高逼格！中英双语！注塑工艺的基本概念汇总

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What is the best flow state:



流体流动状态应该是喷泉状的，最佳的流动状态是流体前端的流动速度在型腔内处处相等。由于流动方向上截面积的不同，在其变化的位置应进行注射速度的调节

The flow state should be like fountain, and the best is that the speed of the front melt is the same everywhere in the cavities. For different areas in the direction that is vertical with the flow way, we must adjust the injection speed.

（注意：机床上所能设定的注射速度是指螺杆的前进速度）

(Attention: The injection speed, which we can set on the machine, is the screw forward speed)What is the best pressure and temperature state:



最佳的压力和温度分布状态是压力和温度分布在型腔内部处处相等，并且随着熔体地逐步冷却而下降并使最终产品的内应力为零。

The best pressure and temperature state should be like this that the pressure and temperature everywhere in cavities are the same, and make the force of the part inside be zero finally as the melt solidified.

实际压力分布状况是浇口附近最大并随着距离的增加而降低。

（记住：螺杆头处的熔体和流动着的熔体前端存在压力差是使熔体发生流动的根本原因）

The actual pressure around the gate is the highest and as the distance goes it’s getting lower and lower。

(Remember: It’s the pressure in front of the flowing melt is lower than in cylinder that makes the melt flow.)

所以,综合来讲,参数设定的一般准则

(1)尽量选用高的注射速度(螺杆前进速度)

(2)尽量选用高的料筒温度

(3)尽量选用高的模具温度

So the general principles when setting parameters are:

(1)As fast injection speed as possible (Screw forward speed)

(2)As high cylinder temperature as possible

(3)As high mold temperature as possible

收缩的原因

（The reasons of shrinkage）

a.热胀冷缩；

b.熔体结晶；(结晶度越高，熔体收缩越严重)

c.分子取向；（一般来说，分子总是沿着流动方向取向的。对于未增强型材料，其熔体在流动方向上的收缩总是大于垂直方向；对于增强型材料，正好相反）

d.状态变化

a. Chang from hot to cold;

b. Crystallization ;( The more crystallization, the more shrinkage)

c. Molecule orientation;

(For non-strengthen material, the shrinkage in the flowing direction is more than that, which is vertical with the flowing direction; and for the strengthen material, the result is just reverse,)

d. Form changing

收缩的阶段

The stages of shrinkage

收缩从注射开始就随着熔体的逐步冷却而开始

The shrinkage starts from injection to forever.

它包括三个阶段：

a.从注射开始到保压结束；

b.从冷却时间开始到脱模前；

c.脱模后

It contains three stages:

a. From injection stage to end of holding stage;

b. From cooling stage to demold stage;

c. After demold

变形

Deformation

变形的根本原因时收缩的不均匀。造成收缩不均匀的原因有：

The root cause of deformation is inhomogeneous shrinkage. The causes of

inhomogeneous shrinkage are as follows:

a.冷却(即温度分布)不均匀

Inhomogeneous cooling

b.壁厚不均匀

Different wall thickness

c.压力分布不均匀

Not average location of pressure location

d.分子取向

Molecule orientation

e.脱模受力不均

Inhomogeneous forces when demolding什么是结晶

What is crystallization

简单的说，结晶就是指分子的有序排列

In a short word, it means to make the molecule in order.

结晶的影响因素

Factors affecting crystallization

结晶的影响因素：冷却速度。冷却速度越快，结晶程度越低。

The cooling speed affects the crystallization. The faster cooling speed the more crystallization

结晶对产品性能的影响

How does crystallization affect the parts

结晶度越高：

密度越高

收缩越大

光洁度越好

强度越高

韧性变差

The more crystallization: The higher density

The more shrinkage

The better surface

The stronger of the parts什么是粘度

What is viscosity

粘度是流体本身的一种性能，它的大小是流体流动性能的一种衡量。数值越大，流体的流动性能越差。

Viscosity is a character of the flowing material. Its value is used to measure the flowing character. The bigger value it is, the worse flowing character it is.

粘度的影响因素

What affect the viscosity

a.温度

Temperature

b.剪切速度

Shear rate

c.压力

Pressure

千万注意：往往粘度是三者共同作用的结果。不同的材料对温度，剪切速度和压力的敏感程度是不同的，并且在不同的注射速度下哪一个起主导作用也是不同的

Attention: The three factors affect the viscosity together all the time. Different material are differently sensitive to temperature, shear rate and pressure, and which factor will be the main factor in different phase is also different.

通常：

（A）

对温度敏感：PA；PC

Sensitive to temperature: PA, PC

对剪切速度敏感：POM；PP；PE

Sensitive to shear rate: POM, PP, PE

对压力敏感：PP；PE

Sensitive to pressure: PP, PE

( B ) 在高速注射的情况下，剪切速度起主导作用(所以,对于薄壁产品或含薄壁部分的产品宜采用高速注射)。

In high injection speed situation, the shear rate is the main factor. (So use high injection speed for thin wall thickness parts)a.止回阀的功能是什么

Function of non-return valve

在注射，保压时防止熔体倒流，从而给予熔体我们所需的压力和速度。

To prevent the melt flowing back when injection and packing

b.怎么判断止回阀或料筒损坏

How to recognize the non-return valve is broken:

初步判断：经常性的出现料垫不稳，或无料垫。

Recognize presumedly: Melt cushion is not stable usually or no cushion.

准确判断：延长保压时间，如果出现零料垫则说明止回阀损坏或料筒损坏。

Recognize precisely:  Prolong the holding time, if there is no melt cushion, the non-return valve is broken or the cylinder is broken.

c.怎么区别止回阀损坏还是料筒损坏

How to recognize the non-return valve is broken or the cylinder is broken

方法一：换上新的止回阀，延长保压时间依然没有料垫，则说明料筒损坏。

Method 1: Change into a new non-return valve; prolong the holding time, if there is still no melt cushion, it means the cylinder is broken.

方法二：放大料垫，延长保压时间依然没有料垫，则说明止回阀损坏；反之则说明料筒损坏。

Method 2: Make the melt cushion big enough; prolong the holding time. If there is still no melt cushion, it means the non-return valve is broken; if there is melt cushion, it means the cylinder is broken.

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