英文翻译封面

合肥学院机械工程系

毕业设计(论文)

英

文

翻

译

专业材料成型及控制工程

年级大四

姓名刘大鹏

学号1106032023

指导教师陈瑛

2014年3月24 日

Crystallinity of parts from multicavity injection mould

Abstract

Purpose: The intention of this research was to test, if injection moulded polyoxymethylene parts, manufactured in different cavities of the multicavity injection mould with geometrically balanced runners, differ in crystallinity degree. Design/methodology/approach: The values of crystallinity degree were calculated on the basis of DSC (Dynamic Scanning Calorimetry) testing method results (DSC curves).

Findings: It was found that there are differences in crystallinity degree for parts from particular mould cavities. The reason of this is the difference in thermal conditions, specific for each cavity.

Research limitations/implications: It is supposed that the parts from each multicavity injection mould would have differences in properties. However, it is always dependent on cavities and runners’ layout. Since in this research a particular injection mould was used, the conclusions can not be directly extrapolated to other moulds. Each case requires its own analysis. Higher crystallinity degree will occur in partsobtained from areas of higher mould temperature.

Practical implications: The results of this investigation are important for mould designers, especially when moulds are used for precision injection moulding. It was proved here that differences in parts’properties can occur for multicavity injection moulds. In order to avoid this it is required to minimize the temperature differences in the mould.

Originality/value: Geometrically balanced runners in the mould were supposed to assure the equal filling of all cavities. The results obtained lately by other researchers have shown that this is not always true. That investigation was mostly focused on filling imbalance that leads for example to difference in weight of parts from different cavities. In this paper it was shown that not only weight of parts can differ but also other properties.

Keywords: Plastic forming; Injection moulding; Crystallinity degr ee

1.I n tr oduc tion

Crystallinity degree of polymer is the percentage of crystalline phase in

a sample of semi-crystalline polymer. It is dependent on thermal conditions during crystallization. In case of injection moulded parts melted polymer is injected from plasticizing unit into the injection mould where is then cooled and became solid. During the solidification the crystallization process occurs. The crystallinity degree of polymer in the moulded part is dependent on mould temperature and melt temperature. Both temperature values determine the cooling rate which is directly the reason of differences in crystalline structure. If the cooling rate is rapid, the conditions are not convenient for crystallization and more amorphous phase is

formed. In case of slow cooling the time of keeping polymer in temperature required

for crystallization is longer and this results in better formed crystalline structure. As the consequence – the crystallinity of injection moulded parts can

be influenced by processing conditions like mould temperature or melt temperature.When the mould temperature is higher the crystallinity degree of moulded parts is also higher. This causes also higher density of parts. The heat treatment of moulded parts, which is sometimes used to improve their properties,

is also the way of increasing the crystallinity degree. This feature of injection moulded parts influences directly their mechanical properties –parts of higher crystallinity degree have higher values of hardness, tensile strength, wear resistance and better dimension stability. There are publications that deal with

the influence of mould temperature on the crystallinity degree of injection moulded parts or their other properties [1]. However, usually they are focused

on parts from single-cavity moulds. It is supposed that in multicavity moulds all parts have the same crystallinity, but, as it was proved in some publications,

it can differ significantly across one part, for example being dependent on the distance from the gate (injection point). Considering this a question can be asked if the cavity location in the mould can impact crystallinity degree of parts.

In multi-cavity injection mould all cavities should be filled at the

same time. If not, the time of crystallization for different cavities would be different.The runner system plays a very important role in injection mould, especially during mould filling phase [2]. It is always a big effort made by mould designers to balance the flow in runners –it means that all cavities are filled simultaneously.

The runner system should be optimized [3].Among runner systems in

injection moulds two main kinds of balanced runners can be distinguished: ?artificially balanced runners,

?geometrically (naturally) balanced runners.

In artificially balanced runners the flow balance is achieved by design of runners cross-section. Since the flow length tothe cavities is different, the runners leading to closer cavities should have smaller cross-section. In this way melt reaches all cavities at the same time. In some cases it is possible to design only different cross-section of gates. Geometrically balanced runners are designed so

that the summary length of runners leading to each cavity is the same. This solution does not require different cross-section of runners, but has also disadvantage: more scrap in case of cold-runner moulds – the total volume of material solidified in runners is significantly bigger [4]. In the past the geometrically balanced runners were supposed to be a good solution considering the flow balance. However, some research works from the last decade proved that even in this solution some problems with achieving the flow balance can occur [5-[12]. The works were focused on flow imbalance and its counteraction rather than on the consequences, that are the differences in parts properties. The investigation of the influence of cavity filling

imbalance on injection moulded parts’ properties is needed. It will allow to estimate if differences between parts are so significant that correction of the mould is required. In practise, filling phase in injection moulding takes only a while usually a fraction of a second up to several seconds. Thus the filling imbalance has little influence on crystallization. More important can be the difference in mould temperature across the cavity. In this paper the injection mould with geometrically balances runners was tested. As it was shown in previous papers, the

geometrical balance did not assure the real balance during cavity filling [13]. The flow imbalance together with the differences in mould temperature contributed to differences in parts’ properties, like the structure and dynamic mechanical properties [13],[14]. In this paper the focus was on difference in crystallinity between parts from particular cavities.

2. E xperimental

For this investigation a multicavity injection mould was used. It was also used for investigation of other parts properties, as it was described in previous publications [13],[14]. Polyoxymethylene (POM) was injected into the mould and the crystallinity degree of parts from different cavities was calculated on the basis of DSC curves.

Among runner systems in injection moulds two main kinds of

balanced runners can be distinguished:

?artificially balanced runners,

?geometrically (naturally) balanced runners.

In artificially balanced runners the flow balance is achieved by design of runners cross-section. Since the flow length to the

cavities is different, the runners leading to closer cavities should have smaller cross-section. In this way melt reaches all cavities at the same time. In some cases it is possible to design only different

cross-section of gates.Geometrically balanced runners

are designed so that the summary length of runners

leading to each cavity is the same.

This solution does not require different cross-section of runners, but has also disadvantage: more scrap in case of cold-runner moulds –the total volume of material solidified in runners is significantly bigger [4]. In the past the geometrically balanced runners were supposed to be a good solution considering the flow balance. However, some research works from the last decade proved that even in this solution some problems with achieving the flow balance can occur [5-[12]. The works were focused on flow imbalance and its counteraction rather than on the consequences, that are the differences in parts properties. The

investigation of the influence of cavity filling imbalance on injection moulded parts’properties is needed. It will allow to estimate if differences between parts are so significant that correction of the mould is required.

In practise, filling phase in injection moulding takes only a while

– usually a fraction of a second up to several seconds. Thus the filling imbalance has little influence on crystallization. More important can

be the difference in mould temperature across the cavity.

In this paper the injection mould with geometrically balances runners was tested. As it was shown in previous papers, the

geometrical balance did not assure the real balance during cavity filling [13]. The flow imbalance together with the differences in mould temperature contributed to differences in parts’properties, like the structure and dynamic mechanical properties [13],[14]. In

this paper the focus was on difference in crystallinity between parts from particular cavities.

2. E xperimental

For this investigation a multicavity injection mould was used. It was also used for investigation of other parts properties, as it was described in previous publications [13],[14]. Polyoxymethylene (POM) was injected into the mould and the crystallinity degree of parts from different cavities was calculated on the basis of DSC curves.

2.1. Ma t erial

Polyoxymethylene (POM) was used for investigation. The grade was Sniatal M8 from Nyltech, Italy, with MFR = 48 g/10 min (2.16 kg, 190oC).

2.2. Machine

The mould was fixed in the injection moulding machine KRAUSS MAFFEI KM 65/160/C1 of the maximum clamping force 650 kN and the plasticizing unit with the screw of 30 mm diameter.

2.3. Injection mould

The moulded parts were manufactured in the experimental 16- cavity injection mould, described in earlier papers [13]-[18]. The parts are small plates (10.0x20.0x2.2mm) grouped in 4 sections, marked A, B, C and D. The layout of runners and cavities is shown in Fig. 1 on the example of short shots result, presented in previous publications. It was found that despite geometrically balanced runner system the cavities are not filled at the same time. The cavities placed around the sprue (numbered with “1”) are filled first. This area is exposed to higher local mould temperature, as it was proved in [16]. The sequence of

cavities filling in each section is shown in Fig. 1 by numbers 1-4.

Fig. 1. Short shots into the multicavity mould –inequality of cavities’ filling; A-D: cavity sections; 1-4: filling sequence

2.4. Processing condi tions

The processing conditions used for injection moulding are as follows: ?melt temperature: T inj = 210 oC

?mould temperature: T m = 35, 65 and 95 oC

?injection velocity: v = 32 mm/s

?holding pressure: p H=30 MPa

2.5. DSC t es ts

DSC test were carried out with the NETZSCH Phox DSC 200P apparatus.

The small pieces of material were cut out of the parts like it is shown in Fig.

2. The samples were taken to DSC measurements

with the skin-layer so the results present the average crystallinity

across the part thickness, together with this layer. The mass of parts was 20 ± 2 mg. The parts were taken from one section of the mould. Fig. 2 shows the numeration of cavities in this section

according the sequence of their filling (1-4). Five samples from each cavity were taken for DSC tests.

Fig. 2. Cutting out of samples from injection moulded parts

During DSC tests the temperature was increased with the rate of 10°C/min. After obtaining the DSC curves the crystallinity degree S k was calculated. It was defined as below:

3. Results and discussion

3.1. DSC curv es

The obtained curves were similar for samples coming from parts from the same cavity. Three exemplary DSC curves of samples from part no. A1 are presented

in Fig. 3. The melt enthalpy for each curve was calculated using the NETZSCH DSC software.

Fig. 3. Exemplary DSC curves

3.2. Crystallinity degr ee

The results of crystallinity degree calculation for parts obtained at different mould temperature are presented in Fig. 4. Beyond discussion is that for each cavity the mould temperature, that was adjusted

at values: 35, 65 and 95°C (measured and controlled in one point), has significant influence on this property. The local mould temperature impact is

also visible. The crystallinity degree values are the highest for cavities

no. 1, exposed to higher local mould temperature.

Fig. 4. Crystallinity degree for samples from different cavities

4. Conclusions

Polyoxymethylene parts from a multicavity injection mould with geometrically balanced runner differ in crystallinity degree. The main reason of it is

different mould temperature for the particular cavities. It is important to place

the cavities in the way that each part is under the same cooling conditions. Otherwise the problems in parts quality can occur like different shrinkage, warpage and other properties. Such a problem is caused by particular cavities

layout that determines exposition of some cavities for higher temperature coming

from heated sprue. When small tolerance of injection moulded parts’ properties

is required, another runner system configuration in the mould should be used or

local cooling conditions should be improved by cooling channels redesign.

Ac k no wledgements

This work was financially supported from Polish Ministry of Scientific Research and Information Technology. Budget for science in years 2005-2006; Grant number: 3 T08E 032 28

Re fer ences

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多腔注塑模具零件的结晶度

文摘

目的:本研究的目的是测试,如果注入聚甲醛模制件,生产在不同腔多腔注射模的几何平衡的滑道,不同结晶度的程度。

设计/方法/方式:结晶度学位的价值的基础上计算DSC(动态扫描量热法)检测方法结果(DSC 曲线)。

发现:发现结晶度程度有差异的部分特定的模腔。这样做的原因是热条件的不同,具体为每个腔。

研究局限性/意义:它应该从每个部分多腔注塑模具性能的差异。然而,它总是依赖膜腔和孔洞的布局。因为在这个研究一个特定的注塑模具,结论不能直接外推到其他模具。每一次需要自己的分析。高结晶度程度将发生在部分输送领域更高的模具温度。

实际意义:本次调查的结果对模具设计师很重要,特别是当模具用于精密注塑成型。这里被证明差异部分的属性可以出现多腔注入模具。为了避免这种情况应减少模具的温度差异。

创意/价值:模具的几何平衡的滑道应该保证所有人的平等的填充孔洞。由其他研究人员最近获得的结果显示,这并不总是真的。调查主要是集中在充填不平衡,例如不同重量的部分从不同的孔洞。本文结果表明,不仅可以不同重量的部分,而且其他属性。

关键词:塑料成型、注塑、结晶度的程度

1.介绍

结晶度的聚合物结晶相的比例是半晶状的聚合物的一个示例。这是依赖在结晶热条件。注射模的部分融化从塑化单元聚合物注入到注塑模具,然后冷却,成为固体。在凝固结晶过程中发生。聚合物的结晶度程度模压部分依赖于模具温度、熔体温度。两个温度的值确定的冷却速率直接晶体结构的差异的原因。如果冷却速度快,条件不方便形成结晶和无定形的阶段。在缓冷温度保持聚合物结晶所需的时间较长,这将导致更好的晶体结构形成。后果——注塑零件的结晶度可以受工艺条件如模具温度或熔体温度。当模具温度越高结晶度模压部分程度也更高。这也导致更高密度的部分。型零件的热处理,有时被用来改善他们的属性,也是增加结晶度的程度。这个特性的注塑零件直接影响其力学性能,较高的结晶度程度有较高的硬度值,抗拉强度、耐磨性和尺寸稳定性更好。有些出版物处理模具温度对结晶度的影响程度的注塑零件或其他属性[1]。然而,通常他们都专注于从单穴模具零件。据推测在多腔模具各部分有相同的结晶度,但是,因为它被证明在某些出版物,它可以跨一个部分显著差异,例如依赖的距离门(注射点)。考虑这一个问题可以问模具的腔的位置会影响结晶度的部分。

多型腔注射模在所有孔洞应了相同的时间。如果不是,结晶时间对不同孔洞就会不同了。滑道在注塑模具系统起着非常重要的作用,特别是在模具填充阶段[2]。它始终是一个巨大的努力由模具设计师平衡流在滑道——它同时意味着所有孔洞了。

优化流道系统[3]。流道系统中

注射模具的两个主要类型的平衡的滑道可以区分:

?人工平衡的滑道,

?几何(自然)平衡的滑道。

在人为的平衡的滑道的流动资产是通过设计截面。自从流长度到孔洞是不同的,导致近腔的滑道应该较小的截面。通过这种方式达到所有孔洞同时融化。在某些情况下可以设计不同截面

的大门。几何滑道设计,以便总结流动导致每个空腔长度是相同的。这个解决方案不需要不同截面的滑道,但也有缺点:废弃的冷流道模具——材料凝固在滑道的总量明显更大的[4]。过去几何平衡滑道应该是一个很好的解决方案考虑流动平衡。然而,一些研究工作从过去十年证明了即使在这种解决方案与实现流动资产可能发生一些问题[5 -[12]。作品关注的是流不平衡及其反动而不是结果,部分属性的差异。调查的影响腔充填不平衡注塑零件的属性是必需的。它将使估计如果差异部分非常重要,需要修正模具。在练习,充盈期在注塑通常只需要一段时间几分之一秒到几秒钟。因此,充填不平衡对结晶的影响不大。更重要的是可以在腔模具温度的差异。本文的注塑模具几何滑道进行了测试。是以前的论文,所示的几何平衡不保证真正的平衡在空腔填充[13]。流动失衡与模具温度的差异导致了不同的部件的属性,如结构和动态力学性能[13],[14]。本文的重点是部件之间的结晶度差异特别孔洞。

2。实验

对于这次调查多腔注塑模具使用。它也被用于调查的其他部分属性,就像以前的出版物中描述[13],[14]。聚甲醛(POM)注入模具和结晶度不同程度的部分腔的基础上计算了DSC曲线。

在注射模具流道系统两个主要类型的

滑道可以区分:

?人工滑道,

?几何(自然)平衡的滑道。

在人为的平衡的运动员跑步者的流动资产是通过设计截面。因为流长度

孔洞是不同的,导致近腔的滑道应该较小的截面。通过这种方式达到所有孔洞同时融化。在某些情况下可以设计不同盖茨的横截面。几何滑道设计,以便总结跑步导致每个空腔长度是相同的。

这个解决方案不需要不同截面的滑道,但也有缺点:废弃的冷流道模具——材料凝固在跑步者的总量明显更大的[4]。过去几何平衡跑步者应该是一个很好的解决方案考虑流动平衡。然而,一些研究工作从过去十年证明了即使在这种解决方案与实现流动资产可能发生一些问题[5 -[12]。作品关注的是流不平衡及其反动而不是结果,部分属性的差异。的

调查的影响腔充填不平衡注塑零件的属性是必需的。它将使估计如果差异部分非常重要,需要修正模具。

在练习,充盈期在注塑只需要一段时间

——通常是几分之一秒到几秒钟。因此,充填不平衡对结晶的影响不大。更重要的是可以

是整个腔模具温度的差异。

本文的注塑模具几何平衡跑步者进行了测试。这是以前的文件所示,

几何平衡不保证真正的平衡在空腔填充[13]。流动失衡与模具温度的差异导致了不同的部件的属性,如结构和动态力学性能[13],[14]。在

本文的重点是部件之间的结晶度差异特别孔洞。

2。实验

对于这次调查多腔注塑模具使用。它也被用于调查的其他部分属性,就像以前的出版物中描述[13],[14]。聚甲醛(POM)注入模具和结晶度不同程度的部分腔的基础上计算了DSC曲线。2.1。材料

聚甲醛(POM)是用于调查。等级从Nyltech Sniatal M8、意大利MFR = 48 g / 10分钟(2.16公斤,190oC)。

2.2。机器

注塑成型机的模具是固定的克劳斯?马斐公里65/160 / C1最大锁模力650 kN,30毫米直径的螺杆塑化单元。

2.3。注塑模具

模制部件制造的实验16 -腔注塑模具,在早些时候描述论文[13]-[18]。部分小板(10.0 x20.0x2.2mm)分为4部分,标记A,B,C和d .滑道和孔洞的布局图1所示的示例的短镜头效果,提出了在以前的出版物。发现,尽管几何平衡流道系统孔洞不同时。孔洞周围放置浇道(编号“1”)都是第一。这个地区暴露在更高的地方模具温度,证明在[16]。孔洞的顺序填写每个部分由数字1 - 4图1所示。

图1。短镜头多腔模具——不平等的孔洞的充填;模拟:腔部分;1 - 4:填充序列

2.4。加工条件

用于注塑的工艺条件如下:

?融化温度:Tinj = 210oC

?模具温度:Tm = 65和95oC

?注入速度:v = 32 mm / s

?保持压力:pH = 30 MPa

2.5。DSC测试

DSC测试进行了与NETZSCH Phox DSC 200 p的装置。

材料的小块的零部件,如图2所示。这些样本被送往DSC测量

与皮肤层,结果现在平均结晶度

在部分厚度,加上这一层。质量的部分是20±2毫克。模具的部分被从一个部分。图2显示了孔洞在这部分的计算

根据序列的填充(1 - 4)。五个样品从每个腔被DSC测试。

图2。从注塑零件切割的样品

在DSC测试温度增加的速度10°C /分钟。在获得结晶度学位Sk的DSC曲线计算。这是定义如下:

3。结果与讨论

3.1。DSC曲线

获得的曲线相似的样本来自部分相同的空腔。三个模范DSC曲线的部分样本。A1呈现在图3。熔化焓为每个使用NETZSCH DSC曲线计算软件。

图3。的DSC曲线

3.2。结晶度程度

的结晶度度计算结果部分介绍了在不同的模具温度在图4。讨论之外,对于每个腔模具的温度,调整后的值:35岁,65和95°C(测量和控制在一个点),对这个属性有很大的影响。当地的模具温度的影响也可见。孔洞的结晶度度值是最高的。1、接触到更高的地方模具温度。

图4。结晶度程度为样本不同的孔洞

4。结论

聚甲醛部分从多腔注塑模具与几何平衡流道不同结晶度的程度。它是不同的模具温度的主要原因为特定孔洞。把孔洞是很重要的,每一部分是相同的冷却条件下。否则零件质量问题发生就像不同的收缩,弯曲和其他属性。这样的问题是由于特定的一些孔洞布局决定博览会更高的

温度来自热浇道。当小公差注塑零件的属性是必需的,其他滑道应该使用系统配置的模具或局部冷却条件应该提高了冷却通道设计。

确认

这项工作从波兰经济支持科学研究和信息技术。预算在2005 - 2006年科学;格兰特数量:3 T08E 032 28

引用

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