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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(yán)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(dá)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(dá)到光潔度。

PA6 (polyamide # nylon 6)/nb40 kk30 NL IL/German milos
USES: automotive parts, electronic components
Remarks: low warping, anti-impact resistance and impact resistance, good electrical performance, good toughness and medium hardness
Important parameters: the density: 1.32 g/cm3, bibulous rate is: molding shrinkage ratio 5.5% : 1.1% : 5 ℃ notched impact strength, vicat softening point deprives the thermal deformation temperature: 180 ℃
Manufacturer: milos, Germany
PA6 (polyamide # nylon 6)/nb40 GR20 NL XC 50 / German milos
USES: automotive parts, electronic components
Characteristics note: anti-impact resistance, good electrical performance, high phosphorus content, low (to no), good toughness, halogen-free, medium hardness, flame retardant properties
Important parameters: the density: 1.33 g/cm3, bibulous rate is: 7% molding shrinkage rate: 1%, 0 ℃ notched impact strength, vicat softening point "thermal deformation temperature: 205 ℃
Manufacturer: milos, Germany
PA6 (polyamide # nylon 6) / 20/20/20/12/ibiss GF30 UV
Purpose: other
Feature note: fiberglass increases by 30%. Performance characteristics: high rigidity, good anti-ultraviolet, good fluidity, high heat resistance, good stripping performance.
Important parameters: the density: 1.36 g/cm3, notched impact strength, tensile strength: 170 MPa elongation at break: 3.5% bending strength: 240 MPa bending modulus: 8000 MPa vicat softening point: 200 ℃ heat distortion temperature: 200 ℃
Manufacturer: abbe plastic co. LTD
PA6 (polyamide # nylon 6)/NG GF 45 SGF/Slovakia
USES: automotive parts, electric tools accessories, electronic electrical components
Properties note: high toughness, high strength, chemical coupling
Important parameters: the melt flow rate, density of 4 g / 10 min: 1.49 g/cm3, molding shrinkage rate: 0.58%, "0 MPa, the bending modulus of the notched impact strength, bending strength: 12800 MPa vicat softening point: 210 ℃ heat distortion temperature: 210 ℃
Manufacturer: Slovakia
PA6 (polyamide # nylon 6)/natural/French rodia 60g1 V30
Purpose: other
Characteristics note: machinability, good and good electrical performance high thermal stability flame retardant property
Important parameters: the density: 1.42 g/cm3, bibulous rate is: 0.9% molding shrinkage rate: 0.7%, 9.6, 2.5% notched impact strength, elongation at break bending strength: 240 MPa bending modulus: 10500 MPa thermal deformation temperature: 205 ℃
Manufacturer: rodia, France
PA6 (polyamide # nylon 6)/SX 218 V50 black 38n-k/France rodia
Purpose: other
Characteristic note: rigid, high and good surface smoothness and high thermal stability
Important parameters: the density: 1.55 g/cm3, bibulous rate is: 0.72% molding shrinkage rate: 0.33%, of the 5% notched impact strength, elongation at break bending strength: 320 MPa bending modulus: 14000 MPa thermal deformation temperature: 210 ℃
Manufacturer: rodia, France
PA6 (polyamide # nylon 6) / 01b30-gf/hangzhou nanmu
Purpose: other
Feature remark: the mechanical type of this product can be excellent, and the fluidity and molding are prominent. The reinforced product with 30% glass fiber is highly rigid and the surface is better after injection.
Important parameters: the density: 1.36 g/cm3, bibulous rate is: 1.25% : 0.4% : 166 MPa molding shrinkage rate tensile strength, elongation at break: 2% bending strength, bending modulus of the 259.7 MPa, 7840 MPa hardness: 121 thermal deformation temperature: 220 ℃
Manufacturer: hangzhou nanmu chemical co. LTD
PA6 (polyamide # nylon 6)/B 240 y0 / Italian taroplas
Purpose: other
Characteristics: low density, phosphorus content, low (to no), high fluidity, electric resistance, thermal stability, without halogen, self-extinguishing.
Important parameters: the density: 1.16 g/cm3, bibulous rate is: 1.4% molding shrinkage rate: 1%, 2.7, 34% notched impact strength of oxygen index, the tensile strength: 77 MPa elongation at break: 8% bending strength: 105 MPa bending modulus: 3100 MPa vicat softening point: 204 ℃ heat distortion temperature: 80 ℃
Manufacturer: Italian taroplast thermoplastic engineering plastics co. LTD
PA6 (polyamide # nylon 6)/B 280 MT5 Y2 / Italian taroplas
Purpose: other
Feature remark: mineral filler 25%. Characteristics: good fluidity, halogen-free flame retardancy.
Important parameters: the density: 1.37 g/cm3, bibulous rate is: 1.5% : 0.6% : 3 molding shrinkage notched impact strength, tensile strength: 75 MPa elongation at break: 3.5% bending strength: 115 MPa bending modulus: 440 MPa vicat softening point: 200 ℃ heat distortion temperature: 170 ℃
Manufacturer: Italian taroplast thermoplastic engineering plastics co. LTD
PA6 (polyamide # nylon 6)/niobium nb40 GR20 NL xc50 / Turkey
Purpose: other
Properties note: glass fiber reinforced material, 20% packing press weight, thermal stability, no halogen, flame retardant property
Important parameters: the density: 1.35 g/cm3, bibulous rate is: 2% molding shrinkage rate: 1%, but the notched impact strength, vicat softening point 0 ℃ heat distortion temperature: 205 ℃
Manufacturer: Turkish company
PA6 (polyamide # nylon 6)/PA6 - ii/rich da plasticization
Purpose: other
Features note: through the mineral filler of nylon 6 and reinforced fiberglass, improves the heat resistance of nylon 6, mechanical properties and dimensional stability, reduce the molding shrinkage rate, linear expansion coefficient.
Important parameters: the density: 1.21 g/cm3, notched impact strength, tensile strength of 50:85 MPa bending strength: 150 MPa bending modulus: 3500 MPa thermal deformation temperature: 170 ℃
Manufacturer: cixi affluent da plasticization co. LTD
PA6 (polyamide # nylon 6)/PA6 - iii/rich to plasticize
Purpose: other
Features note: through the mineral filler of nylon 6 and reinforced fiberglass, improves the heat resistance of nylon 6, mechanical properties and dimensional stability, reduce the molding shrinkage rate, linear expansion coefficient.
Important parameters: