Giao Trinh Gccd(Daiwa)

Chng trnh o to

Daiwa plastics thng long joiventure com. ltd

K8- khu cng nghip thng long - ng anh h ni

fax:84-48813900 tel: 84-48813888/999

Gio trnh o to

o to ni b

---------

k thut c phun

H ni thng 10-2005

Mc lc:

Trang Tit

Phn 1: hng dn c bn

Chng 1: Gii thiu v lch s hnh thnh v pht trin ca c.ty

1/2

Chng 2: An ton lao ng

1/2

Chng 3: Qun l ti liu, h s, vn bn k thut

1

3.1. Ti liu, vn bn k thut.

3.2. H s k thut

3.3. Biu mu k thut

Chng 4: Gii thiu v cng ngh c phun

4.1. Gii thiu v my c phun

2

4.2. Gii thiu v khun c phun

1

4.3. Gii thiu v nguyn liu c phun

1

4.4. Gii thiu v cc thit b ph

1/2

4.5. Con ngi

1/2

Chng 5: Thao tc vn hnh my c c bn

2

Chng 6:Chun b cc iu kin chy my

2

Chng 7 : Khun c- Thao tc tho lp khun

1

Chng 8 : Hng dn s dng cc thit b ph tr

1

Kim tra giy (120 pht)

2

Phn 2: hng dn nng cao

Chng 9 : t ch hot ng ca my

9.1.Lc ch hot ng ca my

2

9.2.t ch ng m khun

2

9.3.t ch cht y v core.

2

9.4.t ch phun

2

Chng 10: Cc yu t v khun c.

Chng 11: Cc li ca sn phm c phun, cch xc nh

2

nguyn nhn v x l.

(Tham kho ti liu li Bayer)

Chng 12: S dng cc thit b do

Chng 13: Danh mc cc ti liu tham kho

Kim tra giy (120 pht)

2

Kim tra thc hnh t d liu c 1 loi sn phm

Phn 3: Ti liu tham kho

TL1: Mitsubishi catalog 550MGII. 650MMG

TL2: Nissei FN1000, FN6000, FS8000, FS8300, FV9100 catalog.

TL3: Sumitomo catalog.

TL4: Multiplas catalog.

TL5: Toshiba catalog FG, GS.

TL6: SM450 catalog.

TL7: Fanuc catalog 150D.

TL8: Guide injection molding

TL9: CD guide injection molding.

TL 10: How to correction inferior.

.

1.Mc ch ca gio trnh:

Lm ti liu s dng cho o to cng nhn mi tuyn dng v o to nng bc theo thi gian quy nh ca cng ty.

2.Phm vi:

o to ni b trong cng ty DAIWA PLASTIC THANG LONG.

3. Ni dung:

Phn chia theo mc ph hp vi yu cu o to nng bc

Ti a 7 bc ngh p phun.

Phn 1

hng dn c bn

1.Mc ch:

Lm ti liu s dng cho o to cng nhn mi tuyn dng trong thi gian th vic tng ng bc 1 ngh p phun.

2.Phm vi:

o to ni b trong hp doanh DMC-DAIWA PLASTIC.

3. Ni dung:

o to c bn cng nhn mi tuyn dng c th thao tc vn hnh my v kim tra sn phm

Chng 1

Gii thiu v lch s hnh thnh v pht trin ca c.ty

1.1.Gii thiu chung v cng ty:

Cng ty Xe p xe my ng a H ni l mt trong cc cng ty ngnh cng nghip nh thuc s qun l ca S cng nghip ca thnh ph H ni.

Cng ty hin nm trn a bn Qun ng a Thnh Ph H ni. Hin Cng ty v mt s cng ty khc ca ngnh nm trong ch trng pht trin ngnh cng nghip ca thnh ph H ni, ang trong giai on tng bc u t nng cp v m rng nhm tn ti v pht trin, chun b cho qu trnh hi nhp kinh t khu vc ng nam 2003-2006.

Lnh vc sn xut l cc ph tng chi tit cho xe p, xe my, t, cung cp cho th trng v mt s cng ty lin doanh sn xut xe my v t min Bc, xut khu nc ngoi v khu ch xut cng nghip,ng thi tham gia sn xut cc sn phm phc v cc lnh vc khc . Cc mt hng nh dy phanh, dy cngt mt, dy le, dy ga, dinamo xe p, n hu, n pha xe p, chi tit nha cho v xe my, v nha cho my in, cho thit b v sinh, cho thit b camera, phanh , bn p, chn chng xe p

Khch hng:

Cng ty Honda Vit nam , Yamaha Vit Nam l cc cng ty lin doanh sn xut xe my.

Cng ty Inax sn xut thit b v sinh ca Nht.

Cng ty Canon Vit Nam chuyn sn xut my in nh v my in mu

Cng ty Machino Auto part , Chiuyi chuyn sn xut v lp rp ph tng xe my.

Cng ty TOA sn xut thit b truyn thng cng cng.

V mt s cng ty khc, ng thi cc sn phm cung cp cho th trng.

Cng ty nm trn din tch 15000m2, vi s cng nhn 800 ngi

M hnh qun l sn xut kinh doanh ca cng ty chia thnh 3 khi

Khi ni a DMC l b phn sn xut kinh doanh chnh ca cng ty.

Khi hp doanh DMC-FER l b phn hp doanh gp vn vi tp on FER ca CHLB c sn xut cc ph tng thit b chiu sng ca xe p, t.

Khi hp doanh DMC-DAIWA l b phn hp doanh gp vn vi tp on DAIWA Nht u t sn xut cc sn phm nha cao cp, cung cp cho lnh vc sn xut t, xemy, thit b v sinh, my in ..v.v.v...

Theo ch trng ca thnh ph v vic di di cc cng ty sn xut ra khu vc ngoi v vy nm.2005. Cng ty chuyn n a im mi thuc L K8, KhuB, khu cng nghip Bc Thng Long, ng Anh, H ni (khu vc pha Bc thnh ph), din tch 16000m.

1.2.Gii thiu chung s c cu t chc ca cng ty

Hp doanh DMC-DAIWA:

Xng hp doanh sn xut nha DMC-DAIWA PLASTIC hnh thnh t s hp tc v gp vn u t gia mt bn l Cng ty Xe p Xe My ng a (DMC) v mt bn l tp on DAIWA PLASTIC, hp doanh hnh thnh v bt u hot ng sn xut kinnh doanh t 6/1997.

Lnh vc kinh doanh sn xut l cc sn phm nha cao cp cung cp cho cc ngnh sn xut xe p xemy, t, my in, thit b v sinh, thit b truyn thng cng cng,v.v.v

S t chc qun l ca xng hp doanh.

Khi di chuyn a im, theo tnh hnh u t, c cu t chc thay i

S t chc qun l ca Cng ty lin doanh Daiwa Plastic Thng Long

Do c th sn xut ca hp doanh l sn xut cc sn phm nha cao cp v vy phn ln trang thit b my mc chnh ca cng ty ch yu l cc thit phc v cho cng ngh c phun gia cng sn xut cc sn phm t nguyn liu polyme cao phn t (nha), v rt nhiu cc thit b ph tr khc phc v cho gia cng cc sn phm t nha.

Cng ngh gia cng p phun nh sau:

Cng ngh nha nhit do:

Nguyn liu v Trang thit b cn thit cho cng ngh gia cng nha nhit do cn thit nh sau:

+Nguyn liu gia cng

+My c phun

+Khun c phun

+H thng lm mt trung tm

+Thng sy v t sy nha

+My n nh nhit nng, lnh

+My nn kh

+My sy kh

+Robot, bng ti

+My in

+My dn nng

+Cu trc.

+Cc thit b dng c o kim

Nguyn liu c phun:

Nguyn liu ch yu ca xng l nha (cc hp cht cao phn t )

PP PolyPropylene.

PE Poly Etylen.

PMMA Poly Menthyl Methacylate.

ABS Poly Acrylonitrile Butadiene Styrene

PA6,PA66,PA12 Poly Amide

POM Poly Oxymetylen (Poly Acetal)

PS

Poly Styren

PC

Poly Cacbonat

v.v.v.

My c phun:

Nhim v lm do ho nha (lm nng chy v p phun nha nng chy vo khun c phun hnh thnh sn phm trong khun

C 35 my t my c phun 15T n my p phun 850T

C th gia cng p phun cc sn phm nh c trng lng 0,1g n cc sn phm ln vi kg.

(Cng sut my c phun cn c vo lc kp khun phn loi, lc kp khun tnh theo din tch b mt kp khun ti a trn h thng kp khun)

Chu trnh hot ng chnh ca my c phun:

Khun p phun:

gia cng cc sn phm nha nhit do ngoi cc my c phun th phn quan trng th hai l cc khun p phun. Khun p phun l phn quan trng nht trong cng ngh p phun, l b phn nh hnh cc sn phm nha theo hnh dng, kch thc thit k ch to trong khun

Khun c c th t vi kg n hng Tn

Thit b n nh nhit khun: c tc ng gi nhit khun p phun 1 nhit gia cng n nh nhm m bo cht lng sn phm p phun t yu cu v hnh dng kch thc, ngoi quan nh mong mun v rt ngn c thi gian gia cng 1 sn phm, chi tit.

H thng lm mt trung tm:

Cung cp nc lm mt cho du thu lc ca cc my c phun, v khun c

Thng sy v t sy nha

Sy kh nha, sy sn phm, sy cc sn phm sau khi in

My n nh nhit nng, lnh:

n nh nhit gia cng ca khun c phun mt gi tr nht nh

My nn kh

Cung cp kh nn cho mt s thit b hot ng nh my in pad, my dn nng, Robot, v sinh sn phm,v.v.v

My sy kh

Lc hi nc, v du c trong kh nn

Robot, bng ti

Thay th ngi vn hnh trong cng on ly sn phm ra khi khun c phun, nhm nng cao nng sut v tng tnh n nh gia cng

My in pad:

In trn cc sn phm nha.

My dn nng

Dn cc lp mng kim loi hay mng bt mu ln b mt sn phm nha di p nn v nhit

Cu trc:

S dng trong vic tho v lp t cc khun p phun ln cc my p phun, sa cha bo dng khun p phun v cc my mc thit b p phun.

Cc thit b dng c o kim

Dng kim tra kch thc sn phm sau khi gia cng, theo bn v thit k, gia cng, theo yu cu cht lng ca khch hng

Thit b o ba chiu, o hai chiu, my phng to, thc o k thut s, my o cao,v.v.v

Chng 2

An ton lao ng

(Thc hin theo ni dung trong quy trnh an ton lao ng c son tho v p dng ban hnh trong cng ty)

2.1. Cc tai nn c th xy ra trong qu trnh sn xut.

Tai nn my mc thit b gy ra.

Tai nn b thng do vt nng ri hoc va vo ngi..

Tai nn bng do thit b nhit ca my, nc nng, nha nng.

Tai nn do in git

Tai nn do ho cht

2.1.1. Tai nn do my mc thit b gy ra:

Do c th sn xut ca cng ty v vy c rt nhiu my mc thit b ln, ngi cng nhn phi thng xuyn lm vic trc tip v vn hnh my ngay ti my do vy rt d b tai nn nu nh khng tun th ng cc cnh bo an ton vn hnh my v thit b, V d: b kp tay chn do cc b phn chuyn ng ca my gy ra, nh th b thng tch, nng c th dn n cht ngi.

2.1.2. Tai nn b thng do vt nng ri hoc va vo ngi

Cc dng c c s dng cho my mc thit b ca xng rt nng, c th ri vo chn hoc va p vo tay gy thng tch

Cu trc, dng nng h cc khun v thit b nng trong khi di chuyn cc vt nng nu khng tun th cc hng dn vn hnh an ton c th gy va p vo ngi v thit b khc gy ra thng tch hay cht ngi v lm h hng my mc thit b.

2.1.3. Tai nn bng do thit b nhit ca my, nc nng, nha nng

Cc my, thit b trong cng ty c cc b phn c nhit cao c th ln ti vi trm V d: cc vng nhit ca my t 200 n 300 C. Nc nng n nh nhit khun c th ln ti 95 C hay cc thanh nhit ca t sy, thng sy.

2.1.4. Tai nn do in git

Cc h thng n chiu sng bn lm vic, cc my v thit b u s dng in cao 200 V, 220 V, 380 V , cng nhn hu ht khi lm vic thng xuyn tip xc vi my mc thit b nu khng tun th cc yu cu an ton v in u c th b tai nn in git.

2.1.5. Tai nn do ho cht

Cc ho cht c hi cho sc kho nh: dung mi, cht bo dng, bt mu trn m ngi cng nhn khng c thit b, trang phc bo h

2.2. Cc yu cu m bo an ton v phng trnh tai nn

2.2.1. Khi vn hnh my phi tun th tuyt i cc cnh bo an ton dn ti cc v tr trn my, v cc hng dn ca ngi c trch nhim ph trch v my , ngi qun l

2.2.2. Mang cc trang thit b bo h an ton trong qu trnh lm vic.

2.2.3. Tun th cc quy nh v an ton ca cng ty.

2.2.4. Khi nhn thy s xy ra s c v an ton cn phi dng my li v bo ngay cho ngi c trch nhim x l.

Chng 3

H thng ISO trong k thut c phun

3.1. Ti liu, vn bn k thut.

Thc hin theo ti liu quy nh trong cc quy trnh ISO ban hnh ti cng ty.

3.1.1. Vn bn ti liu trong QT ISO c lin quan k thut i vi trng ca, ph ca, cng nhn.

3.1.2. Vn bn ti liu trong QT ISO c lin quan i vi nhn vin k thut.

Chng 4

Khi nim chung v cng ngh c phunM t cng ngh c phun so vi cc cng ngh gia cng cht do khc:

Cng ngh c phun l cng ngh dng p lc nn khi nha lng vo khoang khun. Sn phm c nh hnh trong khun, v qu trnh l khng lin tc

Cc yu t to ra sn phm bng cng ngh c phum:

My c phun

Khun c phun

Nguyn liu c phun

Con ngi

4.1. My c phun

M t chu trnh hot ng chnh ca my c phun to sn phm:

Cc b phn ca my v nguyn l lm vic:

Cm kp khun

- Tm kp khun ng

- Tm kp khun tnh

- Ci kp khun

- C cu cht y.

- C cu core

- C cu chnh b khun

Cm phun:

- Nng phun, u phun

- Trc vt

- Vng nhit.

- B np

H thng iu khin

H thng thu lc

Cc thit b ph

4.1.1. Cm kp khun:

Gm cc b phn chnh: Tm kp khun ng v tnh, cht y, core, b g khun, h thng kp ( trc khuu hoc ben thu lc), cc thanh dn hng (tie bar)

- Tm kp khun: c tc dng g lp khun c c nh trn my

- B g khun: c tc dng gi cht khun trn tm kp khun ng v tnh.

- B cht y: c tc dng y sn phm ra khi khun

- B core thu lc: thc hin chuyn ng cho core ca khun

- Cc thanh tie bar: c tc dng dn hng chnh xc cho s chuyn ng ca bn kp khun

-H thng kp (h trc khuu hoc ben thu lc) : Thc hin chuyn ng ca bn kp ng v p cht hai na khun khi phun nha

Trong qu trnh gia cng, lc ng khun lun phi ln hn p sut phun nha lng

C 2 h thng kp khun

Kp khun bng khuu (tay n): Bn kp ng c ni vi b kp qua mt h thng trc khuu. Khi pittong thu lc chuyn ng th h thng cc trc khuu cng chuyn ng (dui ra hoc co li) ng hoc m khun. Lc kp khun c to ra nh p sut trong xylanh thu lc v ch c tc dng dui thng khuu. i vi mi my thng c mt gi tr lc kp khun ti a. Khong cch gia bn kp khun c nh v bn kp khun di ng khi dui thng khuu c th c iu chnh c nh b truyn ng bnh rng hoc truyn ng xch t ng sau my.

Kp khun bng ben thu lc: Bn kp ng c ni cng vi pittng ca ben kp, chuyn ng c nh chuyn ng ca pittng. Lc kp khun l lc trc tip do pittng thu lc to ra.

Hot ng ng m khun

4.1.2. Cm phun:

Gm cc b phn chnh: nng phun, u phun, trc vt, m t thu lc, ben trc vt

Nng phun : L xy lanh bng thp, bn trong c trc vt, bn ngoi c cc vng gia nhit, u nng phun c gn u phun (nozzle )

u phun (Nozzle): L b phn tip xc vi l cung phun ca khun. L u phun nn nh hn l cung phun khun. u phun c nhiu loi, c th thay i v c vng nhit ring.

Trc vt:

Trc vt c nhiu dng tu yu cu cng ngh.

u trc vt c van 1 chiu Trc vt c bn c chia ra lm 3 vng

u trc vt c van 1 chiu Trc vt c bn c chia ra lm 3 vng

Vng nhp liu: chim 1/2 chiu di trc vt, gn phu nhp liu dng chuyn nguyn liu v pha trc, cui vng ny nguyn liu mm v bt u nng chy

Vng nn p: gia trc vt, chim 1/4 chiu di trc vt, c tc dng nn p nguyn liu, cui vng ny nguyn liu nng chy hon ton.

Vng nh lng: chim 1/4 chiu di trc vt, trn v to ng nht nguyn liu trc khi phun vo khun

Trn u trc vt c van 1 chiu nhm ngn khng cho nha chy ngc v pha sau trc vt trong qu trnh phun

M t thu lc : Hot ng nh du thu lc gn cng vi ui trc vt, truyn chuyn ng quay cho trc vt.

Ben trc vt : L ben thu lc, gn vi m t thu lc, truyn chuyn ng tnh tin cho c cm m t thu lc v trc vt.

4.1.3. H thng iu khin:

Gm cc b phn chnh: Bng nt iu khin v t iu khin

Bng iu khin: c cc nt iu khin cc b phn ca my hot ng c lp, iu khin bng tay, t cc thng s cho my hot ng, t d liu c cho mt sn phm

T iu khin :x l cc s liu v iu khin hot ng ca my theo d liu t

Cc sensor : Cm bin v tr cc chuyn ng ca cc b phn trong my.

4.1.4. H thng thu lc

Bao gm: Moto bm du, cc ng dn du, cc van du v ben thu lc

Chc nng: Cung cp du dch chuyn cc pittong thu lc , lm quay ng c thu lc, thc hin cc chuyn ng ca cc b phn theo s iu khin ca b iu khin.

e. Cc thit b ph:

Gm thng sy, my n nhit, my ht nha, v.v.v....

Thng sy c tc dng tch m ra khi nguyn liu nh dng kh nng lu thng, ng thi ng vai tr l phu cha nguyn liu

My n nhit c tc ng n nh nhit khun trong gii hn tiu chun t bng dng nc tun hon. C 2 loi my n nhit: My lm nng nc (my gia nhit ) v my lm lnh nc ( Chiller )

My ht nha c tc dng cp nha vo thng sy thay cho sc con ngi.

4.2 . Khun c phun

L b phn to hnh dng sn phm

Cu to gm cc b phn chnh: Na khun Tnh, na khun ng, vng nh v, cung phun, ng dn nha, cng bm nha ( gate), cht y, h thng ng ng nc n nhit khun, v.v.v...)

Lu ti cc khun c h thng core du, core xin, h thng cht xin. Khi lp khun cn xem k cc hng dn c t ra nhm bo v an ton cho khun c.

VD: Sau khi khun m th core m hoc sau khi kt thc ng khun th core mi hot ng (FR)

4.3. Nguyn liu c phun

4.3.1. Khi nim chung v cht do

Cht do l tp hp ca nhiu phn t c khi lung ln (hay ni cch khc tp hp ca nhiu chui b li vi nhau, mi chui ging nh mt dy xch, mi dy xch li c nhiu mt xch, v mi mt xch uc cu to ging nhau gi l monome. tu theo monome cu to khc nhau m ta c cc loi nha khc nhau nh PP , ABS , PMMA, PA..)

Th no l cht do?

nh ngha:

Cht do l tp hp ca nhiu phn t khi lung ln (hay ni cch khc tp hp ca nhiu chui b li vi nhau, mi chui ging nh mt dy xch, mi dy xch li c nhiu mt xch, v mi mt xch uc cu to ging nhau gi l mnme. tu theo mnme cu to khc nhau m ta c cc loi nha khc nhau nh PP , ABS . PMMA, PA..)

V d a bn

Ti sao cc chui dy xch khng b tch ri nhau ra?

Tr li: v cc chui xch xp xp ri nh a bn, tc ri, v bn thn chng c lc ht.

v d si bao ti da khi x theo chiu dc rt d bi v.. v minh ho.

Ti sao khi t nng chng li do ra v nu tip tc t nng chng s chy ra nh nc.

Tr li: khi t nng nhit s lm cho lc ht gia cc phn t polymer gim i v chui xch tr ln linh ng (c th di chuyn) hn v chng d dng trt ln nhau do d nha b bin dng v chy lng ra.

Ti sao nha b m (ht nc)cn phi sy.

Tr li: cc chui xch xp xp ri to nn kt b rng do hp th cc phn t nc, thm nc ging nh chn bng, vi..

Ti sao c cc loi nha khc nhau v cc tnh cht ca chng khc nhau.

Tr li; v cc mt xch to nn chng khc nhau do quyt nh n tnh cht ca cc loi nha.

S nhit ca cht do

Mm cao > do ho > chy nht > phn hu

Phn loi nha nha nhit do:

nha nhit do chia lm hai loi: Thu tinh v V nh hnh

Loi thu tinh: PE,PP, PA, POM,

Loi v nh hnh: ABS, PS-HI, PMMA,PC, PVC

So snh gia hai loi thu tinh v v nh hnh:

V nh hnh: khi nung nng th mm dn khi nhit cng tng th cng mm cho n khi nho nh nc

Thu tinh(v d PA ) khi t nng nhit thp khng b mm tip tc nung nng n nhit 180 th mi bt u chy mm ra v n 220 th chy nht

VDH: nha trong TT: nha c

VDH cng nhng chng lo ho chng hng; TT; km cng nhng chng lo ho tt bn hn.

Phn loi da trn monomer

Homopolymer: chi mot loi monomer tao nn phn t

Copolymer: nhieu loi monomer cu to nn phn t polymer

Cht do c cc c tnh c trng sau: c kh nng to hnh, bn c hc, cch in cao, bn vi nh sng, dn nhit km...nhiu loi cht do d nhum mu, mt s li trong sut.

Ngoi ra trong thnh phn cht do cn c:

Cht ho do (lm mm): C tc dng lm cho cht do tr nn mm do, bn vi thi tit

Cht n nh: Gip cho polyme khi b phn hu di tc dng ca cht oxi ho, nhit v nh sng.

Cht n (thng l cht rn dng bt hoc dng si): Chng lm cho cht do c bn c hc, bn nhit, cng hoc lm gim gi thnh ca vt liu.

Cht phng lo: chng lo ho, tng bn thi gian cho cht do

Cc ph gia khc : Tu theo yu cu s dng

* Gii thiu v nha nhit do v nha nhit rnNha nhit do: Khi tng nhit s mm ra v nng chy, khi h nhit s tr li trng thi cng ban u

Nha nhit rn: Ban u trng thi lng nht hoc dng rn, b ho tan trong dung mi, khi tng nhit th nng chy ri sau ho cng, khi h nhit khng tr li trng thi ban , khng nng chy v ho tan na.

* Cch nhn bit mt s loi cht do thng dng

a) Poly etylen (PE)

Khi chy cho ngn la, chy thnh dng, c mi nn

b) Poly propylen (PP)

Chy sng, chn ngn la mu xanh nht, cho mi cao su chy.

c) Poly stylen (PS)

Chy vi ngn la sng rc, c mui, mi hc

d) Poly vinylclorit (PVC)

Chy vi ngn la xanh l cy sng. Ri ngn la ra th tt. Mi kht hc.

e) Poly metyl metacrylat (PMMA)

Chy vi ngn la chi sng. Mi kht hc cng vi chua nng

f) Poly amit (PA)

Chy vi ngn la xanh nht nhng cnh vng. Mi sng chy hoc xng chy.

g) Poly formadehit (VD: POM)

Chy nh cn, ngn la xanh, khng mui, c ting lp bp. Mi hc v cay.

4.3.2.Phn loi nha

Nha thng dng:

L loi c s dng vi mt lng ln. Bao gm nhng chng loi nha: PE, PP, PS, ABS, PVC

Nha k thut:

L tn chung ca nhng loi nha m cht lng tri hn nhiu so vi nha thng dng trong tnh cht c l nh bn ko, khng nhit v c s dng sn xut cho cc chi tit my v chi tit yu cu tnh nng cao. Chng c gia cng vi si thu tinh, si carbontheo cng dng yu cu.

Nha hn hp:

L tn chung ca hn hp cc loi nha c phi hp vi nhau, m chng kt hp cc tnh nng vt tri ca tng loi nha.

4.3.3. nhn bit v phn bit nguyn liu trong sn xut.

Theo tn ghi trn v bao

Theo chng loi ( grade, type )

Theo mu sc ( colour)

Theo hnh dng, kch thc, mu sc ht nha

Theo mi

v.v.v....

4.3.4. Sy nguyn liu

a s nguyn liu c c tnh hp th nc ( hoc hi m ). Khi c nha nhit cao, lng m trong nguyn liu s ho hi, ln vi nha nng chy khi c phun vo khun, to nn li bt kh hoc xc tia trn b mt sn phm, khng t yu cu v ngoi quan sn phm. V vy trc khi c cn phi sy nha tch m khi nguyn liu n hm lng m cho php.

V d cn sy nha theo bng tiu chun sau:

Vt liu nhaThi gian sy (gi)Nhit sy ((C)

ABS2 480-100

PA 62 480-100

POM1 490-110

PC2 4120

PS1 270-80

PVC260-80

AES485

PMMA3 585-100

Lu :

hp th nc cao i vi nha c nhm phn cc nh PVC, ABS, PMMA, PC, POM...

hp th nc thp th tt hn v hm lng nc hp th trong nha cao lm mt s tnh cht c l km

Polyme khng phn cc nh PE, PP th khng hp th nc.

c bit Nylon 6 (PA) rt d hp th nc v c phn cc cao.

4.3.5. La chn s dng cc loi nha

Da theo tnh cht, cng dng ca loi nha, mc ch s dng m mi loi sn phm c c t cc loi nha khc nhau:

V d:

Chi tit v xe my phn ln c c bng cc loi nha ABS.

L do cc chi tit ny cn sn v chu nhit, chu thi tit, v c bn va p cao hn cc loi nha khc, t cong vnh.

Cc chi tit c lm t nha PP c tnh cht bn vi thi tit, chu c va p, khng c v khng cn sn

Chi tit c lm t nha PMMA c tnh trong sut, bn c hc.

Nha PA khi hp th nc n mc bo ho th n nh kch thc nhit cao v mi trng m, chu mi mn nn hay c s dng lm bnh rng, tay quay.

4.4. Cc thit b ph

Cc thit b ph bao gm: Cc my n nhit, thng sy, my ht nha.

* Cc my n nhit bao gm:

- My Chiller lm lnh nc: Thng c s dng vi cc sn phm c chu k chy nhanh. Nc c lm mt bng kh gas sau qua my bm vo ng ng lm mt cho khun. Nc khi lnh s trao i nhit vi khun nng v lm h nhit khun xung theo yu cu.

- My gia nhit: Ngc li vi my Chiller, my gia nhit c tc dng lm nng khun ln.Tu tng sn phm c th m c th t nc nng t 45-95 0C.

* Thng sy nha: Nha trong thng c sy kh nh khng kh nng lu thng. Khng kh c ht vo thng qua qut gi v c lm nng ln nh c cc cun dy gia nhit. Sau chng thi sy u cc ht nha nh li chia gi.

* My ht nha: To p sut chn khng ht nha ln bnh thay cho sc con ngi.

4.5.Con ngi

Trong quy trnh sn xut yu t con ngi l mt trong nhng phn quan trng nht quyt nh n hiu qu trong sn sut, nng sut v cht lng sn phm.

Yu t con ngi trong sn xut ch yu li l cc cng nhn trc tip lm ra sn phm,nhng ngi cng nhn c kinh nghim, c tay ngh, hiu bit v cng ngh, hiu bit v tiu chun cht lng i vi sn phm mnh lm ra

Ngi cng nhn thao tc vn hnh my cn phi hiu v thc hin theo c cc tiu chun iu kin c trong sut ca sn xut.

Cc iu kin quan trng cn phi c kim sot tt th sn phm mi c th n nh v cht lng c bit l cc sn phm i hi chnh xc cao v kch thc

Nhit khun ng:

Nhit khun tnh:

Nhit du:

Nhit khun nh hng quyt nh n cht lng sn phm. N nh hng c bit n cc tnh cht nh l ng sut ni, co rt kch thc, trng lng v b mt sn phm. Thi gian lm ngui c xc nh ch yu da vo nhit khun.

Ghi ch:Nhit khun, nhit du u lin quan trc tip ti cc thng s d liu v p lc v tc t. Nu nh khng kim sot c th cc thng s d liu trong bn d liu c tiu chun khng cn gi tr

Tm li cht lng sn phm ti u khi cc yu t sau tng tc hiu qu

Chng 5

Thao tc vn hnh my C c bn

Hng dn ti my v cho tng cng nhn thc hnh, c kim tra v nh gi kt qu sau khi hng dn

- Hng dn vn hnh my i loan 500T,180T,650T (DMC1,DMC2, DMC3,M13,M14,M15,M2,M7,M6)

- Hng dn vn hnh my Mitsubishi 550T,450T,350T (M1,M16,M17,M18)

- Hng dn vn hnh my Nissei 80T,280T(M3,M10,M11)

- Hng dn vn hnh my c khc

M t bng iu khin, cch b tr v nhn bit cc nt iu khin theo biu tng

Chng 6

Chun b cc iu kin chy my

6.1. Chun b iu kin trc khi vn hnh

6.1.1. Chun b nha:

Nha phi c sy trc thi gian vn hnh = thi gian sy kh 1 lng nha cn phi chun b trc

Nha c th sy trong thng sy ca my hoc trong t sy.

Nhit v thi gian sy i vi tng loi nha c th c hng dn dn ngay ti t sy hay thng sy.

6.1.2. Chun b nhit nng phun:

Cn c vo nhit trong bn d liu c tiu chun t nhit cho nng phun v bt nhit

i vi cc my Taiwan th nhit c bt trc t 30~45 pht.

i vi cc my Nht th nhit c bt trc t 45~60 pht.

Trc khi iu khin trc vt phi m bo nng phun nhit v nha trong nng phun c nng chy hon ton (c bit l khi nha pha trc trc vt do khng c phun ht ra khi nng phun khi dng my tt nhit).

6.1.3. Chun b khun c:

Khun c c lp t trn my theo hng dn lp khun.

Nu tiu chun nhit khun c cao c s dng my n nh nhit l my gia nhit th phi bt my n nhit trc khi vn hnh khong 20 pht m bo nhit khun nm trong khong nhit tiu chun.

Kim tra van c m ra trc khi bt my n nhit.

Kim tra r r nc trong khun v cc u kt ni, kim tra ng nc khng b tc.

M khun, lm v sinh b mt phn khun bng gi cotton, ch khng c lau vo b mt khoang c phn mt nhm hay bng.

Kim tra di cht y, khng kt cht y,kim tra vt l c trong khun v cc hin tng g khun, xc hay tnh trng khc.

6.1.4. Np nha:

Kim tra nhit tin hnh phun b 3 shot nha lu trong nng phun v np nha chun b cho shot c u.

Tt p np (bach press) trc khi bt np i vi cc my Nht

Li vt (suck back) v v tr cc v tr np 10mm sau bt np i vi cc y i loan trnh hin tng n nha ra u phun.

Sau khi np nha phi bt li ch back press.

6.2. Cc li thng thng v cc x l:

Chuyn ch bn t ng khun khng ng.

Chuyn ch bn t ng khng phun nha.

Khng chuyn sang c ch bn t ng.

Khng ng c khun p cao.

ang chy ch bn t ng khun khng m ra.

chng 7

khun c - thao tc tho lp khun

7.1. Gii thiu cu to khun p phun

Khun l b phn nh hnh sn phm . Khun c chia thnh nhiu loi nh : khun 2 tm , khun 3 tm , khun c th c mt hay nhiu khoang khun ( mi khoang khun ng vi mt sn phm ) . ..

V c bn khun c phun gm cc b phn c bn sau1. Vng nh v : l vng khp ni gia khun v bn kp tnh my c, c tc dng xc nh v tr khun sao cho l cung phun trn khun thng vi l u phun ca my

+/ C rt nhiu loi vng nh v c kch thc khc nhau v d nh 90 120 , 40 120 , 60 120 , 80 100 . Cc thng s y hiu nh sau v d 90 120 c ngha l ng knh trong ca vng nh v l 90 (mm) ng knh ngoi l 120 (mm) .

2. Cung phun : l b phn tip xc gia khun v u phun .Cung phun c dng cn vi cn theo tiu chun. Thng thng l u phun phi nh hn l cung phun . V tr ca cung phun thng nm ti chnh gia tm khun khun c g ln bn kp v tr gia bn kp, m bo an ton vn hnh my.

3. ng chy nha (runner): l cc ng dn nha t cui cung phun vo khoang khun . Tu tng khun c th c hoc khng c ng chy nha.C 2 kiu ng chy nha

ng chy nha nng (hot runner) : c gia nhit bng cc vng nhit bn trong khun. Hot runner c s dng khi khng th thit k ng chy nha nm trn b mt phn khun, khi ng chy nha qu di hoc khi cn tit kim lng nha ph .

ng chy nha ngui : c s dng ph bin, khi ng chy nha khng qu di v nm trn b mt phn khun. Nhiu trng hp ng chy nha qu di nhng khng mun s ng hot runner th c th thit k tm git cung

4. Khoang khun : l phn to hnh dng v kch thc sn phm . Trong mi khun c th c mt hoc nhiu khoang khun . Tu vo yu cu b mt ca sn phm m b mt ca khoang khun c th l trn bng hoc nhm. i vi b mt nhm yu cu i vi ngi v sinh khun cn ch l dng gi mm sch khng bm bi v sinh v khng t mnh vo b mt nhm .

5. Cht dn hng : gm 4 cht di bn phn khun ng , c tc dng dn hng chnh xc cho khun ng khp kht vi khun tnh

6. H thng cht y : Nm bn khun ng, bao gm tm y , cht hi, l xo hi v cc cht y ( pin y ). Ngoi ra mt s khun khng c l xo hi nn khng t hi v c, khi ng khun cc cht hi t vo mt phn khun tnh p cc cht y hi v .

7. H thng ng nc : l h thng cc ng ng nc chy qua khun, lm mt khun.V nguyn tc lp h thng ng lm mt khun th phn no ca khun b nng nhiu nht th lp ng lm mt vo v phn khun t b nng hn th lp ng lm mt ra 8. H thng core : L c cu dng to l hoc ch lm trn sn phm c phng khng trng vi phng ng m khun . Chuyn ng ca core thng theo phng vung gc vi phng ng m khun

C hai loi core c dng l :

Core c :hot ng nh cc cht xin. Khi hai na khun khp vo nhau th cc cht xin khp vi cc l trn core trt lm cho cc core trt chuyn ng theo phng vung gc vi phng ng khun. Chiu chuyn ng ca core c th ln hay xung , sang phi hay tri .

Core thu lc: hot ng di tc dng ca p sut du thu lc . Ch hot ng ca core thu lc c ci t theo d liu c trn my.

7.2. trnh t tho lp khun

7.2.1. Tho lp khun i vi my c ben kp thng.

7.2.2. Tho lp khun i vi my c kp khuu.

7.2.3. Tho lp khun c cht y t hi v

1. Trc khi tho khun phi tho h thng ng lm mt bt vo khun t ngun , dng sng hi xt ht nc trong ng ng , b mt khun phi kh ro .Sau dng cht bo dng phun u trn ton b b mt khoang khun v ngi tho lp khun c o to v s dng thnh tho v cu. Dng ch moldset (ch tho lp khun ) khi tho lp khun.2. Sau lp h thng cu , cp vo khun . Lu tu vo khi lng ca khun m dng dy cp ph hp , khi lp cp cu khng dy b vn xon , dy chng ln nhau , dy cp cu cng va phi v nghing v pha phi sau khi tho ht g kp khun v m tm khun bn ng ra khun khng b vng ra rt nguy him . 3. Sau khi tho ht cc g khun ra cho m khun my ban u chm ri cho m ra ht c v cho cu nng t t ra khi my khun vo ni quy nh . Ly khun cn c ra lp ln my .4. Trc khi lp khun mi cn kim tra li h thng cht y , vng nh v , h thng ng nc trn khun , khong ng ti a ca my vi chiu dy khun nu dy khun nh hn phi lp thm tm m , nu khun c s dng h thng core thu lc chun b y dng c cn thit . Khi lp cn khun ln my cho h thng khuu thng sau cho b t t tin vo . Khi p cht khun lp g kp khun . Lu khi lp g kp khun chn ca g kp phi cho cao bng dy ca thnh khun kp . Dng ng tup c di theo quy nh xit bulng vi lc xit va phi , trnh hin tng dng lc xit qu ln gy chn tot ren bulng v ren l bt bulng trn my .5. Khi lp khun xong tho cp , cu. a dng c tho lp khun vo ng ni quy nh v lp h thng nc lm mt khun , nu c lp h thng core thu lc th phi kim tra s hot ng ca chng . 7.2.4. tho lp khun c cht y hi v cng bc

i vi nhng khun khi hot ng cht y lui v cng bc v d nh cc khun : COVER SIDE 3 (5SD), COVER SIDE 4(5SD) , CARRIAGE COVER do h thng cht y qu phc tp nn khng c l xo hi th ch tho lp khun theo trnh t sau:

Cc bc 1 v 2 qu trnh tho lp ny ging nh qu trnh trn .

3. Sau khi lp xong cp cu tin hnh tho ht g kp khun bn phn khun ng cn phn bn tnh gi nguyn ri cho khun m rt t t mt khong nh thao tc tho cht y ra thun tin sau khi tho cht y xong li cho khun ng vo ht c theo ch moldset (ch tho lp khun) ri tho ht g kp khun phn khun bn tnh . Sau khi tho ht tt c cc g khun ri m rng khun ra v cho cu nng khun t t ra khi my.

4. Cho khun mi vo my sau khi cn khun lp g kp khun vo phn khun bn tnh ri lp cht y vo khun khi cho ng khun theo ch moldset , tin hnh lp cht y vo tm y ca my , sau lp cc kp g vo phn khun bn ng .

5. Khi lp khun xong tho cp , cu. a dng c tho lp khun vo ng ni quy nh v lp h thng nc lm mt khun . Sau m khun ra kim tra s lm vic ca cht y nu cht y khng hi v bng mt khun cn kim tra li vic lp cht y. chng 8

Hng dn s dng cc thit b ph tr

8.1. Hng dn s dng my Chiller

Trc khi s dng cn kim tra cc yu t sau:

- Cc ng ng cp v thot nc c b tc khng, c b cm sai u khng.

- vn ng cc van theo ng hng dn cha.

- Sau bt in cp cho my. Nhn nt Start

- Bt bm nc. Vn nt Pump start

- Bt bnh gas hot ng. Vn Compressor Switch

Cn ch ti nhit thit t cn lm mt.

8.2. Hng dn s dng my gia nhit

Cn kim tra cc yu t sau:

- Ngun in vo c ng vi cc thng s ghi trn my hay khng (ngun 220V-3 pha hay 380V-3 pha)

- Ngun in vo c ngc pha khng

- ng ng cp nc, van, cc u cm c thng, sch khng.

Cn kim tra ti nhit cn t cho my v cc u cm khng b r r, trnh gy tai nn do nc nng gy ra.

8.3. Hng dn s dng thng sy.

Sau khi ht nha ln thng, bt qut ht gi, bt nhit sy. Ch ti nhit sy tu theo tng loi nha. Thng xuyn kim tra nhit thc sy ca nha qua ng h o trn thng sy.

8.4. Hng dn s dng my ht nha

H thng my ht c ni vi thng sy nha bi 2 ng ng. Mt ng ht nha ln bnh, mt ng ht chn khng. Trc khi ht nha cn kim tra thi sch nha c ra khi ng ng, trnh trng hp ln nha.

Phn 2

hng dn nng caoCc ti liu tham kho:

Guide injection molding

Guide injection molding CD

How to easy way to correct inferior

Bayer

Chuanlifa

Mitsubishi manual machine.

Union manual machine.

Multiplas manual machine.

Cht lng sn phm c phun ph thuc vo cc yu t sau:

My v thit b 15%

Nguyn liu c 20%

K thut c 15%

Khun c

50%

Chng 9

t ch hot ng ca my

* Vn cht lng my mc thit b:

Yu cu n gin v cng l yu t quan trng trong k thut c phun l phi nm r cch vn hnh my v thit b, nm r cht lng my v thit b c th s dng c nhng loi sn phm ph hp vi cht lng my v t cc d liu c cho tng ng

- Chu trnh hot ng chnh ca my c phun:

9.1 t ch ng m khun

9.1.1.Hnh trnh ng/M khun:

My c h thng kp khun thng.

Hnh minh ho

My c h thng kp khun khuu

Hnh minh ho

My c phun nh (80T):

Thng thng c:

3 bc ng khun

3 bc m khun

V d My M3 Nissei 80T

My c phun ln (Mitsubishi 550T):

Thng thng c:

4 bc ng khun

4 bc m khun

My c phun ln (JR 500T):

Thng thng c:

4 bc ng khun

4 bc m khun

Clamp Open/Close

Opn Stroke:

Cls 1Cls 2ProtHipr

Press

Speed

Posn

EndSOpn 2Opn 1StrS

Press

Speed

Posn

Ult.Speed0-No use1-Use

9.1.2. Nguyn tc t ch ng/M khun.

A- Qu trnh ng khuni vi ch ng khun thng thng

Khong ng khun ( t v tr m khun n khi cc cht dn hng ca khun ng bt u khp vo l trn na khun tnh

(do trong hnh trnh ny na khun ng chy t do, cn tit kim thi gian ng khun).

Khong ng khun ( t v tr cc cht dn hng bt u khp l n khi hai na khun ng v tnh tip xc nhau

(hnh trnh ny c cc cht dn hng, cht dn core, cht lui tm y tip xc vi phn khun tnh v vy cn phi chuyn ng chm vi p lc thp, th p bng cch cho cung nha vo phn khe gia 2 mt phn khun, nu khi khun khp li, cung ch b bp 1/2 kch thc l t, nu nh hn th phi gim p hnh trnh ny

Khong ( ti v tr hai na khun tip xc nhau

(hnh trnh ny p lc kp khun cao tnh theo hnh chiu sn phm theo hng u phun ln b mt khun ng, hoc tnh theo p lc sao cho khi p phun khng lm tch khun gy via) .

Kp khun p cao khi v tr khun thc t nh hn gi tr t v tr kp khun p cao ch ng khun chuyn sang p lc kp khun cao.

(Trnh va p hai b mt khun cn c khe h gia 2 b mt chuyn kp khun p cao, Bo v khun trong trng hp nu c vt l nm gia hai b mt khun, nu c vt l hay chi tit sn phm git li lm cho v tr chuyn p cao khng t c, nn khun ang ng giai on p thp khng chuyn sang p cao v vy c th bo v khun)

Ch : i vi my ng m khun bng khuu, kim tra gi tr kp khun cao thc t so vi gi tr t bng cch c gi tr trn ng h bo p thc t. T iu chnh li b khun

i vi ch ng khun my MITSUBISHI

Khong ng khun ( t v tr m khun n v tr cch 50 mm

(Do trng lng khun ln, trng lng tm kp ln, lc qun tnh ln nu tc ng khun nhanh t ngt s gy chn rung my c th dn n gim tui th my, nh hng kt cu my)

Khong ng khun ( t v tr ht khong ng khun( n v tr khi cc cht dn hng ca khun ng bt u khp vo l trn na khun tnh

Khong ng khun ( t v tr cc cht dn hng bt u khp l n khi hai na khun ng v tnh tip xc nhau

Khong ( ti v tr hai na khun tip xc nhau

B- Qu trnh m khun

i vi c ch m khun thng thng v my Missubishi

Khong m khun ( (tch khun ban u) t v tr hai na khun khp kht nhau n khi cc cht core ca khun tnh bt u tch khi l trn na khun ng. (Giai on ny trong khun ang c sn phm v vy cn phi m khun chm trnh bin dng sn phm, m bo an ton cc kt cu khun)

Khong m khun ( t v tr ( n v tr cc cht dn hng bt u tch khi l

Khong ( t v tr ( n v tr na khun ng cn khong 50 mm l m ht khun

(hnh trnh ny na khun ng chy t do) Khong ( t v tr ( n v tr m ht khun.

(Khun chun b dng do vy tc gim trnh tnh trng dng t ngt gy chn ng rung my thng nh sn xut t mc nh sn trong ch my, t gi tr khong ny 3D, nguyn liu nha s lu chuyn nhanh t c phu liu ti u phun, thi gian tc dng ca nhit t v xy lanh s t i, nha c th khng c nng chy tt, khng c khuy trn ng u tt, d ln bt kh, dn n li sn phm ng thi gy hi cho trc vt. Ch c cc trng hp c bit khng nh hng n sn phm hay my mc th mi c th s dng lng nha ngoi khong 1D ~ 3D.9.3.3. Cch thc t lng nha mt sn phm trong thc t

Trng hp 1 : t lng phun cho mt sn phm bit trng lng trn mt my c c th khi bit gi tr lng phun v trng lng ca mt sn phm khc c trn my , thng t trc mt gi tr tnh ton tng ng. V d :

- Trng lng sn phm 1 = 80g

- Lng nha phun sn phm 1 = 50 mm

- Trng lng sn phm 2 = 100g 100 x 50

=> Lng nha phun t cho sn phm 2 xp x = --------------- ~ 60 mm

80Sau c th sn phm v c th iu chnh tng hoc gim lng nha sao cho sn phm t v lng nha d (cushion) va phi (= 2 ~5 mm tr cc trng hp c bit )

Trng hp 2 : Khi bit khi lng ca sn phm mi nhng khng bit gi tr lng nha ca my, ta c th t mt lng phun bt k ri cho my phun ht lng nha ra ngoi. Sau ta em cn s bit khi lng ng vi lng nha t, t c th t lng nha cho sn phm nh trng hp 1.

Trng hp 3 : Khi khng bit khi lng ca sn phm mi , ta t lng nha gi tr c chng tng i bng cch lin h hnh dng vi cc sn phm tng ng. Khi c th ta ch c php in nha dn dn vo khoang c n khi sn phm. Khi my ang hot ng, mn hnh khng bo gi tr lng phun thc t m ch bo gi tr lng nha np thc t ( injection stroke hay injection start ) v lng nha d thc t (cushion hay injection end )

9.3.4. t tc v p sut npQu trnh np nha thng chia lm 3 giai on c gi tr tc v p lc khc nhau. Giai on u v giai on cui thng np vi tc, p thp trnh cho trc vt quay nhanh t ngt hoc dng t ngt, m bo an ton cho hot ng ca my. Giai on np chnh c gi tr tc p ln v ph hp vi mi loi sn phm . i vi mt s my th khng phn chia giai on np do cu to ca b iu khin kiu c.

p sut np : L ng lc thc hin gi tr tc tng ng. Tc np : L tc quay ca trc vt.

i vi mi loi nha hay mi loi sn phm cn thc hin np nha vi tc v p sut thch hp t c cht lng sn phm tt nht.

Nu p, tc np nh :

Trc vt quay chm, nhit do ma st quay nh, nha c khuy trn km dn n khng t c nng chy v ng nht cn thit. Vi lng nha ln th tc, p np nh s dn n thi gian np lu khng c li.

Nu p, tc np ln :

Trc vt quay nhanh, thi gian np nhanh, nhit ma st ln, nha c nng chy v khuy trn ng nht tt. Tuy nhin nu nhit sinh ra ln qu s gy chy nha, nht l i vi loi d chy nh PVC, to nhiu bt kh dn n li xc trng trn sn phm. Mt khc khi trc vt quay nhanh d cun theo nhiu khng kh vo cng vi nguyn liu cng dn n li xc trng. Khi trc vt quay qu nhanh c th lm cho nha c np khng u, cht lng sn phm khng n nh, nht l i vi nha xay, ng thi gy hi cho my.

v d t tc, p np :

#1#2#3

Pressure ( p sut )607060

Speed ( tc )355035

End posn ( v tr )157080

Bng d liu np trn c hiu nh sau :

Lng nha np t = 80

Giai on np 1 : Bt u np t v tr cushion ( = 5 ) n v tr 15 vi p 60, tc 35

Giai on np 2 : Tip tc np t v tr 15 n v tr 70 vi p 70, tc 50

Giai on np 3 : Np chm dn t v tr 70 n v tr cui 80 vi p 60, tc 35.

9.3.5. Back press ( p nn liu )

1.Th no l p back pressKhi trc vt quay trong qu trnh np , vt liu nha nng chy nh ma st c y v pha trc ca u trc vt qua van 1 chiu, lng nha b dn ln s y trc vt li li pha sau mt cch t nhin .

Tuy nhin nu trc vt b y li mt cch t nhin nh vy th phn nha np khng c nn p tt, cha nhiu bt kh ( bao gm hi m, khng kh b cun theo nguyn liu v kh chy do nha b phn hu nhit ), khi c phun vo khun s gy ra li xc tia v mt s li khc.

khi nha np c ng nht v n nh v vy cn thit phi t mt p sut vo pha sau trc vt theo hng ngc li hn ch tc li ca trc vt, gi l p back press . Khi p lc pha trc trc vt phi ln hn p lc back press th trc vt b y li v, ngha l thi gian np tng ln. V tc np ( tc quay ca trc vt ) khng i nn khi thi gian np tng ln, khi lng nha np c s tng ln, ng thi nha nng chy c khuy trn ng u hn. M v tr np khng i ngha l th tch nha khng i trong khi khi lng tng ln, do nn p ca nha c tng ln. Khi cc kh c trong nha s b p ra ngoi v hng ui trc vt. Do p back press cn c gi l p nn liu.

p back press tc dng trong sut qu trnh np

Back Press c iu chnh bng tay hay bng cch thit t s liu trn mn hnh. Gi tr thit t tu theo tng trng hp c th nhng thng thng vo khong 5-15 kg/cm2 ( nhn theo ng h o p back pressure). Gi tr cc i c th t c l 50-60 kg/cm2. ( hay 5-6 MPa )

2. nh hng ca back press i vi qu trnh c

Khi Back press qu cao : - Thi gian np qu di lm gim nng sut.

- Nha nng chy b nn p qu mnh lm tng nhit nha, gy chy nha nhiu (nha b phn hu nhit ) sinh nhiu kh chy, khi phun vo khun to li xc tia.

- V nn p ca nha cao nn khi m khun, nha nng chy s trn qua u phun vo cung phun. Khi nha c th ng cng li gy tc cung phun.

Khi back press qu thp : - Nha khng nn p thot kh , sn phm d b xc tia

- Thi gian np thp, mc ng u ca nguyn liu km

C khi back press qu cao hay qu thp, lng nha np u khng n nh. V vy i vi mi loi nha, mi sn phm c th cn xc nh mt gi tr Back press ph hp sao cho ln thot kh tt trnh li xc tia, nguyn liu nha nng chy t ng u cao nhng khng gy chy nha, lng nha np c n nh .

9.3.5. Suck back ( decompress )

1- Ti sao cn suck back ( gim p )

V c back press, nguyn liu c nn p li pha trc u trc vt. Khi m khun, u phun tr nn b h nn nha nng chy c nn p cao s trn ra cung phun v c th ngui v ng cng li gy tc cung phun. trnh hin tng ny m vn m bo thot kh khi np nha, th sau khi trc vt dng quay (kt thc np), trc vt cn c li li mt khong nh gi l suck back tng th tch khi nha nng chy, qua gim c p sut nn trong lng khi nha (decompress ). Khi nha nng chy s khng p sut trn ra ngoi u phun na.

2- nh hng ca suck back n qu trnh c

Nu suck back t qu : th cha mc gim p, nha vn c th b trn ra ngoi cung phun gy tc cung.

Nu suck back nhiu qu : th s ht thm khng kh vo, gy li xc tia sn phm.

Lng suck back phi thch hp i vi mi sn phm Tu tng sn phm c th, lng suck back c th t t 0,5 n 5 mm.

9.4. Ch phun v bo p

9.4.1. Ch phun ( injection )

Thut ng :

Phun nha = Injection

Bo p = Turn Hold hay Holding pressure

V tr phun = End Posn hay Stroke

p sut phun : L ng lc thc hin phun nha vo khun, c tnh theo n v kg/cm2 hoc % so vi p sut ln nht ca my hay mt n v quy c theo b iu khin ca my.

Vn tc phun : L tc my thc hin phun nha vo khun di tc dng ca p sut phun, c tnh theo n v % tc ln nht hoc mt n v quy c ca my.

Thi gian phun : L thi gian trc vt dch chuyn t v tr bt u phun n v tr gii hn chuyn sang giai on bo p. 1 - Thi gian phun gii hn ( = limit time ) : L thi gian gii hn cho giai on phun. My c th thc hin phun vi thi gian nh hn hoc bng limit time cn nu vt qu limit time th my s t chuyn sang giai on bo p. Thng t sao cho limit time ln hn thi gian phun thc t.

2 - Thi gian phun thc t ( = Thi gian phun p cao, thi gian PH, V=>P switch time ) : L thi gian phun thc t m my thc hin theo gi tr tc , p sut t. Khi nim v qu trnh phun nha.

Di tc dng ca p sut phun, nha nng chy c phun qua h cung phun v knh dn nha vo khoang khun c. Khi dng nha chy n v tr no trong khoang khun, phn nha nng chy tip xc vi b mt khun ngui s ng cng dn li theo hnh dng ca b mt khun, trong khi gia dng nha vn cn chy long. V vy cc phn nha sau tip tc chui qua phn nha ng cng b mt v in y khoang khun. Trong qu trnh dng nha lin tc b ngui v ng cng dn

Hnh trnh phun nha bt u t v tr lng nha np thc t n v tr chuyn sang giai on bo p ( sao cho lng nha phun va in y sn phm ).

V d v bng d liu phun :

#6#5#4#3#2#1

Pressure ( p sut)000607050

Speed ( tc )000122515

End posn ( v tr )101010101870

Limit time8

Bng d liu phun trn c hiu nh sau :

Bc phun 1 : Bt u phun t v tr lng nha np thc t ( = 82.5 ) n v tr 70 vi p 50, tc 15. y l giai on phun qua cng gate

Bc phun 2 : Tip tc phun t v tr 70 n v tr 18 vi p 70, tc 25. y l giai on phun vo phn chnh ca sn phm.

Bc phun 3 : Tip tc phun t v tr 18 n v tr 10 vi p 60, tc 12. y l giai on phun cui lm y sn phm v chuyn sang qu trnh bo p vi v

tr chuyn p l 10 ( v tr nh nht trn dng v tr phun )

Thi gian gii hn cho qu trnh phun ny l 8 giy

nh hng ca p sut, tc phun

n cht lng sn phm.

Tc v p sut phun nh hng rt ln n cc c tnh cht lng sn phm, l cc thng s quan trng nht to hnh sn phm.

9.4.2 nh hng ca p sut phun n cht lng sn phm

p sut phun to ra p sut ca dng nha chy trong khoang khun. Tu tr lc ca h thng cung phun v knh dn nha, p sut cn li ca dng nha s in nha nng chy vo phn th tch rng trong khoang khun

Mc in y khoang khun :

Theo thi gian phun nha vo khun, dng nha nng chy s ngui v ng cng dn. Cng v cui qu trnh phun, nha cng ng cng nhiu. Nu p sut phun khng ln phun nha vo khoang khun trong thi gian cn thit th khi dng nha ng cng hon ton nhng vn cha in y c khoang khun. Nh vy to ra li thiu nha sn phm. V vy p sut phun phi ln in y khoang khun trong thi gian ngn nha cha kp ngui.

co ngt ca sn phm :

Khi dng nha nng chy c phun vo khun, phn nha tip xc vi b mt khun ng cng trc, trong khi gia lng dng nha vn cn chy mm nn ng sut ti nh hn ng sut v tr dng nha ng cng. Khi dng nha c xu hng co ngt v pha tm dng nha. Phn sn phm cng dy th mc co ngt cng ln. Do ti cc v tr c gn, cht, thnh dy mt sau ca sn phm ta thng thy cc vt ngt lm. trnh co ngt, dng nha chy phi c p sut ln hn ch s chnh lch ng sut ni trn. Nh vy p sut phun cng ln th cng hn ch c co ngt. Nhng khi cc phn khc ca sn phm c th chu p sut qu cao dn n sn phm qu cng to ra cc vt hn khng mong mun. V vy i vi mi sn phm c th cn t mt p sut phun ph hp. S to via sn phm :

Nu p sut phun qu cao, dng nha s b p vo cc khe h trn khun to ra via. Cc khe h trn khun thng l khe trn b mt phn khun, cc khe rnh thot kh, cc khe h do cc mnh khun lp ghp khng kht.9.4.3. nh hng ca tc phun n cht lng sn phm

Tc phun th hin qua thi gian phun tha t. Tc phun nh hng n mt s vn chnh sau:

co ngt sn phm :

Theo nguyn l lu bin hc, dng chy c tc cng ln th p sut tnh cng nh v ngc li, tc dng cng nh th p sut tnh cng ln. V vy khi tc phun nha nh th t c p sut dng nha ln, sn phm t co ngt hay ni cch khc l cng hn. Cn khi tc phun ln th sn phm ngt nhiu hn. Mc in y khun :

Nu tc phun qu chm, dng nha cha in y khun m thi gian ng cng th khng th in thm nha c na. Khi xy ra li thiu nha sn phm. V vy tc phun phi ln in y khoang khun trong thi gian cn thit. S to via sn phm :

Nu tc phun qu nhanh qua cc v tr c khe h trong khoang khun, dng nha lc cn chy long cao s d dng len vo cc khe h to ra via trn sn phm. V vy khi dng nha qua cc v tr c khe h nh vy phi phun vi tc va phi trnh to via. cong vnh v kch thc ca sn phm :

V tc phun lin quan n p sut dng nha, ngha l lin quan n mt v s nh hng cc phn t trong sn phm. Do nu tc phun khng thch hp lm cho mt phn t khng ng u ( cng ca sn phm khng u ) dn n sn phm b cong vnh hoc kch thc khng chnh xc, nht l i vi cc sn phm c dng phng. Vt khp nha ( weld line ) :

Ti v tr hai dng nha chy gp nhau bao gi cng hnh thnh vt khp nha. Khi hai dng nha gp nhau, nu nhit cc dng nha nng th s ho trn tt vi nhau, vt khp nha s m, c th ti mc khng nhn thy c. Nu nhit cc dng nha thp th s khng ho trn tt c. Khi ta thy r vt khp nha, sn phm khng t yu cu. Nu dng nha c phun vi tc nhanh khi qua cc v tr khp nha, nhit cc dng nha cn cao do vt khp nha s m. Nu phun chm qua cc v tr , dng nha b gim nhit nhiu nn to vt khp nha r.

Vt chy : i vi mt s loi nha d chy nh PVC, ABS,, khi phun vi tc qu nhanh dng nha s b ma st vi cc im nhn, gc cnh sc trong khun to ra vt chy dng vt xc tia. Ngoi ra khi nha c phun vo khun s chim ch ca khng kh trong khun, dn kh v pha cui ng chy nha. Nu lng kh ny khng c thot ra ngoi s b dn nn li to nhit rt cao gy chy nha. Thng thng ti v tr cui ng chy nha u c thit k rnh thot kh. Tuy nhin, nu tc phun qu nhanh hoc cc rnh thot kh b kt bn th kh s khng kp thot v gy chy nha. V vy cn v sinh sch s rnh thot kh v giai on phun cui cn phun tc chm kh kp thot ra trnh chy nha. Vt dng nha chy : i vi mt s loi nha nhanh ng cng b mt nh PA, PVC,nu dng nha c phun nhanh qua cc im g gh, li lm trong khun, dng nha chy s b cun. Cc dng nha chy cun khng ho trn tt vi nhau to ra cc vt khp nha r nh cc khe, rnh nt trn sn phm. Khi gp trng hp nh vy cn gim tc phun.9.4.4. Cch t p sut, tc phun cho mt sn phm.

Tu cu to ca mi loi my m qu trnh phun nha c chia thnh t 1 n 10 giai on ( bc phun ), thng thng l 3 bc phun. S d nh vy l v mi sn phm cn c c phun trong nhiu giai on vi p sut, tc khc nhau. Mi bc phun tng ng vi mt phn trn sn phm. Gi tr p sut, tc mi bc phun nh hng trc tip n c tnh cht lng ca phn sn phm tng ng , ng thi cn nh hng lin quan n nhau do qun tnh ca du thu lc v dng nha chy.

Bc phun u :

Tu cu to tng sn phm c th nhng nguyn tc chung l thng phun vi tc chm trnh chy nha v trnh ko theo vt nha kh. Sau mi shot phun, phn nha u phun thng b ngui bt ( thng gi l nha kh ). shot phun sau, nu tc phun u qu nhanh s ko theo vt nha kh ny vo sn phm.

Cc bc phun gia :

Tu cu to sn phm c th m t p, tc phun cho ph hp, tun theo cc c tnh nh hng ca p, tc phun n cht lng sn phm v s nh hng ca cc yu t khc nh nhit nha, nhit khun, nhit du thu lc Ni chung thng phun mc nhanh nht c th c tit kim thi gian chu k c.

Bc phun cui :

t tc p phun ph hp cho tng sn phm c th, khng qu chm in sn phm, khng qu nhanh trnh chy nha .

iu quan trng l phn chia c cc phn sn phm cn phun vi tc , p sut khc nhau t cc bc phun ti cc v tr tng ng t trn my. iu ny ch c th th nghim trn mi my c th vi mi sn phm c th.

9.4.5. cc yu t nh hng n tc , p sut v thi gian phun.

a. nh hng ca nhit du thu lc:

i vi cc my thu lc, ton b ng lc ca my l nh p sut ca du thu lc qua h thng bm v ng ng. p sut thu lc ph thuc vo chu nn ca du. chu nn ca du ph thuc vo nht ca du. nht ca du li ph thuc vo nhit ca du. Nh vy nhit ca du nh hng n p sut ca du thu lc, ngha l nh hng n mi qu trnh hot ng c hc ca my. V p sut phun l ng lc thc hin tc phun, nn nhit du nh hng n p sut phun th cng ng thi nh hng n tc phun. Khi nhit du tng, nht ca du tng, chu nn ca du gim i, ngha l p sut du thu lc gim, hay p sut v tc phun u gim i so vi gi tr t trn my, lm thi gian phun thc t di hn. Khi ta thng phi tng cc gi tr p hoc tc hoc c hai t c gi tr p, tc thc t nh c. Ngc li, khi nhit du gim, p sut v tc phun thc t u tng ln, lm thi gian phun thc t ngn li. khi ta li phi gim cc gi tr p, tc t trn my. Nh vy, my chy n nh, ta cn khng ch nhit du thu lc trong mt khong gi tr tiu chun cho php, thng 30~45 0C.

b. nh hng ca nhit khun :

Nhit khun khng nh hng trc tip n p sut v tc phun m my thc hin, nhng nh hng n qu trnh thc t dng nha c phun vo khun. Nu nhit khun cao, mc ngui i ca dng nha nng chy chm, dng nha chy trong khun d dng, thi gian phun thc t ngn hn, tng ng vi khi ta tng p sut v tc phun, lm thi gian phun thc t ngn hn. iu ny thng dn n cc li sn phm do phun qu nhanh. Trong trng hp ny sn phm vn t cht lng nh c, ta phi gim gi tr p, tc phun t trn my. Ngc li khi nhit khun thp, mc ngui i ca dng nha nng chy nhanh, thi gian phun thc t di hn, tng ng vi khi ta gim p sut, tc phun, lm thi gian phun thc t di hn. iu ny thng dn n cc li sn phm do phun qu chm. Khi ta thng phi tng gi tr p, tc t trn my. Nh vy my chy n nh, ta cng phi khng ch nhit khun trong khong tiu chun cho php.

c. nh hng ca nht nha nng chy ( chy long ).

Tng t nh nh hng ca nhit khun n p sut, tc phun, nht nha nng chy ( chy long ca nha ) khng nh hng trc tip n p sut v tc phun m my thc hin, m nh hng n kh nng dng nha c phun nhanh hay chm. nht ca nha nng chy ph thuc vo loi nguyn liu, nhit nha. Nhit nha li ph thuc gi tr nhit v xy lanh, tc np nha, p sut nn nha ( back press ). i vi mi loi nguyn liu, nht ca nha ch cn ph thuc vo nhit nha, ngha l ph thuc nhit xy lanh, tc np nha, p nn nha v thi gian lu trong nng phun. Tc np nha , p nn nha v thi gian lu cng cao th nhit nha cng cao, lm cho nht ca nha cng cao. Ngc li nhit nha cng thp th nht ca nha cng thp. nht ca nha cao tng ng vi trng hp nhit khun cao. nht ca nha thp tng ng vi trng hp nhit khun thp. Tuy nhin i vi mi sn phm ng vi mt loi nha, ta thng gi c nh nht ca nha, ngha l c nh nhit xy lanh, tc np , p sut nn nha v gi thi gian lu ca nha trong nng phun ng u, ngha l thi gian chu k c ng u .

9.5. Ch bo p.

9.5.1. Khi nim v qu trnh bo pBo p l qu trnh duy tr p sut sau khi phun nha in y khoang khun trnh co ngt khi nha ng cng dn trong khun. Ta bit trnh hin tng co ngt xy ra khi nha ng cng trong khun, phi dng nha ng cng di p sut ln. V chu tc dng ca p sut nn trong qu trnh bo p, nha vn tip tc c nn vo khun n khi phn cung nha ng cng hon ton. Tc bo p l tc thc hin p sut bo p. Thi gian bo p l thi gian duy tr p sut.

Qu trnh bo p cng c chia thnh t 1 n 4 giai on tu cu to ca my. Qua ta c th thc hin duy tr p sut trong nhiu giai on vi gi tr tc , p sut, v thi gian khc nhau ph hp vi yu cu ca sn phm. Qu trnh bo p ch c tc dng khi nha trong h thng cung phun, ng chy nha, gate phun v trong lng sn phm cn mm, ngha l cn c th nn thm nha vo.

Hnh trnh bo p bt u t v tr chuyn p n v tr cui cng ca trc vt l v tr cushion

V d v bng ch bo p :

#4#3#2#1

Pressure ( p sut)0308040

Speed ( tc )0154020

Time ( thi gian)00.531.5

Bng d liu trn c hiu nh sau :

Giai on bo p 1 : Thc hin vi p 40, tc 20 trong thi gian 1.5 giy

Giai on bo p 2 : Thc hin vi p 80, tc 40 trong thi gian 3 giy

Giai on bo p 3 : Thc hin vi p 30, tc 15 trong thi gian 0.5 giy

Giai on bo p 4 : Khng s dng

9.5.2. nh hng ca p sut, tc v thi gian bo p n cht lng sn phm.

co ngt ca sn phm:

Tc , p sut v thi gian bo p t l vi cng ca sn phm. Tu yu cu ca mi sn phm v c tnh co ngt ca mi loi nha, ta cn s bc bo p v cc gi tr p, tc, thi gian mi bc khc nhau, sao cho t c mc cht lng theo yu cu. Thng thng i vi cc loi nha lu ng cng nh PP, PVC ta phi duy tr bo p trong thi gian di hn cc loi nha ng cng nhanh, sn phm dy phi bo p lu hn sn phm mng. Nu p sut, tc , thi gian bo p qu ln s dn n sn phm qu cng, c th to ra cc vt hn khng mong mun. S to via sn phm :

Nu p sut v tc bo p qu ln cng d to ra via sn phm. Thng thng trong thc t ban u ta t trc cc gi tr bo p nh, ri tng dn ln n khi sn phm cng mc chp nhn c. Nu sn phm cng mc thp nht chp nhn c m to ra via th phi chp nhn via trn sn phm v phi gt b theo yu cu ca sn phm. Khi lng sn phm :V trong qu trnh bo p nha lin tc c nn vo khun n khi phn cung nha ng cng hon ton, nn mc bo p trong thi gian t l vi khi lng sn phm. cong vnh v kch thc ca sn phm :Tu gi tr p sut, tc , thi gian bo p mi giai on bo p, sn phm t c c cng ng u hay khng , ngha l c b cong vnh v kch thc sn phm c chnh xc hay khng. 9.5.3. Cc y t nh hng n qu trnh bo p.

Thi gian bo p c th t trn my v c my thc hin mt cch chnh xc, n ch ph thuc vo cc yu cu i vi tng sn phm c th. Cn p sut v tc bo p ph thuc vo mt s yu t sau:

Thi im chuyn t qu trnh phun sang qu trnh bo p:

( V tr chuyn p ) .Vic xc nh thi im chuyn ny l rt quan trng. Khi cha phun sn phm m chuyn bo p th c th gy thiu nha nu p, tc bo p khng ln p nha in y khoang khun. Nu chuyn sang bo p qu mun, th tnh t lc in y nha vo khun, tc, p phun cui ng vai tr bo p u, c th gy ra via hoc sn phm qu cng do p sut phun thng ln hn p sut bo p. Mt khc hai iu ny cn gy kh khn cho vic iu khin v qun l cc thng s k thut. V vy cn xc nh ng thi im chuyn bo p l lc sn phm va c in y khoang khun.

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PE, UF, Oxy Este, PU, Silicone

PPO/PS, PC/ABS, PA/PP....

PAR, PEI, PAI

PPS, PTFE, PEEK

Khng kt tinh

Tnh kt tinh

PC, PPO

PA, POM, PBT

Khng kt tinh

Tnh kt tinh

PS, PVC, ABS, PMMA

PE,PP

Nha k thut tnh nng cao

Nha k thut thng dng

Khng kt tinh

Tnh kt tinh

Nha ph thng

Nha hn hp

Nha k thut cao

Nha nhit do

Nha

Nguyn liu

My mc Thit b

Con ngi

Cng ngh Cc iu kin lm vic

Sn phm

Cushion

0

5 15 70 80

cushion

Cushion

+

10 mm

Np 2 nhanh

Np 1 chm

3D

4D

ng knh ngoi

ng knh trong

Khong t lng nha ti u

Trc vt

Lng nha np

Khong chy trc vt ( Lng nha phun )

Tit din trc vt

Lng nha d

( Cushion )

0 Gi tr t trn my (v d )

10 60 End posn

Nha

Cushion

V tr lng nha np

0 ( V tr trc vt kch u phun )

Khun v tr ng

T/g in y

Thi gian cooling

Thi gian

duy tr p sut

Thi gian phun

Thi gian np

M khun

Biu th hin chu k c sn phm theo thi gian

1D

0

D

ng khun

Ban ISO

B phn

Qun l cht lng

B phn

Qun l k thut

B phn

Qun l sn xut

B phn

Nghip v

Ph tng gim c th nht

Ph tng gim c th hai

Tng gim c

Lng nha np

Hnh trnh np nha

Back press

Trc vt quay

Nha

Nha dn ln y li trc vt

B mt khun

B mt khun

Cng phun

Dng nha chy bn trong

Phn nha tip xc vi b mt khun ng cng

0 10 18 70 82.5

Lng

nha np

V tr chuyn bo p

Cc giai on trong

hnh trnh phun

T c,kim line A

T c,kim line B

T c,kim line C

T c,kim line D

Tr v HYPERLINK \l "_Hlk119383403" \s "1,255,265,1,,Mc lc:" Mc lc:


Tr l


Sn phm

Phun nha vo khun

Do ho (Lm nng chy)

Nguyn liu nha

p phun vo khun

Lm ngui

1 chu k

1 chu k

y sn phm

M khun

Lm ngui

Np nha

Np 3

chm

5 mm

3 mm

K hoch sn xut

c sp g?

Khun g?

Lp khun

Nha g? Sy

Sy

Sy

Myg? Sy

ng khun chm

Core vo

ng khun nhanh

ng khun chm

Kp p

cao

Phun

Tch khun

M khun

chm

Np

Lm lnh

(lu ho)

Tin cm phun

Core vo

Core vo

Li cm phun

M khun

nhanh

M

khun

chm

Core vo

Core vo

Core vo

Robot ly sn phm

Cht y

tin

Cht y

li

Li cm phun

Bo p

Lu 1 chu k hot ng ca my c






ng

Khun


1 chu k

y sn phm

M khun

Lm ngui

Np nha

Phun nha vo khun





%

%

%

%

CP3 CP3

CP2

CV2

CV1

%

%

sec

%

TM CP3

OV1

OV2

OV3

8

Documents

Giao Trinh Gccd(Daiwa)