Nghiên cứu, thiết kế khuôn vi ép phun cho sản phẩm connector

NGHIEN CCfU - TRAO DO NGHIEN CLPU, THiiT KE KHUON VI EP PHUN CHO SAN PHAM CONNECTOR / RESEARCH AND DESIGN MICRO-INJECTION MOLDING FOR MICRO CLOCK CONNECTOR ^ ^ ,, T'™ Quang PhiJ6c Thai TU Tin Hi Khoa Cfl Trudng D ^ hpc Bich khoa, Dai hpc Qudc gia TP Hd Chi Minh T M TAT Tfl khda: Con^ nghi vi ip phun, phun vi ep phun ABSTRACT ^pf^^^ti^:eZi:^ -^'^'>-'^ouingf!:::::p^-:!j^^^^^^^^^^^^ Keywords: Micro-injection maiding micro mould, sumilatian in micro molding I.BATVANSE „ , nhieu cfl hpi ve mat ilng dvmg hon, nhU Cdngnghlvilpphunlimdttrongnhang chi tiet hay kit ciu cia mdt sin pham se mang lai nhilu Ifli ich Sin phim cd kit cau nhn hnn irpng nhdt dd la mo gt^^^i^ c i ' c ' b L ' t o r ' N ' " ' • ' ^ " ' " l ' ^ ' " * »»- i - noi day dien-dien tfl Khi sfl dung, ngodi y f i u ^ ISSN 0866 - 7056 T4P CHl CO KHl VlfiT NAM, Sd nam 2016 www.cokhiviefnain.vn NGHIEN CU'U-TRAOD6| cdu chinh xac de lap ghep, tai vi tri ket ndi cdddi^dien chay qua, sinh nhiet n^n bd dau ndi didn phai cd dp ben va khd nang chiu nhiet cao D A C D I E M CUA QUA TRINH VI EP PHUN Cdng nghe vi ep phun la sfl phat trien ke thfla tfl cdng nghe ep phun truyen thong Cdc bfldc chinh cfla quy trinh vi ip phun va ep phim truyen thdng la gidng Tuy nhien, quy trinh cdng ngh^ vi ep phim khdng chi don thudn la mOt quy trinh ep phim truyen thdng thu nhd, ma d mdi bfldc cua quy trinh vi ep phun deu cd nhflng yiu cau ddc biet vi vat lieu, dp suat phun, nhi^t dp khudn, thodt cho khudn, tdc dd phun, tdc dp ldm ngupi, THIET KE K H U N CHO SAN PHAM CONNECTOR Ban ve chi tidt san pham dflflc ihi hi?n tren hinh 1, connector dflflc sfl d\mg cdc bo ket ndi dien, vdy, v^t lieu dflflc sfl dung phdi chiu dflflc nhidt dp cao Bd connector, gdm: Dau noi dm ghep vdi dau ndi dflong, ndn yeu cau ve lap ghep can chinh xac cao, ta chon v§t lieu nhfla ky thuat vd cd he so co rflt nhd Mdt cdc loai nhi^a do, LCP (Liquid crystal polymer) la loai nhfla phu hflp cho sdn pham connector Cac ydu cau ky thudt cua san pham dflflc the hidn trdn ban ve Kich thfldc cdc chi tiit ldi va Idng khudntrong khudn vi ^p phun rat nhd, neu de nguydn khdi gia cdng se rat khd khan vd khd dgit dflpc dp chinh xde gia cdng Do vay, ngfldi ta chia nhd chi tiit cua ldi va Idng khudnd^ gia cdng va sau dd ^ rdp lai thdnh khdi Cdc insert cua khudn cung rat nhd (dfldng kmh tfl 0.1 den 0,3 mm) nin phun nhi^a vdo khudn, dp li^c cua nhiia ldn rat dl ldm cdc insert bj bien d^ng, v^y, biy theo ket cau sdn pham ma ngfldi ta se thiet kd cac insert ghep vdo chi tiet Idng khudn de tdng cflng vflng cho cdc msert ma khdng Iam thay doi ydu cdu ho?c chflc nang cfla sdn phdm Hinh Bdn ve connector Khi ddng khudn, cdc chi tiet ddn hfldng ydu cau dp ddng tam, dd song song rdt Vd ket cau khudn ep phun san pham ldn cao nen kdt can dan hfldng ddng khudn thfldng vd khudn vi dp phun Id tflOng ddi gidng chia nhieu cap d^ vdi dung sai lap ghep vd dd Tuy nhien cdng nghd vi ep phun, khudn chinh xac cfla cdc chi tiet dan hfldng ydu cau nhd ep ludn dflflc gia nhidt vd gifl d mpt nhidt dp tfldng ddi 6n djnh sudt qud trinh ep phun Ngoai ra, kich thfldc cua kenh ddn nhfla nhd nen khudn dflflc gia nhiet de dam 3.1 Tinh todn gia nhiet cho khudn vi 6p phun bao nhtfa di ddng dien day long khudn, nhidt dp khudn se thay ddi flng vdi vat lieu nhi^a khdc - Kich thfldc bao cua khudn dflflc the hien d hhih 2: ISSNOS66-7056 TAP CHi CO KHl VI$T NAM, Sd nam 2016 www.cokhivietnam.vn NGHlfiN CCfU - TRAO DO tinh toin tdn that nhiet mdi trUdng li ddi lui tu nhien Nhiet lupng tdn that li tong nhiit lupng truyln qua mdi tntdng ngoii tai mjt c4a bd khuon Nhiet lupng ton thit: H,nh Kich thudc bao cua khudn Q=axSxAt[7) - Chat lieu: Thep SKD U - Nhiit dd mdi trtjdng: 30"C - Nhiit dp khudn; 80"C - Thdi gian can d l dat nhllt do: 15 phiit - Xac dinh di|n tich cic mat; S„ = 150 xl90 (mm); S^ d= 150 xl90 (mm) S, = 150 X 140 (mm); S, = 190x140 (mm) D l tinh toan cdng suit nhllt trd gia nhi|t cho khudn, ta xlt trln ci khdi lap phuong vdi dien tich trln Nhiet lupng cin cung cap cho khudn bao gdm, nhiet lupng gia nhiit khudn vi nhllt luong tdn thft trao ddi nhiit vdi mdi trudng xung quanh Nhiet lupng cin cung cip de gia nhllt khudn tfl 30 "C lln 80 °C la; (3) HI sd Gr: (4) Tra bing Thdng sd vjt If cia khdng khd (H=760mmHg) [7] V = 16,69 a:10-« Cic thdng sd: g=9.81ni/s2 t+273 313 (5) At =80-30 = 50 "C Cac mat S,.S,; Chpn L = 150 mm (quy Udc chpn kich thudc nhd) Suy 0,^=757,156 Q,=GxCjXAt [7J (1) Cic mat S,,S,; Chpn L = 140 mm (quy Udc chon kich thudc chilu cao) Trong dd; G=V.m=31,122kg Cp = 0.45kl/Kg At=80-30=50°C (2) Suy ra: G_j=615,596 Theo tilu chuin Rayleigh: Suy ra: Q^ = 700,245 kJ H|sd;Ra=GrxPr[7] Miy Ip lam vile mdi trudng cd nhiit dp dn dinh Nhiet dp khudn truyin qua mdi trudng ngoii mdt cich tU nhiin Do viy, ta (g) Tra bang 4,[7] ta cd; Pr = 0,699 Suy ra: Ra,=529,252; Ra,=430,302(7) ISSN 6 - TAP CHl CO KHl VlfiT NAM, Sd nim 2016 www.cokhivietnam.vn «= NGHIEN c u u - T R A O e O l NuxA ^ Cd rit nhilu l o ^ diln trd gia nhiit, ^^1 do, diln trd tru la thich hpp vdi nhiJng khudn cd kich thudc nhd Ta dimg trd tru dddng Tra bang 4, [7] ta cd: A = 2,76 x 10-^ —dp kmh 8mm, mdi 0,25 kw Dien ip siS dung " li 220V Bo tri cho ci tam khudn di dpng vi tam Vahlsd; Nu=CRa"[7] (8) khudncodinh ~ Tra bing 7.1,[7] cd n= 0,25 va C = 0,54 Nu„=l,813 NUj=3,367 Nu=2,46 mnh Nhiet trd tru Suyra; 3.2 Dinh vi d i n hiidng nhilu giai d o ^ a„=0,33a,=0,62^=0,45 Nhiet lupng tda cua cic mat: (9) Q=aSAt [7] Q,= %xS,,xA,=0,476 Q,= OjjXSjjXA =0,884 Q,= ajXS,xA,=0,473 Q,= UjXSxA =0,599 Mdt dilm djc biet khic cho khudn vi Ip phunlicociudan hiidng ddng khudn Vi cac chi tilt rat nhd vi an khdp vdi Do vjy, dung sai lip ghep cho phip cUc k^ nhd, dp chinh xic gia cdng cua cic dan hiidng khoing vai pin.TLiy mile dp chinh xic an khdp cda hai niia khudn ma chdng ta dimg hay nhilu ca ciu dan hudng nhu dupc trinh biyd hinh Nhiit lupng ton that qua mjt khudn: Q=lQi= 0,476+0,884+2x0,473+2x0,599=3,054 kJ Nhiet lupng tong cdng can cung cap: mnh Cdc cd cdu dan hudng Q=Q„+ Q„=3,054+700,245=703,299 kJ Chpn thdi gian gia nhiet khudn tit SO^C Iln din 80°C li 15 phiit Khudn sau dupc thilt ke hoin thi|n dupc trmh bayd hinh vi hinh Cdng suit nhi|t trd can thilt la: „ _ Q 703,299 900 = 0,78 kw (10) Do vay, ta chpn cdng suat diln trd gia nhiit cho khudn la Ikw tSSN 0866-7056 TAP CHl CO KHl VlfiT NAM, Sd nam 2016 www.cokhivietnam.vn anh Khudn thilt klhodn chinh NGHISN CCCU - TRAO OO MM ^ B^Kf^Hrlg M|lj«|y-^^-4 Hinli Ap sudt phun vd nhiit dd trung Unh Hmh Ket cau khudn Mft P H N G CAC QUA TRINH Sau thilt k l so bp, chiing ta tien hinh md phdng nham xac dinh cac khuylt tit cd the xiy Ta thilt Ijp cic thdng sd cdng nghi cia qui trinh Ip phun dUa vio khuyin cio cia cac hing cung cip vjt Ulu nhifa I » Chpn thdng sd miy md phdng: LUc kep ldn nhit: 49kN; Ap Itfc phun ldn nhat; 197MPa; Tdc dp phun; 300min/s Vi s i dung loai nhUa LCP nln thdng sd qui trinh ta chpn nhu sau: Nhiet dp khudn la 70"C Nhi|t dp nhua ndng chay; 340''C Kit qui md phdng cic qua trmh duoc the hiln t i hinh din hinh 9: mnh9.KhldUva vi bi dudng han nhfl! Nhdn xet: Sau md phdng, ta dinh gii + Kha ning diln diy sin pham li 100%, khong cd khuylt tat + Nhiit dp trung bmh cia qua trinh Ip li: 382.3°C ^ + Xac dinh dUflc vi tri dudng hin + Xic dinh dupc cic vj tri dU fiPTHirc NGHIEM Thdng sd miy Ip thic nghilm;LUc km lon nhit; 49kN; Ap lUc phun ldn nhit:197MPaTdc dd phun; 300mm/s Hin* Thdi gian vd ning diln ddy Hmh 10 Mdy ep nhifa Sodick TR05EH ISSN 0866-7056 TAPCHfCOKHlVI$TNAM.Sd7nam2016 www.cokhivietnam.vn NGHIEN C U ' U - T R A O D O I Thfle nghidm dinh Iflflng nhfla: Ket ludn: Sdn pham sau dp tflflnj thich vdi md phdng dien day 99% Tuy sdn phlro Thfle nghidm 1: Nhidt dp khudn:70°C; dd dat ve ngoai quan, ta tiep tuc tdng dinh Iflpng Nhiet dp nhfla phun; 340°C; Ap suat phun: nhfla 30 MPa; Th^tich nhfla: 4.8mm Ep thfle nghiem lan 4: Thl tich nhfla: Htnh 11 Md phong su dien ddyliiu vd ep thtXc nghiem Kit ludn: Sdn pham sau ep tfldng thich vdi md phdng dien day 80% Ta tiep tuc tai^ th^ tich nhfla Thvfc nghi?m 2: Thd tich nhfla: 4.7mm Htnh 14 S,p tht/c nghiim Ket ludn: Sau ta tiep tuc tang Iflflng nhfla thi ddnh gia ngoai quan bd mat san pham tdt hon rat nhieu, hon, bdng hon KIEM TRA KlCH THlTOC SAN PHAM Ta tien hanh vd kilm tra tren may hien vi Micro scope Nikon STM7-CB Hinh 12 Md phdng sU diin ddy lieu vd ip thUc n^i&m Kit ludn: Sdn pham sau ep tfldng thich vdi md phdng dien day 90% Ta tiep tyc tdng dinh Iflflng nhfla Thfle nghi?m 3: Thd tich nhfla:4.6mm Hinh 15 Mdy hien vt Nikon- STM7-CB Hmh 13 Md phdng sU diin ddy lieu vd ep thUc nghiem Cic kich thfldc trdn bdn vd ky thudt, ta tien hanhdo lan trdn san phSm ep thfle te vd ket qua dflflc trinh bdy bdng 1; ISSN 0866-7056 T.^P CHl CO KHf V I | T NAM Sd nam 2016 www.cokhivietnam.vn NGHIEN CLCU - TRAO BCH Bdngl: Bing sdliiu sdnphdm sau ep Mwn xef: Ta thay gid trj xi nhd hdn gia tn kich thfldc ydu cau ban ve Do v^y, ta kit luan kich thfldc sdn pham dat yeu cau kich thfldc cfla banve ni«>i m U) lil 1^3 *^^T"4561 ora n\ 2Ê*S *Hl ' Utl ã ô,=ô3ằ c**** (Jasts-W sjnwtj.io-' ZIV l I M X19' ooos SJOUttW fum iJ9re±z.io-' U)i2iae«s< IMK ams 1MB (unn S.MW+S.10- J-HMfZie" t»S! «.MS8±4.10- tjHI ftlHH um|uH3 25WI oom Bai bdo trmh bay va phdn tich ddc dilm cua sdn pham ep nhfla cd kich thfldc nhd vd thilt ke khudn vi ep phun cho sdn phdm, ddng thdi cung md phdng va ep thfle nghidm de kiem chflng ket qua Trong bdi cung trmh bay mpt sd ddc dilm thilt ke cua khudn vi ep phun giflp mpi ngfldi cd cai nhin tdng quan vl khudn vi dp phun.*:* "saitiio- 3JU0 JJDI ijtil oma uvu KET LUAN IMMlllO-* Ngdy nh|n bai: 17/6/2016 Ngdy phdn bien: 07/7/2016 Tdi li|u tham khdo: lii ^^"/t '^™^'^"^ ""'•"' "^ '"ã* "ằ *"^" ^ 'ô'-" tdm ,1 1% ' S T '"" '•'"I''"'-I' StMdard plastics mould Base, 2015 41 A C U O ^ I H T ^ ^'^"'''"'' " ^ ' ' " ' ' " ' ' ^ " ^ ' ° ' ' " " - "•""''' 2016 LL.t.'^Tdv •iJLri^x;ST8 r2oo6r °^'°""'' -""-""" ™'-™-™ ^'™*- -•* % S ^ L l l T l S o s i r S l s " ''^"•'^""•"^''™- "•" ™ * ^ components with micro channels Microsyst Sc^fng!l2ao^/i"S°"°^*'^"'"^^"^"''""^ m Nguyen Dtah Tin; Cosdti-uylnnhiit, CN.GT.158-10(T), 2010 ISSN 6 - TAP CHI CO KHl VlfiT NAM, Sd nam 2016 www.cokhivietnam.vn NGHIEN CO'U-TRAO D6I Ap suat nhd nhat de cd the gay bij cflng ngudi cho ndng la: Hi-^) Htnh Bien ciing ngudi thdy imh vd md hinh chiu tdi cua ndng phdo bien cdng ngudi thiiy tinh Qua trinh ndng phdo dflflc bien cflng ngudi thuy tinh (hinh 2) trang thdi flng suatbien djtng cfla ndng la trang thai flng suat phang Thdnh ndng theo phfldng hfldng kinh hmh hai vung ridng bidt cd t r ^ g thdi flng suatbidn dang khac nhau, vung cd bien dang chay hoan toan vdi ban kinh bat ddu tfl ban kinh cua ndng phao r^ den ban kinh r^ va vung chi cd biln d^ng ddn hdi cd d^ ldn tfl bdn kmhr din ban kinh ngoai cfla ndngr^ Khi cat tdi cang keo lan nhau, flng suat dfl sd dtiac hinh didnh trdn cd hai vung nay, flng suat dfl theo phfldng hfldng kinh ("TJ) vd tilp tuyin (CT^) hai vflng dflflc xde dinh ldn Iflflt theo cdc phfldng trmh va [2,3]: Nhfl vay, qua trinh lam vi?c dflc dp suat thudc/) thi flng suat hinh than] ndng phao trfldng hflp ndng khdnj dfldc bien cflng ngudi («7^J, cr*) vd trfldng hfl ndng phdo dflflc biln cflng ngu^i ((T^,CTg)lai Iflflt dflflc xac dinh theo cac cdng thfle va 3-a-\) (6) a.^ol+cr: (7) KET QUA T H i r c NGHI$]« d day, ta nghita cdu dinh gii miSc dO tang nang chiu tii cho ndng phio 85fl44 dUdc chf tao tit thep 38XH3M