| Tensile Stress |
7.10 MPa @Strain 100 % |
1030 psi @Strain 100 % |
Across Flow; ASTM D412 |
| Elongation at Break | 527 % | 527 % | Air at 302°F, 168 hr; ASTM D573 |
| 620 % | 620 % | Across Flow; ASTM D412 | |
| Tear Strength | 48.0 kN/m | 274 pli | 73°C, Die C; ASTM D624 |
| Compression Set | 52 % | 52 % | 158°F, 22 hr; ASTM D395 |
| Thermal Properties | Metric | English | Comments |
| Brittleness Temperature | -53.9 °C | -65.0 °F | ASTM D746 |
| UL RTI, Electrical | 100 °C | 212 °F | UL 746 |
| UL RTI, Mechanical with Impact |
90.0 °C @Thickness 1.10 mm |
194 °F @Thickness 0.0433 in |
UL 746 |
|
95.0 °C @Thickness 1.60 mm |
203 °F @Thickness 0.0630 in |
UL 746 | |
|
95.0 °C @Thickness 3.00 mm |
203 °F @Thickness 0.118 in |
UL 746 | |
| Flammability, UL94 |
HB @Thickness 1.10 mm |
HB @Thickness 0.0433 in |
|
|
HB @Thickness 1.60 mm |
HB @Thickness 0.0630 in |
||
|
HB @Thickness 3.00 mm |
HB @Thickness 0.118 in |
||
PP (polypropylene # folding glue | soft) /EG110/ Ishida
Uses: other
Characteristic note: cold resistant
Important beter: melt flow rate: 1 g/10min
Manufacturer: Showa Electric Co., Ltd.
PP (polypropylene # folding glue | soft) /SY721/ Ishida
Uses: other
Important beter: melt flow rate: 0.7 g/10min
Manufacturer: Showa Electric Co., Ltd.
PP (polypropylene # folding glue | soft) /8200E/ MITSUBISHI of Japan
Uses: other
Characteristic note: cold resistance is very good
Important beter: melt flow rate: 1.5 g/10min
Manufacturer: MITSUBISHI Chemical Industrial Co., Ltd.
PP (polypropylene # folding glue | soft) /PY220A/ MITSUBISHI of Japan
Uses: other
Important beter: melt flow rate: 12 g/10min
Manufacturer: MITSUBISHI Chemical Industrial Co., Ltd.
PP (polypropylene # folding glue | soft) /FB116/ Tokuyama soda
Uses: other
Important beter: melt flow rate: 1.7 g/10min
Manufacturer: Tokuyama soda Co.
PP (polypropylene # folding glue | soft /SJ313/ Mitsui Chemicals)
Uses: other
Important beter: melt flow rate: 1.2 g/10min
Mitsui Chemical Corporation
PP (polypropylene # folding glue | soft /J340/ Mitsui Chemicals)
Uses: other
Important beter: melt flow rate: 1.8 g/10min
Mitsui Chemical Corporation
PP (polypropylene # folding glue | soft /PY230/ MITSUBISHI petrochemical)
Uses: other
Important beter: melt flow rate: 2.3 g/10min
MITSUBISHI Petrochemical Co., Ltd.
PP (polypropylene # folding glue | soft) /HF461Y/ Korea Dalin
Uses: other
Important beter: melt flow rate: 1500 g/10min density: 0.9 g/cm3
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /PY240A/ MITSUBISHI of Japan
Uses: other
Important beter: melt flow rate: 4 g/10min
Manufacturer: MITSUBISHI Chemical Industrial Co., Ltd.
PP (polypropylene # folding glue | soft) /T5420/ MITSUBISHI of Japan
Uses: other
Important beter: melt flow rate: 8 g/10min
Manufacturer: MITSUBISHI Chemical Industrial Co., Ltd.
PP (polypropylene # folding glue | soft) /EA120/ Ishida
Uses: other
Characteristic note: cold resistant
Important beter: melt flow rate: 1 g/10min
Manufacturer: Showa Electric Co., Ltd.
PP (polypropylene # folding glue | soft /J330/ Mitsui Chemicals)
Uses: other
Important beter: melt flow rate: 1.5 g/10min
Mitsui Chemical Corporation
PP (polypropylene # folding glue | soft /J430/ Mitsui Chemicals)
Uses: other
Important beter: melt flow rate: 2.5 g/10min
Mitsui Chemical Corporation
PP (polypropylene # folding glue | soft /PY220/ MITSUBISHI petrochemical)
Uses: other
Important beter: melt flow rate: 1.4 g/10min
MITSUBISHI Petrochemical Co., Ltd.
PP (polypropylene # folding glue | soft /KV333/ America Ineos)
Uses: other
Important beter: melt flow rate: 9 g/10min bending modulus: 650 MPa
Manufacturer: America Ineos
PP (polypropylene # folding glue | soft) /1278/ Liaoyang chemical fiber
Application: film grade
Important beter: melt flow rate: 7.75 g/10min tensile strength: 27 MPa
Manufacturer: PetroChina Liaoyang petroleum chemical fiber company
PP (polypropylene # folding glue | soft) /HF461X/ Korea Dalin
Uses: other
Important beter: melt flow rate: 900 g/10min density: 0.9 g/cm3
Manufacturer: Korea Dalin Co.
PP (polypropylene # folding glue | soft) /1156/ Liaoyang chemical fiber
Uses: other
Important beters: melt flow rate: 5.5 g/10min notched impact strength: 16 tensile strength: 7 MPa hardness: 95 VEKA softening point: 150 DEG C
Manufacturer: PetroChina Liaoyang petroleum chemical fiber company
PP (polypropylene # folding glue | soft /1102M/ Oman petrochemical)
Uses: other
Important beters: melt flow rate: 8 g/10min density: 0.91 g/cm3 notched impact strength: 330, elongation at break: 700% bending modulus: 650 MPa
Manufacturer: Oman, Petrochemical Industries Co
