模具及注塑评定过程

1、PURPOSE 目的To establish a standard procedure for tool and molding process qualification and re-qualification. 标准化模具以及注塑过程的评定和再评定程序。1. SCOPE 范围This procedure applicable to the following situation:本程序适用于下面的情况：1.1. New tools arrive in our company and before releasing them to mass production 新模到达本公司后，但尚未量产以前1.2. After tool modification and before it is released to mass production 模具修改以后，但尚未量产以前1.3. Transfer tools, such as used tool or consigned tool transferred by customer 转移模，比如从其它工厂转移来的旧模或从客户处转移过来的

2、模具1.4. Material changes, which should include material component change, material brand change and grade change.物料变更，包括组成物料的成分变更，物料的商标、级别变更1.5. Machine changes, which should include machine brand change, ton change, screw / barrel diameter change.注塑机变更，包括注塑机的商标、吨位、螺杆/料筒的直径变更1.6. Process changes, any process parameters change greater than the pre-defined tolerance or excess material manufacturing specification.加工方法变更，任何超出预先设定参数公差的参数设定，或超出原料供货商提供的规格的设 定。3. DEFFINITIONS AND ABBREVIATIONS 定义和缩写3.1.3

3、.1. FAI First Article Inspection 首件全数尺寸测量3.2. Cpk Capability Index of Process 过程能力指数3.3. QA Quality Assurance 品质保证3.4. Mold modification 改模 Any modification relates to mold structure. 任何牵涉到模具结构变更的模具改变。3.5. Scientific Molding 科学注塑It is a scientific methodology for molding process.用科学的方法注塑成型。3.6. Scientific Molding Study 科学注塑研究 The individual studies of Scientific Molding, which areinstructed by Test Shot Instruction, consist of the following 6 studies:这个研究的要求由试模指示表发出，它包括：3.6.1. Hold Time Study 保压

4、时间研究3.6.2. Part Weight Study 产品重量分析3.6.3. Cavity Balance Study 型腔平衡性分析3.6.4. FAI measurement FAI 测量3.6.5. Short -erm Cpk Study 短期 Cpk 研究3.6.6. Long-term Cpk Study 长期 Cpk 研究3.7. Scientific Molding Binder 科学注塑文件包 It is a binder contains all process and tool qualification data records and documents for a particular tool. It is Scientific Molding Study result which includes:这是一个包含所有关于某模具及其注塑过程的评定记录的文件包，它是科学注 塑分析的结果，它包括：3.7.1. Mold Information Sheet 模具信息3.7.2. Injection molding process setup checklis

5、t 注塑成型过程设置检查表3.7.3. Hold Time Study Report 保压时间研究报告3.7.4. Part Weight Study Report 产品重量分析报告3.7.5. Cavity Balance Study Report 型腔平衡性分析报告3.7.6. FAI Report FAI 报告3.7.7. Molding Condition Form 注塑成型条件表3.7.8. Short -erm Cpk Report 短期 Cpk 报告3.7.9. Long-term Cpk Report 长期 Cpk 报告3.8. Test Shot 试模 It is also the production trial run for molding process, which includes qualification of mold or molding process. 也就是注塑试产，它包含了模具或注塑过程的评定。3.9. Test Shot Instruction The trial run instruction issued by Project Eng

6、ineer, which contains various information for production trial and types of study need to be conducted. 试模指示表由项目工程师发出，内容包括有关试模的各种信息及试模中要做的研究。3.10. Decoupled molding 系统成型法 It is a set-up technique that separates fill from pack of injection molding process. During the molding process, first stage (Molding Filling) is only used for filling that is controlled by velocity, and second stage (Pressurization and Compensation) is controlled by pressure. The point of velocity control to pressure control i

7、s called V-P transfer point. 这是一种在注塑成型过程中把填充从压紧段分出来的设定方法。在这样的注塑过程中，第 一段(填充段)仅用于填充，该段由速度控制；第二段(挤阳补偿段)由压力控制。而速 度控制与压力控制的转化点就被称为V-P转化点。4. RESPONSIBILITIES AND AUTHORITIES 职责及权限4.1. Project Engineer 项目工程师4.1.1. Obtain basic information and physical property of the tool before it arrive our company. This information includes but not limit to mold size, shot size, projected area, core rolls, special heater controls, and resin manufacturing parameters.在模具到达本公司前，获取模具的基本信息，这些信息包括、但不限于：模具尺寸、投影 面积、镶件结构情况、特

8、别的加热/冷却控制情况以及胶料供货商提供的建议的成型条件。4.1.2. Issue Test Shot Instruction.发放试模指示表。4.1.3. Take lead in the qualification and coordinate with the Production Department, Process Engineers, Tooling Engineers and Quality Engineers for all related issues.领导模具/注塑过程的评定，协调、配合生产部、制程工程师、模具工程师和品质工 程师处理评定过程中发生的任何事情。4.1.4. Report the Scientific Molding Study result 报告科学注塑研究的结果。4.1.5. Release Trial Run Report for mass production. 报告科学注塑研究的结果为量产提供依据。4.2. Molding Process Engineers 注塑制程工程师4.2.1. Conduct Scientific Molding

9、Study according to the Test Shot Instruction as well as mechanicaltool test.根据试模指示表实施科学注塑以及模具的机械功能方面的检查。4.2.2. Together with Tooling Engineer, analyze and take actions when one of Scientific Molding Study fails.若任一个科学注塑研究失效/不合格，注塑制程工程师要与模具工程师一起进行不良分析 并采取相应措施。4.2.3. Conduct fast filling to test for adequate venting.用快速填充的办法确定模具的排气是否充分4.3. Quality Engineer 品质工程师4.3.1. Coordinate with Project Engineer, organize QA Team to undertake inspection required in the Scientific Molding Study.配合项目工程师，组织QA按科学注塑研究的要求进行相应的检验工作。4.4. Tooling Engineer 模具工程师4.4.1. Complete the information required in Mold Information Sheet of Scientific Molding Binder. 搜 集信息并填写模具信息表。4.4.2. Responsible for tool modification when Cavity Balance Study Report indicates the tool is out ofbalance.当型腔平衡性分析报告不合格时，负责模具的修改工作。4.4.3. Assist Molding Process Engineer for any Scien

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