洗面奶瓶盖注射模设计【护手霜瓶盖】【一模两腔】【说明书+CAD】
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南京理工大学泰州科技学院毕业设计(论文)外文资料翻译系部: 机械工程系 专 业: 机械工程及自动化 姓 名: 王 锋 学 号: 05010230 外文出处: 中国机械资讯网 BBS.CMIW.CN 附 件: 1.外文资料翻译译文;2.外文原文。 指导教师评语:译文基本符合翻译原文,个别词汇不符合语境。语句较为通顺,条理比较清楚,专业用语翻译基本恰当,符合中文语法,整体翻译质量较好。 签名: 年 月 日附件1:外文资料翻译译文在注塑模应用方面,外形电铸镍的技术注释摘要 在过去几年,快速成型技术及快速模具在发达国家已广泛应用。在这篇文章中,作为一种范例,分析电芯塑料注射模具。通过快速成型,利用差分系统得到镍壳模型。主要目的是分析镍壳力学特征,学习不同方面的金相组织、硬度、内压,失败的可能性。以这些特色的有关参数生产镍壳电设备,终于得到了一个注塑模具核心部分。关键词:电镀; 电制;显微组织; 镍文章概要1. 引言2. 注塑模具制造过程3. 电铸壳获取:设备4. 获得硬度5. 金相组织6. 内压7. 测试的注塑模具8. 结论1引言现代工业遇到的最重要的挑战之一是在很短的时间内向消费者提供更好的产品。因此,现代工业必须有更强的竞争性和适应更合理的生产成本。 毫无疑问,结合时间和质量并不容易,因为他们经常互相变换。生产系统的科技进步,在方式将可更有效和可行的促进组合,例如,如果是演化的观测系统和注塑技术、我们得出的结论是事实上可以用很少的时间和高质量把新产品推向市场。在模具制造领域中,先进的快速模具制造技术有可能改善设计和制造过程注入部分。快速模具制造技术基本上是由程序集中组成,在短短的时间里,以可接受的精度水平使我们获取小型系列的塑料模具零件。其应用领域不仅包括制作塑胶件注,而且他们研制并创造了最高产量。本文包括在广泛试图研究确定分析测试和建议的科研第一线,在产业层次形成从注塑模具获取镍壳核心的可能性,同时用差分模型快速成型设备取得了初步的模型。也将不得不说,无数业内人士事前并没有应用任何新电铸技术,但很大程度上,在快速模具的生产技术上使用这种试图调查研究工作.,运用所有准确,制度化的方式方法并提出了工作。2注塑模具制造过程核心是透过电进程的镍壳。这是一个主管充满金属环氧树脂的一核心板块。模具(图1)制造时可以直接注射A型多用标本,确定SO3167标准的甲状旁腺恩目的是要确定这个试样的力学性能和通过常规手段收集工业材料。图1注塑模具制造与电核心根据这一方法研制工作,该阶段取得核心有以下几方面:(一) CAD系统预期目标的设计(二) 快速原型设备制造模型(频分多路复用)。该材料将被用于ABS塑料(三) 以以往的模式生产事前已经涂了导电涂料的镍电壳(必须有导电)(四) 从模型中清理壳牌(五) 生产背面填充着随着铜管与冷冻槽流动具有抗高温壳牌环氧树脂的核 心 注塑模具有两个空洞,他们一个是电加工的核心,另一个是直接在机械上移动压板。因此,它获得了与同一工具及同一工艺条件同时在空洞里注入两种不同的标本制造技术。3电铸壳获取:设备电镀是一个电化学过程中的化学变化, 当电流通过,它起源于电解质。该电解槽是由金属盐溶液淹没两个电极,一个阳极(镍)、阴极(示范)。通过来自一定强度的直流电。当电流流经电路,目前在溶液中金属离子转化为原子,堆积于阴极或多或少的创造沉淀层。这项工作采用的镀液是由镍、磺酸集中在400 毫升/公升,氯化镍(10微克/公升)、硼酸(50微克/公升),allbrite SLA (30立方厘米/公升),703allbrite(2立方厘米/公升)。这种合成物的选择主要取决于我们打算的应用类型即注塑模具,即使注射了玻璃纤维。磺酸镍让我们获得可以接受的壳内压 (测试结果,不同工艺条件,不高于50兆帕和2兆帕左右最佳条件)。 不过这种程度的内部压力也是使用添加剂Allbrite SLA强硝酸脂、甲醛水溶液产生的后果。这种添加剂当允许较小壳颗粒增加阻力。703allbrite是降解水溶液以减少表面腐蚀。氯化镍,尽管内压有害,增强导电溶液中的金属均匀分布在阴极。硼酸作为pH值的缓冲。一旦已确定浴,有效验的参数测试改变不同条件过程的电流密度(在1至22a/立方分米),温度(35至55)和pH值, 部分的改变镀液组成。4获得硬度在测试期间已获得一个非常有趣的结论,对不同程度硬度的镍壳一直保持在相当高的稳定价值。在图2,在pH40.2,摄氏45时,可以观察到电流密度值为2.5和22之间。硬度值的范围从高压540至580。如果pH值降为3.5,气温下降55,硬度值的范围从高压520以上至高压560以下。由磺酸镍组成的这一特点使得测试不同于其他传统业务,观念是允许经营范围更广;然而这种有限性的将取决于其他因素。例如内应力,因为其工作状态可能在某些变性的pH值、电流密度和温度下。在另一方面,传统的硬度介于200-250高压磺酸浴,远低于在测试中获得的。有必要要考虑到对于注塑模具,接受300高压硬度。其中最常见的材料就可以找到注塑模具钢(高压290),积分硬化钢(高压520-595),casehardened钢(高压760-800)等。这样可以观察到中高幅度硬度水平的镍壳注塑模具材料,有偿壳牌是反对用低延性的环氧树脂填充。因为注塑是一个内压控制进程, 这也是为什么必须要壳厚度尽可能均匀(以上最低值),避免重大失误。如图:图2硬度变化与电流密度4+0.2pH值455金相组织主要是为了改良而分析金相结构、电流密度、温度值。样品分析、横向部分(垂直于沉积)为实现准备便捷,树脂被方便的封装在含有硝酸,醋酸混合物的瓶子,进行每隔15,25,40,50秒收盘后擦拭。为了事后在奥林匹斯金相显微镜碲下观察PME3-ADL 3.3/10。在评论文中的照片之前,有必要讨论用差分快速成型机械制造逐层贯通的熔融塑料 (ABS) 壳模具。 每一层挤出模具留下的螺纹直径约0.15毫米即横向和纵向的中间媒介。因此,在机器的主要表面可以观察到薄线标明的道路。这些线路将作为参考解决水平镍重复性显示。重复性模式将是一个评估注塑模具基本内容的基本要素:表面纹理。该系列测试表1所示:表1检验系列系列pH温度()电流密度A/mm214.20.2552.2223.90.2455.5634.00.24510.0044.00.24522.22图3显示第一次蚀刻的系列表面样本。它显示了频分多路复用机的原理,也就是说有一个良好的重复性。 它仍无法察觉圆形的颗粒结构,在图4系列2之后的第二蚀刻可以观察到一条线道较前明显减少。在图5系列2和3,虽然这时路径很难查出,蚀刻已开始出现了一批颗粒结构。另外,最黑暗的地方显示含有合成物浴的蚀刻过程。图 3. 系列1(150)、蚀刻1图 4. 系列2(300), 蚀刻2图 5. 系列3(300),蚀刻2这一行为表明,工作在低电流密度、高温下,壳以良好的再现能力获得粒度即适当的应用。如果进行了平面沉积的横向分析,它可以在所有的样品和一切条件下测试,沉淀物的增长结构是由薄片组成的(图6)。虽然延展性低,但是取得了高机械阻力。这取决于质量,,首先存在添加剂。因为磺酸镍浴没有添加剂,通常制造纤维和非层结构5。更正直到近似于空值的润湿剂,在任何情况下保持层结构表明这种结构的应力消脂(allbrite习得)。在另一方面,据测试根据不同层结构层厚度的计算电流密度。图 6. 机横向系列2 (600),蚀刻2.6内压其中一个主要特征是壳的应用像输入低水平内压。用阴极张力法在不同电流密度和镀液温度测量系统下做不同的测试。钢铁被用来测试与控制自由和固定(160毫米长度 宽度12.7毫米,厚度0.3毫米)。因为沉积金属是唯一允许检测控制机械应变(拉伸或压应力)和计算内压。对于部分钢铁来说,从弹性的角度来看Stoney模型应用被假定镍底层厚度不够,表面影响小(3微米)。在所有测试情形中最佳条件是内部压力50和极端条件下为2兆帕,为所需的可接受值。最后的结论是在不同的条件和工作参数下电镀浴允许无明显变化内压。7测试的注塑模具试验已在各种代表性热塑性材料中进行如聚丙烯、镁、高密度聚乙烯和PC。分析零件的性能,如注射大小、重量、抗延性僵化。测试拉伸力学性能和分析光破坏性。这一核心进行约500注射量,其余条件下经受更多。一般而言,重大分歧都是未察觉样本核心之间的行为。从加工腔到一整套的材料,但是在分析光弹性时(图七)发现了两种不同张标本,基本上是取决于炎热划转、浇注腔的刚度。这种差异说明延性变化较突出的部分材料,如聚乙烯、六镁。图 7分析光注入标本在所有分析化验中发现高密度聚乙烯管案例是一个较低延性标本。所得镍核心,量化30%左右。在这种情况下六镁值也接近50%。8结论经过连续的测试和不同的条件下已经清查磺酸镍浴已获准使用添加剂。镍壳将获得一些可以接受的注塑模具的机械性能。也就是说,重复性好,高硬度及良好的机械阻力。因而机械层结构不足的部分将取代镍壳的环氧树脂饰面。核心为注塑塑造,允许注入可接受质量水平中型系列塑料零件。附件2:外文原文(复印件)A technical note on the characterization of electroformed nickel shells for their application to injection molds Abstract The techniques of rapid prototyping and rapid tooling have been widely developed during the last years. In this article, electroforming as a procedure to make cores for plastics injection molds is analysed. Shells are obtained from models manufactured through rapid prototyping using the FDM system. The main objective is to analyze the mechanical features of electroformed nickel shells, studying different aspects related to their metallographic structure, hardness, internal stresses and possible failures, by relating these features to the parameters of production of the shells with an electroforming equipment. Finally a core was tested in an injection mold. Keywords: Electroplating; Electroforming; Microstructure; Nickel Article Outline1. Introduction 2. Manufacturing process of an injection mold 3. Obtaining an electroformed shell: the equipment 4. Obtained hardness 5. Metallographic structure 6. Internal stresses 7. Test of the injection mold 8. Conclusions 1. IntroductionOne of the most important challenges with which modern industry comes across is to offer the consumer better products with outstanding variety and time variability (new designs). For this reason, modern industry must be more and more competitive and it has to produce with acceptable costs. There is no doubt that combining the time variable and the quality variable is not easy because they frequently condition one another; the technological advances in the productive systems are going to permit that combination to be more efficient and feasible in a way that, for example, if it is observed the evolution of the systems and techniques of plastics injection, we arrive at the conclusion that, in fact, it takes less and less time to put a new product on the market and with higher levels of quality. The manufacturing technology of rapid tooling is, in this field, one of those technological advances that makes possible the improvements in the processes of designing and manufacturing injected parts. Rapid tooling techniques are basically composed of a collection of procedures that are going to allow us to obtain a mold of plastic parts, in small or medium series, in a short period of time and with acceptable accuracy levels. Their application is not only included in the field of making plastic injected pieces , however, it is true that it is where they have developed more and where they find the highest output. This paper is included within a wider research line where it attempts to study, define, analyze, test and propose, at an industrial level, the possibility of creating cores for injection molds starting from obtaining electroformed nickel shells, taking as an initial model a prototype made in a FDM rapid prototyping equipment. It also would have to say beforehand that the electroforming technique is not something new because its applications in the industry are countless but this research work has tried to investigate to what extent and under which parameters the use of this technique in the production of rapid molds is technically feasible. All made in an accurate and systematized way of use and proposing a working method. 2. Manufacturing process of an injection moldThe core is formed by a thin nickel shell that is obtained through the electroforming process, and that is filled with an epoxic resin with metallic charge during the integration in the core plate 。 This mold (Fig. 1) permits the direct manufacturing by injection of a type a multiple use specimen, as they are defined by the UNE-EN ISO 3167 standard. The purpose of this specimen is to determine the mechanical properties of a collection of materials representative industry, injected in these tools and its coMParison with the properties obtained by conventional tools. Fig. 1.Manufactured injection mold with electroformed core.The stages to obtain a core, according to the methodology researched in this work, are the following: (a) Design in CAD system of the desired object.(b) Model manufacturing in a rapid prototyping equipment (FDM system). The material used will be an ABS plastic.(c) Manufacturing of a nickel electroformed shell starting from the previous model that has been coated with a conductive paint beforehand (it must have electrical conductivity).(d) Removal of the shell from the model.(e) Production of the core by filling the back of the shell with epoxy resin resistant to high temperatures and with the refrigerating ducts made with copper tubes.The injection mold had two cavities, one of them was the electroformed core and the other was directly machined in the moving platen. Thus, it was obtained, with the same tool and in the same process conditions, to inject simultaneously two specimens in cavities manufactured with different technologies. 3. Obtaining an electroformed shell: the equipmentElectrodeposition is an electrochemical process in which a chemical change has its origin within an electrolyte when passing an electric current through it. The electrolytic bath is formed by metal salts with two submerged electrodes, an anode (nickel) and a cathode (model), through which it is made to pass an intensity coming from a DC current. When the current flows through the circuit, the metal ions present in the solution are transformed into atoms that are settled on the cathode creating a more or less uniform deposit layer. The plating bath used in this work is formed by nickel sulfamate and at a concentration of 400ml/l, nickel chloride (10g/l), boric acid (50g/l), Allbrite SLA (30cc/l) and Allbrite 703 (2cc/l). The selection of this composition is mainly due to the type of application we intend, that is to say, injection molds, even when the injection is made with fibreglass. Nickel sulfamate allows us to obtain an acceptable level of internal stresses in the shell (the tests gave results, for different process conditions, not superior to 50MPa and for optimum conditions around 2MPa). Nevertheless, such level of internal pressure is also a consequence of using as an additive Allbrite SLA, which is a stress reducer constituted by derivatives of toluenesulfonamide and by formaldehyde in aqueous solution. Such additive also favours the increase of the resistance of the shell when permitting a smaller grain. Allbrite 703 is an aqueous solution of biodegradable surface-acting agents that has been utilized to reduce the risk of pitting. Nickel chloride, in spite of being harmful for the internal stresses, is added to enhance the conductivity of the solution and to favour the uniformity in the metallic distribution in the cathode. The boric acid acts as a pH buffer. Once the bath has been defined, the operative parameters that have been altered for testing different conditions of the process have been the current density (between 1 and 22A/dm2), the temperature (between 35 and 55C) and the pH, partially modifying the bath composition. 4. Obtained hardnessOne of the most interesting conclusions obtained during the tests has been that the level of hardness of the different electroformed shells has remained at rather high and stable values. In Fig. 2, it can be observed the way in which for current density values between 2.5 and 22A/dm2, the hardness values range from 540 and 580HV, at pH 40.2 and with a temperature of 45C. If the pH of the bath is reduced at 3.5 and the temperature is 55C those values are above 520HV and below 560HV. This feature makes the tested bath different from other conventional ones composed by nickel sulfamate, allowing to operate with a wider range of values; nevertheless, such operativity will be limited depending on other factors, such as internal stress because its variability may condition the work at certain values of pH, current density or temperature. On the other hand, the hardness of a conventional sulfamate bath is between 200250HV, much lower than the one obtained in the tests. It is necessary to take into account that, for an injection mold, the hardness is acceptable starting from 300HV. Among the most usual materials for injection molds it is possible to find steel for improvement (290HV), steel for integral hardening (520595HV), casehardened steel (760800HV), etc., in such a way that it can be observed that the hardness levels of the nickel shells would be within the mediumhigh range of the materials for injection molds. The objection to the low ductility of the shell is compensated in such a way with the epoxy resin filling that would follow it because this is the one responsible for holding inwardly the pressure charges of the processes of plastics injection; this is the reason why it is necessary for the shell to have a thickness as homogeneous as possible (above a minimum value) and with absence of important failures such as pitting. Fig. 2.Hardness variation with current density. pH 40.2, T=45C.5. Metallographic structureIn order to analyze the metallographic structure, the values of current density and temperature were mainly modified. The samples were analyzed in frontal section and in transversal section (perpendicular to the deposition). For achieving a convenient preparation, they were conveniently encapsulated in resin, polished and etched in different stages with a mixture of acetic acid and nitric acid. The etches are carried out at intervals of 15, 25, 40 and 50s, after being polished again, in order to be observed afterwards in a metallographic microscope Olympus PME3-ADL 3.3/10. Before going on to comment the photographs shown in this article, it is necessary to say that the models used to manufacture the shells were made in a FDM rapid prototyping machine where the molten plastic material (ABS), that later solidifies, is settled layer by layer. In each layer, the extruder die leaves a thread approximately 0.15mm in diameter which is compacted horizontal and vertically with the thread settled inmediately after. Thus, in the surface it can be observed thin lines that indicate the roads followed by the head of the machine. These lines are going to act as a reference to indicate the reproducibility level of the nickel settled. The reproducibility of the model is going to be a fundamental element to evaluate a basic aspect of injection molds: the surface texture. The tested series are indicated in Table 1. Table 1. Tested series Series pH Temperature (C) Current density (A/dm2) 14.20.2552.2223.90.2455.5634.00.24510.0044.00.24522.22 Fig. 3 illustrates the surface of a sample of the series after the first etch. It shows the roads originated by the FDM machine, that is to say that there is a good reproducibility. It cannot be still noticed the rounded grain structure. In Fig. 4, series 2, after a second etch, it can be observed a line of the road in a way less clear than in the previous case. In Fig. 5, series 3 and 2 etch it begins to appear the rounded grain structure although it is very difficult to check the roads at this time. Besides, the most darkened areas indicate the presence of pitting by inadequate conditions of process and bath composition. Fig. 3.Series 1 (150), etch 1.Fig. 4.Series 2 (300), etch 2.Fig. 5.Series 3 (300), etch 2.This behavior indicates that, working at a low current density and a high temperature, shells with a good reproducibility of the model and with a small grain size are obtained, that is, adequate for the required application. If the analysis is carried out in a plane transversal to the deposition, it can be tested in all the samples and for all the conditions that the growth structure of the deposit is laminar (Fig. 6), what is very satisfactory to obtain a high mechanical resistance although at the expense of a low ductibility. This quality is due, above all, to the presence of the additives used because a nickel sulfamate bath without additives normally creates a fibrous and non-laminar structure. The modification until a nearly null value of the wetting agent gave as a result that the laminar structure was maintained in any case, that matter demonstrated that the determinant for such structure was the stress reducer (Allbrite SLA). On the other hand, it was also tested that the laminar structure varies according to the thickness of the layer in terms of the current density. Fig. 6.Plane transversal of series 2 (600), etch 2.6. Internal stressesOne of the main characteristic that a shell should have for its application like an insert is to have a low level of internal stresses. Different tests at different bath temperatures and current densities were done and a measure system rested on cathode flexural tensiometer method was used. A steel testing control was used with a side fixed and the other free (160mm length, 12.7mm width and thickness 0.3mm). Because the metallic deposition is only in one side the testing control has a mechanical strain (tensile or compressive stress) that allows to calculate the internal stresses. Stoney model was applied and was supposed that nickel substratum thickness is enough small (3m) to influence, in an elastic point of view, to the strained steel part. In all the tested cases the most value of internal stress was under 50MPa for extreme conditions and 2MPa for optimal conditions, an acceptable value for the required application. The conclusion is that the electrolitic bath allows to work at different conditions and parameters without a significant variation of internal stresses. 7. Test of the injection moldTests have been carried out with various representative thermoplastic materials such as PP, PA, HDPE and PC, and it has been analysed the properties of the injected parts such as dimensions, weight, resistance, rigidity and ductility. Mechanical properties were tested by tensile destructive tests and analysis by photoelasticity. About 500 injections were carried out on this core, remaining under conditions of withstanding many more. In general terms, important differences were not noticed between the behavior of the specimens obtained in the core and the ones from the machined cavity, for the set of the analysed materials. However in the analysis by photoelasticiy (Fig. 7) it was noticed a different tensional state between both types of specimens, basically due to differences in the heat transference and rigidity of the respective mold cavities. This difference explains the ductility variations more outstanding in the partially crystalline materials such as HDPE and PA 6. Fig. 7.Analysis by photoelasticity of injected specimens.For the case of HDPE in all the analysed tested tubes it was noticed a lower ductility in the specimens obtained in the nickel core, quantified about 30%. In the case of PA 6 this value was around 50%. 8. ConclusionsAfter consecutive tests and in different conditions it has been checked that the nickel sulfamate bath, with the utilized additives has allowed to obtain nickel shells with some mechanical properties acceptable for the required application, injection molds, that is to say, good reproducibility, high level of hardness and good mechanical resistance in terms of the resultant laminar structure. The mechanical deficiencies of the nickel shell will be partially replaced by the epoxy resin that finishes shaping the core for the injection mold, allowing to inject medium series of plastic parts with acceptable quality
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