Molding Process

Plastic Resins
Pellets
Products
Powders
………

: ‫ﻓﺮﺁﻳﻨﺪﻫﺎﯼ ﮔﻮﻧﺎﮔﻮﻧﯽ ﻭﺟﻮﺩ ﺩﺍﺭﺩ ﮐﻪ ﻣﻬﻤﺘﺮﻳﻦ ﺁﻧﻬﺎ ﻋﺒﺎﺭﺗﻨﺪ ﺍﺯ‬

Injection Molding :‫• ﻗﺎﻟﺒﮕﻴﺮﯼ ﺗﺰﺭﻳﻘﯽ‬

Molding Liquid Materials :‫• ﻗﺎﻟﺒﮕﻴﺮﯼ ﻣﻮﺍﺩ ﻣﺎﻳﻊ‬
:‫• ﻗﺎﻟﺒﮕﻴﺮﯼ ﻣﻮﺍﺩ ﺩﺍﻧﻪﺍﯼ ﺗﺮﻣﻮﺳﺖ‬
Molding Granular Thermoset Materials

1
 ‫‪Injection molding‬‬
‫• ﺍﻳﻦ ﻓﺮﺁﻳﻨﺪ ﺑﺮﺍﯼ ﻫﻤﺔ ﺗﺮﻣﻮ ﭘﻼﺳﺘﻴﮑﻬﺎ ﻣﻨﺎﺳﺐ ﺍﺳﺖ ﺑﺠﺰ‪:‬‬
‫‪» PTFE: Teflon ← trade name‬‬
‫… ‪» PA: Polyamids ← Nylon 6, 6.10, 6.11,6.12,‬‬
‫« ﻭ ﺑﻌﻀﯽ ﺍﺯ ﺍﻧﻮﺍﻉ )‪ (grades‬ﺧﺎﺹ ﺍﺯ ﭘﻼﺳﺘﻴﮑﻬﺎ‬
‫• ﺑﺎ ﺗﻮﺳﻌﻪ ﺗﺠﻬﻴﺰﺍﺕ ﺟﺪﻳﺪ‪ ،‬ﺑﻌﻀﯽ ﺗﺮﻣﻮﺳﺖﻫﺎ ﻧﻴﺰ ﺑﻪ ﮐﻤﮏ ﺗﺰﺭﻳﻖ ﺗﻮﻟﻴﺪ ﻣﯽﺷﻮﻧﺪ‪.‬‬
‫‪» Phenolics , Melamines , Epoxy , Polyester,….‬‬

‫• ﺩﺭ ﮐﻠﻴﻪ ﻣﻮﺍﺭﺩ‪ ،‬ﻓﺮﺍﻳﻨﺪ ﺷﺎﻣﻞ ﻣﺮﺍﺣﻞ ﺯﻳﺮ ﺍﺳﺖ‪:‬‬

‫→ ﺗﺰﺭﻳﻖ ﺩﺭ ﻗﺎﻟﺐ → ﻣﺎﺩﻩ ﺭﻭﺍﻥ ﻗﺎﺑﻞ ﺗﺰﺭﻳﻖ → ﺣﺮﺍﺭﺕ ‪ +‬ﻣﻮﺍﺩ ﺍﻭﻟﻴﺔ ﺩﺍﻧﻪﺍﯼ‬

‫ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ ﺍﺯ ﻗﺎﻟﺐ → ﻓﺮﺍﻳﻨﺪ ﺷﻴﻤﻴﺎﻳﯽ → ﺧﻨﮏ ﮐﺎﺭﯼ‬

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 Injection Molding Machine

30 ton, 1.5 oz (45 cm3) Engel 3

Injection Molding Machine

4
Plunger injection units

5
Reciprocating screw injection
molding machine

6
2-stage injection molding machine

7
Injection Molding Machine

:‫ﻫﻤﺔ ﺍﻳﻦ ﻣﺎﺷﻴﻦﻫﺎ ﺩﺍﺭﺍﯼ ﭼﻬﺎﺭ ﻭﺍﺣﺪ ﺍﺻﻠﯽ ﻣﯽﺑﺎﺷﻨﺪ‬

»injection unit
»clamping unit
»injection mold
»control system

8
 ‫‪Injection Unit‬‬
‫ﻭﺍﺣﺪ ﺗﺰﺭﻳﻖ‪ ،‬ﻣﺨﻠﻮﻁ ﻣﯽﮐﻨﺪ‪ ،‬ﻧﺮﻡ ﻭ ﺭﻭﺍﻥ ﻣﯽﺳﺎﺯﺩ ﻭ ﺗﺮﻣﻮﭘﻼﺳﺘﻴﮏ ﻣﺬﺍﺏ ﺭﺍ ﺑﻪ ﻗﺎﻟﺐ ﺗﺰﺭﻳﻖ‬
‫ﻣﯽﮐﻨﺪ‪ .‬ﺭﻭﻧﺪ ﮐﻠﯽ ﮐﺎﺭ ﺑﻪ ﺗﺮﺗﻴﺐ ﺯﻳﺮ ﺍﺳﺖ‪:‬‬
‫« ﺷﺮﻭﻉ‪ :‬ﻣﺎﺭﭘﻴﭻ ﺩﺭ ﻭﺿﻌﻴﺖ )‪ B (forward‬ﺷﺮﻭﻉ ﺑﻪ ﭼﺮﺧﺶ ﻣﯽﮐﻨﺪ‪ .‬ﺳﻴﻠﻨﺪﺭ ﺍﻃﺮﺍﻑ ﻣﺎﺭﭘﻴﭻ ﺩﺭ ﺣﺎﻝ‬
‫ﮔﺮﻡ ﺷﺪﻥ ﺍﺳﺖ ﻭ ﻣﻮﺍﺩ ﺩﺍﻧﻪﺍﯼ ﺩﺭ ﺍﺛﺮ ﮔﺮﺩﺵ ﻣﺎﺭﭘﻴﭻ ﺩﺭ ﺩﺍﺧﻞ ﮐﺎﻧﺎﻝ ﻣﺎﺭﭘﻴﭻ ﻭﺍﺩﺍﺭ ﺑﻪ ﺣﺮﮐﺖ ﻣﯽﺷﻮﻧﺪ‪.‬‬
‫ﻧﺎﺣﻴﺔ ﺍﻭﻝ ﻣﺎﺭﭘﻴﭻ ‪ feed section‬ﻧﺎﻡ ﺩﺍﺭﺩ‪.‬‬
‫« ﺩﺭ ﺣﺮﮐﺖ ﺑﻪ ﺟﻠﻮ ﺩﺭ ﺩﺍﺧﻞ ﻣﺎﺭﭘﻴﭻ‪ ،‬ﺩﺍﻧﻪﻫﺎ ﺩﺭ ﻫﻢ ﻣﺨﻠﻮﻁ ﻣﯽﺷﻮﻧﺪ ﻭ ﺑﺎ ﮐﻮﭼﮑﺘﺮ ﺷﺪﻥ ﮐﺎﻧﺎﻝ ﻣﺎﺭﭘﻴﭻ‪،‬‬
‫ﻣﺘﺮﺍﮐﻢ ﺷﺪﻩ ﻭ ﺑﻪ ﭘﻴﺶ ﻣﯽﺭﻭﻧﺪ‪.‬‬
‫« ﺩﺭ ﺍﺛﺮ ﺣﺮﺍﺭﺕ ﺩﺭﻳﺎﻓﺘﯽ ﺍﺯ ﺟﺪﺍﺭ ﺍﺳﺘﻮﺍﻧﻪﺍﯼ ﻭ ﺍﺛﺮ ﺍﺻﻄﮑﺎﮎ ﻭﺟﻮﺩ ﺑﻴﻦ ﺩﺍﻧﻪﻫﺎ ﻭ ﺩﻳﻮﺍﺭ ﻭ ﺳﻄﺢ ﻣﺎﺭﭘﻴﭻ‪،‬‬
‫ﭘﻼﺳﺘﻴﮏ ﺑﻪ ﺻﻮﺭﺕ ﻣﺬﺍﺏ ﺩﺭ ﻣﻲﺁﻳﺪ‪ .‬ﺑﻴﺸﺘﺮ ﻣﺬﺍﺏ ﺩﺭ ﻧﺎﺣﻴﻪ ﺍﯼ ﺍﺯ ﻣﺎﺭﭘﻴﭻ ﮐﻪ ﭘﻼﺳﺘﻴﮏ ﺩﺭ ﺣﺎﻝ ﺗﺮﺍﮐﻢ‬
‫ﺍﺳﺖ ﺗﻮﻟﻴﺪ ﻣﯽﺷﻮﺩ‪transition section :‬‬
‫« ﭘﻠﻴﻤﺮ ﻣﺬﺍﺏ ﺩﺭ ﻧﺎﺣﻴﺔ ‪ metering section‬ﻫﻤﮕﻦ ﺷﺪﻩ ﻭ ﮐﺎﻣ ﹰ‬
‫ﻼ ﻣﺨﻠﻮﻁ ﻣﯽﺷﻮﺩ‪ .‬ﺩﺭﺍﻳﻦ ﻧﺎﺣﻴﻪ ﻗﻄﺮ‬
‫ﺭﻳﺸﻪ ﻣﺎﺭﭘﻴﭻ ﺑﻪ ﻣﻘﺪﺍﺭ ﻧﻬﺎﻳﯽ ﺧﻮﺩ ﻣﯽﺭﺳﺪ ﻭ ﺗﺮﺍﮐﻢ ﺍﺿﺎﻓﯽ ﺻﻮﺭﺕ ﻧﻤﯽﮔﻴﺮﺩ‬

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 ‫‪Injection Unit‬‬
‫« ﭘﻠﻴﻤﺮ ﻣﺬﺍﺏ ﺑﻪ ﺍﻧﺘﻬﺎﯼ ﻣﺎﺭﭘﻴﭻ ﺭﺳﻴﺪﻩ ﻭ ﻓﺸﺎﺭ ﺗﻮﻟﻴﺪ ﺷﺪﻩ ﺩﺭ ﺍﺛﺮ ﺍﻧﺘﻘﺎﻝ ﻣﻮﺍﺩ ﺗﻮﺳﻂ ﻣﺎﺭﭘﻴﭻ‪ ،‬ﺁﻧﺮﺍ ﺑﻪ ﻋﻘﺐ‬
‫ﻣﯽﺭﺍﻧﺪ ﺩﺭ ﺣﺎﻟﻴﮑﻪ ﻣﺎﺭﭘﻴﭻ ﺩﺭ ﺣﺎﻝ ﮔﺮﺩﺵ ﺍﺳﺖ‪.‬‬
‫« ﻣﻮﻗﻌﻴﮑﻪ ﻣﻘﺪﺍﺭ ﻣﺬﺍﺏ ﺗﻮﻟﻴﺪ ﺷﺪﻩ ﺑﻪ ﺣﺪﯼ ﺑﺮﺳﺪ ﮐﻪ ﺑﺮﺍﯼ ﭘﺮ ﮐﺮﺩﻥ ﺣﻔﺮﻩﻫﺎﯼ ﻗﺎﻟﺐ ﻭ ﺭﺍﻫﮕﺎﻫﻬﺎﯼ ﺁﻥ ﮐﺎﻓﯽ‬
‫ﺑﺎﺷﺪ‪ ،‬ﻣﺎﺭﭘﻴﭻ ﻣﺘﻮﻗﻒ ﻣﯽﺷﻮﺩ‪ .‬ﺑﻪ ﺍﻳﻦ ﻣﻘﺪﺍﺭ ﭘﻼﺳﺘﻴﮏ ‪ shot‬ﻳﺎ ﺿﺮﺏ ﮔﻔﺘﻪ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﻣﺎﺭﭘﻴﭻ ﺑﻪ ﺟﻠﻮ ﺭﺍﻧﺪﻩ ﻣﯽﺷﻮﺩ ﻭ ﻣﺬﺍﺏ ﺭﺍ ﺑﻪ ﺩﺍﺧﻞ ﻗﺎﻟﺐ ﺗﺰﺭﻳﻖ ﻣﯽﮐﻨﺪ‪.‬‬
‫« ﺑﻪ ﻣﻨﻈﻮﺭ ﺟﺒﺮﺍﻥ ﺍﺛﺮﺍﺕ ‪ shrinkage‬ﺩﺭ ﺣﻴﻦ ﺳﺮﺩ ﺷﺪﻥ‪ ،‬ﻣﻘﺪﺍﺭﻱ ﻣﻮﺍﺩ ﺍﺿﺎﻓﯽ ﺩﺭ ﭘﺎﻳﺎﻥ ﻋﻤﻞ ﺗﺰﺭﻳﻖ‬
‫)ﮐﻮﺭﺱ ﺗﺰﺭﻳﻖ( ﺩﺭ ﺟﻠﻮﯼ ﻣﺎﺭﭘﻴﭻ ﺑﻪ ﺻﻮﺭﺕ ﺑﺎﻟﺸﺘﮏ ﻧﮕﻬﺪﺍﺷﺘﻪ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﻣﻘﺪﺍﺭﯼ ﻓﺸﺎﺭ ﻫﻴﺪﺭﻭﻟﻴﮏ ﺩﺭ ﭘﺸﺖ ﻣﺎﺭﭘﻴﭻ ﻫﻨﮕﺎﻣﯽ ﮐﻪ ﻣﯽﭼﺮﺧﺪ ﺍﻋﻤﺎﻝ ﻣﯽﺷﻮﺩ ﻭ ﺑﻪ ﺁﻥ‬
‫‪ Backpressure‬ﮔﻔﺘﻪ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﭘﺸﺖ ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﻭ ﺩﻣﺎﯼ ﭘﻠﻴﻤﺮ ﺩﺭ ﺟﻠﻮﯼ ﻣﺎﺭﭘﻴﭻ ﺷﺪﻩ ﻭ ﺑﻪ ﺍﺧﺘﻼﻁ ﺑﻬﺘﺮ ﻣﻮﺍﺩ ﮐﻤﮏ‬
‫ﻣﯽﮐﻨﺪ ﺍﻣﺎ ﻣﻤﮑﻦ ﺍﺳﺖ ﺑﺎﻋﺚ ﺗﺨﺮﻳﺐ ﭘﻠﻴﻤﺮ ﺷﻮﺩ‪.‬‬
‫« ﻓﺸﺎﺭ ﭘﺸﺖ ﺩﺭ ﮐﻤﺘﺮﻳﻦ ﻣﻘﺪﺍﺭ ﺗﻨﻈﻴﻢ ﻣﯽﺷﻮﺩ ﻣﮕﺮ ﺁﻧﮑﻪ ﺍﺧﺘﻼﻁ ﺑﻴﺸﺘﺮ ﻣﻮﺭﺩ ﻧﻴﺎﺯ ﺑﺎﺷﺪ‪.‬‬
‫« ﺳﻴﺴﺘﻢﻫﺎﯼ ﺩﻭ ﻣﺮﺣﻠﻪﺍﯼ ﺑﻪ ﻳﮏ ﺁﮐﻮﻣﻮﻻﺗﻮﺭ ﻣﺠﻬﺰ ﺍﺳﺖ ﮐﻪ ﻣﯽﺗﻮﺍﻧﺪ ﺿﺮﺏﻫﺎﯼ ﺑﺴﻴﺎﺭ ﺑﺰﺭﮒ ﺭﺍ ﺩﺭ ﺯﻣﺎﻥ‬
‫ﮐﻮﺗﺎﻩ ﺗﺰﺭﻳﻖ ﮐﻨﺪ‬

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 ‫‪Injection Unit‬‬
‫ﻣﺸﺨﺼﻪﻫﺎﯼ ﻭﺍﺣﺪ ﺗﺰﺭﻳﻖ‪:‬‬
‫‪9‬ﻇﺮﻓﻴﺖ ﺗﺰﺭﻳﻖ‪ :‬ﻣﺎﮐﺰﻳﻤﻢ ﺍﻧﺪﺍﺯﻩ ﺿﺮﺏ )‪ (shot‬ﭘﻠﯽ ﺍﺳﺘﺎﻳﺮﻥ )‪ (PS‬ﺑﺮ ﺣﺴﺐ ﺍﻭﻧﺲ ‪oz‬‬
‫‪9‬ﺑﺎ ﺗﻮﺟﻪ ﺑﻪ ﺍﺧﺘﻼﻑ ﺩﺭ ﻭﻳﮋﮔﻴﻬﺎﯼ ﻣﺬﺍﺏ ﻣﻮﺍﺩ ﻣﺨﺘﻠﻒ‪ ،‬ﺗﺒﺪﻳﻞ ﻭﺍﺣﺪ ﻓﻮﻕ ﺑﺮﺍﯼ ﻣﻮﺍﺩ ﺩﻳﮕﺮ‬
‫ﺑﻪ ﺳﺎﺩﮔﯽ ﻣﻴﺴﺮ ﻧﻤﯽﺑﺎﺷﺪ‪.‬‬
‫‪ :Injection Rate9‬ﻧﺮﺥ ﻣﺎﮐﺰﻳﻤﻢ ﮐﻪ ﻣﯽﺗﻮﺍﻧﺪ ﺍﺯ ﻧﺎﺯﻝ ﺗﺰﺭﻳﻖ ﺷﻮﺩ‪.‬‬
‫‪ :Injection pressure9‬ﻓﺸﺎﺭ ﻫﻴﺪﺭﻭﻟﻴﮏ ﮐﻪ ﺑﻪ ﻣﺎﺭﭘﻴﭻ ﺩﺭ ﻃﯽ ﺗﺰﺭﻳﻖ ﺍﻋﻤﺎﻝ‬
‫ﻣﯽﺷﻮﺩ‪.‬‬
‫‪9‬ﻓﺸﺎﺭ ﺗﺎﺑﻊ ﻧﻮﻉ ﺭﺯﻳﻦ‪ ،‬ﺩﻣﺎﯼ ﻣﺬﺍﺏ‪ ،‬ﺧﻨﮏ ﮐﺎﺭﯼ‪ ،‬ﻃﺮﺡ ﻗﺎﻟﺐ ﻭ ﻫﻨﺪﺳﻪ ﻗﻄﻌﻪ ﺍﺳﺖ‪.‬‬
‫‪9‬ﺿﺮﺏ‪ :‬ﺑﻴﺸﺘﺮﻳﻦ ﻣﻘﺪﺍﺭ ﻣﺎﺩﻩ ﺑﺮ ﻣﺒﻨﺎﻱ ‪ PS‬ﮐﻪ ﺩﺭ ﻳﮏ ﺳﻴﮑﻞ ﻗﺎﺑﻞ ﺗﺰﺭﻳﻖ ﺍﺳﺖ‪.‬‬

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 ‫‪Screw designs‬‬
‫ﺩﺭ ﻋﻤﻞ ﻃﺮﺍﺣﯽ ﻣﺎﺭﭘﻴﭻ ﺧﺎﺹ ﺑﺮﺍﯼ ﻫﺮ ﭘﺮﻭﮊﻩ ﻏﻴﺮ ﻣﻤﮑﻦ ﺍﺳﺖ ﻭ ﺍﺯ ﻣﺎﺭﭘﻴﭻ ﻫﺎﯼ ‪general‬‬
‫‪ purpose‬ﺍﺳﺘﻔﺎﺩﻩ ﻣﯽﺷﻮﺩ‪.‬‬
‫¾ ﺩﺭ ﻧﺎﺣﻴﻪ ﮐﻢ ﻋﻤﻖ ﮐﺎﻧﺎﻝ ﻣﺎﺭﭘﻴﭻ‪ ،‬ﻣﻮﺍﺩ ﺩﺍﺭﺍﯼ ﺳﺮﻋﺖ ﺑﻴﺸﺘﺮ ﻫﺴﺘﻨﺪ ﻭ ﻣﺬﺍﺏ ﻳﮑﻨﻮﺍﺧﺖﺗﺮ ﻣﯽﺷﻮﺩ‪ .‬ﺳﻪ‬
‫ﻧﺎﺣﻴﻪ ﺩﺭ ﻫﺮ ﻣﺎﺭﭘﻴﭻ ﻭﺟﻮﺩ ﺩﺍﺭﺩ‪:‬‬
‫« ‪ : Feed section‬ﻣﻮﺍﺩ ﺳﺮﺩ ﻣﻨﺘﻘﻞ ﺷﺪﻩ ﻭ ﺷﺮﻭﻉ ﺑﻪ ﺫﻭﺏ ﺷﺪﻥ ﻣﯽﮐﻨﻨﺪ‪.‬‬
‫« ‪ :Transition section‬ﻣﻮﺍﺩ ﻣﺘﺮﺍﮐﻢ‪ ،‬ﺫﻭﺏ ﻭ ﻣﺨﻠﻮﻁ ﻣﯽﮔﺮﺩﺩ‪ .‬ﻫﻮﺍ ﺑﻪ ﺳﻤﺖ ﻗﻴﻒ‬
‫ﺣﺮﮐﺖ ﻣﯽﮐﻨﺪ ﻭ ﺗﺨﻠﻴﻪ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ‪ :Metering section‬ﻣﺬﺍﺏ ﻫﻤﮕﻦ ﺷﺪﻩ ﻭ ﺩﻣﺎﯼ ﺁﻥ ﻳﮑﻨﻮﺍﺧﺖ ﻣﯽﺷﻮﺩ ﻭ ﺷﺮﺍﻳﻂ‬
‫ﺁﻥ ﺑﺮﺍﯼ ﺗﺰﺭﻳﻖ ﺗﻨﻈﻴﻢ ﻣﯽﮔﺮﺩﺩ‪.‬‬
‫¾ ‪ :Barrier screw design‬ﺭﺍﻧﺪﻣﺎﻥ ﺍﺧﺘﻼﻁ ﺭﺍ ﺍﻓﺰﺍﻳﺶ ﻣﯽﺩﻫﺪ ﺑﺪﻭﻥ ﺁﻧﮑﻪ ﻓﺸﺎﺭ ﭘﺸﺖ ﺭﺍ ﺍﻓﺰﺍﻳﺶ‬
‫ﺩﻫﺪ‪ .‬ﺩﺭ ﻃﺮﺍﺣﯽ ﻣﺎﻧﻊ ﺑﺎﻳﺪ ﺗﻮﺟﻪ ﮐﺮﺩ ﮐﻪ ﻧﻘﻄﻪ ﺳﮑﻮﻥ ﺍﻳﺠﺎﺩ ﻧﺸﻮﺩ ﺯﻳﺮﺍ ﭘﻼﺳﺘﻴﮏ ﺑﺎﻗﻴﻤﺎﻧﺪﻩ ﺑﻪ ﻣﺪﺕ‬
‫ﻃﻮﻻﻧﻲ ﺩﺭ ﺍﻳﻦ ﻧﺎﺣﻴﻪ ﺗﺨﺮﻳﺐ ﻣﯽﺷﻮﺩ‪.‬‬

‫‪12‬‬
 ‫‪Screw designs‬‬
‫ﻻ ﺩﺍﺭﺍﯼ ﮐﻠﮕﯽ ﻗﺎﺑﻞ ﺗﻌﻮﻳﺾ ﻫﺴﺘﻨﺪ ﮐﻪ ﮐﺎﺭ ﺁﻧﻬﺎ ﺟﻠﻮﮔﻴﺮﯼ ﺍﺯ ﺑﺮﮔﺸﺖ ﻣﻮﺍﺩ ﺩﺭ ﻓﺮﺁﻳﻨﺪ‬‫¾ ﻣﺎﺭﭘﻴﭻﻫﺎ ﻣﻌﻤﻮ ﹲ‬
‫ﺗﺰﺭﻳﻖ ﺍﺳﺖ‪ .‬ﺩﻭ ﻧﻮﻉ ﺷﻴﺮ ﻳﮏ ﻃﺮﻓﻪ ﮐﺎﺭﺑﺮﺩ ﺩﺍﺭﺩ‪:‬‬
‫« ‪ring value‬‬
‫« ‪ball value‬‬
‫– ﺑﺎ ﺗﻮﺟﻪ ﺑﻪ ﺳﺎﻳﺶ‪ ،‬ﺑﺎﺯﺑﻴﻨﯽ ﻣﺴﺘﻤﺮ ﮐﻠﮕﻲ ﺿﺮﻭﺭﯼ ﺍﺳﺖ‪.‬‬

‫‪Nozzles:‬‬ ‫– ﻧﺎﺯﻟﻬﺎ‪:‬‬
‫• ﻧﺎﺯﻟﻬﺎﯼ ﻭﺍﺣﺪ ﺗﺰﺭﻳﻖ‪ ،‬ﺟﺮﻳﺎﻥ ﻣﺬﺍﺏ ﺭﺍ ﺑﻪ ﻗﺎﻟﺐ ﻭ ﺩﻫﺎﻧﻪ ﺑﻮﺵ ﺗﻐﺬﻳﻪ ﻫﺪﺍﻳﺖ ﻣﻲ ﮐﻨﻨﺪ‪.‬‬
‫• ﻧﺎﺯﻟﻬﺎ ﺗﺎ ﭘﺸﺖ ﻓﮏ ﺛﺎﺑﺖ ﻗﺎﻟﺐ ﻭ ﺩﻫﺎﻧﻪ ﺑﻮﺵ ﺗﻐﺬﻳﻪ ﺍﺩﺍﻣﻪ ﺩﺍﺭﻧﺪ‪.‬‬

‫‪13‬‬
Screw designs

14
Non-return valves

15
 ‫‪Clamp mechanisms‬‬
‫ﻭﺳﻴﻠﻪﺍﯼ ﮐﻪ ﻭﻇﻴﻔﻪ ﺑﺎﺯ ﻭ ﺑﺴﺘﻪ ﺷﺪﻥ ﻗﺎﻟﺐ ﺭﺍ ﻋﻬﺪﻩ ﺩﺍﺭ ﺍﺳﺖ ﻭ ﺩﺭ ﻋﻤﻞ ﺳﻪ ﻧﻮﻉ‬
‫ﺍﺯ ﺁﻥ ﻭﺟﻮﺩ ﺩﺍﺭﺩ‪:‬‬

‫« ﻣﮑﺎﻧﻴﮑﯽ ‪ : mechanical‬ﺍﺭﺍﺯﺍﻧﺘﺮ‪ ،‬ﮐﺎﺭﺑﺮﺩ ﮔﺴﺘﺮﺩﻩ ﺩﺭ ﺳﻴﺴﺘﻢﻫﺎﻳﯽ ﮐﻢ‬

‫ﻇﺮﻓﻴﺖ ﺗﺎ ‪500 ton‬‬

‫« ﻫﻴﺪﺭﻭﻟﻴﮏ ‪ : hydraulic‬ﺳﻴﺴﺘﻢﻫﺎﯼ ‪ 150‬ﺗﺎ ‪1000 ton‬‬

‫« ﻫﻴﺪﺭﻭﻣﮑﺎﻧﻴﮑﯽ ‪ hydro-mechanical‬ﺳﻴﺴﺘﻢﻫﺎﯼ ﺑﺎﻻﺗﺮ ﺍﺯ ‪1000‬‬

‫‪ton‬‬

‫‪16‬‬
 ‫‪Clamp Specifications‬‬
‫ﻣﺸﺨﺼﻪﻫﺎﯼ ﺍﺻﻠﯽ ﻣﻮﺭﺩ ﺗﻮﺟﻪ ﺩﺭ ﺍﻧﺘﺨﺎﺏ ﻣﺎﺷﻴﻦ ﺗﺰﺭﻳﻖ ﻋﺒﺎﺭﺗﻨﺪ ﺍﺯ‪:‬‬
‫¾ ﮐﻮﺭﺱ ‪ :clamp‬ﺣﺪﺍﮐﺜﺮ ﻓﺎﺻﻠﻪﺍﯼ ﮐﻪ ﻓﮏ ﻣﺘﺤﺮﮎ ﻗﺎﻟﺐ ﻣﯽﺗﻮﺍﻧﺪ ﺣﺮﮐﺖ ﮐﻨﺪ‪.‬‬
‫«ﮐﻮﺭﺱ ﺗﻌﻴﻴﻦ ﮐﻨﻨﺪﻩ ﺣﺪﺍﻗﻞ ﺿﺨﺎﻣﺖ ﻗﺎﻟﺐ ﺍﺳﺖ ﮐﻪ ﺭﻭﯼ ﻣﺎﺷﻴﻦ ﻣﯽﺗﻮﺍﻧﺪ ﺑﺴﺘﻪ ﺷﻮﺩ‪.‬‬
‫«ﺩﺭ ﺣﺎﻟﺖ ﺣﺪﺍﮐﺜﺮ ﮐﻮﺭﺱ‪ ،‬ﺣﺪﺍﮐﺜﺮ ﺗﻨﺎﮊ ‪ clamp‬ﺗﺤﻘﻖ ﻣﯽﻳﺎﺑﺪ‬
‫¾ ﺣﺪﺍﮐﺜﺮ ﺩﻫﺎﻧﺔ ﺑﺎﺯ‪ :‬ﺣﺪﺍﮐﺜﺮ ﻓﺎﺻﻠﺔ ﺑﻴﻦ ﺩﻭ ﺻﻔﺤﻪ ﻓﺸﺎﺭ ﺩﻫﻨﺪﻩ ﺑﻪ ﻗﺎﻟﺐ‬
‫«ﺣﺪﺍﮐﺜﺮ ﺩﻫﺎﻧﺔ ﺑﺎﺯ ﺗﻌﻴﻴﻦ ﮐﻨﻨﺪﺓ ﺣﺪﺍﮐﺜﺮ ﺿﺨﺎﻣﺖ ﻗﺎﻟﺐ ﺍﺳﺖ ﮐﻪ ﺑﺎ ﺍﺣﺘﺴﺎﺏ ﺍﻣﮑﺎﻥ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﻩ ﻗﻄﻌﻪ ﻗﺎﻟﺐ‬
‫ﮔﻴﺮﯼ ﺷﺪﻩ ﺑﺪﺳﺖ ﻣﯽﺁﻳﺪ‪.‬‬
‫¾ ﺍﺑﻌﺎﺩ ﺻﻔﺤﺔ ﻧﮕﻬﺪﺍﺭﻧﺪﻩ ﻗﺎﻟﺐ‪:‬‬
‫«ﺑﺎ ﺗﻮﺟﻪ ﺑﻮﺟﻮﺩ ﻣﻴﻞ ﺭﺍﻫﻨﻤﺎ‪ ،‬ﺍﺑﻌﺎﺩ ﻗﺎﻟﺐ ﻫﻤﻴﺸﻪ ﮐﻤﺘﺮ ﺍﺯ ﺍﻳﻦ ﺻﻔﺤﺎﺕ ﺍﺳﺖ ﻭ ﺗﻮﺳﻂ ﻣﻴﻞ ﺭﺍﻫﻨﻤﺎ ﻣﺤﺪﻭﺩ‬
‫ﻣﯽﺷﻮﺩ‪.‬‬
‫¾ ﺗﻨﺎﮊ ‪ :clamp‬ﻣﺎﮐﺰﻳﻤﻢ ﻧﻴﺮﻭﻳﯽ ﮐﻪ ﻣﮑﺎﻧﺰﻳﻢ ‪ clamp‬ﻣﯽﺗﻮﺍﻧﺪ ﺍﻋﻤﺎﻝ ﮐﻨﺪ‪.‬‬
‫«ﻣﺎﺷﻴﻦﻫﺎﯼ ﮐﻮﭼﮏ‪<100 ton :‬‬
‫«ﻣﺎﺷﻴﻦﻫﺎﯼ ﻣﺘﻮﺳﻂ‪ 100 ton :‬ﺗﺎ ‪2000 ton‬‬
‫«ﻣﺎﺷﻴﻦﻫﺎﯼ ﺑﺰﺭﮒ‪>2000 ton :‬‬

‫‪17‬‬
 ‫‪Clamp Specifications‬‬
‫ﺭﻭﺵ ﺑﺮﺁﻭﺭﺩ ﺗﺠﺮﺑﯽ ﻭ ﺳﺮﺍﻧﮕﺸﺘﯽ ﻇﺮﻓﻴﺖ ﻣﺎﺷﻴﻦ‪:‬‬

‫‪Force = 3.5 KN‬‬

‫‪1 Cm of Mold Projected Area‬‬
‫‪2‬‬

‫– ‪ Projected area‬ﺷﺎﻣﻞ ﺳﻄﻮﺡ ﻫﻤﻪ ﺣﻔﺮﻩﻫﺎ ﻭ ﺭﺍﻫﮕﺎﻫﻬﺎ ﺍﺳﺖ‬

‫‪18‬‬
Clamp mechanisms

19
 ‫‪Injection Molds‬‬
‫• ﭘﻠﻴﻤﺮ ﮔﺮﻡ ﻭ ﻣﺨﻠﻮﻁ ﻳﮑﻨﻮﺍﺧﺖ ﺑﺪﺳﺖ ﺁﻣﺪﻩ ﺍﺯ ﺳﻴﺴﺘﻢ ﺗﺰﺭﻳﻖ ﺑﻪ ﺩﺍﺧﻞ ﻗﺎﻟﺐ ﺗﺰﺭﻳﻖ ﻣﯽﺷﻮﺩ‪.‬‬
‫ﺍﻧﻮﺍﻉ ﮔﻮﻧﺎﮔﻮﻥ ﻗﺎﻟﺒﻬﺎ ﮐﻪ ﮐﺎﺭﺑﺮﺩ ﮔﺴﺘﺮﺩﻩ ﺩﺍﺭﻧﺪ ﻋﺒﺎﺭﺗﻨﺪ ﺍﺯ‪:‬‬
‫– ﻗﺎﻟﺐﻫﺎﯼ ﺩﻭ ﺻﻔﺤﻪﺍﯼ ‪two plate molds‬‬
‫– ﻗﺎﻟﺐﻫﺎﯼ ﺳﻪ ﺻﻔﺤﻪﺍﯼ ‪three plate molds‬‬
‫– ﻗﺎﻟﺐﻫﺎﯼ ﭼﻨﺪ ﺻﻔﺤﻪﺍﯼ ‪stack plate molds‬‬

‫• ﻗﺎﻟﺐﻫﺎ ﺍﺯ ﮔﺮﺍﻧﺘﺮﻳﻦ ﻣﺠﻤﻮﻋﻪﻫﺎﯼ ﺗﻮﻟﻴﺪ ﻗﻄﻌﺎﺕ ﭘﻼﺳﺘﻴﮑﯽ ﻣﯽﺑﺎﺷﻨﺪ‪:‬‬

‫– ﺩﻗﺖ ﺳﺎﺧﺖ ﻭ ﺗﻠﻮﺭﺍﻧﺲﻫﺎ ﺑﺴﻴﺎﺭ ﺩﻗﻴﻖ‬
‫– ﻋﻤﻠﻴﺎﺕ ﺣﺮﺍﺭﺗﯽ ﻗﻄﻌﺎﺕ ﺑﺮﺍﯼ ﺳﺨﺖ ﮐﺎﺭﯼ ﺳﻄﺤﯽ ﻭﺍﻣﮑﺎﻥ ﺗﺤﻤﻞ ﺑﺎﺭﮔﺰﺍﺭﻳﻬﺎﯼ ﻓﺮﺁﻳﻨﺪ ﺗﻮﻟﻴﺪ‬
‫– ﻣﺪﺕ ﻃﻮﻻﻧﯽ ﻃﺮﺍﺣﯽ ﻭ ﺳﺎﺧﺖ‬
‫– ﺁﺯﻣﺎﻳﺶ ﻋﻤﻠﮑﺮﺩ ﻭ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ ﻗﻄﻌﻪ‪ ،‬ﺧﻨﮏ ﮐﺎﺭﯼ‪ ،‬ﮔﺮﻡ ﺷﺪﻥ ﻭ ‪...‬‬

‫‪20‬‬
 ‫‪Injection Molds‬‬
‫• ﻗﺎﻟﺐ ﺩﻭ ﺻﻔﺤﻪﺍﯼ‪:‬‬
‫« ﻓﻘﻂ ﻳﮏ ﺧﻂ ﺗﻘﺴﻴﻢ ﻭ ﺟﺪﺍﻳﺶ ﻭﺟﻮﺩ ﺩﺍﺭﺩ ﻭ ﻗﻄﻌﻪ ﻭ ﺭﺍﻫﮕﺎﻩ ﻫﻤﺰﻣﺎﻥ ﻭ ﻣﺘﺼﻞ ﺑﻪ ﻫﻢ ﺑﻴﺮﻭﻥ ﻣﯽﺁﻳﻨﺪ‬
‫ﺑﻨﺎﺑﺮﺍﻳﻦ ﺟﺪﺍ ﮐﺮﺩﻥ ﺩﺳﺘﯽ ﻗﻄﻌﻪ ﺍﺯ ﺭﺍﻫﮕﺎﻩ ﻻﺯﻡ ﺍﺳﺖ‬
‫« ﺩﺭ ﻗﻄﻌﺎﺕ ﺳﺎﺩﻩ ﮐﺎﺭﺑﺮﺩ ﺩﺍﺭﺩ ﻭ ﻫﺮﻳﻨﻪ ﺳﺎﺧﺖ ﻗﺎﻟﺐ ﺍﺭﺯﺍﻥﺗﺮ ﺍﺳﺖ‬

‫• ﻗﺎﻟﺐ ﺳﻪ ﺻﻔﺤﻪﺍﯼ‪:‬‬
‫« ﺩﻭ ﺧﻂ ﺗﻘﺴﻴﻢ ﻭ ﺟﺪﺍﻳﺶ ﻣﺸﺎﻫﺪﻩ ﻣﯽﺷﻮﺩ‪ .‬ﻳﮑﯽ ﺑﺮﺍﯼ ﻗﻄﻌﻪ ﻭ ﺩﻳﮑﺮﯼ ﺑﺮﺍﯼ ﺭﺍﻫﮕﺎﻩ‬
‫« ﺑﺎ ﺑﺎﺯ ﺷﺪﻥ ﻗﺎﻟﺐ‪ ،‬ﺑﻄﻮﺭ ﺧﻮﺩﮐﺎﺭ ﻗﻄﻌﻪ ﻭ ﺭﺍﻫﮕﺎﻩ ﺟﺪﺍ ﻣﯽﺷﻮﻧﺪ‪.‬‬

‫• ﻗﺎﻟﺐﻫﺎﯼ ﭼﻨﺪ ﻃﺒﻘﻪ)ﭼﻨﺪ ﺻﻔﺤﻪﺍﯼ(‪:‬‬

‫« ﺩﺍﺭﺍﯼ ﭼﻨﺪ ﺧﻂ ﺟﺪﺍﻳﺶ ﻫﺴﺘﻨﺪ‪.‬‬
‫« ﭼﻨﺪﻳﻦ ﻗﻄﻌﻪ ﺭﺍ ﺑﺎ ﻳﮏ ﺗﻨﺎﮊ ﺛﺎﺑﺖ ﺳﻴﺴﺘﻢ ‪ clamp‬ﻣﯽﺗﻮﺍﻥ ﺗﻮﻟﻴﺪ ﮐﺮﺩ‪.‬‬
‫« ﺍﻳﻦ ﺳﻴﺴﺘﻤﻬﺎ ﺟﺪﻳﺪ ﺗﺮ ﻫﺴﺘﻨﺪ ﻭ ﺑﺮﺍﯼ ﺗﻮﻟﻴﺪ ﺍﻧﺒﻮﻩ ﻗﻄﻌﺎﺕ ﺑﮑﺎﺭ ﻣﯽﺭﻭﻧﺪ‬

‫‪21‬‬
Two-plate mold

22
 Two-plate mold

Sprue: channel from die nozzle Gates: restrict the polymer

Into the mold Flow into the cavity

Runner: channel from Sprue

Into the cavity
23
Three-plate mold

24
 Three-plate mold
three-plate mold two-plate mold

The three-plate mold is typically used for parts that are gated away
from their edge. The runner is in two plates, separate from the
cavity and core,
25
Stack molds

26
 Mold Elements

¾Sprue and Runner system

¾Gates
¾mold cavity
¾Cooling system
¾Ejector system

27
 ‫‪Sprue and Runner system‬‬
‫• ﻣﺠﺮﺍ ﻫﺎﻳﻲ ﮐﻪ ﻧﺎﺯﻝ ﻣﺎﺷﻴﻦ ﺗﺰﺭﻳﻖ ﺭﺍ ﺑﻪ ﺣﻔﺮﻩﻫﺎ ﻭﺻﻞ ﻣﯽﮐﻨﺪ ﺷﺎﻣﻞ ‪ sprue‬ﻭ ‪ runner‬ﻣﯽﺷﻮﺩ‪.‬‬
‫• ﺩﺭ ﻗﺎﻟﺐ ﺗﮏ ﺣﻔﺮﻩﺍﯼ‪ ،‬ﻣﺠﺮﺍ ﻓﻘﻂ ﺷﺎﻣﻞ ﻣﺠﺮﺍﯼ ﺗﻐﺬﻳﻪ) ‪( sprue‬ﻣﯽﺷﻮﺩ ﻭ ﺭﺍﻫﮕﺎﻩ ﻭﺟﻮﺩ ﻧﺪﺍﺭﺩ‬
‫• ﺩﺭ ﻗﺎﻟﺐﻫﺎﯼ ﭼﻨﺪ ﺣﻔﺮﻩﺍﯼ‪ ،‬ﻃﺮﺍﺣﯽ ﺭﺍﻫﮕﺎﻫﻬﺎ ﺑﺎﻳﺪ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﺑﺎﺷﺪ ﮐﻪ ﻣﻮﺍﺩ ﺩﺭ ﺭﺳﻴﺪﻥ ﺑﻪ ﺣﻔﺮﻩﻫﺎ ﻓﺎﺻﻠﻪﻫﺎﯼ‬
‫ﻧﺴﺒﺘﺎ“ ﻣﺴﺎﻭﯼ ﺭﺍ ﻧﺴﺒﺖ ﺑﻪ ﻣﺠﺮﺍﯼ ﺗﻐﺬﻳﻪ ﺍﺻﻠﯽ ﻃﯽ ﮐﻨﻨﺪ‪.‬‬
‫– ﺍﻧﻮﺍﻉ ‪: Sprue‬‬
‫« ‪Cold sprue‬‬
‫« ‪Hot sprue‬‬
‫• ﺩﺭ ﻣﺠﺮﺍﯼ ﺗﻐﺬﻳﺔ ﮔﺮﻡ‪ ،‬ﺳﻴﺴﺘﻢ ﮔﺮﻡ ﮐﻦ ﻫﻤﻴﺸﻪ ﭘﻼﺳﺘﻴﮏ ﺭﺍ ﺑﻪ ﺻﻮﺭﺕ ﻣﺬﺍﺏ ﻧﮕﻪ ﻣﯽﺩﺍﺭﺩ ﻭ ﺩﻳﮕﺮ ﻧﻴﺎﺯﯼ ﺑﻪ‬
‫ﺟﺪﺍ ﮐﺮﺩﻥ ﺍﺯ ﺭﺍﻫﮕﺎﻩ ﻭ ﺑﺎﺯﻳﺎﺑﯽ ﻣﺠﺪﺩ ﻣﻮﺍﺩ ﻧﻤﯽﺑﺎﺷﺪ‪.‬‬
‫• ﻃﻮﻝ ‪ sprue‬ﺑﺎﻳﺪ ﺗﺎ ﺣﺪ ﻣﻤﮑﻦ ﮐﻮﺗﺎﻩ ﺑﺎﺷﺪ ﺗﺎ ﺍﻓﺖ ﻓﺸﺎﺭ ﮐﻤﺘﺮ ﺷﻮﺩ‪.‬‬
‫• ﻣﺠﺮﺍﯼ ﺗﻐﺬﻳﺔ ﺳﺮﺩ‪ ،‬ﺑﻪ ﺻﻮﺭﺕ ﻣﺨﺮﻭﻃﯽ ﺍﺳﺖ ﺗﺎ ﺑﺘﻮﺍﻧﺪ ﺑﻪ ﺭﺍﺣﺘﯽ ﭘﻼﺳﺘﻴﮏ ﺟﺎﻣﺪ ﺍﺯ ﺁﻥ ﺟﺪﺍ ﺷﻮﺩ‬

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 ‫‪Sprue and Runner system‬‬
‫• ﺍﻧﻮﺍﻉ ﺭﺍﻫﮕﺎﻫﻬﺎ‪:‬‬
‫« ‪Cold runner‬‬
‫« ‪Hot runner‬‬
‫« ‪Insulated runner‬‬
‫• ﺭﺍﻫﮕﺎﻩ ﺳﺮﺩ ﺑﺮﺍﯼ ﻗﺎﻟﺐﻫﺎﯼ ﺩﻭ ﻳﺎ ﺳﻪ ﺻﻔﺤﻪﺍﯼ ﮐﺎﺭﺑﺮﺩ ﺩﺍﺭﺩ ﺍﻣﺎ ﺩﺭ ﻗﺎﻟﺐﻫﺎﯼ ﭼﻨﺪ ﻃﺒﻘﻪ ﮐﺎﺭﺑﺮﺩ ﻧﺪﺍﺭﺩ‪.‬‬
‫• ﺷﮑﻞ ﻣﻘﻄﻊ ﺭﺍﻫﮕﺎﻩ ﺍﻧﻮﺍﻉ ﮔﻮﻧﺎﮔﻮﻥ ﺩﺍﺭﺩ‪:‬‬
‫– ﺭﺍﻫﮕﺎﻩ ﮔﺮﺩ‪:‬‬
‫« ﺳﻬﻮﻟﺖ ﻣﺎﺷﻴﻦ ﮐﺎﺭﯼ‬
‫« ﺍﻓﺖ ﻓﺸﺎﺭ ﮐﻤﺘﺮ ﻧﺴﺒﺖ ﺑﻪ ﺭﺍﻫﮕﺎﻫﻬﺎﯼ ﺩﻳﮕﺮ‬
‫« ﺳﺮﻋﺖ ﺧﻨﮏ ﺷﺪﻥ ﮐﻤﺘﺮ ﺍﺳﺖ ﻭ ﺑﺮﺍﯼ ﺷﮑﻠﻬﺎﻱ ﺳﺮﻳﻊ ﻣﻨﺎﺳﺐ ﻧﻤﯽﺑﺎﺷﺪ‪ .‬ﺯﻳﺮﺍ ﻣﻘﺪﺍﺭ ﻣﺎﺩﻩ ﺩﺍﺧﻞ ﺭﺍﻫﮕﺎﻩ‬
‫ﺑﻴﺸﺘﺮ ﺍﺳﺖ‪.‬‬
‫– ﺩﺭ ﺭﺍﻫﮕﺎﻫﻬﺎﯼ ﻣﺜﻠﺜﯽ‪ ،‬ﻧﻴﻢ ﺩﺍﻳﺮﻩ ﻭ ﺫﻭﺯﻧﻘﻪﺍﯼ ﻓﻘﻂ ﻳﮏ ﻃﺮﻑ ﻗﺎﻟﺐ ﻣﺎﺷﻴﻦ ﮐﺎﺭﯼ ﻣﯽﺷﻮﺩ‪.‬‬
‫• ﺑﺮﺍﯼ ﮐﺎﻫﺶ ﺍﻓﺖ ﻓﺸﺎﺭ ﻭ ﺟﺪﺍ ﺷﺪﻥ )ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ( ﺭﺍﻫﮕﺎﻫﻬﺎ ﺑﺎﻳﺪﮐﺎﻣ ﹰ‬
‫ﻼ ﭘﺮﺩﺍﺧﺖ ﺷﻮﻧﺪ‪.‬‬

‫‪29‬‬
 ‫‪Sprue and Runner system‬‬
‫• ﻗﻄﺮ ﺭﺍﻫﮕﺎﻩ ﺍﻳﺰﻭﻟﻪ ﺑﺰﺭﮒ ﺍﺳﺖ ﻭ ﺑﻪ ﺍﻳﻦ ﺳﻴﺴﺘﻢ ‪ runnerless molding‬ﮔﻔﺘﻪ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺑﻪ ﻋﻠﺖ ﺿﺮﻳﺐ ﺍﻧﺘﻘﺎﻝ ﺣﺮﺍﺭﺕ ﭘﺎﻳﻴﻦ ﭘﻼﺳﺘﻴﮏ‪ ،‬ﺍﮔﺮ ﺩﺭ ﻣﺠﺎﻭﺭ ﺩﻳﻮﺍﺭﻩ ﻳﮏ ﻻﻳﻪ ﺍﺯ‬
‫ﭘﻼﺳﺘﻴﮏ ﺟﺎﻣﺪ ﺷﻮﺩ‪ ،‬ﻣﻐﺰﯼ ﺁﻥ ﺑﻪ ﻋﻨﻮﺍﻥ ﺭﺍﻫﮕﺎﻩ ﻋﻤﻞ ﻣﯽﮐﻨﻨﺪ‪.‬‬
‫« ﻓﺎﻳﺪﻩ‪ :‬ﮐﺎﻫﺶ ﻣﺼﺮﻑ ﻣﻮﺍﺩ ﺍﻭﻟﻴﻪ‪،‬ﺣﺬﻑ ﮐﺎﺭ ﺟﺪﺍ ﮐﺮﺩﻥ ﺭﺍﻫﮕﺎﻫﻬﺎ ﻭ ﺑﺎﺯﻳﺎﺑﯽ ﻣﻮﺍﺩ‬
‫« ﻣﺸﮑﻞ‪ :‬ﺍﻧﺠﻤﺎﺩ ﻣﻮﺍﺩ ﺩﺭ ﺭﺍﻫﮕﺎﻩ ﺩﺭ ﺻﻮﺭﺕ ﺗﻮﻗﻒ ﺳﻴﮑﻞ ﮐﺎﺭﯼ‬
‫• ﺳﻴﺴﺘﻢ ﺭﺍﻫﮕﺎﻩ ﮔﺮﻡ ﺟﺎﻳﮕﺰﻳﻦ ﻣﻨﺎﺳﺒﯽ ﺑﺮﺍﯼ ﺭﺍﻫﮕﺎﻩ ﺍﻳﺰﻭﻟﻪ ﻣﯽﺑﺎﺷﺪ‪.‬‬
‫« ﮔﺮﻣﮑﻦﻫﺎﯼ ﺳﻴﺴﺘﻢ‪ ،‬ﺩﻣﺎﯼ ﭘﻼﺳﺘﻴﮏ ﻣﺎﻳﻊ ﺭﺍ ﺑﻪ ﺻﻮﺭﺕ ﻳﮑﺴﺎﻥ ﻧﮕﻪ ﻣﯽﺩﺍﺭﻧﺪ‬
‫« ﺩﺭ ﺷﺮﻭﻉ ﻣﺠﺪﺩ ﮐﺎﺭ ﺑﺎﻳﺪ ﺑﻪ ﮔﺮﻡ ﺷﺪﻥ ﻗﺎﻟﺐ ﺗﻮﺟﻪ ﮐﺮﺩ‪.‬‬

‫‪30‬‬
 Runner System

• Runner Balancing is an
essential for a balanced filling
pattern with a reasonable
pressure drop

31
Sprues and runners

32
 Hot Runner System
ƒ The ideal injection molding system delivers molded parts of uniform density, and free
from all runners, flash, and gate stubs. To achieve this, a hot runner system, in
contrast to a cold runner system, is employed. The material in the hot runners is
maintained in a molten state and is not ejected with the molded part. Hot runner
systems are also referred to as hot-manifold systems, or runnerless molding.

Hot runner system types:

(a) insulated hot runner

(b) internally heated hot-runner system
(c) externally heated hot-runner system 33
 ‫‪Mold Venting‬‬
‫• ﺩﺭ ﻓﺮﺁﻳﻨﺪ ﻗﺎﻟﺐﮔﻴﺮﯼ‪ ،‬ﺑﺎﻳﺪ ﻫﻮﺍﯼ ﺩﺍﺧﻞ ﺣﻔﺮﻩﻫﺎ ﺗﺨﻠﻴﻪ ﺷﻮﺩ‪.‬‬
‫• ﻣﺴﻴﺮﻫﺎﯼ ﻫﻮﺍﮔﻴﺮﯼ ﺭﻭﯼ ﺧﻂ ﺟﺪﺍﻳﺶ ‪ parting line‬ﺩﺭ ﻗﺎﻟﺐﻫﺎ ﺩﺭ ﻧﻈﺮ ﮔﺮﻓﺘﻪ ﻣﯽﺷﻮﺩ ﻭ ﺩﺭ ﺗﻮﻟﻴﺪ‬
‫ﻗﻄﻌﺎﺕ ﺑﺎ ﮐﻴﻔﻴﺖ ﺑﺎﻻ ﺑﺴﻴﺎﺭ ﻣﻬﻢ ﺍﺳﺖ‪.‬‬
‫• ﻫﻮﺍ ﻣﻤﮑﻦ ﺍﺳﺖ ﺍﺯ ﭘﺮ ﺷﺪﻥ ﻳﮑﻨﻮﺍﺧﺖ ﻗﺎﺏ ﺟﻠﻮﮔﻴﺮﯼ ﮐﻨﺪ‪.‬‬
‫• ﻫﻮﺍ ﺩﺍﻍ ﺷﺪﻩ ﻭ ﺑﺎﻋﺚ ﺍﮐﺴﻴﺪ ﺷﺪﻥ ﭘﻼﺳﺘﻴﮏ ﻳﺎ ﺍﻓﺰﻭﺩﻧﯽﻫﺎﯼ ﺁﻥ ﺷﻮﺩ‪.‬‬
‫• ﻫﻮﺍ ﺍﺯ ﻣﺴﻴﺮﻣﻴﻞﻫﺎﯼ ﭘﺮﺍﻥ ﻧﻴﺰ ﻣﻤﮑﻦ ﺍﺳﺖ ﺗﺨﻠﻴﻪ ﺷﻮﺩ )ﺑﺰﺭﮔﺘﺮ ﮐﺮﺩﻥ ﺳﻮﺭﺍﺥﻫﺎﯼ ﻣﻴﻞ ﭘﺮﺍﻥ(‬
‫• ﺩﺭ ﻋﻤﻞ ﻓﺮﺽ ﻣﯽﺷﻮﺩ ﮐﻪ ﻗﺎﻟﺐ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﭘﺮ ﻣﯽﺷﻮﺩ ﮐﻪ ﻫﻮﺍ ﻣﯽﺗﻮﺍﻧﺪ ﺑﻪ ﺳﻤﺖ ﺧﻂ ﺟﺪﺍﻳﺶ ﺗﺨﻠﻴﻪ ﺷﻮﺩ‪.‬‬
‫• ﺩﺭ ﻗﺎﻟﺐﻫﺎﻱ ﭼﻨﺪ ﺣﻔﺮﻩﺍﯼ ﺭﺍﻫﮕﺎﻫﻬﺎ ﻫﻢ ﺑﺎﻳﺪ ﻫﻮﺍﮔﻴﺮﯼ ﺷﻮﺩ‪.‬‬

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 ‫‪Mold Venting‬‬
‫• ﺭﻭﺵ ﺩﻳﮕﺮ ﻫﻮﺍﮔﻴﺮﯼ ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯﮐﺎﻧﺎﻟﻬﺎﻳﯽ ﺑﺮﺍﯼ ﻫﺪﺍﻳﺖ ﻫﻮﺍﯼ ﺩﺍﺧﻞ ﺣﻔﺮﻩﻫﺎ ﺑﻪ ﺑﻴﺮﻭﻥ ﺍﺳﺖ‪.‬‬
‫• ﮐﺎﻧﺎﻝﻫﺎﯼ ﺗﺨﻠﻴﺔ ﻫﻮﺍ‪ ،‬ﺩﺭ ﺳﻄﺢ ﺟﺪﺍﻳﺶ ﻗﺎﻟﺐ ﺍﻳﺠﺎﺩ ﻣﯽﺷﻮﺩ‪.‬‬
‫• ﺍﺯ ﺍﻳﻦ ﮐﺎﻧﺎﻝ ﺍﻣﮑﺎﻥ ﮔﺬﺭ ﻫﻮﺍ ﻭﺟﻮﺩ ﺩﺍﺭﺩ ﺍﻣﺎ ﭘﻼﺳﺘﻴﮏ ﻟﺰﺝ ﺍﺯ ﺁﻥ ﻋﺒﻮﺭ ﻧﻤﯽﮐﻨﺪ‪.‬‬
‫• ﻋﻤﻖ ﮐﺎﻧﺎﻝ ﺑﺎ ﻓﺎﺻﻠﻪ ﮔﺮﻓﺘﻦ ﺍﺯ ﺣﻔﺮﻩ ﺗﺎ ﺭﺳﻴﺪﻥ ﺑﻪ ﻟﺒﻪ ﺧﺎﺭﺟﯽ ﻗﺎﻟﺐ ﺗﺎ ‪ 0.075 mm‬ﺍﺿﺎﻓﻪ ﻣﯽﺷﻮﺩ‪.‬‬
‫• ﻣﺴﻴﺮ ﺗﺨﻠﻴﻪ ﻫﻮﺍ ﮐﺎﻣ ﹰ‬
‫ﻼ ﭘﺮﺩﺍﺧﺖ ﺷﺪﻩ ﻭ ﺩﺍﺋﻤﺎ“ ﺑﺎﺯﺩﻳﺪ ﻣﯽ ﺷﻮﺩ ﺗﺎ ﻋﻤﻠﮑﺮﺩ ﻣﻄﻠﻮﺏ ﺗﻀﻤﻴﻦ ﮔﺮﺩﺩ‪.‬‬
‫• ﮔﺮﻓﺘﻦ ﮐﺎﻧﺎﻝﻫﺎ ﻋﺪﻡ ﻳﮑﻨﻮﺍﺧﺘﯽ ﺩﺭ ﭘﺮ ﺷﺪﻥ ﻗﺎﻟﺐ ﺭﺍ ﺑﻪ ﺩﻧﺒﺎﻝ ﺩﺍﺭﺩ‪.‬‬
‫• ﻋﺪﻡ ﺗﺨﻠﻴﻪ ﺳﺮﻳﻊ ﻫﻮﺍ ≡ ﻃﻮﻻﻧﯽﺗﺮ ﺷﺪﻥ ﺳﻴﮑﻞ ﻗﺎﻟﺐﮔﻴﺮﯼ ≡ ﺩﺍﻍ ﺷﺪﻥ ﻫﻮﺍ ≡ ﺳﻮﺧﺘﮕﯽ ﻣﻮﺍﺩ ﻭ ﺗﻮﻟﻴﺪ ﻣﻮﺍﺩ‬
‫ﺧﻮﺭﻧﺪﻩ ﺭﻭﯼ ﺳﻄﺢ ﻗﺎﻟﺐ ﻭ ﺍﻳﺠﺎﺩ ﻟﮑﻪ‬

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 ‫‪Gating systems‬‬
‫ﮔﻠﻮﻳﯽ ﺗﺰﺭﻳﻖ ﺭﺍﺑﻂ ﺑﻴﻦ ﺣﻔﺮﻩ ﻭ ﺭﺍﻫﮕﺎﻩ ﺍﺳﺖ ﻭ ﺑﻨﺎ ﺑﻪ ﻧﻮﻉ ﻣﻮﺍﺩ ﻭ ﻃﺮﺍﺣﯽ ﻗﻄﻌﻪ )ﻫﻨﺪﺳﻪ‪ ،‬ﺿﺨﺎﻣﺖ‬
‫ﻭ ‪ (...‬ﺍﻧﻮﺍﻉ ﻣﺨﺘﻠﻔﯽ ﺍﺯ ﮔﻠﻮﻳﯽﻫﺎ ﻭﺟﻮﺩ ﺩﺍﺭﺩ‪.‬‬
‫« ﮔﻠﻮﻳﯽ ﺗﺰﺭﻳﻖ ﺑﺎﻳﺪ ﺗﺎ ﺣﺪ ﺍﻣﮑﺎﻥ ﮐﻮﭼﮏ ﺑﺎﺷﺪ‪.‬‬
‫« ﺑﻪ ﺭﺍﺣﺘﯽ ﺍﺯ ﻗﺎﻟﺐ ﺧﺎﺭﺝ ﺷﻮﺩ‪.‬‬
‫« ﺑﻪ ﺧﻮﺑﯽ ﺍﺯ ﻗﻄﻌﻪ ﺟﺪﺍ ﺷﻮﺩ ﻭ ﻧﻘﺼﯽ ﺭﻭﯼ ﻗﻄﻌﻪ ﺑﺎﻗﯽ ﻧﮕﺬﺍﺭﺩ‪.‬‬
‫« ﺍﺯ ﺍﻳﺠﺎﺩ ﺟﺖ ‪ ،‬ﭘﻮﺩﺭ ﺷﺪﻥ ﻭ ﺟﺪﺍﻳﺶ ﺟﺮﻳﺎﻥ ﺟﻠﻮﮔﻴﺮﯼ ﺷﻮﺩ ﻭ ﭼﺮﺧﺶ ﺭﺥ ﻧﺪﻫﺪ‪.‬‬

‫ﻧﻮﻉ ﻭ ﺍﻧﺪﺍﺯﻩ ﮔﻠﻮﻳﯽ ﭘﺎﺭﺍﻣﺘﺮ ﺑﺴﻴﺎﺭ ﻣﻬﻤﯽ ﺍﺳﺖ ﻭ ﺑﺮ ﺑﺴﻴﺎﺭﯼ ﺍﺯ ﭘﺎﺭﺍﻣﺘﺮﻫﺎﯼ ﺩﻳﮕﺮ ﺗﺎﺛﻴﺮ ﻣﯽﮔﺬﺍﺭﺩ‪:‬‬
‫« ﻣﺤﺪﻭﺩ ﮐﺮﺩﻥ ﺟﺮﻳﺎﻥ ﭘﻠﻴﻤﺮ )ﺩﺑﯽ ﻋﺒﻮﺭﯼ(‬
‫« ﺍﻳﺠﺎﺩ ﻧﺮﺥ ﺑﺮﺷﯽ ﺑﺎﻻ )‪ (high shear rate‬ﻭ ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎﯼ ﻣﺬﺍﺏ‬
‫« ﺍﻓﺖ ﻓﺸﺎﺭ ﺯﻳﺎﺩ ﻭ ﻧﻴﺎﺯ ﺑﻪ ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‬

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 ‫‪Gating systems‬‬
‫• ﺑﺰﺭﮔﺘﺮ ﺷﺪﻥ ﮔﻠﻮﻳﯽ‪:‬‬
‫« ﭘﺮ ﺷﺪﻥ ﺭﺍﺣﺖﺗﺮ ﻗﺎﻟﺐ‪ ،‬ﺍﻓﺖ ﻓﺸﺎﺭ ﮐﻤﺘﺮ‪ ،‬ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎﯼ ﮐﻤﺘﺮ ﻭ ﺩﺭ ﺑﻌﻀﯽ ﻣﻮﺍﺭﺩ ﺧﻨﮏ ﺷﺪﻥ ﻃﻮﻻﻧﯽﺗﺮ ﻭ‬
‫ﺳﻴﮑﻞ ﻃﻮﻻﻧﯽﺗﺮ‬
‫• ﮐﻮﭼﮑﺘﺮ ﺷﺪﻥ ﮔﻠﻮﻳﯽ‪:‬‬
‫« ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﺑﺎﻻﺗﺮ‪ ،‬ﻣﺸﮑﻞ ﭘﺮ ﺷﺪﻥ ﮐﺎﻣﻞ ﻗﺎﻟﺐ‬
‫ﺑﺮﺍﯼ ﺍﻃﻤﻴﻨﺎﻥ ﺍﺯ ﭘﺮ ﺷﺪﻥ ﻳﮑﻨﻮﺍﺧﺖ ﻗﺎﻟﺐ ﺿﺮﻭﺭﯼ ﺍﺳﺖ ﺳﻴﺴﺘﻢ ﺗﻐﺬﻳﻪ ﺷﺎﻣﻞ ‪ sprue, runner‬ﻭ ‪gate‬‬
‫ﺑﺎﻻﻧﺲ ﺑﺎﺷﺪ‪ .‬ﺩﺭﺗﻌﻴﻴﻦ ﻣﻮﻗﻴﻌﺖ ﻭ ﺍﻧﺪﺍﺯﺓ ﮔﻠﻮﻳﯽ‪:‬‬
‫ﺑﺎﻻﻧﺲ ﺷﺪﻥ ﺳﻴﺴﺘﻢ ﺗﻐﺬﻳﻪ ﺑﻪ ﻣﻮﻗﻴﻌﺖ ﻭ ﺳﺎﻳﺰ ﮔﻠﻮﻳﯽ ﺑﺴﺘﮕﯽ ﺷﺪﻳﺪ ﺩﺍﺭﺩ‪.‬‬ ‫«‬
‫ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ﺗﺠﺮﺑﻪ ﻫﺎﯼ ﻗﺒﻠﯽ ﻳﺎ ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ﺷﺒﻴﻪ ﺳﺎﺯﯼ‬ ‫«‬
‫ﺩﺭ ﺗﺰﺭﻳﻖ ﺳﺮﻳﻊ ﻗﻄﻌﺎﺕ ﺟﺪﺍﺭ ﻧﺎﺯﮎ‪ ،‬ﺧﻨﮏ ﮐﺎﺭﯼ )ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ﺁﻟﻴﺎﮊﻫﺎﯼ ﻫﺎﺩﯼ ﺣﺮﺍﺭﺕ‪ ،‬ﻣﺲ – ﺑﺮﻟﻴﻮﻡ(‬ ‫«‬
‫ﺍﻃﺮﺍﻑ ‪ gate‬ﺿﺮﻭﺭﯼ ﺍﺳﺖ‪.‬‬
‫ﻻ ﻣﻌﺎﺩﻝ )‪ %50‬ﺗﺎ ‪ (%80‬ﺿﺨﺎﻣﺖ ﻗﻄﻌﻪ ﺍﺳﺖ‪.‬‬ ‫ﺿﺨﺎﻣﺖ ‪ gate‬ﻣﻌﻤﻮ ﹰ‬ ‫«‬
‫ﺍﺯ ﻣﺤﻞﻫﺎﯼ ﺍﻋﻤﺎﻝ ﻧﻴﺮﻭﯼ ﺑﺰﺭﮒ ﺩﻭﺭ ﺑﺎﺷﺪ‪.‬‬ ‫«‬
‫ﺍﺯ ﻧﻮﺍﺣﯽ ﺿﺨﺎﻣﺖ ﻧﺎﺯﮎ ﻭ ﻳﺎ ﺗﻐﻴﻴﺮ ﻧﺎﮔﻬﺎﻧﯽ ﺿﺨﺎﻣﺖ ﻗﻄﻌﻪ ﺩﻭﺭ ﺑﺎﺷﺪ‪.‬‬ ‫«‬
‫ﻗﺴﻤﺖ ﺿﺨﻴﻢﺗﺮﻗﻄﻌﻪ ﻣﻨﺎﺳﺐﺗﺮ ﺍﺳﺖ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﮐﻪ ﺍﺛﺮ ﺁﻥ‪ ،‬ﻇﺎﻫﺮ ﻗﻄﻌﻪ ﺭﺍ ﺧﺮﺍﺏ ﻧﮑﻨﺪ‪.‬‬ ‫«‬
‫ﺍﺯ ﺗﻮﻟﻴﺪ ﺟﺖ ﺟﻠﻮﮔﻴﺮﯼ ﺷﻮﺩ‪.‬‬ ‫«‬
‫ﻃﻮﻝ ﺁﻥ ﺑﻪ ﻣﻨﻈﻮﺭ ﺍﻓﺖ ﻓﺸﺎﺭ ﮐﻢ ﻭ ﺗﺎ ﺣﺪ ﺍﻣﮑﺎﻥ ﮐﻮﭼﮏ ﺑﺎﺷﺪ‪.‬‬ ‫«‬ ‫‪37‬‬
Gating systems

38
 ‫‪Mold Cooling‬‬
‫ﺍﮔﺮﭼﻪ ﺣﺴﺎﺳﻴﺖ ﺳﻴﺴﺘﻢ ﺧﻨﮏ ﮐﺎﺭﯼ ﺑﺴﻴﺎﺭ ﺟﺪﯼ ﺍﺳﺖ ﻭ ﺑﺮﻣﺪﺕ ﺯﻣﺎﻥ ﺳﻴﮑﻞ ﺗﺰﺭﻳﻖ‪ ،‬ﻣﻴﺰﺍﻥ ﺍﻋﻮﺟﺎﺝ ﻭ‬
‫ﺗﺎﺑﻴﺪﮔﯽ ﻭ ﭘﺮ ﺷﺪﻥ ﺣﻔﺮﻩﻫﺎ ﺗﺎﺛﻴﺮ ﺟﺪﯼ ﺩﺍﺭﺩ ﺍﻣﺎ ﺩﺭ ﻓﺎﺯ ﻃﺮﺍﺣﯽ‪ ،‬ﻇﺮﻓﻴﺖ ﻭ ﺍﻧﺪﺍﺯﻩ ﻭ ﺁﺭﺍﻳﺶ ﻣﺴﻴﺮﻫﺎﯼ ﺧﻨﮏ‬
‫ﮐﻦ ﺩﺭ ﻣﺮﺣﻠﺔ ﺍﻭﻝ ﻃﺮﺍﺣﯽ ﻗﺎﻟﺐ ﻣﻮﺭﺩ ﺗﻮﺟﻪ ﻗﺮﺍﺭ ﻧﻤﯽﮔﻴﺮﺩ‪.‬‬
‫‪ Layout‬ﺳﻴﺴﺘﻢ ﺧﻨﮏ ﮐﺎﺭﯼ‪ ،‬ﻣﺘﻨﺎﺳﺐ ﺑﺎ ﺿﺨﺎﻣﺖ ﻗﻄﻌﻪ ﻭ ﻣﺴﻴﺮ ﭘﺮ ﺷﺪﻥ ﺣﻔﺮﻩ ﺗﻌﻴﻴﻦ ﻣﯽﺷﻮﺩ‬ ‫«‬
‫ﻫﺪﻑ ﺧﻨﮏ ﮐﺎﺭﯼ ﺟﻠﻮﮔﻴﺮﯼ ﮐﺮﺩﻥ ﺍﺯ ﺩﺍﻍ ﺷﺪﻥ ﺩﺭ ﻧﻮﺍﺣﯽ ﺧﺎﺹ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﮐﻪ ﺑﻌﻀﯽ ﺍﺯ ﻧﻮﺍﺣﯽ ﺑﻴﺶ ﺍﺯ‬ ‫«‬
‫ﺍﻧﺪﺍﺯﻩ ﺳﺮﺩ ﻧﺸﻮﺩ ﺯﻳﺮﺍ ﺑﺎﻋﺚ ﺗﺎﺑﻴﺪﮔﯽ ‪ warpage‬ﻣﯽﺷﻮﺩ‪.‬‬
‫ﺩﺭ ﻧﻮﺍﺣﯽ ﺧﺎﺻﯽ ﻣﻤﮑﻦ ﺍﺳﺖ ﺍﺯ ‪ insert‬ﻫﺎﯼ ﻫﺎﺩﯼ ﺣﺮﺍﺭﺕ )‪ (Belyllium – Copper‬ﮐﻤﮏ ﮔﺮﻓﺘﻪ‬ ‫«‬
‫ﺷﻮﺩ‪.‬‬
‫ﮐﺎﻧﺎﻟﻬﺎﯼ ﻣﻮﺍﺩ ﺧﻨﮏ ﮐﺎﺭﯼ ﻭ ﻣﻘﻄﻊ ﺁﻧﻬﺎ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﻃﺮﺍﺣﯽ ﻣﯽﺷﻮﻧﺪ ﺗﺎ ﺟﺮﻳﺎﻥ ﺗﻮﺭﺑﻮﻻﻧﺲ ﺑﺎﺷﺪ‬ ‫«‬
‫ﺑﺎﺯﺩﻳﺪ ﻣﻨﻈﻢ ﻭ ﺍﺳﻴﺪ ﺷﻮﻳﯽ ﺑﺮﺍﯼ ﺭﺳﻮﺏ ﺯﺩﺍﻳﯽ ﺑﺎ ﻫﺪﻑ ﺍﻓﺰﺍﻳﺶ ﺍﻧﺘﻘﺎﻝ ﺣﺮﺍﺭﺕ ﻭ ﺍﻓﺖ ﻓﺸﺎﺭ ﮐﻤﺘﺮ ﺩﺭ ﻣﺪﺍﺭ ﻻﺯﻡ‬ ‫«‬
‫ﺍﺳﺖ‪.‬‬
‫ﺩﺭ ﺣﺎﻟﺖ ﺍﻳﺪﻩﺁﻝ‪ ،‬ﺍﺧﺘﻼﻑ ﺩﻣﺎﯼ ﻭﺭﻭﺩﯼ ﻭ ﺧﺮﻭﺟﯽ ﺁﺏ ﺧﻨﮏ ﮐﻦ‪ 1‬ﺩﺭﺟﻪ ﻣﯽﺑﺎﺷﺪ‪.‬‬ ‫«‬
‫ﺍﻧﺪﺍﺯﻩﮔﻴﺮﯼ ﺩﻣﺎ ﻭ ﻓﺸﺎﺭ ﻣﻮﺍﺩ‪ ،‬ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ﺍﻟﻤﺎﻧﻬﺎﯼ ﺑﺎ ﺍﻓﺖ ﻓﺸﺎﺭ ﭘﺎﻳﻴﻦ ﺑﺴﻴﺎﺭ ﻣﻔﻴﺪ ﺍﺳﺖ‪.‬‬ ‫«‬

‫‪39‬‬
 ‫‪Ejector System‬‬
‫• ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ ﻗﻄﻌﺎﺕ ﻗﺎﻟﺐﮔﻴﺮﯼ ﺷﺪﻩ ﺑﻪ ﺭﻭﺵﻫﺎﯼ ﻣﺨﺘﻠﻒ ﺻﻮﺭﺕ ﻣﯽﮔﻴﺮﺩ‪.‬‬

‫• ﻓﺸﺎﺭ ﻫﻮﺍ ← ﻗﻄﻌﺎﺕ ﺟﺪﺍﺭ ﻧﺎﺯﮎ ﮐﻪ ‪ shrinkage‬ﺩﺍﺷﺘﻪ ﺑﺎﺷﻨﺪ‬

‫• ﺧﻼﺀ‬

‫• ﭘﻴﻦﻫﺎﯼ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯ‬

‫• ﺭﻭﺵ ﺗﺮﮐﻴﺒﯽ‬

‫‪40‬‬
 ‫‪Injection Molding Cycle‬‬
‫ﻓﺮﺁﻳﻨﺪ ﺗﺰﺭﻳﻖ ﭘﻼﺳﺘﻴﮏ ﺩﺭ ﻗﺎﻟﺐ ﺷﺎﻣﻞ ﭼﻨﺪ ﻗﺪﻡ ﻣﺘﻮﺍﻟﯽ ﺍﺳﺖ ﮐﻪ ﭘﺸﺖ ﺳﺮﻫﻢ ﺗﮑﺮﺍﺭ ﻣﯽﺷﻮﺩ‪ .‬ﺩﺭ ﺷﺮﻭﻉ ﺳﻴﮑﻞ‬
‫ﺣﺎﻟﺘﯽ ﺭﺍ ﺩﺭ ﻧﻈﺮ ﻣﯽ ﮔﻴﺮﻳﻢ ﮐﻪ‪:‬‬
‫– ﭘﻴﻦﻫﺎﯼ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯ ﺟﻤﻊ ﺷﺪﻩﺍﻧﺪ‬
‫– ﻭﺍﺣﺪ ﺗﺰﺭﻳﻖ ﺑﺮﺍﯼ ﺿﺮﺏ ﺟﺪﻳﺪ ﺁﻣﺎﺩﻩﺍﺳﺖ‬
‫ﻗﺪﻡﻫﺎﯼ ﻣﺘﻮﺍﻟﯽ ﺳﻴﮑﻞ ﻋﺒﺎﺭﺗﻨﺪ ﺍﺯ‪:‬‬
‫« ﻗﺎﻟﺐ ﺑﺴﺘﻪ ﻣﯽﺷﻮﺩ ﻭ ‪ clamp‬ﻫﺎ ﻓﺸﺎﺭ ﺣﺪﺍﮐﺜﺮ ﺭﺍ ﺑﻪ ﻓﮏ ﻣﺘﺤﺮﮎ ﺍﻋﻤﺎﻝ ﻣﯽﮐﻨﻨﺪ‪(Mold close).‬‬
‫« ﺗﺰﺭﻳﻖ‪ :‬ﻣﻮﺍﺩ ﺑﻪ ﺩﺍﺧﻞ ﺣﻔﺮﻩ ﺗﺰﺭﻳﻖ ﻣﯽﺷﻮﺩ )‪(Injection‬‬
‫« ﻣﻮﺍﺩ ﺩﺭ ﻗﺎﻟﺐ ﺗﺎ ﺣﺪ ﺍﻣﮑﺎﻥ ﭘﺮ ﻣﯽﺷﻮﺩ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﮐﻪ ﻓﺸﺎﺭ ﺍﺿﺎﻓﯽ ﻭﺍﺭﺩ ﻧﺸﻮﺩ ﺍﻣﺎ ﻗﺎﻟﺐ ﮐﺎﻣ ﹰ‬
‫ﻼ ﭘﺮ ﻭ‬
‫ﻳﮑﻨﻮﺍﺧﺖ ﺷﻮﺩ‪.‬‬
‫« ﻓﺸﺎﺭ ﺍﻋﻤﺎﻝ ﺷﺪﻩ ﺗﺎ ﻣﺪﺗﯽ ﺭﻭﯼ ﭘﻼﺳﺘﻴﮏ ﺑﺎﻗﯽ ﻣﯽﻣﺎﻧﺪ ﻭ ﺩﺭ ﻋﻤﻞ ﺑﺎﻋﺚ ﺟﺒﺮﺍﻥ ﻗﺴﻤﺘﯽ ﺍﺯ ‪shrinkage‬‬
‫ﻣﯽﺷﻮﺩ )‪(Packing‬‬
‫« ﺑﺮﮔﺸﺖ ﻣﺎﺭﭘﻴﭻ ﺿﺮﺏ ﺑﻌﺪﯼ ﺭﺍ ﻣﻬﻴﺎ ﻣﯽﮐﻨﺪ‪(Plastication –screw back) .‬‬
‫« ﺧﻨﮏ ﮐﺎﺭﯼ ﻫﻤﺰﻣﺎﻥ ﺑﺎ ﺷﺮﻭﻉ ﺗﻮﻟﻴﺪ ﭘﻼﺳﺘﻴﮏ ﺑﺮﺍﯼ ﺿﺮﺏ ﺑﻌﺪﯼ ﺁﻏﺎﺯ ﻣﯽﺷﻮﺩ‪ .‬ﺩﺭ ﻋﻤﻞ‪ ،‬ﺧﻨﮏ ﮐﺎﺭﯼ ﺑﻪ‬
‫ﻣﺤﺾ ﺗﻤﺎﺱ ﺑﺎ ﺳﻄﺢ ﻗﺎﻟﺐ ﺁﻏﺎﺯ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﻗﺎﻟﺐ ﺑﺎﺯ ﻣﯽﺷﻮﺩ ﻭ ﭘﻴﻦﻫﺎﯼ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯ ﻓﻌﺎﻝ ﻣﯽﺷﻮﻧﺪ )‪(Mold open‬‬
‫« ﻣﺪﺕ ﺯﻣﺎﻥ ﻫﺮ ﻣﺮﺣﻠﻪ ﺑﺴﺘﻪ ﺑﻪ ﻧﻮﻉ ﮐﺎﺭ ﻣﺘﻔﺎﻭﺕ )ﻧﻮﻉ ﻗﻄﻌﻪ‪ ،‬ﻣﺎﺷﻴﻦ‪ ،‬ﻧﻮﻉ ﻗﺎﻟﺐ ‪(...‬‬
‫ﻼ ﺣﺪﻭﺩ ﻧﺼﻒ ﺯﻣﺎﻥ ﻫﺮ ﺳﻴﮑﻞ ﺻﺮﻑ ﺧﻨﮏ ﮐﺎﺭﯼ ﻣﯽﺷﻮﺩ ﺗﺎ ﺍﺯ ﺗﺎﺑﻴﺪﮔﯽ ﭘﺲ ﺍﺯ ﭘﺎﻳﺎﻥ ﻗﺎﻟﺐ ﮔﻴﺮﯼ‬ ‫« ﻋﻤ ﹰ‬
‫ﺟﻠﻮﮔﻴﺮﯼ ﺷﻮﺩ)‪(Post mold distortion‬‬

‫‪41‬‬
 Injection Molding Cycle

(1) Close the mold (2) Inject the melt

(3) Retract the screw (4) Open mold – eject part

42
 Injection Molding Cycle
¾ The total cycle time is: tcycle=tclosing+tinjection+tpacking+tcooling+tejection

43
Typical cavity pressure cycle

Cooling time generally dominates cycle time 44

Typical temperature history in part

Time(sec)

Cooling time generally dominates cycle time

45
 Processing window

¾The temperature must be high

enough to melt the polymer but not
too high to cause thermal
degradation

¾Pressure must be high

enough to avoid short shots
(i.e. partially filled cavities) but
not too high (because we will
have flash at the mold contact
surfaces)

46
Injection molding cycle

47
Injection molding cycle

48
 ‫‪Molding process‬‬
‫• ﻫﻤﮕﻦ ﺷﺪﻥ ﻣﺬﺍﺏ ﻭ ﮐﻴﻔﻴﺖ ﻣﺤﺼﻮﻝ‪:‬‬
‫« ﮐﻴﻔﻴﺖ ﻣﺤﺼﻮﻝ ﻧﻬﺎﻳﯽ ﺑﺴﺘﮕﯽ ﺑﻪ ﺯﻣﺎﻧﺒﻨﺪﯼ ﺳﻴﮑﻞ ﺗﺰﺭﻳﻖ ﺩﺍﺭﺩ‪.‬‬
‫« ﻫﻤﮕﻦ ﺷﺪﻥ ﻣﺬﺍﺏ ﺍﺯ ﻧﻈﺮ ﺩﻣﺎ ﻭ ﺗﺮﮐﻴﺒﺎﺕ ﻭ ﻭﻳﮋﮔﻴﻬﺎﯼ ﭘﻠﻴﻤﺮﯼ ﻭ ﺍﻓﺰﻭﺩﻧﯽﻫﺎ ﺗﺎﺑﻊ ﺯﻣﺎﻧﺒﻨﺪﯼ ﺳﻴﮑﻞ ﺗﺰﺭﻳﻖ‬
‫ﺍﺳﺖ‪.‬‬
‫• ﺍﻧﺪﺍﺯﻩ ﺿﺮﺏ‪:‬‬
‫« ﺍﻧﺪﺍﺯﻩ ﺿﺮﺏ ﺑﺎﻳﺪ ﺑﻪ ﻗﺪﺭﯼ ﺑﺎﺷﺪ ﮐﻪ ﺩﺭ ﻣﺮﺣﻠﺔ ‪ ،packing‬ﺍﻧﺪﮐﯽ ﺍﺯ ﻣﻮﺍﺩ ﺩﺭ ﺍﻧﺘﻬﺎﯼ ﻣﺎﺭﭘﻴﭻ ﺗﺤﺖ ﻓﺸﺎﺭ‬
‫ﺑﻤﺎﻧﺪ‪.‬‬
‫• ﺳﺎﻳﺶ ﺩﺭ ﻣﺎﺭﭘﻴﭻ ﻳﺎ ‪:barrel‬‬
‫ﺳﺎﻳﺶ ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﻓﺎﺻﻠﻪ ﺑﻴﻦ ﻣﺎﺭﭘﻴﭻ ﻭ ﺍﺳﺘﻮﺍﻧﻪ ﺑﻴﺮﻭﻧﯽ ﻣﯽﺷﻮﺩ‪ .‬ﺩﺭ ﻧﺘﻴﺠﻪ‪:‬‬ ‫«‬
‫ﺑﺎﻋﺚ ﺑﺮﮔﺸﺖ ﻣﺬﺍﺏ ﻣﯽﮔﺮﺩﺩ‬ ‫«‬
‫ﺩﺭ ﻣﺴﻴﺮ ﻣﺎﻧﺪﻥ ﻣﺬﺍﺏ ﻣﯽﮔﺮﺩﺩ ﻭ ﺑﻪ ﺟﻠﻮ ﻣﻨﺘﻘﻞ ﻧﻤﯽﺷﻮﺩ‬ ‫«‬
‫ﺑﺎﻋﺚ ﺗﺨﺮﻳﺐ ﭘﻠﻴﻤﺮ ﻣﯽﺷﻮﺩ‬ ‫«‬
‫ﺗﺎﺛﻴﺮ ﺑﺮ ﺍﻧﺪﺍﺯﺓ ﺿﺮﺏ ﻣﯽﮔﺬﺍﺭﺩ‬ ‫«‬

‫‪49‬‬
 ‫‪Molding process‬‬
‫• ﻓﺸﺎﺭ ﭘﺸﺖ‪:‬‬
‫« ‪ B.P‬ﺩﺭ ﮐﻤﺘﺮﻳﻦ ﻣﻘﺪﺍﺭ ﻣﻤﮑﻦ ﺗﻨﻈﻴﻢ ﻣﯽﺷﻮﺩ ﺗﺎ ﺍﻣﮑﺎﻥ ﺍﻧﺘﻘﺎﻝ ﻣﺬﺍﺏ ﻫﻤﮕﻦ ﻣﻴﺴﺮ ﺷﻮﺩ ﻭ ﺍﺯ ﺍﻧﺘﻘﺎﻝ ﻣﻮﺍﺩ‬
‫ﺫﺍﺏ ﻧﺸﺪﻩ ﻭ ﺩﺍﻧﻪﺍﯼ ﺟﻠﻮﮔﻴﺮﯼ ﺷﻮﺩ‪.‬‬
‫« ﻣﻘﺪﺍﺭﯼ ‪ B.P‬ﻧﻴﺎﺯ ﺍﺳﺖ ﺗﺎ ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎﯼ ﻣﺬﺍﺏ ﺷﻮﺩ ﻭ ﭘﻼﺳﺘﻴﮏﻫﺎﯼ ﺭﻧﮕﯽ ﻳﮑﻨﻮﺍﺧﺖﺗﺮﯼ ﺍﻳﺠﺎﺩ‬
‫ﮐﻨﺪ ﺯﻳﺮﺍ ﺩﺭ ﻓﺎﺯ ‪ ،plastication‬ﺍﮐﺜﺮ ﺍﻧﺮﮊﯼ ﻣﻮﺭﺩ ﻧﻴﺎﺯ ﺍﺯ ﺗﻨﺶﻫﺎﯼ ﺑﺮﺷﯽ ﻭ ﺍﺳﺘﻬﻼﮎ ﺍﻧﺮﮊﯼ ﻣﺮﺑﻮﻃﻪ‬
‫ﺣﺎﺻﻞ ﻣﯽﮔﺮﺩﺩ‪.‬‬
‫« ﻫﻨﮕﺎﻣﯽ ﮐﻪ ﻓﺸﺎﺭ ﭘﺸﺖ ﺍﺳﮑﺮﻭ ﺍﻓﺰﺍﻳﺶ ﻣﯽﻳﺎﺑﺪ‪ ،‬ﺑﺮﺍﯼ ﺍﻧﺘﻘﺎﻝ ﻣﻮﺍﺩ ﺗﻮﺳﻂ ‪ screw‬ﮐﺎﺭ ﺑﻴﺸﺘﺮﯼ ﻧﻴﺎﺯ ﺍﺳﺖ ﮐﻪ‬
‫ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎﯼ ﺑﻴﺸﺘﺮ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﮐﺎﺭ ‪ screw‬ﺑﺎﻋﺚ ﺗﻮﻟﻴﺪ ﻣﺬﺍﺏ ﻳﮑﻨﻮﺍﺧﺖﺗﺮ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﺑﻴﺶ ﺍﺯ ﺣﺪ ‪ B.P.‬ﺑﺎﻋﺚ ﺗﺨﺮﻳﺐ ﭘﻼﺳﺘﻴﮏ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﺑﻴﺶ ﺍﺯ ﺣﺪ ‪ B.P.‬ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ‪ screw recovery time‬ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﺑﻴﺶ ﺍﺯ ﺣﺪ ‪ B.P.‬ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﻫﺰﻳﻨﻪ ﺍﻧﺮﮊﯼ ﻣﺼﺮﻓﯽ ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﺑﻴﺶ ﺍﺯ ﺣﺪ ‪ B.P.‬ﺑﺎﻋﺚ ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﺳﺎﻳﺶ ﻣﯽﺷﻮﺩ‪.‬‬

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 ‫‪Molding process‬‬
‫• ﻧﺴﺒﺖ ﺿﺮﺏ ﺑﻪ ﻇﺮﻓﻴﺖ ﻟﻮﻟﺔ ﻣﺎﺭﭘﻴﭻ‪SBCR (shot barrel capacity ratio) :‬‬
‫ﻣﺤﺪﻭﺩﺓ ﺍﻳﺪﻩﺁﻝ ‪ 30‬ﺗﺎ ‪ %60‬ﺍﺳﺖ‪.‬‬ ‫«‬
‫ﮐﻢ ﺑﻮﺩﻥ ‪ SBCR‬ﺑﺪﻳﻦ ﻣﻌﻨﺎﺳﺖ ﮐﻪ ﻣﻘﺪﺍﺭ ﺯﻳﺎﺩﯼ ﺍﺯ ﻣﻮﺍﺩ )ﺑﻪ ﺍﻧﺪﺍﺯﻩ ﭼﻨﺪ ﺿﺮﺏ( ﺩﺭ ﺩﺍﺧﻞ ﻟﻮﻟﻪ ﺩﺭ ﺣﺎﻝ‬ ‫«‬
‫ﮔﺮﻡ ﺷﺪﻥ ﺍﺳﺖ ﮐﻪ ﺑﺎﻋﺚ ﺗﺨﺮﻳﺐ ﭘﻠﻴﻤﺮ ﻣﯽﺷﻮﺩ‪.‬‬
‫ﺑﺰﺭﮒ ﺑﻮﺩﻥ ‪ SBCR‬ﺍﺯ ‪ %60‬ﺑﻪ ﻣﻌﻨﯽ ﺍﻳﻦ ﺍﺳﺖ ﮐﻪ ﻣﻘﺪﺍﺭ ﻣﻮﺍﺩ ﮐﻤﺘﺮ ﺍﺯ ‪ 2‬ﺿﺮﺏ ﺍﺳﺖ ﮐﻪ ﺩﺭ ﺍﻳﻦ‬ ‫«‬
‫ﺷﺮﺍﻳﻂ ﺭﺳﻴﺪﻥ ﺑﻪ ﺗﻌﺎﺩﻝ ﺩﻣﺎﻳﯽ ﻣﺸﮑﻞ ﺍﺳﺖ‪.‬‬
‫ﺑﺰﺭﮒ ﺑﻮﺩﻥ ‪ SBCR‬ﺑﻪ ﻣﻌﻨﯽ ﺯﻣﺎﻥ ﮐﻤﺘﺮ ﺑﺮﺍﯼ ﺗﻬﻴﻪ ﺿﺮﺏ ﺟﺪﻳﺪ ﺧﻮﺍﻫﺪ ﺑﻮﺩ ﻭ ﻣﻤﮑﻦ ﺍﺳﺖ ﺿﺮﺏ ﺟﺪﻳﺪ‬ ‫«‬
‫ﮐﺎﻣﻞ ﻧﺸﻮﺩ‪.‬‬
‫ﺑﺮﺍﯼ ﺩﺳﺘﻴﺎﺑﯽ ﺑﻪ ﭘﻼﺳﺘﻴﮏ ﻫﻤﮕﻦ‪ ،‬ﺗﻤﺎﻣﯽ ﻣﻮﺍﺩ ﺩﺍﻧﻪﺍﯼ ﺑﺎﻳﺪ ﺗﺎ ﻗﺒﻞ ﺍﺯ ﺭﺳﻴﺪﻥ ﺑﻪ ﻣﻴﺎﻧﺔ ﻧﺎﺣﻴﻪ ‪transition‬‬ ‫«‬
‫‪ zone‬ﻣﺎﺭﭘﻴﭻ ﺫﻭﺏ ﺷﻮﻧﺪ‪ .‬ﻣﻌﻤﻮﻻ ﺣﺪﻭﺩ ‪ %70‬ﺍﻧﺮﮊﯼ ﻣﻮﺭﺩ ﻧﻴﺎﺯ ﺗﺎ ﺍﻳﻦ ﻧﻘﻄﻪ ﺑﻪ ﻣﻮﺍﺩ ﻣﻨﺘﻘﻞ ﻣﯽ ﺷﻮﺩ‪.‬‬
‫ﺣﺮﺍﺭﺕ ﺩﺭﻳﺎﻓﺘﯽ ﺍﺯ ﮔﺮﻣﮑﻦﻫﺎ ﺳﻬﻢ ﮐﻤﺘﺮﯼ ﺭﺍ ﺩﺭ ﺍﻧﺘﻘﺎﻝ ﺍﻧﺮﮊﯼ ﺑﻪ ﻣﺬﺍﺏ ﺩﺍﺭﺩ‪ .‬ﺑﻴﺸﺘﺮ ﺣﺮﺍﺭﺕ ﺻﺮﻑ ﮔﺮﻡ‬ ‫«‬
‫ﮐﺮﺩﻥ ﺩﺍﻧﻪﻫﺎ ﺩﺭ ‪ feed zone‬ﻭ ﮔﺮﻡ ﻧﮕﻪ ﺩﺍﺷﺘﻦ ﻟﻮﻟﻪ ﺩﺭ ﻓﺮﺁﻳﻨﺪ ﺗﺰﺭﻳﻖ ﻣﯽﺷﻮﺩ‪.‬‬

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Energy needed to process

52
 ‫‪Molding process‬‬
‫• ﭘﺮ ﺷﺪﻥ ﻗﺎﻟﺐ‪:‬‬
‫« ﻭﻳﺴﮑﻮﺯﻳﺘﻪ ﻋﺎﻣﻞ ﻣﻘﺎﻭﻣﺖ ﺩﺭ ﻣﻘﺎﺑﻞ ﺍﻳﺠﺎﺩ ﺣﺮﮐﺖ ﺍﺳﺖ‬
‫« ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎﯼ ﻣﺬﺍﺏ ≡ ﮐﺎﻫﺶ ﻟﺰﺟﺖ ≡ ﭘﺮ ﺷﺪﻥ ﺁﺳﺎﻥﺗﺮ ﺣﻔﺮﻩﻫﺎ‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ≡ ﺍﻓﺰﺍﻳﺶ ﻧﺮﺥ ﺗﺰﺭﻳﻖ ≡ ﺍﻓﺰﺍﻳﺶ ‪shear rate‬‬
‫ﺑﻨﺎﺑﺮﺍﻳﻦ‪ ،‬ﺑﺮﺍﯼ ﺣﺎﻟﺖ ﻣﺸﺨﺺ ﺷﺎﻣﻞ ﺭﺯﻳﻦ‪ ،‬ﻣﺎﺷﻴﻦ ﻭ ﻗﺎﻟﺐ‪ ،‬ﺳﻪ ﻣﺘﻐﻴﺮ ﻭﺟﻮﺩ ﺩﺍﺭﺩ ﮐﻪ ﻣﯽﺗﻮﺍﻧﺪ ﺩﺭ ﭘﺮ ﺷﺪﻥ ﻗﺎﻟﺐ ﻣﻮﺭﺩ ﺗﻮﺟﻪ ﺑﺎﺷﺪ‪:‬‬
‫« ﻓﺸﺎﺭ ﭘﺮ ﺷﺪﻥ ﻗﺎﻟﺐ ‪injection / packing pressure‬‬
‫« ﻧﺮﺥ ﺗﺰﺭﻳﻖ ‪injection rate‬‬
‫« ﺩﻣﺎﯼ ﻣﺬﺍﺏ ‪melt temperature‬‬
‫• ﺗﻨﻈﻴﻢ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‪:‬‬
‫« ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﺑﻪ ﺩﻣﺎﯼ ﭘﻠﻴﻤﺮ ﻭ ‪ MI‬ﺁﻥ ﺑﺴﺘﮕﯽ ﺩﺍﺭﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ‪ ≡ MI‬ﺍﻓﺰﺍﻳﺶ ﻧﺮﺥ ﺗﺰﺭﻳﻖ ﻣﺬﺍﺏ ≡ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﮐﻤﺘﺮ ﻭ ﻳﺎ ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ ﮐﻤﺘﺮﯼ ﻣﻮﺭﺩ ﻧﻴﺎﺯ ﺍﺳﺖ‪.‬‬

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Temperature-pressure relationships

54
 ‫‪Molding process‬‬
‫ﺩﺭ ﻳﮏ ﻗﺎﻟﺒﮕﻴﺮﯼ ﺧﺎﺹ ﺑﺎ ﺯﻣﺎﻧﺒﻨﺪﯼ ﺳﻴﮑﻞ ﻭ ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ ﻳﮑﺴﺎﻥ‪ ،‬ﻳﮏ ﺭﺯﻳﻦ ﺑﺎ ‪ MI‬ﺑﺎﻻﺗﺮ‪:‬‬
‫« ﺑﻪ ﻓﺸﺎﺭ ﮐﻤﺘﺮ ﺗﺰﺭﻳﻖ ﻧﻴﺎﺯ ﺩﺍﺭﺩ‪ %25 :‬ﮐﺎﻫﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ≡ ﺩﻭ ﺑﺮﺍﺑﺮ ﺷﺪﻥ ‪MI‬‬
‫« ﺑﻪ ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ ﮐﻤﺘﺮﯼ ﻧﻴﺎﺯ ﺩﺍﺭﺩ‪ 40oC :‬ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ ﮐﻤﺘﺮ ≡ ﺩﻭ ﺑﺮﺍﺑﺮ ﺷﺪﻥ ‪MI‬‬
‫ﺗﺎﺛﻴﺮ ﺍﻓﺰﺍﻳﺶ ‪ MI‬ﺑﺮ ﻓﺸﺎﺭ ﻭ ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ ﻧﺸﺎﻥ ﻣﯽ ﺩﻫﺪ ﮐﻪ ﺑﺎ ﺍﻓﺰﺍﻳﺶ ‪ ، MI‬ﺩﻣﺎ ﻳﺎ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﮐﻤﺘﺮ‬
‫ﻣﯽﺷﻮﺩ‪ .‬ﺑﻨﺎ ﺑﺮﺍﻳﻦ‪ ،‬ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﺍﻭﻟﻴﻦ ﭘﺎﺭﺍﻣﺘﺮﯼ ﺍﺳﺖ ﮐﻪ ﺑﺎﻳﺪ ﺗﻨﻈﻴﻢ ﺷﻮﺩ ﻭ ﺑﺮ ﺭﻓﺘﺎﺭ ﻗﺎﻟﺐﮔﻴﺮﯼ ﭘﺎﺳﺦ ﺳﺮﻳﻊ‬
‫ﺑﺪﺳﺖ ﻣﯽﺩﻫﺪ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﻣﯽﺗﻮﺍﻧﺪ ﺑﺎﻋﺚ ﻣﺎﻧﺪﻥ ﺣﺒﺎﺏﻫﺎﯼ ﻫﻮﺍ ﺩﺭ ﻗﺎﻟﺐ ﺑﺎﺷﺪ ﮐﻪ ﺩﺭ ﻧﺘﻴﺠﻪ ﺳﻮﺧﺘﮕﯽ ﺳﻄﺢ ﻗﺎﻟﺐ ﺭﺍ ﺑﻪ‬
‫ﺩﻧﺒﺎﻝ ﺩﺍﺭﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‪ ،‬ﺑﺎﻋﺚ ﻓﺸﺮﺩﻩﺗﺮ ﺷﺪﻥ ﻗﻄﻌﻪ ﻭ ﮐﺎﻫﺶ ‪ shrinkage‬ﺍﺳﺖ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‪ ،‬ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎﯼ ﮔﻠﻮﻳﯽ ﺍﺳﺖ‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‪ ،‬ﺑﺎﻋﺚ ﮔﻴﺮ ﮐﺮﺩﻥ ﻗﻄﻌﻪ ﺩﺭ ﻗﺎﻟﺐ ﻣﯽ ﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‪ ،‬ﺑﺎﻋﺚ ﺍﻓﺰﺍﻳﺶ ﺗﻨﺶﻫﺎ ﺩﺭ ﻗﺎﻟﺐ ﻣﯽ ﺷﻮﺩ‪.‬‬

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Effect of Melt Index on injection
temperature and pressure

56
 ‫‪Molding process‬‬
‫• ﺍﻓﺰﺍﻳﺶ ﻧﺮﺥ ﺗﺰﺭﻳﻖ‪:‬‬
‫« ﮐﺎﻫﺶ ﻟﺰﺟﺖ ﺭﺯﻳﻦ‬
‫« ﺩﻣﺎﯼ ﻳﮑﻨﻮﺍﺧﺖﺗﺮ ﻗﻄﻌﻪ ﺩﺭ ﺍﺛﺮ ﺳﺮﻋﺖ ﻗﺎﻟﺐﮔﻴﺮﯼ‬
‫« ﻳﮑﻨﻮﺍﺧﺖ ﺷﺪﻥ ‪ shrinkage‬ﻭ ‪warpage‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻧﺮﺥ ﺗﺰﺭﻳﻖ ﺑﺪﻭﻥ ﮐﺎﻫﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﺑﺎﻋﺚ ‪ flash‬ﺩﺭ ﺻﻔﺤﻪ ﺟﺪﺍﻳﺶ ﻣﯽﺷﻮﺩ‪.‬‬
‫• ﺗﻨﻈﻴﻢ ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ‪:‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎ ≡ ﮐﺎﻫﺶ ﻟﺰﺟﺖ‬
‫« ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎ ≡ ﺗﺨﺮﻳﺐ ﭘﻠﻴﻤﺮ‬
‫« ﺍﻓﺰﺍﻳﺶ ﺩﻣﺎ ≡ ﺧﻨﮏ ﮐﺎﺭﯼ ﻃﻮﻻﻧﯽﺗﺮ‬
‫« ﺩﻣﺎﯼ ﭘﺎﻳﻴﻦ≡ ﺿﺮﺏﻫﺎﯼ ﻧﺎﻳﮑﻨﻮﺍﺧﺖ ﻭ ﻧﺎ ﻣﻄﻤﺌﻦ‬
‫« ﺩﻣﺎﯼ ﭘﺎﻳﻴﻦ≡ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﺑﺎﻻﺗﺮ‬
‫« ﺩﻣﺎﯼ ﭘﺎﻳﻴﻦ≡ ﺳﺎﻳﺶ ﺑﺎﻻﺗﺮ ﺩﺭ ﻭﺍﺣﺪ ﺗﺰﺭﻳﻖ‬

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 ‫‪Molding process‬‬
‫• ﻫﺪﻑ ؟‪:‬‬
‫• ﻫﺪﻑ ﺍﺯ ﺗﻨﻈﻴﻢ ﻧﺮﺥ ﺗﺰﺭﻳﻖ‪ ،‬ﺩﻣﺎ ﻭ ﻳﺎ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ‪ ،‬ﺭﺳﻴﺪﻥ ﺑﻪ ﺷﺮﺍﻳﻂ ﺍﻧﺘﻘﺎﻝ ﻳﮑﻨﻮﺍﺧﺖ ﻣﻮﺍﺩ ﺑﻪ ﻗﺎﻟﺐ ﺍﺳﺖ‪.‬‬
‫• ﺗﺎﺛﻴﺮ ﺗﻨﻈﻴﻤﺎﺕ ﺑﺮ ﺭﻭﯼ ﻗﻄﻌﻪ ﺑﻪ ﺻﻮﺭﺕ ﻫﺎﯼ ﻣﺨﺘﻠﻒ ﻣﺸﺎﻫﺪﻩ ﻣﯽﺷﻮﺩ‪:‬‬
‫« ﺟﺒﻬﻪ ﺟﺮﻳﺎﻥ ﺩﺭ ﻗﺎﻟﺐ ﻧﺎﻣﻨﻈﻢ ﻣﯽﺷﻮﺩ ← ﻋﻴﻮﺏ ﺳﻄﺤﯽ ﻗﻄﻌﻪ‬
‫« ﺧﻂﻫﺎﯼ ﺟﻮﺵ ﺿﻌﻴﻒ ﺩﺭ ﻗﻄﻌﻪ‬
‫« ‪ Flashing‬ﺍﺯ ﻣﺤﻞﻫﺎﯼ ﻣﺨﺘﻠﻒ‬
‫• ﺩﺭ ﻋﻤﻞ ﺑﻴﺶ ﺍﺯ ‪ %95‬ﻭﺯﻥ ﻗﻄﻌﻪ ﺩﺭ ﻣﺮﺣﻠﺔ ﺗﺰﺭﻳﻖ ﭘﺮ ﻣﯽﺷﻮﺩ‪.‬‬
‫• ﺩﺭ ﻣﺮﺣﻠﺔ ‪ paking‬ﻗﺴﻤﺖ ﮐﻤﯽ ﺍﺯ ﻗﺎﻟﺐ ﭘﺮ ﻣﯽﺷﻮﺩ ﻭ ﻗﻄﻌﻪ ﻭﺯﻥ ﻧﻬﺎﻳﯽ ﺧﻮﺩ ﺭﺍ ﭘﻴﺪﺍ ﻣﯽﮐﻨﺪ ﻭ ﺩﺭ ﺍﻳﻦ ﻣﺮﺣﻠﻪ ﺯﻣﺎﻥ‬
‫ﮐﺎﻓﯽ ﺑﺮﺍﯼ ﺍﻧﺠﻤﺎﺩ ‪ gate‬ﻭﺟﻮﺩ ﺩﺍﺭﺩ‪.‬‬
‫• ﺩﺭ ﻃﯽ ﻣﺮﺣﻠﺔ ‪ ،paking‬ﺧﻨﮏ ﮐﻦ )ﻣﻌﻤﻮ ﹰ‬
‫ﻻ ﺁﺏ ﻭ ﻳﺎ ﻫﻤﺮﺍﻩ ﺑﺎ ﺍﺗﻴﻠﻦ ﮔﻠﻴﮑﻮﻝ( ﻗﺎﻟﺐ ﺭﺍ ﺳﺮﺩ ﻣﯽﮐﻨﺪ‪.‬‬
‫• ﺩﺭﻋﻤﻞ ﺑﺎ ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ﺟﺮﻳﺎﻥ ﺩﺭ ﻫﻢ ﻭ ﺍﻓﺰﺍﻳﺶ ﺩﺑﯽ ﺟﺮﻳﺎﻥ ﺧﻨﮏ ﮐﻦ ﻣﯽﺗﻮﺍﻥ ﺳﺮﻋﺖ ﺧﻨﮏ ﮐﺎﺭﯼ ﺭﺍ ﺍﻓﺰﺍﻳﺶ ﺩﺍﺩ ﻭ ﺍﺯ‬
‫ﮐﺎﻫﺶ ﺩﻣﺎﯼ ﺳﻴﺎﻝ ﻣﻮﺛﺮ ﺗﺮ ﺍﺳﺖ‪.‬‬

‫‪58‬‬
 ‫‪Molding process‬‬
‫ﺑﺎ ﺗﻤﺎﺱ ﺭﺯﻳﻦ ﺑﺎ ﻗﺎﻟﺐ‪ ،‬ﭘﻼﺳﺘﻴﮏ ﻣﺠﺎﻭﺭ ﺩﻳﻮﺍﺭﻩ ﺟﺎﻣﺪ ﻣﯽﺷﻮﺩ ﻭ ﻻﻳﻪﺍﯼ ﺟﺎﻣﺪ ﺩﺭ ﻣﺠﺎﻭﺭ ﺩﻳﻮﺍﺭﻩ ﺍﻳﺠﺎﺩ ﻣﯽﺷﻮﺩ ﻭ ﺟﺮﻳﺎﻥ ﺍﺯ ﺩﺍﺧﻞ‬ ‫•‬
‫ﻼ ﺟﺎﻣﺪ ﻣﯽﺷﻮﺩ‪.‬‬‫ﻣﺠﺮﺍﯼ ﺍﻳﺠﺎﺩ ﺷﺪﻩ ﭘﻴﺶ ﻣﯽﺭﻭﺩ‪ .‬ﺑﺎ ﺍﺩﺍﻣﻪ ﺳﺮﺩﻥ ﺷﺪﻥ‪ ،‬ﻣﺴﻴﺮ ﮐﺎﻣ ﹰ‬
‫« ﻃﺮﺍﺣﯽ ﻣﻄﻠﻮﺏ ﺑﻪ ﮔﻮﻧﻪﺍﯼ ﺍﺳﺖ ﮐﻪ ﭘﻼﺳﺘﻴﮏ ﮐﺎﻣ ﹰ‬
‫ﻼ ﻗﺎﻟﺐ ﺭﺍ ﭘﺮ ﮐﻨﺪ ﻗﺒﻞ ﺍﺯ ﺁﻧﮑﻪ ﻣﺠﺮﺍ ﺑﺴﺘﻪ ﺷﻮﺩ‪.‬‬
‫« ﺩﺭ ﻓﺎﺯ ﺧﻨﮏﮐﺎﺭﯼ‪ ،‬ﻧﺰﺩﻳﮏ ‪ gate‬ﺩﺍﻏﺘﺮﻳﻦ ﻧﺎﺣﻴﻪ ﺍﺳﺖ ﺯﻳﺮﺍ ﻣﺬﺍﺏ ﺩﺭ ﻓﺎﺯ ‪ packing‬ﻧﻴﺰ ﻭﺍﺭﺩ ﻗﺎﻟﺐ ﻣﯽﺷﻮﺩ‪ .‬ﻧﻮﺍﺣﯽ ﺍﻧﺘﻬﺎﻳﯽ‬
‫ﮐﻤﺘﺮﻳﻦ ﺩﻣﺎ ﺭﺍ ﺧﻮﺍﻫﻨﺪ ﺩﺍﺷﺖ‪.‬‬
‫« ﺍﺧﺘﻼﻑ ﺩﻣﺎﯼ ﻧﻘﺎﻁ ﻣﺨﺘﻠﻒ ﻗﻄﻌﻪ ≡ ﺍﺧﺘﻼﻑ ﺩﺭ ﻣﻴﺰﺍﻥ ‪ shrinkage‬ﻭ ‪warpage‬‬
‫ﺑﻨﺎﺑﺮﺍﻳﻦ ﺑﺎﻳﺪ ﺍﺧﺘﻼﻑ ﺩﻣﺎﯼ ﻗﻄﻌﻪ ﺭﺍ ﺣﺪﺍﻗﻞ ﻧﻤﻮﺩ‪:‬‬ ‫•‬
‫« ﻭﺭﻭﺩﯼ ﺁﺏ ﺳﺮﺩ ﺑﻪ ﻧﺰﺩﻳﮑﯽ ﮔﻠﻮﻳﯽ ﮐﻪ ﺩﺍﻏﺘﺮﻳﻦ ﻧﺎﺣﻴﻪ ﺍﺳﺖ ﻭ ﺧﺮﻭﺟﯽ ﺩﺭ ﺩﻭﺭﺗﺮﻳﻦ ﻭ ﺳﺮﺩﺗﺮﻳﻦ ﻧﻘﺎﻁ ﻗﺎﻟﺐ ﻗﺮﺍﺭ ﮔﻴﺮﺩ ‪ .‬ﺩﺭ ﺍﻳﻦ‬
‫ﺷﺮﺍﻳﻂ‪ ،‬ﺧﻨﮏ ﮐﺎﺭﯼ ﻗﺎﻟﺐ ﻳﮑﻨﻮﺍﺧﺖ ﻧﻴﺴﺖ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻧﺮﺥ ﺗﺰﺭﻳﻖ ﺑﺎﻋﺚ ﻳﮑﻨﻮﺍﺧﺖﺗﺮ ﺷﺪﻥ ﺩﻣﺎﯼ ﻗﻄﻌﻪ ﺧﻮﺍﻫﺪ ﺷﺪ‪.‬‬
‫ﻻ ﺩﻣﺎﯼ ﻗﺎﻟﺐ ﺩﺭ ﺁﺳﺘﺎﻧﻪ ﺗﺰﺭﻳﻖ ‪50oC‬ﺗﺎ ‪ 20‬ﺍﺳﺖ ﻭ ﺩﻣﺎﯼ ﺁﺏ ﮐﻤﺘﺮ ﺍﺯ ‪15oC‬ﺍﺳﺖ‪.‬‬
‫ﻣﻌﻤﻮ ﹰ‬ ‫•‬
‫« ﻗﺎﻟﺐ ﺧﻨﮏ ≡ ﺍﺯ ﺻﻴﻘﻠﯽ ﺷﺪﻥ ﺳﻄﺢ ﻗﻄﻌﻪ ﻣﯽﮐﺎﻫﺪ‬
‫« ﻗﺎﻟﺐ ﺧﻨﮏ ≡ ﻣﺤﺪﻭﺩ ﮐﺮﺩﻥ ﺟﺮﻳﺎﻥ ﺩﺭ ﻗﺎﻟﺐ‬
‫« ﻗﺎﻟﺐ ﺧﻨﮏ ≡ ﺍﻓﺰﺍﻳﺶ ﺗﻨﺶﻫﺎﯼ ﺣﺮﺍﺭﺗﯽ ﺩﺭ ﻗﺎﻟﺐ‬
‫« ﻗﺎﻟﺐ ﮔﺮﻡ ﺗﺮ≡ ﺍﻓﺰﺍﻳﺶ ﻣﻴﺰﺍﻥ ﺻﻴﻘﻠﯽ ﺷﺪﻥ ﺳﻄﺢ ﻗﻄﻌﻪ‬
‫« ﻗﺎﻟﺐ ﮔﺮﻡ ﺗﺮ≡ ﺍﻓﺰﺍﻳﺶ ﻣﺪﺕ ﺳﻴﮑﻞ ﺗﺰﺭﻳﻖ‬
‫‪59‬‬
 Injection Molding Operations

Hot resin flow from the middle of the flow channel cools

60
 ‫‪Molding process‬‬
‫ﺍﺧﺘﻼﻑ ﺍﺑﻌﺎﺩ ﺑﻴﻦ ﻗﻄﻌﻪ ﻭ ﻗﺎﻟﺐ ﺩﺭ ﺍﺛﺮ ﺗﻐﻴﻴﺮ ﺩﺍﻧﺴﻴﺘﻪ ﭘﻼﺳﺘﻴﮏ )‪: (shrinkage‬‬ ‫•‬
‫« ﺭﺯﻳﻦﻫﺎﯼ ﺁﻣﻮﺭﻑ ﻣﺜﻞ ‪ ABS‬ﻭ ‪ PC‬ﻭ ‪ PS‬ﻧﺴﺒﺖ ﺑﻪ ‪ Polyolefin‬ﻫﺎ ﺍﻋﻮﺟﺎﺝ ﮐﻤﺘﺮﯼ ﺩﺍﺭﻧﺪ‪.‬‬
‫« ﺩﺭ ﭘﻠﯽﺍﻭﻟﻔﻴﻦﻫﺎ‪ ،‬ﺣﺠﻢ ﻣﺬﺍﺏ ﻭ ﺣﺠﻢ ﻣﺎﺩﻩ ﺟﺎﻣﺪ ﺍﺧﺘﻼﻑ ﺯﻳﺎﺩﯼ ﺩﺍﺭﺩ‪.‬‬
‫‪HDPE>LLDPE>LDPE>PP‬‬
‫ﺍﮔﺮ ﭘﻼﺳﺘﻴﮏ ﻣﻮﺭﺩ ﻧﻈﺮ ﺍﻧﺘﺨﺎﺏ ﺷﻮﺩ‪ ،‬ﺑﻪ ﮐﻤﮏ ﻃﺮﺍﺣﯽ ﻣﻨﺎﺳﺐ ﻗﺎﻟﺐ ﻭ ﮐﻨﺘﺮﻝ ﻓﺮﺁﻳﻨﺪ ﻣﯽﺗﻮﺍﻥ ﻣﻴﺰﺍﻥ ﺍﻋﻮﺟﺎﺝ ﺭﺍ ﮐﻨﺘﺮﻝ ﻧﻤﻮﺩ‪.‬‬ ‫•‬
‫ﺗﺠﺮﺑﻪ ﺩﺭ ﺗﺰﺭﻳﻖ ﻳﮏ ﺻﻔﺤﻪ ﺗﺨﺖ ﻧﺸﺎﻥ ﻣﯽﺩﻫﺪ ﮐﻪ‪:‬‬
‫« ﺍﻋﻮﺟﺎﺝ ﺑﺎ ﮐﺎﻫﺶ ﺿﺨﺎﻣﺖ ﻗﻄﻌﻪ ﮐﺎﻫﺶ ﻣﯽﻳﺎﺑﺪ‪.‬‬
‫« ﺍﻋﻮﺟﺎﺝ ﺑﺎ ﮐﺎﻫﺶ ﺳﻄﺢ ﮔﻠﻮﻳﯽ ﮐﺎﻫﺶ ﻣﯽﻳﺎﺑﺪ‪.‬‬
‫« ﻣﻴﺰﺍﻥ ‪ shrinkage‬ﺑﺎ ﮐﺎﻫﺶ ﺩﻣﺎﯼ ﺗﺰﺭﻳﻖ ﻭ ﺩﻣﺎﯼ ﺍﻭﻟﻴﺔ ﺧﻨﮏﺗﺮ ﻗﺎﻟﺐ ﮐﺎﻫﺶ ﻣﯽﻳﺎﺑﺪ‬
‫« ﻋﻤﻠﮑﺮﺩ ﺑﻬﺘﺮ ﻓﺎﺯ ‪ ،packing‬ﺑﺎﻋﺚ ﮐﺎﻫﺶ ‪ shrinkage‬ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﻭ ﻃﻮﻻﻧﯽﺗﺮ ﺷﺪﻥ ﻓﺎﺯ ‪ packing‬ﺑﺎﻋﺚ ﮐﺎﻫﺶ ﻣﯽﺷﻮﺩ )ﻣﺸﮑﻞ ﻃﻮﻻﻧﯽﺗﺮ ﺷﺪﻥ ﻓﺎﺯ ‪،packing‬‬
‫ﻃﻮﻻﻧﯽﺗﺮ ﺷﺪﻥ ﺳﻴﮑﻞ ﻭ ﺍﻋﻤﺎﻝ ﺗﻨﺶﻫﺎﯼ ﺍﺿﺎﻓﯽ ﺑﻪ ﻗﺎﻟﺐ ﻣﯽﺑﺎﺷﺪ(‬
‫« ﻃﻮﻻﻧﯽﺗﺮ ﺷﺪﻥ ﻓﺎﺯ ﺧﻨﮏ ﮐﺎﺭﯼ‪ ،‬ﺑﺎﻋﺚ ﮐﺎﻫﺶ ‪ shrinkage‬ﻣﯽﺷﻮﺩ‪.‬‬
‫« ﻣﺸﮑﻞ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺯﯼ ﺭﺍ ﻣﯽﺗﻮﺍﻥ ﺑﺎ ﺯﺍﻭﻳﻪ ﺩﺍﺩﻥ ﺣﻞ ﮐﺮﺩ ← ﻣﺨﺮﻭﻃﯽ ﮐﺮﺩﻥ‬
‫« ﭘﺪﻳﺪﺓ ‪ shrinkage‬ﻳﮏ ﭘﺪﻳﺪﺓ ﺯﻣﺎﻧﯽ ﺍﺳﺖ‪ .‬ﺩﺭ ﭘﻠﯽ ﺍﻭﻟﻔﻴﻦﻫﺎ ‪ %90‬ﺗﺎ ‪ 48hr‬ﺭﺥ ﻣﯽﺩﻫﺪ‪.‬‬
‫« ﺩﺭ ﺷﺮﺍﻳﻂ ﺍﻧﺒﺎﺭﺩﺍﺭﯼ ﮔﺮﻡ ﺍﺩﺍﻣﻪ ﻣﯽﻳﺎﺑﺪ ← ﻧﮕﻬﺪﺍﺭﯼ ﻣﺤﺼﻮﻻﺕ ﺗﻮ ﺩﺭ ﺗﻮ‪.‬‬ ‫‪61‬‬
 ‫‪Molding process‬‬
‫• ﺍﻋﻮﺟﺎﺝ ﺍﺑﻌﺎﺩﯼ ﻗﻄﻌﺔ ﻗﺎﻟﺐﮔﻴﺮﯼ ﺷﺪﻩ )‪: (warpage‬‬
‫« ﻋﻠﺖ ‪ warpage‬ﺧﻨﮏ ﮐﺎﺭﯼ ﻧﺎﻳﮑﻨﻮﺍﺧﺖ ﻭ ﻋﻤﻠﮑﺮﺩ ﺗﻨﺘﺶﻫﺎﯼ ﭘﺲ ﻣﺎﻧﺪ ﺍﺳﺖ‬
‫« ﻗﻄﻌﻪ ﭘﺲ ﺍﺯ ﻗﺎﻟﺒﮕﻴﺮﯼ ﻭ ﻋﻤﻞ ﺗﻨﺶﻫﺎﯼ ﭘﺲ ﻣﺎﻧﺪ‪ ،‬ﺷﮑﻞ ﻃﺒﻴﻌﯽ ﺧﻮﺩ ﺭﺍ ﭘﻴﺪﺍ ﻣﯽﮐﻨﺪ‬
‫« ﺭﺍﻩ ﺣﻞ‪ :‬ﮐﻤﻴﻨﻪ ﮐﺮﺩﻥ ﻣﻴﺰﺍﻥ ﺗﻨﺶﻫﺎﯼ ﭘﺲ ﻣﺎﻧﺪ‬
‫« ‪ warpage‬ﺩﺭ ﻗﻄﻌﺎﺕ ﺩﺍﺭﺍﯼ ﺿﺨﺎﻣﺖﻫﺎﯼ ﻣﺨﺘﻠﻒ‪ ،‬ﺷﺪﻳﺪﺗﺮ ﺍﺳﺖ‬
‫• ﺭﺍﻩ ﺣﻞ ﺳﺎﺩﻩﺍﯼ ﺑﺮﺍﯼ ﺍﻳﻦ ﻣﺸﮑﻞ ﻭﺟﻮﺩ ﻧﺪﺍﺭﺩ‪.‬‬
‫« ﺗﻨﻈﻴﻢ ﺗﺠﺮﺑﯽ ﺷﺮﺍﻳﻂ ﻗﺎﻟﺐ ﮔﻴﺮﯼ‬
‫« ﻃﺮﺍﺣﯽ ﻣﺠﺪﺩ ﻗﻄﻌﻪ ﻭ ﻗﺎﻟﺐ‬
‫« ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ﻣﻮﺍﺩ ) ‪ MWD(Molecular weight distribution‬ﮐﻮﭼﮑﺘﺮ‬
‫ﺩﺭ ﻋﻤﻞ ﺣﺪﺍﻗﻞ ‪ warpage‬ﺩﺭ ﺯﻣﺎﻧﯽ ﻣﺸﺎﻫﺪﻩ ﻣﯽﺷﻮﺩ ﮐﻪ‪:‬‬ ‫•‬
‫« ﺩﻣﺎﯼ ﻣﺬﺍﺏ ﻣﺎﮐﺰﻳﻤﻢ ﺑﺎﺷﺪ‬
‫« ﺩﻣﺎﯼ ﻗﺎﻟﺐ ﺑﺎﻻﺗﺮﻳﻦ ﺑﺎﺷﺪ‬
‫« ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﮐﻤﺘﺮﻳﻦ ﺑﺎﺷﺪ‬
‫« ﻣﺪﺕ ﺗﺰﺭﻳﻖ ﮐﻮﺗﺎﻫﺘﺮﻳﻦ ﺑﺎﺷﺪ‬ ‫‪62‬‬
 ‫‪Molding process‬‬
‫ﺩﻣﺎﯼ ﺑﺎﻻﯼ ﺗﺰﺭﻳﻖ ﺑﺎﻋﺚ ﻣﯽﺷﻮﺩ ﮐﻪ ﺗﻨﺶﻫﺎﯼ ﺍﻳﺠﺎﺩ ﺷﺪﻩ ﺩﺭ ﻃﯽ ﻓﺮﺍﻳﻨﺪ ﺗﺰﺭﻳﻖ ﻗﺒﻞ ﺍﺯ ﺷﮑﻞ ﮔﻴﺮﯼ ﻗﻄﻌﻪ ﮐﺎﻫﺶ ﻳﺎﺑﻨﺪ‬ ‫•‬
‫ﻓﺸﺎﺭ ﺗﺰﺭﻳﻖ ﻭ ‪ packing‬ﺑﺎﻳﺪ ﺑﻪ ﻣﻴﺰﺍﻥ ﮐﺎﻓﯽ ﺑﺎﺷﺪ ﻭ ﺑﺎﻻﺗﺮ ﺑﻮﺩﻥ ﺁﻥ ﻣﻤﮑﻦ ﺍﺳﺖ ﺑﺎﻋﺚ ﺟﻠﻮﮔﻴﺮﯼ ﺍﺯ ﺁﺯﺍﺩ ﺷﺪﻥ ﺗﻨﺶﻫﺎﻱ ﻓﺮﺍﻳﻨﺪ‬ ‫•‬
‫ﺗﺰﺭﻳﻖ ﺷﻮﺩ‬
‫« ﺍﻓﺰﺍﻳﺶ ﻧﺮﺥ ﺗﺰﺭﻳﻖ ≡ ﮐﺎﻫﺶ ﺯﻣﺎﻥ ﺗﺰﺭﻳﻖ ≡ ﭘﺮ ﺷﺪﻥ ﺳﺮﻳﻌﺘﺮ ﻗﺎﻟﺐ ≡ ﻋﺪﻡ ﺍﻧﺠﻤﺎﺩ ﭘﻼﺳﺘﻴﮏ ﻧﺰﺩﻳﮏ ﺩﻳﻮﺍﺭ‬
‫≡ ﺍﻣﮑﺎﻥ ﺧﻨﮏ ﺷﺪﻥ ﻭ ﺍﻧﺠﻤﺎﺩ ﻳﮑﻨﻮﺍﺧﺖﺗﺮ ﻣﻮﺍﺩ ≡ ﮐﺎﻫﺶ ﺍﻋﻮﺟﺎﺝ‬
‫ﺑﻌﻀﯽ ﺍﺯ ﺭﺍﻩﺣﻞﻫﺎﯼ ﻓﻮﻕ ﺑﺎﻋﺚ ﻃﻮﻻﻧﯽﺗﺮ ﺷﺪﻥ ﺳﻴﮑﻞ ﺗﺰﺭﻳﻖ ﻣﯽﺷﻮﺩ‬ ‫•‬
‫ﺭﺯﻳﻦﻫﺎﯼ ﺑﺎ ‪ MI‬ﺑﺎﻻﺗﺮ‪ ،‬ﻣﯽﺗﻮﺍﻧﺪ ﺍﻓﺰﺍﻳﺶ ﺯﻣﺎﻥ ﺳﻴﮑﻞ ﺗﺰﺭﻳﻖ ﺭﺍ ﺟﺒﺮﺍﻥ ﮐﻨﺪ‬ ‫•‬
‫• ﺍﺧﺘﻼﻑ ﻣﻴﺰﺍﻥ ‪ shrinkage‬ﺑﻴﻦ ﺟﻬﺖ ﺟﺮﻳﺎﻥ ﻭ ﻋﻤﻮﺩ ﺑﺮ ﺟﻬﺖ ﺟﺮﻳﺎﻥ ﻧﻴﺰ ﻣﯽﺗﻮﺍﻧﺪ ﺑﺎﻋﺚ ﺍﻋﻮﺟﺎﺝ ‪ warpage‬ﺷﻮﺩ)ﻣﺜﺎﻝ‬
‫‪(HDPE‬‬
‫ﺑﻨﺎﺑﺮﺍﻳﻦ ‪ warpage‬ﻭ ‪ shrinkage‬ﺷﺪﻳﺪﹰﺍ ﺑﻪ ﺧﻨﮏ ﮐﺎﺭﯼ ﻗﺎﻟﺐ ﻭ ﻫﻨﺪﺳﺔ ﻗﻄﻌﻪ ﻭ ﺩﺭ ﻧﺘﻴﺠﻪ ﺑﻪ ﺿﺨﺎﻣﺖ ﻭ ﺍﻟﮕﻮﯼ ﺟﺮﻳﺎﻥ ﻭﺍﺑﺴﺘﻪ‬ ‫•‬
‫ﺍﺳﺖ ﻭ ﺑﺎﻳﺪ ﺍﺯ ﺍﻭﻟﻴﻦ ﻗﺪﻣﻬﺎﯼ ﻃﺮﺍﺣﯽ ﻣﻮﺭﺩ ﺗﻮﺟﻪ ﺑﺎﺷﻨﺪ‪.‬‬

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shrinkage and warpage controll in polyolefins

64
 ‫‪Molding process‬‬
‫ﭘﺨﺶ ﺭﻧﮓ ﺩﺍﻧﻪﻫﺎ ﻭ ﺟﻠﻮﮔﻴﺮﯼ ﺍﺯ ﻭﺭﻭﺩﺣﺒﺎﺏﻫﺎﯼ ﻫﻮﺍ )‪: (Color dispersion and air entrapment‬‬ ‫•‬
‫« ﺑﺮﺍﯼ ﺑﻬﺒﻮﺩ ﮐﻴﻔﻴﺖ ﻗﻄﻌﻪ‪ ،‬ﺑﺎﻳﺪ ﺭﻧﮓ ﺩﺍﻧﻪﻫﺎ ﺑﻪ ﺧﻮﺑﯽ ﭘﺨﺶ ﺷﻮﻧﺪ ﻭ ﺣﺒﺎﺏﻫﺎﯼ ﻫﻮﺍ ﻭﺍﺭﺩ ﻗﺎﻟﺐ ﻧﺸﻮﻧﺪ‪ .‬ﺍﺛﺮ‬
‫‪ back pressure‬ﺑﺮ ﺗﻮﻟﻴﺪ ﻣﺬﺍﺏ ﺑﺪﻭﻥ ﻫﻮﺍ ﺑﺴﻴﺎﺭ ﺟﺪﯼ ﺍﺳﺖ‪.‬‬
‫« ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯ ‪ breaker plate‬ﺑﺮ ﺗﺤﻘﻖ ﻫﺪﻑ ﻓﻮﻕ ﻣﻮﺛﺮ ﺍﺳﺖ‪ .‬ﺍﻳﻦ ﺻﻔﺤﻪ ﺩﺭ ﻭﺭﻭﺩ ﺑﻪ ﻧﺎﺯﻝ ﻭ ﺍﻧﺘﻬﺎﯼ‬
‫ﻣﺤﻔﻈﺔ ﻣﺎﺭﭘﻴﭻ ﻗﺮﺍﺭ ﻣﯽﮔﻴﺮﺩ‪.‬ﺍﺑﻌﺎﺩ ﺻﻔﺤﻪ ‪: breaker plate‬‬

‫ﺿﺨﺎﻣﺖ ﺻﻔﺤﻪ‪ 6 :‬ﺗﺎ ‪ 8‬ﻣﻴﻠﻴﻤﺘﺮ‬

‫ﺗﻌﺪﺍ ﺳﻮﺭﺍﺧﻬﺎ‪ 40 :‬ﺗﺎ ‪20‬‬
‫ﻗﻄﺮ ﺳﻮﺭﺍﺧﻬﺎ‪ 0/8 :‬ﻣﻴﻠﻴﻤﺘﺮ‬
‫« ﻫﺪﻑ‪:‬‬
‫‐ ﺍﻓﺰﺍﻳﺶ ﻓﺸﺎﺭ ﭘﺸﺖ‬
‫‐ ﺗﻮﻟﻴﺪ ﻣﺬﺍﺏ ﻫﻤﮕﻦ ﺍﺯ ﻧﻈﺮ ﺭﻧﮓ ﻭ ﺩﻣﺎ‬

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Color dispersion and air entrapment

66
 ‫‪Molding process‬‬
‫• ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ )‪:(Part ejection‬‬
‫« ﻗﻄﻌﺎﺕ ﺩﺍﺭﺍﯼ ﺳﻄﻮﺡ ﺑﺮﺍﻕ ﺳﺨﺖﺗﺮ ﺍﺯ ﻗﺎﻟﺐ ﺟﺪﺍ ﻣﯽﺷﻮﻧﺪ‪ .‬ﺑﺮﺍﯼ ﺑﻬﺒﻮﺩ ﻋﻤﻠﮑﺮﺩ ﺑﻴﺮﻭﻥ‬
‫ﺍﻧﺪﺍﺯﯼ ﮔﺎﻫﯽ ﺍﻓﺰﻭﺩﻧﯽﻫﺎﻳﯽ ﺍﺿﺎﻓﻪ ﻣﯽﺷﻮﺩ‬
‫« ﺍﮔﺮ ﻗﻄﻌﻪ ﺑﻪ ﻣﻴﺰﺍﻥ ﺯﻳﺎﺩ ‪ pack‬ﺷﺪﻩ ﺑﺎﺷﺪ ﺍﺯ ﻗﺎﻟﺐ ﺭﺍﺣﺖ ﺟﺪﺍ ﻧﻤﯽﺷﻮﺩ‬
‫« ﺍﮔﺮ ﺳﻴﮑﻞ ﻗﺎﻟﺐ ﮔﻴﺮﯼ ﻃﻮﻻﻧﯽ ﺷﻮﺩ ﻭ ‪ shrinkage‬ﮐﺎﻣﻞ ﺷﻮﺩ ﻗﻄﻌﻪ ﺭﺍﺣﺖ ﺟﺪﺍ‬
‫ﻧﻤﯽﺷﻮﺩ‬
‫« ﺻﺎﻓﯽ ﺳﻄﺢ ﺩﺍﺧﻠﯽ ﻗﺎﻟﺐ ﺑﺮ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ ﻣﻮﺛﺮ ﺍﺳﺖ‬
‫« ﺍﺳﺘﻔﺎﺩﻩ ﺍﺯﭘﻴﻦﻫﺎﯼ ﭘﺮﺍﻥ ﻳﺎ ﺳﻴﺴﺘﻢ ﻫﺎﯼ ﺩﻳﮕﺮ ﺑﺮﺍﯼ ﺑﻴﺮﻭﻥ ﺍﻧﺪﺍﺯﯼ ﺿﺮﻭﺭﯼ ﺍﺳﺖ‬

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Injection Molding Terms

68
‫‪Molding process‬‬
‫• ﻣﺴﺎﺋﻞ ﻭ ﻣﺸﮑﻼﺕ ﺩﺭ ﺗﺰﺭﻳﻖ ﭘﻼﺳﺘﻴﮏ ﻭ ﺭﺍﻩﺣﻞ ﺁﻥ‬

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70
71
72
73
 ‫‪Molding process‬‬
‫ﺗﺤﻠﻴﻞ ﺟﺮﻳﺎﻥ ﺩﺭ ﻓﺮﺁﻳﻨﺪ ﭘﺮ ﺷﺪﻥ ﻗﺎﻟﺐ‪:‬‬ ‫•‬
‫• ﺩﺭ ﺭﻭﻧﺪ ﻃﺮﺍﺣﯽ ﻗﺎﻟﺐ‪ ،‬ﺿﺮﻭﺭﯼ ﺍﺳﺖ ﻓﺮﺁﻳﻨﺪ ﭘﺮ ﺷﺪﻥ ﻣﻮﺭﺩ ﺍﺭﺯﻳﺎﺑﯽ ﻗﺮﺍﺭ ﮔﻴﺮﺩ ﺗﺎ ﺑﺘﻮﺍﻥ ﺩﺭﺑﺎﺭﺓ‬
‫ﻣﻮﺍﺭﺩ ﺯﻳﺮ ﺍﻇﻬﺎﺭ ﻧﻈﺮ ﻧﻤﻮﺩ‪:‬‬
‫« ﺍﺭﺯﻳﺎﺑﯽ ﻣﻮﻗﻴﻌﺖ ﮔﻠﻮﻳﯽ‬
‫« ﻣﺤﻞﻫﺎﯼ ﺧﻄﻮﻁ ﺟﻮﺵ‬
‫« ﻣﺤﻞﻫﺎﯼ ﺗﻠﻪﻫﺎﯼ ﻫﻮﺍ‬
‫« ﺗﺨﻤﻴﻦ ﺗﻮﺯﻳﻊ ﻓﺸﺎﺭ‪ ،‬ﺩﻣﺎ‪ ،‬ﺗﻨﺶﻫﺎﯼ ﺑﺮﺷﯽ‪ ،‬ﺳﺮﻋﺖ ﻭ ‪...‬‬
‫« ﭘﻴﺶ ﺭﻭﯼ ﺟﺒﻬﺔ ﻣﺬﺍﺏ ‪Melt-front advancement‬‬
‫« ﻫﺮ ﻳﮏ ﺍﺯ ﺧﻄﻮﻁ ﺟﺒﻬﺔ ﻣﺬﺍﺏ‪ ،‬ﻣﻌﺎﺩﻝ ﭘﺮ ﺷﺪﻥ ﻣﺮﺣﻠﻪﺍﯼ ﻳﮏ ﻗﺎﻟﺐ ﺩﺭ ﻃﻮﻝ ﻳﮏ ﺯﻣﺎﻥ ﻣﺸﺨﺺ ﺍﺳﺖ‬
‫« ﺑﻪ ﮐﻤﮏ ﺍﻳﻦ ﺧﻄﻮﻁ ﻣﯽﺗﻮﺍﻥ ﺧﻄﻮﻁ ﺟﻮﺵ ﻳﺎ ﺗﻠﻪﻫﺎﯼ ﻫﻮﺍ ﺭﺍ ﻗﺒﻞ ﺍﺯ ﺳﺎﺧﺖ ﻗﻄﻌﻪ ﭘﻴﺶﺑﻴﻨﯽ ﻧﻤﻮﺩ‪.‬‬

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