I. Rapid Anchoring Method Utilising Baseline Parameters
Initially, adjust the temperatures of the barrel and mould to the appropriate range in accordance with the material's properties. Initially, the injection pressure was set to 60% of the maximum value of the equipment, the holding pressure to 30% of the maximum value, and the injection speed to 40% of the maximum value. Regulate the back pressure within the range of 3 to 8 bar. This rapidly establishes the initial parameter framework.
This method directly bypasses ineffective large-range parameter exploration and secures the starting point of machine adjustment within a reasonable process window.
II. Rapid Positioning Method for Pressure Switching
Set the holding pressure to 0 for a temporary period and gradually increase the injection pressure until the mould is fully filled without any short shots. This is the optimal switching pressure point, as indicated by the screw stop position.
Avoid premature switching (insufficient filling) or excessive holding pressure (over-holding pressure) by accurately locking the switching boundary between filling and holding pressure within 10 minutes, eliminating the need for repetitive trial and error.
III. Boundary Locking Method for Segmented Parameters
Adjust the injection speed exclusively, while maintaining the other parameters at a constant level. Determine the lowest speed at which short shots are produced and the maximum speed at which burrs are produced. Assume that the optimal injection speed is the midpoint.
In the same vein, adjust the holding pressure individually to determine the minimum pressure at which shrinkage marks appear and the maximum pressure at which flash appears. The optimal holding pressure is determined by the midpoint.
This method can rapidly establish the secure range of each core parameter, thereby achieving a balance between product quality and filling efficiency.
IV. Method for Quickly Determining Gate Cooling Time: Gradually increase the holding pressure time until the product weight no longer increases significantly. This time is designated as the gate chilling time and is used as the standard for determining the holding pressure time.
This prevents the occurrence of contraction marks as a result of insufficient holding pressure and the wastage of moulding cycles as a result of excessive holding pressure, thereby securing the optimal holding pressure time in a single step.
V. Rapid Optimisation Method for Cooling Time
While verifying that the product is not deformed, cracked, or whitening upon ejection, gradually decrease the cooling time. The optimal cooling time is the shortest possible at this juncture.
This directly reduces superfluous cooling redundancy, thereby maximising the reduction of the moulding cycle and ensuring product quality.
VI. Mature formulations can be reused with a single click.
Store previously verified and qualified parameter sets of the same materials and moulds in the formula database, document the material batch number and environmental temperature and humidity information, and directly access them with a single click when changing production. In order to promptly restore stable production, only minor adjustments within ±5% are required.
