1. 什么是最佳的流動(dòng)狀態(tài)：

What is the best flow state:

流體流動(dòng)狀態(tài)應(yīng)該是噴泉狀的,，最佳的流動(dòng)狀態(tài)是流體前端的流動(dòng)速度在型腔內(nèi)處處相等。由于流動(dòng)方向上截面積的不同,，在其變化的位置應(yīng)進(jìn)行注射速度的調(diào)節(jié) （注意：機(jī)床上所能設(shè)定的注射速度是指螺桿的前進(jìn)速度）,。

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.

2. 什么是最佳的壓力,溫度分布

狀態(tài)：

What is the best pressure and

temperature state:

最佳的壓力和溫度分布狀態(tài)

是壓力和溫度分布在型腔內(nèi)

部處處相等，并且隨著熔體

地逐步冷卻而下降并使最終

產(chǎn)品的內(nèi)應(yīng)力為零,。

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. 

實(shí)際壓力分布狀況是澆口附近最大并隨著距離的增加而降低,。 （記住：螺桿頭處的熔體和流動(dòng)著的熔體前端存在壓力差是使熔體發(fā)生流動(dòng)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,。

所以,綜合來講,參數(shù)設(shè)定的一般準(zhǔn)則:

(1) 盡量選用高的注射速度(螺桿前進(jìn)速度)

(2) 盡量選用高的料筒溫度

(3) 盡量選用高的模具溫度

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

1. 收縮：Shrinkage:

（1）收縮的原因：.a.熱脹冷縮,；

.b.熔體結(jié)晶；

.c.分子取向,；對(duì)于未增強(qiáng)型材料,，其熔體在流動(dòng)方向上的收縮總是大于垂直方向；對(duì)于增強(qiáng)型材料,，正好相反

. d.狀態(tài)變化

The reasons of shrinkage: a. Chang from hot to cold;

b. Crystallization ;c. Molecule orientation;

d. Form changing

（2）收縮的階段：

The stages of shrinkage:

它包括三個(gè)階段：

a.從注射開始到保壓結(jié)束,；

b.從冷卻時(shí) 間開始到脫模前；

c.脫模后

It contains three stages: 

a. From injection stage to end of holding stage;

b. From cooling stage to demold stage;

c. After demold.

（3）變形：

Deformation

變形的根本原因時(shí)收縮的不均勻,。造成收縮不均勻的原因有：

The root cause of deformation is inhomogeneous shrinkage. The causes of inhomogeneous shrinkage are as follows:

a. 冷卻(即溫度分布)不均勻

Inhomogeneous cooling

b. 壁厚不均勻

Different wall thickness

c. 壓力分布不均勻

Not average location of pressure location

d. 分子取向

Molecule orientation

e. 脫模受力不均

Inhomogeneous forces when demolding

2. 結(jié)晶

Crystallization:

（1）什么是結(jié)晶：

What is crystallization:

簡(jiǎn)單的說,，結(jié)晶就是指分子的有序排列

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

（2）結(jié)晶的影響因素：

Factors affecting crystallization:

結(jié)晶的影響因素：冷卻速度。冷卻速度越快,，結(jié)晶程度越低,。

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

more crystallization

（3）結(jié)晶對(duì)產(chǎn)品性能的影響：

How does crystallization affect the parts:

結(jié)晶度越高：密度越高

收縮越大

光潔度越好

強(qiáng)度越高

韌性變差

The more crystallization: The higher density

The more shrinkage

The better surface

The stronger of the parts

3. 粘度：

（1）什么是粘度：

What is viscosity:

粘度是流體本身的一種性能，它的大小是流體流動(dòng)性能的一種衡量,。數(shù)值越大,，流體的流動(dòng)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.

（2）粘度的影響因素：

What affect the viscosity:

a.溫度

Temperature

b.剪切速度

Shear rate

c.壓力

Pressure

速度和壓力的敏感程度是不同的,，并且在不同的注射速度下哪一個(gè)起主導(dǎo)作用也是不同的

4. 止回閥:

Non-return valve:

a. 止回閥的功能是什么:

Function of non-return valve:

在注射,，保壓時(shí)防止熔體倒流,，從而給予熔體我們所需的壓力和速度。

To prevent the melt flowing back when injection and packing.

b. 怎么判斷止回閥或料筒損壞

How to recognize the non-return valve is broken:

（3）注射速度太快：易出現(xiàn)焦斑,，飛邊,，內(nèi)部氣泡或造成熔體噴射

Too fast injection speed: burns, flash, air bubble inside or melt jet.

注射速度太慢：易出現(xiàn)流動(dòng)痕， 熔接痕,，并且造成表面粗糙,，無(wú)光澤 Too slow injection speed: Flow line; weld line, or bad surface.

* 注射速度和注射時(shí)間設(shè)定的一般原則:

General principles when setting injection speed or injection time:

2. 轉(zhuǎn)壓點(diǎn)： Switch point:

（1）怎么確定轉(zhuǎn)壓點(diǎn)： How to set switch point:

一般來說，轉(zhuǎn)壓點(diǎn)是指在零保壓壓力的情況下把產(chǎn)品打到95％滿時(shí),， 由注射到保壓的切換點(diǎn),。

Normally the switch is the changing point of screw from injection phase to holding phase, when the parts are 95% of their volume. 

對(duì)于薄壁產(chǎn)品（如：扎帶）：一般打到產(chǎn)品的98％

To the thin wall thickness parts (Example: Cable strap): Up to 98% of their volume.

對(duì)于非平衡流道：一般為70％-80％，應(yīng)視具體情況而定,。并建議采 用慢-快-慢多級(jí)注射,。

To non-balance runners: Normally it’s up to 70% to 80%. It should be

determined by the reality. We suggest using step injection speed (Slow-

Fast- Slow).

（2）轉(zhuǎn)壓點(diǎn)太高：產(chǎn)品充模不足，熔接痕,，凹陷,，尺寸偏小等 Too high switch point: empty part, weld line, sink mark, and small dimension

轉(zhuǎn)壓點(diǎn)太低：飛邊，脫模困難,尺寸偏大等

Too low switch: flash, difficult to demold,， big dimension. 

3. 保壓壓力：

Holding pressure:

（1）怎么確定保壓壓力：

How to set the holding pressure: 

優(yōu)化的保壓壓力一般為最低保壓壓力和最高保壓壓力的中間值,。 

The optimized holding pressure is in the middle of the maximum and minimum normally.

最低保壓壓力：在準(zhǔn)確的轉(zhuǎn)壓點(diǎn)基礎(chǔ)上，給予一定的保壓壓力,，當(dāng)產(chǎn)品剛出現(xiàn)充模不足時(shí)的保壓壓力,。

Minimum holding pressure: based on the correct switch point, the pressure when the parts start to be empty .

最高保壓壓力：在準(zhǔn)確的轉(zhuǎn)壓點(diǎn)基礎(chǔ)上，給予一定的保壓壓力,，當(dāng)產(chǎn)

品剛出 現(xiàn)毛刺時(shí)的保壓壓力,。

Minimum holding pressure: based on the correct switch point, the pressure when the parts start to have flash.

（2）一般來說： Normally:

PA保壓壓力=50% 注射壓力

POM保壓壓力= 80% 注射壓力；

PP/PE 保壓壓力=30-50％ 注射壓力

PA Holding pressure = 50% Injection pressure

POM Holding pressure = 80% Injection pressure;

PP / PE Holding pressure = 30-50% injection pressure

4. 保壓時(shí)間： Holding time:

（1）怎么確定保壓時(shí)間： How to set holding time:

保壓時(shí)間的確定以澆口冷凝為依據(jù),。通過產(chǎn)品稱重來確定,。

Holding time is determined by the solidification time of the gate. We decide it according to the weight. 

（2）保壓時(shí)間太長(zhǎng)： 影響周期

Too long holding time: Waste time

保壓時(shí)間太短：重量不足，產(chǎn)品內(nèi)部空洞,，尺寸偏小

Too short holding time: Not enough weight, empty inside, small dimension

*

5. 螺桿轉(zhuǎn)速

Rotation Speed:

預(yù)塑的目標(biāo)是：獲得均一穩(wěn)定的熔體

（1）怎么確定螺桿轉(zhuǎn)速：

How to set the rotation speed:

作為原則,，螺桿轉(zhuǎn)速的確定必須使螺桿的預(yù)塑時(shí)間，回吸時(shí)間與射臺(tái) 的回退時(shí)間之和略短于冷卻時(shí)間,。

As a rule, the rotation speed is determined by that the total dosing time, retract of screw and retract of injection unit must be a little bit shorter than the cooling time.

（2）螺桿轉(zhuǎn)速太快：塑化不均（從而造成產(chǎn)品冷料,，充模不足和斷裂 等），材料分解（從而造成焦斑,，色差,，斷裂等） 

Too fast rotation speed: Inhomogeneous melt (which cause empty parts, broken), material decomposed (which cause burns, different color, broken etc) 

螺桿轉(zhuǎn)速太慢：影響周期

Too slow rotation speed: Waste time.

6. 冷卻時(shí)間： Cooling time:

作為原則，冷卻時(shí)間的設(shè)定應(yīng)越短越好，以產(chǎn)品不變形,，不粘模,，無(wú)過深的頂出痕為基本要求。并且：螺桿轉(zhuǎn)速： PA<1.0m ;="" pom="">< 0.7="">

As a rule, the cooling is the shorter the better based on the parts are not deformed, not sticky and without too deep impressed by ejectors.

* 推薦的脫模溫度如下:

Suggested demolding temperature is as follows:

7. 背壓：

Backpressure:

（1）什么是背壓：

What is backpressure:

背壓是指螺桿預(yù)塑時(shí),，液壓缸阻止螺桿后退的力,，其大小等于螺桿前 端熔體對(duì)螺桿的反作用力。

Backpressure is the hydraulic force preventing the screw going back as

dosing, the value is equal to the force that the melt in front of the cylinder to the screw.

（2）怎么確定背壓：

Ho to set the backpressure:

背壓的確定取決于不同材料的性能,，通常由材料供應(yīng)商提供,。 

一般來說：PA: 20-80 Bar ; POM : 50-100 Bar ; PP/PE : 50-200 Bar 

The backpressure is determined by the material character and its value is offered by the supplier.

Normally: PA: 20-80 Bar; POM: 50-100 Bar; PP/PE: 50-200 Bar

20％時(shí)： 噴嘴下料口 When one-shot quantity is less than 20% of maximum ：

b. 一次注射量在20％-70％之間時(shí)：噴嘴下料口

c. 一次注射量大于70％時(shí)：噴嘴下料口

（2）熔體溫度太高：材料分解（從而造成產(chǎn)品氣泡，色差,，焦斑,，斷裂 等）

Too high melt temperature: Material decomposed (Which cause air bubble, different color, burns, broken etc.)

熔體溫度太低：材料塑化不均，熔體內(nèi)含冷料（從而造成充模不足,， 冷料,，產(chǎn)品斷裂等）

Too low melt temperature: Inhomogeneous melt with cold material inside (Which cause empty parts, broken parts etc.)

11. 模具溫度：

Mold temperature:

（1）為什么需要模溫：

Why the mold temperature is needed:

無(wú)論模具溫度高低，它的作用始終是為了在穩(wěn)定生產(chǎn)過程中使模具維

持一定的溫度,，起冷卻作用的。 

a. 一次注射量小于總料量的

真正重要的模溫是指模具型腔的溫度,，而不是模溫機(jī)上顯示的溫度,。

通常，在穩(wěn)定生產(chǎn)過程中型腔溫度會(huì)達(dá)到一個(gè)穩(wěn)定的動(dòng)態(tài)平衡,，并高于

顯示溫度10度左右（對(duì)于大模具在生產(chǎn)之前必須使模具充分加熱,，尤其是薄壁，且流長(zhǎng)比 很大的產(chǎn)品模具）

Whatever the mold temperature is high or low, its function is to keep the cavity temperature on the same level. It is for cooling.

For the big mold, it must be heated enough before start production .

（2）模具溫度會(huì)影響什么

What the mold temperature affect:

會(huì)影響熔體的流動(dòng)性和冷卻速度,。

Affect the melt flow rate and the cooling speed.

因?yàn)橛绊懥鲃?dòng)性,，從而影響產(chǎn)品外觀（表面質(zhì)量，毛刺）和注塑壓

力,；

For affecting the flow rate, the mold temperature affects the appearance of

the parts and the injection pressure.

因?yàn)橛绊懤鋮s速度,，從而影響產(chǎn)品結(jié)晶度，進(jìn)而影響產(chǎn)品收縮率和機(jī)

械強(qiáng)度性能.

For affecting cooling speed, the mold temperature affects the crystallized rate and then affects the shrinkage and the mechanical strength.

（3）模溫高：流動(dòng)性好,；結(jié)晶度高,；收縮率大（從而造成尺寸偏小）,；變 形,；需要更長(zhǎng)的冷卻時(shí)間

High mold temperature: good flow character; high-crystallized rate; big shrinkage (Which cause small dimension); need more cooling time

模溫低：流動(dòng)性差（從而造成流動(dòng)紋，熔接痕）,；結(jié)晶度低,；收縮率

小（從而造成尺寸偏大）

Low mold temperature: bad flow character; high-crystallized rate; small shrinkage (Which cause big dimension)

（1）流涎：.

Material escaping from nozzle:

a. 材料烘干不徹底或材料受潮

The material is not dried enough or it is wet.

b. 預(yù)塑速度 (螺桿轉(zhuǎn)速) 太快

Dosing speed is too fast.

c. 噴嘴溫度太高

The nozzle temperature is too high.

d. 不好的回料 (粉狀)

Too much powder in regrinds.

e. 回吸量不夠

Not enough retract

f. 噴嘴接觸力不足

Not enough force between the nozzle and the mold bush.

g. 噴嘴與模具澆口套尺寸不匹配

The dimension of the nozzle and the mold bush is not correct.

h. 噴嘴接觸表面臟 (造成表面不平)

Dirty interface of the nozzle

（2）預(yù)塑不穩(wěn):

Plastification unstable：

a. 回料比不合理或不穩(wěn)定

Regrind rate is unreasonable or unstable

b. 背壓太低

Back pressure is too low

c. 長(zhǎng)料桿架橋

Long regrind

d. 材料受潮

Wet material

e. 下料處溫度不合理（太高）

Unreasonable cylinder temperature around the hopper (Too high)

（3）飛邊

Flashes

a. 參數(shù)設(shè)置不準(zhǔn)確 (轉(zhuǎn)壓點(diǎn)太低，保壓太高,，射速太快,，溫度

太高)

Wrong setting parameters (Too low switch point, too high

holding pressure, too fast injection speed, too high temperature

etc)

b. 模具臟

Mold is dirty

c. 鎖模力不足

Locking force is not enough

d. 模具問題（損壞）

Mold is injured

e. 設(shè)備問題（壓力不穩(wěn)）

Machine problems (Unstable pressure)

f. 噴嘴溫度過低

Too low nozzle temperature

g. 塑化不均（長(zhǎng)料桿，螺桿轉(zhuǎn)速過快,，背壓太低等）造成冷料

Inhomogeneous melt

h. 回吸太小造成止回閥關(guān)閉不穩(wěn)定

Too little retract to cause the non-return valve closing unstably

（4）充模不足

Incomplete:

a. 參數(shù)設(shè)置不準(zhǔn)確 (轉(zhuǎn)壓點(diǎn)太高,，保壓太低，射速太慢,，溫度 太低)

Wrong setting parameters (Too low switch point, too high

holding pressure, too fast injection speed, too high temperature

etc)

b. 模具臟

Mold is dirty

c. 噴嘴溫度過低, 結(jié)構(gòu)不合理

Low temperature in the tip of nozzle, and wrong structure 

d. 止回閥或料筒損壞

Non-return valve or cylinder is broken

e. 澆口, 流道尺寸太小

Too small gate, runners

f. 不干凈的回料 (含雜料)

Other material in the regrind

g. 材料受潮

Wet material

h.設(shè)備問題(壓力不足)

Machine problem (Not enough pressure)

I. 射臺(tái)沒對(duì)準(zhǔn)

The nozzle is not in the centre of the runner.

h. 回吸太小造成止回閥關(guān)閉不穩(wěn)定

Too little retract to cause the non-return valve closing unstably

（5）不時(shí)充模不足：

Sometimes Incomplete：

a. 射速太低（特別是PA, POM）

Injection speed is too low (Especially for POM)

b. 對(duì)大產(chǎn)品,，熔體溫度不夠

Melt temperature is too low

c. 塑化不均（背壓太低，轉(zhuǎn)速太快）

Not homogeneous melt (Back pressure is too low, rotation speed

is too fast)

d. 噴嘴溫度不夠

Nozzle temperature is too low

e. 止回閥或料筒損壞

Non-return valve or cylinder is broken

f. 雜質(zhì)

Other materials inside

g. 模具臟

Mold is dirty

h. 材料烘干不徹底或材料受潮

Material is wet

I. 射臺(tái)沒對(duì)準(zhǔn)

The nozzle is not in the centre of the runner.

h. 回吸太小造成止回閥關(guān)閉不穩(wěn)定

Too little retract to cause the non-return valve closing unstably

（6）焦斑

c. 產(chǎn)品頂出不均

Part is ejected not balance

d. 冷卻時(shí)間不夠

Not enough cooling time

e. 射速太低

Too low injection speed

f. 壓力太大造成粘模

Too high pressure to cause sticky on cavities

g. 塑化不均造成內(nèi)應(yīng)力

Not homogeneous melt to cause force inside

h. 模具溫度分布不均

Mold temperature not uniform

（9）尺寸不穩(wěn)

Dimension not stable

a. 參數(shù)控制不穩(wěn) (模溫, 料溫,，保壓太低或太高, 冷卻時(shí)間)

Parameter control not is precise (mold temperature, melt temperature, cooling time)

b. 回料比不合理或不穩(wěn)定

Regrind rate is unreasonable or unstable

c. 止回閥或料筒損壞

Non-return valve or cylinder is broken

d. 回吸太小造成止回閥關(guān)閉不穩(wěn)定

Too little retract to cause the non-return valve closing unstably

（10）重量不穩(wěn)定

Unstable weight

a. 參數(shù)設(shè)置不準(zhǔn)確 (模溫, 料溫,，保壓太低或太高, 冷卻時(shí)間，保

壓時(shí)間不夠)

Not correct setting parameter (mold temperature, melt temperature, cooling time)

b. 噴嘴溫度太低

Nozzle temperature is too low

c. 保壓時(shí)間太短

Holding time is too low

d. 止回閥或料筒損壞

Non-return valve or cylinder is broken

e. 回料比不穩(wěn)定

Unstable regrind rate

f. 回吸太小造成止回閥關(guān)閉不穩(wěn)定

Too little retract to cause the non-return valve closing unstably

（11）產(chǎn)品易斷裂

Easily broken parts

a. 熔體溫度太高或太低

Melt temperature is too high or too low

b. 材料濕

Wet material

c. 射速太低或太高

Injection speed is too low or too fast

d. 模具溫度太高或太低

Mold temperature is not reasonable

e. 熔接痕

Welding line

f. 雜質(zhì)

Other materials inside

g. 塑化不均（背壓太低,，轉(zhuǎn)速太快,，回料長(zhǎng)料桿）

Not homogeneous melt (Back pressure is too low, rotation speed is

too fast, long sprue)

h. 模具銳邊

Mold sharp place

i. 不穩(wěn)定回料比

Unstable regrind rate

（12）熔接痕：

Welding line:

a. 射速太慢

Too low injection speed

b. 熔體溫度太低

Too low melt temperature

c. 模具溫度太低

Too low mold temperature

d. 排氣不暢

Bad vent

d. 色母；塑化不均

Pigment; inhomogeneous melt

e.模具,，產(chǎn)品設(shè)計(jì)不合理

Design of mold or parts not reasonable

（13）表皮分層：

Delamination:

a. 材料潮濕

Wet material

b. 雜料

Mixed material

c.色母有問題

Pigment problem

d.射速太快

Too fast injection speed

（1）你必須搞清楚問題：

You must be sure the problem:

a.問題是什么

What is the problem?

b.什么時(shí)候發(fā)生的

When does the problem happen?

c.發(fā)生在哪一部位,，哪一個(gè)型腔

Where is the problem and which cavity? 

d.每模都發(fā)生還是偶爾有

How often does it happen? Sometimes or always.

（2）你必須思考可能的原因有哪些

You must think what are the possible reasons

（3）你必須確認(rèn)材料是否有問題

You must be sure the material has problem or not:

a.材料干燥嗎

The material is dry or not

b.原材料質(zhì)量好嗎

The quality of raw material is good or not

c.回料質(zhì)量好嗎（是否無(wú)長(zhǎng)料桿，無(wú)其他雜料,，無(wú)

污物,，無(wú)太多粉塵等）

The quality of regrind is good or not (Any long sprue, mixed material, dirty things, too much powder, etc.)

d.回料比添加合理嗎，過程控制準(zhǔn)確嗎

The regrind ratio is reasonable and stable or not,

（3）你必須確認(rèn)模具是否有問題

You must be sure the mold has problem or not:

a.水路,，氣路連接正確嗎

Are the water pipes and air pipes connected

correctly?

b.型腔內(nèi)部清潔嗎

Are the cavities clean?

c.模具型腔有損壞嗎

Is there any injury in cavities?

（4）你必須確認(rèn)機(jī)床是否有問題：

You must be sure the machine has problem or not;

a.機(jī)床止回閥壞嗎

Is the non-return valve broken?

b.料筒磨損了嗎

Is the cylinder broken?

c.注塑時(shí)實(shí)際壓力能達(dá)到嗎

Is the actual pressure from machine enough?

* 通常,，在穩(wěn)定生產(chǎn)24小時(shí)以上而沒有任何問題出現(xiàn)的話，我們認(rèn)為該生產(chǎn)工 藝參數(shù)是穩(wěn)定并合理的,。所以一般來說,，在穩(wěn)定生產(chǎn)過程中出現(xiàn)的問題不應(yīng)是工 藝參數(shù)問題，應(yīng)主要查找其他方面,。

Normally if the production is running for more than 24 hours without any

problems, we will think the parameters are stable and reasonable. So when you have problems in a mass production, it should not be the parameters’ problem and we need to try to check down the others.

微注塑整理,，轉(zhuǎn)載需注明來源，未注來源將視為侵權(quán),。