The first chapter plastic molding base

First, the basic content of this chapter:

The theoretical foundation of the plastic molding; structural

characteristics and properties of the polymer, the plastic composition and

classification, process performance plastics, plastics thermal properties,

rheological properties, and the plastic melt flow state in the physical and

chemical changes in the molding process ; structure, properties and use

common plastics. Four commonly used plastic molding method, molding

principle, molding process and process parameters. Design principles

plastic parts, plastic parts dimensional accuracy and the surface roughness

is determined; surface defects that occur when the plastic molding and

causes; Design of plastic parts of each structural unit.

Second, learning objectives and requirements:

1, basic knowledge of plastic molding, understand the physical and

chemical changes in the plastic molding process, familiar with the

performance and the use of commonly used plastic.

2, understand the methods commonly used plastic molding process,

and be familiar with the advantages and disadvantages of the use of

various molding methods, an injection molding process selection control

and process parameters.

3 for dimensional tolerances and precision plastic parts selection,

learn to analyze the causes of the plastic surface defects.

 4, grasp the structural units of each design principles plastic parts.

Third, the focus of this chapter, difficulties:

Wherein plastic; molding principle; injection molding process;

selection and control of molding process conditions: design principles of

plastic parts; manufacturability plastic structure; plastic molding of

surface defects and the Cause.

1, the molecular structure of the polymer

Plastic resin is a synthetic polymer as the basic raw material, adding

a certain amount of the additive composition, temperature and pressure at

a certain structure having a certain shape made of plastic, which can

maintain their shape at ambient temperature material.

The synthetic resin is a polymer compound one or more simple

compounds generated by the polymerization reaction, the polymer is also

called, these simple compounds are also called monomers. The main

component is plastic resin, the resin is a polymer, the analysis of the

molecular structure of the plastic is substantially analysis of molecular

structure of the polymer.

1), the polymer molecular structural features

(1) low molecular weight contained in the number of atoms are

small, and a polymer containing thousands, tens of thousands, even

millions of atoms.

(2) from the point of view relative molecular mass, such as water

molecular weight of 18, 100 limestone, alcohol 46, 324 sucrose, these

low molecular weight compounds which only a relative molecular mass

of tens or hundreds, and the polymer compound molecular weight much

higher than the low molecular weight, generally from tens of thousands to

hundreds of thousands, millions or even tens of millions. Nylon such as

molecular weight is about twenty-three thousand molecules, natural

rubber 400,000.

(3) the length of the molecular point of view, for example, the length

of the low molecular weight ethylene approximately 0.0005, and the

length was 6.8 m high molecular weight polyethylene, which is 13,600

times the former.

2), a schematic structure of polymer chain

If the molecular chain of the polymer irregular line (or slug), the

polymer is a root of the molecular chains, it is called linear polymer, a

shown in FIG. If the chain between the macromolecule and some short

chain to connect them, the structure becomes three-dimensional,

polymeric body is called, as shown in FIG. C. In addition, with some of

the polymer main chain of the macromonomer some small or long or

short chain branched, dendritic shape of the whole chain, shown in Figure

b, referred to as a linear polymer having branched chains.

3), properties of the polymer

Different molecular structure of the polymer, its nature is different.

Physical properties (1) is a linear polymer having elastic and plastic,

may be dissolved in an appropriate solvent, when the temperature rises,

the softened molten state to flow, can be repeatedly formed, such

polymers having a thermoplastic.

Physical properties (2) type polymer that is brittle, low plasticity and

high elasticity, before molding is soluble and fusible, and a hardened

molding (chemical crosslinking reaction) after it became insoluble and

infusible solid even (even charred carbide) does not soften at a higher

temperature, therefore, this material has also called thermosetting.

4), aggregation of the structure and properties of the polymer

Since the polymer molecule is particularly large and intermolecular

attraction is large, easy to assemble a liquid or a solid, without the

formation of gaseous. Structure of the solid polymer molecules are

arranged in a geometric features can be divided into non-crystalline and

crystalline (or amorphous) two.

(1) crystalline polymers

 Crystalline polymers by the "crystal zone" (molecular closely spaced

as a regular area) and "the amorphous area" (a state of disorder of the

regions of the molecule) composed of, as shown in FIG. Weight percent

of area occupied by crystal crystallinity referred to, for example,

low-pressure polyethylene crystallinity at room temperature of 85% to

90%. Typically simple molecular structure of the polymer with a small

volume of the side groups in the main chain, high symmetry and large

intermolecular force, it is beneficial to the crystallization; conversely, the

adverse crystallization or crystalline regions can not form. Crystallization

occurs only linear polymers and crosslinkable polymer small in size.

Crystals have a greater impact on the properties of the polymer.

Since the crystalline state resulting in a close molecular aggregation,

enhance the intermolecular forces, so that the strength of the polymer,

hardness, melting point and stiffness, heat resistance and chemical

resistance and other properties improved, but the performance of motion

associated with the chain such as elasticity, elongation and impact

strength are decreased.

(2) a non-crystalline polymer

For the structure of the non-crystalline polymer, which has been

considered that the molecular arrangement is haphazard, interpenetrating

entangled. However, observation under an electron microscope, it was

found amorphous polymer particle arrangement is not completely

disordered, the disorder rather large distance range, within a small

distance range order, i.e., "Remote disorder, orderly process."

Dimensional polymer chain since the presence of large intermolecular

crosslinking, the molecular chain is difficult to be orderly arranged, so

that most of an amorphous polymer.

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2, the composition and classification of plastics

1), the plastic composition

Plastics is a synthetic resin as a main component, and then adding

various additives to improve its properties (also known as adjuvants)

made. In plastics, resins play a decisive role, but can not be ignored

additive.

(1) Resin

Plastic resins are the most important component which determines

the basic performance and the type of plastic (e.g. thermal properties,

physical properties, chemical properties, mechanical properties, etc.). In

plastics, which contact adhesive or other adhesive component, and a

plastic having plasticity and fluidity, so as to have moldability.

It includes natural resins and synthetic resins. In the production of

plastics, synthetic resins are generally used.

(2) filler

Also known as packing filler, plastic is important but not essential

for every plastic components. Mechanical mixing with the other

ingredients of the filler in the plastics, chemically inert therebetween, but

the resin gluing together firmly.

Fillers in plastics has two functions: one is to reduce the amount of

resin, reduced the cost of plastic; second is to improve certain properties

of the plastic, the plastic to expand the scope of applications. In many

cases, the role of the filler is large, such as polyethylene, polyvinyl

chloride resin added after the flour, not only to overcome their brittleness

and reduce the cost. Glass fiber as the filler of the plastic, the plastic can

greatly improve the mechanical properties, and use of asbestos as a filler

can be improved in heat resistant plastic. Some fillers may have a plastic

resin does not have properties, such as conductivity, permeability, thermal

conductivity and the like.

Commonly used fillers wood flour, pulp, mica, asbestos, glass fibers

and the like.

(3) Plasticizer

Some thermoplastic resins (e.g., nitrocellulose, cellulose acetate,

polyvinyl chloride, etc.) is very small, the flexibility is poor, in order to

reduce melt viscosity and melting temperature of the resin, to improve its

molding properties, improved flexibility of the plastic member, the

resilient and various other properties required, can be added generally

compatible with the resin, less volatile high boiling organic compounds,

such substances called plasticizers.

After the resin is added the plasticizer, the plasticizer molecules

inserted between the resin polymer chains, increasing the distance

between the polymer chains, thereby weakening the force between the

polymer, the polymer resin is relatively prone to slip shift, so that the

plastic has excellent plasticity and flexibility at lower temperatures. For

example, polyvinyl chloride resin was added dibutyl phthalate, may

become rubber-like soft plastic.

Adding a plasticizer in the plastic molding while improving

processability, sometimes reduce certain properties of the resin, such as

hardness, tensile strength, and therefore a plasticizer moderation.

Plasticizers requirements: the resin has good compatibility; volatile

small, easily precipitated from the plastic member; non-toxic, colorless

and odorless; relatively stable to light and heat; not hygroscopic.

(4) Colorant

In order to obtain various desired colors plastic parts, often adding

a colorant in the plastic component. Many varieties of coloring agents,

but generally divided into organic pigments, inorganic pigments and dyes

three categories. Some other effects both colorant, such as

polyoxymethylene plastic qualities after coloring carbon black can help

prevent photoaging some extent.

General requirements for the colorant are: strong coloring; the resin

has good compatibility; do not chemically react with other components in

the plastic; molding process is not due to temperature, pressure change

color decomposition, the plastic parts and long-term during use remains

stable.

(5) Stabilizer

In order to prevent or suppress the plastic molding, storage and use,

performance variation due to external factors (such as heat, light, oxygen,

radiation, etc.) caused by the action of so-called "aging", it is necessary to

add some in the polymer can stable chemical properties of substances,

these substances are called stabilizers.

Stabilizer requirements: good stabilizing effect on the polymer, the

ability of water, oil resistance, chemical corrosion, and the resin have

good compatibility, are not decomposed during the molding process,

small volatile, colorless.

The stabilizer may be divided into heat stabilizers, light stabilizers,

antioxidants and the like. Usual stabilizers include stearic acid salts, lead

compounds, epoxy compounds.

 (6) curing agent

A curing agent, also known as hardeners, crosslinking agents.

Molding thermosetting plastic, a synthetic resin structure of linear

polymer crosslinking reaction needs a shift to a high-integrated structure.

The curing agent is added for the purpose of promoting the crosslinking

reaction. Such as ethylenediamine, triethanolamine and the like in an

epoxy resin.

Plastic additives, blowing agent, a flame retardant, an antistatic

agent, a conductive agent, and the like permeability. Not every plastics

additives to be added to all of these, but by the use of plastic parts and

plastic varieties required by the need to select certain additives added.

2)

classification of plastic

More varieties of plastic, classified a lot of ways, commonly used

classification following two methods:

(1) The molecular structure and thermal properties of plastic resin

Classification

Plastic can be divided into two categories: thermoplastics and

thermosets.

a) a thermoplastic

The plastic resin molecular structure is linear or branched structure.

It is made of plastic upon heating the shaped plastic parts, has cooled
maintains the shape of the shape. The reheating, softening and melting

but also can be made into shaped plastic parts once again, thus can be

used repeatedly. Usually only the physical change and no chemical

change in the above process. As this process is reversible, resulting in

scrap plastics processing waste can be recycled and re-used after

pulverized into particles.

Such as: polyethylene, polypropylene, polyvinyl chloride,

polystyrene, ABS, polyamide, polyacetal, polycarbonate, PMMA,

polysulfone, thermoplastic fluorine plastics are examples.

b) thermosetting plastics

This molecule is the beginning of the heated plastic linear structure,

having plasticity and solubility, shaped plastic made of plastic parts.

When heating is continued, the plastic shape of the fixed element

chemically bonded (i.e., cross-linked), molecular reticular structure,

molecular structure ultimately becomes body becomes neither melting

nor dissolution between linear polymer main chain formed down not

change. In the molding process, there are both physical change chemical

change. Because thermosetting plastics above characteristics, the

processing of waste and non-recyclable scrap recycling.

Such as: phenolics, aminoplasts, epoxy plastic, a silicone plastic, a

silicone plastic, etc. to thermosets.

(2) Category The plastic properties and uses

 a) General Plastics

Such plastics means that yield big, versatile, low-cost plastic.

Including: polyethylene, polyvinyl chloride, polystyrene, polypropylene,

phenolics and aminoplasts six cultivars, their total yield of more than half

of the plastic, the body constitutes the plastics industry.

b) plastic

Such plastics often refers to a plastic used as structural materials in

the engineering art. In addition to having high mechanical strength, but

such plastic also has good wear resistance, corrosion resistance,

self-lubricating properties and dimensional stability. They have some

characteristics of the metal, thereby now increasingly replace metal for

some mechanical parts.

The most commonly used engineering plastics include polyamide,

polyacetal, polycarbonate, ABS, polysulfone, polyphenylene oxide,

polytetrafluoroethylene.

c) reinforced plastics

Filler such as glass fiber as a reinforcing material in a plastic, to

further improve the mechanical properties and electrical properties of the

material, this new composite materials reinforced plastic commonly

referred to. It has excellent mechanical properties, high specific strength

and just. Reinforced plastic into a thermoplastic and thermosetting

reinforced plastic reinforced plastics.

 d) special plastic

Special plastic means a plastic other special properties. The

fluoroplastic, polyimide plastic, a silicone resin, an epoxy resin, a

conductive plastic, magnetic plastic, the plastic is thermally conductive

plastic and modifying certain specialized purposes obtained.

3), the performance of plastic

(1) low density

(2) specific strength and stiffness

Good (3) chemical stability

(4) electrical insulation, thermal insulation, sound insulating

properties

(5) wear and good self-lubricating

(6) bonding ability

(7) and forming a good coloring property

(8) more protective properties

(9) poor heat resistance, the operating temperature of the plastic

is generally only about 100 ° C, otherwise it will degrade and aging.

(10) poor thermal conductivity, it is not used in the case of good

thermal conductivity requirements.

(11) high hygroscopicity, prone to hydrolytic aging.

(12) easy to aging, for the case of longer service life, the choice

of metal.
3, the thermodynamic properties of the plastic

Closely related to the physical, mechanical properties and

temperature of the plastic, the temperature changes, mechanical behavior

by plastic changes, showing a different physical state, showing the

mechanical performance characteristics phased. Physical and mechanical

properties of the plastic state when heated has a very important

significance for molding plastics.

1), the thermodynamic properties of the plastic

(1) the physical state of the thermoplastic when heated

The physical state of the heated thermoplastics often present as

glassy :: (also known as crystalline polymer crystalline), high elastic state

and viscous flow state, shown as a linear amorphous and crystalline linear

polymer by the degree of deformation curves versus temperature constant

pressure, also known as thermal curve.

Thermoplastic tristate
 a) glassy

Plastics in temperatureθgThe following state, into a hard solid,

using the state of most plastic parts.θgReferred to as glass transition

temperature, temperature is the upper limit of most plastics.θb is the

embrittlement temperature of the polymer, the lower limit temperature of

the plastic is used.

b) rubbery state

When the heating temperature exceeds plastic θ g, since the

segmental motion of the polymer, the plastic enters a high elastic state.

Plastic in this state is a state of rubber-like elastic body still has a

reversible deformation properties.

Curve can be seen from FIG. 1, the linear amorphous polymers have

significant elastomeric state, while the curve 2 can be seen, no significant

linear crystalline polymer elastomeric state, because the polymer is

completely crystalline no elastomeric state, or that would not be

significant elastic deformation, but the crystalline polymers is generally

impossible to complete crystallization at a high temperature elastic state,

the non-crystalline portion contains, they still rubbery state temperature in

stage a certain degree of deformation, but it is relatively small.

c) viscous flow state

When the heating temperature exceeds plasticθf, due to the overall

movement of the molecular chains, plastics have a significant flow of

plastic viscous flow state entered into the viscous flow of liquid, usually

we also call the melt. In this state the plastic deformation of the

non-reversible nature, by forming and cooling the latter, its shape is

always preserved.

θf is called viscous flow temperature, the polymer is a transition

from a high elastic state to a viscous flow state (or viscous flow state

transitions high elastic state) the critical temperature. When the plastic

heating is continued, to a temperature θ D, the polymer begins to

decompose color,θd is called a thermal decomposition temperature, the

polymer begins to decompose at a high temperature critical temperature.

(2) the physical state of a thermosetting plastics on heating

Thermosetting plastic when heated, due to the chemical reaction

accompanying its physical state with the thermoplastic significantly

different. When the start of heating, since the resin is a linear structure,

and similar thermoplastics, is heated to a certain temperature, so that the

resin molecular chains moving rapidly from a solid state to become

viscous flow, which it has molding properties. However, such a flow

condition exists for a short time, due to fast chemical reactions, molecular

structure into a mesh, molecular motion stops, hardened plastic becomes

hard solid. After heating can not recover, the chemical reaction proceeds,

the molecular structure becomes integral, plastic or hard solid. When the

temperature reaches a certain value, the plastic begins to decompose.

2), processing plastics

In the physical state of the plastic is heated determines the properties

of the plastic molding.

When the temperature is higher thanθf, the change from the plastic

state to a solid glass-like viscous liquid i.e. melt flow regime. Fromθf

start thermal motion of molecules is greatly intensified, reducing the

modulus of elasticity to a minimum value, then the plastic deformation is

characterized by a melt, under less large external force can cause bulk

flow, this time is mainly irreversible deformation sticky plastic

deformation, cooling the polymer can be preserved permanently

deformed. Thus, this temperature range commonly used for injection,

extrusion, blow molding and laminating and other processing.

Too high a temperature will greatly reduce the viscosity of the

plastic, the fluidity is increased unduly prone to flash such as injection

molding and extrusion of plastic parts distorted shape, and fracture

reduction of the capillary fibers during the spinning process and so on.

High temperature to the decomposition temperatureθd near also cause

decomposition of the polymer, so as to degrade physical and mechanical

properties and poor appearance or cause product.

4, the plastic flow state in the molding process

1), the plastic melt flow in the simplified section of the duct
 Plastic melt in the molding process often flows through the various

conduits (including the flow path in the mold), so as to heat, pressure,

cooling and shaping. In order to design the mold, to develop a reasonable

process conditions, and to understand the relationship between the flow

rate control when the plastic melt flow in the conduit and the pressure

drop and flow velocity distribution along the cross section of the catheter

is necessary.

(1) flow in a circular conduit

In order to study plastic melt flow conditions within a circular duct,

the catheter is assumed that the radius R, the melt in the tube do

isothermal steady laminar flow, and obey the exponential law. Taken from

the center of the conduit radius r of the fluid cylinder unit having a length

L, as shown in FIG 1. FIG 4.

When it is under the effect of pressure p, is moved from left to right,

frictional force is generated between the fluid layer, then, where the

pressure dropΔpThe product of the cylinder must be equal to the

cross-sectional shear stress [tau], the product of the fluid layer between

the contact area, i.e.,

Δ p( Π r ² ) = τ (2 π r L)
 Therefore, shear stress

In the tube wall R = r τ = τw

which is

It can be seen, zero shear stress at the center of the tube, gradually

increasing to the maximum force wallτw. Accordingly further derive the

flow rate and pressure relationship can be drawn down as follows:

Where: K is a liquid

consistency.

(2) flows in the guide groove of the flat

 At isothermal conditions, the polymer melt to make steady laminar

flow through the guide groove flat (flat groove), which is the case in FIG.

1. FIG. 5.

In the flat plane of the center groove to take the center of a

rectangular unit cell, having a thickness of 2, taking a unit length of the

width, length L. Flat upper and lower surfaces of the groove is assumed

infinitely wide parallel faces (flat groove width W should be greater than

the vertical distance from groove flat parallel surfaces 20 times 2B, in

which case flat side walls of the groove acting to slow the flow rate is

negligible) the pressure and the shear stress relations, available

 The formula (1-5) and integrated on a generation formula, from the

center plane have the relationship of y plane and any point of the flow

rate of pressure drop

2) Comparison of thermoplastic and thermosetting polymers

rheological behavior

(1) a thermoplastic polymer and a thermosetting different

rheological behavior of the polymer.

The thermosetting polymer is heated initial flowability is increased

(reduced viscosity) as a result of thermal relaxation effects, the period of

time before curing reaches, little change in the viscosity with time, then

this too, with a further cross-linking reaction is carried out , flowability

decreases rapidly.

(2) Effect of temperature on the flowability is determined by the

viscosity and cure speed

Effect of temperature on the viscosity at the lower temperature range

plays a dominant role, inθmax, the viscosity decreases with increasing

temperature, so the total flowability prior to crosslinking with increasing

temperature increases; and at a higher temperature range (i.e.θmax

above), the chemical crosslinking reaction plays a dominant role, with

increasing temperature, a crosslinking reaction rate decreases rapidly melt

flow.
 Crosslinking rate (3) a thermosetting polymer can be controlled by

temperature

This characteristic temperature is thermosetting plastics injection

molding machine with an injection mold temperatures are employed for

different reasons. For example, the optimum temperature is injected to

produce minimum viscosity without causing rapid crosslinking

temperature, and the gate of the mold should be conducive to the rapid

hardening temperature. Thus, for a thermosetting polymer, the key is the

correct process flow of the polymer component to complete the process

prior to crosslinking.

Pressure increases, the melt by a large shearing effect mobility tends

to increase.

3), the orientation behavior of the plastic molding process

Orientation is under stress, the polymer chains tend to be aligned

parallel to the direction along the stress phenomenon. Plastic molding, the

orientation is divided into two cases:

(1) an injection, pressure injection molded plastic parts in the

direction of flow of the solid filler

Solid filler in the polymer will be injected, pressure injection

molding process of alignment, and the alignment direction depends on the

shape and position of the gate. Packing a direction along the arrangement

direction of the main flow, the resistance encountered (e.g., mold wall or
the like), to change its flow resistance perpendicular to the direction,

shape and Click.

(2) injection pressure injection molding flow direction of the

polymer molecules in the plastic parts

Polymer injection and pressure injection molding process, there is

always a flow of the melt. There will be a flow of molecular orientation.

Since the morphology, size and melt in the case of different plastic parts

to flow mold cavity, the orientation can be divided into structural and

uniaxially oriented multi-axis alignment (or orientation flat). When

uniaxial orientation, the orientation of the structural units are orderly

arranged along a flow direction; while multiaxial orientation, the

structural unit may be ordered in two or more flow directions.

Anisotropic molecular orientation will cause the mechanical

properties of plastic parts, along the direction of molecular orientation

(also called straight) the mechanical strength and elongation in the

direction perpendicular thereto is always larger than (also referred to as

lateral direction) on.

Plastic anisotropy is sometimes required, such as producing an

oriented film and a monofilament, so make plastic parts in the stretching

direction and tensile strength has been enhanced glossiness. But for some

plastic parts (e.g., a larger thickness of plastic parts), but also seeks to

eliminate this anisotropy. Because inconsistent orientation, degree of

orientation of different portions of the plastic parts, plastic parts in a

certain direction, the mechanical strength is improved, while the lower

intensity in the other direction, it will warp, break during use.

Effects of each of the molecular orientation of the molding

conditions are not simply increased or decreased. Injection, pressure

injection molding, the factors which affect the alignment of the following

areas:

a) With the mold temperature, part thickness (i.e., thickness of the

cavity), filling the mold temperature increases, the degree of molecular

orientation will gradually weaken.

b) increase in the gate length, pressure, and filling time, the degree

of molecular orientation increases.

c) the degree of molecular orientation (including fillers oriented in

the flow) is very much related to the position and shape of the gate

opening. To reduce the degree of molecular orientation, the gate is

preferably located in the larger portion of the cavity depth.

5, process performance thermoplastic

1), contractility

Plastic parts removed from the mold after cooling to room

temperature, the size of each part has narrowed than the original size of

the mold, this property is called shrinkage. Due to this shrinkage it is not
only caused by thermal expansion and contraction of the resin itself, but

also on the various molding elements, and therefore shrinkage after

molding of plastic parts is called molding shrinkage.

Plastic molding shrinkage values can be used to represent the

shrinkage ratio, is calculated as follows:

Where

S '---- actual shrinkage;

---- shrinkage ratio S is calculated;

LC---- unidirectional size plastic parts during the molding

temperature;

The LS-way plastic parts ---- size at room temperature;

---- LM mold at room temperature the size of the check.

The actual rate of contraction due to shrinkage values calculated

difference is small, the size of the die design often with no shrinkage ratio

calculated design parameters, calculates the cavity and the core and the

like.

The impact of changes in shrinkage factor

In the actual molding, not only different types of plastic shrinkage is

different, but shrinkage values of different parts of different batches of the

same varieties of plastic, the same or different plastic parts often. The
main factors affecting the shrinkage include

(1) plastic varieties

Various plastics has its own range of shrinkage, because the same

molecular weight plastic, such as different fillers, and ratio, and

anisotropy of the shrinkage rate are also different.

(2) structure of plastic parts

Shaped plastic parts, size, thickness, with or without the insert, the

insert number and layout, there is a great impact on the shrinkage values,

such as a large plastic wall thickness shrinkage, the insert has a small

shrinkage ratio.

(3) die structure

Parting surface, the pressing direction, forms the gating system,

layout and size of the mold shrinkage and the like is also a great influence

on the directivity, in particular extrusion and injection molding is more

obvious.

(4) molding process

Extrusion and injection molding generally larger shrinkage, the

directivity is also evident. Charge have a greater impact in the form of

plastics, preheating, molding temperature, molding pressure, dwell time

and direction of shrinkage. E.g. using tableting addition, preheating, a

lower molding temperature, a higher molding pressure, etc. to extend the

dwell time is an effective measure to reduce the shrinkage and directivity.

 Shrinkage rate is not a fixed value, but changes within a certain

range, fluctuation will cause shrinkage dimensional fluctuation plastic

parts, mold design should therefore consider shrinkage of the plastic

selected based on the above factors, high precision plastic parts should be

selected small plastic shrinkage fluctuation range, and leave room for the

corrected test mode.

2) flowability

In the molding process, the plastic melt in the ability to fill the mold

cavity at a certain temperature, known as the pressure of the flow of

plastic. Plastic poor fluidity, is not easy to fill the cavity, easy to produce

defects such as lack of material, or weld line, and therefore requires a

large molding pressure to the molding. In contrast, good fluidity of the

plastic, the cavity may be filled with a smaller molding pressure. But

good mobility, can have serious side overflow during molding.

(1) molecular size and structure of mobility related to plastic

Linear molecules having little or no crosslinked structure of the resin

mobility. Plastic filler is added, the fluidity of the resin decreases, and

adding a plasticizer or a lubricant, the plastic can be increased mobility.

Plastic parts rational design may improve the fluidity, such as

improved fluidity of the melt flow path at the corner of the rounded

corners and the plastic structure.

(2) thermoplastic flowability index

 Available thermoplastic flowability size relative molecular mass, the

melt index, the length of the helix, to compare the apparent viscosity and

fluidity (flow length / plastic wall thickness) and a series of index

analysis, small molecular weight, high melt index, length of the helix, a

small apparent viscosity, fluidity and good flow ratio.

(3) the main factors affecting liquidity

a) temperature: high temperature material, the mobility, but different

plastics varies. Flow of the plastic polystyrene, polypropylene, polyamide,

polymethyl methacrylate, ABS, AS, polycarbonate, cellulose acetate and

the like with a large influence of temperature change; and polyethylene,

polyoxymethylene fluidity by less affected by temperature changes.

b) Pressure: Injection pressure increases, the melt by a large

shearing effect mobility increases, in particular polyethylene,

polyoxymethylene more sensitive.

c) die structure: gating system form, size, arrangement (e.g.,

surface roughness of the cavity, the runner section thickness, a cavity

forms, the exhaust system), the cooling system design, the melt flow

resistance and other factors have a direct impact frit mobility.

Where the cause melt temperature decrease, increased flow

resistance factors (e.g., plastic wall thickness is too thin, sharp corner use,

etc.), the fluidity is lowered.

3) compatibility
 Compatibility refers to different kinds of plastic two or more,

without the ability to produce phase separation in a molten state. If the

two incompatible plastics, surface defects of the parts will be

delamination, peeling and the like when mixed melt. Compatibility their

molecular structure different plastics have a certain relationship, similar

to the molecular structure are more likely to be compatible, for example,

high pressure polyethylene, low-pressure polyethylene, polypropylene,

immiscibility between each other; are not simultaneously difficult

compatible molecular structure, e.g. immiscibility between the

polyethylene and polystyrene. Compatibility with plastic and known as

the blending of.

By the nature of the plastic, you can get a similar overall

performance of the copolymer, it is one of the important ways to improve

the performance of plastics.

4), hygroscopic

Hygroscopic refers to the degree of closeness of plastic water. Thus

plastics can be divided into two categories: one is a plastic or adhesive

between the moisture absorbent was poured, such as polyamide,

polycarbonate, polysulfone, ABS and the like; other is neither moisture

absorbent hardly adhered plastics, such as polyethylene, polypropylene,

polyoxymethylene and the like.

Any tendency to absorb moisture or moisture adhering plastic, such

as moisture is not removed before the molding, the molding process due

to moisture in the gas becomes a high temperature in a cylinder of the

molding apparatus, and to promote hydrolysis of plastic, plastic air

bubbles, and the like after forming silver defect. Thus, not only increases

the difficulty of molding, but also reduces the surface quality and

mechanical properties of plastic parts. Therefore, to ensure the smooth

and the quality of molded plastic parts, large hygroscopic tendency, and

moisture adhering plastic, should be dried before the molding, the

moisture will be controlled to 0.2% or less of 0.5, a water content should

be controlled to 0.2 ABS %the following.

5), heat-sensitive

Some heat-sensitive refers to a difference of thermal stability of the

plastic, will produce degradation sink material temperature is high and a

long heating time case, decomposition, discoloration properties,

heat-sensitive heat-sensitive plastic known as a strong plastic, such as

PVC, polychlorotrifluoroethylene, POM.

Heat-sensitive plastic decomposition, discoloration is actually a

polymer material deterioration, damage, not only affect the properties of

the plastic, and the decomposition gases or solids, especially on the

human body and some gas, equipment and tooling are damage, some

decomposition products are often It is the catalyst for the decomposition

of plastic, such as polyvinyl chloride decomposition products, can cause

polymer decomposition further. Thus the mold design, care should be

taken when selecting an injection molding machine and. Optional Screw

Injection Molding, increased cross-sectional dimension of gating system,

molds and chrome cartridge, does not allow the material stagnation dead,

strictly control the molding temperature, mold temperature, heating time,

back pressure and screw speed measures. Stabilizers may also be added in

the heat-sensitive plastic, may be to reduce thermal performance.

6, process performance thermosets

Process performance thermosets thermoplastics significantly

different, have the main shrinkage performance, fluidity, moisture and

volatile matter content of the curing speed.

1), shrinkage

As with thermoplastics, thermosetting plastics molding by cooling

dimensional shrinkage occurs, which calculation means of the shrinkage

of the same thermoplastic. The main reason for the contraction are:

(1) heat-shrinkable

After cooling, the thermal shrinkage is generated due to contraction

of the thermal expansion and contraction molded plastic parts. Heat

shrinkage proportional to the temperature of the mold is one of the major

shrinkage of molding shrinkage factor.

Contraction (2) structural changes

 Thermosetting plastics crosslinking reaction during the forming

process, the linear molecular structure into a network structure, since the

reduction of the pitch of the molecular chain structure becomes compact,

and therefore produces a volume change.

(3) elastic recovery

After the plastic removed from the mold, the pressure on the plastic

parts disappears due to elastic recovery, shrink plastic parts will cause a

negative volume (expansion). In forming glass fiber cloth filler and

thermosetting plastics, which is particularly evident.

(4) plastically deformed

When a release plastic parts, molding pressure is rapidly lowered,

but the mold is pressed against the wall around the plastic parts to

produce plastic deformation. Shrinkage than the deformed portion does

not occur a large portion of the deformation, and therefore tend to plastic

shrinkage parallel to the pressing direction is small in shrinkage in a large

vertical pressure direction. To prevent shrinkage in both directions

difference is too large, the method can be used to quickly release remedy.

Effects shrinkage factors and thermoplastics are also the same, there

are raw materials, mold structure and forming method of molding process

conditions. Type and content of plastic resin and a filler, will directly

affect the size shrinkage. When many of the resins used in the curing

reaction releasing low molecular weight volatiles, when there are fewer
larger shrinkage ;; low molecular weight volatiles evolved, more

shrinkage when the plastic increases higher filler content or the filler an

inorganic filler, shrinking a smaller rate.

Where help improve molding pressure, increased plastic mold filling

the mold structure dense plastic parts, can reduce shrinkage of the plastic

parts, plastic parts, for example, by compression or injection-molded

plastic parts than the injection molding shrinkage small. Where can dense

plastic parts, the front molding element low molecular weight volatiles

overflow, shrinkage plastic parts can be reduced, e.g. phenolics preheated

before molding, pressing or the like.

2) flowability

Significance of mobility and flowability similar thermoplastics,

thermosetting plastics, but typically Raschig flowability represented.

Measuring a mass of the plastic preform to be pressed into ingots,

the ingot mold release, at a certain temperature and pressure, measuring

the length of its extruded from the die orifice (not counting coarse

portion), namely the pull Seeger liquidity, its value is large, the flow is

good.

Each plastic flowability species can be divided into three different

levels:

Raschig flow value of 100 ~ 13lmm, for pressing insertfree simple

shape, the average thickness of plastic parts;

 Raschig flow value of 131 ~ 150mm, plastic parts for pressing a

moderately complex; Raschig flow is 150 ~ 180mm, for complex

structures pressing, deep cavity, insert more thin-walled plastic

member or for transfer molding.

3), specific volume (specific volume) and the compression ratio

Specific volume is the volume occupied by a loose plastic mass

units; compression rate ratio or volume ratio of both the plastic and the

plastic volume, which is consistently greater than 1.

The volume ratio of the compression rate represents the degree of loose

short fibers or powdered plastics, compression molding may be used to

determine the size of the volume of the loading chamber.

Larger than the volume and the compression ratio, the loading

chamber requires a large volume, but also that the inflatable plastic more

difficult the exhaust gas, the molding cycle is long, productivity is low;

and the volume is smaller than the compression ratio, and is conducive to

the compression tableting, pressure Note. However, the volume ratio is

too small, the charge will result in the volumetric method places the feed

amount is not accurate. Volume ratio and compression are different kinds

of plastic, with a plastic, which in turn plastic shape, particle size and

uniformity vary the volume ratio and compression ratio. 4), moisture and

volatile matter content

Thermosets moisture and volatiles from the two aspects, one

inherited from the plastic production process and transportation before

molding, the absorption upon storage; second process of forming

chemical reaction byproducts. If the molded plastics excessive moisture

and volatile matter but not processed in a timely manner, the following

problems occur: increased mobility, easy to produce burrs, molding cycle

is long, shrinkage, plastic parts easy to produce bubbles, loose tissue,

warpage, corrugations and other defects.

Furthermore, some gases have a corrosive effect on the mold, has a

stimulating effect on the human body, it is necessary to take appropriate

measures to eliminate or suppress the generation of harmful gases,

including through the material preheating dried before molding, in a mold

defines vent grooves or provided when the exhaust process step pressing

operation, chrome plated mold measures.

5) curing properties

Thermoset curing properties is unique performance, it means to

carry out cross-linking reaction thermosetting plastics molding. Curing

speed not only varieties of plastic, but also to shape plastic parts, wall

thickness, mold temperature and molding process conditions, using a

preload ingot preheating, molding temperature increase, pressure increase

can accelerate the curing time speed. In addition, the curing rate should

meet the requirements of the forming process. For example, injection

molding or pressure injection, the plasticized request, the crosslinking

reaction is slow during filling, to maintain the fluidized state for a long

time. But when the cavity is filled, at high temperature and pressure

should be fast curing. Slow curing plastics will molding cycle becomes

long, productivity is lowered; plastic fast curing speed, is not easy to

large complex shaped plastic parts.

7, commonly used plastic

1), polyethylene (PE)

(1) Basic Characteristics

Yield of polyethylene plastic crown of the plastics industry, of which

the largest production of high-pressure polyethylene. Polyethylene resin

is non-toxic, odorless, white or milky white, soft, translucent marble-like

pellets, a density of 0.91 ~ 0.969 / cm³, a crystalline plastic.

When polymerization polyethylene by using different pressures, can

be divided into high, intermediate and low pressure polyethylene. The

molecular structure of LDPE is not a simple line, but with a number of

branched dendrimer. Thus it is not a high degree of crystallinity (degree

of crystallinity of only 60% to 70%), low density, relatively small

molecular weight, often referred to as low density polyethylene. Its heat

resistance, hardness, mechanical strength and so low. However, its

dielectric properties, has good flexibility, impact resistance and

transparency, molding processability is also good. , The molecular

structure of low-pressure polyethylene is a branched rarely linear

molecule, which molecular weight, high degree of crystallinity (87% ~

95%), high density, high molecular weight, often referred to as high

density polyethylene ethylene. Its high heat resistance, hardness,

mechanical strength, county, but the flexibility, impact resistance,

transparency, and molding processability are poor.

Polyethylene minimal water absorption, and the dielectric properties

with temperature and humidity independent. Therefore, polyethylene is

the ideal frequency electrically insulating material, only in the dielectric

properties of polystyrene, polyisobutylene, and polytetrafluoroethylene

can be compared.

(2) The main purpose

Low pressure polyethylene can be used in the manufacture of plastic

pipe, plastic plate, a plastic rope, and the carrier is not high parts, such as

gears, bearings and the like; pressure polyethylene molding method most

suitable high-speed blow molding bottles may be manufactured, the

packaging films and various injection molded articles and molded articles

of rotation, can also be used in wire and cable thereon; high-pressure

polyethylene used in the production of a plastic film (preferably

packaging materials), hose, cable sheath insulation parts and plastic

bottles and electrical industry and the like.

(3) forming characteristics

Molding shrinkage and shrinkage range large, clear direction, easily

deformed and warpage. Mold temperature should be controlled to

maintain cooling uniformity, stability; good fluidity and is sensitive to

pressure changes; high-pressure injection is appropriate, uniform melt

temperature, the filling rate should be fast, fully packing; cooling rate,

must be sufficiently cooled, the mold should be set when the release force

may be easy to mold soft, plastic parts have a shallow side cavity; with a

cooling system.

2), polypropylene (PP)

(1) Basic Characteristics

Polypropylene is colorless, odorless, non-toxic. Polyethylene-like

appearance, but more transparent than polyethylene, and lighter. Density

is only 0.90 ~ 0.91g / cm³. It does not absorb water, good gloss, easy

coloring.

Polypropylene polyethylene having all of the excellent properties,

such as excellent dielectric properties, water resistance, chemical stability,

suitable for molding and the like; polyethylene has many properties that

are not, such as yield strength, tensile strength, compression strength and

hardness and good flexibility than polyethylene. After orientation

stretched polypropylene hinge can be made, particularly high bending

fatigue strength. The integrally injection-molded polypropylene with a

hinge (various container cap and body unity), through bending the end of

the opening and closing times 70,000,000 cause damage and breakage.
Melting point of polypropylene is 164 ° C ~ 170 ° C, heat resistance,

sterilization can be performed at a temperature above 100 ° C. Low

temperature use temperature of -15 ° C, will be brittle when below

-35 ° C. Good high-frequency insulating properties of polypropylene,

and because of its non-absorbent, insulation performance is not affected

by humidity, but at easy depolymerization by oxygen, heat, light and

aging, it is necessary to join the anti-aging agent.

(2) The main purpose

Polypropylene can be used as various mechanical parts such as

flanges, fittings, pump Ye Lun, bicycle parts and automobile parts; as

water, steam, acid and other various lining, surface coating pipelines,

chemical containers and other equipment; cap and body may be

manufactured unity enclosure, a variety of insulation parts, and used in

the pharmaceutical industry.

(3) forming characteristics

Molding shrinkage and shrinkage range large, prone to shrinkage,

strong dents, deformation, directivity; excellent mobility, easy to form a

large thermal capacity, the injection mold must be designed to sufficiently

cool the cooling circuit, note that the molding temperature control . When

the material temperature low directivity evident, especially low

temperature, more pronounced at high voltages. Suitable polypropylene

molding a mold temperature of about 80 ° C, not lower than 50 ° C,

otherwise it will result into a shaping surface gloss difference or weld line

and other defects. Higher temperatures and warpage deformation.

3), polyvinyl chloride (PVC)

(1) Basic Characteristics

PVC is one of the most productive varieties of plastic. Its rich source

of raw materials, low price, excellent performance, widely used. The

resin was white or light yellow powder, just like flour, granulated after

the transparent block, similar to alum.

Depending on the different additives to increase the use of polyvinyl

chloride plastic parts may exhibit different physical and mechanical

properties. Increase the amount of the plasticizer in the polyvinyl chloride

resin, it can be made from a variety of hard, soft products. Pure PVC

density 1.4g / cm³, the added plasticizer and filler density in the range of

PVC plastic is generally 1.15 ~ 2.00 g / cm³.

PVC containing no or small amount of plasticizer. Its mechanical

strength is high, a better tensile, flexural, compressive and impact

resistance, can be used as a structural material alone; good dielectric

properties, resistance to strong acid, the chemical stability ; however,

harder to form, the heat resistance is not high.

Soft polyvinyl chloride containing a plasticizer more flexible and

elastic, rubber-like, but more light than the rubber, more durable. At room

temperature is less than the elastic rubber, but corrosion resistance than
rubber, are not afraid of concentrated acid, of concentrated alkali damage,

not affected by oxygen and ozone, cold ability. Good formability, but low

heat resistance, mechanical strength, wear resistance and dielectric

properties and the like are not hard polyvinyl chloride, and easy to aging.

In general, PVC has good electrical insulation properties, low

dielectric material can be used, chemical stability is also good. Because

of the poor thermal stability of PVC, prolonged heating can cause

decomposition and emit hydrogen chloride gas, discoloration of polyvinyl

chloride, so its application range is narrow, the temperature is generally

between -15 ° C ~ 55 ° C.

(2) The main purpose

Due to the high chemical stability of PVC, it can be used to make

anti-corrosion pipe, tube, pipeline, centrifugal pumps and blowers. PVC

hard board is widely used in the production of construction material sump

chemical industrial liners, building corrugated board, door structure, wall

decorations and the like; due to good electrical insulation properties, may

be in the electrical, electronics industry using for the manufacture of

sockets, plugs, switches and cables. In everyday life, used in the

manufacture of sandals, raincoats, toys and leather and so on.

(3) forming characteristics

Its poor fluidity, easily break overheating, it is necessary to increase

the stabilizers and lubricants, and strict control of temperature and

residence time of forming the melt. Forming a small temperature range,

the material temperature must be strictly controlled, the cooling device

should die; preplasticizing belt apparatus using a screw injection machine.

Die casting system should be chunky, the gate should be large

cross-section, the material stagnation may not have a blind spot. Mold

should be cooled, the surface should be chrome plated.

4), polystyrene (PS)

(1) Basic Characteristics

Polystyrene is after the third PVC and polyethylene plastic varieties.

Polystyrene colorless, transparent, glossy, non-toxic, odorless, ringing

metallic sound landing, a density of 1.054 g / cm³. Polystyrene is the best

high frequency insulating material, be on a par with the molten Shi Ying.

Its good chemical stability to alkali, sulfuric acid, phosphoric acid,

10% -30% hydrochloric acid, dilute acetic acid and other organic acids,

nitric acid, and the oxidizing agent but intolerant effect, water, ethanol,

gasoline, vegetable oils and various salts there was also sufficient

corrosion resistance. Its low heat resistance, are not only used at high

temperatures, hard and brittle texture, internal stresses plastic cracks

easily understood. Polystyrene good transparency, high light

transmittance, the optical properties after the plexiglass. Its excellent

rendering capabilities, can be dyed various bright colors.

In order to improve the heat resistance of polystyrene and its

reduced brittleness, and modified polystyrene copolymer is used as the

polystyrene matrix, which greatly expanded the use of polystyrene.

(2) The main purpose

Polystyrene can be used on an industrial instrument housing, shade,

chemical equipment parts, transparent models; in terms of electrical

insulating material is used as well, a junction box, a battery case; daily

necessities is widely used in packaging materials, various containers and

toys.

(3) forming characteristics

Polystyrene brittle crack easily, prone to crack, so that the draft

angle to the shaping member should not be too small, uniform force to the

ejector; large thermal expansion coefficient, the plastic insert should have,

because otherwise they will both heat expansion coefficient much

difference caused by cracking; as good flowability, die gap should be

noted that, to prevent the forming of burrs, and the mold design mostly

point gate form; appropriate to high melt temperature, high mold

temperature, low pressure injection molding, and prolonged injection

time, in order to prevent shrinkage and deformation, reduce stress, but

appears silver in very high temperature materials; multi-releasing agent or

a low melt temperature, the plastic parts poor in transparency.

5), an acrylonitrile - butadiene - styrene copolymer (ABS)

(1) Basic Characteristics

 ABS is acrylonitrile, butadiene, styrene copolymer of three

monomers, cheap, easily available raw materials, is currently the largest

output, the most widely used engineering plastics. ABS odorless, white to

yellowish opaque or pellets, molded plastic parts with a good gloss, a

density of 1.02 ~ 1.05 g / cm³.

Since the ABS is composed of three components, so it has the

mechanical properties of the three components, and each component has

inherent therein plays a role. ABS acrylonitrile make good surface

hardness, heat resistance, and chemical resistance, toughness of

ABS-butadiene, styrene it is excellent in formability and coloring

property.

Heat distortion temperature than ABS, and so on polystyrene,

polyvinyl chloride, nylon, good dimensional stability, a certain chemical

stability and good dielectric properties, the toner can be formulated

through any color. The disadvantage is that the heat resistance is not high,

continuous operating temperature is about 70 ° C, the heat distortion

temperature of about about 93 ° C. Opaque, poor weather resistance,

ultraviolet rays easily in hard brittle.

Depending on the ratio between the three components ABS, its

performance is slightly different to accommodate different applications.

(2) The main purpose

ABS in the machinery industry to make gears, pump impellers,

bearings, handles, pipes, motor housing, instrument case, instrument

panel, tank shell, battery slot, refrigerators and refrigerator liners and the

like; manufactured by automobile fender ABS Automobile Industry

panels, armrests, a hot air-conditioning duct, a heater, etc., can also be

used sandwich panel production car body ABS; ABS may also be used to

make the case of water, textile equipment, electrical parts, stationery and

sporting goods, toys, and tape recorders keyboard housing, food

packaging meals, a pesticide sprayers and furniture.

(3) forming characteristics

ABS easy to absorb water, so that the mark appears to shape the

surface, defects such as moire. To this end, the forming process should be

dried before processing, under normal molding conditions, the thickness,

temperature of the melt minimal effect on shrinkage; requires high

precision plastic parts, the mold temperature may be controlled at 50 ~

60 ° C, required when the heat-resistant and glossy plastic parts,

should be controlled at 60 ° C ~ 80 ° C; ABS low specific heat

capacity, high plasticizing efficiency, faster solidification, so that short

molding cycle; ABS apparent viscosity dependence on shear rate is strong,

so most of the mold design point gate form.

6), polyamide (PA)

(1) Basic Characteristics

Polyamides known as nylon (Nylon). Nylon is a linear thermoplastic

resin containing an amide group of nylon is a general term for this type of

plastic. Depending on materials used, the common varieties of nylon

nylon 1010, nylon 610, nylon 66, nylon 6, nylon 9, nylon 11 and the like.

(2) Characteristics and uses

Nylon has excellent mechanical properties, tensile, compression,

wear. Stretched nylon alignment treatment, its tensile strength is very

high, close to the level of the steel. Due to the highly crystalline nylon,

surface hardness, friction coefficient is small, it has a very outstanding

wear resistance and self-lubricating. It is generally higher than the wear

resistance of the bearing material is used as copper, copper alloy, ordinary

steel. Nylon alkali, weak acid, but strong acids and oxidants can erode

nylon. Nylon disadvantage is absorbent, shrinkage rate is often caused by

dimensional changes due to water absorption. Its poor stability, generally

only used between 80 ° C ~ 100 ° C.

In order to further improve the performance of nylon, often increase

the friction reducing agents, stabilizers, lubricants, fillers like glass fibers

in nylon, to overcome some disadvantages of nylon, improve the

mechanical strength.

Nylon is widely used for various industrial mechanical, chemical

and electrical parts, such as bearings, gears, rollers, rollers, pulleys, pump

Ye Lun, fan blades, worm, high pressure seal snap rings, gaskets, valve

seats, pipeline, oil container, a rope, a belt, a battery case, electrical coils
and other parts, may also be thermally sprayed onto a nylon powder metal

part surface, or to improve wear resistance as the wear parts of the repair

use.

(3) forming characteristics

The nylon material is easily hygroscopic, and therefore must be

dried before shaping. Nylon poor thermal stability, to avoid oxidation of

the material is dried at elevated temperatures, preferably vacuum drying;

low melt viscosity nylon, good fluidity, high strength is particularly

beneficial made of thin-walled plastic parts, but is more prone to fly side,

the mold must be selected so that a minimum gap; nylon poor thermal

stability in the molten state, plastic parts will be prone to degradation

performance degradation, the nylon is not allowed to stay in the high

temperature for too long a cylinder; nylon molding shrinkage and

shrinkage range large, clear direction, easy to produce flaw shrinkage,

dents, deformation, thus forming conditions should be strictly controlled.

7), polyoxymethylene (POM)

(1) Basic Characteristics

POM is an excellent developed after nylon engineering

thermoplastics, nylon inferior performance, low prices than nylon.

Polyacetal resin as a white powder, the granulated light yellow or white,

shiny translucent durum. POM has a high tensile strength, compression

performance, and outstanding fatigue resistance, particularly suitable for

use as a gear material is repeatedly subjected to prolonged external force;

polyoxymethylene dimensional stability, water absorption is small, has

excellent friction, wear performance; distortion capability, have

outstanding resilience, the spring may be used to manufacture plastic

products; room temperature is generally insoluble in organic solvents,

ability aldehydes, esters, ethers, hydrocarbons and weak base, resistance

to gasoline and lubricating performance is also good, but not resistant to

strong acids; has good electrical insulation properties.

POM is the big drawback of molding shrinkage, poor thermal

stability at molding temperatures.

(2) The main purpose

Polyoxymethylene particularly suitable for making bearings, cams,

rollers, rolls, gears and other transmission parts wear, can also be used to

manufacture automotive instrument panels, carburetor, a variety of

instruments housing, cover, housing, chemical containers, pump Ye Lun,

fan blades , switchboard, a coil holder, the various pipelines, plastic

spring.

(3) forming characteristics

Polyoxymethylene large shrinkage; small its melting temperature

range, poor stability cooked, thus allowing overheating or prolonged

heating at a temperature, will cause the decomposition products of

formaldehyde are harmful to human body and equipment.

Polyoxymethylene or melt solidified very rapidly, faster melting rate,

facilitate molding, to shorten the molding cycle, but will melt

solidification rate of crystallization is faster, easier to plastic weld marks

and other surface defects. So, faster injection, injection pressure is not too

high. Low coefficient of friction, high elasticity, shallow groove side

extrusion can be forced, with the plastic surface may wrinkle pattern.

8), polycarbonate (PC)

(1) Basic Characteristics

Polycarbonate is a colorless transparent pellets, a density of 1.02 ~

1.05 g / cm³. Polycarbonate is an excellent engineering thermoplastics,

tough and rigid, impact resistance of thermoplastic in the top; shaped

parts can achieve good dimensional accuracy and maintain their

dimensional stability over a wide temperature range; constant molding

shrinkage of 0.5% to 0.8%; creep, wear, heat, cold; brittle temperature

-100 ° C or less, long-term temperature of 120 ° C; low water

absorption of polycarbonate, can to maintain a good electrical properties

over a wide temperature range. Polycarbonate is a transparent material,

the visible light transmittance close to 90%.

The disadvantage is the poor resistance to fatigue, the stress is large

molded plastic parts, easy to crack. Polycarbonate reinforced with glass

fibers may overcome the above disadvantages, a polycarbonate having

better mechanical properties, better dimensional stability, a smaller

molding shrinkage, and improve the heat resistance and chemical

resistance, reduced cost.

(2) The main purpose

It is mainly used in a variety of mechanical gears, worm wheel,

worm, rack, cam, bearing, various housings, covers, containers, freezing

and cooling apparatus parts. In electrical terms, used as electrical parts,

fan assembly, dial, instrument case, wiring boards. The polycarbonate can

also produce lighting, temperature of the lens, depending on the aperture

mirror, a cover glass and other optical components.

(3) forming characteristics

Although the water absorption is small, but more sensitive to high

temperature water, there will be silver, bubbles and strength decrease

phenomenon, it must be dried before processing, but is preferably a

vacuum drying process; high melt temperature, high melt viscosity, poor

mobility , it requires a higher temperature and pressure molding; melt

viscosity is very sensitive to temperature, increasing the temperature of

the general methods used to increase the fluidity of the molten plastic.

9), polymethyl methacrylate (PMMA)

(1) Basic Characteristics

Poly (methyl methacrylate) commonly known as "glass", is a

light-transmissive plastic having a high transparency and is excellent in

transparency, light transmission rate of 92%, better than ordinary silica

glass.

Plexiglass density of 1.18g / cm³, half lighter than ordinary silica

glass. The mechanical strength of at least 10 times that of ordinary silica

glass; it is light and tough, easy to color, has good electrical insulation

properties; chemical stability, the general chemical corrosion resistant,

but soluble in aromatic hydrocarbons, chlorinated hydrocarbons and other

organic solvents; size stable under normal conditions. It can be made of

plexiglass rods, tubes, plates and other profiles, for secondary processing

into plastic; powder may also be prepared for molding. Its biggest

disadvantage is the low surface hardness, easy to scratch hard objects

nap.

(2) The main purpose

The main components used in plexiglass shock, explosion and the

like was observed with certain aspects of the transparency and strength of

manufacturing requirements, such as automobile and aircraft window

glass, airplane covers, oil cup, optical lenses, transparent model,

transparent pipes, lamp shade , oil standard parts and a variety of

instruments, also used as insulating material, advertising nameplate.

(3) forming characteristics

In order to prevent the bubble plastic, turbidity, defects such as

yellowing and silver influence the quality of plastic parts, the raw

material should be well dried before molding; to obtain a good quality of

appearance, plastic surface to prevent a flow mark, weld lines mark air

bubbles and undesirable phenomena, is generally used as a low injection

speed; resistance to mold gating system stream should be as small as

possible, and should be made sufficient draft angle.

10), Bakelite (PF)

(1) Basic Characteristics

Bakelite is a larger yield of thermosetting plastics, which are based

on phenolic resin is prepared. Phenol resin itself is very brittle, amber

glassy form, must be added in order to obtain a certain performance

requirements Bakelite people of all the fiber or powder filler. Bakelite can

be divided into four categories: laminated plastic, plastic pressure,

pressure fibrous plastic, plastic clastic pressure.

Compared with the general thermoplastic phenolics, rigid, small

deformation, heat-resistant, long-term use in the temperature range of

150 ° C ~ 200 ° C; in water-lubricated conditions, low coefficient of

friction; the excellent electrical insulation properties. Bakelite

disadvantage is brittle, the impact strength is poor.

(2) The main purpose

Phenolic through the sheet-like laminated plastic impregnated with

phenolic resin solution is made of a filler, it may be made of profiles and

plates. The different filler used, there are paper, cloth, wood, glass and

asbestos cloth, and other laminated plastic. Phenolic cloth and glass cloth
laminated plastic has excellent mechanical properties, oil resistance and a

certain dielectric properties, can be used in the manufacture of gears,

bearings, guide wheels, silent gears, bearings and electrical and structural

materials for electric insulating materials; Wood for the production of

laminated plastic bearings and gears in the lubrication and cooling water;

asbestos cloth laminated plastic working parts are mainly used at high

temperatures.

Phenolic plastics may be heated fibrous pressure molded into a

variety of complex mechanical parts and electrical parts, with excellent

electrical insulation properties, heat resistance, water resistance, abrasion

resistance, can produce a variety bobbin, wiring boards, electric tool

housings, fan leaves , acid pump Ye Lun, gears, and cams and the like.

(3) forming characteristics

Good formability, especially suitable for compression molding.

Mold temperature greater impact on fluidity, in general when the

temperature exceeds 160 ° C rapidly decreased mobility; emit a lot of

heat during curing, the internal temperature of the thick-walled plastic

parts easily too large, uneven curing and overheating occur.

11), epoxy resin (EP)

(1) Basic Characteristics

Epoxy resins are epoxy group-containing polymer compound.

Before the end of curing, which is a thermoplastic resin linear, only (e.g.,
compounds such as amines and anhydrides) after cross-linking curing

agent was added to the polymer infusible body structure, it has practical

value as plastic.

Many types of epoxy resin, widely used, there are many excellent

performance, its most prominent feature is a bond strong, people familiar

with the "all-purpose adhesive" main component. In addition, the epoxy

resin is also resistant to chemicals, heat resistance, good electrical

insulation properties, low shrinkage, better mechanical properties than a

phenolic resin. The disadvantage is that poor weather resistance, impact

resistance is low, crisp texture.

(2) The main purpose

Epoxy adhesives can be used as the metal and non-metallic materials,

for encapsulating a variety of electronic components, together with a

variety of casting molds can be Shi Ying powder, various products can

also serve as anti-corrosion coatings.

(3) forming characteristics

Good fluidity, fast curing speed; epoxy heat poor rigidity, small

curing shrinkage, difficult to release, the release agent should be added

before pouring; not precipitate any byproducts during curing, without the

exhaust gas during molding.

12), aminoplast

Aminoplast amino compound and an aldehyde group is (mainly

formaldehyde) obtained by polycondensation of plastics, including urea -

formaldehyde, melamine - formaldehyde.

(1) Basic Characteristics and aminoplast main purpose

1) a urea-formaldehyde plastics (UF)

Urea - is a urea-formaldehyde plastics - formaldehyde resin molding

powder and the like made of bleached pulp. Urea - formaldehyde plastic

can be dyed a variety of bright colors, bright appearance, partially

transparent, high surface hardness, good arc resistance, resistance to

mineral oils, mold-resistant, but its poor water resistance after long-term

immersion in water, the electrically insulating performance degradation.

Urea - formaldehyde plastics and a large number of commodities for

pressing electrical lighting equipment parts, telephones, tape recorders,

clocks housing, switches and sockets and electrical insulation parts.

2) Melamine - formaldehyde plastics (MF)

Formaldehyde resins made with asbestos and talc, also known as

melamine plastics - melamine. Melamine - formaldehyde Plastic dyed

various colors, made of light, arc-resistant, non-toxic plastic, its

properties change less in the temperature range -20 ° C ~ 100 ° C,

the ability of the boiling water resistance and tea, coffee and other

pollution strong material, such as a ceramic can be conveniently removed

as a class of tea stains contamination

Thereof, and a light weight, non-brittle characteristics.

 Melamine is mainly used to produce plastic cutlery, cups and

aviation electrical switches, explosion-proof electrical arc chute and

accessories.

(2) an aminoplast forming characteristics

Common aminoplast compression, transfer molding. Large

shrinkage during injection-molding, moisture content and volatile matter,

therefore the pre-dried before use; melamine plastic since weak acid

decomposition and the water analysis, it should be chrome-plated mold

corrosion, and note that the exhaust gas during the molding ; as good

fluidity, fast curing speed, and thus preheating the molding temperature

should be appropriate, loading, clamping and processing faster; melamine

plastic parts with plastic insert Shen easy to produce stress concentration,

so that dimensional stability is poor .

8, plastic molding process

injectionMolding

1), injection molding principles and characteristics

Injection molding, also known as injection molding, fluorine plastic

so far, almost all of the thermoplastic molding unit can use this method, a

number of thermosetting plastics may be injection molding.

Injection molding principle: the granular or powdered plastic fed

from the hopper of the injection machine barrel is heated, the feedstock
was heated and melted flowable state after forward movement of the

plunger or a screw driven through the cartridge to the tip of the nozzle

very high speed low temperature closed injection mold cavity, the cavity

filled with the melt solidified after cooling to retain the shape imparted by

the mold cavity, and mold parting obtain a molded plastic parts.

The above operation process is a molding cycle, typically from a

few seconds to several minutes, depending on the length of time of the

plastic parts of the size, shape and thickness of the mold structure, and a

variety of molding process conditions and the type of plastic injection

machine and other factors .

Injection Molding Characteristics: molding cycle is short, forming a

complex shape can be, precise dimensions, with a metal or non-metallic

plastic insert parts, adaptability to various plastics, high production

efficiency, easy to realize a fully automated production series advantage.

This solid, injection-molded plastic parts are widely used in the

production of its products is currently about 30% of the production of

plastic parts.

2), the injection molding process

Plastic injection molding process comprising preparation before

molding, injection process, the article to be treated.

(1) preparation before injection molding

In order to smoothly carry out injection molding to ensure the

quality of plastic, prior to injection molding should be carried out

following preparations:

Pre-test and a) raw material before molding response for

appearance and performance testing process, dyeing and drying.

Test feedstock comprises measuring aspects of color, size and

uniformity, fluidity, thermal stability, shrinkage, moisture content and the

like. In order to make the plastic molded out more beautiful, or to meet

the requirements in the use of (parts of optical instruments need prevent

light leakage in black), usually of plastic material to be dyed.

Thermoplastics or less contain moisture and volatile matter, an

appropriate amount of moisture and volatile matter may serve plasticizing

effect. However, when the content of moisture and volatile matter

exceeds a certain amount, it will cause defects of the plastic parts will

have serious bubbles affect the quality of the precision plastic parts and

plastic parts, so it should be dried at this time.

Drying the moisture content is high temperature plastic is reduced,

there is an oven drying method, infrared drying, hot plate drying, high

frequency drying and the like.

Thermoplastics usually the first two drying methods.

b) preheating the insert metal inserts for plastic shrinkage rate and

vary greatly, so that when the plastic is cooled, the insert is generated

around the large internal stress, resulting in the plastic layer around the
insert and cracks decrease the strength. Thus preheating of the metal

insert prior to the molding temperature of the plastic base of the insert

and the small difference.

For stress cracking less likely to occur when the plastic molding, and

the insert member is small, the preheating may not be necessary. Preheat

temperature not to damage the surface of the metal insert zinc plated or

chrome plating is limited, typically 110 ~ 130 ° C. Coating the surface

of an aluminum alloy or a copper-free inserts, preheat temperature of up

to 150 ° C.

c) washing the cartridge prior to injection molding, if the injection

barrel originally remaining in the plastic and the plastic to be used when a

different or inconsistent color, must be cleaned.

D) When the release agent is selected injection molded plastic parts

release is mainly dependent on the process conditions reasonable and

proper mold design, but because of the complexity of the plastic parts or

unstable control of process conditions, may result in release difficult, so

often used in actual production release agent.

Since the raw material injection type, shape, structure plastic parts,

and the presence or absence of the insert requirements of different kinds

of preparations prepared before molding plastic parts are not exactly the

same.

(2) injection process

 Generally it includes feed injection process, the plasticizing,

injection, cooling and releasing steps.

a) for an amount (volume) addition, to ensure stable operation,

uniform plasticizing and, ultimately, a good feed when the injection

molding of plastic parts. Excessive addition, the heating time is too long

and so likely to cause thermal degradation of plastics, the injection

machine while power loss increases; the addition is too small, lacks

pressure transmission medium within the cartridge, the plastic melt in the

cavity pressure is reduced, is difficult to fill the plastic (i.e. fill pressure),

plastic parts prone to contraction, depression, and even lack of material

defects such as voids.

b) plasticizing the plastic is heated in the barrel, the conversion of

solid particles into a viscous state to form a homogeneous melt, and

having good plasticity called plasticizing process. The main factors that

determine the quality of the plastic is heated plastics material situation

and shear suffered.

By heating the material of the cartridge, the polymer molecular

relaxation, transition occurs from a solid to a liquid; for the mechanical

action of shearing forces and mixing the way to strengthen the

plasticizing process, the temperature distribution of the plastic melt, the

material composition and molecular morphological change portion, and

tends to be more uniform; while the shearing action of the screw can
generate more friction heat in the plastic, to promote the plasticization of

the plastic, thus plasticizing screw injection plunger type plastic injection

ratio confidential better.

c) injection machine regardless of the form of injection, the injection

process can be divided into filling, packing, back, the gate cooling stages

after freezing and demoulding.

 Filling Good melt plasticizing screw or plunger is pushed to the

front end of the barrel, through a nozzle and into the mold gating system

and filled cavity, called the filling stage.

Packing Cooling of the melt in the mold contraction, to maintain

pressure on the plunger or a screw to force the state of the melt

continuously added near the gate into the mold cavity in the plastic

molding a form capable of complete and compact plastic parts, which a

stage called packing.

Backflow After holding pressure plunger or screw retreat,

releasing the pressure in the cavity, the melt pressure in the cavity at this

time is higher than the front of the gate, if the gate has not been frozen,

occurs in the cavity through the sprue melt gating system backflow flow,

so that plastic shrinkage, deformation and other defects loose texture. If

the security gate before the end of the press had been frozen and then

back phenomenon does not exist.

After cooling gate freeze When the plastic casting system has

frozen, no longer needed to continue to packing hexyl, plunger or screw

so retractable, removable plastic pressure in the barrel, and the addition of

new material, while Walter cooling water, oil or air other cooling medium,

further cooling of the mold, this phase is called the gate to freeze after

cooling. In fact the cooling process from the plastic into the cavity begins,

comprising the filling is completed, the packing of this period of time

before release.

StrippingPlastic parts can be cooled to a temperature mold, under

the action of the eject mechanism pushed out of the mold the plastic parts.

(3) post-treatment of plastic parts

Due to the uneven or plasticized plastic in the cavity in the crystal,

and the orientation uneven cooling, resulting in plastic shrink inconsistent

portions, as secondary processing or impact plastic and metal insert of the

original solid improper, the internal plastic parts inevitably some internal

stress. Existence of internal stress often lead to plastic deformation or

crack during use, and should try to eliminate.

The properties of plastics and use requirements, plastic parts can be

subjected to annealing treatment and humidity conditioning treatment.

Annealing

The plastic parts in a constant temperature oven or a liquid medium

(such as hot water, hot mineral oils, glycerol, propylene glycol and liquid

paraffin and the like for some time, and then slowly cooled.

Annealing temperature is controlled at a temperature above the

plastic parts using 10 ~ 20 ° C lower than the thermal deformation

temperature of the plastic, or 10 ~ 20 ° C. Temperature should not be

too high, otherwise the plastic parts will have warpage; temperature is not

too low, otherwise reach the purpose of post-processing.

Annealing time depends on the types of plastic, the temperature of

the heating medium, the shape and wall thickness of the plastic parts,

plastic parts accuracy and other factors.

Annealing purposes: to eliminate the internal stress of plastic parts,

size stability; the crystalline plastics can improve crystallinity, thereby

improving the stable crystal structure of the elastic modulus and hardness,

but the elongation at break decreased.

Steaming

Freshly demolded plastic (polyamide) on the hot water in the

absence of air, to prevent oxidation, in addition to a little internal stress,

in order to accelerate the absorption Ping Heng to achieve stability in size,

referred to humidity conditioning treatment. Because when the

polyamide-based plastic parts demolded easily oxidized in contact with

air at elevated temperature discoloration. Further, such plastic parts used

or stored in air and absorbs water easily expanded, need a very long time

to stabilize dimension, so to humidity conditioning treatment.

After humidity conditioning treatment, it can also improve the

toughness of the plastic member, so that the impact toughness and tensile

strength increased.

The humidity treatment temperature is generally 100 ~ 120 ° C,

high heat distortion temperature of the plastic to take maximum species;

the contrary, take the lower limit.

The humidity of the processing time depends upon the kind of

plastic, plastic parts shape, thickness and crystallinity size. After reaching

the humidity treatment time should pity slowly to room temperature.

But not after all the plastic parts to be processed, you can not post

processing if the plastic parts is not strictly required. Chlorinated

polyethers such as polyoxymethylene and plastic parts, although the

presence of internal stress, but a greater flexibility of the dry polymer

itself is lower and the glass transition temperature, the internal stress can

be slow elimination itself, can not be worked up.

3), the injection molding process parameters

In the production of plastic parts, the selection and control of

process conditions is a key factor to ensure the smooth and molded plastic

parts by mass, the injection molding is the most important process

conditions of temperature, pressure and time.

(1) Temperature

In injection molding, the need to control the barrel temperature,

mold temperature and nozzle temperature.

a) a cylinder temperature on the selection of the cylinder

temperature, involves many factors, mainly in the following aspects:

A viscous flow temperature or melting point of the plastic parts for

the non-crystalline plastic, barrel temperature should be controlled not

end in its viscous flow temperature (Tf) or more; for plastics should be

controlled in the crystalline melting point (Tm) above. But whatever type
amorphous or crystalline plastic, the cylinder temperature can not exceed

the decomposition temperature of the plastic itself (Td). That is, the barrel

temperature should be controlled between viscous flow temperature (or

melting point) and decomposition temperature (Tf ~ Td or Tm ~ Td).

For narrower plastic (e.g., PVC) between the viscous flow

temperature and the decomposition temperature, in order to prevent

decomposition of the plastic, the cylinder temperature low number should

be taken. For the wide range between viscous flow temperature and the

decomposition temperature of the plastic (e.g., polystyrene, polyethylene,

polypropylene), a cylinder temperature may be much higher than the

viscous flow temperature.

But for the heat-sensitive plastic (such as polyoxymethylene,

polyvinyl chloride, etc.), pay attention to controlling the maximum

temperature and time of the cartridge in the barrel of the plastic stay,

preventing it stays at a high temperature for a long time to generate

degradation.

B plastic varieties with a plastic, a high average molecular weight,

narrow molecular weight distribution, melt viscosity is large barrel

temperature should be higher; low average molecular weight, broad

distribution, low melt viscosity, a cylinder temperature can be lower.

Glass fiber reinforced plastics, with increasing glass fiber content, melt

flow decreases, and therefore the cylinder temperature to be increased

accordingly.

C plunger type injection machine heated the plastic injection

molding machine alone and torpedo cartridge wall surface of the heat,

and the material layer is thick, slow warming, and therefore the cylinder

temperature is higher; Screw Injection Molding Machine plastic screw

will be mixed and stirred to obtain more shear frictional heat, the material

layer is thin, rapid heating, and therefore the cylinder temperature can be

below the ram 10 ~ 20 ° C.

D plastic parts and a mold structure for thin-walled plastic parts, its

respective narrow cavity, the melt filling resistance, fast cooling, in order

to improve the melt flow, easy to fill the cavity, barrel temperature should

be chosen higher. In contrast, for thick-walled products, some

low-cylinder temperature is desirable. Complex shape with plastic parts

or inserts, or a long touch melt filling process, more tortuous barrel

temperature should also be taken higher.

The entire cylinder temperature distribution is not uniform, the

temperature was kept constant gradient, close to the hopper section (feed

section) minimum temperature, mainly for preheating plastics; the first

half of a compression section to be slightly below the melting point of the

plastic, after and half of the metering section temperature is higher than

the melting point of the plastic; maximum temperature of the front end of

the nozzle.
 b) nozzle temperature slightly lower than the nozzle temperature is

generally the maximum temperature of the cylinder to prevent the melt to

produce "drooling" phenomenon at the nozzle; but the temperature can

not be too low, otherwise easily clog the nozzle.

Barrel and nozzle temperature should be combined with other

process conditions are considered together, such as the use of high

injection pressure, a cylinder temperature can be lower; contrary barrel

temperature should be higher. If the molding cycle is long, the plastic in

the barrel long heating time, barrel temperature should be slightly more;

if the molding cycle is short, the barrel temperature should be higher.

c) The lower the temperature of the mold temperature of the mold, a

plastic mold cavity cooling rate faster, can greatly shorten the molding

cycle, improve production efficiency. The mold temperature is too low,

however, prone to fusion marks, sink marks etc. defects, affecting the

appearance of the plastic mass weight. The mold temperature is too high,

plastic parts slow cooling, the molding cycle is made longer; easy

stripping of plastic parts after warpage, dimensional accuracy influence

plastic parts.

Mold temperature is generally made through meditation temperature

of the cooling medium is controlled; also by way of melt into the mold

was naturally warmed and natural heat equilibrium to maintain a certain

temperature; in special cases, also be resistance wire and a resistance

heating rod pairs heating the mold to keep the mold temperature constant.

(2) Pressure

a) plasticizing a pressure (back pressure)

When using screw means the injection machine, the screw top of the

melt in the screw rotates suffered backward pressure.

Plasticized pressure increase, and the temperature of the melt to

improve the uniformity, and the toner mixed exhaust gas in the melt.

Plasticizing rate reduction, to extend the molding cycle.

In general operation, under the premise of ensure the quality of

plastic, the plasticized pressure should be as low as possible, generally

about 6MPa, typically less than 20MPa

b) Injection pressure

It means a pressure plunger or screw tip on the plastic melt is

applied.

Action: to overcome the flow resistance of the melt flow during

injection filling process, the melt having a certain filling rate; melt

backflow preventing compaction and dwell time.

Size: depending on the type of injection machine, the plastic

varieties, mold structure, a mold temperature, structure and size and

thickness of the plastic parts of the gating system and the like.

In general:

High viscosity plastic injection pressure> low plastic viscosity;

 Thin-walled, large area, the complex shape of high plastic injection

pressure;

Simple mold structure, a larger gate size, a lower injection pressure;

The plunger injection machine injection pressure> Screw Injection

Molding;

Cylinder temperature, a high mold temperature, lower injection

pressure.

(3) time (molding cycle)

Injection time required to complete a process called injection

cycle. It includes the following sections: injection time (filling time 3 ~

5s, dwell time of 20 ~ 120s), mold cooling time (30 ~ 120s), other times

(mold opening, mold release, a release agent spraying, the insert is placed

clamping time)

Compression molding process

1), compression molding principle and characteristics

Compression molding, also known as compression molding, press

molding, press molding, loose form (powder, granular, or fibrous debris)

was added directly to solid molding material into the mold cavity at the

molding temperature, it gradually softening and melting, and to make the

material under pressure to fill the cavity, when the plastic polymer

chemical crosslinking reactions, transformed into the final plastic article

after curing.

Compression molding employed has advantages common hydraulic

press, the compression mold structure is simple (no gating system), the

production process is relatively simple, compact plastic parts oriented

internal organization less uniform properties, molding shrinkage ratio

small plastic parts and the like. The disadvantage is that the molding

cycle is long, low production efficiency, labor-intensive, and manually

operating a multi-production difficult to automate the production; plastic

burrs often with burrs, dimensional accuracy is difficult to control the

height direction; mold easy to wear, so the service life shorter.

Compression molding is mainly used for thermosetting plastics,

thermoplastics can also be used (e.g., polytetrafluoroethylene). Except

that there is no cross-linking reaction thermoplastic molding, so after

filling the cavity, the mold is cooled to solidify the need to obtain a

release article. Typical articles have a compression meter housing, panel

gates, electrical switches, sockets and the like.

2), a compression molding process

Compression molding process generally includes a preparation

before compression molding and compression two-stage process.

(1) preparation before compression molding

Mainly it refers to the pre-press, preheating and pre-drying step.

a) Preloading
 Using a pre-die on the material pressed into a mass pre-press, similar

to the shape of ingots. When the forming ingot at a number into the

compression molding. Generally the shape of the ingot can be preheated

to facilitate the very compact zoom appropriate mold. Ingot shape

generally used mostly disc-shaped, has an elongated, flat spherical,

hollow body of plastic parts like or simulated shape.

b) drying and preheating

Thermosetting plastic molded coping before heating. Heating two

purposes: First, the plastic was dried to remove moisture and other

volatiles; second is to improve the material temperature, easy to shorten

molding cycle and improve the internal plastic parts uniformity of cure,

thereby improving the physical and mechanical plastic parts performance.

While improving the fluidity of the plastic melt, reducing the molding

pressure to reduce die wear.

Production of preheating and drying ovens are commonly used

equipment and infrared furnace.

(2) compression forming

Mounted on the press after the mold is preheated. Usually

thermosetting plastic compression process can be divided into feed,

clamping, exhaust, and release the curing several stages, during the

molding of plastic articles with inserts, the insert should be preheated

prior to addition and mount positioned mold.

 a) feeding

The key addition is the increase of quantity. There are three ways of

quantitative weighing method, a volumetric method, and counting.

Weighing method is more accurate, but the operation is troublesome;

Volumetric weight sensing method, though not as accurate, easy to

operate; pre-count method is used only for feeding tabletting material.

When the material added to the cavity, a logical stack, so as to avoid local

plastic parts loose and so on.

b) closing the mold

Mold clamping is performed after the addition. Mold two steps:

when the punch Shangmo contact material, in order to shorten molding

cycle, to avoid a chemical reaction occurs before the plastic mold, should

speed up the rate of addition; after the punch contacts the plastic, to

prevent the insert or mold molded parts are damaged, and the cavity

sufficient to exclude air, should slow down the speed of mold, i.e. a

so-called slow speed after the first mold clamping manner.

c) an exhaust

Compression thermosetting plastic, when the mold is closed,

sometimes need to punch the relief loose some time, so that the exhaust

gas therein. The number is usually one to two times of the exhaust gas,

each time by a few seconds to tens of seconds.

d) curing
 When the compression molding of thermosetting plastics, plastics

rely on a crosslinking reaction curing shape, often a production process

called hardening. In this process, as a thermosetting plastic viscous flow

state within the mold cavity a reaction with a curing agent to form a

crosslinked structure, and forming a period of time at a temperature so as

to achieve the best performance. Cure rate of the plastic is not high, in

order to improve productivity, the whole may not necessarily placed in

the mold to complete the curing process (especially some plastics harden

too slow), a release complete can be simply plastic molding to end, then

using the method of after-treatment (post bake) to complete the cure. The

curing time should be moderate mold, generally ranging from 30 seconds

to several minutes. Time is too short, the mechanical strength of a

thermosetting plastic, creep resistance, heat resistance, chemical stability,

electrical insulation properties are lowered, thermal expansion, the

shrinkage increases, sometimes cracks; too long, the plastic member of

high mechanical strength, high brittleness, surface density vesicles

appeared and the like.

e) demolding the plastic

The method of demolding and manual release into a motor Release

Release release. When the core or with lateral inserts must use special

tools to tighten them off in order to remove the plastic parts.

(3) after the pressure treatment

 After demolding the plastic parts, the mold should be cleaned,

sometimes the plastic to be processed.

a) cleaning the mold

When necessary, the required release of copper or a copper brush

blade to remove residual plastics in the waste side of the mold, then the

mold with compressed air blowing. If the plastic mucosal phenomenon,

the polishing agent is not easy to wipe clean deleted by the above method.

b) after treatment

In order to further improve the quality of plastic parts, thermoset

plastic member after demolding normally holding time at a higher

temperature. After treatment can become more complete curing of the

plastic, while reducing or eliminating internal stresses of plastic parts,

reducing the moisture and volatile matter, etc., will help improve the

electrical properties and strength of plastic parts.

3), the compression molding process parameters

Compression molding process parameters mainly refers compression

pressure, the compression molding temperature and the compression

time.

(1) compression molding pressure

Compression molding pressure means is a compression press by the

pressure of the plastic melt when the punch and the cavity filled with the

cured applied to the parting surface unit projected area, referred to as

molding pressure.

Molding pressure is applied to the object causes the flow of filling

material to increase the density and the intrinsic quality of plastic parts,

overcoming the force of the plastic resin expansion molding in the

molding process due to chemical changes in the release of low-molecular

substances and moisture plastic produced, the mold closed, to ensure that

the plastic has a dimensionally stable shape to reduce the burr, preventing

deformation. But too much pressure molding reduces die life.

Compression molding size and type of plastic pressure, plastic

structure and a mold temperature and other factors, in general, the smaller

the flow of plastic, plastic and thicker the more complex shape, and the

plastic compression ratio, the higher the curing speed, the desired forming

pressure is also greater.

(2) compression molding temperature

Compression molding the mold temperature is the temperature

required for compression molding. It is a thermosetting plastic to flow,

filling the mold and finally cured primary forming process factors,

determines the speed of the forming process of the polymer crosslinking

reaction, thus affecting the final properties of the plastic parts.

Compression molding the molding temperature in the melt affect the

level of filling is smooth, but also affect the curing speed during molding,

thereby affecting the quality of plastic. As the temperature increases, the

plastic solid powder gradually melted, the viscosity of big to small, the

crosslinking reaction began, when its flowability increases with

temperature peaks, the molding pressure is rapidly increased, the

temperature of the plastic is not full of high flows during each part of the

cavity and larger.

In a certain temperature range, the mold temperature, molding cycle

time, productivity is improved. If the mold temperature is too high, the

resin will decompose and organic, plastic surface color is dark. Since the

outer layer is first cured plastic parts, affect the flow of material, filling

will cause dissatisfaction, particularly complex shape molded, thin-walled,

large depth most obvious plastic parts. Meanwhile, since the moisture and

volatile matter difficult to remove, large internal stress of plastic parts,

plastic parts prone to swelling when the module is turned on, cracking,

warping and the like; if the mold temperature is too low, insufficient

hardening, will matte plastic surface which physical and mechanical

properties decline.

(3) compression time

When the compression molding of thermosetting plastics, to be

maintained at a certain temperature and a certain pressure is constant

Division, crosslinking can be sufficiently become excellent performance

plastic parts, this time is called the compression time. Compression time

and type of plastic (resin type, volatile content, etc.), the shape of plastic
parts, the compression molding process conditions and other procedures

(whether the exhaust gas, preload, preheating) and so on.

Compression molding temperature, the plastic parts to accelerate the

curing speed, reducing the time required for compression, thus improving

the compression cycle with a mold temperature will be reduced. When

molding material is preheated or pre-press and the use of high pressure

molding, compression time can be shortened, the thickness of plastic

parts typically increase the compression time will increase.

The length of time a great influence on the compression

performance of plastic parts. Compression time is too short, insufficient

hardening plastic, the plastic parts appearance properties will deteriorate

the mechanical properties decreased deformation. Appropriately

increasing the compression time may be reduced plastic shrinkage,

improve the heat resistance and other physical and mechanical properties.

However, if the compression Division too, not only reduces the

productivity but also causes excessive crosslinking of the resin to increase

the plastic shrinkage, internal stress, resulting in lowered mechanical

properties of plastic parts, plastic parts would be severe cracking.

Pressure injection molding process

1), transfer molding principle and features

Pressure injection molding, also known as transfer molding, it is an

important method for forming thermosetting plastics, compression

molding method is forming a thermosetting plastics developed on the

basis of.

Forming principle:

First solid forming material (preferably a pre-pressed into the

preheated ingot or material) was added in the feed chamber mounted on

the closure of the injection-molding tool, so that the heat-softened state

into a viscous flow, and the plunger in a press after the plastic melt

casting system filled cavity under pressure, continue to heat the plastic in

the cavity is compressed, generating a crosslinking reaction and cured

shape, and finally remove the plastic mold.

Transfer molding and injection molding are the similarities are melt

into the cavity through the runner system, except that the former is in the

plastic filling the mold cavity plasticized, while the latter is in the plastic

injection molding machine cylinder of. Transfer molding is compression

molding to overcome the disadvantages, the absorbent developed on the

basis of merit injection molding.

The main advantages are:

(1) injection-molding the front mold has been closed, the plastic

melted in the heating chamber and the heating, by injection-molding in a

press plunger which passes crowded cavity and the narrow runner and

gate, due to friction, the plastic can uniformly and quickly through the
heat curing. Therefore, even dense product performance, good quality.

When the burr (2) injection-molding when less than a compression

molding, and flash thin, easily removed. Accordingly, higher dimensional

accuracy of plastic parts, in particular parts of much higher accuracy than

the height dimension of the compression part.

(3) since the forming material has been plasticized before entering

the large-size cavities, the small cores or inserts to the pressing force

generated, so deep cavity can be shaped thin-walled plastic parts or

plastic parts with deep holes may be formed more complex shapes and

Narrow band or frangible plastic insert, may also be molded plastic parts

molded difficult compression method.

(4) feeding the molding material in the cavity has been softened by

heat, and therefore, when the temperature of the material into the mold

cavity and uniform heat absorption, Division shorter crosslinking

required for curing, resulting in shorter molding cycle, high production

efficiency.

Disadvantages:

Higher than the compression molding pressure molding; than the

compression molding process conditions more stringent requirements

than the compression molding operation is difficult; injection mold more

complicated than compression molding structure; addition after forming

the cavity
Leaving a portion of the total feed I and feed condensate pouring system

application, can not be recovered because the production of raw material

consumption will increase; alignment problems exist, the alignment tends

to produce plastic parts and stress anisotropy, in particular when the fiber

reinforced plastic molding, plastic and fiber orientation as

macromolecules together, easier to increase the degree of anisotropy of

plastic parts.

2), transfer molding process

Process transfer molding and compression molding are substantially

similar. The main difference is that: compression molding a first mold

closing after the addition, the injection molding pressure is generally

required to feed the mold closing.

3), transfer molding process parameters

Injection molding pressure of the main process parameters include

pressure molding, molding temperature and molding time, a variety of

factors which are related to plastic varieties, mold structure, plastic and so

on.

(1) forming pressure

Refers to a press molding pressure through the injection-pressure

loading of the piston chamber of the plastic melt is applied. Since the

pressure loss as the melt by casting system, so that when the

injection-molding pressure is generally 2 to 3 times during the

compression.

(2) Mold temperature

Injection-molding mold temperature is usually lower than the

compression molding temperatures of some, generally about 130 ° C ~

190 ° C, because the heat from the friction part made of plastic by

casting when system. Loading chamber and a lower mold temperature to

be lower, and the temperature of the block to be higher, thereby ensuring

smooth plastic Beng person without making burr phenomena, but also to

avoid plastic material shortage occurs, blistering, seams and other defects.

(3) Molding Time

Transfer molding time comprises feeding time, filling time,

crosslinking or curing time, release time and taking clean mold plastic

parts time. Filling time when injection-molding is generally 5 ~ 50s,

while the cure time depends on types of plastic, plastic parts of the size,

shape, thickness, structure and mold preheat conditions, generally 30 ~

180s.

Extrusion molding process

1), extrusion molding principle and characteristics

Extrusion molding, also known as extrusion molding, in which the

thermoplastic molding is a widely used, a large proportion of the

processing method.
 Thermoplastic extrusion molding principle: First, particulate or

powdered plastic is added to the extruder barrel, in the action of the

rotating extruder screw, heated plastic conveyed forward along the screw

spiral groove. In this process, the plastic is heated continuously between

the outer and the screw receiving material and the shear frictional heat

between the material and the material between the barrel and the

materials, the melt was gradually viscous flow state, then the action of the

extrusion system under the plastic melt through an extrusion die having a

certain shape (head) and a series of auxiliary die means (shaping, cooling,

drawing, cutting, etc. means), to thereby obtain a certain cross-sectional

shape of the plastic profile.

The extrusion apparatus is an extruder, the resulting plastic parts

which are continuous with a constant cross-sectional shape of the profiles,

such as tubes, rods, wires, plates, films, wire and cable coating and the

like coating of plastic parts. Coloring extrusion, granulation and the like

can be used for blending modification of plastics. This molding method

has the following characteristics:

(1) Continuous molding yield, high productivity, low cost,

significant economic benefits.

(2) the geometry of the plastic parts a simple cross-sectional shape

constant, and therefore the mold structure is relatively simple, easy to

manufacture maintenance.
 (3) plastic parts within an organization closely balanced, more stable

and accurate size.

(4) adaptability, fluorine plastic, all thermoplastics can be extrusion

molding, may also be part of thermosetting plastic extrusion molding.

Change the die head, cross-sectional shape and size of the product

changed accordingly, so that we can produce different specifications of

various plastic parts. The extrusion process equipment of simple structure,

convenient operation, widely used.

2), extrusion molding process

Thermoplastic extrusion process can be divided into four stages.

(1) plasticizing stage

After the plastic material is dried after treatment by the hopper of the

extruder barrel were added, at a cylinder temperature and the screw

rotation, mixing and compaction, the transition from a solid powder or

granule having a homogeneous melt a certain fluidity, this process is

called plasticizers.

(2) extrusion molding stage

Plasticized plastic melt with uniform rotation of the screw moves the

front end of the cartridge, under the action of the rotating screw extrusion,

through a die to obtain a shaped continuous uniform shape and

cross-sectional profile die.

(3) cooling setting stage

 By an appropriate treatment method, such as sizing process, the

cooling process, so that the continuous plastic extrusion profile has cured

plastic article. In most cases, the cooling and shaping are done

simultaneously, only extrusion bar and the various tubes, have a separate

calibration procedure, and the extruded film, monofilament without shape,

it can be cooled only by . The sheet extruded sheet, sometimes by a pair

of press rolls flattened, shape and has a cooling effect. Available methods

styling pipe sizing sleeve, the sizing ring and the sizing plate, there is also

a special die can be cooled by water to the sizing. Irrespective of the

approach, the inner and outer tube is a pressure differential firmly against

the sizing sleeve in the cooling and sizing.

Generally using air cooling or water cooling, the cooling rate has a

great influence on the performance of plastic parts. Hard plastic (e.g.,

polystyrene, PVC, and low density polyethylene, etc.) can not cool too

quickly, otherwise easily lead to residual stress, and affect the appearance

of the quality of plastic parts; soft plastic or the crystalline cooling

requirements in a timely manner, in order to avoid plastic deformation.

Traction (4) of the plastic parts, a winding and cutting

After the plastic extruded from the die, usually due to a sudden

release pressure die swell phenomenon occurs, and then cooling the

shrink phenomenon occurs, so that the size and shape of the plastic parts

is changed. In addition, since plastic parts are continuously extruded,

more and more weight, if not guided, it can cause stagnation of plastic

parts, plastic parts can not be successfully extruded. Thus, while cooling,

to be continuously and uniformly drawn plastic parts, which is traction.

Traction by the pulling device to complete the process of one of the

auxiliary extruder. Pulling speed should be compatible with the extrusion

rate is generally slightly larger than the pulling speed of the extrusion rate,

so as to eliminate variations in the value of the size of plastic parts,

plastic parts while proper stretching can improve quality. Different plastic

parts of different pulling speed. Normally, the pulling speed of the film

and the monofilament can be faster, because of its large drawing speed,

the thickness of the plastic parts and a reduced diameter, longitudinal

break strength increase, decrease elongation. For rigid extruded plastic

parts, take-up speed is not so large, the traction usually takes a

predetermined speed within a certain range, and to be very uniform,

otherwise it will affect the size and uniformity of the mechanical

properties.

By pulling the plastic parts can be cut according to the requirements

(such as a rod, tube, plate, sheet, etc.) on the cutting device, or wound on

a winding device made volumes (such as films, monofilaments, wire and

cable). Further, some plastic parts, such as a film or the like may also

need to be post-treated to improve the dimensional stability.

3), extrusion molding process parameters

 Extrusion molding process parameters including temperature,

pressure, extrusion speed and towing speed.

(1) Temperature

Temperature is one of the important conditions for the smooth

extrusion molding. Starting from powdery or granular solid material, the

high temperature article extruded from the head, through a complex

process temperature. Strictly speaking, the temperature of the extrusion

molding temperature of the plastic melt shall refer to, but it largely

depends on the temperature of the barrel temperature and screw, frictional

heat generated in the cylinder from mixing a small portion, so often

approximated by a cylinder temperature of the molding temperature.

And plastic screw barrel temperature of each section is different, in

order to make the plastic in the cartridge conveying, melting,

homogenization and extrusion process to work, in order to efficiently

produce high-quality products, the problem is to control the key cylinder

each zone temperature, is adjusted by the heating and cooling system and

a temperature control system to achieve the extruder.

Head temperature must be a thermal decomposition temperature of

the plastic, the temperature at the die head temperature lower than, but

should ensure that the plastic melt has a good flowability.

In addition, fluctuations in temperature during the forming and

temperature, the plastic parts will residual stress, strength and surface
unevenness points dull matte defects. Many factors such fluctuations and

the temperature difference, such as heating, cooling system instability,

screw speed changes, but the choice of screw design and quality of the

greatest impact.

(2) Pressure

In the extrusion process, since the flow resistance of the material,

changing the screw groove depth filter and the filter plate, and the like

hinder the die, and thus in the axial direction of the cartridge, a certain

pressure inside the plastic. This pressure is obtained and a homogeneous

melt plastic becomes an important condition for a dense plastic parts.

Increase the head pressure can improve the mixing uniformity and

stability of the extruded melt, increase product density, but too great head

pressure on the yield.

As temperature and pressure will produce cyclical fluctuations over

time, such fluctuations adversely affect the quality of plastic Similarly,

changes in the screw speed, the heating, cooling systems are unstable

causes pressure fluctuations. In order to reduce pressure fluctuations, the

screw speed should be reasonable control, heating and cooling means to

ensure that the temperature control accuracy.

(3) extrusion speed

Extrusion rate (also known as extrusion rate) per unit time within the

extruder die extruded plastic mass (in kg / h) or the length (in m / min).
Characterization of the size of the rate of extrusion of low extrusion

capacity.

Many factors affect the rate of extrusion, such as the structure of the

head, and the screw barrel, the screw speed, heating and cooling

characteristics of the system configuration and the plastic. Theory and

practice have proved that the extrusion rate with a screw diameter, depth

of spiral groove, and the length of each screw speed increases, with the

end of the screw and the screw to the barrel melt pressure gap increases.

In the case of the structure and the types of plastic and plastic parts of the

extruder type has been determined, the extrusion rate and screw speed

only, and therefore, the screw speed is adjusted to control the extrusion

rate of the main measures.

Extrusion rate there is fluctuation in the production process, this will

affect the accuracy of the geometry and size of plastic parts. Thus, in

addition to correctly determine the dimensions of the structure and

parameters of the screw, the screw speed should be strictly controlled,

strict control of the extrusion temperature, to prevent temperature changes

caused by changes in extrusion pressure and melt viscosity, leading to

fluctuations in the extrusion speed.

(4) drawing speed

The main producing a continuous extrusion molding of plastic parts,

the traction means must be provided. Extruded from the die head and the
plastic parts, stretch orientation will occur in the traction force. The

higher the degree of stretching alignment, the alignment direction of the

plastic parts in greater tensile strength, but also large length contraction

after cooling. Typically, traction speed comparable to the speed of

extrusion. The ratio of drawing speed to the extrusion speed of said draw

ratio, this must be greater than 1.

9, Design of plastic parts

1), and the size accuracy of plastic parts

(1) plastics dimension

Design Principles:

a) restricted by the plastic flowability, good flowability can be

plastic molded plastic parts of larger size, whereas the size of plastic parts

can be formed is small.

b) Restricted forming apparatus, the size of the injection molding of

plastic parts is restricted by the amount of injection of the injection

molding machine, clamping force and the size of the template;

compression and transfer molding of plastic parts to be subjected to size

press and the press working pressure of maximum limit the maximum

size of the table.

c) Under the premise to meet the requirements, plastic parts should

be designed to be compact, small size number.

(2) dimensional precision plastic parts

 It refers to the size of plastic parts and the obtained product conform

to the dimensions of the degree of accuracy, i.e. the size of plastic parts

obtained. Under the premise of meeting the requirements of use, as far as

possible be designed lower.

Plastics dimension tolerance "engineering plastic molded

dimensional tolerance standards" is determined according to GB / T14486,

plastics dimension tolerance code for MT, rating 7 tolerance. On the

plastic parts of the one-way positive hole tolerance deviation tolerance of

plastic shaft member unidirectional negative deviation from the central

position of the dimensional tolerance, and other two-way equivalent

deviation.

2), the surface quality of plastic parts

(1) the surface roughness of plastic parts

Referring plastic surface roughness GB / T14234 "plastic surface

roughness standard - different processing methods and different

materials can reach the surface roughness" selection, determinants on

the surface roughness of the forming die part, the roughened surface of

the plastic parts of generally 1.6 ~ 0.2μm, the mold surface roughness

value than a lower plastic parts 1 and 2.

(2) the apparent mass of plastic parts

The apparent mass of plastic parts after an apparent plastic

molding defect states, such as lack of material, flash, flash, recesses,

 pores, weld marks, wrinkles, warpage and shrinkage, dimensional

instability and the like. Visual defects by the plastic molding process

conditions, choice of raw materials a variety of factors, the overall

design of the mold caused by molding plastic parts.

3), the structural design of plastic parts

Structure of plastic parts must be designed to meet the

requirements of the process and has good structure - plastic parts meet

the requirements under the premise that the structure forming process

should meet the requirements as far as possible, thereby simplifying

the mold structure, to reduce production costs.

Process structure of plastic parts design principles should be

followed:

(1) In the performance of plastic parts to ensure physical, chemical,

dielectric properties and mechanical properties of the premise, and try

to use inexpensive plastic molded better performance, and the simple

structure sought, uniform thickness, to facilitate molding.

（2） Plastic parts should be considered in the design of the

overall structure of the mold, the mold cavity is easy to design and

manufacture of molds and ejection mechanism simple core pulling.

（3） In designing plastic parts should be considered forming

process of the raw material, such as fluidity, shrinkage and the like,

plastic shaped facilitate mold parting, the exhaust gas, feeding and
 cooling.

（4） When plastic parts designs require higher, it should be by

molding, then gradually drawn pattern.

shape

Inner and outer surface shape of the molded plastic parts should be

easy to use as possible to meet the requirements of the case.

Draft angle

Generally, the material properties of the brittle, hard, require large

stripping slope, but the following should be noted in the specific draft is

selected points:

（1） Where high precision plastic parts, using a smaller draft angle

should

（2） Where higher, larger size, should use a smaller draft angle

（3） Plastic parts having a complicated shape and difficult to

release should use a larger draft angle

（4） Large shrinkage of plastic parts should be used in a large value

of the slope

（5） When plastic parts thicker wall, causes mold shrinkage

increases, stripping slope value should be greater

（6） If required the molded piece is held in the release draft angle

of the inner surface side of the core, the plastic parts may be

selected smaller than the outer surface; conversely, releasing the

 plastic parts required to remain in the cavity, the plastic parts when

the draft angle should be less than the outer surface of the inner

surface, but when the inner and outer surfaces of the draft angle

inconsistent requirements, they can not guarantee the uniform wall

thickness

（7） Should take a large reinforced plastic, since the lubricant

containing preferably less easy to mold plastic

（8） And the draft angle tolerance plastic parts relationship:

① draft angle is not included in the tolerance range of plastic parts,

the shaft, the small end of the size of the big end by the size reduction

required to ensure the slope. Guaranteed by the small end hole size

requirements, the big end upsizing slope.

② draft angle included within a tolerance range of plastic parts, the

size of the size of the end to take two limit calculated stripping slope.

Wall thickness

Thermoplastics and thermosetting plastics compared to allow for a

smaller wall thickness, the minimum thickness allowed the thermoplastic

to 0.25 mm, is generally not less than 0.6 usually 2 ~ ~ 0.9 ㎜ 4 ㎜;

thermoset plastic small minimum wall thickness is 0.6 - 2.5 mm, large

plastic parts take 3.2 to 8 mm.

Reinforcing ribs

Strengthening the role of ribs: plastic parts to improve the strength,

rigidity without increasing the wall thickness, to avoid warpage; to some

extent may improve the fluidity of the plastic filling.

Strengthening rib design requirements:

① reinforcing ribs should be less than the thickness of the part thickness,

and the walls with transition arcs

② reinforcing rib end surface height should not exceed the height of

plastic, should be less than 0.5mm or more

③ height as far as possible a number of shorter ribs instead of isolated

high ribs, the distance between the ribs and the ribs should be greater than

twice the width of the rib.

④ direction of reinforcing ribs provided should be consistent with the

direction of the force, and as far as possible consistent with the direction

of melt flow, flat plate-like plastic parts, reinforcing ribs should be

parallel to the expected direction of flow, a number of reinforcing ribs

designed to be shorter.

The boss bearing surface

Projecting frustum plastic parts or support block to provide a

fastener such as a screw is located site, or holes in the reinforcing strength

plastic parts.

Projections should be located as far as possible at the corner molding

parts, should have adequate draft angle, it should be provided with side

gussets, to disperse stress loads. Boss junction with the base surface
should have a sufficient amount of arc transition. It should be at least

twice the diameter of the boss aperture. Projection height should not

exceed twice the outer diameter of the boss. Boss wall thickness should

not exceed 3/4 of the wall thickness of the base surface, as well 1/2.

Rounded

Plastic fillet not less than 0.5 ~ 1mm, typically 1.5 bullnose, fillet R1

is 0.5.

Plastic fillet to avoid stress concentration, improve the strength of plastic

parts, improve the melt flow, to facilitate release, the mold cavity is not

easy due to stress concentration cracking.

Hole design

Design principles hole is designed: to ensure adequate strength to

meet the requirements; to avoid side hole. Particular attention should be

compression molding, the through-holes not to exceed 3.75 times the

depth of the aperture.

Design principles blind holes:

① injection pressure, injection molding, H <4d

② compression molding: parallel to the pressing direction, H <2.5d;

perpendicular to the pressing direction, H <2d

③ When the diameter is less than 1.5 mm or depth (H) is greater than the

value obtained manner machining applications.

Hole should be designed to split molding method, avoids side core.

Common hole design considerations:

When two holes are similar, the design should be an elongated hole,

such as hole should be provided for the fixing bosses; punch holes

designed to be noted that the structure of the core is provided.

Plastic thread design

The method of forming a mold in a direct thread forming,

machining shape.

Plastic thread design principles: the diameter is not too small, an

outer diameter of 4mm, inner diameter of no less than 2mm; plastic screw

member threadedly engaged with the metal is no longer than 1.5 to 2

times the diameter of the screw; screw innermost rim and the outermost

left step, to prevent deformation of the thread crack.

Insert design

Insert non-ferrous material, ferrous metals, non-metals. Insert can

improve the strength, hardness, wear resistance, electrical conductivity,

permeability and the like; to improve the accuracy, the dimensional

stability of the plastic parts. In the plastic insert member must be reliably

secured. The insert must be positioned reliably within the mold, the insert

and the fit of the template holes H8 / f8 molding. Thickness around the

insert should be large enough to ensure the strength and rigidity.

Polychrome surface marker symbols and

Mark symbol should be placed parallel to the direction of the parting

surface, and have an appropriate slope greater than 10 °, to facilitate

release. Mark projection height of not less than 0.2 ㎜, the line width of

not less than 0.3 mm, typically 0.8 mm, the distance is not less than two

lines of 0.4 mm, 0.3 mm high above the border pattern than the pattern.

Hinge design

Polypropylene, ethylene-propylene copolymers, ABS certain

species like can be made directly to the hinge, the hinge portion should be

thin, typically 0.25 to 0.4 mm, the melt must flow through a hinge portion,

the hinge portion of the cross section is not too long.