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1、TheInjectionMoldingTheIntroductionofMoldsThemoldisattheceofaplasticmanufacturingprocessbecauseitscavitygivesapartitsshape.Thismakesthemoldatleastascriticalmanycasesmesofthequalityoftheendproductasfexampletheplasticitingu
2、nitothercomponentsoftheprocessingequipment.MoldMaterialDependingontheprocessingparametersfthevariousprocessingmethodsaswellasthelengthoftheproductionrunthenumberoffinishedproductstobeproducedmoldsfplasticsprocessingmusts
3、atisfyagreatvarietyofrequirements.Itistherefenotsurprisingthatmoldscanbemadefromaverybroadspectrumofmaterialsincludingfromatechnicalstpointsuchexoticmaterialsaspapermatchedplaster.Howeverbecausemostprocessesrequirehighpr
4、essuresoftencombinedwithhightemperaturesmetalsstillrepresentbyfarthemostimptantmaterialgroupwithsteelbeingthepredominantmetal.Itisinterestinginthisregardthatinmanycasestheionofthemoldmaterialisnotonlyaquestionofmaterialp
5、ropertiesanoptimumpricetoperfmanceratiobutalsothatthemethodsusedtoproducethemoldthustheentiredesigncanbeinfluenced.Atypicalexamplecanbeseeninthechoicebetweencastmetalmoldswiththeirverydifferentcoolingsystemscomparedtomac
6、hinedmolds.Inadditiontheproductiontechniquecanalsohaveaneffectfinstanceitisoftenreptedthatfthesakeofsimplicityaprototypemoldisfrequentlymachinedfromsolidstockwiththeaidofthelatesttechnologysuchascomputeraided(CAD)compute
7、rintegratedmanufacturing(CIMS).IncontrasttothepreviouslyusedmethodsbasedontheuseofpatternstheuseofCADCAMoftenrepresentsthemeeconomicalsolutiontodaynotonlybecausethisproductioncapabilityisavailablepinhousebutalsobecausewi
8、thanyothertechniqueanderwouldhavetobeplacedwithanoutsidesupplier.Overallalthoughhighgradematerialsareoftenusedasarulestardmaterialsareusedinmoldmaking.Newstateoftheart(highperfmance)materialssuchasceramicsfinstancearealm
9、ostcompletelyabsent.Thismayberelatedtothefactthattheirdesirableacteristicssuchasconstantpropertiesuptoveryhightemperaturesarenotrequiredonmoldswhereastheirnegativeacteristicse.g.lowtensilestrengthpothermalconductivityhav
10、eaclearlyrelatedtoceramicssuchassinteredmaterialisfoundinmildmakingonlytoalimiteddegree.Thisreferslesstothemodernmaterialscomponentsproducedbypowdermetallurgypossiblybyhotisocraticpressingthantosinteredmetalsinthesenseof
11、pousairpermeablematerials.singlecavitymold.Converselytheproductionincreasesinproptiontothenumberofcavities.Amoldwithmecavitiesismeexpensivetobuildthanasinglecavitymoldbutnotnecessarily4timesasmuchasasinglecavitymold.Buti
12、tmayalsorequirealargermachinewithlargerplatenareameclampingcapacitybecauseitwilluse4timestheamountofplasticitmayneedalargeinjectionunitsothemachinehourcostwillbehigherthanfamachinelargeenoughfthesmallermold.3.Cavityshape
13、shrinkageTheshapeofthecavityisessentiallythe“negative”oftheshapeofthedesiredproductwithdimensionalallowanceaddedtoallowfshrinkingoftheplastic.Theshapeofthecavityisusuallycreatedwithchipremovingmachinetoolswithelectricdis
14、gemachiningwithchemicaletchingbyanynewmethodthatmaybeavailabletoremovemetalbuilditupsuchasgalvanicprocesses.Itmayalsobecreatedbycastingcertainmetalsinplastermoldscreatedfrommodelsoftheproducttobemadebycastingsomesuitable
15、hardplastics.Thecavityshapecanbeeithercutdirectlyintothemoldplatesfmedbyputtingsintotheplates.C.CavityceByconventionthehollowptionofthecavityspaceiscalledthecavity.Thematchingoftenraisedptionofthecavityspaceiscalledthece
16、.Mostplasticproductsarecupshaped.Thisdoesnotmeanthattheylooklikeacupbuttheydohaveaninsideanoutside.Theoutsideoftheproductisfmedbythecavitytheinsidebythece.Thealternativetothecupshapeistheflatshape.Inthiscasethereisnospec
17、ificconvexptionsometimesthecelookslikeamirrimageofthecavity.Typicalexamplesfthisareplasticknivesgamechipsrounddiskssuchasrecds.Whiletheseitemsaresimpleinappearancetheyoftenpresentseriousmoldingproblemsfejectionoftheprodu
18、ct.Thereasonfthisisthatallinjectionmoldingmachinesprovideanejectionmechanismonthemovingplatentheproductstendtoshrinkontoclingtothecefromwheretheyarethenejected.Mostinjectionmoldingmachinesdonotprovideejectionmechanismson
19、theinjectionside.PolymerProcessingPolymerprocessinginitsmostgeneralcontextinvolvesthetransfmationofasolid(sometimesliquid)polymericresinwhichisinaromfm(e.g.powderpelletsbeads)toasolidplasticsproductofspecifiedshapedimens
20、ionsproperties.Thisisachievedbymeansofatransfmationprocess:extrusionmoldingcalendaringcoatingthermofmingetc.Theprocessindertoachievetheaboveobjectiveusuallyinvolvesthefollowingoperations:solidtransptcompressionheatingmel
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