Also known as plastic molding processing. It is a general term for various processes for converting synthetic resins or plastics into plastic products and is a large production department in the plastics industry. Plastic processing generally includes the formulation, molding, machining, joining, modification and assembly of plastics. The latter four processes are carried out after the plastic has been formed into a product or a semi-finished product, also known as plastic secondary processing.
While the output of plastic products is growing rapidly, the electricity consumption is growing at an alarming rate. Based on a single consumption of 500 kWh/ton, this year's plastics industry is expected to use more than 25 billion kWh. According to the reporter's understanding, at the place where plastic processing enterprises such as Taizhou and Yuyao are concentrated, plastic processing enterprises have generally entered the ranks of power cuts, and are in a state of suspension or semi-discontinuation.
As an authoritative figure in the field of plastic presses in China, Qi Jinping, vice president of South China University of Technology, believes that in the long run, the continued rise in electricity prices has become inevitable, which will affect the production costs of plastic processing enterprises and the price of electricity. It will become one of the important factors that restrict the development of enterprises. It is estimated that by 2015, the output of China's plastic products will reach 80 million tons. According to the current average electricity consumption, if it can save 25%, the electricity saving will reach 10 billion kWh, saving 3.5 million tons of standard coal, reducing carbon dioxide and sulfur dioxide. Wait about 1.4 million tons. The application of advanced plastic processing energy-saving technology to achieve the goal of 25% energy saving is not difficult.
At present, domestic energy-saving new technologies have been launched from injection machines, extruders to auxiliary equipment and key equipment for plastic processing. For example, electromagnetic heating can replace the resistance heating method in the past, and the power saving can exceed 30%. The plastic energy-saving processing technology of the tensile deformation control breaks through the technical bottleneck that the plastic processing thermomechanical process is difficult to shorten, and realizes the shear-based to the tensile flow. The transformation of the plasticized transport mechanism, the material plasticization and mixing process dominated by the tensile deformation, and the screw-free plasticized transport of the plastic short thermal mechanical history, compared with the traditional method, the process energy saving is more than 30%, and The volume and weight of the equipment are greatly reduced; the new molding technology and plasticization concepts such as super-shear plasticization and differential forming theory are used to guide the plastic processing process, which not only saves energy and reduces consumption, but also greatly improves the processing technology level.
Plastic processing is developed with the development of synthetic resins, which promotes the development of plastic machinery. Many plastic processing technologies are based on rubber, metal and ceramic processing. The history of plastic processing can be traced back to the 1890s. After the birth of celluloid, because of its flammability, it can only be formed into a block by molding, and then mechanically processed into a sheet, which can be processed by thermoforming. This is the earliest plastic processing. Casting was successfully developed with the advent of phenolic resin; injection molding began in the 1920s for processing cellulose acetate and polystyrene; in the mid-1930s, soft polyvinyl chloride extrusion was successfully developed, plastic-specific A single-screw extruder was introduced; in 1938, the twin-screw extruder was also put into production. In the early 1940s, polyurethane foam was produced and blow molding technology was used to produce polyethylene hollow products. In 1952, the reciprocating screw injection machine was introduced, which brought the injection molding technology to a new stage. In the 1960s and 1970s, the newly developed plastic processing technologies included: various new plastic forming methods such as winding, pultrusion, sheet molding, reaction injection molding, structural foam molding, profile extrusion, and sheet materials. Solid phase molding and co-extrusion, co-injection, and the like. In the 1980s, plastic processing was moving toward high efficiency, high speed, high precision, energy saving, large-scale or ultra-small, ultra-thin, etc. Computer technology entered this field and raised the entire plastic processing technology to a new level.
Ingredients used in plastic processing of ingredients, in addition to polymers, generally add various plastic additives (such as stabilizers, plasticizers, colorants, lubricants, reinforcing agents and fillers) to improve the molding process and products. Use performance or reduce the cost of the product. The additive and the polymer are mixed and uniformly dispersed into a powder, which is also referred to as a dry blend. Sometimes the powder needs to be processed into pellets by mastication. Such powders and pellets are collectively referred to as batch or molding compound.
The key link in the processing of shaped plastics. Various forms of plastic (powder, pellets, solution or dispersion) are made into articles or blanks of the desired shape. There are more than thirty methods of forming. Its choice depends mainly on the type of plastic (thermoplastic or thermoset), the starting form, and the shape and size of the product. Commonly used methods for processing thermoplastics include extrusion, injection molding, calendering, blow molding, and thermoforming. The thermosetting plastics are generally molded, transferred, and injection molded. Lamination, molding, and thermoforming are the shaping of plastic on a flat surface. The above plastic processing methods can be used for rubber processing. In addition, there are castings using liquid monomers or polymers as raw materials. Among these methods, extrusion and injection molding are used most and are the most basic molding methods.
Machining uses plastic and wood processing methods to produce plastic products of very precise or small quantities. It can also be used as an auxiliary process for forming, such as sawing of extruded profiles. Because the properties of plastic are different from those of metal and wood, the thermal conductivity of plastic is poor, the coefficient of thermal expansion and the modulus of elasticity are low. When the clamp or tool is too pressurized, it is easy to cause deformation, it is easily melted by heat during cutting, and it is easy to adhere to the tool. on. Therefore, when the plastic is machined, the tools used and the corresponding cutting speeds must be adapted to the plastic characteristics. Commonly used machining methods include sawing, shearing, punching, turning, planing, drilling, grinding, polishing, and threading. In addition, plastic can also be cut, punched and welded with a laser.
The method of joining the plastic parts is welding and bonding. The welding method is hot air welding using electrodes, hot melt welding using hot poles, and high frequency welding, friction welding, induction welding, ultrasonic welding, and the like. The bonding method can be divided into a flux, a resin solution and a hot melt adhesive according to the adhesive used.
The purpose of surface modification is to beautify the surface of plastic products, usually including: mechanical modification, that is, using enamel, grinding, polishing and other processes, removing burrs, burrs, and size corrections on the parts; finishing, including coating the surface of the parts with paint, The solvent brightens the surface, and the surface of the product is coated with a patterned film; the color is applied, including painting, printing and hot stamping; the metal plating includes vacuum coating, electroplating, and chemical silver plating. The hot stamping is to transfer the colored aluminum foil layer (or other film layer) on the hot stamping film to the workpiece under heating and pressure. Many household appliances, construction products, daily necessities, etc., use this method to obtain patterns such as metallic luster or wood grain.
The assembly uses the methods of bonding, welding, and mechanical joining to assemble the finished plastic parts into a complete product. For example: plastic profiles are assembled into plastic window frames and plastic doors through steps such as sawing, welding and drilling.
In plastic machining, a variety of plastic processing failures are often encountered. These terms are more accurately expressed in the plastic machinery industry. Let's analyze the terminology of plastic processing failures one by one. .
1. Under-injection: In the plastic processing, the shape of the plastic part is incomplete due to the filling of the cavity.
2. Spilled flash: During the plastic molding process, the remaining material overflows between the gaps of the mold clamping surface and remains on the plastic part.
3. Weld marks: A kind of linear trace on the surface of a plastic part. It is divided and merged in the desert by injection or extrusion. The melt is not completely fused at the interface, and cannot be welded together to form a fusion. Imprinting, affecting the appearance quality and mechanical properties of the plastic parts.
4, wave flow marks: due to the improper flow of the melt in the mold cavity, resulting in plastic parts of the table to produce annual, spiral or cloud-like waveform irregularities.
5, surface turbidity: refers to the surface of the plastic parts with cracks and the resulting damage. The phenomenon of cracking outside or inside the plastic part due to long-term or repeated application of stress lower than the mechanical properties of the plastic is called stress cracking; the plastic part is suddenly completely broken due to the constant load acting at a certain temperature for a certain time. The phenomenon is called stress cracking; cracks and cracks that occur when some thermoplastic sheets are overexposed at higher temperatures are called thermal stress cracking.
6. Fracturing: Refers to the resin layer covered by the surface to see the obvious crack in the laminated plastic or the outer layer or layers of reinforcing material.
7. Wrinkle: A defect in which the laminated plastic surface is cracked and clearly separated.
8. Wrinkles: In the process of plastic processing, one or more layers of plastic parts have appearance defects such as creases or wrinkles.
9. Cracking and whitening: The relatively obvious micro-cracks on the surface of plastic parts are called cracks. The frost-like micro-cracks similar to cracks are called whitening, and cracks and whitening are fine cracks without cracks. Environmental stress cracking occurs when a plastic part is exposed to a chemical environment or under stress.
10, silver silk pattern: the surface of the plastic part is produced in the direction of the flow of the needle-like silver white as frost-like fine lines.
11. Stripes: Linear stripe defects on the surface or inside of plastic parts.
12. Speckle: Due to the dispersion or poor mixing of the colorant and other reasons, the surface of the plastic part has a dark spot defect of mica flakes.
13. Orange peel: The appearance of the surface of the plastic part is as uneven as the orange peel.
14. Cell fringe: refers to a cell layer in a foam that differs greatly from its inherent cell structure.
15. Black spots: During the plastic processing and forming process, the melt is thermally decomposed under high temperature and high pressure conditions, resulting in black carbonization points on the surface of the plastic parts.
16. White spots or bright spots: In the transparent or translucent plastic film, sheet or plastic parts, there are not fully plasticized particles. When transmitted by light, white particles can be seen. This kind of grain is called “fish eyeâ€. ". If the material is opaque or colored, the grain is called a white spot or a bright spot.
17. Pitting: Regular or irregular small pits appearing on the surface of plastic parts, usually with the same depth and width.
18, filler spots: plastic parts due to the presence of wood powder or asbestos and other fillers caused by obvious marks.
19. Dark spot: A dark stain that appears in a laminate structure based on a fabric.
20, charring and paste: in the plastic processing process, under high temperature and high pressure molding conditions, the melt is carbonized due to overheating decomposition, carbonized coke is blended in the melt, forming defects on the surface and inside of the plastic parts.
21. Bubbles: During the filling process of plastic processing, if a large amount of gas remains in the molten material, or the air in the cavity is not completely drained, the defects of small volume or string of pores are formed inside the plastic part after molding.
22, vacuum bubble or dark bubble: plastic parts in the plastic processing cooling solidification, due to different internal and external cooling speed, sometimes the outer surface has been cooled and solidified, but the interior is still in the hot melt state, once the central part cooling shrinks, the plastic parts inside Vacuum holes are created. These holes are generally called vacuum bubbles or dark bubbles, also known as shrinkage holes.
23. Pinhole: A through-hole defect in the size of a needle eye present in a plastic sheet or film.
24. Foaming: The defect that the local density of the foam is increased due to the destruction of the cell structure during the manufacturing process.
25. Depression and shrinkage: In the process of plastic processing and cooling, the surface layer is cooled and solidified first, and the internal or wall thickness portion is cooled and solidified. When the volume shrinks, the internal and external shrinkage speeds are inconsistent, and the surface of the plastic part is internally pulled. Extending into a depression, creating a shallow pit or dimple.
While the output of plastic products is growing rapidly, the electricity consumption is growing at an alarming rate. Based on a single consumption of 500 kWh/ton, this year's plastics industry is expected to use more than 25 billion kWh. According to the reporter's understanding, at the place where plastic processing enterprises such as Taizhou and Yuyao are concentrated, plastic processing enterprises have generally entered the ranks of power cuts, and are in a state of suspension or semi-discontinuation.
As an authoritative figure in the field of plastic presses in China, Qi Jinping, vice president of South China University of Technology, believes that in the long run, the continued rise in electricity prices has become inevitable, which will affect the production costs of plastic processing enterprises and the price of electricity. It will become one of the important factors that restrict the development of enterprises. It is estimated that by 2015, the output of China's plastic products will reach 80 million tons. According to the current average electricity consumption, if it can save 25%, the electricity saving will reach 10 billion kWh, saving 3.5 million tons of standard coal, reducing carbon dioxide and sulfur dioxide. Wait about 1.4 million tons. The application of advanced plastic processing energy-saving technology to achieve the goal of 25% energy saving is not difficult.
At present, domestic energy-saving new technologies have been launched from injection machines, extruders to auxiliary equipment and key equipment for plastic processing. For example, electromagnetic heating can replace the resistance heating method in the past, and the power saving can exceed 30%. The plastic energy-saving processing technology of the tensile deformation control breaks through the technical bottleneck that the plastic processing thermomechanical process is difficult to shorten, and realizes the shear-based to the tensile flow. The transformation of the plasticized transport mechanism, the material plasticization and mixing process dominated by the tensile deformation, and the screw-free plasticized transport of the plastic short thermal mechanical history, compared with the traditional method, the process energy saving is more than 30%, and The volume and weight of the equipment are greatly reduced; the new molding technology and plasticization concepts such as super-shear plasticization and differential forming theory are used to guide the plastic processing process, which not only saves energy and reduces consumption, but also greatly improves the processing technology level.
Plastic processing is developed with the development of synthetic resins, which promotes the development of plastic machinery. Many plastic processing technologies are based on rubber, metal and ceramic processing. The history of plastic processing can be traced back to the 1890s. After the birth of celluloid, because of its flammability, it can only be formed into a block by molding, and then mechanically processed into a sheet, which can be processed by thermoforming. This is the earliest plastic processing. Casting was successfully developed with the advent of phenolic resin; injection molding began in the 1920s for processing cellulose acetate and polystyrene; in the mid-1930s, soft polyvinyl chloride extrusion was successfully developed, plastic-specific A single-screw extruder was introduced; in 1938, the twin-screw extruder was also put into production. In the early 1940s, polyurethane foam was produced and blow molding technology was used to produce polyethylene hollow products. In 1952, the reciprocating screw injection machine was introduced, which brought the injection molding technology to a new stage. In the 1960s and 1970s, the newly developed plastic processing technologies included: various new plastic forming methods such as winding, pultrusion, sheet molding, reaction injection molding, structural foam molding, profile extrusion, and sheet materials. Solid phase molding and co-extrusion, co-injection, and the like. In the 1980s, plastic processing was moving toward high efficiency, high speed, high precision, energy saving, large-scale or ultra-small, ultra-thin, etc. Computer technology entered this field and raised the entire plastic processing technology to a new level.
Ingredients used in plastic processing of ingredients, in addition to polymers, generally add various plastic additives (such as stabilizers, plasticizers, colorants, lubricants, reinforcing agents and fillers) to improve the molding process and products. Use performance or reduce the cost of the product. The additive and the polymer are mixed and uniformly dispersed into a powder, which is also referred to as a dry blend. Sometimes the powder needs to be processed into pellets by mastication. Such powders and pellets are collectively referred to as batch or molding compound.
The key link in the processing of shaped plastics. Various forms of plastic (powder, pellets, solution or dispersion) are made into articles or blanks of the desired shape. There are more than thirty methods of forming. Its choice depends mainly on the type of plastic (thermoplastic or thermoset), the starting form, and the shape and size of the product. Commonly used methods for processing thermoplastics include extrusion, injection molding, calendering, blow molding, and thermoforming. The thermosetting plastics are generally molded, transferred, and injection molded. Lamination, molding, and thermoforming are the shaping of plastic on a flat surface. The above plastic processing methods can be used for rubber processing. In addition, there are castings using liquid monomers or polymers as raw materials. Among these methods, extrusion and injection molding are used most and are the most basic molding methods.
Machining uses plastic and wood processing methods to produce plastic products of very precise or small quantities. It can also be used as an auxiliary process for forming, such as sawing of extruded profiles. Because the properties of plastic are different from those of metal and wood, the thermal conductivity of plastic is poor, the coefficient of thermal expansion and the modulus of elasticity are low. When the clamp or tool is too pressurized, it is easy to cause deformation, it is easily melted by heat during cutting, and it is easy to adhere to the tool. on. Therefore, when the plastic is machined, the tools used and the corresponding cutting speeds must be adapted to the plastic characteristics. Commonly used machining methods include sawing, shearing, punching, turning, planing, drilling, grinding, polishing, and threading. In addition, plastic can also be cut, punched and welded with a laser.
The method of joining the plastic parts is welding and bonding. The welding method is hot air welding using electrodes, hot melt welding using hot poles, and high frequency welding, friction welding, induction welding, ultrasonic welding, and the like. The bonding method can be divided into a flux, a resin solution and a hot melt adhesive according to the adhesive used.
The purpose of surface modification is to beautify the surface of plastic products, usually including: mechanical modification, that is, using enamel, grinding, polishing and other processes, removing burrs, burrs, and size corrections on the parts; finishing, including coating the surface of the parts with paint, The solvent brightens the surface, and the surface of the product is coated with a patterned film; the color is applied, including painting, printing and hot stamping; the metal plating includes vacuum coating, electroplating, and chemical silver plating. The hot stamping is to transfer the colored aluminum foil layer (or other film layer) on the hot stamping film to the workpiece under heating and pressure. Many household appliances, construction products, daily necessities, etc., use this method to obtain patterns such as metallic luster or wood grain.
The assembly uses the methods of bonding, welding, and mechanical joining to assemble the finished plastic parts into a complete product. For example: plastic profiles are assembled into plastic window frames and plastic doors through steps such as sawing, welding and drilling.
In plastic machining, a variety of plastic processing failures are often encountered. These terms are more accurately expressed in the plastic machinery industry. Let's analyze the terminology of plastic processing failures one by one. .
1. Under-injection: In the plastic processing, the shape of the plastic part is incomplete due to the filling of the cavity.
2. Spilled flash: During the plastic molding process, the remaining material overflows between the gaps of the mold clamping surface and remains on the plastic part.
3. Weld marks: A kind of linear trace on the surface of a plastic part. It is divided and merged in the desert by injection or extrusion. The melt is not completely fused at the interface, and cannot be welded together to form a fusion. Imprinting, affecting the appearance quality and mechanical properties of the plastic parts.
4, wave flow marks: due to the improper flow of the melt in the mold cavity, resulting in plastic parts of the table to produce annual, spiral or cloud-like waveform irregularities.
5, surface turbidity: refers to the surface of the plastic parts with cracks and the resulting damage. The phenomenon of cracking outside or inside the plastic part due to long-term or repeated application of stress lower than the mechanical properties of the plastic is called stress cracking; the plastic part is suddenly completely broken due to the constant load acting at a certain temperature for a certain time. The phenomenon is called stress cracking; cracks and cracks that occur when some thermoplastic sheets are overexposed at higher temperatures are called thermal stress cracking.
6. Fracturing: Refers to the resin layer covered by the surface to see the obvious crack in the laminated plastic or the outer layer or layers of reinforcing material.
7. Wrinkle: A defect in which the laminated plastic surface is cracked and clearly separated.
8. Wrinkles: In the process of plastic processing, one or more layers of plastic parts have appearance defects such as creases or wrinkles.
9. Cracking and whitening: The relatively obvious micro-cracks on the surface of plastic parts are called cracks. The frost-like micro-cracks similar to cracks are called whitening, and cracks and whitening are fine cracks without cracks. Environmental stress cracking occurs when a plastic part is exposed to a chemical environment or under stress.
10, silver silk pattern: the surface of the plastic part is produced in the direction of the flow of the needle-like silver white as frost-like fine lines.
11. Stripes: Linear stripe defects on the surface or inside of plastic parts.
12. Speckle: Due to the dispersion or poor mixing of the colorant and other reasons, the surface of the plastic part has a dark spot defect of mica flakes.
13. Orange peel: The appearance of the surface of the plastic part is as uneven as the orange peel.
14. Cell fringe: refers to a cell layer in a foam that differs greatly from its inherent cell structure.
15. Black spots: During the plastic processing and forming process, the melt is thermally decomposed under high temperature and high pressure conditions, resulting in black carbonization points on the surface of the plastic parts.
16. White spots or bright spots: In the transparent or translucent plastic film, sheet or plastic parts, there are not fully plasticized particles. When transmitted by light, white particles can be seen. This kind of grain is called “fish eyeâ€. ". If the material is opaque or colored, the grain is called a white spot or a bright spot.
17. Pitting: Regular or irregular small pits appearing on the surface of plastic parts, usually with the same depth and width.
18, filler spots: plastic parts due to the presence of wood powder or asbestos and other fillers caused by obvious marks.
19. Dark spot: A dark stain that appears in a laminate structure based on a fabric.
20, charring and paste: in the plastic processing process, under high temperature and high pressure molding conditions, the melt is carbonized due to overheating decomposition, carbonized coke is blended in the melt, forming defects on the surface and inside of the plastic parts.
21. Bubbles: During the filling process of plastic processing, if a large amount of gas remains in the molten material, or the air in the cavity is not completely drained, the defects of small volume or string of pores are formed inside the plastic part after molding.
22, vacuum bubble or dark bubble: plastic parts in the plastic processing cooling solidification, due to different internal and external cooling speed, sometimes the outer surface has been cooled and solidified, but the interior is still in the hot melt state, once the central part cooling shrinks, the plastic parts inside Vacuum holes are created. These holes are generally called vacuum bubbles or dark bubbles, also known as shrinkage holes.
23. Pinhole: A through-hole defect in the size of a needle eye present in a plastic sheet or film.
24. Foaming: The defect that the local density of the foam is increased due to the destruction of the cell structure during the manufacturing process.
25. Depression and shrinkage: In the process of plastic processing and cooling, the surface layer is cooled and solidified first, and the internal or wall thickness portion is cooled and solidified. When the volume shrinks, the internal and external shrinkage speeds are inconsistent, and the surface of the plastic part is internally pulled. Extending into a depression, creating a shallow pit or dimple.
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