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1、题 目 微型液压卧式螺杆注塑机系统设计 注射成型机 注射成型机是塑料机械的一种，简称注射机或注塑机，是将热塑性塑料或热固性料利用塑料成型模具制成各种形状的塑料制品的主要成型设备。注射成型是通过注塑机和模具来实现的。类型 注射成型机的类型有:立式、卧式、全电式，但是无论那种注塑机，其基本功能有两个（1）加热塑料，使其达到熔化状态（2）对熔融塑料施加高压，使其射出而充满模具型腔。 工作原理和模式注射成型机的工作原理与打针用的注射器相似，它是借助螺杆（或柱塞）的推力，将已塑化好的熔融状态（即粘流态）的塑料注射入闭合好的模腔内，经固化定型后取得制品的工艺过程。注射成型是一个循环的过程，每一周期主要包括
2、：定量加料熔融塑化施压注射充模冷却启模取件。取出塑件后又再闭模，进行下一个循环。 注射成型机操作项目：注塑机操作项目包括控制键盘操作、电器控制系统操作和液压系统操作三个方面。分别进行注射过程动作、加料动作、注射压力、注射速度、顶出型式的选择，料筒各段温度的监控，注射压力和背压压力的调节等。一般螺杆式注塑机的成型工艺过程是：首先将粒状或粉状塑料加入机筒内，并通过螺杆的旋转和机筒外壁加热使塑料成为熔融状态，然后机器进行合模和注射座前移，使喷嘴贴紧模具的浇口道，接着向注射缸通人压力油，使螺杆向前推进，从而以很高的压力和较快的速度将熔料注入温度较低的闭合模具内，经过一定时间和压力保持（又称保压）、冷却
3、，使其固化成型，便可开模取出制品（保压的目的是防止模腔中熔料的反流、向模腔内补充物料，以及保证制品具有一定的密度和尺寸公差）。注射成型的基本要求是塑化、注射和成型。塑化是实现和保证成型制品质量的前提，而为满足成型的要求，注射必须保证有足够的压力和速度。同时，由于注射压力很高，相应地在模腔中产生很高的压力（模腔内的平均压力一般在2045MPa之间），因此必须有足够大的合模力。由此可见，注射装置和合模装置是注塑机的关键部件。 对塑料制品的评价主要有三个方面，第一是外观质量，包括完整性、颜色、光泽等；第二是尺寸和相对位置间的准确性；第三是与用途相应的物理性能、化学性能、电性能等。这些质量要求又根据制
4、品使用场合的不同，要求的尺度也不同。制品的缺陷主要在于模具的设计、制造精度和磨损程度等方面。但事实上，塑料加工厂的技术人员往往苦于面对用工艺手段来弥补模具缺陷带来的问题而成效不大的困难局面。 生产过程中工艺的调节是提高制品质量和产量的必要途径。由于注塑周期本身很短，如果工艺条件掌握不好,废品就会源源不绝。在调整工艺时最好一次只改变一个条件，多观察几回，如果压力、温度、时间统统一起调的话，很易造成混乱和误解，出了问题也不知道是何道理。调整工艺的措施、手段是多方面的。例如：解决制品注不满的问题就有十多个可能的解决途径，要选择出解决问题症结的一、二个主要方案，才能真正解决问题。此外，还应注意解决方案
5、中的辨证关系。比如：制品出现了凹陷，有时要提高料温，有时要降低料温；有时要增加料量，有时要减少料量。要承认逆向措施的解决问题的可行性。 分类及特点注射成型机按照注射装置和锁模装置的排列方式，可分为立式、卧式和立卧复合式。其各自的特点如下：（一）立式注塑机的特点：1、注射装置和锁模装置処于同一垂直中心线上，且模具是沿上下方向开闭。其占地面积只有卧式机的约一半，因此，换算成占地面积生产性约有二倍左右。2、容易实现嵌件成型。因为模具表面朝上，嵌件放入定位容易。采用下模板固定、上模板可动的机种，拉带输送装置与机械手相组合的话，可容易地实现全自动嵌件成型。3、模具的重量由水平模板支承作上下开闭动作，不会
6、发生类似卧式机的由于模具重力引起的前倒，使得模板无法开闭的现象。有利于持久性保持机械和模具的精度。4、通过简单的机械手可取出各个塑件型腔，有利于精密成型。5、一般锁模装置周围为开开放式，容易配置各类自动化装置，适应于复杂、精巧产品的自动成型。6、拉带输输送装置容易实现串过模具中间安装，便于实现成型自动生产。7、容易保证模具内树脂流动性及模具温度分布的一致性。 8、配备有旋转台面、移动台面及倾斜台面等形式，容易实现嵌件成型、模内组合成型。9、小批量试生产时，模具构造简单成本低，且便于卸装。10、经受了多次地震的考验，立式机由于重心低，相对卧式机抗震性更好。 （二）卧式注塑机的特点： 1、即是大型
7、机由于机身低，对于安置的厂房无高度限制。2、产品可自动落下的场合，不需使用机械手也可实现自动成型。3、由于机身低，供料方便，检修容易。4、模具需通过吊车安装。5、多台并列排列下，成型品容易由输送带收集包装。 用途和现状注射成型机具有能一次成型外型复杂、尺寸精确或带有金属嵌件的质地密致的塑料制品，被广泛应用于国防、机电、汽车、交通运输、建材、包装、农业、文教卫生及人们日常生活各个领域。 我国塑料加工企业星罗其布，遍布全国各地，设备的技术水平参差不齐，大多数加工企业的设备都需要技术改造。这几年来，我国塑机行业的技术进步十分显著，尤其是注塑机的技术水平与国外名牌产品的差距大大缩小，在控制水平、产品内
8、部质量和外观造型等方面均取得显著改观。选择国产设备，以较小的投入，同样也能生产出与进口设备质量相当的产品。这些为企业的技术改造创造了条件。 六、我国注射成型机的发展现状 目前中国生产注塑机的厂家较多，据不完全统计已超过60家。注塑机的结构形式有立式和卧式两种。按生产出的制品可分为普通型和精密型注塑机。一次注射量45-51000g；锁模力200-36000kN；加工原料有热固性塑料、热塑性塑料和橡胶三种。热塑性塑料包括聚苯乙烯、聚乙烯、聚丙烯、尼龙、聚氨酯、聚碳酸酯、有机玻璃、聚砜及(丙烯腈/丁二烯/苯乙烯)共聚物(ABS)等。从加工出的制品来看，有单色、双色的一般和精密塑料制品。上述产品的主要
9、生产厂家都有自己的系列，各有自己的特点。如广东震德塑料机械厂有限公司生产的捷霸CJ系列注塑机每一种规格均有数控和电脑控制两种形式。又如浙江省宁波海天机械有限公司生产的HTF80X-HFT3600X型系列注塑机，可用于生产各种高精密的热性塑料制品，机器采用线型移动传感器控制注射、合模、顶出，采用多重CPU电控系统、大幅面彩色LED显示、全电脑自动控制。 普通卧式注塑机仍是注塑机发展的主导方向，其基本结构几乎没有大的变化，除了继续提高其控制及自动化水平、降低能耗外，生产厂家根据市场的变化正在向组合系列化方向发展，如同一型号的注塑机配置大、中、小三种注射装置，组合成标准型和组合型，增加了灵活性，扩大
10、了使用范围，提高了经济效益。? 近几年来，世界上工业发达国家的注塑机生产厂家都在不断提高普通注塑机的功能、质量、辅助设备的配套能力，以及自动化水平。同时大力开发、发展大型注塑机、专用注塑机、反应注塑机和精密注塑机，以满足生产塑料合金、磁性塑料、带嵌件的塑料制品的需求。 注塑机是目前中国塑料机械中发展速度最快、水平与工业发达国家差距较小的塑机品种之一。但主要指普通型注塑机，在特大型、各种特殊、专用、精密注塑机的多数品种方面，有的产品尚属空白，这是与工业发达国家的主要差距。 Injection molding machine The injection molding machine is a k
11、ind of plastic machinery, referred to as the injection molding machine or injection molding machine, thermoplastic or thermosetting material the use of plastic mold into various shapes of plastics molding equipment. Injection molding by the injection molding machine and mold.Type The type of injecti
12、on molding machine: vertical, horizontal, all-electric, but no matter the kind of injection molding machines, the basic functions of two (1) heating plastic to reach the molten state (2) to exert high pressure on the molten plastic. it shot full of mold cavity.Working principle and mode of The worki
13、ng principle of injection molding machine and injection syringe, it is with the thrust of the screw (or plunger), the plasticizing good molten state (ie, viscous flow state), the plastic injected into the mold cavity closed good After curing stereotypes made the process of the products. Injection mo
14、lding is a cyclical process, with each cycle including: dosing - molten plastics - to put pressure injection - filling Cooling - Kai-mode pickup. Remove the plastic parts and then re-closed mode, the next cycle. Injection molding machine operating items: injection molding machine operating projects
15、including the control keyboard operation, the operation of electrical control system and hydraulic systems operating in three aspects. Separate action of the injection process, feeding action, injection pressure, injection speed, the top choice of the type, barrel temperature of each monitor, inject
16、ion pressure and back pressure regulation. Screw injection molding machine molding process: First, granular or powdered plastic in the machine barrel, through which the screw rotates and the outer wall of the barrel, heating the plastic to become molten state, then the machine before clamping and in
17、jection shift, so that the nozzle closely aligns the mold gate Road, then the oil pressure to the injection cylinder Walter, screw forward to high pressure and a faster speed will melt into the closed mold temperature is low , after a certain period of time and pressure to keep (also known as pressu
18、re), cooling, curing, the mold can be opened to remove the products (the purpose of holding pressure to prevent the reflux of the melt in the mold cavity, supplementary material to the mold cavity, and to ensure that products have a certain density and dimensional tolerances). The basic requirements
19、 of the injection molded plastics, injection and molding. The plasticizing premise to achieve and guarantee the quality of the molded part, to meet the requirements of forming, injection must ensure there is enough pressure and speed. The same time, due to the high injection pressure, the correspond
20、ing cavity to produce a high pressure (average pressure of the cavity is generally between 20 45MPa), so there must be large enough clamping force. Thus, the injection unit and clamping devices are key components of the injection molding machine. Mainly in three aspects of the evaluation of plastic
21、products, and the first appearance of quality, integrity, color, luster; the second is between the size and relative position accuracy; the third is to use the corresponding physical properties, chemical properties, electrical properties. These quality requirements are also different according to th
22、e different products using the occasion to require the scale. Defects of products is that the mold design, manufacturing precision and wear. In fact, the technical staff of the plastic processing plants often suffer from the face of technology means to compensate for the problems brought about by th
23、e mold defects but not the effectiveness of a difficult situation. Regulation of technology in the production process is the essential way to improve product quality and yield. Injection cycle is very short, if the process conditions are handled badly, the waste will be an endless supply. Adjustment
24、 process when the best time to change a condition to observe a few times, pressure, temperature, time, all with the tone, it could easily lead to confusion and misunderstanding, a problem do not know what reason. Measures to adjust the process, means, in many ways. Example: solving products Note dis
25、satisfaction there is more than a dozen possible solutions to choose to address the crux of the problem, two major programs, in order to really solve the problem. In addition, attention should be paid to the dialectical relationship between the solution. Such as: products the depression, sometimes t
26、o raise the melt temperature, sometimes to reduce the melt temperature; sometimes to increase the quantity, and sometimes to reduce the feeding amount. To recognize the reverse feasibility of measures to solve the problem.Classification and characteristics Injection molding machine in accordance wit
27、h the arrangement of the injection unit and clamping devices can be divided into vertical, horizontal and vertical and horizontal composite. Its own characteristics as follows: (a) the characteristics of vertical injection molding machine: 1, the injection unit and clamping devices in the same verti
28、cal center line, and the mold opening and closing along the upper and lower direction. Its covers an area of only about half of the horizontal plane, therefore, converted into an area of production around about twice. 2, easy to insert molding. Mold surface facing up, insert into the positioning eas
29、y. Using fixed under the template, the template movable machine, pull the belt conveyor, then a combination of plant and machinery palmistry can easily implement automatic insert molding. 3, the weight of the mold level template support for up and down the opening and closing movements, similar to t
30、he horizontal plane not occur before mold gravity down, making the template can not be opening and closing of the phenomenon. Conducive to the persistence to maintain the accuracy of the machinery and tooling. 4, through a simple robot can remove each plastic cavity, is conducive to precision moldin
31、g. 5, generally around the clamping device open open, easy to configure various types of automated devices, adapted to the automatic forming of the complex and sophisticated products. Drawstring lose conveying device is easy to achieve string mold the middle of installation, ease of forming automati
32、c production. 7, is easy to ensure the consistency of the resin flow and mold temperature distribution within the mold. 8, equipped with a rotary table, mobile table and tilt table is easy to insert molding, combination molding mold. 9, small batch trial production, the mold structure is simple, low
33、 cost, and easy to uninstall. 10, has stood the test of several earthquakes, the vertical plane due to the low center of gravity, the relative horizontal plane better shock resistance. (B) the characteristics of the horizontal injection molding machine: 1, ie, the mainframe due to low body height re
34、strictions for the placement of the plant. 2, the product can be automatically fall occasions, without the use of the robot can also be automatically molding. 3, the fuselage, easy feeding, maintenance easy. 4, the mold needs to be installed by crane. 5, multiple parallel arrangement, the moldings e
35、asily collected from the conveyor belt packaging.Use and the status quo The injection molding machine has a complex shape, size, precision, or with metal inserts, texture, dense plastics molding, widely used in defense, electromechanical, automotive, transportation, building materials, packaging, ag
36、riculture, culture, education, health and people daily life in various fields. Chinas plastics processing enterprises Xing Luo cloth across the country, the skill levels of the equipment, the equipment of most of the processing enterprises need technological innovation. In recent years, Chinas press
37、 industrys technological progress is very significant, especially the gap between the technological level of the injection molding machine with foreign brand names is greatly reduced, and made a significant change in the level of control, internal quality and appearance. Select the domestic equipmen
38、t, a smaller investment, also can produce the quality of imported equipment products. These create the conditions for the technological transformation of enterprises. , China Injection Molding Machine Development of Chinas production of injection molding machine manufacturers more, according to inco
39、mplete statistics, more than 60. The structure of the injection molding machine with vertical and horizontal. Press to produce the products can be divided into common type and precision injection molding machine. An injection volume of 45-51000g; 200-36000kN The clamping force; processing raw materi
40、als, thermosetting plastics, thermoplastics and rubber three. Thermoplastics, including polystyrene, polyethylene, polypropylene, nylon, polyurethane, polycarbonate, acrylic, polysulfone and (acrylonitrile / butadiene / styrene) copolymer (ABS). From the processed products, monochrome, color and gen
41、eral and precision plastic products. Of the major manufacturers of these products has its own series, each with its own characteristics. Such as Guangdong Chen De Plastics Machinery Co., Ltd. Jie tyrants CJ Series injection molding machine for each specification are two forms of numerical control an
42、d computer control. Again, Zhejiang Province, Ningbo Haitian Machinery Co., Ltd. the production HTF80X-HFT3600X series injection molding machine can be used for the production of various high-precision thermal plastic, the machine uses linear movement sensors to control the injection mold, ejector,
43、using multiple CPU power control systems, large format color LED display, automatic control of the entire computer. Ordinary horizontal injection molding machine is still the dominant direction of the injection molding machine, its basic structure is almost no major changes in addition to continue t
44、o improve its control and level of automation, reducing energy consumption, manufacturers according to market changes is the combination of series direction as a model of the injection molding machine configuration, the small three injection device, a combination of standard and combination, increas
45、e flexibility, expanding the scope of use, and improve economic efficiency. ? In recent years, industrial countries in the world of injection molding machine manufacturer in the continuous improvement of the supporting capacity of the function, quality of ordinary injection molding machines, auxilia
46、ry equipment, as well as the level of automation. Vigorously develop the development of large injection molding machines, injection molding machines, reaction injection molding machines and precision injection molding machines to meet the production of plastic alloys, magnetic plastic, with the dema
47、nd for plastic products inserts. The injection molding machine is one of the fastest, the gap between the level of industrial countries small presses varieties of the pace of development in Chinas plastics machinery. But mainly refers to the ordinary injection molding machine, in most varieties of extra large, a variety of special, dedicated, precision injection molding machine, and some still blank, which is the main gap with industrial countries
