酒瓶大官帽上蓋注塑模具設(shè)計與工藝分析-塑料注射模1模4腔含proe及7張CAD圖

酒瓶大官帽上蓋注塑模具設(shè)計與工藝分析-塑料注射模1模4腔含proe及7張CAD圖,酒瓶,大官,帽上蓋,注塑,模具設(shè)計,工藝,分析,塑料,注射,proe,cad 任務(wù)書及指導(dǎo)書 一、任務(wù)書 擬定題目 酒瓶大官帽上蓋注塑工藝分析與模具設(shè)計 指導(dǎo)教師 專 業(yè) 學(xué)號 姓名 課題內(nèi)容： （1） 完成畢業(yè)實習(xí)的所有工作； （2） 對超過5000字的外文文獻(xiàn)進(jìn)行翻譯；? （3） 查閱關(guān)于設(shè)計的文獻(xiàn)不少于15篇，還有部分英文文獻(xiàn)，總結(jié)并對畢業(yè)設(shè)計做規(guī)劃；? （4） 完成畢業(yè)設(shè)計的開題報告；? （5） 撰寫不少于1萬字的設(shè)計說明書，理論分析與計算正確，格式符合要求； （6） 完成圖紙折合A0圖紙2張，制圖符合國家標(biāo)準(zhǔn)。 課題任務(wù)要求： 對畢業(yè)設(shè)計的制品“酒瓶大官帽上蓋模具”零件結(jié)構(gòu)進(jìn)行了分析，確定零件形狀與大小及分模形式。使用Pro/e完成零件圖、零件型腔圖、三維模架圖，使用CAD將三維圖結(jié)構(gòu)改為二維工程圖。然后完成1萬字左右的畢業(yè)設(shè)計論文，對設(shè)計的相關(guān)方法、計算作出合理的解釋。最終對產(chǎn)品進(jìn)行質(zhì)量分析。 預(yù)期目標(biāo)： 完成酒瓶大官帽上蓋注塑模具設(shè)計與分析，掌握和熟悉上蓋的零件結(jié)構(gòu)與工作性能。根據(jù)零件大小合理選用相應(yīng)的注塑機，完成零件的模架設(shè)計，記下相關(guān)數(shù)據(jù)進(jìn)行計算，最后進(jìn)行匯總作出總結(jié)。 二、指導(dǎo)書 1.設(shè)計方法和思路： （1）查閱模具設(shè)計手冊，參照其余模具設(shè)計的例子，確定上蓋的設(shè)計參數(shù) （2）根據(jù)上蓋的設(shè)計參數(shù)，進(jìn)行注塑件工藝性分析及確定工藝方案和模具結(jié)構(gòu)設(shè)計方案 （3）明確使用注塑機的型號及規(guī)格 （4）注塑工藝計算：最大注射量、注射力、鎖模力等計算；注塑機壓力與行程；注塑機主要技術(shù)參數(shù)等計算 （5）模具的總體結(jié)構(gòu)設(shè)計：筆筒制件在模具中的成型位置；分型面和型腔數(shù)量的確定；澆注系統(tǒng)形式和澆口的設(shè)計；成型零件的設(shè)計；脫模推出機構(gòu)的設(shè)計；側(cè)向分型與抽芯機構(gòu)的設(shè)計；合模導(dǎo)向機構(gòu)的設(shè)計；排氣系統(tǒng)和溫度調(diào)節(jié)系統(tǒng)的設(shè)計及模架的選擇等 （6）裝配圖的設(shè)計：初繪模具裝配草圖，各部分的結(jié)構(gòu)設(shè)計，協(xié)調(diào)好各零部件之間的裝配關(guān)系，完成裝配工作圖 （7）零件工作圖的設(shè)計：繪制指定的成型零件工作圖 （8）整理和撰寫設(shè)計說明書 （9）進(jìn)行畢業(yè)設(shè)計總結(jié)，完成答辯準(zhǔn)備工作 2.設(shè)計的重點和難點： （1） 成型方案確定 ABS屬于熱塑型塑料。它具有低重量、高強度的特點，外觀呈淺象牙且不透明，最主要ABS不溶于大部分醇類和烴類溶劑且無毒無味。 （2） 分型面的確定 塑料上蓋為圓形回轉(zhuǎn)件，取塑件的最大回轉(zhuǎn)面處為分型面。截圖中豎直那條線上的任意一點都可以做一個分型面且都滿足不影響零件外觀，利于脫模。 （3） 型腔的確定 確定注塑模型腔數(shù)目主要考慮如下幾個因素： ①塑件的尺寸精度； ②模具制造成本和制造難度； ③注塑成型的生產(chǎn)效益； 根據(jù)上蓋的尺寸精度及生產(chǎn)要求，為了提高生產(chǎn)效率，采用一模四腔。 （4）型腔位置的排布 酒瓶上蓋采用一模四腔的結(jié)構(gòu)形式，那么澆注系統(tǒng)的設(shè)計應(yīng)盡量采用從主流到到各個型腔的分流道設(shè)計成長度相等、形狀及截面尺寸不相同（即對稱平衡式布置）。 3.所學(xué)相關(guān)知識： （1）注塑模具設(shè)計； （2）注塑工藝及設(shè)備； （3）模具CAD/CAM及Pro/E軟件的應(yīng)用； （4）型腔、型芯的設(shè)計；澆口的設(shè)計；型腔數(shù)目的設(shè)計；側(cè)抽芯的設(shè)計； （5）塑料成型工藝及模具設(shè)計等相關(guān)知識。 4. 畢業(yè)設(shè)計（論文）進(jìn)度： （1） 完成上蓋注塑工藝分析； （2） 完成上蓋模具結(jié)構(gòu)設(shè)計； （3） 完成畢業(yè)設(shè)計論文總體及字?jǐn)?shù)要求； （4） 暫未完成二維工程圖。 5. 畢業(yè)設(shè)計說明書的撰寫要領(lǐng)與格式、答辯準(zhǔn)備： （1）畢業(yè)設(shè)計說明書撰寫： 1、要領(lǐng)：①上蓋注塑工藝分析：ABS材料的工藝性分析；上蓋塑件的工藝與結(jié)構(gòu)分析。 ②上蓋模具結(jié)構(gòu)設(shè)計：上蓋型腔、型芯的設(shè)計；上蓋型腔數(shù)目、型腔排布位置、澆口設(shè)計、各系統(tǒng)的設(shè)計；上蓋模具結(jié)構(gòu)的設(shè)計；二維工程圖的確定。 2、格式：第一章 塑件的設(shè)計 第二章 注塑成型模具的設(shè)計 第三章 標(biāo)準(zhǔn)模架的選用 第四章 合模導(dǎo)向機構(gòu)的設(shè)計 第五章 抽芯系統(tǒng)的設(shè)計 第六章 推出機構(gòu)的設(shè)計 第七章 溫度調(diào)節(jié)系統(tǒng)的設(shè)計 第八章 模具的裝配 第九章 模具材料 第十章 模具壽命與維護(hù) （2）答辯準(zhǔn)備：①完成科研訓(xùn)練、外文翻譯、開題報告、畢業(yè)論文等文字說明； ②完成上蓋塑件零件、上蓋模具的三維結(jié)構(gòu)圖及二維工程圖等繪圖說明； ③制作答辯PPT：總結(jié)畢業(yè)設(shè)計的簡要精確要點； ④組織答辯言語內(nèi)容及問題分析，完成答辯。 6. 主要參考文獻(xiàn) [1] 游劍文.注射成型塑料制品常見缺陷及其解決方案[J].科技經(jīng)濟(jì)市場.2010,(6)：6-7. [2] 齊衛(wèi)東.塑料模具設(shè)計與制造[M].北京:高等教育出版社,2004 [3] 葉久新.王群.塑料成型工藝及模具設(shè)計[M].機械工業(yè)出版社.2007:11. [4] 張維合.瓶蓋注射模設(shè)計[J].模具工業(yè),2009,35(9). [5] 彭建生 模具設(shè)計與加工速查手冊. 機械工業(yè)出版社, 2004 [6] 郭廣思.注塑成型技術(shù)[M].北京:機械工業(yè)出版社,2002. [7] 劉昌祺.塑料模具設(shè)計[M].北京:機械工業(yè)出版社,1998. [8] 王孝培.塑料成型工藝及模具簡明手冊[M].北京:機械工業(yè)出版社,2000. [9] 劉昌祺. 塑料模具設(shè)計[M]. 機械工業(yè)出版社, 1998 [10] 何修旭，黃瑤，王雷剛. 基于Pro/E和Master CAM的注塑模設(shè)計與加工[J].模具技術(shù). 2010,（1）: 40-43，63. [11] 石艷，黃亞純，黃文權(quán).注塑模具的CAD/CAM[J]. 重慶工學(xué)院學(xué)報.2005,（1）:31-33，43. [12] 陳萬林. 實用塑料注射模設(shè)計與制造[M]. 機械工業(yè)出版社, 2002 [13] 卜新建. 塑料模具設(shè)計[M]. 中國輕工業(yè)出版社, 2005 [14] 李海梅.申長雨. 注塑成型及模具設(shè)計實用技術(shù)[M]. 化學(xué)工業(yè)出版社, 2002 [15] 塑料模具技術(shù)手冊編委會.塑料模具技術(shù)手冊[M].北京:機械工業(yè)出版社,1997. [16] 許發(fā)樾. 實用模具設(shè)計與制造手冊[M]. 機械工業(yè)出版社, 2001 [17] 大連理工大學(xué)工程畫教研室. 機械制圖[M]. 高等教育出版社, 1993 [18] 廖念釗.莫雨松. 李碩根等. 互換性與技術(shù)測量[M]. 中國計量出版社, 2000 [19] Jong WR,Wu CH, Liu HH, Li MY (2009) A collaborative navigation system for concurente mold design. Int J Adv Manuf Technol 40(3–4):215–225 [20] Low MLH,Lee KS (2003) Application of standardization for initial design of plastic injection moulds. Int J Prod Res 41:2301– 2324 [21] Lin BT,Chang MR, Huang HL, Liu CHY (2008) Computeraided structural design of drawing dies for stamping processes based on functional features. Int J Adv Manuf Technol 42:1140–1152 [22] Zhou H, Shi S, Ma B (2009) A virtual injection molding system based on numerical simulation. Int J Manuf Technol 40:297–306 7. 檢索關(guān)鍵詞（中英）： （1）塑料 注塑模 Pro/e CAD （2）plastic injection mold Pro / e CAD A CAD/CAE-integrated injection mold design system for plastic products Abstract ?Mold design is a knowledge-intensive process. This paper describes a knowledge-based oriented, parametric, modular and feature-based integrated computer-aided design/computer-aided engineering (CAD/CAE) system for mold design. Development of CAx systems for numerical simulation of plastic injection molding and mold design has opened new possibilities of product analysis during the mold design. The proposed system integrates Pro/ENGINEER system with the specially developed module for the calculation of injection molding parameters, mold design, and selection of mold elements. The system interface uses parametric and CAD/CAE feature-based database to streamline the process of design, editing, and reviewing. Also presented are general structure and part of output results from the proposed CAD/ CAE-integrated injection mold design system. Keywords ?Mold design . Numerical simulation . CAD . CAE 1 Introduction Injection molding process is the most common molding process for making plastic parts. Generally, plastic injection molding design includes plastic product design, mold design, and injection molding process design, all of which contribute to the quality of the molded product as well as production efficiency [1]. This is process involving many design parameters that need to be considered in a concurrent manner. Mold design for plastic injection molding aided by computers has been focused by a number of authors worldwide for a long period. Various authors have developed program systems which help engineers to design part, mold, and selection parameters of injection molding. During the last decade, many authors have developed computer-aided design/computer-aided engineering (CAD/CAE) mold design systems for plastic injection molding. Jong et al. [2] developed a collaborative integrated design system for concurrent mold design within the CAD mold base on the web, using Pro/E. Low et al. [3] developed an application for standardization of initial design of plastic injection molds. The system enables choice and management of mold base of standard mold plates, but does not provide mold and injection molding calculations. The authors proposed a methodology of standardizing the cavity layout design system for plastic injection mold such that only standard cavity layouts are used. When standard layouts are used, their layout configurations can be easily stored in a database. Lin at al. [4, 5] describe a structural design system for 3D drawing mold based on functional features using a minimum set of initial information. In addition, it is also applicable to assign the functional features flexibly before accomplishing the design of a solid model for the main parts of a drawing mold. This design system includes modules for selection and calculation of mold components. It uses Pro/E modules Pro/Program and Pro/Toolkit, and consists of modules for mold selection, modification and design. Deng et al. [6, 7] analyzed development of the CAD/CAE integration. The authors also analyzed systems and problems of integration between CAD and CAE systems for numerical simulation of injection molding and mold design. Authors propose a feature ontology consisting of a number of CAD/CAE features. This feature represents not only the geometric information of plastic part, but also the design intent is oriented towards analysis. Part features contain the overall product information of a plastic part, wall features, development features (such as chamfer, ribs, boss, hole, etc.), treatment features which contain analysis-related design information and sub wall developed features. Wall and development features are so called “component features”. God ec et al. [8, 9] developed a CAE system for mold design and injection molding parameters calculations. The system is based on morphology matrix and decision diagrams. The system is used for thermal, rheological and mechanical calculation, and material base management, ? Fig. 1 General structure of integrated injection mold design system for plastic products ? but no integration with commercial CAx software is provided. Huang et al. [10] developed a mold-base design system for injection molding. The database they used was parametric and feature-based oriented. The system used Pro/E for modeling database components. Kong et al. [11] developed a parametric 3D plastic injection mold design system integrated with solid works. Other knowledge-based systems, such as IMOLD, ESMOLD, IKMOULD, and IKBMOULD, have been developed for injection mold design. IMOLD divides mold design into four major steps; parting surface design, impression design, runner system design, and mold-base design. The software uses a knowledge-based CAD system to provide an interactive environment, assist designers in the rapid completion of mold design, and promote the standardization of the mold design process. IKB-MOULD application consists of databases and knowledge bases for mold manufacturing. Lou et al. [12] developed an integrated knowledge-based system for mold base design. The system has module for impression calculation, dimension calculation, calculation of the number of mold plates and selection of injection machine. The system uses Pro/ Mold Base library. This paper describes KBS and key technologies, such as product modeling, the frame-rule method, CBS,? and the neural networks. A multilayer neural network has been trained by back propagation BP. This neural network adopts length, width, height and the number of parts in the mold as input and nine parameters (length, width, and height of up and down set-in, mold bases side thickness, bottom thickness of the core, and cavity plates) as output. Mok et al. [13, 14] developed an intelligent collaborative KBS for injection molds. Mok at el. [15] has developed an effective reuse and retrieval system that can register modeled standard parts using a simple graphical user interface even though designers may not know the rules of registration for a database. The mold design system was developed using an Open API and commercial CAD/computer aided manufacturing (CAM)/CAE solution. The system was applied to standardize mold bases and mold parts in Hyundai Heavy Industry. This system adopted the method of design editing, which implements the master model using features. The developed system provides methods whereby designers can register the master model, which is defined as a function of 3D CAD, as standard parts and effectively reuse standard parts even though they do not recognize the rules of the database. Todic et al. [16] developed a software solution for automated process planning for manufacturing of plastic injection molds. This CAD/CAPP/CAM system does not provide CAE calculation of parameters of injection molding and mold design. Maican et al. [17] used CAE for mechanical, thermal, and rheological calculations. They analyzed physical, mechanical, and thermal properties of plastic materials. They defined the critical parameters of loaded part. Nardin et al. [18] tried to develop the system which would suit all the needs of the injection molding for selection of the part–mold–technology system. The simulation results consist of geometrical and manufacturing data. On the basis of the simulation results, part designers can optimize part geometry, while mold designers can optimize the running and the cooling system of the mold. The authors developed a program which helps the programmers of the injection molding machine to transfer simulation data directly to the machine. Zhou et al. [1] developed a virtual injection molding system based on numerical simulation. Ma et al. [19] developed standard component library for plastic injection mold design using an object-oriented approach. This is an objector iented, library model for defining mechanical components parametrically. They developed an object-oriented mold component library model for incorporating different geometric topologies and non-geometric information. Over the years, many researchers have attempted to automate a whole ? ? Fig. 2 Structure of module for numerical simulation of injection molding process ? Fig. 3 Forms to define the mold geometry mold design process using various knowledge-based engineering (KBE) approaches, such as rule-based reasoning (RBR), and case base (CBR) and parametric design template (PDT). Chan at al. [20] developed a 3D CAD knowledge-based assisted injection mold design system (IKB mold). In their research, design rules and expert knowledge of mold design were obtained from experienced mold designers and handbooks through various traditional knowledge acquisition processes. The traditional KBE approaches, such as RBR, CBR, and simple PDT have been successfully applied to mold cavity and runner layout design automation of the one product mold. Ye et al. [21] proposed a feature-based and object-oriented hierarchical representation and simplified symbolic geometry approach for automation mold assembly modeling. The previously mentioned analysis of various systems shows that authors used different ways to solve the problems of mold design by reducing it to mold configureator (selector). They used CAD/CAE integration for creating precision rules for mold-base selection. Many authors used CAE system for numerical simulation of injection molding to define parameters of injection molding. Several also developed original CAE modules for mold and injection molding process calculation. However, common to all previously mentioned systems is the lack of module for calculation of mold and injection molding parameters which would allow integration with the results of numerical simulation. This leads to conclusion that there is a need to create a software system which integrates parameters of injection molding with the result obtained by numerical ? ? Fig. 4 Forms to determine the distance between the cooling channels and mold cavity ? Fig. 5 Mold-base selector forms simulation of injection molding, mold calculation, and selection. All this would be integrated into CAD/CAE-integrated injection mold design system for plastic products. ? 2 Structure of integrated CAD/CAE system As is well known, various computational approaches for supporting mold design systems of various authors use design automation techniques such as KBE (RBR, CBR, PDT) or design optimisation techniques such as traditional (NLP,LP, BB, GBA, IR, HR) or meta heuristic search such as (TS, SA, GA) and other special techniques such as (SPA, AR, ED). The developed interactive software system makes possible to perform: 3D modeling of the parts, analysis of part design and simulation model design, numerical simulation of injection molding, and mold design with required calculations. The system consists of four basic modules: & Module for CAD modeling of the part & Module for numerical simulation of injection molding process ? Fig. 6 Form for mechanical mold calculation & Module for calculation of parameters of injection molding and mold design calculation and selection & Module for mold modeling (core and cavity design and design all residual mold components) The general structure of integrated injection mold design system for plastic products is shown in Fig. 1. ? 2.1 Module for CAD modeling of the part (module I) The module for CAD modeling of the part is the first module within the integrated CAD/CAE system. This module is used for generating CAD model of the plastic product and appropriate simulation model. The result of this module is solid model of plastic part with all necessary? geometrical and precision specifications. Precision specifications are: project name, number, feature ID, feature name, position of base point, code number of simulation annealing, trade material name, material grade, part tolerance, machine specification (name, clamping force, maximal pressure, dimensions of work piece), and number of cavity. If geometrical and precision specification is specified (given) with product model, the same are used as input to the next module, while this module is used only to generate the simulation model. ? 2.2 Module for numerical simulation of injection molding process (module II) Module II is used for numerical simulation of injection molding process. User implements an iterative simulation process for determining the mold ability parameters of injection molding and simulation model specification. The structure of this module is shown in Fig. 2. After a product model is imported and a polymer is selected from the plastic material database, user selects the best location for gating subsystem. The database contains rheological, thermal, and mechanical properties of plastic materials. User defines parameters of injection molding and picks the location for the gating subsystem. Further analyses are carried out: the plastic flow, fill time, injection pressure, pressure drop, flow front temperature, presence of weld line, presence of air traps, cooling quality, etc. The module offers four different types of mold flow analysis. Each analysis is aimed at solving specific problems: & Part analysis—This analysis is used to test a known gate location, material, and part geometry to verify that a part will have acceptable processing conditions. & Gate analysis—This analysis tests multiple gate locations and compares the analysis outputs to determine the optimal gate location. & Sink mark analysis—This analysis detects sink mark locations and depths to resolve cosmetic problems before the mold is built eliminating quality disputes that could arise between the molder and the customer. The most important parameters are the following: [22] & Part thickness & Flow length & Radius and drafts, & Thickness transitions & Part material & Location of gates & Number of gates & Mold temperature & Melt temperature & Injection pressure & Maximal injection molding machine pressure In addition to the previously mentioned parameters of injection molding, the module shows following simulation results: welding line position, distribution of air traps, the distribution of injection molding pressure, shear stress ? Fig. 7 Segment of the mechanical calculation algorithm distribution, temperature distribution on the surface of the simulation model, the quality of filling of a simulation model, the quality of a simulation model from the standpoint of cooling, and time of injection molding [22, 23]. A part of output results from this module are the input data for the next module. These output results are: material grade and material supplier, modulus of elasticity in the flow direction, modulus of elasticity transverse direction, injection pressure, ejection temperature, mold temperature, melting temperature, highest melting temperature thermoplastic, thermoplastic density in liquid and solid state, and maximum pressure of injection molding machine. During implementation of iterative SA procedure, user defines the moldability simulation model and the parameters of injection molding. All results are represented by different colors in the regions of the simulation model. ? 2.3 Module for calculation of parameters of injection molding and mold design calculation and selection (module III) This module is used for analytical calculations, mold sizing, and its selection. Two of the more forms for determining the dimensions of core and cavity mold plates are shown in Fig. 3. Based on the dimensions of the simulation model and clamping force (Fig. 3) user selects the mold material and system calculates the width and length of core and cavity plates. Wall thickness between the mold cavity to the cooling channel can be calculated with the following three criteria: criterion allowable shear stress, allowable bending stress criterion, and the criterion of allowable angle isotherms are shown in Fig. 4 [22, 24]. The system adopts the maximum value of comparing the values of wall thickness calculated by previously mentioned criteria. ? Fig. 8 Forms for standard mold plates selection ? Fig. 9 Forms for mold plate model generation Based on the geometry of the simulation model, user select shape and mold type. Forms for the selection mold shape, type, and subsystems are shown in Fig. 5. Once these steps are completed, user implements the thermal, rheological, and mechanical calculation of mold specifications. An example of one of the several forms for mechanical mold calculation is shown in Fig. 6. Segment of the algorithm of mechanical calculations is????? shown in Fig. 7. Where, fmax ????maximal flexure of cavity plate fdop? ???allowed displacement of cavity plate ε ?????elastic deformation αmin ???minimal value of shrinkage factor Ek??????? ?modulus of elasticity of cavity plate G????? ?shear modulus Sk ?????wall thickness distance measuring between cavity and waterline dKT ???????cooling channel diameter After the thermal, rheological, and mechanical calculations, user selects mold plates from the mold base. Form for the selection of standard mold plates is shown in Fig. 8. The system calculates the value of thickness of risers, fixed, and movable mold plates (Fig. 8). Based on the calculated dimensions, the system automatically adopts the first major standard value for the thickness of risers, movable, and fixed mold plate. Calculation of the thickness and the adoption of standard values are presented in the form as shown in Fig. 8. The interactive system recommends the required mold plates. The module loads dimensions from the database and generates a solid model of the plate. After the plate selection, the plate is automatically dimensioned, material plate is ? Fig. 10 Structure of module IV assigned, and 3D model and 2D technical drawing are generated on demand. Dimensions of mold component (e.g., fixed plate) are shown in the form for mold plate mode generation, as shown in Fig. 9. The system loads the plate size required from the mold base. In this way, load up any other necessary standard mold plates that make up the mold subassembly. Subassembly mold model made up of instance plates are shown in Fig. 10 Then get loaded other components of subsystems as shown in Fig. 5. Subsystem for selection other components include bolts and washers. The way of components selection are based on a production rules by authors and by company “D-M-E” [25, 26]. ? 2.4 Module for mold modeling (core and cavity design and design all residual mold components; module IV) This module is used for CAD modeling of the mold (core and cavity design). This module uses additional software tools for automation creating core and cavity from simulation (reference) model including shrinkage factor of plastics material and automation splitting mold volumes of the fixed and movable plates. The structure of this module is shown in Fig. 11. Additional capability of this module consists of software tools for: & Applying a shrinkage that corresponds to design plastic part, geometry, and molding conditions, which are computed in module for numerical simulation & Make conceptual CAD model for nonstandard plates and mold components & Design impression, inserts, sand cores, sliders and other components that define a shape of molded part & Populate a mold assembly with standard components such as new developed mold base which consists of DME mold base and mold base of enterprises which use this system, and CAD modeling ejector pins, screws, and other components creating corresponding clearance holes & Create runners and waterlines, which dimensions was calculated in module for calculating of parameters of injection molding and mold design calculation and selection & Check interference of components d