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技术分享：注塑制品尺寸不稳定怎么办？
型条件不一致或操作不当
注射成型时，温度，压力及时间等各项工艺参数，必须严格按照工艺要求进行控制，尤其是每种塑件的成型周期必须一致，不可随意变动。如果注射压力太低，保压时间太短，模温太低或不均匀，料筒及喷嘴处温度太高，塑件冷却不足，都会导致塑件形体尺寸不稳定。
一般情况下，采用较高的注射压力和注射速度，适当延长充模和保压时间，提高模温和料温，有利克服尺寸不稳定故障。
如果塑件成型后外型尺寸大于要求的尺寸，应适当降低注射压力和熔料温度，提高模具温度，缩短充模时间，减小浇口截面积，从而提高塑件的收缩率。
若成型后塑件的尺寸小于要求尺寸，则应采取与之相反的成型条件。
值得注意的是，环境温度的变化对塑件成型尺寸的波动也有一定的影响，应根据外部环境的变化及时调整设备和模具的工艺温度。
成型原料选用不当
成型原料的收缩率对塑件尺寸精度影响很大。如果成型设备和模具的精度很高，但成型原料的收缩率很大，则很难保证塑件的尺寸精度。一般情况下，成型原料的收缩率越大，塑件的尺寸精度越难保证。因此，在选用成型树脂时，必须充分考虑原料成型后的收缩率对塑件尺寸精度的影响。对于选用的原料，其收缩率的变化范围不能大于塑件尺寸精度的要求。
应注意各种树脂的收缩率差别较大，根据树脂的结晶程度进行分析。通常，结晶型和半结晶型树脂的收缩率比非结晶型树脂大，而且收缩率变化范围也比较大，与之对应的塑件成型后产生的收缩率波动也比较大；对于结晶型树脂，结晶度高，分子体积缩小，塑件的收缩大，树脂球晶的大小对收缩率也有影响，球晶小，分子间的空隙小，塑件的收缩较小，而塑件的冲击强度比较高。
此外，如果成型原料的颗粒大小不均，干燥不良，再生料与新料混合不均匀，每批原料的性能不同，也会引起塑件成型尺寸的波动。
模具故障
模具的结构设计及制造精度直接影响到塑件的尺寸精度，在成型过程中，若模具的刚性不足或模腔内承受的成型压力太高，使模具产生变形，就肝造成塑件成型尺寸不稳定。
如果模具的导柱与导套间的配合间隙由于制造精度差或磨损太多而超差，也会使塑件的成型尺寸精度下降。
如果成型原料内有硬质填料或玻璃纤维增强材料导致模腔严重磨损，或采用一模多腔成型时，各型腔间有误差和浇口，流道等误差及进料口平衡不良等原因产生充模不一致，也都会引起尺寸波动。
因此，在设计模具时，应设计足够的模具强度和刚性，严格控制加工精度，模具的型腔材料应使用耐磨材料，型腔表面最好进行热处理及冷硬化处理。当塑件的尺寸精度要求很高时，最好不采用一模多腔的结构形式，否则为了保证塑件的成型精度，必须在模具上设置一系列保证模具精度的辅助装置，导致模具的制作成本很高。
当塑件出现偏厚误差时，往往也是模具故障造成的。如果是在一模一腔条件下塑件壁厚产生偏厚误差，一般是由于模具的安装误差及定位不良导致模腔与型芯的相对位置偏移。此时，对于那些壁厚尺寸要求很精确的塑件，不能仅靠导柱和导套来定位，必须增设其他定位装置。
如果是在一模多腔条件下产生的偏厚误差，一般情况下，成型开始时误差较小，但连续运转后误差逐渐变大，这主要是由于模腔与型芯间的误差造成的，特别是采用热流道模成型时最容易产生这种现象。对此，可在模具内设置温度差异很小的双冷却回路。如果是成型薄壁圆型容器，可采用浮动型芯，但型芯和模腔必须同心。
此外，在制作模具时，为了便于修模，一般总是习惯于将型腔做得比要求尺寸小一些，型芯做得比要求尺寸大一些，留出一定的修模余量。当塑件成型孔的内径甚小于外径时，芯销应做得大一些，这是由于成型孔处塑件的收缩总是大于其它部位，而且向孔心方向收缩的。反之，若塑件成型孔的内径接近于外径时，芯销可以做得小一些。
设备故障
如果成型设备的塑化容量不足，加料系统供料不稳定，螺杆的转速不稳定，停止作用失常，液压系统的止回阀失灵，温度控制系统出现热电偶烧坏，加热器断路等，都会导致塑件的成型尺寸不稳定。这些故障只要查出后可采取针对性的措施予以排除。
测试方法或条件不一致
如果测定塑件尺寸的方法，时间，温度不同，测定的尺寸会有很大的差异。其中温度条件对测试的影响最大，这是因为塑料的热膨胀系数要比金属大工业10倍。因此，必须采用标准规定的方法和温度条件来测定塑件的结构尺寸，并且塑件必须充分冷却定型后才能进行测量。一般塑件在脱模式10小时内尺寸变化是很大的，24小时才基本定型。
| Physical Properties | Metric | English | Comments |
|---|---|---|---|
| Density | 1.16 g/cc | 0.0419 lb/in3 | ISO 1183 |
| Moisture Absorption at Equilibrium | 0.200 % | 0.200 % | ISO 62 |
| Water Absorption at Saturation | 0.500 % | 0.500 % | ISO 62 |
| Viscosity |
225000 cP @Frequency 1000 Hz, Temperature 260 °C |
225000 cP @Frequency 1000 Hz, Temperature 500 °F |
ISO 1133 |
| Linear Mold Shrinkage, Flow | 0.00550 - 0.00750 cm/cm | 0.00550 - 0.00750 in/in | 150x105x3 mm; 260 °C / MT 80 °C; b.o. ISO 2577 |
| Linear Mold Shrinkage, Transverse | 0.00550 - 0.00750 cm/cm | 0.00550 - 0.00750 in/in | 150x105x3 mm; 260 °C / MT 80 °C; b.o. ISO 2577 |
| Melt Flow |
31 g/10 min @Load 5.00 kg, Temperature 260 °C |
31 g/10 min @Load 11.0 lb, Temperature 500 °F |
estimated from MVR using room temperature density; ISO 1133 |
| Mechanical Properties | Metric | English | Comments |
| Tensile Strength at Break | 62.0 MPa | 8990 psi | 50 mm/min; ISO 527-1/-2 |
| Tensile Strength, Yield | 63.0 MPa | 9140 psi | 50 mm/min; ISO 527-1/-2 |
| Elongation at Break | >= 50.0 % | >= 50.0 % | 50 mm/min; ISO 527-1/-2 |
| Elongation at Yield | 5.0 % | 5.0 % | 50 mm/min; ISO 527-1/-2 |
| Tensile Modulus | 2.45 GPa | 355 ksi | 1 mm/min; ISO 527-1/-2 |
| Izod Impact, Notched (ISO) |
15.0 kJ/m2 @Temperature -20.0 °C |
7.14 ft-lb/in2 @Temperature -4.00 °F |
ISO 180-A |
|
45.0 kJ/m2 @Temperature 23.0 °C |
21.4 ft-lb/in2 @Temperature 73.4 °F |
ISO 180-A | |
| Izod Impact, Unnotched (ISO) |
NB @Temperature 23.0 °C |
NB @Temperature 73.4 °F |
ISO 180-U |
|
NB @Temperature -30.0 °C |
NB @Temperature -22.0 °F |
ISO 180-U | |
| Electrical Properties | Metric | English | Comments |
| Volume Resistivity | 1.00e+14 ohm-cm | 1.00e+14 ohm-cm | IEC 60093 |
| Surface Resistance | 1.00e+16 ohm | 1.00e+16 ohm | IEC 60093 |
| Dielectric Constant |
2.80 @Frequency 1.00e+6 Hz |
2.80 @Frequency 1.00e+6 Hz |
IEC 60250 |
PET (polyethylene terephthalate # polyester /PT70 GR30 NL/ Germany Melos)
Uses: electronic and electrical components
Characteristics: semi crystalline, good dimensional stability, gloss, high thermal resistance, good thermal stability, good toughness, medium hardness
Important beters: density: 1.57 g/cm3 water absorption: 0.7% molding shrinkage: 0.9% notched impact strength: 9 bending strength: 240 MPa bending modulus: 9000 MPa VEKA softening point: 225 degrees of hot debation temperature: 220 degrees centigrade
Manufacturer: Melos, Germany
PET (polyethylene terephthalate polyester #) /9035-104/ Taiwan Changchun
Uses: other
Note: the properties of glass fiber reinforced materials, 35% low warpage electrical properties bing perbance of anti solubility good chemical resistance and good abrasion resistance, good resistance to impact perbance of good thermal climate, high oil resistance, oil resistance
Important beters: density: 1.59 g/cm3 water absorption: 3% notched impact strength: 93, elongation at break: 3% bending strength: 186 MPa bending modulus: 9810 MPa, hot debation temperature: 215 DEG C
Manufacturer: Taiwan Changchun enterprise group
PET (polyethylene terephthalate # polyester /PT74 GR30 BK002 DA/ Turkey Eurotec)
Uses: other
Characteristic note: glass fiber reinforced material, 30% packing according to weight, lubrication, thermal stability
Important beters: density: 1.55 g/cm3 water absorption: 0.2% molding shrinkage: 0.9% notched impact strength: 9, VEKA softening point: 225 degrees of hot debation temperature: 215 degrees centigrade
Manufacturer: Turkey Eurotec company
PET (polyethylene terephthalate polyester #) /KP132G30V0BL/ Korea Kolon
Uses: other
Features: good dimensional stability. Flame retardant additives: flame retardant
Important beters: melt flow rate: 25 g/10min density: 1.66 g/cm3 absorption rate: 0.05% notched impact strength: 54 tensile strength: 118 MPa elongation: 4.6% bending strength: 177 MPa flexural modulus of 8630 MPa hot debation temperature: 220 degrees
Manufacturer: Korea long Corporation
PET (polyethylene terephthalate # polyester) /WB-8828B/ Changzhou Huarun
Uses: other
Characteristic note: the product has the characteristics of low heavy bl content, low acetaldehyde content, good color value and stable viscosity. In view of the particularity of carbonated beverage application, the unique process bulation and technical production, low processing temperature, wide processing range, good transparency and high yield of products.
Important beter:
Huarun polyester (Changzhou) Co., Ltd.
PET (polyethylene terephthalate # polyester) /WB-8828AA/ Changzhou Huarun
Uses: other
Characteristic note: the product has the characteristics of low heavy bl content, low acetaldehyde content, good color value and stable viscosity. In view of the particularity of carbonated beverage application, the unique process bulation and technical production, low processing temperature, wide processing range, good transparency and high yield of products.
Important beter:
Huarun polyester (Changzhou) Co., Ltd.
PET (polyethylene terephthalate # polyester /PT70 GR30 NL XA) 20/ Melos in Germany
Uses: other
Characteristics: semi crystalline, good dimensional stability, gloss, high thermal resistance, good thermal stability, good toughness, medium hardness
Important beters: density: 1.67 g/cm3 water absorption: 0.65% molding shrinkage: 0.9% notched impact strength: 8 bending strength: 190 MPa bending modulus: 9500 MPa VEKA softening point: 220 degrees of hot debation temperature: 215 degrees centigrade
Manufacturer: Melos, Germany
PET (polyethylene terephthalate polyester #) /2550GN20/ Korea Miyaki
Uses: other
Note: the properties of glass fiber reinforced materials, 20% dimensional stability, good rigidity, high rigidity, high strength and good electrical perbance of the crystal chemical resistance good heat resistance, high production, fast absorbing flammability of moisture
Important beters: water absorption: 0.1% molding shrinkage: 0.2% notched impact strength: 790 bending strength: 157 MPa bending modulus: 6860 MPa, hot debation temperature: 220 DEG C
Manufacturer: SAMYANG engineering plastics division
PET (polyethylene terephthalate polyester #) /111 G5/ Taroplas in Italy
Uses: other
Characteristics: glass fiber reinforced material, 25% dimensional stability, good electrical perbance, good chemical resistance, heat resistance, high moisture absorption
Important beters: density: 1.53 g/cm3 molding shrinkage: 0.7% notched impact strength: 75, elongation at break: 2.2% bending strength: 185 MPa bending modulus: 7800 MPa, hot debation temperature: 225 DEG C
Manufacturer: Italy Taroplast thermoplastic engineering plastics company
PET (polyethylene terephthalate # polyester /PT74 GR20 BK XA20/ Turkey Eurotec)
Uses: other
Characteristic note: glass fiber reinforced material, 20% packing according to weight, thermal stability, flame retardant perbance
Important beters: density: 1.62 g/cm3 water absorption: 0.2% molding shrinkage: 0.9% notched impact strength: 7, VEKA softening point: 215 degrees of hot debation temperature: 205 degrees centigrade
Manufacturer: Turkey Eurotec company
PET (polyethylene terephthalate polyester # BRICI) /303-G0/
Uses: other
Features: easy to crystallize, wear resistance, good electrical perbance, high gloss, good moisture resistance, high temperature resistance, chemical resistance
Important beters: density: 1.54 g/cm3, water absorption: 0.08% molding shrinkage: 1.5% notched impact strength: 4 tensile strength: 68 MPa bending strength: 110 MPa, hot debation temperature: 78 DEG C
Manufacturer: Beijing Chemical Industry Research Institute (Enterprise Group)
PET (polyethylene terephthalate # polyester /PT70 GR30 NL XA20/ Turkey Eurotec)
Uses: other
Characteristic note: glass fiber reinforced material, 30% packing according to weight, thermal stability, flame retardant perbance
Important beters: density: 1.69 g/cm3 water absorption: 0.18% molding shrinkage: 0.9% notched impact strength: 8, VEKA softening point: 250 degrees of hot debation temperature: 215 degrees centigrade
Manufacturer: Turkey Eurotec company
PET (polyethylene terephthalate # polyester /PT74 KK30 BK XA20/ Turkey Eurotec)
Uses: other
Characteristic note: glass fiber reinforced material, 30% packing according to weight, thermal stability, flame retardant perbance
Important beters: density: 1.65 g/cm3 water absorption: 0.17% molding shrinkage: 0.9% notched impact strength: 7, VEKA softening point: 250 degrees of hot debation temperature: 215 degrees centigrade
Manufacturer: Turkey Eurotec company
PET (polyethylene terephthalate # polyester /PT74 GR20 BK DA/ Melos, Germany)
Uses: electronic and electrical components
Characteristics: semi crystalline, good dimensional stability, gloss, high thermal resistance, good thermal stability, good toughness, medium hardness
Important beters: density: 1.47 g/cm3 water absorption: 0.9% molding shrinkage: 1% notched impact strength: 6 bending strength: 170 MPa bending modulus: 6000 MPa VEKA softening point: 220 degrees of hot debation temperature: 210 degrees centigrade
Manufacturer: Melos, Germany
PET (polyethylene terephthalate polyester #) /9045-104/ Taiwan Changchun
Uses: other
Note: the properties of glass fiber reinforced materials, 45% low warpage electrical properties bing perbance of anti solubility good chemical resistance and good abrasion resistance, good resistance to impact perbance of good thermal climate, high oil resistance, oil resistance
Important beters: density: 1.68 g/cm3 water absorption: 0.05% notched impact strength: 100, elongation at break: 3.5% bending strength: 235 MPa bending modulus: 12300 MPa, hot debation temperature: 218 DEG C
Manufacturer: Taiwan Changchun enterprise group
PET (polyethylene terephthalate # polyester /A3 LF CRLA010 PG301/ Brazil Petropol)
Uses: other
Features: good dimensional stability, high impact resistance, good chemical resistance, high clarity, and good compliance of food contact
Important beters: density: 1.33 g/cm3 notched impact strength: 49 tensile strength: 2.45 MPa, elongation at break: 50% bending strength: 1.18 MPa
Manufacturer: Brazil Petropol Polymer Co
PET (polyethylene terephthalate polyester #) /111 G3/ Taroplas in Italy
Uses: other
Characteristic note: glass fiber reinforced 15%. Perbance characteristics: good dimensional stability, good electrical perbance, good chemical resistance, poor moisture absorption, medium viscosity.
Important beters: density: 1.4 g/cm3 absorption rate: 0.08% molding shrinkage rate: 0.7% notched impact strength: 6 oxygen index: 22% tensile strength: 100 MPa elongation: 1.9% bending strength: 140 MPa flexural modulus: 9000 MPa VEKA softening point: debation temperature of 220 DEG C heat: 218 degrees
Manufacturer: Italy Taroplast thermoplastic engineering plastics company
PET (polyethylene terephthalate polyester #) /111 G8/ Taroplas in Italy
Uses: other
Characteristic note: glass fiber reinforced 40%. Perbance characteristics: good dimensional stability, good electrical perbance, good chemical resistance, poor moisture absorption, medium viscosity.
Important beters: density: 1.64 g/cm3 absorption rate: 0.05% molding shrinkage rate: 0.4% notched impact strength: 12 tensile strength: 185 MPa elongation: 2.1% bending strength: 265 MPa flexural modulus: 12500 MPa VEKA softening point: debation temperature of 242 DEG C heat: 230 degrees
Manufacturer: Italy Taroplast thermoplastic engineering plastics company
PET (polyethylene terephthalate polyester #) /7030 GY6128/ Germany BASF
Uses: other
Characteristics: glass fiber reinforced material, 30% dimensional stability, good rigidity, good surface finish, good creep resistance, good strength, high flowability, heat resistance, high
Important beters: density: 1.55 g/cm3 molding shrinkage: 0.4% notched impact strength: 100, elongation at break: 3% bending modulus: 9090 MPa, hardness: 118
Manufacturer: German Basf Inc
PET (polyethylene terephthalate polyester #) /JC-Z530-N-V0/ Jiangsu nine Sichuan
Uses: other
Characteristic note: high heat resistance, good mechanical strength and self slip; environmental protection flame retardant
Important beters: density: 1.6 g/cm3 absorption rate: 0.06% molding shrinkage rate: 0.167% notched impact strength: 8.5 tensile strength: 130 MPa elongation: 3% bending strength: 190 MPa flexural modulus: 9500 MPa hardness: 121 VEKA softening point of 238 DEG C heat debation temperature: 227 degrees
Manufacturer: Jiangsu Jiu Chuan nanometer Mstar Technology Ltd
