工艺参数对iPP注射成型制品翘曲度和结晶度影响的实验研究
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摘要
随着对注射成型制品的精度要求不断提高,成型工艺参数对制品翘曲变形的影响越来越受到研究人员的关注。目前,研究不同工艺参数对翘曲的影响较多。但是这些研究对因素的影响机理研究较少。由于iPP为结晶性塑料,晶态iPP和非晶态iPP的密度相差可达13%,这对材料的收缩会产生影响,而收缩不均往往会导致制品发生翘曲。
本文利用5因素4水平正交试验表安排16组实验,通过对注射成型参数进行调节,研究了iPP制品翘曲变形和结晶度随成型工艺参数发生变化的规律,并对二者之间的关系进行探究。文章得出如下结论。
1)对翘曲度影响较大的因素有保压时间和熔体温度,影响中等的为模具温度和注射速度,影响较小的是保压压力。
2)对结晶度影响较显著的因素有保压压力,影响较大的是模具温度,熔体温度、保压时间和注射速度的影响则较小。
3)通过研究相同工艺参数对翘曲度和结晶度的影响及之间关系的探索,本文认为,在本文研究的工艺参数取值范围内,结晶度变化与翘曲度变化之间没有必然的联系,结晶度的变化不一定是影响制品翘曲的主要因素。
With a rapid development of accuracy about injection molding process, an increasing number of researches pay attention to the influence of process parameters on the warp distortion of Injection Molding.Current studies mainly focus on the influence of different process parameters on the wrap. But the factors for its influence are not usually in their concern.The difference of density rate between crystalline iPP and amorphous iPP can be 13%; and this results in shrink nonconformity followed by the warp.
This paper is based upon 16 groups of experiments designed by 5-factor/4-level orthogonal test. Through adapting injection molding process parameters, it studies the effect and the relationship between the warp of iPP process and the changes of process parameters on the warp distortion according to the crystallinity. Several conclusions are indicated as follow:
1)The packing time and the melt temperature have major influences on the degree of warp; the mold temperature and the injection velocity, medium; the packing pressure, minor.
2)The packing time has an outstanding influence on the crystallinity; the mold temperature and the melt temperature, major; the melt temperature, packing time and injection velocity, minor.
3)This paper argues, by exploring the effects of the same process parameter on the degree of warp and crystallinity as well as the relations between them, that inevitable connections exist between the change of the crystallinity and that of the degree of the warp, and that the change of the crystallinity is not the main factor of the warp of the process.
本文利用5因素4水平正交试验表安排16组实验,通过对注射成型参数进行调节,研究了iPP制品翘曲变形和结晶度随成型工艺参数发生变化的规律,并对二者之间的关系进行探究。文章得出如下结论。
1)对翘曲度影响较大的因素有保压时间和熔体温度,影响中等的为模具温度和注射速度,影响较小的是保压压力。
2)对结晶度影响较显著的因素有保压压力,影响较大的是模具温度,熔体温度、保压时间和注射速度的影响则较小。
3)通过研究相同工艺参数对翘曲度和结晶度的影响及之间关系的探索,本文认为,在本文研究的工艺参数取值范围内,结晶度变化与翘曲度变化之间没有必然的联系,结晶度的变化不一定是影响制品翘曲的主要因素。
With a rapid development of accuracy about injection molding process, an increasing number of researches pay attention to the influence of process parameters on the warp distortion of Injection Molding.Current studies mainly focus on the influence of different process parameters on the wrap. But the factors for its influence are not usually in their concern.The difference of density rate between crystalline iPP and amorphous iPP can be 13%; and this results in shrink nonconformity followed by the warp.
This paper is based upon 16 groups of experiments designed by 5-factor/4-level orthogonal test. Through adapting injection molding process parameters, it studies the effect and the relationship between the warp of iPP process and the changes of process parameters on the warp distortion according to the crystallinity. Several conclusions are indicated as follow:
1)The packing time and the melt temperature have major influences on the degree of warp; the mold temperature and the injection velocity, medium; the packing pressure, minor.
2)The packing time has an outstanding influence on the crystallinity; the mold temperature and the melt temperature, major; the melt temperature, packing time and injection velocity, minor.
3)This paper argues, by exploring the effects of the same process parameter on the degree of warp and crystallinity as well as the relations between them, that inevitable connections exist between the change of the crystallinity and that of the degree of the warp, and that the change of the crystallinity is not the main factor of the warp of the process.
引文
[1]中国石化总公司生产部组织编写.合成树脂服务指南[M].中国石化出版社,1997：48.
[2]李正光.聚丙烯生产技术与应用[M].石油工业出版社.2006：1-2,12-13,17-20,29-31.
[3]http://finance.jrj.com.cn/2008/10/2109372442246.shtml[OL].
[4]李笑喃.聚丙烯在拉伸力场下的结晶行为和力学性能的研究[D].四川大学,2007.
[5]上官勇刚.聚丙烯合金的结晶行为及其动力学研究[D].浙江大学.2005.
[6]Padden FJ, Keith HD.,Spherulitic crystallization in polypropylene, J. Appl.Phys.1959,30:1479-1484.
[7]Padden FJ, Keith HD., Evidence for a second crystal form of polypropylene, J. Appl. Phys.1959,30:1485-1488.
[8]Padden FJ, Keith HD.,Crystallization in thin films of isotactic polypropylene, J. Appl. Phys.1966,37:4013-4020.
[9]Padden FJ, Keith HD., Mechanism for lamellar branching in isotactic polypropylene, J. Appl. Phys.1973,44:1217-1223.
[10]Samuels RJ, Yee RY., Characterization of the structure and organization of β-form crystals in type III and type IV isotactic polypropylene spherulites, J. Polym. Sci.1972, A-2,10:385-432.
[11]Turner-Jones A,Aizlewood JM, Beckett D., Crystalline forms of isotactic polypropylene, J. Makromol. Chem.1964,75:134-158.
[12]何曼君,陈维孝,董西侠.高分子物理(修订版)[M].复旦大学出版社.1990：57,58,72,78-81.
[13]马德柱.高聚物的结构与性能(第二版)[M].科学出版社.1995：100,101,113-127,135.
[14]Wunderlish, B. Academic press. Macromolecular Physics.1976, Vol.2, P.1-347.
[15]徐振森,陈寿羲.高分子通讯.1979,3：129.
[16]冯金华,张利华,陈东霖.Chinese. J. Polym. Sci.1989,7(1):54.
[17]Turnbull, D. and Fisher, J. C., J. Chem. Phys.1949,17,71.
[18]孙辉.高聚物在有限体积元中的等温结晶动力学过程研究[D].2004：16-17.
[19]Ozawa T. Kinetics of non-isothermal crystallization. Polymer 1971,12:150-158.
[20]eziorny A. Parameters characterizing the kinetics of the non-isothermal crystallization of poly(ethylene terephthalate) determined by d. s. c. Polymer 1978,19:1142-1144.
[21]Piorkowska E,Galesk iA,Haudin J-M. Critical assessment of overall crystallization kinetics theories and Predietions. Prog Polym Sci 2006,31:549-575.
[22]Lorenzo M L D, Silvestre C. Non-isothermal crystallization of polymers. Prog Polym Sci 1999,24:917-950.
[23]Long Y Shanks R A, Stachurski Z H. Kinetics of polymer crystallization. Prog Polym Sci 1995,20：651-701.
[24]张志英.测定高聚物结晶动力学参数的非等温理论和方法[J].高分子通报.1994,(3)：167-173.
[25]邹晓轩,戴文利,田际波.非等温条件下聚合物结晶动力学模型研究进展[J].高分子通报2004,(6)：15-21,62.
[26]张志英.聚合物结晶动力学理论和方法研究[D].2006：17.
[27]Hasan Kurtaran, Tuneay Erzurumlu. Effieient warpage optimization of thin shell plastie parts using response surface methodology and genetie algorithm. Advaneed Manufaeturing Teehnology,2006,27(1):5-6.
[28]B A Mlekusch. Residual Stresses in Short-Fibre Reinforced Injeetion-Moulded Thermoplastie Parts. Meehanies of Time-Dependent Materials,2002,2(6):10-14.
[29]Chiaming Yen,J C Lin, Wujeng Li et al.An abduetive neural network approach to the design of runner dimensions for the minimization of warpage in injeetion mouldings. Materials Proeessing Teehnology,2006,174:22-28.
[30]Babur Ozeelik,Tuneay Erzurumlu. Determination of Effeeting Dimensional Parameters on Warpage of Thin Shell Plastic Parts Using Integrated Resvonse Surfaee Method and Genetie Algorithm. International Conununieations in Heat and Mass Transfer,2005,32:1085-1094.
[31]申长雨,李海梅,高峰,等.注塑制品的翘曲变形分析[J].中国塑料.1993,2.
[32]李海梅,谢英,余晓容,等.注射压力对塑件残余应力和翘曲变形的影响[J].模具工业.1999,7：27-30.
[33]董斌斌,申长雨,李倩.注射成型薄壁制品收缩与翘曲因素[J].化工学报.2005,56(4)：727-732.
[34]吴海宏,赵振峰,黄明等.聚合物注塑内应力和翘曲变形的数值模拟[J].高分子材料科学与工程.2007,23(6)：16-19.
[35]郭志英,梁书云,张宜生,等.聚苯乙烯平板翘曲变形的实验研究[J].中国塑料.2000,10：43-47.
[36]郭志英,张宜生,梁书云,等.高密度聚乙烯平板翘曲变形实验研究[J].塑料工业.2001,3：37-40.
[37]郭志英,阮雪榆,李德群.注塑制品翘曲变形数值分析模型[J].中国机械工程.2002,13(17)：1515-1519.
[38]康俊远,严丽,李永鸿.CAE技术在薄壳注塑件翘曲变形分析中的应用[J].工程塑料应用.2006,34(1)：32-34.
[39]连昌伟,胡广洪,王兆远.工艺参数对注塑制品变形影响的研究[J].模具技术.2006,(2)：36-40.
[40]杨志强,王静波.注射成型工艺参数对注塑制品翘曲变形的影响研究[J].工程塑料应用.2007,35(2)：32-34.
[41]高月华,王希诚.注塑制品的翘曲优化及影响因素分析[J].化工学报.2007,58(6)：1575-1580.
[42]杨凤霞,王爱荣,许日光,等.工艺参数对ABS, PP注塑件翘曲变形影响的对比研究[J].塑 料工业.2008,36(3)：43-46.
[43]王桂龙,赵国群,李辉平.薄壁注塑制品翘曲影响因素分析与工艺优化[J].中国机械工程.2009,20(4)：488-492.
[44]周标,邓小雷.CAE技术结合正交实验法分析注塑工艺参数对翘曲的影响[J].轻工机械.2008,12：23-26.
[45]刘健.Moldflow在塑件翘曲分析中的应用[J].模具工业,2007,33(2)：6-10.
[46]骆志高,王忙忙,李瑾.薄壁件翘曲变形CAE分析[J].塑料工业.2007,35(6)：32-34.
[47]郭志英,李德群.注塑制品翘曲变形的研究[J].塑料科技.2001,01：22-24,48.
[48]盛永莉.正交试验设计及其应用[J].济南大学学报.1997,3：69-73.
[49]赵选民.试验设计方法[M].科学出版社.2006：78-100.
[50]张承琦.热塑性塑料注射制件的尺寸准确性[J].工程塑料应用.1982,1：12-16.
[51]姜开宇,横井秀俊.注射成型过程熔体前沿充填不平衡现象的试验研究[J].机械工程学报.2009,2：294-300.
[52]Guo J X,Narh K A. Polym Eng Sci.2001,41(11):1996-2012.
[53]Guo J X,Narh K A. Adv Polym Technol.2002,21(3):214-222.
[54]Guo X, Isayev A I,Guo L. Polym Eng Sci.1999,39(10):2096-2114.
[55]Guo X, Isayev A I,Demiray M. Polym Eng Sci.1999,39(11):2132-2149.
[56]谢刚,注射成型工艺参数对聚丙烯结晶度的影响[J].黑龙江大学自然科学学报,2007,2：23-26
[57]严波,李阳,孔啸,等.塑料注射成型结晶过程三维数值模拟[J].高分子学报.2011,2：173-179
[58]曾盛渠,刘芬,黄志高,等.注射成型工艺对制品收缩与翘曲的不同影响[J].化工学报.2011,3：846-855.
[59]Ying Jiru(应继儒). Microstructure and properties of PP/POE blends[D]. Wuhan:Huazhong University of Science and Technology.2008.
[2]李正光.聚丙烯生产技术与应用[M].石油工业出版社.2006：1-2,12-13,17-20,29-31.
[3]http://finance.jrj.com.cn/2008/10/2109372442246.shtml[OL].
[4]李笑喃.聚丙烯在拉伸力场下的结晶行为和力学性能的研究[D].四川大学,2007.
[5]上官勇刚.聚丙烯合金的结晶行为及其动力学研究[D].浙江大学.2005.
[6]Padden FJ, Keith HD.,Spherulitic crystallization in polypropylene, J. Appl.Phys.1959,30:1479-1484.
[7]Padden FJ, Keith HD., Evidence for a second crystal form of polypropylene, J. Appl. Phys.1959,30:1485-1488.
[8]Padden FJ, Keith HD.,Crystallization in thin films of isotactic polypropylene, J. Appl. Phys.1966,37:4013-4020.
[9]Padden FJ, Keith HD., Mechanism for lamellar branching in isotactic polypropylene, J. Appl. Phys.1973,44:1217-1223.
[10]Samuels RJ, Yee RY., Characterization of the structure and organization of β-form crystals in type III and type IV isotactic polypropylene spherulites, J. Polym. Sci.1972, A-2,10:385-432.
[11]Turner-Jones A,Aizlewood JM, Beckett D., Crystalline forms of isotactic polypropylene, J. Makromol. Chem.1964,75:134-158.
[12]何曼君,陈维孝,董西侠.高分子物理(修订版)[M].复旦大学出版社.1990：57,58,72,78-81.
[13]马德柱.高聚物的结构与性能(第二版)[M].科学出版社.1995：100,101,113-127,135.
[14]Wunderlish, B. Academic press. Macromolecular Physics.1976, Vol.2, P.1-347.
[15]徐振森,陈寿羲.高分子通讯.1979,3：129.
[16]冯金华,张利华,陈东霖.Chinese. J. Polym. Sci.1989,7(1):54.
[17]Turnbull, D. and Fisher, J. C., J. Chem. Phys.1949,17,71.
[18]孙辉.高聚物在有限体积元中的等温结晶动力学过程研究[D].2004：16-17.
[19]Ozawa T. Kinetics of non-isothermal crystallization. Polymer 1971,12:150-158.
[20]eziorny A. Parameters characterizing the kinetics of the non-isothermal crystallization of poly(ethylene terephthalate) determined by d. s. c. Polymer 1978,19:1142-1144.
[21]Piorkowska E,Galesk iA,Haudin J-M. Critical assessment of overall crystallization kinetics theories and Predietions. Prog Polym Sci 2006,31:549-575.
[22]Lorenzo M L D, Silvestre C. Non-isothermal crystallization of polymers. Prog Polym Sci 1999,24:917-950.
[23]Long Y Shanks R A, Stachurski Z H. Kinetics of polymer crystallization. Prog Polym Sci 1995,20：651-701.
[24]张志英.测定高聚物结晶动力学参数的非等温理论和方法[J].高分子通报.1994,(3)：167-173.
[25]邹晓轩,戴文利,田际波.非等温条件下聚合物结晶动力学模型研究进展[J].高分子通报2004,(6)：15-21,62.
[26]张志英.聚合物结晶动力学理论和方法研究[D].2006：17.
[27]Hasan Kurtaran, Tuneay Erzurumlu. Effieient warpage optimization of thin shell plastie parts using response surface methodology and genetie algorithm. Advaneed Manufaeturing Teehnology,2006,27(1):5-6.
[28]B A Mlekusch. Residual Stresses in Short-Fibre Reinforced Injeetion-Moulded Thermoplastie Parts. Meehanies of Time-Dependent Materials,2002,2(6):10-14.
[29]Chiaming Yen,J C Lin, Wujeng Li et al.An abduetive neural network approach to the design of runner dimensions for the minimization of warpage in injeetion mouldings. Materials Proeessing Teehnology,2006,174:22-28.
[30]Babur Ozeelik,Tuneay Erzurumlu. Determination of Effeeting Dimensional Parameters on Warpage of Thin Shell Plastic Parts Using Integrated Resvonse Surfaee Method and Genetie Algorithm. International Conununieations in Heat and Mass Transfer,2005,32:1085-1094.
[31]申长雨,李海梅,高峰,等.注塑制品的翘曲变形分析[J].中国塑料.1993,2.
[32]李海梅,谢英,余晓容,等.注射压力对塑件残余应力和翘曲变形的影响[J].模具工业.1999,7：27-30.
[33]董斌斌,申长雨,李倩.注射成型薄壁制品收缩与翘曲因素[J].化工学报.2005,56(4)：727-732.
[34]吴海宏,赵振峰,黄明等.聚合物注塑内应力和翘曲变形的数值模拟[J].高分子材料科学与工程.2007,23(6)：16-19.
[35]郭志英,梁书云,张宜生,等.聚苯乙烯平板翘曲变形的实验研究[J].中国塑料.2000,10：43-47.
[36]郭志英,张宜生,梁书云,等.高密度聚乙烯平板翘曲变形实验研究[J].塑料工业.2001,3：37-40.
[37]郭志英,阮雪榆,李德群.注塑制品翘曲变形数值分析模型[J].中国机械工程.2002,13(17)：1515-1519.
[38]康俊远,严丽,李永鸿.CAE技术在薄壳注塑件翘曲变形分析中的应用[J].工程塑料应用.2006,34(1)：32-34.
[39]连昌伟,胡广洪,王兆远.工艺参数对注塑制品变形影响的研究[J].模具技术.2006,(2)：36-40.
[40]杨志强,王静波.注射成型工艺参数对注塑制品翘曲变形的影响研究[J].工程塑料应用.2007,35(2)：32-34.
[41]高月华,王希诚.注塑制品的翘曲优化及影响因素分析[J].化工学报.2007,58(6)：1575-1580.
[42]杨凤霞,王爱荣,许日光,等.工艺参数对ABS, PP注塑件翘曲变形影响的对比研究[J].塑 料工业.2008,36(3)：43-46.
[43]王桂龙,赵国群,李辉平.薄壁注塑制品翘曲影响因素分析与工艺优化[J].中国机械工程.2009,20(4)：488-492.
[44]周标,邓小雷.CAE技术结合正交实验法分析注塑工艺参数对翘曲的影响[J].轻工机械.2008,12：23-26.
[45]刘健.Moldflow在塑件翘曲分析中的应用[J].模具工业,2007,33(2)：6-10.
[46]骆志高,王忙忙,李瑾.薄壁件翘曲变形CAE分析[J].塑料工业.2007,35(6)：32-34.
[47]郭志英,李德群.注塑制品翘曲变形的研究[J].塑料科技.2001,01：22-24,48.
[48]盛永莉.正交试验设计及其应用[J].济南大学学报.1997,3：69-73.
[49]赵选民.试验设计方法[M].科学出版社.2006：78-100.
[50]张承琦.热塑性塑料注射制件的尺寸准确性[J].工程塑料应用.1982,1：12-16.
[51]姜开宇,横井秀俊.注射成型过程熔体前沿充填不平衡现象的试验研究[J].机械工程学报.2009,2：294-300.
[52]Guo J X,Narh K A. Polym Eng Sci.2001,41(11):1996-2012.
[53]Guo J X,Narh K A. Adv Polym Technol.2002,21(3):214-222.
[54]Guo X, Isayev A I,Guo L. Polym Eng Sci.1999,39(10):2096-2114.
[55]Guo X, Isayev A I,Demiray M. Polym Eng Sci.1999,39(11):2132-2149.
[56]谢刚,注射成型工艺参数对聚丙烯结晶度的影响[J].黑龙江大学自然科学学报,2007,2：23-26
[57]严波,李阳,孔啸,等.塑料注射成型结晶过程三维数值模拟[J].高分子学报.2011,2：173-179
[58]曾盛渠,刘芬,黄志高,等.注射成型工艺对制品收缩与翘曲的不同影响[J].化工学报.2011,3：846-855.
[59]Ying Jiru(应继儒). Microstructure and properties of PP/POE blends[D]. Wuhan:Huazhong University of Science and Technology.2008.