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塑料模具材料開裂分析及解決對策

1

基本數(shù)據(jù)

2

調(diào)查結(jié)果

2.1.可見一處開裂，開裂部附件的成型面可見因漏水而形成的褐色銹跡；

2.2.通過金相分析材料無異常，熱處理硬度在最高限度范圍內(nèi)；

2.3.冷卻水孔的地方可見應(yīng)力腐蝕開裂。

3

原因分析

3.1在成型豎立面可見橫裂紋，是以背后冷卻水孔A的應(yīng)力腐蝕開裂部為起點，延伸到成型面；

3.2成型面的豎立面到背后冷卻水孔A的壁厚約4MM較薄，對模具的剛性差。

4

分析圖片

成型面?zhèn)龋☉?yīng)力腐蝕開裂）

5

解決對策

5.1加厚冷卻水孔A部的壁厚，對于冷卻水孔直徑D的目標(biāo)，能否將其壁厚改為1～1.5D左右；

5.2變更回火條件，對于耐應(yīng)力腐蝕，中溫回火（350～400℃）比現(xiàn)在施行的高溫回火（500℃）更有利。

ABS注塑件怎么才能增加光亮度

在注塑生產(chǎn)中，塑件光澤不良的主要是：模具、注塑工藝、原料這三方面的原因。以下就此問題作如下簡述，歡迎指正評論!

一、注塑模具

1.模具型腔加工不良

如模具型腔有傷痕、微孔、磨損、粗糙等不足，勢必會反應(yīng)到塑件上，使塑件光澤不良，對此，要精心加工模具，使型腔表面有較小的粗糙度，必要時可拋光鍍鉻。2.型腔表面污漬

如型腔表面有油污、水漬，或脫模劑使太多，會使塑件表面發(fā)暗、沒有光澤，對此，要及時清除油污和水漬，并限量使用脫模劑。

3.塑件脫模斜度太小

脫模斜度太小會造成脫模困難，或脫模時受力過大，使塑件表面光澤*佳，對此，要加大脫模斜度。

4.模具排氣不良

若排氣不良會造成過多氣體停留在模型內(nèi)，也會導(dǎo)致光澤不良，對此，要檢查和修正模具排氣系統(tǒng)。

5.澆口或流道設(shè)計不當(dāng)

澆口或流道截面積過小或突然變化，熔體在其中流動時受剪力作用太大，呈湍流動態(tài)流動，導(dǎo)致光澤不良，對此，應(yīng)適當(dāng)加大澆口和流道截面積。

二、注塑工藝

1.注射速度過小

注射速度過小造成塑件表面不密實，顯現(xiàn)光澤不良，對此，可適當(dāng)提高注射速度。2.塑件冷卻不充分

如對于厚壁塑件冷卻不充分，其表面會發(fā)毛，光澤偏暗，對此，應(yīng)改善冷卻系統(tǒng)。

3.保壓操作不當(dāng)

如保壓壓力過小、保壓時間太短，使塑件密度不夠而光澤不良，對此，應(yīng)增大保壓壓力和保壓時間。

4.若熔體溫度過低

當(dāng)熔體流動過低時，使得流動性較差，易導(dǎo)致光澤不良，對此，應(yīng)適當(dāng)提高熔體溫度。

5.結(jié)晶樹脂冷卻不均勻

如PE、PP、POM等制作的塑件，如冷卻不均勻會導(dǎo)致光澤不良，對此，應(yīng)改善冷卻系統(tǒng)，使之均勻冷卻。

6.注射速度與澆口面積不匹配

如注塑速度過大，而澆口截面積又過小，則澆口附近會發(fā)暗而光澤不良，對此，可適當(dāng)降低注射速度和增大澆口截面積。

三、原材料

1.原材料粒度差異較大

粒度差異較大使得難以均勻塑化，而光澤不良，對此，應(yīng)將原材料進行篩分處理。

2.原料中二次料太多

如再生料或水口料加入太多，影響熔體的均勻塑化而光澤不良，對此，應(yīng)減少再生料或水口料加入量。

3.原料耐溫性不良

有些原材料在調(diào)溫時會分解變色導(dǎo)致光澤不良，對此，應(yīng)選用耐溫性較好的原材料。

4.原材料中含有易揮發(fā)物

如原料中水分或易揮發(fā)物含量過高，受熱時揮發(fā)成氣體，在型腔和熔體中凝縮，導(dǎo)致塑件光澤不良，對此，應(yīng)對原材料進行預(yù)干燥處理。

5.添加劑的分散性不好

有些添加劑的分散性太差而使塑件光澤不良，對此，應(yīng)改用流動性能較好的添加劑。

6.原材料不純

如原料中混有異物，雜料或不相溶的物料，它們不能與其原料均勻混熔在一起而導(dǎo)致光澤不良，對此，應(yīng)事先嚴格排除這些雜料。

7.潤滑劑用量過少

如潤滑劑用量太少，熔體的流動性較差，塑件表面不致密，使得光澤不良，對此，應(yīng)適當(dāng)增加潤滑劑的用量。

所以，也要根據(jù)你的模具拋光度是否達到要求，如果模具本身沒有問題的話，要確定你的ABS的特性來確定，可以選擇高模溫，高速高壓;用冷凍水也能達到光潔度。

PA6 (polyamide # nylon 6)/B 240 / Taroplas 
Purpose: other 
Features: low viscosity, good lubrication, good uv resistance, thermal stability, fast production. 
Important parameters: the melt flow rate: the 25 g / 10 min density: 1.13 g/cm3 bibulous rate: 12% molding shrinkage rate: 1.1% notched impact strength: 3 oxygen index: 23% tensile strength: 70 MPa elongation at break: 100% bending strength: 105 MPa bending modulus: 2750 MPa vicat softening point: 210 ℃ heat distortion temperature: 74 ℃ 
Manufacturer: Italian Taroplast thermoplastic engineering plastics co. LTD 
PA6 (polyamide # nylon 6) / 6G50AFHUV/deutschland 
Purpose: other 
Properties note: glass fiber reinforced material, 50% packing press weight, anti-uv performance good, good fluidity, thermal stability 
Important parameters: the density: 1.56 g/cm3 molding shrinkage rate: 0.4% notched impact strength, tensile strength: 210 MPa elongation at break: 2% bending strength: 320 MPa bending modulus: 14000 MPa vicat softening point: 215 ℃ heat distortion temperature: 210 ℃ 
Manufacturer: deutschland deutschland LTD 
PA6 (polyamide # nylon 6)/B3 GF 504 RM - M black (3221)/German akro-plastic 
USES: electronic electrical parts, automobile parts 
Important parameters: the density: 1.6 g/cm3 molding shrinkage rate: 0.3% notched impact strength: 20 tensile strength: 210 MPa bending strength: 320 MPa bending modulus: 16800 MPa thermal deformation temperature: 205 ℃ 
Manufacturer: akro-plastic, Germany 
PA6 (polyamide # nylon 6) / 136F6Q31H/Austria SAX 
Purpose: other 
Characteristics: improved impact resistance, high strength, high impact resistance and thermal stability 
Important parameters: the density: 1.27 g/cm3 notched impact strength: 18 tensile strength: 100 MPa elongation at break: 4% bending strength: 153 MPa bending modulus: 5100 MPa vicat softening point: 193 ℃ heat distortion temperature: 191 ℃ 
Manufacturer: Austria SAX polymer industrial co. LTD 
PA6 (polyamide # nylon 6)/SFRWGB208H BLACK 8229 / French AD majoris 
USES: automotive parts, electronic components 
Features: good surface finish, halogen free, flame retardant performance, glass fiber reinforced 25% 
Important parameters: the density: 1.35 g/cm3 bibulous rate: 1% molding shrinkage rate: 0.4% notched impact strength: 36 tensile strength: 70 MPa elongation at break: 2.5% bending modulus: 5400 MPa thermal deformation temperature: 193 ℃ 
Manufacturer: AD majoris of France 
PA6 (polyamide # nylon 6)/NST60P90L/Italian rantiche 
Purpose: other 
The characteristics are: through plasticizing, good melt strength, good flexibility, good chemical resistance and good toughness 
Important parameters: the density: 1.06 g/cm3 bibulous rate: 1.5% notched impact strength, tensile strength of 800:48.3 MPa elongation at break: 100% bending strength, bending modulus of the 20.7 MPa, 448 MPa, thermal deformation temperature of 40.6 ℃ 
Manufacturer: rantich engineering plastics co. LTD 
PA6 (polyamide # nylon 6)/S RV300R/Italian lantiche 
Purpose: other 
Characteristic remarks: good size stability, high rigidity, good impact resistance, glass fiber reinforced material 30% packing press weight 
Important parameters: the density: 1.36 g/cm3 bibulous rate: 6.7% notched impact strength, tensile strength: 175 MPa elongation at break: 3.8% vicat softening point: 210 ℃ heat distortion temperature: 200 ℃ 
Manufacturer: rantich engineering plastics co. LTD 
PA6 (polyamide # nylon 6) / 1900 / carele million 
Purpose: automobile parts 
Features: high impact strength, high rigidity, good surface finish, low temperature impact, oil resistance, glass fiber reinforced material 45% packing press weight 
Important parameters: the density: 1.53 g/cm3 molding shrinkage rate: 0.1% notched impact strength: 230 tensile strength: 190 MPa elongation at break: 2.5% bending strength: 280 MPa bending modulus: 11500 MPa thermal deformation temperature: 205 ℃ 
Manufacturer: kelleyimei engineering plastics (Malaysia) co. LTD 
PA6 (polyamide # nylon 6)/PA6G40HSL - BK10 / American Pier One 
Purpose: other 
Feature note: the glass fiber reinforced material 40% packing by weight, lubrication and heat stability 
Important parameters: the density: 1.45 g/cm3 notched impact strength: 130 tensile strength: 207 MPa elongation at break: 3% bending strength: 290 MPa bending modulus: 10300 MPa thermal deformation temperature: 210 ℃ filler content: 38% 
Manufacturer: Pier One, USA 
PA6 (polyamide # nylon 6) / 2326 UV/us Nycoa 
Purpose: other 
Features: improved anti-impact, high rigidity, good rigidity, high impact resistance, good anti-uv performance, good processability, good chemical resistance and good toughness. 
Important parameters: the density: 1.06 g/cm3 bibulous rate: 1.7% molding shrinkage rate: 1.4% notched impact strength, tensile strength of 850:50 MPa elongation at break: 75% bending strength, bending modulus of the 58.6 MPa, 1540 MPa hardness: 118 thermal deformation temperature: 48.9 ℃ 
Manufacturer: Nycoa, USA 
 
 
 
 
 
PA6 (polyamide # nylon 6) / 4112 FR/American Nycoa 
Purpose: automobile parts 
Feature note: glass fiber reinforced 12%. Features: good dimensional stability, high rigidity, good melt strength, resistance to hydrocarbons, oil resistance, grease resistance, high viscosity, flame retardancy. 
Important parameters: the density: 1.32 g/cm3 bibulous rate: 1% molding shrinkage rate: 0.4% notched impact strength, tensile strength of 130:75.2 MPa elongation at break: 15% bending strength, bending modulus of the 86.2 MPa, 3030 MPa hardness: 120 thermal deformation temperature: 204 ℃ 
Manufacturer: Nycoa, USA 
PA6 (polyamide # nylon 6)/HN301 - G30F/beihua hospital 
USES: electronic electrical components 
Features: high heat resistance, rigidity, good weather resistance and so on 
Important parameters: the density: 1.38 g/cm3 bibulous rate: 1.13% molding shrinkage rate: 0.4% notched impact strength, elongation at break: 3.5% bending strength: 195 MPa thermal deformation temperature: 200 ℃ 
Manufacturer: Beijing chemical industry research institute (enterprise group) 
PA6 (polyamide # nylon 6)/ASN 27 300 SR UV/us Nycoa 
Purpose: other 
Feature note: fiberglass increases by 30%. Characteristics: good dimensional stability, good rigidity, good strength, good chemical resistance, hydrocarbon resistance, oil resistance and grease resistance. 
Important parameters: the density: 1.35 g/cm3 bibulous rate: 1.2% molding shrinkage rate: 0.3% notched impact strength: 850 tensile strength: 150 MPa elongation at break: 3% bending strength: 210 MPa bending modulus: 7910 MPa hardness: 120 thermal deformation temperature: 210 ℃ 
Manufacturer: Nycoa, USA 
PA6 (polyamide # nylon 6)/PA - 213XO12 / clariant chemical 
Purpose: other 
Characteristics: properties: copolymer, good impact resistance, good melt strength, good flexibility, good abrasion resistance, thermal stability, good toughness. 
Important parameters: the density: 1.08 g/cm3 bibulous rate: 1.2% molding shrinkage rate: 1.3% notched impact strength, tensile strength: 53 45.5 MPa elongation at break: 200% bending strength, bending modulus of the 46.2 MPa, 1170 MPa hardness: 40 thermal deformation temperature: 46.1 ℃ 
Manufacturer: clariant chemical group 
PA6 (polyamide # nylon 6)/b25r-1-nc/Shanghai day crystal 
Purpose: other 
Feature note: it can be removed at high speed, suitable for all kinds of electronic electrical connection plug-in and bearing, gear, CAM roller, pulley, nut, gasket, high pressure tubing, oil storage container and other industrial parts. 
Important parameters: the density: 1.13 g/cm3 bibulous rate: 9% molding shrinkage rate: 0.7% notched impact strength: 4.8 tensile strength: 77 MPa bending strength: 119 MPa bending modulus: 2631 MPa thermal deformation temperature: 67 ℃ 
Manufacturer: Shanghai suncrystal engineering plastic technology co. LTD 
PA6 (polyamide # nylon 6)/B 280 X0 / Italian Taroplas 
Purpose: other 
Characteristics: good fluidity, thermal stability, good stripping performance, medium viscosity, self-extinguishing, flame retardant property. 
Important parameters: the density: 1.21 g/cm3 bibulous rate: 1.4% molding shrinkage rate: 1% notched impact strength: oxygen index 2.8:29% tensile strength: 66 MPa elongation at break: 6% bending strength: 100 MPa bending modulus: 3000 MPa vicat softening point: 200 ℃ heat distortion temperature: 72 ℃ 
Manufacturer: Italian Taroplast thermoplastic engineering plastics co. LTD 
PA6 (polyamide # nylon 6)/B 280 Y0 / Italian Taroplas 
Purpose: other 
Characteristics: low density, good fluidity, phosphorus content, low (to no), electrothermal resistance, thermal stability, no halogen, medium viscosity, self-extinguishing. 
Important parameters: the density: 1.16 g/cm3 bibulous rate: 1.4% molding shrinkage rate: 1% notched impact strength: 3 oxygen index: 34% tensile strength: 65 MPa elongation at break: 8% bending strength: 110 MPa vicat softening point: 200 ℃ heat distortion temperature: 80 ℃ 
Manufacturer: Italian Taroplast thermoplastic engineering plastics co. LTD 
PA6 (polyamide # nylon 6)/NB NB40 GR20 NL XA20 / Turkey Eurotec 
Purpose: other 
Properties note: glass fiber reinforced material, 20% packing press weight, thermal stability, flame retardant property 
Important parameters: the density: 1.47 g/cm3 bibulous rate: 2% molding shrinkage rate: 1% notched impact strength, vicat softening point: 210 ℃ heat distortion temperature: 205 ℃ 
Manufacturer: Eurotec, Turkey 
PA6 (polyamide # nylon 6)/B3 GK 30 1 L black (4674)/German akro-plastic 
USES: electronic electrical parts, automobile parts 
Important parameters: the melt flow rate: 30 g / 10 min density: 1.25 g/cm3 molding shrinkage rate: 0.7% notched impact strength, tensile strength: 3.5 45 MPa thermal deformation temperature: 66 ℃ 
Manufacturer: akro-plastic, Germany 
PA6T (polyphthalylhexylenediamine #)/G335 / mitsui chemistry 
Purpose: other 
Feature note: 35% glass fiber reinforced 
Important parameters: the density: 1.47 g/cm3 bibulous rate: 0.3% molding shrinkage rate: 0.2% notched impact strength: 100 tensile strength: 200 MPa elongation at break: 3% bending strength: 340 MPa bending modulus: 11000 MPa thermal deformation temperature: 280 ℃ filler content: 35% 
Manufacturer: mitsui chemical plant type