注塑成型型腔平衡的填充诊断

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1、The5STEPPROCESSMoldfillingdiagnosticmethodology2103East33rdStreetErie,PA16510-2529Ph:(814)899-6390Ext.132Fax:(814)899-7117Email:drose@runnertech.netWeb:www.meltflipper.comToday'sToolingRequirements•Lowercost•Higherqualitymoldbuild•ShorterLeadTimes•DesignResponsibiliti

2、es•IncreasedproductionoutputIncreasecavitationCreatestoolingandprocessINCREASEDRISKissuesrelatedtomoldfillingimbalances•Moldqualification&support“NaturallyBalanced”Or“NaturallyImbalanced”(?)FlowAnalysisResultsActualResultsProductionStartDelayedWhy?LongTermManufacturin

3、gCostOverrunsDifficultiesQuestion:Whyistherunnersystemimportant?60%-70%ofmoldingrelateddefectsarerelatedtoimbalancescausedbytherunnersystem.FoodforThought:Alltheplasticmakinguptheparthastotravelthroughthemeltdeliverysystem.Howmanytimeshaveyoubattledthisproblem?SinkFla

4、shFactorsContributingtoFillingImbalance•Shear-inducedmeltpropertyvariations•SteeldimensionaldifferencesMoldDesign101QUIZ:Giventhefollowingscenarios,whichrunnerlayoutwouldyouuse?ABFactorsContributingtoSteelImbalances•Runnerlayout(ladderorgeometricallybalanced)•Venting•

5、Core/cavitydimensions(wallthicknesses)•Gate&Runnersizevariations–AffectspressuredropandshearrateintoacavityResponsibility=ToolMakersDiagnosingtheMoldFillingImbalance-ReducingTimeandCostofCommissioningNewMoldsMoldCommissioningProcedureDesignedtoReduceLeadTimes“THE5STEP

6、PROCESS”“TheFiveStepProcess”IsolatingtheCauseofCavity-to-CavityVariation1.IDENTIFYFLOWGROUPS2.MOLDSHORTSHOTSAMPLES3.WEIGHPARTSSEPARATINGBYFLOWANDCAVITY4.DETERMINEMOLDSTEELVARIATIONS5.DETERMINESHEARINDUCEDVARIATIONUnderstandingthePhysicalChangesthatOccurasthePolymerFlo

7、ws.NumberofFlowGroupsisDependentupon:•NumberofCavities•RunnerConfigurationPlasticFlowCharacteristicsAnnularHighShearZoneNonNon--SymmetrySymmetryDevelopedDevelopedataataRunnerRunnerBranchBranchAsymmetricmeltconditionsinthesecondaryrunnersresultinflowvariationstoeachoft

8、hefollowingbranchesinthemold.ExpectedMeltConditionsDevelopedinaExpectedMeltConditionsDevelopedinaConventionalGeometricallyBa