装配图板(框)类制品叠层式注射模具设计(有cad图)
装配图板(框)类制品叠层式注射模具设计(有cad图),装配,图板,制品,叠层式,注射,模具设计,cad
毕业设计(论文)板(框)类制品叠层式注射模具设计 DESIGN OF STACK INJECTION MOULD PRODUCTS FOR FRAME学生姓名学院名称专业名称机械设计制造及其自动化指导教师年月日 摘要本论文设计了仪器外壳的叠层式热流道模具结构。该模具有2层,每层8个型腔,一次可成型16个产品,该模具是普通注射成型产量的2倍,大大提高生产力。本次模具设计采用的是无流道凝料浇筑系统,不考虑浇道的凝料脱出,减少了分型面,并缩短了成型周期,降低了整个生产成本。而且还采用了齿轮齿条开模机构,在确保俩层型腔同时开模又比较经济。使热流道板的热胀变形问题和浇口的平衡问题有一个很好的解决,基本确保同时充模和充模的稳定可靠性。该模具还采用闭合式喷嘴和闭合式主流道杯,解决了浇口和主流道始端的流涎问题,它采用热电偶控制喷嘴温度和流道板温度。在设计中,为减少热传导热损失。在流道板和型腔板之间采用空气隔热,并加隔热垫,从而降低模具和流道板之间的接触面积,并发挥了支撑热流道板的作用。喷嘴和主流道杯均采用隔热套隔热。关键词 热流道;叠层式模具;浇口平衡;防流涎AbstractThis design introduces the mould structure of instrument of outer cover, which has piles of type and thermal current dishes. The mould has 2 layers of types, 8 for each layer, which can shape 16 products for once, the mould can produce 2 times of products ordinary inject shaping, and it boosts productivity greatly . The mould uses a thermal current dish of congeal material , without consideration of the deviatation of water dish congeal material, which has reduced dividing type, and shortened shaping cycle. And it has reduced the cost of the production on the whole. The mould which is economic adopts a gear and rack to turn on , making sure the two types of the mould turning on at the same time. The mould gives a good settlement of the expansion problem of the board of the thermal current dishes and the balance problem of runner, guaranting to fill the mould steadily and basically making sure the mould filling at the same time. The mould adopts the spray nozzle of closing type and the cup of mainstream dishes, solve the saliva problem of runner and the top shed of mainstream dishes, and it adopts the electric thermocouple to control the temperature of the spray nozzle and the flow dishes board. In the design, for reducing losing heat of the heat-conduction. Between the flow dishes board and the mould board, there is air to against heat, there are against heat cushions to against heat ,which reduces the area of contact between the mould board and the flow dishes and plays a role of supporting of the board of the thermal current. The spray nozzles and the cup of the mainstream dishes have heat insulation set.Keywords Thermal current one One pile of types mould Balance the runner Prevent saliva flowsII目 录摘要IIAbstractIII1 绪论12 制品设计32.1制件图32.2产品使用要求42.3产品材料43 工艺分析53.1 塑料特性53.2 塑料的注射工艺条件53.3 塑件使用材料的工艺分析64选择设备75模具设计85.1 模具结构设计85.1.1 选择分型面85.1.2 布置型腔85.1.3 确定成型零部件结构95.1.4 浇注系统结构设计95.1.5 开模机构设计105.1.6 脱模机构设计115.1.7 温控系统设计115.2主要零部件尺寸计算115.2.1 成型零部件尺寸计算115.2.2 确定模具各部分结构尺寸175.2.3 浇注系统计算185.2.4 冷却系统计算215.2.5 推出机构计算255.3 校核285.3.1 模具与注射机关系校核285.3.2 物料流程与流动比校核29结论30致谢31参考文献32331 绪论模具是现代化工业生产的重要工艺装备,被称为“工业之母”。而注塑模具又是在整个模具工业中一枝独秀,发展极为迅速,在汽车、航空航天、通信电子、家用电器等领域有着极为广泛的应用。热流道技术是指从注射机喷嘴送往浇口的塑料始终保持熔融状态,在每次开模时不需将其固化作为废料取出,滞留在浇注系统中的熔料可在下一次注射时被注入型腔。该项技术具有节约原料、提高产品性能、缩短生产周期等优点。 叠层注射模又称多层注射模,是一种特殊的注射模。与普通注射模不同,叠层注射模的型腔是分布在2个或多个层面上的,且型腔呈重叠式排列。即相当于将多副模具叠放组合在一起。与常规模具相比,叠层式模具锁模力只提高了5%10%,但产量可增加90%95%,这就极大地提高了设备利用率和生产效率,并降低了成本。 将热流道技术与层叠式模具相结合,仅需增加少量的模具成本却能成倍地增加产量和实现高效自动化。最初的叠层模具因使用普通流道,每次注射都要去除浇道,是实现自动化生产的主要障碍,因而应用较少。当叠层式模具应用了热流道技术后,不用考虑浇道凝料的脱出,减少了分型面,缩短了开模行程及成型周期,其应用才得到了较大的提高。叠层式模具最适于成型大型扁平制件、小型多腔薄壁制件和需大批量生产的制件。热流道技术具有节约原料、易于自动化、提高产品性能、缩短生产周期等优点,将其与叠层式模具结合,仅需增加少量的模具成本却能成倍地增加产量和实现高效自动化,故叠层式热流道模具技术日趋受到世人的关注。本次设计是一个属薄壁制件,需大批量生产仪表外壳的叠层式热流道模具,叠层式热流道模具可以提高生产自动化和生产率,降低生产成本。叠层热流道模具设计的内容主要是模具结构设计,其包括:热流道系统设计,温控系统设计,开模机构设计,熔料传递方式。热流道系统主要由喷嘴、歧管、热流道板、加热装置等组成。喷嘴形式有多种,常用的有开式喷嘴、针阀式喷嘴和井式喷嘴。开式喷嘴会引起流涎,塑件表面会有点并且成型塑件性能也会降低,形成的冷料甚至会堵塞浇口,叠层式热流道系统通常采用阀式热喷嘴。热流道板和喷嘴上装有加热元件,而且通过温控系统对加热温度进行控制。叠层式热流道模具温度控制系统有加热系统和冷却系统,加热系统是为了持续让流道中的塑料呈熔融状态,冷却系统是为了完成塑料和模具之间的热量交换。加热系统中温度不能过高或过低,温度过高,可能导致塑料分解变色,在塑件上形成缺陷,乃至报废;温度过低,塑料会在流道中形成较厚的固化层,影响实现连续注射因此,应严格控温。热流道的温度控制是热流道技术的难点之一,为了控制好温度,可以选用闭环控制的热流道系统,再根据塑料的性能、成型温度和制品要求选择合适的温控数值和精度。叠层式热流道模具热流道系统的主流道设置在模具中心部分,由于叠层式模具型腔有多个分型面,着意味着需要有一个机构使这些分型面能同时分型。叠层式模具在开模时,不仅动模部分移动,中间部分同时移动,即应同时开2个分型面,并由两侧的顶出机构使塑件脱模。目前叠层式模具的开模方式一般有铰接杠杆或齿条来同步开模,也可使用液压系统。叠层式热流道模具设计在设计时需注意以下几个问题:热膨胀问题,浇口平衡问题,冷却系统的平衡,防止流涎,隔热措施。浇注系统无凝料、拉丝现象;实现自动化生产;具结构尽量简单,组装、拆卸比较容易。2 制品设计2.1制件图产品的制件图如下所示 图1-1 制件图 图1-1 制件图2.2产品使用要求该产品是一种仪表外盖,因需从外面能看到里面,故要求材料透明外表面光洁度R小于0.5。另外还要求外盖的绝缘性能良好,并且由于外盖是暴露在外面的,所以要求材料的抗腐蚀能力较强。2.3产品材料根据上述使用要求,经查表选用塑料ABS55。3 工艺分析3.1 塑料特性透明ABS树脂的透明度较高,耐容剂性能好,而且冲击强度和机械强度都比较高。ABS55(通用)树脂的性能如下:相对密度: 1.07 g/cm3拉伸强度: 42.2MPa弯曲强度: 71.6MPa弯曲弹性模量: 1.96GPa热变形温度(1.82MPa): 86压缩比: 1.82.0成型收缩率: 0.30.8与钢的摩擦因数: 0.21泊松比: 0.353.2 塑料的注射工艺条件螺杆转速: 3060r/min取45r/min喷嘴温度: 190200取190料筒温度: 后部: 190200取200 中部: 220240取220 前部: 200220取200模具温度: 5070取60注射压力: 70100MPa取90MPa保压压力: 5060MPa取56MPa注射时间: 14s取4s保压时间: 1540s取20s冷却时间: 1030s取15s成型周期: 3080s取45s3.3 塑件使用材料的工艺分析ABS属于热塑性塑料,流动性好,其成型性能好;比热容低,在料筒中塑化效率高,在模具中凝固校快,成形周期短,可在柱塞式或螺杆式卧式注射机上成形;成形收缩率较小(0.30.8)。ABS吸水率大(0.20.45),成形前必须充分干燥。干燥条件:在空气循环干燥中,温度为8090,干燥34小时即可使用。 塑件尺寸不大,外部形状结构简单,注射成型容易,无抽芯机构。4选择设备根据塑料ABS的特性,其成型压力为70100MPa,预选2层模16腔,每层8腔。塑件体积为33.41cm,塑件总体积为33.4116534.56 cm。由于采用叠层式注射模,且流道比较长,考虑注射机的注射能力,所以选用XS-ZY1000型卧式注射机。其成型技术规格如下:最大注射量: 1000 cm 螺杆直径: 85mm 注射压力: 121MPa注射行程: 260mm 注射时间: 3s螺杆转速: 21、27、35、40、45、50、65、83 选用45r/min注射方式: 螺杆式注射合模力: 4500KN最大成型面积: 1800cm2模板行程: 700mm模具厚度:最大: 700mm最小: 300mm拉杆间距: 750650mm合模方式 : 特殊液压油泵流量: 200、18、1.8L/min 选用200L/min压力: 14MPa加热功率: 16.5KW机器尺寸: 7.671.742.38m喷嘴球半径: R18mm喷嘴直径: 7.5mm推出中心孔: 150mm5模具设计5.1 模具结构设计5.1.1 选择分型面根据分型面选择原则,分型面应选在最大截面处,再根据制件特点,四侧面与外底面属外表观面,应在型腔内整体成型,因此选用截面A作为分型面(如图5-1所示)。 图5-1 分型面示意图5.1.2 布置型腔根据设计高效率叠层注射模以及结合制件尺寸结构,布置型腔。制件结构简单,壁厚较小,体积不大,截面尺寸也不大,长 / 宽115 / 72=1.6 由上所述,设计模腔一模十六腔,每层八腔,由于塑件的长是宽的1.6倍,将型腔排成两排,一排四个,在长宽度方向各排列四个。这样让模具型腔排布比较紧密,充分发挥了模具生产能力。(分布如图5-2) 图5-2 型腔分布示意图5.1.3 确定成型零部件结构图5-3 型芯结构图5.1.4 浇注系统结构设计由于采用一模16腔的高效叠层模具,型腔多,流道长,改变方向次数多,采用冷流道注射较困难,且凝料体积大,材料浪费率高,若采用热流道,将大大减少凝料,且能保证物料流程。热流道技术费用高,适用于高效无凝料生产,通过提高生产率,减少凝料来弥补这个缺陷,合适时可降低塑件总成本。1)选用浇口根据浇口选用原则,浇口设在塑件底面中心位置处,采用针点浇口。浇口很小,基本上无痕迹,不影响外观质量。2)流道结构设计根据型腔布置和模具结构的特点,采用无流道技术在流道板上加工流道,钻削流道末端,流道末端用螺栓密封。(见流道板零件图)3)选用喷嘴类型由于ABS熔料较稀,在开模过程中浇口处会出现流涎、拉丝等现象,可能导致熔料在模板上冷凝,从而阻止模具型腔的密封导致生产无法进行。为了防止此现象的发生,选用闭合式喷嘴,且采用压缩弹簧驱动机构。当型腔压力降低到保压力,注射机停止注射时,压缩弹簧驱动柱销闭合浇口,而且这样还可以防止倒流现象。当塑件取出,注射机开始注射时,注射熔料的在高压力下会把柱销的斜锥面柱销推开,从而打开浇口,进行注射。喷嘴与流道板处用螺纹联接,这样既可以防止了漏料现象又使流道板的热膨胀问题得到简化,喷嘴与流道板固定,让喷嘴与喷嘴对应孔在热膨胀方向有一定间隙并且可解决热膨胀问题。4)主流道杯因为采用热流道技术,主流道采用线圈加热的热流杯,采用外加热式线圈加热装置,主流道杯与其穿过的各个模板用导热率较低的材料隔热。同样为防止流涎现象,采用闭合式主流道杯。在其前端加一个顶针,当注射机注射时,顶针被打开,当注射机停止注射,由于流道内的熔料有一定压力,压着顶针使其闭合,这样就防止了熔料流涎。 5.1.5 开模机构设计开模机构采用了较经济的齿轮齿条开模机构。在模具的中间板上安装一齿轮,齿轮装在轴承上,轴承固定在中间板上的轴上。齿条的另一端固定在动模板上,齿轮上下各一根,当开模时,注射机拉动动模座板,使第二层的动模板运动,第二层动模板通过齿条使中间板上的齿轮转动,齿轮会给第一层上的齿条一个力,使第一层动模板固定不动,中间板受到齿条一推力,使中间板与第一层动模板分离,中间板两面都是型腔,也即使第一层分型面分开。(如图5-4) 图5-4 开模机构简图5.1.6 脱模机构设计由于模具的型腔多,每层各8腔,若采用推杆或推管推出,比较麻烦,制件壁厚并非过小,塑件在开模方向高度又不是很大,完全可以采用推件板推出方式推出制件。这样做的前提是塑件在开模后留在型芯上。模具一共两层,第二层与单板式模具一样用注射机液压做动力来源,第一层只能用弹簧、拉杆或其他的部件,在开模时给推件板一推力或拉力,完成开模。本模具型腔多,脱模力可能会太大,不适合用压缩弹簧来脱模,可采用拉块拉动推件板来推出塑件。5.1.7 温控系统设计对主流道和喷嘴的加热,课采用线圈加热,对流道板可采用加热棒加热。制件的体积小,热量少,在一个方向冷却即可。5.2主要零部件尺寸计算5.2.1 成型零部件尺寸计算计算方法有两种:平均值法和公差带法。在讨论计算方法之前,对塑件尺寸和成形零部件的尺寸偏差统一规定按“入体”原则标注,即对包容面(型芯和塑件外表面)尺寸采用单向正偏差标注,基本尺寸为最小。设为塑件公差,z为成形零件制造公差,则塑件内径为l ,型腔尺寸为L。而对被包容面(型芯和塑件外表面)尺寸采用单向负偏差标注,基本尺寸为最大,如型芯尺寸为l,塑件外形尺寸为L。而对于中心距则采用双相对称偏差标注,例如,塑件间中心距为C,而型芯间的中心距为C。当塑件原有偏差的标注方法与此不符合时,应按此规定换算。平均值法是按塑件收缩率、成型零件制造公差和磨损量均为平均值时制品获得的平均尺寸来计算的。公差带法是使成型后的塑件尺寸均在规定的公差带范围内,具体求法是先以在最大塑料收缩率时满足塑件最小尺寸要求,计算出成型零件的工作尺寸,然后校核塑件可能出现的最大尺寸是否在规定的公差带范围内;或者反之,按最小塑料收缩率时满足塑件最大尺寸要求计算成型零件工作尺寸,然后,校核塑件可能出现的最小尺寸是否在其公差带范围内。为便于修模,延长模具寿命,型腔按最小塑件尺寸计算,型芯按最大塑件尺寸计算。5.2.1.1 型腔尺寸计算塑件型腔尺寸有长:115,宽:72,高:26.51)型腔长计算对应于塑件尺寸 115 ,塑料平均收缩率Scp=0.55%, z =0.193,介于IT10IT11之间。按平均值法:L=Ls+LsSc p-=115+1150.55% -0.58 =115.20 (mm)按公差带法:型腔尺寸以塑件最小尺寸计算 L=(1+Smax)Ls =(1+0.8%)115 0.58 =115.34 (mm)校核:L+z+ cLS Lc=0.096 115.34+0.193+0.096 115 0.3%=115.352115不满足要求,因此必须对凹模制造公差z和磨损量c加以修正,从寿命角度考虑,在精度不是很高时,不希望c缩小,若按IT7级制造精度:z=0.035mm ; 型腔基本尺寸按115.20计算 115.20+0.035+0.096 1150.3%=114.98272若型腔宽基本尺寸取72.05,校核满足条件。即型腔宽为:72.05mm3)型腔高: 对应于塑件尺寸26.5按平均值法:z =0.093,制造精度在IT10IT11之间,按IT10级制造精度制造z =0.084,c=0.046H=H+HS =26.5+26.50.55%0.28 =26.46(mm)按公差带法:由于型腔修模时,修模板比修型腔底部容易,型腔高应按最大尺寸计算,H=(1+S)Hz =(1+0.3%)26.50.084 =26.5 (mm)校核:HHS+H 26.526.50.8%+0.28=26.5726.5满足要求,由于型腔应取大值便于修模,所以:型腔高为26.5mm.5.2.1.2 型芯尺寸计算型芯尺寸按IT10级精度制造,z =0.1401) 型芯长:对应于塑件尺寸112,按平均值法:l=(1+Scp)l+ =(1+0.3%)112+0.58 =113.44 (mm)公差带法:型芯修模时可修小,不易修大,按最大尺寸计算。l =(1+S)l + =(1+0.3%)112+0.58 =112.92(mm) 校核:l(z +c)S ll c=0.096mm 112.92(0.084+0.096)0.8%112=111.844112不满足要求,取lm=113.44校核可以满足,即型芯长为113.44mm2)型芯宽:对应于塑件尺寸69 按IT10级精度制造z=0.140 按平均值算法:l=(1+Scp) l+ =(1+0.55%)69+ =69.72 (mm)按公差带法计算:l(z +c)S llc=0.076mm 69.69(0.140+0.076)0.8%69=68.90269用较大值型芯基本尺寸lm=69.72,制造精度不变可满足要求,即型芯宽为69.72mm3)型芯高:对应于塑件尺寸24.5按IT10级精度制造,z=0.084按平均值算法:h=(1+Scp)h+ =(1+0.55%)24.5+0.28 =24.82(mm)按公差带法:型芯为轴肩连接组合式结构,试模与修模时修磨型芯固定板上的平面较为容易,应按塑件最小尺寸计算。h=(1+S) h+z =(1+0.8%)24.5+0.084 =24.78 (mm)校核:hS hh24.7824.50.3%0.28=24.4324.5可以满足要求即型芯高为24.78mm.5.2.1.3 型芯中心距计算1)横向中心距: 对应于塑件尺寸104平均值法计算:Cm=Cs+Cs Scp 与公差带法计算结果相同,若按z=, z=0.073mm现按IT8级精度制造,z=0.054mm.C=C+ CS =104+1040.55% =104.57(mm)2)纵向中心距:对应于塑件尺寸61,按IT8 级精度制造,z=0.046mmC= C+ CS =61610.55% =61.34(mm)5.2.1.4 型腔壁厚与底板厚计算型腔采用整体式,直接在模板上加工1)型腔壁厚S计算按刚度条件:S= C常数,随l/h而变化; P型腔压力,MPa; h型腔深度,mm; E型腔板的弹性模量,MPa;变形量,mm. l/h=115/26.5=4.34,查得C=0.1407;初选型腔压力p=30MPa; 型腔深度h=26.5mm; 钢的弹性模量E=2.210MPa,许用变形量=0.05mmS=5.50(mm) 型腔壁厚应S5.5mm2)型腔底板厚t计算 按刚度计算:t= C常数,与l/b有关; l/b=115/72=1.597,查得C=0.0251 型腔压力p=30MPa,型腔宽b=72mm,E=2.210MPa,=0.05mm t=12.25(mm)按强度计算:t=b=b/l,b型腔宽,l型腔长; 型腔板的许用应力,查得=785MPa;t=72 =8.5(mm)型腔底板厚度应满足t12.25mm5.2.2 确定模具各部分结构尺寸模具结构(如附装配图)各模板尺寸均按标准模板选取, 长宽厚 来源定模座板尺寸: 50056030mm 从标准模架上选用动模固定板尺寸:50056030mm从标准模架上选用动模板尺寸: 50056030mm GB4169.81984型腔板尺寸: 50056050mmGB4169.81984 中间板尺寸: 500560130mm由于其厚度受限制,选用非标准的或由标准模板加工而成垫板尺寸: 100560100mm 从标准模架上选用动模座板尺寸: 50063030mm从标准模架上选用推件板尺寸: 50056063mmGB4169.81984推板尺寸: 28656040mmGB4169.71984推板固定板尺寸:28656025mmGB4169.71984导柱: 4025025mm GB4169.41984导套: 4063mm GB4169.21984 4063mm(两个) GB4169.31984推杆: 25120mm GB4169.11984联接坚固零件:定模座板到第二动模板固定螺栓: 6M16 GB578386动模座板与第一动模板固定螺栓: 6M16 GB578386推板与推板固定板固定螺栓: 4M12 GB578386两型腔板与中间板固定螺栓: 4M12 GB578386两半流道板的固定螺栓: 4M8 GB578386齿条与动模板固定螺栓: 8M8 GB578386其它零部件:推出机构中的齿轮齿条机构:齿轮m=3,z=30,B=25mm,(两个) 齿条m=3,宽20mm,厚10mm,长300mm(4根) 主流道杯上加热棒:20280mm(4根)5.2.3 浇注系统计算流道系统采用的是热流道系统,由前面确定的流道结构和型腔分布,计算并确定各个主分流道的尺寸,其中包括主流道杯,流道,浇口,喷嘴,喷嘴驱动装置,以及流道板的尺寸。5.2.3.1主流道杯尺寸确定注射机喷嘴头的球面半径为R18,为防止漏料,注射机的喷嘴球半径要与模具的主流道杯配合,一般R1应比主流道始端球的半径小12mm。主流道杯配合球半径取R19。注射机喷嘴孔直径为75mm,主流道杯流道直径取8mm。5.2.3.2 流道和浇口尺寸确定实践证明当注射模主流道和分流道的剪切速率=浇口的剪切速率=s时,所成型的塑件质量较好。对于一般热塑性塑料,上面推荐的剪切速率可作为计算模具流道尺寸的依据。在计算中可使用如下经验公式:=3.3 R表征流道断面尺寸的当量半径,cm 体积流量,cm/s。在计算各流道尺寸时可先计算各流道的体积流量,据经验预先确定各流道的剪切速率,再计算求出流道的当量半径或查 R关系曲线也可。 =113.6 (cm/s)预选主流道剪切速率=,=113.6 cm/s,流道当量半径R= =0.39(cm),取D=8mm第一分流道=,=113.62 cm/s56.8 cm/s,流道当量半径R= = (cm),取D=8mm第二分流道=,=56.8 cm/s28.4 cm/s,流道当量半径R= =0.18(cm),取D=6mm浇口处=,=33.44 cm/s8.4 cm/s,浇口当量半径R= =0.06(cm),取浇口直径d=1.2mm设第一浇口直径为d=1.2mm,对离主流道较远的第二浇口用流动平衡的平衡系数法求得。该法的原理是使各个型腔的平衡系数相等或成比例,其公式为 k=K浇口平衡系数,它与通过浇口的熔体质量成比例;S浇口的断面积,mm;L浇口长度,mm;a主流道到型腔浇口的距离,mm.取喷嘴流道与第二分流道直径相等,d=6mm,浇口长设为mm,根据型腔分布流道及浇口尺寸如图k=k=,即d=1.43mm,由于第二浇口距离主流道比较远,压力降较大,为尽量平衡进料取d=1.5mm。 5.2.3.3 喷嘴和喷嘴驱动装置(图5-5) 1流道板2锁紧螺母3弹簧4垫块5驱动柱销6喷嘴7热电偶8加热线圈9隔热套10型腔板 图55 热流道喷嘴喷嘴流道直径取d=6mm,其与流道板联接用M20螺纹联接。刚开始保压时,保压力为p=56MPa,第一浇口驱动柱销直径为1.2mm柱销受力 F1 =3.14 1.210 56 10 =63.3(N)柱销驱动弹簧压缩力应63.3N且要小于注射时在注射压力下柱销所受的力,让浇口能够在注射时打开。注射型腔压力下柱销受力F2=3.14 1.2103010 =33.912(N)压缩弹簧的压缩力33.912NF33.912,当注射时弹簧压缩力F=76.9=48.363.3, 可满足要求。5.2.3.4流道板的尺寸确定由型腔分布和浇口位置确定末级分流道长为(46+92)2=276(mm),再考虑到流道末端用螺纹密封,给密封螺栓留一定安装尺寸,取流道板尺寸为:310290120mm。为安装喷嘴驱动装置,流道板厚度上分为两半5.2.4 冷却系统计算5.2.4.1 计算单位时间里型腔内总热量Q(kJ/h) Q=Q1单位质量的塑料制件从熔体进入型腔开始到冷却结束时所放出的热量,kJ/kg,又称单位热流量之差或热焓之差;W单位时间内注入型腔中的塑料质量,kg/h; N每小时注射次数。查得Q1=3.11024.0102,取Q1=4.0102kJ/kg注射时间为=4s,保压时间为=20s,冷却时间为=15s,开模时间为=6s总成型周期为4+20+15+6=45(s) N=3600/45=80每个塑件体积为33.4cm3,=1.07g/ cm3每次注射总质量为 33.41.0716g=0.572kg取G=0.6kgQ=800.64.0102=18304(kJ/h)5.2.4.2 通过自然冷却所散发的热量Q,Q,1)由对流所散发的热量(kJ/h)模具表面积,模具平均温度,室温,传热系数,kJ/(h)当06000时,= =20, =,=65, = 模板的热导率,kJ/(h) 模具型腔壁与冷却水管壁之间距离,m 、冷却水管壁表面尺寸,m 、型腔壁表面尺寸,m。 = =2.510h/kJ =,=3.1 h/kJ =65-8188.4=65-2.4=62.6() = =9.6 ()冷却管表面积为163.140.0120.56=0.34()9.63)所需冷却水管总长度LL= = =0.034(m)冷却水管总长为8根0.56m的,显然够用。5.2.4.6 冷却水流动状态校核为保证冷却效率,使冷却水处于紊流状态,雷诺数600010000= v冷却水平均流速,d冷却水管直径,水运动黏度,=1.6=144001000005.2.5 推出机构计算5.2.5.1 推件板厚度t计算 按刚度计算:t=0.54LL推件板长度上两推杆的最大距离,mm;B推件板宽度,mm;F脱模力,N; 推出板中心所允许的最大变形量,一般可取制件在被推出方向上的尺寸公差的计算脱模力:脱模力按矩环形断面薄壁制件(t/d0.05) 计算,F=+0.1AK无量纲系数,随f和而变,K=1+fsincos也可查表求得; 脱模斜度,;矩环形制件的平均壁厚,mm;S塑料平均收缩率;E塑料的弹性模量,MPa;L制件对型芯的包容长度,mm;f制件与型芯之间的摩擦因数;塑料的泊松比;A盲孔制品型芯在垂直于脱模方向上的投影面积,mm,通孔制件的A等于零. =0,=1.5mm,E=1.410MPa,L=24.5mm,S=0.55%,f=0.21,=0.35,A=88=64mm,K=1+0.2101=1F=+0.1A =+0.164 =18085.4+6.4 =18091.8(N)按刚度计算推件板厚度:初选标准模架A250056016Z1 GB/T12556.190模板长560mm,宽500mm,取=400mm,B=500mm,F=18091.8 N,E=2.210MPa,=0.04由于脱模力分散,是均布力,把每层上的8个型腔的脱模力折合成四个集中力来计算,此时t= =0.54 =59.6(mm)推件板厚度必须满足t59.6mm5.2.5.2 推杆直径计算稳定性计算:d=k安全系数,取k=1.5;L推杆长度,mm;n推杆数量, F脱模力,N; E钢材的弹性模量,MPaL=170mm,F=818091.8N,n=2,E=2.1105MPad=1.5 =4.1(mm)按强度计算: 推杆的许用应力,MPa;查得45钢的=600MPa d=19.4(mm)所以推杆直径d5.3 校核5.3.1 模具与注射机关系校核1)注射量校核: =1633.4+0.62(4.3516+28.44)+ 0.82(23.3+902) =534.4+33.3+107.2=674.9(cm3)10000.8=800 cm32)注射压力校核注射机最大注射压力为121MPa,塑料需要的注射压力为70100MPa3)锁模力校核型腔内塑料熔体沿注射机轴向的推力,N;A塑料与浇注系统在分型面上的投影面积,mm2型腔内塑料熔体的平均压力,MPa, =30MPa注射压力,MPa, =90MPa k压力损耗系数,与塑料口种,注射要形式,喷嘴阻力等因素有 关,一般取0.20.4,取k=0.3A=11572=8280 mm2=82800.390=223560N注射机锁模力4500N4)模具安装部分尺寸校核模具厚度:模具厚度为300mm656mm700mm满足要求模具长度和宽度:注射机拉杆间距为750650,模具长宽尺寸为630560mm定位环尺寸:模具定位环尺寸与注射机定位环尺寸都是150,用较小的间隙配合,给模具开模垂直平面上固定。喷嘴尺寸:注射机喷嘴球半径为R18,模具上与之对应的配合尺寸为R19,符合要求。5)开模行程校核:由于采用的是热流道,无需脱凝料,制件在开开模方向尺寸为26.5mm,第二层靠的是推杆推出制件,推杆的行程为100-40-25=35mm26.5mm5.3.2 物料流程与流动比校核流道走最远路程为主流道杯段d=8mm长233mm,一级分流道段d=8mm长92.5mm ,二级分流道段d=6mm长45mm,末级分流道段d=6mm长138mm,喷嘴段d=6mm长43.5mm。总共是d=8mm,长325.5mm,d=6mm,长226.5,平均取d=7mm,则l/d=226.5+325.5/7=78.9,ABS流动比为240120,显然能满足物料流程。结论本次设计采用的是热流道叠层式注射模具,这种注射模具既可以充分发挥注塑机的能力,又节省人力和设备资源,而且极大地提高生产效率。该设计的热流道浇注系统,总体来说结构简单,可以实现自动化生产,适用于大批量生产,而无凝料生产,一模多腔,双层型腔,这些优点大大提高了生产率,降低了生产成本。但在生产中对加热温度要严加控制,防止加热过度与不够。致谢 经过半年的艰苦努力,我的毕业设计已接近尾声。作为一个本科生,由于经验匮乏,难免有许多考虑不周的地方,如果没有导师的督促和指导,以及一起学习的同学们的支持,想要完成这个设计是难以想象的。在此首先感谢我的导师黄传辉副教授。他时刻关注我的研究进程,虽然他工作繁忙,但每周还是腾出固定时间来指导我,帮助我开拓研究思路。而且每当我有疑问的时候,他不论问题简单与否都细心解说。在此谨向黄传辉副教授致以诚挚的谢意和崇高的敬意。同时也要感谢和我一起奋斗的同学们,每当我遇到困难时,你们的帮助和支持给了我很大的动力去克服它们。在论文即将完成之际,我的心情无法平静,从开始选择课题到论文的顺利完成,有多少可敬的师长、同学、朋友给了我无言的帮助,在这里请接受我诚挚的谢意!参考文献1宋满仓.注塑模具设计M.电子工业出版社,2010.2G曼格斯,P默兰.塑料注射成型模具的设计与制造M.北京:中国轻工业出版社,1993.3刘延华 .塑料成型机械使用维修手册M.机械工业出版社,2004(2).4任威,卢军.热流道层叠式注射模具的研究J.电加工与模具,2008.2412425张信群,忘春香.模具设计与制造M.合肥工业大学出版社,2010.6王振保,李辉,方少明.叠层式注塑模具的研究J.橡塑技术与装备,2006.38437王振保,王勇.双层型腔的包装盒注塑模具设计J.塑料工业,1999(7):2627.8李树,揣成智.双层热流道注射模成型技术J.模具工业,1997(10):2830.9黄虹.塑料成型加工与模具M.化学工业出版社,2003(3).10任威,卢军。电加工与模具J.陕西科技大学出版,2008(5):6163.11阎亚林,黄晓燕.叠层注射模的应用与设计J.模具工业,2003(12):3134.毕业设计附件外文及翻译学生姓名学院名称专业名称机械设计制造及其自动化指导教师 新一代注塑技术 外文出处 University Hospital Zurich, Zurich, Switzerland 摘要:本文介绍新一代瓶坯注塑技术的特点以及通过一个循环所实现的瓶性能。这一循环使瓶胚冷却不再需要机械手和引出板,而是瓶胚直接在模芯上冷却,在进一步通过2.5 注射循环冷却之后被顶出。这使制件的冷却得以改进,从而大大提高了每个阴模的产量。从工作单元去掉机械手减少了空间需求,并大大简化了系统。 关键词: 注塑模具设计 循环速度 1、概述 转位瓶胚注塑技术是在Husky 注塑系统双压板机器设计发展起来的。该系统有一个四面动压板绕横轴旋转。每一面配一个典型的半冷塑模。原模系统是一个48 阴模,从而提供192 个模芯。定压板上装有一个标准的热流道和半阴模。 本系统配备一个标准两级注塑装置,该装置有一个120 毫米挤塑机和120 毫米注射压料塞,注射压料塞上有一个机筒头和分配阀连接两级。用目前的瓶胚设计,目标重量是47.3 克瓶胚,从而注射量为2270 克。两42 个不同的聚对苯二甲酸乙二醇酯螺杆用于本系统,每个都取得了可以接受的效果。 当机器循环时,塑料首先注射到A 面。由于瓶胚要留在模芯上,瓶胚在开模不需要象在传统系统上那么硬。因此,循环的绝大部分冷却可以在随后的机器循环期间从闭模转到在模芯上冷却。然后循环需要一个非常短的冷却期间以允许模具释压,注射和保压也是如此。当开模时,这一面转位到压板的顶部表面,然后塑料在B 面注射。当D 面到达前端时,此时A 面在压板的底部位置,顶杆在这里被启动,瓶胚被从机器卸到制件引出传送器上。注射行程对循环时间没有影响,因而可以较慢地完成。重力帮助确保制件脱离模具落下。制件落在其格端头的传送器上,造成表面擦伤的可能性较小。 在顶部、背部和底部位置,气冲成型系统对瓶胚提供表面冷却。由于瓶胚保持在模具的模芯上,它们还容易在内表面得到传导冷却。总体上讲,瓶胚的整体温度比它在传统模塑系统和冷却引出板中呆类似的时间要冷。 2、瓶性能 我们分析转位系统的一个重要方面是拿这种系统生产的瓶胚制造出来的瓶的性能与传统工作单元上生产的类似瓶胚制造出来的瓶相比较。表1 给出从进行的试验中得出的比较数据。 转位瓶胚的性能在强度测试中一直较好,这是因为改进的浇口质量允许材料在瓶内较好地分布,没有迹象表明使用这种系统在瓶的任何地方结晶度升高。生产的转位样品可能平均较轻,因为它们的重量分布要紧密得多。 3、系统的特点 这种托坯最明显的好处是需要的模内冷却时间减少了,从而减少了整个循环的时间长度。目前,这种系统用最大壁厚为4 毫米的47.3 克瓶胚工作。这种瓶胚加工循环时间测定为22.5 秒,对于一个阴模系统来说是最佳的了。转位48 阴模系统实现14.2 秒的循环,能取得较好的商业质量结果。图2 给出循环细分的比较情况。 旋转塔台不再需要机械手。这样,就减少了由传统系统上机械手故障造成的干扰告警和服务停机时间。制件顶出现在不是机械循环时间的一个因素。随着消除机械手需要的开模间隙减少了,随着模具行程的减少还提高了空循环速度。 系统的另一个好处是需要的地板面积减少,以及由于没有机械手和引出板冷却系统,系统的可靠性得以提高的潜力。预计不发生机械手故障的整个系统可靠性可允许系统可用性提高30%。转位系统的地板面积只有传统48 阴模系统所需面积的55%。与之相伴的还有每英尺地板面积的产量进一步提高。 使用转位系统使瓶胚的浇口质量得到改进。在阀浇口区冷冻之后,瓶胚在较短时间内与阀杆的热点接触,因为瓶胚在阴模内的冷却时间被大大减少。去掉这一热源就消除一个结晶源。除了较好的视觉效果,还导致浇口区更结实,从而使得整个瓶侧壁区更好,及有更多的机会减轻基础区瓶胚的重量。 瓶胚留在模芯较长时间。与标准瓶胚注塑系统相比,整个瓶胚冷却得到改进。在一个传统的机械手冷却板内,制件遇到被冷却的管表面就会收缩,这样热传递就不完美。在转位系统中,制作在模芯上收缩,从而保持热传递,在被顶出时,转位瓶胚的全面整体温度比瓶胚从传统系统的引出位置取出时要低。还有,对于目前的瓶胚设计来说,不向颈模圈区供应冷却水,在顶出时仍比标准系统要冷得多。对于一个典型的成型系统来说,冷却该区能限制循环。 转位系统用几种不同材料及测试的两种不同材料和两种不同的聚对苯二甲酸乙二醇酯螺杆设计,可以看到乙醛(AA)量一直较低。与注射量相比这一循环时间对注射装置提出非常高的要求,注射装置连续不断地冲刷没有一点滞留时间的螺杆。 由于模具内的峰值阴模与两个不同的螺杆相符,并与不同的加工设置一致,乙醛量到底有多低主要原因在于模具集料管。用目前的模具可以看到的第二个好处是有非常好的重量分布,从而允许在目前制件规格的允差内把整个制件的重量降到最低程度。 4、介绍IKB-MOULD设计的基础注塑模组成的分析处理分为两部份:设计的首字母和详细的设计,初期的设计决定模具的组成,例如模具类型、型腔数、流道的类型、浇口类型等。详细设计是型芯型腔的组成、浇注系统的设计、冷却和排气系统的设计、集成分析和最后的草图。他们需要什么,分析什么是好的CAIMDS的发展方向。 他们所拥有的客户对产品的要求。包括产品外形和详细的尺寸。 一个已经设计好的模具方案这个方案包括模具设计的初级部分和标准部分举例来说模具设计的基础动模和定模的一部分填充和顶出的一部分。注塑模具设计的行业知识等。 设计者从专业知识中得出模具设计的设计计划和详细步骤这些知识包括原材料的选择型腔型芯分型面的规划和其他相关细节的介绍。 他们所想要得一个先进的交互式模具设计环境。模具设计是由一系列细小的环节组成的设计程序。这些程序通常需要将已有的模块和制作好的模件装配好。这些模具设计系统不需要自动完成尤其是对切口部分特征比较复杂的产品。先进的交互式程序善于整合自动化运算法则和有经验的设计者的在线知识交流。 标准件/早期设计部分/组装/产品管理。一个注塑模具在其它注塑模里相同的形状尺寸分别有型腔型芯。这些部分与注塑模产品无关。他们使用在不同模具中重复使用的大概标准。 有用的工具包括实体设计和分析计算在模具型腔型芯中的设计。型芯和型腔的外形和大小直接影响模具产品。这些部分也是模具设计中相当重要的环节。他们的几何形状要求可能相当苛刻。因此一些模芯设计工具的发展方向基于自动生成模具型芯交互作用是相当有用的。 组装设计在传统的CAD/CAM设计系统中模具的实体形状被当作几何图形储存模型在一个三维空间以边和面的形式生成。象这样的一个以严密的几何计算表现的视觉外形可以完成工程分析和模拟。但是这种工作方式不适合设计高层数据和产 品的几何实体外形的关系。 模具设计者更喜欢装配环境的设计而不是一种简单的固体模型环境。这个方案被 Ye et al 提出。 5、循环速度的限制因素 在整个循环期间对转位循环的影响因素可以分为五个组成部分: (1)机器空循环时间(这是完成开模、旋转塔台90 度,闭模和为注射做准备的循环的时间); (2)阴模充料时间; (3)为避免正冷却的制件形成凹陷的保压要求; (4)模内冷却以使模具从保压期间要求的合模力吨数中释压; (5)在顶出时瓶胚的大量热造成的表面热以及热再生,以避免后续处理期间制件被刮伤或有粘性。 系统的机器空循环时间被优化。模具不必开那么多,以允许转位旋转,象传统系统为允许机械手进入模具区所要求的那样,从而减少了开模和闭模时间。转位速度也比机械手进去,转移制件和机械手再出去快。目前4.3秒的机器空循环已经充分优化,改进的余地很小。 如果注射装置尺寸过小,生成熔体可能是一个限制因素。已经在循环速度低达11.6 秒,用2280 克注射量的0.82IV 树脂测试过目前120 毫米的螺杆可接受的塑炼能力。这时没有剩余的滞留时间,这样循环将受螺杆性能限制。 充料和保压时间大约为9 秒。现正在做试验以量化最佳的充料速度和保压外形。 冷却0.5 秒可以实现模具释压,但目前的工艺需要冷却1.3 秒,循环目前受到在制件上形成凹陷限制。这受到包装数量、保压压力和开模的速度的影响。由于转位循环的冷却时间非常短,瓶胚遇到阴模壁收缩的时间非常少。正在研究改进这方面的循环性能的机会。 目前出模时的瓶胚温度将允许循环时间远远少于13 秒,如果仅这一方面是循环的限制因素的话。 6、瓶胚设计的考虑因素 根据最初比较原型系统中使用的瓶胚以及为促进使用转位方法减少转位循环而对各种瓶胚设计做的试验。因此,实施一种转位系统而非较传统的成型方法的决定是由于其他许多考虑因素)转位系统要求四套制件模芯,这样模芯的复杂性以及由此导致的整个模具成本是选择的一个因素。其他因素包括生产能力要求、可用的地板面积、资本成本。 The Fresh Generation Injection Mould TechniqueAbstract : The original is introduced fresh generation vase earthen brick mould plastics technique distinguishing feature along with by means of the vase performance that the cycle was achieved That this cycles causes an a jar of embryo become cool not needing manipulator and the lead-out plank again , but is an a jar of embryo directly is living that the standard becomes cool on the rush pith , and is living further by means of 2.5 to inject after the cycle cooling being come out by the peak This causes the finished piece cooling may improve , thereby lift every one the overcast standard yield enormously Decreased the demand in room through the work cell gets rid of the manipulator , and simplify the system enormously Keyword : Injection mould design Cycle velocity 1、Summary The indexing vase embryo mould plastics technique is designed the development at twin teeterboard machinerys of Huskys mould plastics system Ought to systematically there be an all sides to stir the teeterboard to coil the cross axle to circle Each one section is matched somebody with somebody a type semi to cool to mold the standard The master stamper systematically is 48 an overcast standard , thereby supplys 192 standard rushs pith Fiing teeterboard jacket possess criterion heat flux a road and semi an overcast standard Standardized two steps of moulds plastics units are equipd to this system , and that unit possessone 120 millimeters to pack the engine molding and 120 millimeters to inject the pressure stuff to squeeze in , and injecting along the Great Wall the pressure stuff possess engine a thick tube-shaped head and a distribution valve to join two grades Designing in the way of the vase embryo at the moment , target weight is the 47.3 grams vase embryos , thereby injecting amount is 2270 grams Two 42 differences is gatherd being used a system to the benzol two methanoic acid glycol ester studs , and every one wholly acquireed the effect that may be receiveed When the machinery cycles , the plastic material first of all injects up A Since the fact that the vase embryo will remain the standard rush pith on , the vase embryo is living to turn on the standard not necessaries , and that traditional system goes up such as being living is stiff in that way Hence , the machinery cycle that the overwhelming majority cooling may be living soon afterwards perioc through shuts the standard revolves up to become cool on the rush pith at the standard Afterwards the cycle needs an extraordinary brief cooling perioc in order to permit the pattern to elucidate the pressure , injects and defends and to be getting near also is such in this way Afterwards the plastic material are living Bs surface is injected on this peak ministry face that the teeterboard was reachd in the indexing on one section when turning on the standard As D before arrival when the extremity , now A is living teeterboard base place , and the push rod is switched on here , and the vase embryo is unloaded the finished piece through the machinery and leads to on the conveying utensil Injecting the stroke adjust the cycle time not effect , as a result may complete more slowly Gravitational force help is guarranteed that the finished piece breaks away from that the pattern drops secondly The finished piece drops such the curtain squares formed by crossed lines tip conveying utensil on , and the probability that creates the surperficial gall is littleer A ministry is living 、Gas dashing systematic twin vase embryo of forming supplys the face and becomes cool the place of back and base Since the fact that the vase embryo maintains the pattern standard rush pith on , the face obtains the conduction cooling included they are still convenient Says in the total , the entire temperature of vase embryo than it is living traditional compression molding system and cooling leads to in the plank to stay analogous time will cool 2、The Bottle Function Significant respect that we analyse the indexing system analogous a of jar of vase that the embryo was manufacture out that to be the performance takeing this kind of vase that the vase embryo that the system was gived birth to was manufacture out against traditional work gived birth to on the cell one another contrasts The comparand that obtaines in the eperiment that the table 1 is give out through is underway is depenied on The indexing vase embryo performance is living and is better always in the intensity quiz , and this is better distributing for the runner quality which improved permits the stuff to be living inner place the vase , and does not there is the indication to make known that use this kind of system is living whatever space crystallinity of vase and ascendes The indexing specimen gived birth to is probably equally light , for their weight distributions is to be much inseparable .、This kind of system distinguishing feature Inner place the standard that to support with the hand the obviousest advantage of earthen brick is needs the cooling time decreased , thereby decreased entire time length that cycles At the moment , this kind of system employ the largesttest breastwork thickly act as 4 millimeters the 47.3 grams vase embryos do This kind of vase embryo process cycle time ascertains by measuring to 22.5 seconds , was optimum as to the overcast standard system Overcast standard system implementation 14.2 seconds of indexing 48 cycle be able to be acquireed the better trade quality killing The picture 2 is give out the cycle subdivided comparing situation Circling the control tower does not need the manipulator again Like this , therefore decreased from the tradition system to go up the jam that the manipulator block created is giveed an alarm and the service ceases engine time The finished piece peak has ariseed to be living not to be the inflexible cycle time the element Decreased in the standard the turning on gap that needs in the wake of removing the manipulator , in the wake of decreasing of pattern stroke still lift empties cycle velocity Systematic another advantage is the floor area that needs decreases , along with thanks to does not there is manipulator and lead-out plank cooling system , latent capacity that the dependability of system may be liftd Calculate in advance entire systematic dependability that therefore the manipulator obstructs does not happen permit the systematic usability to lift 30% Merely traditional 48 55% of overcast areas that the standard system requires of indexing system floor area Against the person who one another accompanies the yield that still possess per foot of floor area lifts further.Employ the indexing systematically to cause an a jar of embryo runner quality obtain the modification Being living , the valve runner district is freezed afterwards , the vase embryo is living brieflyer time inner place the heatpoint contact against the valve staff , for the cooling that the vase embryo is living inner place the overcast standard time by enormously decreases Geing rid of this heat source removes a crystal source Except for better vision effect , still causes that the runner district is more sturdy , thereby causes entire a of jar of side wall district better , and possess the weight that even more opportunitys ease the vase embryo in base district The vase embryo to remain at the standard rush pith elderer time Systematically being contrastd against a criterion a jar of embryo mould plastics , entire a of jar of embryo becomes cool obtainning the modification Being living , tradition manipulator becomes cool inner place the plank , and the finished piece is encounter and be able to be shrinked by the tube face becoming cool , and such heat transfer is imconsummate In being living the indexing system manufactures at the standard shrinking on the rush pith , thereby maintain heat transfer , and is living when being come out , and will let drop when comprehensive entirety temperature of indexing vase embryo contrasts the a jar of embryo lead-out place through traditional system brings out by the peak .Still possesing , and designs as to the vase embryo at the moment , not to the throat standard ring district supply cooling water , being living , the peak when comeing out yet systematically will be cooled far more than the criterion Become cool that district threshold energy system cycling as to the forming system of type The distinct stuffs of indexing system in the way of some kinds reaches the difference of two kinds of distinct stuffs testing with two kinds to gather designing to the benzol two methanoic acid glycol ester studs , and may catch sight of that the acetaldehyde ( AA ) amount lets drop always against injecting amount is contrastd this cycle time adjust injects the unit proposes the very much tall demand , injects the unit constinuously scousrs not to there is a few is held up time the stud . Since the overcast standard of peak value inner place the pattern tallys with against the two differences studs , and against the difference process installation unanimously , the acetaldehyde is measured ever to possess to let drop that the main reason rests with that the pattern gathers materials the tube more Second advantage may catch sight ofin the way of the pattern at the moment is possesing the very much good weight distributions , thereby permits to be living at the moment finished piece standard allows bad inside entire finished piece weight to drop the thest least degree 4 、The injection mould design process requirementanalysis An injection mould design is composed of two steps: theinitial design and the detailed design. The initial design iscomposed of decisions made at the early stage of themould design, such as the type of mould configuration,the number of cavities, the type of runner, the type of gate and the type of mould base. The detailed design iscomposed of the insert (core/cavity) design, the ejectionsystem design, the cooling and venting component design,the assembly analysis and the final drafting. To develop a good CAIMDS, an analysis of whatthey have and what they want needs to be performed.What they have: The customers requirements for the product. Thisincludes the detailed geometry anddimension requirementsof the product. An existing mould design library. This library coversthe standard or previously designedcomponents andassemblies of the mould design, for example, themould base (the fixed half and the moving half) andthe pocket (the fixed half and the moving half). An expert knowledge in injection mould design. Expertknowledge of both initial and detailed designs forthe injection mould is obtained mainly from experiencedmould designers. Such knowledge includesmaterial selection, shrinkage suggestion, cavity layoutsuggestion and others. What they want: An intelligent and interactive mould design environment.Mould design is often composed of a series ofdesign procedures. These procedures usually requirecertain mould parts to be created and existing mouldparts to be assembled. Such a mould design environmentneed not be fully automatic, especially forcomplicated products with many undercuts. Anintelligent and interactive environment will be a goodchoice to integrate some useful automation algorithms,heuristic knowledge and on-lineinteraction by the experienced mould designer. Standard/previous designed components/assemblies(product-independent parts) management. Apart from the core and cavity, an injection mould hasmany other parts that are similar in structure and geometrical shape that can be used in other injectionmould designs. These parts are independent of the plastic mould products. They are mostly standardcomponents that can be reused in different mould designs and mould sets. Useful tools (including solid design and analysiscalculation) in the core and the cavity (productdependentparts) design. Geometrical shapes and thesizes of the core and cavity system are determineddirectly by the mould product. All components insuch a system are product dependent. Also, theseparts are the critical components in the mould design Their geometrical requirements may be complicated.Thus, some tools developed to design the core and thecavity based on partial automation and partialinteraction can be quite useful. Design for assembly. In conventional CAD/CAMsystems, moulds are represented and stored as a complete geometric and topological solid model. Thismodel is composed of faces, edges and vertices in athree dimensional (3D) Euclidean space. Such a representationis suitable for visual display and performinggeometrically computation-intensive taskssuch as engineering analysis and simulation. However,this form is not appropriate for tasks thatrequire decision-making based on high-level informationabout product geometric entities and theirrelationships. Mould designers prefer a design forassembly environment instead of a simple solid modelenvironment. This idea is also presented in Ye et al.s work 24. A design for manufacture. A complete injectionmould design development cycle can be composed ofthe mould design and mould manufacturing process.To integrate CAD/CAM into the mould design, themanufacturing features on the mould should be abstracteand analysed for the specific NC machine. Both the process plan and the NC code should beautomatically generated to enable the final designed mould to be manufactured. A design for engineering drawings. For manycompanies, the injection mould design has to be represented in the form of engineering drawingswith detailed dimensions. CAD/CAM tools that are able to automatically generate these engineeringdrawings from the final injection mould design will be useful.Based on the above analysis, our research focus is todevelop techniques to represent what they have andwhat they want.Representing what they want is actually the representationof the knowledge and injection mould object.Developing what they want means to integrate the representation with intelligent and interactive tools forthe injection mould design into a completed designenvironment. Therefore, an IKB-MOULD is proposedfor mould designers to realise the above two requirements 5、 Limitational factor of cycle velocity Is living the entire cycle perioc to the indexing what cycles the effect element may be divided into five component part : (1)Machinery emptying cycle time ( this is completeing turning on the standard 、Circles the control tower 90 degrees , shuts standard and in the interest of injects acting the ready cycle time ) ; (2)The overcast standard charges to anticipate time ; (3)The demand is getting near in the interest of averting the finished piece that becomes cool to take shape sunken guarantor ; (4)Becomes cool the pattern inner place the standard in order to cause through guarantor to be getting near perioc in the person who requires the standard the shuing force tonne figure elucidates the pressure ; (5)The vase embryo greats quantity of peak when comeing out being living warm that the face creating warms up along with warm up regeneration , in order to avert the follow-up handle perioc finished piece is fleeced the injury either is possess viscosity Systematic machinery the emptying cycle time is optimized The pattern need not turned on so manyly ,in order to permit the indexing to circle , such as the tradition systematically by permits themanipulator gos into the pattern district demand , thereby decreases turns on the standard with shuts the standard time Indexing velocity is also get in than the manipulator , and transfers finished piece and manipulator geting out quickly again The machinery of 4.3 seconds at the moment empties to cycle sufficiently to optimize , and the margin of modification is very little Unduly little in case injecting the unit dimensions , the part of the body is melte
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