培訓(xùn)課程 2 工藝參數(shù)的優(yōu)化

培訓(xùn)課程2工藝參數(shù)的優(yōu)化培訓(xùn)課程2工藝參數(shù)的優(yōu)化受訓(xùn)者手冊德馬格注塑機工藝參數(shù)優(yōu)化的步驟指導(dǎo)頁面周期分析3注塑工藝參數(shù)優(yōu)化6步驟1找出轉(zhuǎn)壓點7步驟1結(jié)果8步驟2找出保壓時間澆口冷凝時間9步驟2結(jié)果10步驟3優(yōu)化注射速度11步驟3結(jié)果12步驟4采用正確的螺桿轉(zhuǎn)速13步驟4結(jié)果14步驟5優(yōu)化多級螺桿轉(zhuǎn)速和背壓曲線15步驟5結(jié)果16步驟6優(yōu)化松退17步驟6結(jié)果18步驟7優(yōu)化保壓曲線19步驟7結(jié)果20TABULATEDRESULTS21步驟8優(yōu)化鎖模力22步驟8結(jié)果22步驟9設(shè)定注射壓力23步驟9結(jié)果23典型工藝參數(shù)公差設(shè)定24成型周期分析采用下面表格估計注塑過程中的每一階段對周期的影響然后去機床看正在運行的模具,寫下實際的時間并計算出百分比哪一階段在整個周期中占最多的時間那里可以是最有效的縮短成型周期模具1估計實際實際評價合模射臺前進(jìn)和后退注射時間保壓時間冷卻時間開模頂出整個成型周期100SECONDS100模具2估計實際實際評價合模射臺前進(jìn)和后退注射時間保壓時間冷卻時間開模頂出整個成型周期100SECONDS100工藝參數(shù)優(yōu)化目標(biāo)一步步改進(jìn)工藝過程穩(wěn)定性評估各個參數(shù)的更改對工藝過程穩(wěn)定性的影響TODEMONSTRATETHECUMULATIVEIMPROVEMNTINTHEPROCESSANDPRODUCTCONSISTENCY方法ATEACHSTAGE,AFTERTHEPROCESSHASBEENGIVENSUFFICIENTTIMETOSTABILISE,ARUNOFSIXTEENCONSECUTIVEMOULDINGSISTOBEMADETHESEMOULDINGSWILLBEASSESSEDFORCONSISTENCYBYWEIGHTADIMENSION,APHYSICALPROPERTYORSOMEOTHERATTRIBUTECOULDEQUALLYWELLBEUSED,WEIGHTISSIMPLYTHEMOSTWIDELYAPPLICABLE穩(wěn)定性通過計算重量的標(biāo)準(zhǔn)偏差來衡量同時打印出機床IBED上的過程統(tǒng)計數(shù)據(jù)找出轉(zhuǎn)壓點找出澆口冷卻時間優(yōu)化注射速度采用正確的螺桿轉(zhuǎn)速優(yōu)化多級預(yù)塑曲線優(yōu)化松推優(yōu)化多級保壓曲線優(yōu)化鎖模力設(shè)定注射壓力限定步驟1找出轉(zhuǎn)壓點在沒有保壓壓力和保壓時間的基礎(chǔ)上填滿產(chǎn)品9598,然后設(shè)定一定的保壓和保壓時間生產(chǎn)16模初始設(shè)置時的指導(dǎo)1采用行程切換2設(shè)定切換位置為1012MM逐步增加預(yù)塑量直到產(chǎn)品打滿9598的位置3設(shè)置注射壓力為最大值4設(shè)定保壓壓力和保壓時間均為05設(shè)定注射速度60MMS16設(shè)定松推速度為最大值7設(shè)定鎖模力為最大值8選擇適當(dāng)?shù)穆輻U轉(zhuǎn)速9根據(jù)材料物性表,設(shè)定料桶溫度10配置過程統(tǒng)計控制11設(shè)定保壓壓力和保壓時間生產(chǎn)完整的產(chǎn)品稱12模產(chǎn)品的重量,計算標(biāo)準(zhǔn)偏差打印頁面20工藝參數(shù)優(yōu)化頁面50工藝過程統(tǒng)計步驟1結(jié)果輸入實際值平均值范圍最小最大沒保壓時的重量有保壓后的重量填充的百分比標(biāo)準(zhǔn)偏差16模G料墊平均值和范圍預(yù)塑時間平均值和范圍螺桿停止位置平均值和范圍注射時間平均值和范圍注射壓力峰值,PINJMAX轉(zhuǎn)壓壓力,PNPRESS轉(zhuǎn)壓位置步驟2找出澆口冷凝時間設(shè)定保壓壓力為步驟1上找出的注射壓力峰值的50左右設(shè)定保壓時間為1S生產(chǎn)數(shù)模產(chǎn)品使過程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量和平均值增加保壓時間至2S,生產(chǎn)數(shù)模產(chǎn)品使過程穩(wěn)定后連續(xù)取5模產(chǎn)品稱出每模重量在保壓時間3S,4S5S時重復(fù)上述過程直到產(chǎn)品重量不再增加作出產(chǎn)品重量和保壓時間的關(guān)系圖記錄RECORDTHETCUSETTINGANDTHEACTUALMOULDTEMPERATURE打印頁面30溫度XLSPREADSHEETGRAPH為什么記錄模具溫度很重要還有什么因素會影響澆口冷凝時間步驟2結(jié)果輸入實際值TCUSETTINGFHTEMPERATUREMHTEMPERATURECCC重量1重量2重量3重量4重量5平均重量時間保壓重量1重量2重量3重量4重量5平均重量時間保壓所需的保壓時間S步驟3優(yōu)化注射速度采用多級注射曲線,使注射行程最后的1020采用逐步降低的注射速度每次更改注射速度,必須重新建立轉(zhuǎn)壓點注意每次保壓和保壓時間都設(shè)定為0連續(xù)取16模,計算出標(biāo)準(zhǔn)偏差打印頁面24MWE使用和沒使用多級保壓時的曲線頁面26多級注射頁面50工藝過程統(tǒng)計為什么轉(zhuǎn)壓點要更改注射壓力發(fā)生了什么為什么在數(shù)社的末端采用逐步降低的注射速度是有用的步驟3結(jié)果輸入實際值平均值范圍最小最大沒有保壓時的重量采用保壓的重量填充百分比標(biāo)準(zhǔn)偏差16模G料墊平均值和范圍預(yù)塑時間平均值和范圍螺桿停止位置平均值和范圍注射時間平均值和范圍注射壓力峰值,PINJMAX轉(zhuǎn)壓壓力,PNPRESS轉(zhuǎn)換位置步驟4采用正確的螺桿轉(zhuǎn)速SELECTTHECORRECT,OPTIMUMSCREWSPEEDFORTHEMATERIALBEINGPROCESSEDSEET01NOTES,SECTION5USETHISSINGLESPEEDFORTHEWHOLEPLASTICISINGSTROKESETABACKPRESSUREOF5TO10BARHYDRAULICREADJUSTDOSINGSTROKETOACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE50PROCESSSTATISTICSWHYISITIMPORTANTTOUSETHEMANUFACTURERSRECOMMENDEDSCREWSPEEDSTEPFOURRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPFIVEOPTIMISESCREWSPEEDANDBACKPRESSUREPROFILEUSETHEDOSINGPROFILEPAGETOSLOWDOWNTHESCREWROTATIONSPEEDFORTHELAST10OFTHEMETERINGSTROKEREADJUSTDOSINGSTROKETOACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE21DOSINGPROFILESPAGE50PROCESSSTATISTICSWHATHASHAPPENEDTOTHEDOSINGSTOPPOSITIONSTEPFIVERESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPSIXOPTIMISEDECOMPRESSIONFINDTHEDECOMPRESSIONSPEEDWHICHGIVESBESTSCREWSTROKEANDMELTCUSHIONCONSISTENCYSETADECOMPRESSIONSTROKEOF5MMCHECKTHATYOUSTILLACHIEVE9598FILLTAKESIXTEEENCONSECUTIVEMOULDINGSANDDETERMINETHESTANDARDDEVIATIONOFTHEWEIGHTSPRINTOUTPAGE21DOSINGPROFILESPAGE50PROCESSSTATISTICSWHATHASHAPPENEDTOTHESCREWSTOPPOSITIONWHATISHAPPENINGTOTHECHECKRINGSTEPSIXRESULTSINSERTACTUALVALUESINTHERELEVANTBOXESMEANVALUERANGEMINMAXWEIGHTWITHOUTHOLDINGPRESSUREWEIGHTWITHHOLDINGPRESSUREPERCENTAGEFILLSTANDARDDEVIATION16SHOTSGMELTCUSHIONMEANANDRANGEDOSINGTIMEMEANANDRANGESCREWSTOPPOSITIONMEANANDRANGEINJECTIONTIMEMEANANDRANGEPEAKINJECTIONPRESSURE,PINJMAXINJECTIONPRESSUREATCHANGEOVER,PNPRESSCHANGEOVERSTROKESTEPSEVENOPTIMISEHOLDINGPRESSUREPROFILEUSETHEHOLDINGPROFILEPAGETOSETAHOLDINGPRESSUREPROFILEWHICHENSURESASMOOTHTRANSITIONFROMINJECTIONTOTHEHOLDINGPRESSUREPHASEANDUSEAHIGHENOUGHPRESSURETOPACKTHEPARTPROPERLYADDASTEPWHICHREDUCESHOLDINGPRESSUREGRADUALLYTOZEROTAKE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