HPVC帶支承彎管成型工藝及注塑模具設計

HPVC帶支承彎管成型工藝及注塑模具設計,hpvc,支承,彎管,成型,工藝,注塑,模具設計 哈爾濱工業(yè)大學華德應用技術院 畢業(yè)設計（論文）中期報告 題 目：HPVC帶支撐彎管成型及模具設計 系 （部） 機電工程系 專 業(yè) 材料成型及控制工程 學 生 劉國軍 學 號 1069360112 班 號 0693601 指導教師 劉穎輝 開題報告日期 2009年11月27日 哈工大華德學院 說 明 一、中期報告應包括下列主要內容： 1．論文工作是否按開題報告預定的內容及進度安排進行； 2．目前已完成的研究工作及成果； 3．后期擬完成的研究工作及進度安排； 4．存在的困難與問題； 5．如期完成全部論文工作的可能性。 二、中期報告由指導教師填寫意見、簽字后，統(tǒng)一交所在系（部）保存，以備檢查。 指導教師評語： 指導教師簽字： 檢查日期： 一、論文工作是否按開題報告預定的內容及進度安排進行 1、論文工作按開題報告預定的內容及進度正常進行 二、目前已完成的研究工作及成果 1、塑件注射成型工藝性分析 2、模具總體方案設計 3、有關塑件尺寸計算 4、注射機選擇 5、分型面選擇 6、澆注系統(tǒng)選擇 7、成型零部件設計與計算 8、導向及脫模機構設計 9、標準模架的選擇 10、注射機有關參數(shù)校核 11、總裝圖的繪制 三、后期擬完成的研究工作及進度安排 1、11月27日-12月18日 完成部裝圖及零件圖設計 2、12月21日-12月31日 撰寫畢業(yè)設計論文及準備答辯 3、2010年1月6日-1月8日 畢業(yè)答辯 四、存在的困難與問題 1、側向分型與抽芯機構的設計 2、限位機構的設計 3、滑塊與導滑槽的設計 五、如期完成全部論文工作的可能性 1、根據(jù)進度安排可如期完成全部論文工作 哈爾濱工業(yè)大學華德應用技術學院 畢業(yè)設計（論文）任務書 學生姓名 劉國軍 系部 機電工程系 專業(yè)、班級 材料成型 指導教師姓名 劉穎輝 職稱 助教 從事 專業(yè) 模具 是否外聘 □是□否 題目名稱 HPVC帶支承彎管成型工藝及模具設計 一、設計（論文）目的、意義 隨著社會科學和塑料模具的進步及快速發(fā)展，人們對塑料制件的性能和質量也有了越來越高的要求，從而對制造業(yè)提出了越來越高的要求。由于塑料制件具有質量輕﹑比強度高﹑良好的可塑性，并易于成型等特點，得到了越來越廣泛的應用，使得塑料件成為日用品領域以及其他領域里經(jīng)常采用的結構件材料。從而使得注塑成型成為塑料成型件的重要方法，注塑模具也成為塑料制件成型必備的工具。 二、設計（論文）內容、技術要求（研究方法） 主要研究內容: 技術條件： 材料：HPVC 厚度：2mm 生產(chǎn)量：小批量 本課題以塑料彎管件為設計對象，制件外形及大體尺寸如上圖所示，要求采用HPVC為塑料材料。首先對制件特點和材料進行分析，制定合理的工藝方案并優(yōu)化模具結構；再進行模具結構設計計算，并利用三維設計軟件完成模具實體設計；最后完成工程圖紙繪制和設計計算說明書編寫。 三、設計（論文）完成后應提交的成果 1 HPVC帶支承彎管總裝圖及部裝圖設計，零號圖各1張； 2 定模型芯、動模型芯、滑塊零件圖設計，2或3號圖各1張； 3 寫畢業(yè)設計論文：10000字。 四、設計（論文）進度安排 ⒈第一階段：開題 10月12日—10月23日（2周） ⒉第二階段：設計階段（實驗工作階段） 10月26日—12月11日（7周） ⒊第三階段：撰寫畢業(yè)設計論文與準備答辯 12月14日—12月25日（2周） 五、主要參考資料 1、賴華清. 塑料模具及設計[M]. 北京. 機械工業(yè)出版社,2006 2、田雁晨，田寶善，王文廣.注塑模設計技巧與實例[M].化學工業(yè)出版社，2006 3、機械設計手冊編委會. 機械設計手冊[M]. 北京. 機械工業(yè)出版社. 2004 4、李德群. 中國模具設計大典第二卷[M]. 南昌. 江西科學技術出版社. 2003 5、王三民. 機械原理與設計[M]. 北京. 機械工業(yè)出版社. 2001 6、王衛(wèi)衛(wèi). 材料成形設備[M]. 北京. 機械工業(yè)出版社. 2004 六、備注 指導教師簽字： 年 月 日 教研室主任簽字： 年 月 日 It is the new-type inject by shaping technology 1. inject by shaping altogether( inject shaping of at core layers) Adopt and inject shaping help and observe and make one unique structure altogether. " first" of plastic is injected and fill and enter some types first, then the plastic: " second" follow " first" inject person who enter one and keep initial to drive pressure field of flowing closely. At epidermis district and core the sizes of one, measure and publish" first" and the materials quantities of" second" according to correct proportionate relationship, Make one at" first" complete at" second" to make one parcel appearance core each. In addition, in cosmetics application, the material is put after" second" material injecting to have" first" of epidermis of the small part, So that the epidermis of the part of the runner can be totally closed. Inject making one of shaping altogether with the resin of 2 kinds of different colors, form a piece of a layer of blocks of epidermis and core apt to distinguish (Realize inject shaping one as much as all have and have and one very much important this core similar epidermis. )If there is not advanced detection technique, usually difficult to distinguish the epidermis - core area and boundary of layer. Inject shaping a new technology altogether. British ici company began to use this technology in the 1970s early, and had made the basic theory of including, Produce several patents, such as the products and machinery equipment,etc.. Now similar to " mould mould sandwiches" what has been adopted generally ici production technologies,last outer the materials of the epidermis at moulds and in layers is material different on core occasionally, So two a kind of material person who a certain one inclusives, and core require and have high radiations very, issue and steep shaping and retrieve performance of utilizing etc at 100% by layers of material. Should be fixed relatively by the excellent choice to select the material for use. After injecting the shaping technology and come out in 15 altogether, can really just popularize and popularize . One a kind of adoptions inject the thick teeth of shaping fails and produces horizontal cross-section altogether. Material to pack nylon epidermis, and pearl material pack the nylon at - - glass layers of material core. A rate that shrinks material of pearl of glass is extremely low in core one, have good size stabilities. Nylon prevent pearl from grains of material easy problem of denuding that produces by epidermis person who give good and lubricated tooth tooth gear wheel. Already developed several kinds and processed the method of improving new-typly at present on the basis of the basic theory of injecting shaping altogether. At however, in the mould"" and gas assist paint mould mould. Mould have and paint processing method to adopt low molecular weight polymers as the outer material, Gas assist mould mould shaping to adopt the nitrogen or another kind of gas as the core one( or core ones) material. Produce and process equipment constant to perfect and improve, satisfy of different use newly and the new technologies demands with product design, Inject technology and will become the rich and potential industrialized extensive production technology method altogether. 2. inject by - it compress shaping Inject and compress shaping move perpendicular on dividing into mould line direction by medium-sized s of walls at -. Adopt the method at the shaping, fill mould stage and produce pressure drive melting body flow according to process, But this flowed the degree of depth of one melted variably. At flowing one deeply relatively, pressure drop relatively low, so that heavy areas make pieces of shaping excessive to pigeonhole melting body, And has prevented the material in the twinkling of an eye from responding, these 2 kinds of factors will hinder the flow of the melting body equally. It injects forming process type make pieces of the 14%s of thickness finally by s of degree of depth, After the plastic has been packed 60% - 75% of the type roughly, stop injecting, a of walls of mould is bulldozed at the same time , Until make the wall original shaping of one finally. The final size of making one is defined at this stage . If at mould wall at process fulling of more type before moving, this kind of technology is usually called and cast and press shaping. On the whole, cast and press shaping to adopt pressure that become to making one go on and protect and pigeonhole in one a piece of variable the type ones of volumeses. Cast and press stage to increase the stages of density, density and then in lying between and solid state plastic change melting body. Adopt and cast and press way shaping pre- pressing discs, remaining stress degree of minimising, Make pieces of have remain stress produce and become phenomenon of refracting. It cast and press shaping improvement type activities types types for kinds of new technology in s of walls,inject its make. Already someone call outside gas to assist shaping law the method, actually these are a kind of misunderstanding, Because the gas has not influenced the melting body flow in type of plastic . During routine inject shaping, protecting and press is while a of volume of keeping type does not change , Under the function that the pressure flows, add and enter more plastics. Unite, Being emerged by the runner position of the high pressure and making a defect probably. 3. computers supplementary shaping Adopt computer assist project( cae) design and analyse and help and shorten design cycle and prevent cost from expensive mechanical fault processing. Commercial emulations daily to indicate size on flowing one code, melt material flows in flowing dishes of system and type with balance, The figure of offeredding and put bestly and runner defining runner at the same time . Calculate pressure of injecting and shut mould want at different processing terms and material fix by tonnage. And warping rate combine initial to flow into too very accurate to estimate out person who shrink. What is important is and want and make the design tool help and analyse personnel process and go on the operation judged while studying or in a certain plan of design skillfully. Understand at results and can't process in order that it is by research object /materials from prerequisite. After consider adopting this kind of method accurate data-in , can make enormous benefit . In addition, economic make design cycle not to be short and needs produce shorter time the analysis. The one that should point out is, commercial cae procedures usually can't be used directly. It fills and imitate and produce valuable experience but the result must rethink its limitation to estimate again . Use modern computers go on and inject shaping simulated test and limited to pure viscidity fluids only( include the melting plastic of viscoplasticity ). One actual flow form measurable melting body person who flow intoes and performance announce etc. structure by speed, If can carry on the viscoplasticity analysis of high accuracy . At present adopt any other to process way reach this advanced competences, And recent years, at emulation the industrial circle person who take the leads of equipment and the research groups of university already made good progress. Have several a of companies make great efforts and probe emulation technology, in order to be be able to be being explained moulding the sex instinct act and process the phenomenon of more reality correctly. For example, get together on the influence that the orientation of the possessive chain is distributed to some physics performance and performance . Processing physics is very complicated, but some viscoplasticity is embodied too alike to still totally understood , Perfect the rational processing way and taking shape slow at present even more. These stronger strong ways will be exceeded the production capacity that will be designed at present greatly . 4. reversal inject shaping Comparatively speaking, it is that a relatively new inject shaping chooses parameters that the reversal is injected. The greatest difficult point of this technology is lain in when processing the condition suddenly changeses, To the thing that it will be known little about what kind of change behavior plastic melting body will demonstrate . About the rudimentary knowledge of melting body rheology, is not merely the regular shear . Say exactly , the melting body responds( the viscidity and elastic behavior) the characteristic needing expressing, Not only common stable state flow speed or shear speed and temperature, but also including pressure and flow the speed in the twinkling of an eye. These characteristics including a lot of content and very difficult to understand. However, if not in heterotypic materials inject respect make substantive progress, need and make and publish many kinds of different the concrete operational procedures of plasticses. Need and increase a in common use one tired to try on law is in order to getting ripe and accurate control method also another. During routine inject shaping, the type immobilizes in a of walls, some situations are left, Still utilize and filling on the mould and protect and press and fall section and move the mould wall . Can adopt 2 kinds of different methods : Person who move s of perpendicular on dividing into mould line direction wall; Rotate a of walls of the slipping type . Fill stage rotatory type cores with increasing mould. Through this kind of processing technology, the crooked performance and other mechanical performance of making one has gotten great improvement. Polyphenyl drink the water and polypropylene syringe adopt cup the processing method get great to change and break through the ground 2 a piece of products just by second.  新型注射成型技術 1. 共注射成型（芯層注射成型） ????采用共注射成型有助于觀察到制件中獨特的結構。塑料“甲”先注射充入部分型腔，然后塑料：“乙”緊跟著“甲”注射進入型腔并保持初始推動流動壓力場。根據(jù)表皮區(qū)和芯層的尺寸大小，按正確的比例關系計量出“甲”和“乙”的用料量，可制得1個內芯層為“甲”外表完全由“乙”包裹的制件。 ????另外，在化妝品應用方面，有小部分的表皮“甲”料放在“乙”料之后注射，以使?jié)部诓糠值谋砥つ芡耆]合。用2種不同顏色的樹脂進行共注射成型的制件，形成一個容易區(qū)分的表皮和芯層區(qū)間（認識到所有的注射成型件中存在有類似的表皮和芯層這一點非常重要。）如果沒有先進的檢測技術，通常難以區(qū)分表皮—芯層的區(qū)域及其分界面。 ????共注射成型并非一門新的工藝技術。英國ici公司早在70年代就開始應用這一技術，并取得了包括基礎理論，生產(chǎn)產(chǎn)品及機器設備等幾項專利?，F(xiàn)普遍采用的ici生產(chǎn)工藝類似“三明治模塑”，由于模塑外層表皮的材料與中間或芯層的材料不同，因此兩種材料必須有一定的相容性，并且芯層材料要求具有可高度輻射、發(fā)泡成型和100%回收利用等性能。選用材料應經(jīng)多種選擇比較而定。 共注射成型工藝問世15年后，才真正得以普及推廣。一種采用共注射成型的厚齒輸制作橫截面。 ????表皮材料是非填充尼龍，而芯層材料是玻璃-珠料-填充尼龍。芯層中玻璃珠粒料收縮率極低，具有良好的尺寸穩(wěn)定性。尼龍表皮賦予齒輪齒牙良好的潤滑性并避免了珠粒料容易產(chǎn)生的磨蝕問題。 ????基于共注射成型的基礎理論目前已開發(fā)出幾種新型加工改進方法。例如，模內“上漆”和氣體輔助模塑成型擴大了采用這種工藝的范圍。模內上漆加工方法是采用低分子量聚合物作為外層材料，而氣體輔助模塑成型是采用氮氣或另一種氣體作為芯層（或部分芯層）材料。隨著產(chǎn)品設計與生產(chǎn)加工設備的不斷完善改進，將滿足各種新應用和新技術的需求，共注射技術必將成為富有潛力的工業(yè)化大規(guī)模生產(chǎn)工藝方法。 2. 注射—壓縮成型 ????注射—壓縮成型中型腔壁移動方向垂直于分模線。采用這種方法成型時，在充模階段，按工序產(chǎn)生壓力驅熔體流動，但這一個流道的深度是可變化的。在較深的流道中，壓力下降得較低，以使大面積的制件成型中熔體沒有過度受壓，并避免了瞬間的材料響應，這2種因素同樣會阻礙熔體的流動。注射成型過程中，型腔深度可能是最終制件厚度的14%，在塑料填充了大致60%—75%的型腔后，停止注射，模腔壁周圍同時受到推壓，直至最終制件的壁原成型為止。制件的最終尺寸在這階段確定。 ????如果在模壁按工序移動之前充滿了型腔，該種工藝通常稱為鑄壓成型。大體上，鑄壓成型是在一個可變體積的型腔內采用不變的壓力對制件進行保壓。鑄壓階段是增加密度的階段，密度緊接著在介于熔體和固態(tài)塑料之間起變化。采用鑄壓方式成型致密圓盤，可把殘留應力減至最低程度，制件上的殘留應力可產(chǎn)生變折射現(xiàn)象。 ????鑄壓成型的改進型活動式型腔壁是一種新技術，其由注射全體制件固化階段通過多孔的金屬型腔壁以“保壓”制件。這種方法已有人稱為外部氣體輔助成型法，其實這是一種誤解，因為氣體并沒有影響塑料熔體在型腔內的流動。在常規(guī)的注射成型當中，保壓就是在保持型腔體積不變的同時，在壓力流的作用下，添加入更多的塑料。 聯(lián)同在型腔內的保壓流形成了不均勻的壓力分布，有可能在受高壓的澆口位置產(chǎn)生制件缺陷。 3. 計算機輔助成型 ????采用計算機輔助工程（cae）對加工設計及分析有助于縮短設計周期并可避免代價昂貴的機械失誤。商業(yè)性仿真代碼常用于流道上標明尺寸，以平衡熔料在流道系統(tǒng)及型腔內的流動，同時確定澆口的最佳開設置和澆口的數(shù)目。計算注射壓力和合模噸位要根據(jù)不同的加工條件和材料而定。收縮率及翹曲率結合初始流向也可準確估算出來。重要的是要使得這種設計工具幫助熟練分析人員在某個設計方案或加工研究時進行判斷的操作。結果必須理解為以研究對象和加工/材料為前提。當考慮采用這種方法準確輸入數(shù)據(jù)后，可取得巨大的效益。另外，這種分析經(jīng)濟性可使設計周期更短和所需的生產(chǎn)時間更短。 ????應該提醒注意的是，商業(yè)性的cae程序通常是不可直接使用的。充模仿真可產(chǎn)生有價值的見識，但結果必須重新對其局限性進行重新考慮估計。應用現(xiàn)代計算機進行注射成型模擬試驗，僅限于純粘性流體（不包括粘彈性的熔融塑料）?？深A測熔體流入型腔的實際流動速率組成結構和性能公布等，如可進行高精度的粘彈性分析。目前所采用的任何其它加工方式都不可能達到這種先進水平，并且最近幾年來，由仿真設備的工業(yè)界帶頭者和大學里的研究小組已取得了良好的進展。有幾家公司正在努力探索仿真技術，以求能正確地解釋更多現(xiàn)實的塑性行為和加工現(xiàn)象。例如，聚合物主鏈的取向對局部的物理性能和性能分布的影響。加工物理學是非常復雜的，而某些粘彈性體現(xiàn)象仍然沒有完全弄清楚，更完善合理的加工方式目前正緩慢形成。這些更強的有力的方式將獲得大大超過目前所設計的生產(chǎn)能力。 4. 交變注射成型 ????相比較而言，交變注射是一個比較新的注射成型選擇參數(shù)。這項技術的最大難點在于當加工條件突然改變時，對塑料熔體將呈現(xiàn)出怎樣的變化行為知之甚少。有關熔體流變學的基礎知識，不僅僅是固定的剪切粘度。確切地說，熔體響應（粘性和彈性行為）需要表達的特性，不僅是通常的穩(wěn)態(tài)流動速率或剪切速率及溫度，也包括壓力及瞬間流動速率。這些特性包括很多內容而且十分難于弄清楚。然而，如果在異型材注射方面取得實質性進展，將需制訂出多種不同塑料的具體操作規(guī)程。另還需增加通用的累試法，以求得到成熟和精確的控制方法。 ????在常規(guī)的注射成型中，型腔壁固定不變，某些情況下，還有利用在充模和保壓陷段移動模壁?？刹捎?種不同的方法：移動型腔壁方向垂直于分模線；旋轉或滑動型腔壁。在充模階段旋轉型芯以增加對制件尤其是表皮部分分子的變軸取向。通過這種加工工藝，制件的彎曲性能與其它機械性能得到了極大的提高。聚苯乙飲水杯和聚丙烯注射器就是采用這種加工方法獲得重大改變突破地2個產(chǎn)品。