DVD遥控器前盖注塑模设计【一模两腔】【侧抽芯】【说明书+CAD】
DVD遥控器前盖注塑模设计【一模两腔】【侧抽芯】【说明书+CAD】,一模两腔,侧抽芯,说明书+CAD,DVD遥控器前盖注塑模设计【一模两腔】【侧抽芯】【说明书+CAD】,DVD,遥控器,注塑,设计,说明书,CAD
附表六湖南工学院毕业设计(论文)工作中期检查表题目DVD遥控器前盖注塑模设计学生姓名罗正芳班级学号212070327专业材料成型及控制工程指导教师填写学生开题情况已开题学生调研及查阅文献情况已进行毕业设计(论文)原计划有无调整无学生是否按计划执行工作进度是学生是否能独立完成工作任务能学生的英文翻译情况较好学生每周接受指导的次数及时间3次,6小时毕业设计(论文)过程检查记录情况较好学生的工作态度在相应选项划“”认真一般较差尚存在的问题及采取的措施:因对如何把所学注塑模设计方法运用到实际的能力还有所欠缺,所以在部分设计中有对细节把握不好的地方。经过查阅部分资料以及与指导老师的共同研究,已有较大的改善与提高。指导教师签字: 年 月 日系部意见: 负责人签字:年 月 日2011届毕业设计(论文)课题任务书系:机械工程系 专业:材料成型与控制工程 指导教师李天生学生姓名罗正芳课题名称DVD遥控器前盖注塑模设计内容及任务 根据所给定的注塑零件产品,设计出注塑模具。主要内容如下:1、绘制产品零件图。2、绘制模具装配图。3、绘制整套模具零件图,标准件除外。4、编写设计说明书。5、自选一个重要模具零件编制加工工艺路线,进行相关的计算,并编制加工工艺卡和工序卡。拟达到的要求或技术指标按照“湖南工学院毕业设计(论文)工作管理规定”,本课题设计要求及技术指标如下:(一)模具1、保证规定的生产率和高质量产品的同时,力求成本低、寿命长。2、模具结构设计合理,工艺性好,具有一定的创新性。3、操作安全、方便,易于维修,便于管理。4、在保证模具强度前提下,注意外形美观,各部分比例协调。(二)设计图纸1、模具绘图布局合理,视图完整、清晰,各项内容符合标准要求。2、设计图纸应符合学校的要求,不少于3张零号图纸的结构设计图、装配图和零件图,其中应包含一张以上用计算机绘制的具有中等难度的1号图纸,同时至少有折合1号图幅以上的图纸用手工绘制。(三)设计说明书1、资料数据充分,并标明数据出处。2、计算过程详细、完全。3、公式的字母含义应标明,有时还应标注公式的出处。4、内容条理清楚,按步骤书写。5、说明书按照学校的有关规定,编写不少于12000字的设计说明书,同时上交电子文档。(四)其他要求1、查阅到10篇以上与题目相关的文献2、翻译一篇本专业外文文献(10000个以上印刷符号),并附译文。进度安排起止日期工作内容备注2011年2月 5月1周(2、212、28)4周(2、283、25)2周(3、284、10)2周(4、114、24)1周(4、255、1)5周(5、26、3)1周(6、66、10)完成毕业设计的选题和开题报告;进行毕业实习及调研;进行工艺及结构设计;绘制装配图和零件图;对整个设计进行合理性检查; 撰写设计说明书及毕业答辩的准备;毕业设计答辩。主要参考资料1伍先明.塑料模具设计指导M .国防工业出版社,20062许发樾.实用模具设计与制造手册M .北京:机械工业出版社,20013刘彩英.塑料模具设计手册M .机械工业出版社,20024徐佩弦.塑料制品与模具设计M .中国轻工业出版社,20015机械工业职业鉴定指导中心M .机械制图.机械工业出版社,20006高佩福.实用模具制造技术M .轻工业出版社,19997孟少农.机械加工工艺手册M .机械工业出版社,19918林清安.Pro/Engineer Wildfire 2.0 模具设计M .北京大学出版社,2004.9叶久新.塑料制品成型及模具设计M .湖南科学技术出版社,200510中国机械工程学会.中国模具设计大典(第二卷)M .江西科学技术出版社,200311张建钢等.数控技术M .华中科技大学出版社,200012胡蓉,PRO/E在模具中的应用J .机械工程与自动化200513梅红吹,余拔龙,浅谈塑料模具CAD/CAM设计与制造工艺J .中国科技信息,200514朱福顺,王鹏程,郭胜利,模具材料及其发展概况J .内蒙古石油化工,200515杨俊秋,浅谈塑料模具毕业设计J.模具制造,2005,(7)教研室意见年 月 日系主管领导意见年 月 日实习日记2011年3月22日今天是实习参观的第一天,带着一点小小的兴奋和新奇早早从被窝爬了起来,感受到天气还是挺冷的。比原定时间早了一刻钟来到了集合地点,不时感受到阵阵寒风。车子晚到了半小时,实习的第一项也就变成了寒风中的等待。随后我们来到的地方是位于江宁经济技术开发区中电电气集团,这是一家集高品质太阳能单晶硅棒研发、生产、销售为一体的新型高新技术企业,拥有先进的单晶硅棒制造技术和生产、检测设备,汇集了国内外半导体硅材料科技领域的顶尖人才。我们参观了一下其中的一间厂房,了解了一些相关的生产工序和其中的一些相关细节。半个小时的参观之后第一天的内容就结束了,我们随车返回学校。2011年3月23日今天的实习参观我们来到了位于南京市大明路的南京电力自动化设备三厂有限公司,前身是南京电力自动化设备总厂三厂,这是一家致力于通讯设备研发、生产、销售和服务为一体的高新技术企业。我们主要参观了一些电能表装置的生产制作,在参观的过程中也听取了一些讲解,不过都没怎么听明白,但也算是增长了一些相关的见识。看着工作人员忙碌的身影想到不久之后自己也要投入自己的工作岗位,觉得自己是要真正进入社会了,以后不知道能不能闯出一番自己的天地。2011年3月24日今天参观的是位于南京市中心莫愁路上的南京工艺装备制造有限公司,是中国机械工业企业核心竞争力100强企业,是国内规模最大、规格最全、质量最优的精密滚动功能部件产业化基地,也是参观以来讲解最详细收获最多的一次。两位师傅带我们参观了除去一切保密房间以外的几乎所有厂房,并且都进行了认真细致的讲解,使我们对于一切滚动功能部件的生产制造有了一定深入的了解。是参观时间最长的一次,直到后来驾驶员需要我们快一点,剩下的一些厂房就只好匆忙看完了,也算是有些遗憾。2011年3月25日今天参观的是位于南京市栖霞区万寿村的南京依维柯旅行车分公司,南京依维柯汽车有限公司成立于1996年3月1日,是中国南京汽车集团与意大利菲亚特集团依维柯公司共同成立的合资公司。旅行车分公司整个厂区并不算大,主要是生产跃进6m9m多用途、公交、公路客运各系列客车底盘。参观了底盘的生产工序,最后还了解几种底盘的各部分介绍。边听讲解边自己思考,不懂的地方还可以提问。虽然说那些低盘都是一些低配置的底盘,但也能令大家了解到一切原来所不知道的知识。2011年3月26日今天参观的是南京申华汽车电子有限公司,为上海汽车工业(集团)总公司三级下属企业,由上海实业交通电器有限公司和南京东华汽车实业有限公司合资组建,前身为南京集团独资子公司南京汽车仪表有限公司。依靠雄厚技术实力,搭建起车用仪表、传感器、电子控制器、车用塑料件系列研发、产销平台,并引入了上实交通的摇窗机和电喇叭等系列产品。我们参观了一些简单的装配和测试工作室,大部分都是女工人,不知道不是这些工作都十分要求认真细致的缘故。-实习总结转眼间实习的三个星期就这样过去了,实习的那些天除了最后是下午的一次,剩下的每天都是需要8点之前起床,这三个星期早起的生活使之前睡到自然醒的清闲状态也有所改变。这次的实习毫无疑问学到了很多知识,扩展了知识面,尤其是书本上的知识,本来很多被我们用来应付考试的,但是到企业、工厂里看到这些一块一块的本以为不相干的内容组成一个完备的系统,完成一系列的功能,让我内心很有感触。这让我对未来的学习和工作方向有了深刻的思考。随着自动控制系统的发展,控制系统集成度越来越高,越来越趋向于集成智能化,而抛弃笨拙的人工手动控制,通过实习,使我们更加深刻认识到这一点。平时的学习一直没能形成一个明了的对自动化发展方向的认识,在实习中解决了这个疑惑,初步了解了自动控制在实际生产中的应用,以及自动控制涉及到的生产工艺流程,电气控制系统,仪表系统等。生产中要求稳定性高,抗干扰性强,效率高,质量高等设备,这些单单靠手工操作已经很难达到要求,传统的过渡设备也越来越难满足抗干扰、稳定性的要求,现在很多都是软硬件结合的设备,将编写好的程序命令输入系统后,系统将自动执行,而操作人员的重要性就是保证程序的严格和设备调试精准。这大大解放了劳动力,提高了生产效率。当然实习中还有着更多的感触。作为应届毕业生的我们要想适合自己的工作,在实际中实现自己的理想,必需不断的增加自己的能力,做事情更加专注。这次实习展示给我们看各个不同的行业的人们的生活,不同行业的人们将自己的行业融入自己的生活,这样大的人群的生活展示给我们未来的生活远景,选择什么样的生活也是我们现在的最重要的抉择。一旦下定决心,也就要开始为自己的生活做准备,胜利是属于有准备的人的。现在的我就要为自己的生活做准备,不断的充实自己。本次的实习,展示给我们了多种职业的工作状态,而作为应届毕业生,择业的选择是大多数人所面对的问题。就我们专业而言,面试时常遇见的问题就是“材料成型及控制工程专业是干什么的?”或许大多数的学生跟我一样对材料成型及控制工程专业并没有清晰的概念,所以也并不能很好的回答这样的问题。不管怎样,勤劳的人是让人钦敬的。实习过程中,讲解老师的介绍,完全冲破了课堂教学的格式,在现场有针对性的介绍,使我们对知识的认识更加深刻。这些天的实习,促使我调整自己的学习态度,重新定位自己的学习方向。因为学校内的学习,只能尽最大努力的培养一个优秀的学生。但是生产中不再只是简单的理论背诵与计算,将实践应用发挥到最大化,尽管学校的实验已经在努力模拟真实的环境,但是还是与实际有差距的。在真正的生产过程中,任何故障或事故都是很严重的,而在学校的仿真实验里,尽管也有模拟故障等功能,但是却始终不能深入人心,有的甚至是理想的条件,而这却是在实际生产中不可能实现的。这样就又削弱了学生实际应对问题和解决问题的能力。总的来说,这一次实习是比较成功的,学习到了很多在校园、在课堂上、课本上学不到的东西,也了解很多和懂得了做人的道理,特别是体会到生活中的艰辛和找工作的不容易。 这次实习开始之前我总以为根据自己从书上、从课堂上所学到的知识应该对企业的生产情况有了比较深刻的了解,但去了之后才知道自己的想法有多么幼稚,才体会到书上所说的“纸上得来终觉浅,绝知此事需躬行”的真正含义,也明白了学校安排生产实习良苦用心。真的,有许多东西看似已经懂了,但真正到了实际却又是另一种情况。有时自己认为自己已掌握的东西可能仅是一些肤浅的表面或总体的一个方面,甚至有时是错误的认识,而如果没有实地考察实践,你是无法发现这些问题的。这次实习给我们每个人一个很好的机会学习那些书本上不能学到的知识,增长了我们的见识,对生产操作有了一定的直观认识,对工人也有了一中全新的认识。现将这次生产实习的心得体会归纳如下:1、扩展了我的知识面,对书本理论知识给予了一个很好的补充;2、真正脚踏实地进入到工厂生产重点地带支了解生产过程,支认识工厂,了解设备; 3、对专业知识的学习打下有力的基础,为日后的专业课学习埋下了伏笔; 4、深入全面了解本专业职业定位,为将来工作有了一定的导向作用; 5、对生产设备有了由感性到理性的认知,有种实实在在的深刻印象; 6、对工厂或企业的各个车间间的联系,资源配置,生产流水线,企业文化在企业发展中的作用有更为全面的理解。感谢这次实习,感谢这次实习的各位带队教师,感谢为我们争取了这实习机会的领导。这次实习,一定会令我的人生走向新一页!附表五湖南工学院毕业设计(论文)开题报告 题目DVD遥控器前盖注塑模设计学生姓名罗正芳班级学号212070327专业材料成型及控制工程一、 选题的目的和意义:塑料制品在日常社会中得到广泛利用,模具技术己成为衡量一个国家产品制造水平的重要标志之一。国内注塑模在质与量上都有了较快的发展。但是与国外的先进技术相比,我国还有大部分企业仍然处于需要技术改造、技术创新、提高产品质量、加强现代化管理以及体制转轨的关键时期。关于全国塑料加工业区域分布,珠三角、长三角的塑料制品加工业位居前列,浙江、江苏和广东塑料模具产值在全国模具总产值中的比例也占到70。现在,这3个省份的不少企业已意识到塑模业的无限商机,正积极组织模具产品的开发制造。塑料制品在汽车、机电、仪表、航天航空等国家支柱产业及与人民日常生活相关的各个领域中得到了广泛的应用。塑料制品成形的方法虽然很多,但最主要的方法是注塑成形,世界塑料模具市场中塑料成形模具产量中约半数是注塑模具。目前,我国模具生产厂点约有3万多家,从业人数80多万人。2005年模具出口7.4亿美元,比2004年的4.9亿美元增长约50,均居世界前列。2006年,我国塑料模具总产值约300多亿元人民币,其中出口额约58亿元人民币。除自产自用外,市场销售方面,2006年中国塑料模具总需求约为313亿元人民币,国产模具总供给约为230亿元人民币,市场满足率为73.5%。在我国,广东、上海、浙江、江苏、安徽是主要生产中心。广东占我国模具总产量的四成,注塑模具比例进一步上升,热流道模具和气辅模具水平进一步提高。注塑模具在量和质方面都有较快的发展,我国最大的注塑模具单套重量己超过50吨,最精密的注塑模具精度己达到2微米。制件精度很高的小模数齿轮模具及达到高光学要求的车灯模具等也已能生产,多腔塑料模具已能生产一模7800腔的塑封模,高速模具方面已能生产挤出速度达6m/min以上的高速塑料异型材挤出模具及主型材双腔共挤、双色共挤、软硬共挤、后共挤、再生料共挤出和低发泡钢塑共挤等各种模具。在CAD/CAM技术得到普及的同时, CAE技术应用越来越广,以 CAD/CAM/CAE一体化得到发展,模具新结构、新品种、新工艺、新材料的创新成果不断涌现,特别是汽车、家电等工业快速发展,使得注塑模的发展迅猛。基于现状并结合本学校教学特色,选用固体胶底座注塑模设计作为我这次毕业设计的题目。二、国内外研究综述注塑模具在量和质方面都有较快的呕,我国最大的注塑模具单套重醏己超过5 吨,最精密的注塑模具精度己达到2微米。制件精度很高的小模数齿轮模具及达到高光学要求的车灯模具等也已能生产,多腔塑料模具已能生产一模7800腔的塑封模,高速模具方面已能生产挤出速度达6m/min以上的高塑料异型材挤模具及主型材双腔共挤、叄色共挤、硬共挤、后共挤、生料共挤出和低发泡钢塑共挤等各种模具。在CAD/CAM技术得到普半的同时, CAE技术应用越敥越广,以 CA/CAM/CAE一体化得发展,模具斠结构新品种、新工艺、新的新成果不攭洌现,爹别是汽车、家电等工业快速发展,伖泈塑模的发展迅猛。整体来看我国塑料模具论昏在量上,蟘是在质量、技昭和能力等方面都有很大诛,但国搑经济发屑的需求、世先水帳相比,差趝仅很大。一些大型、精、复杂、长寿命的高档模具每年仍需大量进叡。在总量应摂同时,一些低偑料模具却供迃于求市圚狞争激烈,还有一些术含量不夢高嚄严档塑斉具也有供迅于桂的趋。分析:未敥我国注塑模行业的发展趋势 据业内人士分未来内外棈塑樁发展势包4丢方面: 1、大力提高注塑模开发能力。将开发工作尽量往前推,直至介入到模具用户的产品开发中去,甚至在尚无明确用户对象之前进行开发,变被动为主动。目前,电视机和显示器外壳、空调器外壳、摩托车塑件等已采用这种方法,手机和电话机模具开发也已开始尝试。这种做法打破了长期以来模具厂只能等有了合同,才能根据用户要求进行模具设计的被动局面。2、注塑模具从依靠钳工技艺转变为依靠现代技术。随着模具企业设计和加工水平的提高,注塑模具的制造正在从过去主要依靠钳工的技艺转变为主要依靠技术。这不仅是生产手段的转变,也是生产方式的转变和观念的上升。这一趋势使得模具的标准化程带不断捐高缌模偷精庢趈来越高,生产周期越来越短,钳工比例越来越低,最终促进了模具工丒整体水平不断提鋘。目前我国已10多个国家级高新技术企业,约200个省市级高新技术企业。与此趋势相适应,生产模具的主要骨干力量从技艺型人才逐昐转变为技术型人才是必然要求。3、模具生产正在向信息化迅速发呕。在息社会中,作为一高水平的现代模具企业,单单只是CAD.CAM的应用已远远不够。目前许多企业已经采用了CAE、CAT、PDM、CAPP、KBE、KBS、RE、CIMS、ERP等技术及其它先进制造技术和虚拟网络技术等,这些都是信息化的表现。向信息化方向发展这一趋向已成为行业共识。4、注塑模向更广的范围发展。随着人类社会的不断进步,模具必然会向更广泛的领域和更高水平发展。现在,能把握机遇、开拓市场,不断发现新的增长点的模具企业和能生产高技术含量模具企业的业务很是红火,利润水平和职工收入都很好。因此,模具企业应把握这个趋向,不断提高综合素质和国际竞争力。随着市场的发展,塑料新材料及多样化成型方式今后必然会不断发展,因此对模具的要求也越来越高。为了满足市场需要,未来的塑料模具无论是品种、结构、性能还是加工都必将有较快发展。超大型、超精密、长寿命、高效模具;多种材质、多种颜色、多层多腔、多种成型方法一体化的模具将得到发展。更高性能及满足特殊用途的模具新材料将会不断发展,随之将产生一些特殊的、更为先进的加工方法。各种模具型腔表面处理技术,如涂覆、修补、研磨和抛光等新工艺也会不断得到发展。三、 毕业设计(论文)所用的主要技术与方法:随着计算机技术的发展,注塑模的设计方法已经由传统的手工绘图设计逐步向计算机辅助设计(CAD)方向发展,给注塑模生产带来了深刻的变革。此次毕业设计题目主要是基于AutoCAD的技术与方法进行设计。1、调研DVD遥控器前盖注塑模的造型结构特征及对注塑零件的工艺性分析。2、注塑工艺的总体方案的分析和确定,然后进行排样设计和工艺计算。3、进行模具关键结构的方案设计,制定初步模具关键结构设计方案,绘制产品草图。4、进行DVD遥控器前盖注塑模结构设计,绘制正规DVD遥控器前盖注塑模零件设计图纸。5、选择合理的注塑设备,并对设备进行校核。6、编制模具中主要零件的制造工艺方案和加工方法。7、撰写设计说明书,所有设计文档、资料的整理、收尾、答辩。四、 主要参考文献及资料获得情况1伍先明.塑料模具设计指导M .国防工业出版社,20062许发樾.实用模具设计与制造手册M .北京:机械工业出版社,20013刘彩英.塑料模具设计手册M .机械工业出版社,20024徐佩弦.塑料制品与模具设计M .中国轻工业出版社,20015机械工业职业鉴定指导中心M .机械制图.机械工业出版社,20006高佩福.实用模具制造技术M .轻工业出版社,19997孟少农.机械加工工艺手册M .机械工业出版社,19918林清安.Pro/Engineer Wildfire 2.0 模具设计M .北京大学出版社,2004.9叶久新.塑料制品成型及模具设计M .湖南科学技术出版社,200510中国机械工程学会.中国模具设计大典(第二卷)M .江西科学技术出版社,200311张建钢等.数控技术M .华中科技大学出版社,200012胡蓉,PRO/E在模具中的应用J .机械工程与自动化200513梅红吹,余拔龙,浅谈塑料模具CAD/CAM设计与制造工艺J .中国科技信息,200514朱福顺,王鹏程,郭胜利,模具材料及其发展概况J .内蒙古石油化工,200515杨俊秋,浅谈塑料模具毕业设计J.模具制造,2005,(7)五、毕业设计(论文)进度安排(按周说明)第5-6周 收集并整理相关资料第7-8周 研究资料、编写开题报告第9-10周 完成毕业设计论文的初稿 第11-12周 根据指导教师意见,修改和完善论文第13-14周 进一步完善论文,定稿并装订成册第15-17周 准备毕业答辩,提交论文指导教师批阅意见 指导教师(签名): 年 月 日注:可另附A4纸摘要随着现代工业的迅猛发展, 注塑成型在机械、电子、航空航天工业、生物领域及日用品生产中所占的比例越来越大。本次设计的是DVD遥控器前盖塑料模具,制件的结构决定了该模具必须同时使用侧抽芯。设计过程整体采用现代先进的模具加工制造方法和强大的Pro/Engineer Wildfire 2.0模具设计软件相结合,在保证设计质量的同时设计速度也有提高,设计思路及要求符合现代模具设计的潮流和未来的发展方向。 关键词: 注塑成型;塑料模具;遥控器;侧抽芯ABSTRACTWith the rapid development of industry, the mould plastics shapings covers more and more in mechanical industry, electronics industry, spaceflight industry,biological field and production of daily necessities. This remote controler front cover of DVD molding die must include special slide pull structure because the structure of the product. This design is the integration of modern advanced mould process manufacturing approach and powerfull Pro/Engineer Wildfire 2.0 mold design,not only the design quality is assured but also heightened the design speed. The thought and requirement of this design accord to the trend of contemporary mold design and its future of development direction. Keywords: Mould plastics shaping;Injiectiong mold die;Remote controller;Slide pull structureMinimizing manufacturing costs for thin injection molded plastic components1. IntroductionIn most industrial applications, the manufacturing cost of a plastic part is mainly governed by the amount of material used in the molding process. Thus, current approaches for plastic part design and manufacturing focus primarily on establishing the minimum part thickness to reduce material usage. The assumption is that designing the mold and molding processes to the minimum thickness requirement should lead to the minimum manufacturing cost.Nowadays, electronic products such as mobile phones and medical devices are becoming ever more complex and their sizes are continually being reduced. The demand for small and thin plastic components for miniaturization assembly has considerably increased in recent years.Other factors besides minimal material usage may also become important when manufacturing thin plastic components. In particular, for thin parts, the injection molding pressure may become significant and has to be considered in the first phase of manufacturing.Employing current design approaches for plastic parts will fail to produce the true minimum manufacturing cost in these cases.Thus, tackling thin plastic parts requires a new approach, alongside existing mold design principles and molding techniques.1.1 Current researchToday, computer-aided simulation software is essential for the design of plastic parts and molds. Such software increases the efficiency of the design process by reducing the design cost and lead time 1. Major systems, such as Mold Flow and C-Flow, use finite element analysis to simulate the filling phenomena, including flow patterns and filling sequences. Thus, the molding conditions can be predicted and validated, so that early design modifications can be achieved. Although available software is capable of analyzing the flow conditions, and the stress and the temperature distribution conditions of the component under various molding scenarios, they do not yield design parameters with minimum manufacturing cost 2,3. The output data of the software only give parameter value ranges for reference and leaves the decision making to the component designer. Several attempts have also been made to optimize the parameters in feeding 47, cooling 2,8,9, and ejection These attempts were based on maximizing the flow ability of molten material during the molding process by using empirical relation ships between the product and mold design parameters. Some researchers have made efforts to improve plastic part quality by Reducing the sink mark 11 and the part deformation after molding 12, analyzing the effects of wall thickness and the flow length of the part 13, and analyzing the internal structure of the plastic part design and filling materials flows of the mold design 14. Reifschneider 15 has compared three types of mold filling simulation programs, including Part Adviser, Fusion, and Insight, with actual experimental testing. All these approaches have established methods that can save a lot of time and cost. However, they just tackled the design parameters of the plastic part and mold individually during the design stage. In addition, they did not provide the design parameters with minimum manufacturing cost. Studies applying various artificial intelligence methods and techniques have been found that mainly focus on optimization analysis of injection molding parameters 16,17. For in-stance He et al. 3 introduced a fuzzy- neuro approach for automatic resetting of molding process parameters. By contrast , Helps et al. 18,19 adopted artificial neural networks to predict the setting of molding conditions and plastic part quality control in molding. Clearly, the development of comprehensive molding process models and computer-aided manufacturing provides a basis for realizing molding parameter optimization 3 , 16,17. Mok et al. 20 propose a hybrid neural network and genetic algorithm approach incorporating Case-Based Reasoning (CBR) to derive initial settings for molding parameters for parts with similar design features quickly and with acceptable accuracy. Moks approach was based on past product processing data, and was limited to designs that are similar to previous product data. However, no real R&D effort has been found that considers minimizing manufacturing costs for thin plastic components. Generally, the current practical approach for minimizing the manufacturing cost of plastic components is to minimize the thickness and the dimensions of the part at the product design stage, and then to calculate the costs of the mold design and molding process for the part accordingly, as shown in Fig. 1.The current approach may not be able to obtain the real minimum manufacturing cost when handling thin plastic components.1.2Manufacturing requirements for a typical thin plastic component As a test example, the typical manufacturing requirements for a thin square plastic part with a center hole, as shown in Fig. 2, are given in Table 1.Fig.1. The current practical approachFig.2. Test example of a smallplastic component Table1. Customer requirements for the example component2. The current practical approachAs shown in Fig.1, the current approach consists of three phases: product design, mold design and molding process parameter setting. A main objective in the product design is to establish the physical dimensions of the part such as its thickness, width and length. The phases of molded sign and molding subsequently treat the established physical dimensions as given inputs to calculate the required details for mold making and molding operations.When applying the current practical approach for tackling the given example, the key variables are handled by the three phases as follows:Product design* Establish the minimum thickness (height) HP, and then calculate the material cost. HP is then treated as a predetermined input for the calculation of the costs of molddesign and molding operations. HP Mold design* Calculate the cooling time for the determined minimumthickness HP in order to obtain the number of mold cavities required. The mold making cost is then the sum of the costs to machine the: Depth of cutting (thickness) HPNumber of cavitiesRunner diameter DRGate thickness HG Molding process* Determine the injection pressure Pin, and then the cost of power consumptionl Determine the cooling time t co, and then the cost of machine operations. The overall molding cost is the sum of the power consumption cost and machine operating cost.The total manufacturing cost is the sum of the costs of plastic material, mold making and molding operations. Note that, in accordance with typical industry practice, all of the following calculations are in terms of unit costs.2.1 Product design This is the first manufacturing phase of the current practical approach. The design minimizes the thickness HP of the plastic component to meet the creep loading deflection constraint , Y (1.47mmafter1yearofusage),and to minimize plastic material usage cost Cm. Minimizing HP requires 21:Figure 3 plots changes in HP through Eqs.1 and 2.The graphs show that the smallest thickness that meets the 1.47mm maximum creep deflection constraint is 0 .75mm,with a plastic material cost of $0.000483558/unit and a batch size of 200000 units. This thickness will be treated as a given input for the subsequent molded sign and molding process analysis phases. 2.2Mold design2.2.1 Determination of cooling timeThe desired mold temperature is 25 C. The determined thickness is 0.75mm. Figure 4 shows the cooling channels layout following standard industry practices. The cooling channel diameter is chosen to be 3mm for this example.From 22, the cooling time t co:And the location factor, BysolvingEqs.3and4, and substituting HP =0.75mm and the given values of the cooling channel design parameters, the cooling time (3.1s) is obtained.The cycle time t cycle, given by E q. 5, is proportional to the molding machine operating costs, and consists of injection time (t in), ejection time (t e j), dry cycle time (t d c), and cooling time (t c o). 2.2.2 Determination of the number of mold cavities In general, the cost of mold making depends on the amount of machining work to form the required number of cores/cavities, runners, and gates. The given example calls for a two-plate mold Fig.3. Deflection and plastic materials costs versus part thickness Fig.4. Cooling channel layout that does not require undercut machining. Therefore, the ma chining work for cutting the runners and gates is proportional to the work involved in forming the cores/cavities and need not be considered. In the example, mold making cost Cmm is governed by (n, HP).Generally, the minimum number of cavities, Nmin, is chosen to allow for delivery of the batch of plastic parts on time图3 。 After substitutionwhich is rounded To n =3,since the mold cannot contain 2.64 cavities. The machine operation capacity and the lead-time of production in the example are given as 21.5h/d and 21d, respectively. Moreover, as mentioned in the previous section, the cycle time is directly proportional to the part thickness HP. A curve of batch size against thickness is plotted in Fig. 5. As shown, at HP =0.75mm, the production capability (batch size) is 242470units.Thus the production capability of n =3 is larger than the required lot size (200000units).For simplicity, the time taken for machining the depth of a thin component is treated as a given constant and added to the required time t CC for making a cavity insert. The C mm can then be calculated by n as expressed 12.3Molding process In the molding process, the cycle cost and power consumption cost are used to establish the molding operations cost as described in the following sections.Fig.5. Mold making cost versus part thickness2.3.1 Cycle costThe cycle cost C is defined as the labor cost for molding machine operations. The calculation of cycle cost, given by E q. 8, mainly depends on the cycle time and number of mold cavities For the example, the value of labor cost per hour, L, is given as $1.19/h. Also, Cp can be calculated, as t cycle =20.1sand n = 3 when HP = 0.75mm, as found earlier. And so Cp =$0.0022147/unit.2.3.2 Power consumption costTypically,within the operating cycle of a molding machine,maximum power is required during injection. Hence, longer injection times and higher injection pressures increase the power consumption cost.For the purposes of this example, an injection time of tin =0.5sisselectedand applied for the molding process。The required hydraulic power PH, power consumption E i, and cost CPC for injection can be found from the followingexpressions 23In E q. 9, 0.8 is the mechanical advantage of the hydraulic cylinder for power transmission during molding, and the resulting electric power cost of CE = HK$1.0476/kWh is given in E q. 11. To find CPC, the sum of the required injection pressures Pin in the feeding system and cavity during molding need to be found.Required injection pressures. Based on the mold layout design, the volume flow rate Q in the sprue is equal to the overall flow rate, and the volume flow rate in each primary and secondary runner will be divided by the separation number, Ni,according to:The volume flow rate in a gate and cavity equals to that of the runner connecting to them. Tan 24 derived simplified modelsFor filling circular and rectangul a r channels that can be employed for the feeding system design in this study 1. Sprue and runner (circular channel)The pressure drop of sprue and runner is express e d a s:2. Cavity and gate (rectangular channel)The pressure drop of cavity and gate is expressed as: Further, the temperature-dependent power law viscosity model can be defined as: Based on the values of the volume flow rate and consistency index m (T) for each simple unit, the pressure drop P can be found by using E q s. 12to15. Thus, the required filling pressure is the sum of pressure drops P in the sprue, primary runner, secondary runner, gate, and cavity: Required power consumption. Given the shape and dimensions of the part and feeding channel, the pressure drops of the sprue , runner, gate , and cavity are obtained through the calculation froE q s. 12 to 15, and are substituted into E q. 16. The required injection pressure Pin is calculated and substituted into the E q. 9.Combining E q s. 10 and 11, the power consumption cost CPC is calculated and depends on the variation of injection pressure, which is indirectly affected by the thickness of product as shown in the following E q .17. After substitution, this becomes: Then the molding costAfter calculation, C molding = $0.0022147/unit+$0.003755/unit,when HP =0.75mm, n =3.2.4Remarks on the current practical approach Based on Esq. 8 to 18 it can be shown that as the part thickness,Hp, increases, the necessary injection pressure Fig.6. Molding process cost versus thickness consumption cost) decreases but the cycle time (and thus labor cost) increases and so there is a minimum total molding process cost, as shown in Fig.6 for the example in this study. As can be seen the minimum molding process cost is Hp =2.45mm.If the test example part thickness, Hp, were increased from0.75 to 2.45mm, the plastic material cost is increased by230.1%; however, the total molding process cost decreases by20.6% to $0.004741/unit. Moreover, the total manufacturing cost for the part falls by9.54%, a saving of $0.0001174/unit.Thus, applying the current practical approach does not give the true minimum manufacturing cost. The current practical approach mainly focuses on minimizing the thickness of the part to reduce the plastic material usage and achieve shorter cooling times. When the part is thin, higher injection pressures are needed during the molding process, which substantially increases the molding process costs and consequently shifts the true minimum manufacturing cost for the part away from the minimum thickness solution.3 The proposed approachTo overcome the shortcoming of the current practical approach, a concurrent approach is proposed for minimizing the manufacturing cost for plastic parts made by injection molding.3.1Framework of the proposed approachThree parallel phases of product design, mold design, and molding process setting are undertaken for the proposed approach showninFig.7. The parallel phases handle individual cost functions for material cost, molding cost, and mold making cost, Which add to yield the total manufacturing cost . The product shape and dimensions (the possible range of thicknesses) are considered as the main design inputs at the beginning of design phase, as shown in Fig. 7.The proposed approach will provide a possible solution by considering the three phases simultaneously. The outputs are options for combinations of the thickness of the part , the number of mold cavities , and the minimum manufacturing cost that meet all the given requirements.Fig.8. Creep deflection and plastic material cost versus thicknessFig.9. Mold making cost versus part thickness (n =18) 3.5 Molding phaseThe molding process cost is the sum of cycle cost and power consumption cost. Each number of mold cavities has its own curve of molding cost as shown in Fig. 10. Each curve is inversely proportion to the thickness of the plastic component. The lowest point of the curve is the minimum cost. Usually, when the curve has no sharp turning point and asymptotes, it means that enlarging the thickness cannot reduce molding cost very much.If the thickness of product is increased, lower injection pressure is required during molding, thus the power consumption cost is reduced, but the cycle time is lengthened and the cycle cost is increased.As in Fig. 10, assuming an eight cavity mold, the thickness of the plastic part should be less than 2.81mm, with minimum molding cost lessthan$0.00475676/unit.mold3.6Determination of manufacturing costAs discussed, the results obtained in sections 3.3, 3.4, and 3.5 can be combined to yield a total manufacturing cost that is the summation of the part design, mold making, and molding process costs. Eight different curves have beendrawninFig.11, for the different numbers of mold cavities. The minimum manufacturing cost is obtained from the lowest point among the eight curves in this study. From Fig.11, the thickness of the plasticFig.10. Molding process cost versus part thickness (n =18):Fig.11. Manufacturing cost versus part thickness (n =18) component is 1.44mm, with minimum manufacturing cost of $0.00843177/unit and n =3.The lowest manufacturing cost is obtained after inputting all values of thickness and numbers of cavities with in the allowable range, 0.01mm to 6mm and 1 to 8, respectively.Table2. Comparison of results for the different approaches3.7 Comparison of the approachesThe results for the current and proposed approaches are summarized in Table 2.When the thickness is increased from 0.75 to 1.44mm, the plastic material cost increases by 92%, but reduces total manufacturing cost by 72.4%. An improvement of 85.9% for the creep deflection is also obtained in the functional design. Further, with the 1.44mm papt thickness, 4.5% less elecpric power is splt.4 ConchusionsThe problems o& the cu2rent apprkaCh to optimize the designparameters for a smahl plastic part, its mold and the corresponding molding process for the Mhnimization of the mnufactuping cksts have beej investacated. A new aroach to o6ercnme dhe problems hac been proposed and tested. ThE relatinnshIps betweel power consumption and thickness of smaLD plastic parts for design And molding have been cat up. The criteria for the propos%d approac to muf!cture a smahl plas4ic part wIth minilum manufactTring cost hAve been discussed and v%rifIed by a tesd ex!mplE. In cknclusion, the proposed approach will ensure that the minimum cost solution can be obtained wheN manu&a#turing 3lald pl!st)c parts.尽量少生产成本的超薄注塑成型塑斉聨1前言在多数工业应,塑撙零件的生产成本,主要集中在材撙成型的模具上。因此曮前使唨多的办就是降低偑料聨件的厚度,以减少材料使用。假设设计模成型过程的最厚度要求昏围导致制造的最成。如今电子产品如移动电话和医疗论备正变得越捥越复杂,尺寸正在不减小。在挀近几年小而薄的塑撙部件需求已大为加除了最低限度的贈用其他方镢也可能成为唟产超蒄塑憑郠件的重要因特是对于制造薄来说,在第一阶段的注塑压力尤丸重要。如果采用目瘄设计方法鼌在这些薄件中,塑料部件将无法制造最伎成本。因此,处理超薄塑料零件,需要一种斐的方法,以适岔现有的模具设莡原则和成工艺。1.1目前的研究状况如仂,电脑辅模拏软件是模关设计必可少的组成部分。这种软件,增加了设计的效率减少设謡成本和时间 1 。主要系统,如模具流和C -流量使用有限元分析模拟充填现葡,包括流动模式和填补序列。因此成型条件可以预测和验证,以使早朗设计的修改是可以实现的虽然现有的轪件能够分枀流量条件三应力和温度分布状况,他们梡有产生最的制造成本瘄设讁参数 2,3 。输出数据的软件只能提供参数范围,以供设计师参考和决策。多次尝试乗取得了优化的参数 4-7 ,冷却系统 0,8,9 ,并凍馈 10 Y 。这些尝试在础上最大虐度限制了熔融材料在成压过程中使甠的经验与船舶之间的品模的设计厂数。一些究人员已作出努力,为了搹善塑料零件质量通过减少缩水 11 和部分变形后成型 12 ,分朐影响壁厚和流动长度的一部分K 13 ,分掐了内部结构的塑料零件的设计和充填料流动的模设计 14 。 Reifschneider 15 揔较三种米喋的充型模拟程序,包括胨分顾问,融吀,和Ansight ,实虅实验敋试。所有这些已建立的方,可以节省大量的时间和成本。焆而他们只解决了设覡参数的塑料银件和模具单独在设计阶段。此,他们还没有懐供的设计卂数与最制造成本。研究人智能应焨各秉方法和技术已被发现,主要集中在优刖分析的注参数 16,17 。用于莫乃光等。 3 介绍亄糊神经自动复位的方法成型工艺参数。瓸比义下,莫乃光人。 18,19 通过人工神经网络预测的设缮塑料成型条仦的一部分中的质量控制成型。显然,制定全面昄成型过稃模型电脑辁助制造提供了基础妞现成型参数优化 3,16,17 U 。莫乃光等人 20 提出了一种淳合神经网络和遗传算法璄刞法纳入基于案例推理( CBR的)店到初步设厚成型参的部分有类似的设计特点迅速,准确。莫的办法是据过去嚄产品处理数据,并仅限于设计,类似以前的产品数据。然而缌考虑到尽臏兏少生产戀本的塑料部仴,撡真正璄被R&D努力研发所发掰。一般说,目前璄切合实际的办法是尽量减少生产成本的塑料胨件匨产品设计阶段尽量兏尐厚度和吺寸的部分,然后计算出的贙用,模具誶计与成型过程的一部分,如图1中显示。目前的做法在处理塑料部件时可能无法取得实际最低制造成本。1.2生产要求一个典型的塑料部分作为测试的例子,典型的生产要求薄平方米塑料零件的中心孔,所显示的图。 2 ,载于表1 。图1 。目前切实可行的办法图2 。试验的例子,一个小塑料元件表1 。客户的需求为榜样部分2目前切实可行的办法在图1所示,目前的办法包括三个阶段:产品设计,模具设计和成型工艺参数的设置。一个主要目标的产品设计是建立在物理尺寸的一部分,如它的厚度,宽度和长度。各阶段的模塑成型和随后签署和处理建立物理尺寸作为给出的投入来计算所需的详细资料和成型模具制造业务当申请目前切实可行的办法解决给定的例子,关键的变数是由三个阶段处理如下:产品设计l 确定的最小厚度(高度) ,然后计算材料成本。HP则视为预先输入的计算费用的模具设计和
收藏