開發(fā)注塑塑料零件變形分析的測試方法中英文翻譯、外文文獻翻譯
開發(fā)注塑塑料零件變形分析的測試方法中英文翻譯、外文文獻翻譯,開發(fā),注塑,塑料零件,變形,分析,測試,方法,法子,中英文,翻譯,外文,文獻
外文出處: Polymer Testing 30 (2011) 5435471外文資料翻譯譯文(約 3000 漢字):開發(fā)注塑塑料零件變形分析的測試方法J.G. Iovacs*, B. SilcloDepartment of Polymer Engineering, Budapest University of Technology and Economics,H-1111 Budapest, Mhegyetem rkp. 3, Hungary摘要:描述注塑塑料零件的彎曲不是一定的,而且由于彎曲的過程其本質(zhì)是很復雜的, 所以這是很嚴重的問題。本文提出一種分析和測量注塑塑料零件變形的新方法。在彎曲方面特別介紹了一個特定的部分用一個特殊的模具設計,用以描述不同的工藝參數(shù)和模具的影響元素設計。通過實驗的使用證明了系統(tǒng)的適用性。通過調(diào)查模具溫度的影響, 模具溫度的差異,保持壓力和玻璃纖維材料研究使用不同的模具澆口類型。此外,評估彎曲的新的軟件正在開發(fā)。根據(jù)結(jié)果,得出的結(jié)論是,沿著邊緣角的變形長度可以由曲線進行描述。關鍵詞: 注塑模具;注塑變形;彎曲角效果1.介紹注塑熱塑性塑料部件的質(zhì)量很大程度上取決于所使用的工藝參數(shù)和模具設計。注塑塑料零件的一個主要問題是彎曲引起的不均勻收縮。冷卻不均勻,收縮不均勻和取向嚴重影響了這種變形。幾個研究人員研究了彎曲的形成和特點而且使用各種方法,特別是多種類型的標本幾何圖形。許多研究調(diào)查使用矩形板收縮標本,并且這個幾何的應用程序擴展到翹曲測量。唐家璇等用變形的部分確定刻度盤介紹 two-cavity,two-plate 注塑模具生產(chǎn)丙烯腈丁二烯苯乙烯(ABS)板材彎曲測試,。作者得出結(jié)論,彎曲主要是受熔體溫度的影響, 其次是包裝時間和包裝壓力。熱分析是進行檢查模具的熱殘余應力的影響。相關調(diào)查表明彎曲增強熱塑性塑料圓盤和顯示不同的取向引起的各種變形,也就是說,他們觀察了杯和構(gòu)象馬鞍的構(gòu)造。Kikuchi 和 Koyam 還分析了磁盤標本和盤子,他們引入了一個彎曲指數(shù)作為一種記錄注塑零件的特征。鄭等人也承認由于其簡單的幾何形狀,無法測量彎曲的標本注塑零件,并提出應該使用更復雜的形狀。他們繼續(xù)執(zhí)行測量肋板與注塑仿真模型, 但是他們只能想象肋的影響,而不是整個形變。詹森不僅在模具里研究了非晶態(tài)材料的彎曲還在 l 型標本不同圓角半徑和尖角。平板產(chǎn)品的翹曲被定位在三個支持評估針和測量長度的垂直位移上作為協(xié)調(diào)長度的函數(shù)。實驗表明, 模具在使用非晶聚合物的溫度之間的差異下形變線性增加。結(jié)果還表明,在低壓力下塑料朝熱端的方向彎曲, 而在高壓力下彎向冷端。半徑較大的角落比半徑較小的標本對模具溫度差異更敏感。比例角度偏轉(zhuǎn)的長度徑向部分是對結(jié)果的解釋。Akay 等人還分析了彎曲和溫度之間的關系差異的兩半模具。測量了變形的平板和 l 型標本并且用有限元軟件和坐標測試機進行了計算。然后,分析了使用統(tǒng)一的冷卻和溫度兩個下模之間的區(qū)別。觀察到一個更高的模具腔端的溫度導致增加的角角落的部分。一些調(diào)查使用框幾何分析翹曲 16。Kabanemi et al。17 用箱形部分分析翹曲。提出了不同情況下顯示的在變形和殘余應力下影響的幾何形狀的復雜性。得出結(jié)論,不對稱熱剖面是負責彎曲引起的彎矩。得出結(jié)論,不對稱熱剖面是負責彎曲引起的彎矩。Mlekusch18 分 析 了 翹 曲 與 各 種 類 型 的 專 門 設 計 的 部 分 角 落 。 對 于short-fibre-reinforcement 的影響進行了研究,認為是材料的各向異性。多層模型用來計算圓柱段的冷卻。模型預測與實驗測量比較顯示,附加彎曲觀察材料可以歸因于材料的各向異性。里奇- et al。19使用一個有四個角不同的半徑的標本。他們得出結(jié)論,造成彎曲有兩種現(xiàn)象: 第一個是不對稱冷卻,第二個是春天的遠期效果。由于厚度方向的熱膨脹系數(shù)的增大,增強了春天的遠期效應生成纖維材料。變形轉(zhuǎn)角和最初的變形平面是杰出的。相同的模具溫度誘導兩個模具的顯著角變形為 30 - 50。兩模之間的部分有 40 0 的不同引起約 1.50 的角度的變化。本研究的目的是不僅是創(chuàng)建標本,而且是描述彎曲的一個復雜的方法。主要目標是設計和創(chuàng)建一個特定的樣品和模具,它允許以不同的方式獲得變形。2方法和測量設備描述彎曲的注塑零件的角落,設計了一個特殊的部分。主要目標是衡量不同技術參數(shù)在彎曲模具的模具設計或材料屬性的影響。生產(chǎn)所謂的 V-top 標準,一個特殊的模具設計和多變的變量插入(圖 1),構(gòu)造的嵌件注塑滑進可快速調(diào)換的框架,并且一個插線孔有兩個可變的澆到體系。模具的固定的側(cè)面僅僅包含了唯一的可變的型腔嵌件;改變這些嵌件允許將部分的壁厚變化,用這些方法,可以選為壁厚 1mm 或 2mm。頂端的門鎖裝置完美的使兩個模具兩等分,保證厚度均勻的部分。圖 1 插入移動和固定的模具 3 十 1 門在變形中,材料的方向和注射位置的定位有顯著的效果,因此,三個不同的閘口類型在之前的模型中被用作門插入(如圖 2)。一個標準的閘口前面的邊緣,一個標準的門的邊緣,或者沿著整個邊緣的電影門。圖 2 門的設計:a)標準門在前面的邊緣,b)標準門的中間,c)膜狀澆口沿著整個邊緣V-top 本近 900 年一個角度,造成的變形技術或其他參數(shù)可以通過改變這幾個角度來量化。除了單向的窩洞填充外,雙向的填充可以實現(xiàn)可旋轉(zhuǎn)的插入的應用(如圖 3)。在角落,這些特點允許調(diào)查焊線20的影響。圖 3插入可旋轉(zhuǎn)的 V-top 標本變形受冷卻的高度影響,在角落里是非常重要的。模具的核心的散熱速度必須比腔快, 否則,內(nèi)部區(qū)域的角落凝固速度較慢,導致它自身被磨角。面對高要求的變形測試,高效的冷卻系統(tǒng)是必須的(如圖 4)。對于最高的控制精確度,溫度傳感器將被安裝進模具的核心和腔。不僅是溫度,而且壓力控制也很重要。由于這個原因,兩個壓力傳感器將會被安裝;一個距離閘門 5mm,一個在年底前流路徑的 5mm 處。在這些傳感器的幫助下,轉(zhuǎn)換點會被精確的控制,這是基本穩(wěn)定和一致的重要性。圖 4 模具的冷卻系統(tǒng)V-top 樣本的變形評估,特殊的圖像分析軟件被開發(fā)。軟件的掃描圖像分析的標本和關閉角沿著邊緣的長度計算拐角點的步驟(如圖 5)。圖 5 計算關閉角理論的圖像3實驗在這項研究中,實驗的進行證明了測量技術的效率。整潔的聚丙烯與玻璃纖維和聚丙烯增強不同重量的內(nèi)容為(10、20、30 wt ),在一個廣泛的變形部分檢查全面評估的新方法。矩陣(北歐化工、HD120M0)和玻璃纖維混合在 Brabender 塑度計雙螺桿擠出機,和一個 Brabender 制粒機是用于生產(chǎn)擠出物的顆粒。V-top 標本是注塑的 Arburg 全能球員3200 c 600 - 250 注塑成型機。標本被塑造的厚度為 2 毫米使用所有 3 門的類型。對玻璃纖維含量的影響,溫度移動一側(cè)的模具(30、50、70 0 c)和壓力的保持(100、300、500 條) 進行分析。所有其他工藝參數(shù)保持不變。熔體溫度是 230 0 c,固定的模具的溫度保持時間是 5 s,注入率為 50 15 秒冷卻時間。切換壓力傳感器達到 25 條。4. 結(jié)果與討論所述空腔之間的區(qū)別被控制體重的測量,顯示出從不同的腔中的樣本的權(quán)重之間的相關系數(shù)為 0.994。因此,可以得出結(jié)論,試件的重量是獨立的腔體,和變形在上模腔中產(chǎn)生的試樣的外邊緣進行分析。該實驗的典型結(jié)果示于圖 6,具有關閉角為相對邊緣長度的函數(shù)??梢钥闯觯摐y量是準確的,標準偏差是比較小的在每個測量點。柵型的影響進行了分析,其結(jié)果表明, 熔體入口點和類型,因為它們穿過材料(圖 6)的定向性的影響,結(jié)果不能被忽略。圖 6 影響關閉位置角沿著邊緣的相對位置的函數(shù)(模具溫度:70 0,纖維內(nèi)容:20%,持有壓力:300)下面,一些成果將提交給驗證了該方法的廣泛適用性。實驗結(jié)果表明,在保持壓力對純 PP(圖 7)的變形有很大影響??拷战堑谋3謮毫τ休^小影響,而進一步遠離拐角的角度的增加而增加保持壓力。圖 7 在 5%和 85%位置拐角角度保壓壓力(圖 8)的纖維含量分別降低翹曲。然而,兩個半模之間的溫度差對翹曲的影響最大。當用于較高的模具溫度對可動模具側(cè),試件的表面之間的閉合角減小為一個較大的變形的結(jié)果。正在分析變形為沿著邊緣的相對位置的函數(shù),它被觀察到,在截止角單調(diào)減少,與角度的依賴于移動模側(cè)的(圖 9)的溫度的斜率。圖 8 持有關閉壓力角的影響作為相對位置的功能纖維內(nèi)容(模具沿邊緣:50%)圖 9 動模側(cè)的溫度的影響在關閉角的函數(shù)沿邊緣的相對位置(持有壓力:100)5、總結(jié)在本論文中,介紹了一種新的測量方法,來分析注塑塑料零件。就是最新引進的 V-top 樣本,允許調(diào)查不同變形工藝的參數(shù)和材料性能的影響。另外一種新的可變形的注塑模具設計和建造 V-top 標本的生產(chǎn)。這個新方法是經(jīng)過測試的,并且經(jīng)過了實驗的研究, 門類型和位置的影響,材料的玻璃纖維含量,模具溫度不同,限檔壓力也會被研究?;趯嶒灁?shù)據(jù),得出結(jié)論,翹曲強烈依賴于纖維內(nèi)容和模具溫度,但是當使用聚丙烯和玻璃纖維時,這幾乎不依賴于限檔壓力。這些實驗強有力的支持了新的翹曲分析技術,相對于以前的翹曲測量方法有一個很大的優(yōu)勢。參考文獻1J.M.Fischer,HandbookofMouldedPartShrinkageandWarpagefirsted.Plastics Design Library/William Andrew Inc, Norwich, 2003.2M. 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Keizer, Warpage of injection moulded plates and corner products, Int. Polym. Proc. 13 (4) (1998) 417.9M. Akay, S. Ozden, T. Tansey, Prediction of process-induced warpage in injection moulded thermoplastics, Polym. Eng. Sci. 1996 (13) (1839) 36.10S.H. Tang, Y.J. Tan, S.M. Sapuan, S. Sulaiman, IV. Ismail, R. Samin, The use of Taguchi method in the design of plastic injection mould for reducing warpage, J. Mater. Process Tech. 182 (1-3) (2007) 418.11S.H. Tang, Y.M. Kong, S.M. Sapuan, R. Samin, S. Sulaiman, Design and thermal analysis of plastic injection mould, J. Mater. Process Tech. 171 (2) (2006) 259.12E.J. Fahy, Modeling warpage in reinforced polymer disks, Polym.Eng. Sci. 38 (7) (1998) 1072.13H. Kikuchi, K. Koyama, Generalized warpage parameter, Polym. Eng.Sci. 36 (10) (1996) 1309.14H. Kikuchi, K. Koyama, The relation between thickness and warpage in a disk injection moulded from fibre reinforced PA66, Polym. Eng.Sci. 36 (10) (1996) 1317.15R. Zheng, P. Kennedy, IV. Phan-Thien, X.J. Fan, Thermoviscoelastic simulation of thermally and pressure-induced stresses in injection moulding for the prediction of shrinkage and warpage for fibre reinforced thermoplastics, J. IVon-Newton Fluid 84 (2-3) (1999) 159. 16K. Prashantha, J. Soulestin, M.F. Lacrampe, E. Lafranche, P. Krawczak G. Dupin, M. Claes,Taguchianalysisofshrinkageandwarpageofinjection-moulded polypropylene/multiwallcarbonnanotubes nanocomposites, Express Polym. Lett. 3 (10) (2009) 630.17K.K. Kabanemi, H. Vaillancourt, H. Wang, G. Salloum, Residual stresses, shrinkage, and warpage of complex injection moulded products: Numerical simulation and experimental validation Polym. Eng. Sci. 38 (1) (1998) 21.18B. Mlekusch, The warpage of corners in the injection moulding of short-fibre-reinforced thermoplastics, Compos Sci. Technol. 1999 (12)(1923)59.19A. Ammar, V. Leo, G. Regnier, Corner deformation of injected thermoplastic parts, Int. J. Form Proc. 6 (1) (2003) 53.20J.G.Kovacs, B. Siklb, Experimental validation of simulated weld line formation in injection moulded parts, Polym. Test. 29 (7) (2010) 910.21B. Solymossy, J.G. Kovacs, The examination of weld line properties in injection moulded PP composites, Mater. Sci. Forum 589 (2008) 263.2外文資料原文(與課題相關,至少 1 萬印刷符號以上):Test method development for deformation analysis of injection moulded plastic partsJ.G. Kovcs*, B. SiklDepartment of Polymer Engineering, Budapest University of Technology and Economics, H-1111 Budapest, Mhegyetem rkp. 3, HungaryAbstract : The characterisation of warpage of injection moulded plastic parts is notstandardised and is extremely problematic due to the complex nature of the warping process. This paper presents a novel method for the analysis and measurement of the deformation of injection moulded plastic parts. A specic part with a special mould design was introduced for the characterisation of the effect of different technological parameters and different mould element design on warpage. The applicability of the system was demonstrated via its experimental use. The effects of mould temperature, mould temperature difference, holding pressure and the glass bre content of the material were investigated using different gate types in the mould. Additionally, new software was developed to evaluate warpage. Based on the results, it was concluded that the deformation of the corner along the edge length can be described by a curve.Keywords:Warpage Corner effect;Injection moulding; Deformation Injection mould1、IntroductionThe quality of injection moulded thermoplastic parts is largely determined by the process parameters and the mould design used. One of the main problems with injec- tion moulded plastic parts is warpage caused by non-uniform shrinkage. This deformation is strongly inuenced by non-uniform cooling, differential shrinkage and orientation effects 1.Several researchers have investigated the formation and characteristics of warpage using various methods, partic- ularly multiple types of specimen geometries. Many studies have investigated shrinkage using rectangular plate speci- mens 2,3, and the application of this geometry was extended to warpage measurements 49.Tang et al. 10,11 introduced a two-cavity, two-plate injection mould producing acrylonitrile butadiene styrene (ABS) plates for warpage testing, with deformation of the parts being determined with a dial gauge. The authors concluded that warpage was mostly inuenced by melt temperature, followed by packing time and packing pres- sure. Thermal analysis was performed to check the effect of any thermal residual stress in the mould.Fahy 12 investigated the warpage of reinforced ther- moplastics on a circular disk and showed that different orientation caused various deformations; namely, they observed cup- and saddle-shaped conformations. Kikuchi and Koyama 13,14 also analysed disk specimens and plates, and they introduced a warpage index as a means of recording the characteristics of injection moulded parts.Zheng et al. 15 acknowledged that plate-like speci- mens were incapable of measuring warpage of injection moulded parts because of their simple geometry, and proposed that a more complex shape should be used. They continued to perform measurements with the injection moulding simulation on a ribbed plate model, but they were only able to visualise the effect of the rib and not the entire deformation 15.Jansen 8 studied the warpage of amorphous materials not only on plates but also on L-shaped specimens with different corner radii and sharp corners. The warpage of at plate products was assessed by positioning the plate onthree supporting pins and measuring the vertical displacement as a function of the length coordinate. The experiments showed that deformation linearly increased with the difference between the temperatures of the mould halves when using amorphous polymers. The results also showed that at low holding pressure the plates curved towards the hot side, whereas at high holding pressure the plates curved towards the cold side. The corners with larger radii were more sensitive to mould temperature differences than were specimens with smaller radii. The result was explained by the proportionality of the angle deection to the length of the radial section.Akay et al. 9 also analysed the relationship between warpage and the temperature difference of the two halves of the mould. The deformation of both the at plate and the L-shaped specimens was measured and calculated with nite element software and a coordinate-measuring machine. Then, it was analysed using uniform cooling and also withtemperature difference between the two mould halves. It was observed that a higher mould temperature on the cavity side resulted in increase of the angle in the corner of the part.Some investigations used box geometry for warpage analysis 16,17. Kabanemi et al.17 analysed warpage on box-like parts. Different cases were presented to show the inuence of the geometrical complexity of the shape on the deformations and residual stresses. It was concluded that the asymmetrical thermal prole was responsible for the bending moment that caused warpage.Mlekusch 18 analysed the warpage on a specically designed part with various types of corners. The effect of short-bre-reinforcement was studied and attributed to the anisotropy of the material. A multi-layer model was used to calculate the cooling of a cylindrical segment. The model predictions were compared with experimental measurements showing that the additional warpage observed for short-bre-reinforced materials could be attributed to the anisotropy of the material.Ammar et al. 19 used a specimen with four corners with different radii. They concluded that two phenomena caused warpage: the rst was asymmetrical cooling and the second was the spring forward effect. The spring forward effect was generated in bre-reinforced materials due to the higher thermal expansion coefcient in the thickness direction. The deformation around the corner and the deformation of the initially at surfaces were distinguished. Using polypropylene (PP) in their experi- ments, equal mould temperatures in both mould halves induced a signicant angle deformation of 3oand 5o. A difference of 40 oC between the two mould halves caused an angle variation of about 1.5.The aim of this research was to create not only a spec- imen but also a complex method for warpage character- isation. The main goal was to design and create a specic sample and mould, which allows deformation measure- ments to be obtained in different manners.2、Methodology and measuring equipmentTo characterise the warpage at the corners of injection moulded parts, a special part was designed. The main goal was to measure the effect of varying technological param- eters, mould design or material properties on warpage.To produce the so called V-top specimens, a special mould was designed with changeableand variable inserts (Fig. 1.). The constructed insert mould slides into a quick- change frame and has two cavities with a variable runner system. The stationary side of the mould contains only the changeable cavity inserts; changing these inserts allows the parts wall thickness to be varied. In this way, the wall thickness can be chosen as either 1 mm or 2 mm. Top locks guarantee the perfect closing of the two mould halves assuring a uniform part thickness.The orientation of the material and the positioning of the injection location have signicant effects on the deformation. Therefore, three different gate types can be used by changing the gate inserts in the mould (Fig. 2.): a standard gate at the front of the edge, a standard gate at the middle of the edge or a lm gate along the whole edge. The sides of the V-top specimen close an angle of 90o, and the deformation caused by the technological or other parameters can be quantied by changing this angle. In addition to unidirectional cavity lling, bidirectional lling can be achieved with the application of rotatable inserts (Fig. 3.). This feature allows investigation of the inuence ofthe weld lines 20,21 at the corners.Warpage is highly inuenced by cooling and is very signicant at corners. The core of the mould has to dissipate heat faster than the cavity; otherwise the internal area of the parts corner solidies slower and causes a sharpening of the corner itself. To meet the high requirements of warpage tests, an efcient cooling system is required (Fig. 4.). For the highest control precision, temperature sensors were installed into both the core and the cavity of the mould. Not only the temperature but also the pressure control is important. For this reason, two pressure sensors were mounted; one at a distance of 5 mm from the gate (PGS; post-gate-sensor) and one at a distance of 5 mm before the end of the ow path (EOC; end-of-cavity sensor). With the help of these sensors, the switchover point can be controlled precisely, which is of fundamental importance for a stable and consistent cycle.To evaluate the warpage of the V-top specimen, special image analysis software was developed. The software analysed scanned images of the side of the specimens and calculated the closing angle along the edge length from the corner point (Fig. 5.) in 5% steps.3、ExperimentalIn this study, experiments were carried out to prove the efciency of the novel measuring technique. Neat poly- propylene and polypropylene reinforced with glass bre of different weight contents (10, 20, 30 wt%) were examined to comprehensively evaluate the new method in a wide range of deformed parts. The matrix (Borealis, HD120MO) and the glass bres were mixed on a Brabender Plasticorder twin-screw extruder, and a Brabender pelletizer was used to produce pellets from the extrudate. From these mate- rials, V-top specimens were injection moulded on an Arburg Allrounder 320oC 600250 injection moulding machine. The specimens were moulded with a thickness of 2 mm using all 3 gate types. The effects of glass bre content, temperature of the moving side of the mould (30, 50, 70 oC) and holding pressure (100, 300,500 bar) were analysed. All other technological parameters were kept constant. The melt temperature was 230 oC, the tempera- ture of the stationary side of the mould was 50 oC, the holding time was 5 s, the injection rate was 50 cm3/s and the cooling time was 15 s. The switchover took place when the end-of-cavity pressure sensor reached 25 bar.4、Results and discussionThe difference between the cavities was controlled with weight measurements, showing that the correlation between the weights of the samples from the different cavities was 0.994. Therefore, it was concluded that spec- imen weight is independent of the cavity, and deformation was analysed on the outer edge of the specimens produced in the upper cavity.A typical result of the experiments is shown in Fig. 6, with the closing angle as a function of the relative edge length. It can be seen that the measurement is accurate and the standard deviation is relatively small at each measurement point. The inuence of gate type was ana- lysed, and it was shown that the melt entrance point and type cannot be neglected because they inuenced the results through the orientation of the material (Fig. 6).Below, some results will be presented to demonstrate the wide applicability of the method. The experimental results showed that the holding pressure had a consider- able effect on the deformation of neat PP (Fig. 7.). Close to the corner the holding pressure had a minor effect, whereas further away from the corner the angle increased with increase in holding pressure.Fibre content decreased warpage independently of holding pressure (Fig. 8.). However, the temperature difference between the two mould halves had the biggest effect on warpage. When higher mould temperatures on the movable mould side were used, the closing angle between the faces of the specimen was decreased as a result of a larger deformation. Analysing the deformation as a function of relative position along the edge, it was observed that the closing angle decreased monotonically, with the slope of the angle depending on the temperature of the moving mould side (Fig. 9.).5、ConclusionsIn this paper, a new measurement method was intro- duced for the deformation analysis of injection moulded plastic parts. The new
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