LED导光柱注塑模具设计【说明书+CAD】
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编 号 无锡太湖学院 毕 业 设 计 ( 论 文 ) 题目: LED 导光柱注塑模具设计 信 机 系 模 具 设 计 与 制 造 专 业 学 号: 0923259 学生姓名: 谢兵兵 指导教师: 范圣耀(职称:副教授) (职称: ) 2013 年 5 月 25 日 无锡太湖学院本科毕业设计(论文) 诚 信 承 诺 书 本人郑重声明:所呈交的毕业设计(论文) LED 导光柱注塑模 具设计 是本人在导师的指导下独立进行研究所取得的成果,其内容 除了在毕业设计(论文)中特别加以标注引用,表示致谢的内容外,本 毕业设计(论文)不包含任何其他个人、集体已发表或撰写的成果作品。 班 级: 机械 96 学 号: 0923259 作者姓名: 2013 年 5 月 25 日 I 无 锡 太 湖 学 院 信 机 系 模 具 设 计 与 制 造 专 业 毕 业 设 计 论 文 任 务 书 一、题目及专题: 1、题目 LED 导光柱注塑模具设计 2、专题 二、课题来源及选题依据 本次毕业设计题目是 LED 导光柱注塑模具设计,课题来源于无锡新区 某模具有限公司。其研究的内容是电子产品中 LED 导光柱的注塑模具设计。 LED 导光柱主要起导光作用,它能够使一切 LED 灯发光,透光度达到 98%。注塑模具在现代生活中的地位越来越高,因此对塑料模具质量的要求 也越来越高,这就要求塑料模具的开发、设计与制造的水平也必须越来越高。 LED 导光柱在工厂生产中属于大批量生产,故将要求我们精确设计出相应的 塑料模具。 本课题的选择主要有下面几方面的依据: 1、塑料模具与自己的专业接近,完成该课题可对我们大学期间所学知 识进行一次全面的专业训练,可以培养我们掌握如何运用过去所学知识去解 决生产中实际问题的方法。 2、我在无锡一家模具厂实习,该厂正好生产导光柱,我对制件的尺寸 都有深入的了解,可以减少许多不必要的麻烦。 II 三、本设计(论文或其他)应达到的要求: 正确合理分析零件工艺用途及结构; 理解并掌握注塑模具的原理; 了解注塑模具的各种结构以及各自的特点; 能够掌握注塑模具上各个部分的作用; 对于注塑模具设计,能够掌握模具中各个部分的设计原则以及能够合 理分析各因素对设计的影响; 熟练使用各种制图软件。 四、接受任务学生: 机械 96 班 姓名 谢兵兵 五、开始及完成日期: 自 2012 年 11 月 12 日 至 2013 年 5 月 25 日 六、设计(论文)指导(或顾问): 指导教师 签名 签名 签名 教 研 室 主 任 学科组组长研究所所长 签名 系主任 签名 2012 年 11 月 12 日 III IV 摘 要 本次毕业设计的题目是 LED 导光柱注塑模具设计。目前,塑料制件几乎已经进入了 一切工业部门以及人民生活的各个领域。随着工业塑料制件和日用塑料制件的品种和需 求量日益增加,这些产品更新换代的周期越来越短,因此对塑料的品种、产量和质量都 提出了越来越高的要求,这就要求塑料模具的开发、设计与制造的水平也必须越来越高。 在现代塑料成型生产中,塑料制件的质量与塑料成型模具、塑料成型设备和塑料成 型工艺这三项因素密切相关。在这三项要素中,塑料成型模具质量最为关键,它最能反 映出整个塑料成型生产过程的技术含量及经济效益,它的功能是双重的:赋予塑料熔体 以期望的形状、性能、质量;冷却并推出成型的制件。 本文主要内容是对 LED 导光柱注塑模具的成型部位、浇注系统、导向机构、推出机 构、排气系统及冷却系统等进行详细的分析、计算及设计。在设计过程中,我们需要充 分考虑塑料变形、收缩率、排气等各种因素的影响,使其满足总体的设计要求。 关键词:LED 导光柱;注塑成型;注塑模具;结构设计。 V Abstract My graduation thesis topic is LED guide beam injection mold design. Plastic parts almost go into all industrial sectors and the people of all areas of life today. With the variety and the demand of industrial plastic parts and plastic parts for daily use increasing, the product replacement cycles are getting shorter, which causes higher and higher demands for the plastic varieties, yield and quality, so the development of plastic mold design and manufacturing level should also grow. In modern injection molding production, the quality of the plastic parts is closely related to the three factors which include plastic mold, plastic molding equipment and plastic molding process. In these three elements, plastic mold quality is the most critical, it is best to reflect the technical content and economic benefits of the plastic molding production process, its function is twofold: making the plastic melt the desired shape, performance, quality ; cooling and launched the formed workpieces. This article main content is about a detailed analysis, calculation and design of the LED light guide forming parts of injection mould, pouring system, guide mechanism, institution, exhaust system and cooling system, etc. In the design process, we need to fully consider the plastic deformation, shrinkage rate, exhaust and other factors, making it satisfy the requirement of the overall design. Key words: LED guide beam; Injection molding; Injection mould; structural design. V 目 录 摘 要 .III ABSTRACT .IV 目 录 .V 1 绪论 .1 1.1 本课题的研究内容和意义 .1 1.1.1 本课题的研究内容.1 1.1.2 本课题的意义 .2 1.2 国内外的发展概况 .3 1.2.1 注塑模具国外研究现状 .3 1.2.2 注塑模具国内研究现状 .3 1.2.3 注塑模具发展趋势.4 1.3 本课题应达到的要求 .4 2 塑料制件的工艺性 .5 2.1 塑料的基本组成及分类 .5 2.2 塑件材料的物理性质及其用途和成型特点 .8 2.2.1 塑件材料物理性质.8 2.2.2 主要用途以及成型特点 .9 2.3 LED 导光柱的几何结构 .9 2.4 LED 导光柱相关数据的确定 .12 2.4.1 塑件厚壁的确定 .12 2.4.2 脱模斜度的确定 .13 2.4.3 圆角的的确定 .13 2.4.4 LED 导光柱的体积及质量 .13 3 注射成型原理以及注塑机的选择 .14 3.1 注射成型原理 .14 3.1.1 柱塞式注塑机注射成型原理 .14 3.1.2 螺杆式注塑机注射成型原理 .14 3.2 注射成型工艺 .16 3.2.1 成型前的准备 .16 3.2.2 注射过程 .16 3.2.3 塑件的后处理 .16 3.3 注塑机的选择 .17 3.3.1 注塑机的分类 .17 3.3.2 注塑机的类型选择.18 VI 3.3.3 注塑机参数的校核.19 4 分型面的选择与浇注系统的设计 .21 4.1 分型面及其选择 .21 4.1.1 型腔数目的确定和布置 .21 4.1.2 分型面的形式 .22 4.1.3 分型面的设计原则.22 4.2 浇注系统的设计 .22 4.2.1 普通浇注系统设计的基本原则 .23 4.2.2 主流道的设计 .23 4.2.3 分流道的设计 .24 4.2.4 浇口的设计 .25 5 成型零部件设计 .27 5.1 成型零件的结构设计 .27 5.1.1 凹模的结构分析 .27 5.1.2 型芯和成型杆的结构分析 .27 5.2 影响塑料尺寸精度的主要因素 .27 5.2.1 塑料制品的成型收缩 .27 5.2.2 模具成型零件的制造公差 z.28 5.2.3 模具成型零件的磨损 c.28 5.3 成型零件的工作尺寸的计算 .28 6 导向机构和推出机构的设计 .31 6.1 导向机构的设计 .31 6.1.1 导向机构的功用 .31 6.1.2 导向装置类型 .31 6.1.3 导柱导向机构 .31 6.1.4 导套的设计 .32 6.2 推出机构的设计 .33 6.2.1 推出机构的结构组成 .33 6.2.2 推出机构的设计原则 .33 6.2.3 顶出部件 .34 6.2.4 复位部件 .35 6.2.5 导向部件和限位零件 .35 7 其它部件的设计 .36 7.1 温度调节系统的设计 .36 7.1.1 冷却系统的设计原则 .36 7.1.2 冷却系统的计算 .36 VII 7.2 模架的设计 .38 7.2.1 模板的布置 .38 7.2.2 模板的标准化 .38 7.3 排气系统的设计 .39 7.3.1 排气槽的位置及作用 .40 7.3.2 排气方式 .40 7.3.3 溢流槽 .40 8 结论 .41 致 谢 .42 参考文献 .43 LED 导光柱注塑模具设计 1 1 绪论 注塑模具设计是对所学模具专业知识的一次巩固,是在进行社会实践工作之前对所 学各课程的一次综合性总复习,也是对在校学习的一次全面检测。注塑模具是一种生产 塑胶制品的工具,也是赋予塑胶制品完整结构和精确尺寸的工具。注塑成型是批量生产 某些形状复杂部件时用到的一种加工方法,具体指将受热融化的材料由高压射入模腔, 经冷却固化后,得到成形品,其原理是将颗粒状或粉末状的塑料从注射机的料斗送进加 热的料筒中,经过加热融化成流动状态后,在柱塞或螺杆的推动下,熔融塑料被压缩并 向前移动,通过料筒前端的喷嘴以很快的速度注入温度较低的闭合模腔中,充满形腔的 熔料在受压的情况下,经冷却固化后即可保持模具形腔所赋予的形状,然后开模分型获 得成型塑件。到目前为止,除氟塑料外,几乎所有的热塑性塑料都可以采用这种方法成 型。它具有成型周期短,能一次成型外形复杂、尺寸精确、带有金属或非金属的嵌件的 塑料制品。根据产品的批量、结构、尺寸与精度,可采用一模一腔,也可采用一模多腔。 注射成型加工方式通常只适用于热塑料品的制品生产,用注射成型工艺生产的塑料 制品十分广泛,从生活日用品到各类复杂的机械,电器、交通工具零件等都是用注射模 具成型的,它是塑料制品生产中应用最广的一种加工方法。 1.1 本课题的研究内容和意义 1.1.1 本课题的研究内容 本课题来源于无锡新区某模具有限公司。其研究的内容是电子产品中LED导光柱的注 塑模具设计。LED 导光柱是用在一切 LED灯上的导光作用,透光度可达到 98%以上。导光 柱就是将光以最小的损耗从一个光源传输到距离该光源一定距离的另一个点的装置。导 光柱可以用来将PCB上LED的光传输到产品面板上来显示相关的状态,也可以聚集和指引 光线用做LCD显示屏的背光,同时也可以用来照亮在透过式窗口上的图案。导光柱最佳 最有效的设计就是将LED固定到导光柱的内部。在这种结构中LED 是植入导光柱内部的, LED发出的所有光线全部会被导光柱所捕获,考虑到 LED与导光柱之间存在空气间隙而产 生的菲涅耳损耗,光线捕获率可以达到92%。通常情况下,如果LED在导光柱的外部,并 且与导光柱之间有空气间隙时光线的耦合和捕获效率是较低的,相反,如果LED处于导光 柱表面空气的交界面内部时,效率是最高的。 注塑模,又称为注射模,是由动模和定模两大部分组成。动模是安装在注射机的移 动工作台上,定模则安装在注射机的固定工作台面上。动模和定模闭合后已经塑化的塑 料可以通过浇注系统注入到模具型腔中冷却、固化与定型。一般通常要求注射模分开以 后,制品尽量滞留在动模一侧,然后由设置在动模内的推出机构将塑料制品从模内推出。 无锡太湖学院学士学位论文 2 一般来说,注塑模的总体结构主要分为七大部分:成型部件、浇注系统、导向和定 位部件、推出机构、温度调节系统、侧向分型抽芯机构以及标准模架,具体结构如图 1.1 所示。因此,本课题的研究主要围绕这七大部分进行。 (1)成型部件的设计 成型部件是指构成模具型腔、直接与塑料熔体相接触并成型 制品的模具零件或部件。通常有凸模、型芯、成形杆、凹模、镶件等零件或部件。在动 模与定模闭合后,成形零部件便确定了制品的内、外轮廓和尺寸。 (2)浇注系统的设计 浇注系统是指由注射机喷嘴到型腔之间的进料通道,主要是 由主流道、分流道、浇口和冷料穴组成。浇注系统的设计主要是确定主流道的结构、分 流道的截面形状以及浇口的类型和数量。 (3)导向和定位部件的设计 为确保动模和定模闭合时能准确导向和定位对中,需 要分别在动模和定模上设置导柱和导套。深腔注射模还应在主分型面上设有锥面定位装 置。此外,为了保证脱模机构的运动与定位,通常在推板和动模板之间也设置导向机构。 (4)推出机构的设计 每次注射模在注射机上合模注射结束后,都必须将模具打开, 然后把成型后的塑料制件及浇注系统的凝料从模具中脱出,完成推出脱模的机构称为推 出机构或脱模机构。 推出机构主要由推杆、拉料、推杆固定板、推板以及复位杆等组成。 (5)温度调节系统 为了满足注射成形工艺对模具温度的要求,模具应设有冷却或 加热的温度调节系统。模具的冷却主要采用循环水冷却,模具的加热有通入热水、蒸汽、 热油或置入加热元件等,有的注射模还须配备模具温度自动调节装置。 (6)侧向分型抽芯机构 带有侧凹或侧孔的制品,在被脱出模具之前,必须进行侧 向分型将侧向型芯抽出。 (7)标准模架 标准模架的主要标志位国标代号、外形尺寸和模具结构形式等。 图 1.1 注塑模具的结构 1-动模板;2-定模板;3- 冷却水道;4-定模座板;5- 定位圈; 6-浇口套;7-凸模;8- 导柱;9-导套; 10-动模座板;11- 支承板;12-支承柱;13- 推板;14-推板固定板; 15-拉料杆;16- 推板导柱; LED 导光柱注塑模具设计 3 17-推板导套;18- 推杆;19- 复位杆;20-垫块 1.1.2 本课题的意义 高精度、高效率长寿命的塑料模具,可成形加工几十万件,甚至几千万件产品零件, 这类模具称为大批量生产用模具。进入 21 世界以来,各种塑料模具越来越趋于微型化、 精密化,其零件结构设计中的槽逢孔尺寸要求在 以下,尺寸精度要求越来越高。0.3m 比如 BP 机中零件尺寸极其微小,对模具的要求更高。这类微型冲件和塑件用的模具,已 成为高技术模具或专利型模具。随着现代化工业和科学技术的发展,塑料模具的应用越 来越广泛,其适应性也越来越强,已成为工业国家制造工艺水平的标志和独立的基础工 业体系。 塑料模具是决定最终产品性能、规格、形状及尺寸精度的载体,塑料成型模具是使 塑料成型生产过程顺利进行、保证塑料成型制件质量不可缺少的工艺装备,是体现塑料 成型设备高效率、高性能和合理先进塑料成型工艺的具体实施者,也是新产品开发的决 定性环节。由此可见,为了周而复始地获得符合技术经济要求及质量稳定的塑料制件, 塑料成型模具的优劣是成败的关键,它最能发映出整个成型生产过程的技术含量及经济 效益。 本课题正是为了设计出高质量的塑料成型模具来满足现实生活中的需求。 1.2 国内外的发展概况 1.2.1 注塑模具国外研究现状 塑料模具是工业产品生产用的重要工艺装备,在现代工业生产中, 的工业60%9 产品需要使使用模具,模具工业已成为工业发展的基础,许多新产品的开发和研制在很 大程度上都依赖于模具生产。塑料模具工业发展的关键是塑料模具技术的进步。塑料模 具作为一种高附加值和技术密集型产品,其技术水平的高低已成为衡量一个国家制造水 平的重要标志之一,世界上许多国家,特别是一些工业发达国家都十分重视模具技术的 经济效益。因此,模具工业被称为不衰的工业,而以塑料模具为主的研究更是成为各个 国家研究的重点。 1.2.2 注塑模具国内研究现状 当前来看,国内塑料模具市场以注塑模具需求量最大,其中发展重点为工程塑料模 具。近来我国模具工业发展迅速,前景光明。以上海为主的长三角洲地区是中国塑料模 具工业最为发达的地区。目前相当多的发达国家塑料模具企业移师中国,是国内塑料模 具工业迅速发展的重要原因之一。中国技术人才水平普遍提高以及平均劳动力成本低都 是吸引外资的优势,这些都是塑料模具市场迅速成长的重要因素所在,所以中国塑模市 场的前景一片光明。 无锡太湖学院学士学位论文 4 近几年来,虽然我国塑料模具无论是在数量上,还是在质量、技术和能力等方面都 有了很大发展,但总体上还是与工业发达的国家相比仍有较大的差距。例如,许多先进 的技术如 CAD/CAE/CAM 技术的普及率还不高。另外,我国塑料模具行业与其发展需要 和国外先进水平相比,还存在很多方面的问题。现在应用模具 CAD/CAM 技术设计模具 已较为普遍,随着通用机械 CAD/CAM 技术的发展,塑料注射模 CAD/CAM 已经不断的 深化。现代模具是多学科知识集聚的高新技术产业的一部分,是国民经济的装备产业, 其技术、资金与劳动相对密集。 1.2.3 注塑模具发展趋势 考察国内外注塑模具的发展现状,从塑料成型模具的设计理论、设计实践和制造技 术出发,塑料成型技术主要有以下趋势: (1)提高塑料模具标准化水平 塑料模具标准化的水平在某种意义上体现了一个国 家塑料模具工业发展的水平。采用标准模架和使用标准零件,可以满足大批量制造模具 和缩短模具制造周期的需要。经过一段时期的建设,我国塑料模具标准化程度正在不断 提高。为了适应塑料模具工业的发展,塑料模具标准化工作必将加强,塑料模具标准化 程度将进一步提高,塑料模具标准件生产也必将得到发展。 (2)塑料模具向复杂化、精密化与大型化方面发展 为了满足塑料制件在各种工业 产品中使用要求,塑料成型技术正朝着复杂化、精密化与大型化方向发展。 (3)CAD/CAE/CAM 技术在塑料模具设计与制造中的应用 经过多年的推广应用, 模具设计“软件化”与模具制造“数控化”已经在我国模具企业中成为现实。采用 CAD 技术是模具生产的一次革命,是模具技术发展的一个显著特点。近年来,CAD/CAE/CAM 技术发展主要有以下几点:模具 CAD 技术及其应用日趋成熟;基于网络化的的 CAD/CAE/CAM 一体化系统结构初见端倪; CAD/ CAM 软件的智能化程度正在逐渐提高; CAE 技术正在逐步推广; (4)大力发展快速原型制造技术。 (5)模具成型新技术与新工艺的不断涌现和推广。 1.3 本课题应达到的要求 本课题要求跟据图纸以及任务书设计出结构优化的 LED 注塑模具。该塑件为受压塑 件,批量不是很大,为中批量生产。这个课题能充分体现专业知识,对模具设计能力有 一定的锻炼。通过本课题的研究,我们需要达到的要求有: (1)正确合理分析零件工艺用途及结构; (2)理解掌握注塑模具的原理; (3)了解注塑模具的各种结构以及各自的特点; (4)能够掌握注塑模具上各个部分的作用; (5)对于注塑模具设计,能够掌握模具中各个部分的设计原则以及合理分析各因素 LED 导光柱注塑模具设计 5 对设计的影响; (6)熟练使用各种制图软件。 通过对本次注塑模具的设计,可以巩固专业知识为以后从事本专业实际工作和研究 工作奠定了重要的思想基础,也同时具有一定的初步开发模具能力。另外加深了对机械 基础知识的应用,提高了整体的设计能力。 2 塑料制件的工艺性 塑料是一大类庞杂的合成材料,由于制造工艺过程和用途的不同,导致塑料制件的 形状复杂多变。同一种塑料可以用多种方法加工成型。塑料的应用范围非常广泛,几乎 各行各业都少不了塑料的存在。塑料之所以用途如此广泛,是因为塑料有很多实用性能: 塑料一般比较轻,普通塑料的密度较小;大多数塑料具有良好的电气绝缘性,不少塑料 即使在高压、高频条件下,也能用作电气绝缘和电容器介质物质材料;由于塑料柔顺而 富有弹性,当它受到外在的机械冲击震动或频繁机械震动作用时,材料内部产生粘弹内 耗,将机械能转变为热能,因此塑料还具有减震消音性能;大多数塑料具有良好的减模、 耐磨和自润滑特性很多由工程塑料制成的摩擦零件可以在各种液体摩擦、边界摩擦和干 摩擦等条件下有效地工作;塑料具有耐腐蚀性;有些塑料还具有透光性。 2.1 塑料的基本组成及分类 塑料是以高分子量的合成树脂为主要成分,在一定条件下(如温度、压力等)可塑 制成一定形状在常温下保持形状不变的材料。 塑料按受热后表现的性能,可分为热固性塑料和热塑性塑料两大类。热固性塑料是 指在受热或其他条件下能固化或具有不溶(熔)特性的塑料,如酚醛塑料、环氧塑料等。 热固性塑料的树脂固化前是线型或带支链的,固化后分子链之间形成化学键,成为三度 的网状结构,不仅不能再熔触,在溶剂中也不能溶解。加热时变软以至流动,冷却变硬, 这种过程是可逆的,可以反复进行。热塑性塑料指具有加热软化、冷却硬化特性的塑料。 我们日常生活中使用的大部分塑料属于这个范畴。加热时变软以至流动,冷却变硬,这 种过程是可逆的,可以反复进行。 本课题设计的是注塑模具设计,应该选择热塑性塑料。常见的热塑性塑料主要分为 以下几类: 1:聚乙烯(PE) PE 是世界上产量最大的塑料品种,目前的产量约占塑料总产量 的 ,其主要特性:/3 (1)外观呈乳白色,有似蜡的手感。无毒、无味,低密度低,聚乙烯的熔点为 ,高密度(低压)聚乙烯的熔点在 范围。05 123 (2)具有优异的电绝缘性能、耐化学腐蚀性能、耐低温性能和易加工性能,但耐热 无锡太湖学院学士学位论文 6 性、耐老化性较差,表面不易粘接和印刷。 (3)强度、刚度、硬度、耐热性都低于一般塑料。 2:聚丙烯(PP) 聚丙烯属于线型烯烃类聚合物,是 20 世纪 60 年代发展起来的热 塑性塑料,其主要特性: (1)无色、无味、无毒。外观似聚乙烯,但比聚乙烯更透明、更轻,密度约 0.91 。不吸水,光泽好,易着色。熔点为 ,耐热性好,能在 100 以上的3/gcm1607 温度下进行消毒灭菌。其低温使用温度达-15 ,低于-35 时会脆裂。 (2)具有优异的电绝缘性能,高频绝缘性能好,而且不吸水,绝缘性能不受湿度的 影响。耐化学腐蚀性能,常见的酸、碱和有机溶剂对它几乎不起作用(多用于食具) 。耐 老化性比 PE 较差。但在氧、热、光的作用下极易解聚、老化,所以必须加入防老化剂。 (3)具有优良的机械性能,耐弯曲疲劳性能优于其它般塑料,屈服强度、抗拉强 度、抗压强度和硬度及弹性比聚乙烯好。定向拉伸后聚丙烯可制作铰链,有特别高的抗 弯曲疲劳强度。 3: 聚氯乙烯(PVC) 聚氯乙烯是世界上产量仅次于聚乙烯而占第二位的塑料,其 主要特性: (1)聚氯乙烯树脂为白色或浅黄色粉末,纯聚氯乙烯的密度为 1.4,加入了增塑剂 和填料等的聚氯乙烯塑件的密度一般在 范围内,在 温度范围内1.52.03/编号无锡太湖学院毕业设计(论文)相关资料题目: LED导光柱注塑模具设计 信机 系 模具设计与制造专业学 号: 0923259学生姓名: 谢兵兵 指导教师: 范圣耀 (职称:副教授 ) (职称: )2013年5月25日目 录一、毕业设计(论文)开题报告二、毕业设计(论文)外文资料翻译及原文三、学生“毕业论文(论文)计划、进度、检查及落实表”四、实习鉴定表无锡太湖学院毕业设计(论文)开题报告题目: LED导光柱注塑模具设计 信机 系 模具设计与制造 专业学 号: 0923259 学生姓名: 谢兵兵 指导教师: 范圣耀 (职称:副教授) (职称: )2012年11月25日 课题来源经学校老师的介绍,我在无锡某模具厂实习,该厂大批量生产导光柱,经过几个月时间的亲身实践,我对导光柱的尺寸以及加工的流程都有了一定程度的了解,因此选择自己熟悉的产品作为毕业论文的课题是一个明智的选择。科学依据(包括课题的科学意义;国内外研究概况、水平和发展趋势;应用前景等) (1)课题科学意义塑料模具在现代生活中的地位越来越高,因此对塑料模具质量的要求也越来越高,这就要求塑料模具的开发、设计与制造的水平也必须越来越高。各种塑料模具越来越趋于微型化、精密化,其零件结构设计中的槽逢孔尺寸要求在0.3mm以下,尺寸精度要求越来越高。如BP机中零件尺寸极其微小,对模具的要求更高。这类微型冲件和塑件用的模具,已成为高技术模具或专利型模具。随着现代化工业和科学技术的发展,塑料模具的应用越来越广泛,其适应性也越来越强。已成为工业国家制造工艺水平的标志和独立的基础工业体系。(2)国内外研究概况、水平和发展趋势当前来看,国内塑料模具市场以注塑模具需求量最大,其中发展重点为工程塑料模具。近来我国模具工业发展迅速,前景光明。以上海为主的长三角洲地区是中国塑料模具工业最为发达的地区。目前相当多的发达国家塑料模具企业移师中国,是国内塑料模具工业迅速发展的重要原因之一。中国技术人才水平普遍提高以及平均劳动力成本低都是吸引外资的优势,这些都是塑料模具市场迅速成长的重要因素所在,所以中国塑模市场的前景一片光明。近几年来,虽然我国塑料模具无论是在数量上,还是在质量、技术和能力等方面都有了很大发展,但总体上还是与工业发达的国家相比仍有较大的差距。例如,许多先进的技术如CADCAECAM技术的普及率还不高。另外,我国塑料模具行业与其发展需要和国外先进水平相比,还存在很多方面的问题。现在应用模具CADCAM技术设计模具已较为普遍,随着通用机械CAD/CAM技术的发展,塑料注射模CAD/CAM已经不断的深化。现代模具是多学科知识集聚的高新技术产业的一部分,是国民经济的装备产业,其技术、资金与劳动相对密集。研究内容 分析零件工艺用途及结构; 掌握注塑模具的原理; 了解注塑模具的各种结构以及各自的特点; 掌握注塑模具上各个部分的作用; 对于注塑模具设计,能够掌握模具中各个部分的设计原则以及合理分析各因素对设计的影响。 拟采取的研究方法、技术路线、实验方案及可行性分析在毕业实习调研以及查阅有关资料的基础上,结合零件的外形及加工要求,可以先分析本课题的装配图以及各部分零件图,然后通过工艺性分析,分别进行成型部分的设计、浇注系统的设计、导向机构的设计、推出机构的设计、排气系统的设计等等,最后设计出来的制件还要通过相应的检验。 研究计划及预期成果研究计划:2012年11月12日-2012年12月2日:按照任务书要求查阅论文相关参考资料,填写毕业设计开题报告书。2012年12月3日-2013年3月1日 :填写毕业实习报告。2013年3月4日-2013年3月14日 :按照要求修改毕业设计开题报告。2013年3月15日-2013年3月21日:学习并翻译一篇与毕业设计相关的英文材料。2013年3月22日-2013年4月11日:注塑模具正文设计。2013年4月12日-2013年4月25日:绘制装配图和零件图。2013年4月26日-2013年5月20日:毕业论文撰写和修改工作。预期成果:通过不同方案的比较,以及考虑不同因素的影响,最后确定合理的LED导光柱注塑模具设计方案,该方案能够最大程度地满足使用要求。特色或创新之处(1)适用于本厂的某生产线的优化设计;(2)在不影响加工精度的前提下最大限度的减少成本,并降低工人的劳动强度和生产成本;(3)本课题的在满足使用要求的同时,充分考虑产品的外形美观。已具备的条件和尚需解决的问题(1)设计思路已经非常明确,对注塑模具的设计流程有充分的认识;(2)通过四年的大学学习,我已经积累了一定的相关方面的经验;(3)学院图书馆收藏了许多有关专业方面的知识书籍和期刊等;(4)虽然在老师的指导下设计了相应的方案,但是依然会有某些因素没有充分考虑,另外产品能否符合人们的要求也依然未知。指导教师意见 指导教师签名:年 月 日教研室(学科组、研究所)意见 教研室主任签名: 年 月 日系意见 主管领导签名: 年 月 日Chinas plastic mold industry and its development trendFirst: chinas plastic mold industryChinas industrial plastic moulds from the start to now, after more than half a century, there has been great development, mold levels have been greatly enhanced. Mould has been at large can produce 48-inch big-screen color TV Molded Case injection mold, 6.5 kg capacity washing machine full of plastic molds, as well as the overall car bumpers and dashboards, and other plastic mould precision plastic molds, the camera is capable of producing plastic mould , multi-cavity mold small modulus gear and molding mold. -Such as Tianjin and Yantai days Electrical Co., Ltd Polaris IK Co. manufactured multi-cavity mold VCD and DVD gear, the gear production of such size precision plastic parts, coaxial, beating requirements have reached a similar foreign the level of product, but also the application of the latest gear design software to correct contraction as a result of the molding profile error to the standard involute requirements. Production can only 0.08 mm thickness of a two-cavity mold and the air Cup difficulty of plastic doors and windows out of high modulus, and so on. Model cavity injection molding manufacturing accuracy of 0.02 to 0.05 mm, surface roughness Ra0.2 m, mold quality, and significantly increase life expectancy, non-hardening steel mould life up to 10 30 million, hardening steel form up to 50 10 million times, shorten the delivery time than before, but still higher than abroad.The present condition of the plastic mould level at home and abroad:The whole, China plastic mould whether in quantity, or in quality, technology and ability has made a great progress, but with the needs of the development of the national economy, the world advanced level, compared to a gap still. Some large, sophisticated, complex, the long life of high-grade plastic mould still need to import a lot of every year. In the total amount of demand exceeding supply at the same time, some cheap plastic mold but supply exceeds demand, market competition is intense, and some technical content is too high middle-grade plastic mould also has the trend of supply exceeds demandJoining the WTO, plastic mold and die industry to bring huge challenge, at the same time bring more opportunities. Because of Chinas cheap plastic mold to products, product price obvious advantages, some even only 1/5 of the price the foreign product one third to, to join the WTO, foreign similar products to domestic little impact, and cheap Chinese exports of mould is increase; In the high precision mould, before joining the WTO was mainly rely on imports, join WTO, not only for the exquisite products import has brought more convenient, but also lead to more foreign investment to China factory, bring foreign advanced mould technology and management experience, to cultivate Chinese professional mould talents to the role.In recent years, Chinese plastic mould manufacturing conditions have improved greatly. Large plastic mould has produced single set of weight can up to 50 tons of injection mold, precision plastic mould has reached the accuracy of 2 m, precision parts high small module gear mould and reach the requirements of the highlights learn lamp mould etc has also can produce, plastic mold cavity has been able to produce a mode of plastic mold cavity 7800, high-speed mold production speed can have up to 6 m/min above the high-speed plastic different profile extrusion die and the dual chamber co-extrusion profiles, double-color coextrusion, soft hard co-extrusion, were crowded, again of extrusion and low foaming raw steel-plastic co-extrusion, etc. Various kinds of mold. In the production means, mould enterprise equipment to numerical control rate has increased greatly, CAD/CAE/CAM technology has greatly expanded the applications, high speed processing and RP/RT adoption of advanced technologies such as has been more and more, standard mould using coverage and die commercialization rate is greatly improved, the share of mould of hot flow path are improved greatly. In addition, foreign invested enterprise vigorous development of further promoted the plastic mould design and manufacture level and improve the management level of enterprises, some enterprise already informatization management and digital no PIC manufacturing.As mould design and processing enterprises to raise the level of, mould manufacturing is from the past relies mainly on the transformation of the skills of fitter mainly rely on technology. This is not only the means of production change, and change the way of production and the rise of the concept. This is a trend that the standardization of mould continuous improvement, the precision of more and more high, production cycle is more and more short, fitter proportion more and more low, and finally promote the overall level of the die and mould industry is rising. China mold and die industry at present more than 10 national high and new technology enterprise, about 200 high technology and new technology enterprise. And adapt to the trend, the main production mold backbone strength from skill talented person gradually into technology talents is an inevitable requirement. Of course, now and for quite a long time, and highly talented person still very important, because after all, hard to get rid of mould to skill depend on.Existing main problemsChina plastic mould industry and foreign standards, mainly exist in the following questions.(1) the unbalanced development, product overall level is low. Although the individual enterprise products has reached or come close to the advanced international level, but overall, the accuracy, the roughness of the cavity surface, production cycle, life index and international advanced level there is a big gap between compared. Including production mode and the overall level of enterprise management, with foreign industrial developed countries there are compared for more than 10 years the gap.(2) process equipment backward, organization and coordination ability is poor. Though some of the technological transformation of the enterprise after in recent years, has been more advanced technology and equipment level, some of the foreign invested enterprise level of equipment is not behind abroad, but most of the enterprise process equipment is still lag behind. More importantly, the enterprise organization coordinated ability is poor, difficult to integrate or transfer of social resources use, thus it will be difficult to undertake larger projects.(3) most enterprise development ability is weak, the innovation ability is not enough. On the one hand, low level of technical personnel proportion is not quite high, on the other hand is the scientific development less input; More important concepts backward, insufficient attention to innovation and development. Mould enterprise not only to pay attention to the development of the mould, also want to pay attention to the innovation of the product.(4) short-term relief to the contradiction between supply and demand. In recent years, domestic plastics mould domestic market meet rate has been less than 74%, including a large, precision, long life mold meet more rate low, less than 60% estimate. Meanwhile, industrial developed countries are accelerating the mould transferring to China, international purchasing more and more, the international market has a good prospect. The market demand, production is difficult to keep up with development at that time, in short supply situation will continue for a period of time.There are many reasons which creates the above disparity ,the mold long-term has not obtained the value besides the history in as the product which should have, as well as the most state-owned enterprises mechanism cannot adapt the market economy, but also has the following several reasons: .(1) Country to mold industry policy support dynamics also insufficientlyAlthough the country already was clear about has promulgated the mold profession industrial policy, but necessary policy few, carried out dynamics to be weak. At present enjoyed the mold product increment duty enterprise nation 185, the majority enterprise still the tax burden is only overweight. The mold enterprise carries on the technological transformations introduction equipment to have to pay the considerable amount the tax money, affects the technology advancement, moreover privately operated enterprise loan extremely difficult .(2) Talented person serious insufficient, the scientific research development and the technical attack investment too urine Mold profession is the technology, the fund, the work crowded industry, along with the time progress and the technical development, grasps the talented person which and skilled utilizes the new technology exceptionally short, the high-quality mold fitter and the enterprise management talent extremely is also anxious. Because the mold enterprise benefit unsatisfactory and takes insufficiently the scientific research development and the technical attack, the scientific research unit and the universities, colleges and institutes eye stares at is creating income, causes the mold profession invests too few in the scientific research development and the technical attack aspect, causes the mold technological development step not to be big, progresses not quick .(3) The craft equipment level to be low, also necessary is not good, the use factor low recent years our country engine bed profession progressed quickly, has been able to provide the quite complete precision work equipment, but compared with the overseas equipment, still had a bigger disparity. Although the domestic many enterprises have introduced many overseas advanced equipment, but the overall equipment level low are very more than the overseas many enterprises. As a result of aspect the and so on system and fund reason, introduces the equipment not necessary, the equipment and the appendix not necessary phenomenon are extremely common, the equipment utilization rate low question cannot obtain the comparatively properly solution for a long time .(4) Specialization, standardization, commercialized degree low, the cooperation ability Because receives large and complete small and entire the influence since long ago, mold specialization level low, the specialized labor division is not careful, the commercialized degree is low. At present domestic every year produces mold, commodity mold minister 40% About, other for from produce uses for oneself. Between the mold enterprise cooperates impeded, completes the comparatively large-scale mold complete task with difficulty. Mold standardization level low, mold standard letter use cave rare is low also to the mold quality, the cost has a more tremendous influence, specially has very tremendous influence .(5) To the mold manufacture cycle) the mold material and the mold correlation technology falls The mold material performance, the quality and the variety question often can affect the mold quality, the life and the cost, the domestically produced molding tool steel and overseas imports the steel products to compare has a bigger disparity. Plastic, plate, equipment energy balance, also direct influence mold level enhancement .Process, the multi-material plastic molding die, efficient multicolor injection mould, inserts exchange structure and core pulling Stripping the innovative design has also made great progress. Gas-assisted injection molding, the use of more mature technologies, such as Qingdao Hisense Co., Ltd., Tianjin factory communications and broadcasting companies, such as mold manufacturers succeeded in 29 34-inch TV thick-walled shell, as well as some parts on the use of gas-assisted mould technology Some manufacturers also use the C-MOLD gas-assisted software and achieved better results. Prescott, such as Shanghai, such as the new company will provide users with gas-assisted molding equipment and technology. Began promoting hot runner mold, and some plants use rate of more than 20 percent, the general heat-thermal hot runner, or device, a small number of units with the worlds advanced level of rigorous hot runner-needle device, a small number of units with World advanced level of rigorous needle-hot runner mould. However, the use of hot runner overall rate of less than 10%, with overseas compared to 50 80%, the gap larger.In the manufacturing technology, CAD / CAM / CAE technology on the level of application of a new level to the enterprise for the production of household appliances representatives have introduced a considerable number of CAD / CAM systems, such as the United States EDS UG , the United States Parametric Technology Pro / Engineer, the United States CV CADS5 company, the British company DOCT5 Deltacam, HZSs CRADE Japan, the companys Cimatron Israel, the United States AC-C-Tech Mold Company and Australias MPA Mold flow Mold analysis software, and so on. These systems and the introduction of the software, although a lot of money spent, but in our country die industry, and achieving a CAD / CAM integration, and to support CAE technology to forming processes such as molding and cooling, such as computer simulation, and achieved certain The technical and economic benefits, promote and facilitate Chinas CAD / CAM technology. In recent years, Chinas own development of the plastic mould CAD / CAM system has achieved significant development, the main guarantor Software Engineering Institute, is the development of CAXA, Huazhong University of Science HSC5.0 development of the system and injection mold CAE software, and so on, these Die of domestic software with the specific circumstances in the application of computer and lower prices, and other characteristics, in order to further universal CAD / CAM technology has created good conditions.In recent years, China has been more extensive use of some new plastic mold steel, such as: P20, 3Cr2Mo, PMS, SM , SM , and the quality of life of mold has a direct significant impact on the overall use of the still less . Plastic Moulds standard model planes, such as standard putter and spring has given more applications, and there have been some of the commercialization of domestic hot runner system components. However, at present China Die level of standardization and commercialization in the general level of below 30 percent and foreign advanced industrial countries has reached 70 percent compared to 80 percent, still a large gap. Table 1, at home and abroad plastic mould technology comparison table? Domestic projects abroad cavity injection model mm0.02 accuracy of 0.005 0.01 0.05mm cavity surface roughness Ra0.01 0.05 mRa0.20 m non-hardened steel die life 10 to 60 million 10 30 million hardened steel die life 160 300 million of 50 100 million hot runner mould overall utilization rate of more than 80 per cent less than 10 per cent level of standardization of 70 80% less than 30% of medium-sized plastic mould production cycle about a month 2 4 months in the mold industry in the amount of 30 to 40% 25 to 30% According to the parties concerned forecast, the markets overall vigorous mold is a smooth upward, in the next Die market, the development of plastic mould faster than the other Die, die in the proportion of industry will gradually improve. With the continuous development of the plastics industry, put on the plastic mold growing demands is a normal, and so sophisticated, large-scale, complex, long-life plastic mould development will be higher than the overall pace of development. At the same time, imports in recent years because of the mold, precision, large, complex, long-life die in the majority, therefore, reduce imports, increase Guochanhualu: perspective, in the mold of such high-end market share will gradually increase. The rapid development of the construction industry so that the various Profile Extrusion Die, PVC plastic pipe fittings Die Die market become a new economic growth point, the rapid development of highways, car tires also put a higher demand, radial tire Die, Die particularly active pace of development will also be higher than the overall average level of the plastic and wood, plastic and metal to make plastic molds in the automotive, motorcycle industry in the demand for huge household appliances industry in the 10th Five-Year Plan period have greater development, especially refrigerators, air-conditioners and microwave ovens, and other parts of the great demand for plastic moulds, and electronics and communications products, in addition to audio-video products, such as color televisions, laptop computers and set-top boxes will be given a wider network development, which are Plastic Mold market is the growth point.Second:the direction
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