Professional Documents
Culture Documents
16 ER Siminiati Pomenic Orsic 28 1 PDF
16 ER Siminiati Pomenic Orsic 28 1 PDF
UDK 678.027.74:678.073
Sažetak: Danas je proizvodnja strojeva za preradu plastike masovna. Njihova struktura i principi rada nisu nikakva
tajna; najčešće su to strojevi s hidrauličkim pogonom i elektroničkom regulacijom. Korisnik stroja odabire tip stroja,
prema vrsti proizvoda, vrsti plastike i veličini serije. Proizvođač strojeva ne osigurava pripremu alata te izbor
parametara za pojedine faze procesa prerade. Ovaj rad daje smjernice i osnovne relacije za određivanje parametara
pomoću kojih će se stroj podesiti za rad prilikom uvođenja novog proizvoda.
Abstract: Injection moulding machines are mass produced nowadays. Their structures and working principles are not a
secret at all: most often they have a hydraulic drive with electronic regulation. The customer chooses the machinery
type depending on the product type, the type of the plastics and the series quantity. But what the machinery producer
does not provide is the tools preparation and the choice of parameters for each phase of the production cycle. This
article provides the guidelines and basic directions for parameter adjustment, which can help in the process of setting
the machine when introducing a new product.
1. UVOD 1. INTRODUCTION
Strojevi za injekcijsko prešanje plastike koriste se za Injection plastic moulding machines are used for making
izradu predmeta u automobilskoj industriji, za plastične parts in the automotive industry, for household machine
dijelove kućanskih aparata te izradu jednostavnih parts and simple plastic elements as well [1,2]. An
plastičnih elemenata [1,2]. U ovom će radu biti prikazan overview will be presented in this article for
pristup načinu određivanja osnovnih parametara pomoću approaching the base parameters in machine regulation
kojih se podešava stroj prilikom uvođenja u proizvodnju when a new product is in the adoption phase. The
novog proizvoda. Polimer akrilonitril-butadien-stiren, polymer Acrylonitrile-Butadiene-Styrene (ABS) is
(ABS) odabran je kao primjer materijala za izradu selected as an example of material for simple production
velikoserijske proizvodnje jednostavnih dijelova. line products.
Polimeri su tvari nastale međusobnim povezivanjem Polymers are materials whose structure is made up of
malih molekulskih jedinki monomera kovalentnom many repeating molecular units called mers. The small
vezom u dugačke makromolekulske lance. U molecules, or mers, are covalently bonded together to
makromolekuli može biti od nekoliko stotina do nekoliko form long macromolecular chains. A macromolecule can
desetaka tisuća monomera. Struktura makromolekula be formed from a few hundred mers up to several ten
polimera je različita. Linearni polimeri nemaju bočnih thousands of mers. A polymers molecular structure
lanaca, granati polimeri imaju bočne lance povezane s varies. A linear polymer consists of a long chain of
osnovnim lancem makromolekule, umreženi polimeri monomers. A branched-polymer has branches covalently
imaju lance međusobno povezane kovalentnim vezama attached to the main chain. A cross-linked polymer has
(gume), a mrežastim polimerima kovalentnom su vezom monomers of one chain covalently bonded with
makromolekule povezane trodimenzionalno. monomers of another chain (rubbers). Network polymers
120 D. Siminiati, L. Pomenić, F. Oršić: Određivanje osnovnih parametara …
____________________________________________________________________________________________________________________________________________________
Polimeri mogu biti: prirodni – kao celuloza, svila, vuna, are by covalent bond attached three-dimensionally to
prirodni kaučuk, prirodne smole itd., kemijski macromolecules linked in the network.
modificirani prirodni – kao što su celuloid i viskoza iz Polymers may be: natural – such are cellulose, silk, wool,
celuloze itd., vulkanizirani (kemijski umrežen) prirodni natural rubber, and natural resins etc., modified natural –
kaučuk ili sintetski – polimeri kao što su polietilen, such as, from cellulose – celluloid, viscose etc., from
polipropilen itd., koji se dobivaju iz petrokemijskih natural rubber – vulcanised rubber or synthetic – such as
proizvoda kemijskom reakcijom polimerizacije. polyethylene, polypropylene etc., obtained from
petrochemicals with chemical reactions of
polymerisation.
Plastične mase su polimeri kojima su dodani različiti Plastics are polymers with various additives. According
aditivi. S obzirom na ponašanje kod prerade i primjene, to their behaviour in production and implementation, they
dijele na dvije skupine: plastomere i duromere [2]. can be subdivided in two groups: thermoplastics and
Duromeri su na početku mekani, ali tijekom zagrijavanja thermosets, [2]. Thermosets are initially soft, but during
na povišenoj temperaturi nastaje ireverzibilno heating at increased temperature they change irreversibly
3D-umrežavanje u čvrsti materijal. Daljnim to 3D in the form of a hard network. At a higher
zagrijavanjem dolazi do njihove termodegradacije. temperature they are thermo degradable. Thermoplastics
Plastomeri, u koje se svrstava i već spomenuti ABS, and the aforementioned ABS are of polymer material
polimerni su materijali s linearnim i granatim with a linear and branched structure. They are soluble in
strukturama. Otapaju se u otapalima i taljivi su. solvents and fusible. Heating to softening temperatures
Zagrijavanjem do temperature omekšavanja ili taljenja ne they do not change structure, therefore, their
mijenjaju svoju strukturu te stoga njihova prerada manufacturing consists of reversible changes. Desired
obuhvaća samo reverzibilne promjene. Na tim se shapes can be formed at these temperatures. The structure
temperaturama mogu formirati u željene oblike. Struktura of the thermoplastics can be amorphous or crystalline.
plastomera može biti amorfna ili kristalna.
Polimerni materijali postaju tehnički uporabljivi kada se Polymers become technically applicable when additives
osnovnom polimeru dodaju aditivi za poboljšanje are added to the original polymer in order to improve
svojstva. Modifikacije se mogu postići ili kemijskim their properties. Modifications can be made by chemical
reakcijama ili fizikalnim postupcima. Aditivi se po or physical procedures. Additives are divided according
svojim funkcijama dijele u nekoliko skupina [2,3]: their functions into a few groups [2,3]:
dodaci za preradu: toplinski stabilizatori, maziva, processing additives: heat stabilizers, lubricants,
odjeljivači, regulatori viskoznosti i tiksotropni dodaci, delimiters, viscosity regulators and thixotropic additives,
dodaci za umrežavanje (koriste se kod duromera) curing agents/initiator (used at thermosets)
modifikatori mehaničkih svojstava (plastifikatori, mechanical properties modifiers (plasticizers, additives
dodaci za povećanje žilavosti, punila, ojačala, prianjala) for amplification of toughness, fillers, strengthens,
modifikatori površinskih svojstava: vanjska maziva, adherers)
regulatori adhezivnosti, antistatici surface properties modifiers: outward lubricants,
modifikatori optičkih svojstava: pigmenti adhesive regulators, antistatics
dodaci za povećanje trajnosti (postojanosti): svjetlosni optical properties modifiers: pigments
stabilizatori, antioksidansi, biocidi additives for amplification of durability (stability),
ostali dodaci: za smanjenje gorivosti, pjenila itd. light stabilizers, antioxidants, biocides
other additives: flame retardants, foamers etc.
3. ABS 3. ABS
ABS je sintetiziran tijekom Drugoga svjetskog rata kao ABS was synthesized during WWII as a replacement for
zamjena za gumu. To je polimer sastavljen od tri različita rubber. It is a polymer that consists of three different
monomera: akrilonitrila, koji mu daje kemijsku monomers: acrylonitrile provides chemical resistance,
otpornost, butadiena, koji mu daje otpornost na udar i butadiene provides impact resistance, and styrene
stirena, koji mu daje čvrstoću, krutost i laku obradivost. provides rigidity and easy processing of ABS. Figure 1.
Na Slici 1. prikazani su monomeri od kojih se sintetizira shows the monomers from which ABS is synthesized.
ABS.
Eng. Rev. 28-1 (2008) 119-127 121
____________________________________________________________________________________________________________________________________________________
Najvažniji ciklički postupak prerade plastomera je The most important cyclic procedure for thermoplasts is
injekcijsko prešanje. To je postupak brzog brizganja injection moulding. That is a process of the rapid
plastomerne taljevine u temperiranu kalupnu šupljinu i injection of melt into the tempered mould and its’
njezino skrućivanje u izradak. Postoji mogućnost solidification into a product. There is the possibility for
automatizacije procesa, pa je stoga prikladan za automating the process; therefore it is convenient for a
velikoserijsku proizvodnju izradaka. great array of products.
Osnovni koraci u procesu injekcijskog prešanja su [4]: The base steps in the injection moulding process are [4]:
1. zatvaranje kalupa 1. mold clamping
2. brizganje 2. injection
3. zadržavanje plastike u kalupu 3. plastics holding in the mould
4. hlađenje 4. cooling
5. otvaranje kalupa 5. mould opening
6. izbacivanje izratka. 6. product ejection.
Proces se kontinuirano ponavlja dok se ne proizvede The process is continuously repeated until a desirable
traženi broj izradaka. number of products have been produced.
Na Slici 2. prikazana je pojednostavnjena shema stroja za In Figure 2. a simplified overview of the machinery for
injekcijsko prešanje plastike. injection moulding is shown.
Jedinica za otvaranje
Lijevak
Brizgaljka /zatvaranje
Hopper Kalup Vodilica
Nozzle Clamping unit
Grijači Mold Tie bar
Heaters Izbacivač
Ejector
Hidromotor i
cilindar
Cilindar
Hydro-motor and
Barrel
cylinder
Pumpa
Pump
Materijal ulazi kroz lijevak u cilindar za taljenje, koji se The material that enters through the hopper into the barrel
zagrijava uz pomoć grijača, gdje ga zahvaća pužni vijak. is heated with heaters. The screw catches it. The screw is
Pužni vijak rotira uz pomoć hidromotora. Rastaljeni activated by the hydro-motor. The moulded material is
122 D. Siminiati, L. Pomenić, F. Oršić: Određivanje osnovnih parametara …
____________________________________________________________________________________________________________________________________________________
materijal potiskuje se k vrhu pužnog vijka. Nakon što se collected at the top of the screw. When enough material is
potisnulo dovoljno materijala, pužni se vijak pomiče collected, the screw is moved by hydraulic cylinder
prema naprijed uz pomoć hidrauličkog cilindra, pri čemu forwards. At the same time the mould injection through
počinje brizganje taljevine kroz mlaznicu u kalup. the nozzle begins. The melt is under injection pressure,
Taljevina se drži pod tlakom brizganja, a materijal se and at the same time the material is cooling. After that,
istodobno hladi. Nakon toga kalup se otvara, a proizvod the mould is opened, and the product is ejected. The
izbacuje. Kalup je sastavljen od nepomičnog dijela, koji mould is made up of the stationary platen, which is
je povezan s uljevnim kanalom, i pomičnog kalupa koji connected with the sprue gate, and the moveable platen
se uz pomoć posebne jedinice otvara/zatvara. that opens/closes with the help of the clamping unit.
Hidraulička shema na Slici 3. prikazuje razmještaj In Figure 3., the hydrostatic layout shows the
pogonskih elemenata, elemenata za upravljanje te arrangement of the drive circuit, regulating elements and
izvršnih elemenata [5]. Radni ciklus sastavljen je od actuating elements [5]. The operating cycle has eighteen
osamnaest koraka. steps.
Elektromotor (35) pogoni krilnu pumpu (1), koja tlači The electro-motor (35) activates the vane pump (1),
radnu tekućinu u sustav. Uvjet je pokretanja ciklusa da su which presses the working fluid into the system. The rear
prednja i stražnja zaštitna vrata stroja zatvorena. Ako and front sluice gates have to be closed for the cycle to
stražnja zaštitna vrata nisu zatvorena, sigurnosni ventil begin. If the rear gate is not closed, the relief valve (11)
(11) onemogućava uspostavljanje tlaka u sustavu. prevents the restoration of the system pressure.
32 33 28 31 29 30 2
36 12
21
10 14
23
27 14 38 P4 P5
15
8
M19
22
36 6 M9 M10
16
P1
M8 M5 M2 M1 M4 M3 M14 M6 M7
P2
7 24 TO
9 3 13 6 12 5 37
12 19 19 3
3 4 P2 P3
11
M12 M11
M13
17
35 18
P1 P6
PODACI O RADNIM TLAKOVIMA :
1
P1 - max radni tlak 140 bar
P2 - sniženi tlak zatvaranja alata 10-25 bar 34 20
P3 - naknadni tlak ubrizgavanja 0-140 bar
P4 - tlak ubrizgavanja 0-140 bar 26
P5 - protutlak plastifikacije 0-50 bar 25 Kom. Naziv dijela Poz. Nacrt br. Materijal Standard Mas
Crtao 19.01.2005.
Franjo Oršić Tehnički fakultet
97100026
Pregledao
- Rijeka -
Vidio
Diplomski rad
Mjerilo:
Hidraulička shema stroja za List: 1 Listova: 2
Ako prednja zaštitna vrata nisu zatvorena, ventil (10) If the front sluice gate is not closed, the valve (10)
prekida dovod radne tekućine u cilindre (28), kojima se terminates the working fluid supply into the cylinder
Eng. Rev. 28-1 (2008) 119-127 123
____________________________________________________________________________________________________________________________________________________
zatvara kalup. Ta su dva ventila osobito važna za zaštitu (28), which is used for closing the mould. These two
radnika koji poslužuje stroj. valves are the key to worker protection.
Otvaranje/zatvaranje alata obavljaju dva hidraulička Two hydraulic cylinders (28) open/close the platens. The
cilindra (28). Način njihova gibanja (sporo/brzo) ovisi o speed of their movement (slowly/quickly) depends on the
vrsti radnog ciklusa. Za sporo otvaranje/zatvaranje type of the working cycle. For a slow open/close, a
cilindri će se pokretati preko magnetskog razvodnika (5). magnetic valve (5) actuates the cylinders.
Nakon što je alat zatvoren, pomiče se mlaznica prema After the platens are closed, the nozzle moves forward
naprijed uz pomoć razvodnika (6) uključivanjem with the assistance of the valve (6) by activating the
elektromagneta M6. Pri tome se puni desna strana electromagnet M6. Thus, the right side of the cylinder
cilindra (29), a cijela injekcijska jedinica dolazi do (29) is filled, and the whole injection unit reaches the
nepomičnog dijela kalupa. Uključivanje cilindra (33), tzv. stationary platen.
brave, kojom se osigurava pokretni dio alata od otvaranja, Activation of the cylinder (33), otherwise referred to as
obavlja se pomoću razvodnika (3) uključivanjem M5. the lock, ensures the locking of the movable platen, and is
Zatvaranje alata, pomicanje mlaznice i zatvaranje brave performed with the valve (3) and the activation of M5.
obavlja se niskim tlakom, koji se regulira regulatorom Closing the mould, moving the nozzle and the shutting of
tlaka P2. Zatvaranje brave izaziva povećanje tlaka kako the lock are performed under low pressure, which is
bi se uz pomoć razvodnika (9), a uključivanjem M8, regulated with the pressure regulator P2. Closing of the
stavio u funkciju cilindar (32), kojim se kalup zadržava u mould causes the pressure to rise, so the valve (9) and the
zatvorenom položaju za vrijeme operacije brizganja. activation of M8 put the cylinder (32) into function. The
Brizganje se obavlja uz pomoć cilindra (30) pokretanog cylinder (32) holds the mould in the closing position
preko ventila (7), djelovanjem M10. Proces brizganja during the injection. The injection is performed with the
treba teći određenom brzinom za što se koristi regulator cylinder (30), by valve (7) acting along with M10. The
protoka (23), a tlak se regulira regulatorom tlaka P4. injection process should be performed at a specific speed,
which is controlled by the flow regulator (23), and the
pressure is regulated with pressure regulator P4.
Nakon ubrizgavanja, a zbog hlađenja i skupljanja After injection, and because of the material cooling and
materijala, potrebno je osigurati naknadni tlak uz pomoć shrinkage, it is necessary to provide additional pressure
razvodnika (4) uključivanjem M12 te ventila za with valve (4), by actuating the electromagnet M12 and
regulaciju tlaka (19) na naknadni tlak P3. Tim se tlakom the pressure regulator (19) to the additional pressure P3.
ubrizga još sirovine kako bi se kalup popunio zbog With that pressure, an additional quantity of raw material
stezanja materijala. Nakon što je sirovina u potpunosti is injected into the fill mould due to material shrinkage.
ubrizgana u kalup, počinje priprema sirovine za sljedeći After the raw material is completely injected into the
ciklus. Proces punjenja cilindra za taljenje smatra se mould, preparation for the next cycle begins. The phase
fazom plastifikacije sirovine. Pri tome hidromotor (2) of raw material plasticization arrives when the moulding
okreće pužni vijak, a sirovina iz lijevka dolazi u obliku cylinder is filled. Therefore the hydro-motor (2) rotates
granula. Da se ne bi pojavili lunkeri u taljevini, pomoću the screw, and the granule from the hopper occurs. The
regulacijskog ventila P5 regulira se protutlak cavities should not appear hence the pressure regulator P5
plastifikacije u desnoj komori cilindra (30). Kada se regulates plasticization with counter pressure in the right
izradak ohladio u kalupu, otvara se alat pod maksimalnim chamber of the cylinder (30). When the product is cooled
tlakom. Otvaranje alata pokreće se razvodnicima (5) ili in the mould, it opens under maximum pressure. The
(5) i (6) uz pomoć elektromagneta M4 i M2. Kakva će se mould opening is activated with the valve (5) or valves
kombinacija koristiti ovisi o potrebnoj brzini otvaranja. (5) and (6) with the aid of the electromagnets M4 and
Izradak se izbacuje iz kalupa uz pomoć cilindra (31), a M2. The combination depends on the required opening
njega se uključuje razvodnikom (3) uz pomoć M14. speed. The product is ejected with the cylinder (31). The
Tablica 1. prikazuje korake u jednom ciklusu rada stroja s activation of that cylinder is through valve (3) and the
režimima uključivanja elektromagnetskih ventila. electromagnet M14. Table 1. shows the steps in a
working cycle of the machine with regimes of the
electromagnetic valve activation.
Za jedan određeni stroj, ovisno o vrsti izratka i veličini For specific machinery, depending on the type of product
serije, potrebno je podesiti određene parametre. and the series quantity, adjustment of specific parameters
is required.
6.1. Potrebna količina sirovine po jednom ciklusu
6.1. Raw material quantity per one cycle
Najvažnija veličina kod postupka definiranja injekcijske
jedinice je potreban volumen sirovine za jedan ciklus. The most important quantity in the phase of defining the
Teorijska vrijednost potrebnog volumena za jedan ciklus unit of injection is the volume of raw material per cycle
je [4]: [4]:
mn
Vth = . (1)
ρ
Kako se određena količina sirovine gubi u uljevnom A specific quantity of the raw material is lost in the
kanalu i odvodnim kanalima do šupljine kalupa te zbog feeding and bend canals to the mould holes and because
skupljanja materijala prilikom hlađenja, potrebni nasipni of the material shrinkage during the cooling process.
volumen po jednom ciklusu je [4]: Actual filling volume per cycle is [4]:
Vth
Vstv = , (2)
M
gdje je M = 0,2 K 0,8 , a što ovisi o preciznosti izratka. where M = 0,2K0,8 , and this is dependent on the
product precision.
6.2. Brzina rotacije pužnog vijka
6.2. Barrel rotational speed
Kada su poznati volumen i sila zatvaranja, određuje se
brzina vrtnje hidromotora, koji pokreće pužni vijak. When the raw material volume and clamping force are
Obodna brzina pužnog vijka vt definirana je vrstom known, the hydro-motor rotational speed for screw
materijala sirovine (za ABS iznosi 650 mm/s). Za svaki je activation has to be determined. Tangential velocity of
stroj poznat promjer pužnog vijka, pa se temeljem the screw vt is defined by the type of material (for ABS it
sljedećeg izraza određuje brzina vrtnje hidromotora, koji is 650 m/s). For every specific machine the screw
Eng. Rev. 28-1 (2008) 119-127 125
____________________________________________________________________________________________________________________________________________________
vt
nv = . (3)
dv π
140
R e a ln o u b r iz g a n v o lu m e n ( c m )
100
80
67,22
60
40
20
0
0 20 40 60 80 82 100
Hod plastificiranja / mm
Plastification stroke / mm
Pomoću dijagrama prikazanog na Slici 4., a temeljem From the chart shown on the Figure 4., and on the basis
poznatoga nasipnog volumena prema izrazu (2), određuje of the actual filling volume known from term (2), the
se potreban hod plastificiranja. plasticization stroke can be estimated.
1800
1600
Specific material pressure/bar
Specifični tlak sirovine /bar
1400
1200
1000
800
600
400
200
0
0 20 40 60 80 100 120 140 160
Tlak brizganja /bar
Injection pressure /bar
Rotacijom pužnog vijka cilindar za taljevinu puni se When the screw rotates, the cylinder is fed with dissolved
sirovinom pri čemu se pužni vijak pomiče prema natrag. raw material, and the screw moves backwards. The
Sakupljanjem taljevine stvara se tlak, koji se mora collected mould makes the pressure that the cylinder has
savladati u cilindru za prešanje prilikom procesa to suppress during the ejecting phase. For ejecting
brizganja u kalup. Za određivanje tlaka brizganja od pressure estimation, the chart shown in Figure 5. is used.
pomoći je dijagram prikazan na Slici 5., a koji osigurava The machine manufacturer provides the chart. The
proizvođač stroja. Tlak se brizganja tada regulira uz ejecting pressure is regulated with the pressure regulation
pomoć ventila za regulaciju tlaka P4. valve P4.
126 D. Siminiati, L. Pomenić, F. Oršić: Određivanje osnovnih parametara …
____________________________________________________________________________________________________________________________________________________
Sila za otvaranje/zatvaranje definira se prema Clamping force is defined according to the maximum
maksimalnoj sili koja se mora ostvariti da bi alat ostao force for holding the mould closed under the ejecting
zatvoren pod djelovanjem tlaka brizganja. Do veličine pressure. The clamping force is acquired by multiplying
sile zatvaranja dolazi se tako da se ortogonalna projekcija the orthogonal projection of the cavity by the coefficient,
otvora u kalupu pomnoži s koeficijentom, koji je ovisan o which depends on the material [4]:
materijalu [4]:
Fz = A k , (4)
900 30
800
25
700
( )
600 20
j /kN
Sila zatvaranja /kN
500
15
400
300 10
200
5
100
0 0
0 20 40 60 80 100 120 140 0 20 40 60 80 100 120 140
Tlak zatvaranja /bar Tlak razdvajanja /bar
Clamping pressure/bar Opening pressure/bar
a) b)
7. ZAKLJUČAK 7. CONCLUSION
U radu je prikazan način rada stroja za injekcijsko This paper explains the working principle of plastic
prešanje plastike, a posebno za preradu ABS-a. Dan je injection moulding machines, especially for ABS
kratak opis plastičnih materijala i načina njihove prerade manufacturing. The short description of the plastic
u gotove proizvode. S obzirom na brojnost i raznolikost materials and their manufacturing are presented, too.
strojeva teško je dati jednoznačne upute za određivanje Because of the mass-production and variety of plastic
parametara tehnološke obrade. Pokušalo se sažeti podatke moulding machines, it is very difficult to provide
koje je dužan osigurati proizvođač strojeva i podatke koje unambiguous instructions for technologic parameter
mora osigurati korisnik stroja. To je način kako se, prije estimation. An effort has been made to describe the data
compression that the machine producer and consumers
Eng. Rev. 28-1 (2008) 119-127 127
____________________________________________________________________________________________________________________________________________________
uvođenja novog proizvoda, reguliraju parametri rada have to ensure. That is the way in which to regulate the
kako hidrauličkog tako i elektroničkog dijela parameters for the hydraulic and electronic part of the
regulacijskog sustava stroja. machine before introducing a new product.
LITERATURA
REFERENCES