674 板(框)類制品疊層式注射模具設計【優(yōu)秀含7張CAD圖+文獻翻譯+說明書】
674 板(框)類制品疊層式注射模具設計【優(yōu)秀含7張CAD圖+文獻翻譯+說明書】,優(yōu)秀含7張CAD圖+文獻翻譯+說明書,674,板(框)類制品疊層式注射模具設計【優(yōu)秀含7張CAD圖+文獻翻譯+說明書】,制品,疊層式,注射,模具設計,優(yōu)秀,優(yōu)良,cad,文獻,翻譯,說明書,仿單
畢業(yè)設計(論文)板(框)類制品疊層式注射模具設計 DESIGN OF STACK INJECTION MOULD PRODUCTS FOR FRAME 摘要本論文設計了儀器外殼的疊層式熱流道模具結構。該模具有2層,每層8個型腔,一次可成型16個產(chǎn)品,該模具是普通注射成型產(chǎn)量的2倍,大大提高生產(chǎn)力。本次模具設計采用的是無流道凝料澆筑系統(tǒng),不考慮澆道的凝料脫出,減少了分型面,并縮短了成型周期,降低了整個生產(chǎn)成本。而且還采用了齒輪齒條開模機構,在確保倆層型腔同時開模又比較經(jīng)濟。使熱流道板的熱脹變形問題和澆口的平衡問題有一個很好的解決,基本確保同時充模和充模的穩(wěn)定可靠性。該模具還采用閉合式噴嘴和閉合式主流道杯,解決了澆口和主流道始端的流涎問題,它采用熱電偶控制噴嘴溫度和流道板溫度。在設計中,為減少熱傳導熱損失。在流道板和型腔板之間采用空氣隔熱,并加隔熱墊,從而降低模具和流道板之間的接觸面積,并發(fā)揮了支撐熱流道板的作用。噴嘴和主流道杯均采用隔熱套隔熱。關鍵詞 熱流道;疊層式模具;澆口平衡;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 錄摘要IIAbstractIII1 緒論12 制品設計32.1制件圖32.2產(chǎn)品使用要求42.3產(chǎn)品材料43 工藝分析53.1 塑料特性53.2 塑料的注射工藝條件53.3 塑件使用材料的工藝分析64選擇設備75模具設計85.1 模具結構設計85.1.1 選擇分型面85.1.2 布置型腔85.1.3 確定成型零部件結構95.1.4 澆注系統(tǒng)結構設計95.1.5 開模機構設計105.1.6 脫模機構設計115.1.7 溫控系統(tǒng)設計115.2主要零部件尺寸計算115.2.1 成型零部件尺寸計算115.2.2 確定模具各部分結構尺寸175.2.3 澆注系統(tǒng)計算185.2.4 冷卻系統(tǒng)計算215.2.5 推出機構計算255.3 校核285.3.1 模具與注射機關系校核285.3.2 物料流程與流動比校核29結論30致謝31參考文獻32331 緒論模具是現(xiàn)代化工業(yè)生產(chǎn)的重要工藝裝備,被稱為“工業(yè)之母”。而注塑模具又是在整個模具工業(yè)中一枝獨秀,發(fā)展極為迅速,在汽車、航空航天、通信電子、家用電器等領域有著極為廣泛的應用。熱流道技術是指從注射機噴嘴送往澆口的塑料始終保持熔融狀態(tài),在每次開模時不需將其固化作為廢料取出,滯留在澆注系統(tǒng)中的熔料可在下一次注射時被注入型腔。該項技術具有節(jié)約原料、提高產(chǎn)品性能、縮短生產(chǎn)周期等優(yōu)點。 疊層注射模又稱多層注射模,是一種特殊的注射模。與普通注射模不同,疊層注射模的型腔是分布在2個或多個層面上的,且型腔呈重疊式排列。即相當于將多副模具疊放組合在一起。與常規(guī)模具相比,疊層式模具鎖模力只提高了5%10%,但產(chǎn)量可增加90%95%,這就極大地提高了設備利用率和生產(chǎn)效率,并降低了成本。 將熱流道技術與層疊式模具相結合,僅需增加少量的模具成本卻能成倍地增加產(chǎn)量和實現(xiàn)高效自動化。最初的疊層模具因使用普通流道,每次注射都要去除澆道,是實現(xiàn)自動化生產(chǎn)的主要障礙,因而應用較少。當疊層式模具應用了熱流道技術后,不用考慮澆道凝料的脫出,減少了分型面,縮短了開模行程及成型周期,其應用才得到了較大的提高。疊層式模具最適于成型大型扁平制件、小型多腔薄壁制件和需大批量生產(chǎn)的制件。熱流道技術具有節(jié)約原料、易于自動化、提高產(chǎn)品性能、縮短生產(chǎn)周期等優(yōu)點,將其與疊層式模具結合,僅需增加少量的模具成本卻能成倍地增加產(chǎn)量和實現(xiàn)高效自動化,故疊層式熱流道模具技術日趨受到世人的關注。本次設計是一個屬薄壁制件,需大批量生產(chǎn)儀表外殼的疊層式熱流道模具,疊層式熱流道模具可以提高生產(chǎn)自動化和生產(chǎn)率,降低生產(chǎn)成本。疊層熱流道模具設計的內(nèi)容主要是模具結構設計,其包括:熱流道系統(tǒng)設計,溫控系統(tǒng)設計,開模機構設計,熔料傳遞方式。熱流道系統(tǒng)主要由噴嘴、歧管、熱流道板、加熱裝置等組成。噴嘴形式有多種,常用的有開式噴嘴、針閥式噴嘴和井式噴嘴。開式噴嘴會引起流涎,塑件表面會有點并且成型塑件性能也會降低,形成的冷料甚至會堵塞澆口,疊層式熱流道系統(tǒng)通常采用閥式熱噴嘴。熱流道板和噴嘴上裝有加熱元件,而且通過溫控系統(tǒng)對加熱溫度進行控制。疊層式熱流道模具溫度控制系統(tǒng)有加熱系統(tǒng)和冷卻系統(tǒng),加熱系統(tǒng)是為了持續(xù)讓流道中的塑料呈熔融狀態(tài),冷卻系統(tǒng)是為了完成塑料和模具之間的熱量交換。加熱系統(tǒng)中溫度不能過高或過低,溫度過高,可能導致塑料分解變色,在塑件上形成缺陷,乃至報廢;溫度過低,塑料會在流道中形成較厚的固化層,影響實現(xiàn)連續(xù)注射因此,應嚴格控溫。熱流道的溫度控制是熱流道技術的難點之一,為了控制好溫度,可以選用閉環(huán)控制的熱流道系統(tǒng),再根據(jù)塑料的性能、成型溫度和制品要求選擇合適的溫控數(shù)值和精度。疊層式熱流道模具熱流道系統(tǒng)的主流道設置在模具中心部分,由于疊層式模具型腔有多個分型面,著意味著需要有一個機構使這些分型面能同時分型。疊層式模具在開模時,不僅動模部分移動,中間部分同時移動,即應同時開2個分型面,并由兩側的頂出機構使塑件脫模。目前疊層式模具的開模方式一般有鉸接杠桿或齒條來同步開模,也可使用液壓系統(tǒng)。疊層式熱流道模具設計在設計時需注意以下幾個問題:熱膨脹問題,澆口平衡問題,冷卻系統(tǒng)的平衡,防止流涎,隔熱措施。澆注系統(tǒng)無凝料、拉絲現(xiàn)象;實現(xiàn)自動化生產(chǎn);具結構盡量簡單,組裝、拆卸比較容易。2 制品設計2.1制件圖產(chǎn)品的制件圖如下所示 圖1-1 制件圖 圖1-1 制件圖2.2產(chǎn)品使用要求該產(chǎn)品是一種儀表外蓋,因需從外面能看到里面,故要求材料透明外表面光潔度R小于0.5。另外還要求外蓋的絕緣性能良好,并且由于外蓋是暴露在外面的,所以要求材料的抗腐蝕能力較強。2.3產(chǎn)品材料根據(jù)上述使用要求,經(jīng)查表選用塑料ABS55。3 工藝分析3.1 塑料特性透明ABS樹脂的透明度較高,耐容劑性能好,而且沖擊強度和機械強度都比較高。ABS55(通用)樹脂的性能如下:相對密度: 1.07 g/cm3拉伸強度: 42.2MPa彎曲強度: 71.6MPa彎曲彈性模量: 1.96GPa熱變形溫度(1.82MPa): 86壓縮比: 1.82.0成型收縮率: 0.30.8與鋼的摩擦因數(shù): 0.21泊松比: 0.353.2 塑料的注射工藝條件螺桿轉(zhuǎn)速: 3060r/min取45r/min噴嘴溫度: 190200取190料筒溫度: 后部: 190200取200 中部: 220240取220 前部: 200220取200模具溫度: 5070取60注射壓力: 70100MPa取90MPa保壓壓力: 5060MPa取56MPa注射時間: 14s取4s保壓時間: 1540s取20s冷卻時間: 1030s取15s成型周期: 3080s取45s3.3 塑件使用材料的工藝分析ABS屬于熱塑性塑料,流動性好,其成型性能好;比熱容低,在料筒中塑化效率高,在模具中凝固校快,成形周期短,可在柱塞式或螺桿式臥式注射機上成形;成形收縮率較?。?.30.8)。ABS吸水率大(0.20.45),成形前必須充分干燥。干燥條件:在空氣循環(huán)干燥中,溫度為8090,干燥34小時即可使用。 塑件尺寸不大,外部形狀結構簡單,注射成型容易,無抽芯機構。4選擇設備根據(jù)塑料ABS的特性,其成型壓力為70100MPa,預選2層模16腔,每層8腔。塑件體積為33.41cm,塑件總體積為33.4116534.56 cm。由于采用疊層式注射模,且流道比較長,考慮注射機的注射能力,所以選用XS-ZY1000型臥式注射機。其成型技術規(guī)格如下:最大注射量: 1000 cm 螺桿直徑: 85mm 注射壓力: 121MPa注射行程: 260mm 注射時間: 3s螺桿轉(zhuǎn)速: 21、27、35、40、45、50、65、83 選用45r/min注射方式: 螺桿式注射合模力: 4500KN最大成型面積: 1800cm2模板行程: 700mm模具厚度:最大: 700mm最?。?300mm拉桿間距: 750650mm合模方式 : 特殊液壓油泵流量: 200、18、1.8L/min 選用200L/min壓力: 14MPa加熱功率: 16.5KW機器尺寸: 7.671.742.38m噴嘴球半徑: R18mm噴嘴直徑: 7.5mm推出中心孔: 150mm5模具設計5.1 模具結構設計5.1.1 選擇分型面根據(jù)分型面選擇原則,分型面應選在最大截面處,再根據(jù)制件特點,四側面與外底面屬外表觀面,應在型腔內(nèi)整體成型,因此選用截面A作為分型面(如圖5-1所示)。 圖5-1 分型面示意圖5.1.2 布置型腔根據(jù)設計高效率疊層注射模以及結合制件尺寸結構,布置型腔。制件結構簡單,壁厚較小,體積不大,截面尺寸也不大,長 / 寬115 / 72=1.6 由上所述,設計模腔一模十六腔,每層八腔,由于塑件的長是寬的1.6倍,將型腔排成兩排,一排四個,在長寬度方向各排列四個。這樣讓模具型腔排布比較緊密,充分發(fā)揮了模具生產(chǎn)能力。(分布如圖5-2) 圖5-2 型腔分布示意圖5.1.3 確定成型零部件結構圖5-3 型芯結構圖5.1.4 澆注系統(tǒng)結構設計由于采用一模16腔的高效疊層模具,型腔多,流道長,改變方向次數(shù)多,采用冷流道注射較困難,且凝料體積大,材料浪費率高,若采用熱流道,將大大減少凝料,且能保證物料流程。熱流道技術費用高,適用于高效無凝料生產(chǎn),通過提高生產(chǎn)率,減少凝料來彌補這個缺陷,合適時可降低塑件總成本。1)選用澆口根據(jù)澆口選用原則,澆口設在塑件底面中心位置處,采用針點澆口。澆口很小,基本上無痕跡,不影響外觀質(zhì)量。2)流道結構設計根據(jù)型腔布置和模具結構的特點,采用無流道技術在流道板上加工流道,鉆削流道末端,流道末端用螺栓密封。(見流道板零件圖)3)選用噴嘴類型由于ABS熔料較稀,在開模過程中澆口處會出現(xiàn)流涎、拉絲等現(xiàn)象,可能導致熔料在模板上冷凝,從而阻止模具型腔的密封導致生產(chǎn)無法進行。為了防止此現(xiàn)象的發(fā)生,選用閉合式噴嘴,且采用壓縮彈簧驅(qū)動機構。當型腔壓力降低到保壓力,注射機停止注射時,壓縮彈簧驅(qū)動柱銷閉合澆口,而且這樣還可以防止倒流現(xiàn)象。當塑件取出,注射機開始注射時,注射熔料的在高壓力下會把柱銷的斜錐面柱銷推開,從而打開澆口,進行注射。噴嘴與流道板處用螺紋聯(lián)接,這樣既可以防止了漏料現(xiàn)象又使流道板的熱膨脹問題得到簡化,噴嘴與流道板固定,讓噴嘴與噴嘴對應孔在熱膨脹方向有一定間隙并且可解決熱膨脹問題。4)主流道杯因為采用熱流道技術,主流道采用線圈加熱的熱流杯,采用外加熱式線圈加熱裝置,主流道杯與其穿過的各個模板用導熱率較低的材料隔熱。同樣為防止流涎現(xiàn)象,采用閉合式主流道杯。在其前端加一個頂針,當注射機注射時,頂針被打開,當注射機停止注射,由于流道內(nèi)的熔料有一定壓力,壓著頂針使其閉合,這樣就防止了熔料流涎。 5.1.5 開模機構設計開模機構采用了較經(jīng)濟的齒輪齒條開模機構。在模具的中間板上安裝一齒輪,齒輪裝在軸承上,軸承固定在中間板上的軸上。齒條的另一端固定在動模板上,齒輪上下各一根,當開模時,注射機拉動動模座板,使第二層的動模板運動,第二層動模板通過齒條使中間板上的齒輪轉(zhuǎn)動,齒輪會給第一層上的齒條一個力,使第一層動模板固定不動,中間板受到齒條一推力,使中間板與第一層動模板分離,中間板兩面都是型腔,也即使第一層分型面分開。(如圖5-4) 圖5-4 開模機構簡圖5.1.6 脫模機構設計由于模具的型腔多,每層各8腔,若采用推桿或推管推出,比較麻煩,制件壁厚并非過小,塑件在開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。這樣做的前提是塑件在開模后留在型芯上。模具一共兩層,第二層與單板式模具一樣用注射機液壓做動力來源,第一層只能用彈簧、拉桿或其他的部件,在開模時給推件板一推力或拉力,完成開模。本模具型腔多,脫模力可能會太大,不適合用壓縮彈簧來脫模,可采用拉塊拉動推件板來推出塑件。5.1.7 溫控系統(tǒng)設計對主流道和噴嘴的加熱,課采用線圈加熱,對流道板可采用加熱棒加熱。制件的體積小,熱量少,在一個方向冷卻即可。5.2主要零部件尺寸計算5.2.1 成型零部件尺寸計算計算方法有兩種:平均值法和公差帶法。在討論計算方法之前,對塑件尺寸和成形零部件的尺寸偏差統(tǒng)一規(guī)定按“入體”原則標注,即對包容面(型芯和塑件外表面)尺寸采用單向正偏差標注,基本尺寸為最小。設為塑件公差,z為成形零件制造公差,則塑件內(nèi)徑為l ,型腔尺寸為L。而對被包容面(型芯和塑件外表面)尺寸采用單向負偏差標注,基本尺寸為最大,如型芯尺寸為l,塑件外形尺寸為L。而對于中心距則采用雙相對稱偏差標注,例如,塑件間中心距為C,而型芯間的中心距為C。當塑件原有偏差的標注方法與此不符合時,應按此規(guī)定換算。平均值法是按塑件收縮率、成型零件制造公差和磨損量均為平均值時制品獲得的平均尺寸來計算的。公差帶法是使成型后的塑件尺寸均在規(guī)定的公差帶范圍內(nèi),具體求法是先以在最大塑料收縮率時滿足塑件最小尺寸要求,計算出成型零件的工作尺寸,然后校核塑件可能出現(xiàn)的最大尺寸是否在規(guī)定的公差帶范圍內(nèi);或者反之,按最小塑料收縮率時滿足塑件最大尺寸要求計算成型零件工作尺寸,然后,校核塑件可能出現(xiàn)的最小尺寸是否在其公差帶范圍內(nèi)。為便于修模,延長模具壽命,型腔按最小塑件尺寸計算,型芯按最大塑件尺寸計算。5.2.1.1 型腔尺寸計算塑件型腔尺寸有長:115,寬:72,高:26.51)型腔長計算對應于塑件尺寸 115 ,塑料平均收縮率Scp=0.55%, z =0.193,介于IT10IT11之間。按平均值法:L=Ls+LsSc p-=115+1150.55% -0.58 =115.20 (mm)按公差帶法:型腔尺寸以塑件最小尺寸計算 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不滿足要求,因此必須對凹模制造公差z和磨損量c加以修正,從壽命角度考慮,在精度不是很高時,不希望c縮小,若按IT7級制造精度:z=0.035mm ; 型腔基本尺寸按115.20計算 115.20+0.035+0.096 1150.3%=114.98272若型腔寬基本尺寸取72.05,校核滿足條件。即型腔寬為:72.05mm3)型腔高: 對應于塑件尺寸26.5按平均值法:z =0.093,制造精度在IT10IT11之間,按IT10級制造精度制造z =0.084,c=0.046H=H+HS =26.5+26.50.55%0.28 =26.46(mm)按公差帶法:由于型腔修模時,修模板比修型腔底部容易,型腔高應按最大尺寸計算,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滿足要求,由于型腔應取大值便于修模,所以:型腔高為26.5mm.5.2.1.2 型芯尺寸計算型芯尺寸按IT10級精度制造,z =0.1401) 型芯長:對應于塑件尺寸112,按平均值法:l=(1+Scp)l+ =(1+0.3%)112+0.58 =113.44 (mm)公差帶法:型芯修模時可修小,不易修大,按最大尺寸計算。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不滿足要求,取lm=113.44校核可以滿足,即型芯長為113.44mm2)型芯寬:對應于塑件尺寸69 按IT10級精度制造z=0.140 按平均值算法:l=(1+Scp) l+ =(1+0.55%)69+ =69.72 (mm)按公差帶法計算:l(z +c)S llc=0.076mm 69.69(0.140+0.076)0.8%69=68.90269用較大值型芯基本尺寸lm=69.72,制造精度不變可滿足要求,即型芯寬為69.72mm3)型芯高:對應于塑件尺寸24.5按IT10級精度制造,z=0.084按平均值算法:h=(1+Scp)h+ =(1+0.55%)24.5+0.28 =24.82(mm)按公差帶法:型芯為軸肩連接組合式結構,試模與修模時修磨型芯固定板上的平面較為容易,應按塑件最小尺寸計算。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可以滿足要求即型芯高為24.78mm.5.2.1.3 型芯中心距計算1)橫向中心距: 對應于塑件尺寸104平均值法計算:Cm=Cs+Cs Scp 與公差帶法計算結果相同,若按z=, z=0.073mm現(xiàn)按IT8級精度制造,z=0.054mm.C=C+ CS =104+1040.55% =104.57(mm)2)縱向中心距:對應于塑件尺寸61,按IT8 級精度制造,z=0.046mmC= C+ CS =61610.55% =61.34(mm)5.2.1.4 型腔壁厚與底板厚計算型腔采用整體式,直接在模板上加工1)型腔壁厚S計算按剛度條件:S= C常數(shù),隨l/h而變化; P型腔壓力,MPa; h型腔深度,mm; E型腔板的彈性模量,MPa;變形量,mm. l/h=115/26.5=4.34,查得C=0.1407;初選型腔壓力p=30MPa; 型腔深度h=26.5mm; 鋼的彈性模量E=2.210MPa,許用變形量=0.05mmS=5.50(mm) 型腔壁厚應S5.5mm2)型腔底板厚t計算 按剛度計算:t= C常數(shù),與l/b有關; l/b=115/72=1.597,查得C=0.0251 型腔壓力p=30MPa,型腔寬b=72mm,E=2.210MPa,=0.05mm t=12.25(mm)按強度計算:t=b=b/l,b型腔寬,l型腔長; 型腔板的許用應力,查得=785MPa;t=72 =8.5(mm)型腔底板厚度應滿足t12.25mm5.2.2 確定模具各部分結構尺寸模具結構(如附裝配圖)各模板尺寸均按標準模板選取, 長寬厚 來源定模座板尺寸: 50056030mm 從標準模架上選用動模固定板尺寸:50056030mm從標準模架上選用動模板尺寸: 50056030mm GB4169.81984型腔板尺寸: 50056050mmGB4169.81984 中間板尺寸: 500560130mm由于其厚度受限制,選用非標準的或由標準模板加工而成墊板尺寸: 100560100mm 從標準模架上選用動模座板尺寸: 50063030mm從標準模架上選用推件板尺寸: 50056063mmGB4169.81984推板尺寸: 28656040mmGB4169.71984推板固定板尺寸:28656025mmGB4169.71984導柱: 4025025mm GB4169.41984導套: 4063mm GB4169.21984 4063mm(兩個) GB4169.31984推桿: 25120mm GB4169.11984聯(lián)接堅固零件:定模座板到第二動模板固定螺栓: 6M16 GB578386動模座板與第一動模板固定螺栓: 6M16 GB578386推板與推板固定板固定螺栓: 4M12 GB578386兩型腔板與中間板固定螺栓: 4M12 GB578386兩半流道板的固定螺栓: 4M8 GB578386齒條與動模板固定螺栓: 8M8 GB578386其它零部件:推出機構中的齒輪齒條機構:齒輪m=3,z=30,B=25mm,(兩個) 齒條m=3,寬20mm,厚10mm,長300mm(4根) 主流道杯上加熱棒:20280mm(4根)5.2.3 澆注系統(tǒng)計算流道系統(tǒng)采用的是熱流道系統(tǒng),由前面確定的流道結構和型腔分布,計算并確定各個主分流道的尺寸,其中包括主流道杯,流道,澆口,噴嘴,噴嘴驅(qū)動裝置,以及流道板的尺寸。5.2.3.1主流道杯尺寸確定注射機噴嘴頭的球面半徑為R18,為防止漏料,注射機的噴嘴球半徑要與模具的主流道杯配合,一般R1應比主流道始端球的半徑小12mm。主流道杯配合球半徑取R19。注射機噴嘴孔直徑為75mm,主流道杯流道直徑取8mm。5.2.3.2 流道和澆口尺寸確定實踐證明當注射模主流道和分流道的剪切速率=澆口的剪切速率=s時,所成型的塑件質(zhì)量較好。對于一般熱塑性塑料,上面推薦的剪切速率可作為計算模具流道尺寸的依據(jù)。在計算中可使用如下經(jīng)驗公式:=3.3 R表征流道斷面尺寸的當量半徑,cm 體積流量,cm/s。在計算各流道尺寸時可先計算各流道的體積流量,據(jù)經(jīng)驗預先確定各流道的剪切速率,再計算求出流道的當量半徑或查 R關系曲線也可。 =113.6 (cm/s)預選主流道剪切速率=,=113.6 cm/s,流道當量半徑R= =0.39(cm),取D=8mm第一分流道=,=113.62 cm/s56.8 cm/s,流道當量半徑R= = (cm),取D=8mm第二分流道=,=56.8 cm/s28.4 cm/s,流道當量半徑R= =0.18(cm),取D=6mm澆口處=,=33.44 cm/s8.4 cm/s,澆口當量半徑R= =0.06(cm),取澆口直徑d=1.2mm設第一澆口直徑為d=1.2mm,對離主流道較遠的第二澆口用流動平衡的平衡系數(shù)法求得。該法的原理是使各個型腔的平衡系數(shù)相等或成比例,其公式為 k=K澆口平衡系數(shù),它與通過澆口的熔體質(zhì)量成比例;S澆口的斷面積,mm;L澆口長度,mm;a主流道到型腔澆口的距離,mm.取噴嘴流道與第二分流道直徑相等,d=6mm,澆口長設為mm,根據(jù)型腔分布流道及澆口尺寸如圖k=k=,即d=1.43mm,由于第二澆口距離主流道比較遠,壓力降較大,為盡量平衡進料取d=1.5mm。 5.2.3.3 噴嘴和噴嘴驅(qū)動裝置(圖5-5) 1流道板2鎖緊螺母3彈簧4墊塊5驅(qū)動柱銷6噴嘴7熱電偶8加熱線圈9隔熱套10型腔板 圖55 熱流道噴嘴噴嘴流道直徑取d=6mm,其與流道板聯(lián)接用M20螺紋聯(lián)接。剛開始保壓時,保壓力為p=56MPa,第一澆口驅(qū)動柱銷直徑為1.2mm柱銷受力 F1 =3.14 1.210 56 10 =63.3(N)柱銷驅(qū)動彈簧壓縮力應63.3N且要小于注射時在注射壓力下柱銷所受的力,讓澆口能夠在注射時打開。注射型腔壓力下柱銷受力F2=3.14 1.2103010 =33.912(N)壓縮彈簧的壓縮力33.912NF33.912,當注射時彈簧壓縮力F=76.9=48.363.3, 可滿足要求。5.2.3.4流道板的尺寸確定由型腔分布和澆口位置確定末級分流道長為(46+92)2=276(mm),再考慮到流道末端用螺紋密封,給密封螺栓留一定安裝尺寸,取流道板尺寸為:310290120mm。為安裝噴嘴驅(qū)動裝置,流道板厚度上分為兩半5.2.4 冷卻系統(tǒng)計算5.2.4.1 計算單位時間里型腔內(nèi)總熱量Q(kJ/h) Q=Q1單位質(zhì)量的塑料制件從熔體進入型腔開始到冷卻結束時所放出的熱量,kJ/kg,又稱單位熱流量之差或熱焓之差;W單位時間內(nèi)注入型腔中的塑料質(zhì)量,kg/h; N每小時注射次數(shù)。查得Q1=3.11024.0102,取Q1=4.0102kJ/kg注射時間為=4s,保壓時間為=20s,冷卻時間為=15s,開模時間為=6s總成型周期為4+20+15+6=45(s) N=3600/45=80每個塑件體積為33.4cm3,=1.07g/ cm3每次注射總質(zhì)量為 33.41.0716g=0.572kg取G=0.6kgQ=800.64.0102=18304(kJ/h)5.2.4.2 通過自然冷卻所散發(fā)的熱量Q,Q,1)由對流所散發(fā)的熱量(kJ/h)模具表面積,模具平均溫度,室溫,傳熱系數(shù),kJ/(h)當06000時,= =20, =,=65, = 模板的熱導率,kJ/(h) 模具型腔壁與冷卻水管壁之間距離,m 、冷卻水管壁表面尺寸,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 ()冷卻管表面積為163.140.0120.56=0.34()9.63)所需冷卻水管總長度LL= = =0.034(m)冷卻水管總長為8根0.56m的,顯然夠用。5.2.4.6 冷卻水流動狀態(tài)校核為保證冷卻效率,使冷卻水處于紊流狀態(tài),雷諾數(shù)600010000= v冷卻水平均流速,d冷卻水管直徑,水運動黏度,=1.6=144001000005.2.5 推出機構計算5.2.5.1 推件板厚度t計算 按剛度計算:t=0.54LL推件板長度上兩推桿的最大距離,mm;B推件板寬度,mm;F脫模力,N; 推出板中心所允許的最大變形量,一般可取制件在被推出方向上的尺寸公差的計算脫模力:脫模力按矩環(huán)形斷面薄壁制件(t/d0.05) 計算,F(xiàn)=+0.1AK無量綱系數(shù),隨f和而變,K=1+fsincos也可查表求得; 脫模斜度,;矩環(huán)形制件的平均壁厚,mm;S塑料平均收縮率;E塑料的彈性模量,MPa;L制件對型芯的包容長度,mm;f制件與型芯之間的摩擦因數(shù);塑料的泊松比;A盲孔制品型芯在垂直于脫模方向上的投影面積,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)按剛度計算推件板厚度:初選標準模架A250056016Z1 GB/T12556.190模板長560mm,寬500mm,取=400mm,B=500mm,F(xiàn)=18091.8 N,E=2.210MPa,=0.04由于脫模力分散,是均布力,把每層上的8個型腔的脫模力折合成四個集中力來計算,此時t= =0.54 =59.6(mm)推件板厚度必須滿足t59.6mm5.2.5.2 推桿直徑計算穩(wěn)定性計算:d=k安全系數(shù),取k=1.5;L推桿長度,mm;n推桿數(shù)量, F脫模力,N; E鋼材的彈性模量,MPaL=170mm,F=818091.8N,n=2,E=2.1105MPad=1.5 =4.1(mm)按強度計算: 推桿的許用應力,MPa;查得45鋼的=600MPa d=19.4(mm)所以推桿直徑d5.3 校核5.3.1 模具與注射機關系校核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)注射壓力校核注射機最大注射壓力為121MPa,塑料需要的注射壓力為70100MPa3)鎖模力校核型腔內(nèi)塑料熔體沿注射機軸向的推力,N;A塑料與澆注系統(tǒng)在分型面上的投影面積,mm2型腔內(nèi)塑料熔體的平均壓力,MPa, =30MPa注射壓力,MPa, =90MPa k壓力損耗系數(shù),與塑料口種,注射要形式,噴嘴阻力等因素有 關,一般取0.20.4,取k=0.3A=11572=8280 mm2=82800.390=223560N注射機鎖模力4500N4)模具安裝部分尺寸校核模具厚度:模具厚度為300mm656mm700mm滿足要求模具長度和寬度:注射機拉桿間距為750650,模具長寬尺寸為630560mm定位環(huán)尺寸:模具定位環(huán)尺寸與注射機定位環(huán)尺寸都是150,用較小的間隙配合,給模具開模垂直平面上固定。噴嘴尺寸:注射機噴嘴球半徑為R18,模具上與之對應的配合尺寸為R19,符合要求。5)開模行程校核:由于采用的是熱流道,無需脫凝料,制件在開開模方向尺寸為26.5mm,第二層靠的是推桿推出制件,推桿的行程為100-40-25=35mm26.5mm5.3.2 物料流程與流動比校核流道走最遠路程為主流道杯段d=8mm長233mm,一級分流道段d=8mm長92.5mm ,二級分流道段d=6mm長45mm,末級分流道段d=6mm長138mm,噴嘴段d=6mm長43.5mm??偣彩莇=8mm,長325.5mm,d=6mm,長226.5,平均取d=7mm,則l/d=226.5+325.5/7=78.9,ABS流動比為240120,顯然能滿足物料流程。結論本次設計采用的是熱流道疊層式注射模具,這種注射模具既可以充分發(fā)揮注塑機的能力,又節(jié)省人力和設備資源,而且極大地提高生產(chǎn)效率。該設計的熱流道澆注系統(tǒng),總體來說結構簡單,可以實現(xiàn)自動化生產(chǎn),適用于大批量生產(chǎn),而無凝料生產(chǎn),一模多腔,雙層型腔,這些優(yōu)點大大提高了生產(chǎn)率,降低了生產(chǎn)成本。但在生產(chǎn)中對加熱溫度要嚴加控制,防止加熱過度與不夠。致謝 經(jīng)過半年的艱苦努力,我的畢業(yè)設計已接近尾聲。作為一個本科生,由于經(jīng)驗匱乏,難免有許多考慮不周的地方,如果沒有導師的督促和指導,以及一起學習的同學們的支持,想要完成這個設計是難以想象的。在此首先感謝我的導師黃傳輝副教授。他時刻關注我的研究進程,雖然他工作繁忙,但每周還是騰出固定時間來指導我,幫助我開拓研究思路。而且每當我有疑問的時候,他不論問題簡單與否都細心解說。在此謹向黃傳輝副教授致以誠摯的謝意和崇高的敬意。同時也要感謝和我一起奮斗的同學們,每當我遇到困難時,你們的幫助和支持給了我很大的動力去克服它們。在論文即將完成之際,我的心情無法平靜,從開始選擇課題到論文的順利完成,有多少可敬的師長、同學、朋友給了我無言的幫助,在這里請接受我誠摯的謝意!參考文獻1宋滿倉.注塑模具設計M.電子工業(yè)出版社,2010.2G曼格斯,P默蘭.塑料注射成型模具的設計與制造M.北京:中國輕工業(yè)出版社,1993.3劉延華 .塑料成型機械使用維修手冊M.機械工業(yè)出版社,2004(2).4任威,盧軍.熱流道層疊式注射模具的研究J.電加工與模具,2008.2412425張信群,忘春香.模具設計與制造M.合肥工業(yè)大學出版社,2010.6王振保,李輝,方少明.疊層式注塑模具的研究J.橡塑技術與裝備,2006.38437王振保,王勇.雙層型腔的包裝盒注塑模具設計J.塑料工業(yè),1999(7):2627.8李樹,揣成智.雙層熱流道注射模成型技術J.模具工業(yè),1997(10):2830.9黃虹.塑料成型加工與模具M.化學工業(yè)出版社,2003(3).10任威,盧軍。電加工與模具J.陜西科技大學出版,2008(5):6163.11閻亞林,黃曉燕.疊層注射模的應用與設計J.模具工業(yè),2003(12):3134.畢業(yè)設計附件外文及翻譯學生姓名學院名稱專業(yè)名稱機械設計制造及其自動化指導教師 新一代注塑技術 外文出處 University Hospital Zurich, Zurich, Switzerland 摘要:本文介紹新一代瓶坯注塑技術的特點以及通過一個循環(huán)所實現(xiàn)的瓶性能。這一循環(huán)使瓶胚冷卻不再需要機械手和引出板,而是瓶胚直接在模芯上冷卻,在進一步通過2.5 注射循環(huán)冷卻之后被頂出。這使制件的冷卻得以改進,從而大大提高了每個陰模的產(chǎn)量。從工作單元去掉機械手減少了空間需求,并大大簡化了系統(tǒng)。 關鍵詞: 注塑模具設計 循環(huán)速度 1、概述 轉(zhuǎn)位瓶胚注塑技術是在Husky 注塑系統(tǒng)雙壓板機器設計發(fā)展起來的。該系統(tǒng)有一個四面動壓板繞橫軸旋轉(zhuǎn)。每一面配一個典型的半冷塑模。原模系統(tǒng)是一個48 陰模,從而提供192 個模芯。定壓板上裝有一個標準的熱流道和半陰模。 本系統(tǒng)配備一個標準兩級注塑裝置,該裝置有一個120 毫米擠塑機和120 毫米注射壓料塞,注射壓料塞上有一個機筒頭和分配閥連接兩級。用目前的瓶胚設計,目標重量是47.3 克瓶胚,從而注射量為2270 克。兩42 個不同的聚對苯二甲酸乙二醇酯螺桿用于本系統(tǒng),每個都取得了可以接受的效果。 當機器循環(huán)時,塑料首先注射到A 面。由于瓶胚要留在模芯上,瓶胚在開模不需要象在傳統(tǒng)系統(tǒng)上那么硬。因此,循環(huán)的絕大部分冷卻可以在隨后的機器循環(huán)期間從閉模轉(zhuǎn)到在模芯上冷卻。然后循環(huán)需要一個非常短的冷卻期間以允許模具釋壓,注射和保壓也是如此。當開模時,這一面轉(zhuǎn)位到壓板的頂部表面,然后塑料在B 面注射。當D 面到達前端時,此時A 面在壓板的底部位置,頂桿在這里被啟動,瓶胚被從機器卸到制件引出傳送器上。注射行程對循環(huán)時間沒有影響,因而可以較慢地完成。重力幫助確保制件脫離模具落下。制件落在其格端頭的傳送器上,造成表面擦傷的可能性較小。 在頂部、背部和底部位置,氣沖成型系統(tǒng)對瓶胚提供表面冷卻。由于瓶胚保持在模具的模芯上,它們還容易在內(nèi)表面得到傳導冷卻??傮w上講,瓶胚的整體溫度比它在傳統(tǒng)模塑系統(tǒng)和冷卻引出板中呆類似的時間要冷。 2、瓶性能 我們分析轉(zhuǎn)位系統(tǒng)的一個重要方面是拿這種系統(tǒng)生產(chǎn)的瓶胚制造出來的瓶的性能與傳統(tǒng)工作單元上生產(chǎn)的類似瓶胚制造出來的瓶相比較。表1 給出從進行的試驗中得出的比較數(shù)據(jù)。 轉(zhuǎn)位瓶胚的性能在強度測試中一直較好,這是因為改進的澆口質(zhì)量允許材料在瓶內(nèi)較好地分布,沒有跡象表明使用這種系統(tǒng)在瓶的任何地方結晶度升高。生產(chǎn)的轉(zhuǎn)位樣品可能平均較輕,因為它們的重量分布要緊密得多。 3、系統(tǒng)的特點 這種托坯最明顯的好處是需要的模內(nèi)冷卻時間減少了,從而減少了整個循環(huán)的時間長度。目前,這種系統(tǒng)用最大壁厚為4 毫米的47.3 克瓶胚工作。這種瓶胚加工循環(huán)時間測定為22.5 秒,對于一個陰模系統(tǒng)來說是最佳的了。轉(zhuǎn)位48 陰模系統(tǒng)實現(xiàn)14.2 秒的循環(huán),能取得較好的商業(yè)質(zhì)量結果。圖2 給出循環(huán)細分的比較情況。 旋轉(zhuǎn)塔臺不再需要機械手。這樣,就減少了由傳統(tǒng)系統(tǒng)上機械手故障造成的干擾告警和服務停機時間。制件頂出現(xiàn)在不是機械循環(huán)時間的一個因素。隨著消除機械手需要的開模間隙減少了,隨著模具行程的減少還提高了空循環(huán)速度。 系統(tǒng)的另一個好處是需要的地板面積減少,以及由于沒有機械手和引出板冷卻系統(tǒng),系統(tǒng)的可靠性得以提高的潛力。預計不發(fā)生機械手故障的整個系統(tǒng)可靠性可允許系統(tǒng)可用性提高30%。轉(zhuǎn)位系統(tǒng)的地板面積只有傳統(tǒng)48 陰模系統(tǒng)所需面積的55%。與之相伴的還有每英尺地板面積的產(chǎn)量進一步提高。 使用轉(zhuǎn)位系統(tǒng)使瓶胚的澆口質(zhì)量得到改進。在閥澆口區(qū)冷凍之后,瓶胚在較短時間內(nèi)與閥桿的熱點接觸,因為瓶胚在陰模內(nèi)的冷卻時間被大大減少。去掉這一熱源就消除一個結晶源。除了較好的視覺效果,還導致澆口區(qū)更結實,從而使得整個瓶側壁區(qū)更好,及有更多的機會減輕基礎區(qū)瓶胚的重量。 瓶胚留在模芯較長時間。與標準瓶胚注塑系統(tǒng)相比,整個瓶胚冷卻得到改進。在一個傳統(tǒng)的機械手冷卻板內(nèi),制件遇到被冷卻的管表面就會收縮,這樣熱傳遞就不完美。在轉(zhuǎn)位系統(tǒng)中,制作在模芯上收縮,從而保持熱傳遞,在被頂出時,轉(zhuǎn)位瓶胚的全面整體溫度比瓶胚從傳統(tǒng)系統(tǒng)的引出位置取出時要低。還有,對于目前的瓶胚設計來說,不向頸模圈區(qū)供應冷卻水,在頂出時仍比標準系統(tǒng)要冷得多。對于一個典型的成型系統(tǒng)來說,冷卻該區(qū)能限制循環(huán)。 轉(zhuǎn)位系統(tǒng)用幾種不同材料及測試的兩種不同材料和兩種不同的聚對苯二甲酸乙二醇酯螺桿設計,可以看到乙醛(AA)量一直較低。與注射量相比這一循環(huán)時間對注射裝置提出非常高的要求,注射裝置連續(xù)不斷地沖刷沒有一點滯留時間的螺桿。 由于模具內(nèi)的峰值陰模與兩個不同的螺桿相符,并與不同的加工設置一致,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個好處是有非常好的重量分布,從而允許在目前制件規(guī)格的允差內(nèi)把整個制件的重量降到最低程度。 4、介紹IKB-MOULD設計的基礎注塑模組成的分析處理分為兩部份:設計的首字母和詳細的設計,初期的設計決定模具的組成,例如模具類型、型腔數(shù)、流道的類型、澆口類型等。詳細設計是型芯型腔的組成、澆注系統(tǒng)的設計、冷卻和排氣系統(tǒng)的設計、集成分析和最后的草圖。他們需要什么,分析什么是好的CAIMDS的發(fā)展方向。 他們所擁有的客戶對產(chǎn)品的要求。包括產(chǎn)品外形和詳細的尺寸。 一個已經(jīng)設計好的模具方案這個方案包括模具設計的初級部分和標準部分舉例來說模具設計的基礎動模和定模的一部分填充和頂出的一部分。注塑模具設計的行業(yè)知識等。 設計者從專業(yè)知識中得出模具設計的設計計劃和詳細步驟這些知識包括原材料的選擇型腔型芯分型面的規(guī)劃和其他相關細節(jié)的介紹。 他們所想要得一個先進的交互式模具設計環(huán)境。模具設計是由一系列細小的環(huán)節(jié)組成的設計程序。這些程序通常需要將已有的模塊和制作好的模件裝配好。這些模具設計系統(tǒng)不需要自動完成尤其是對切口部分特征比較復雜的產(chǎn)品。先進的交互式程序善于整合自動化運算法則和有經(jīng)驗的設計者的在線知識交流。 標準件/早期設計部分/組裝/產(chǎn)品管理。一個注塑模具在其它注塑模里相同的形狀尺寸分別有型腔型芯。這些部分與注塑模產(chǎn)品無關。他們使用在不同模具中重復使用的大概標準。 有用的工具包括實體設計和分析計算在模具型腔型芯中的設計。型芯和型腔的外形和大小直接影響模具產(chǎn)品。這些部分也是模具設計中相當重要的環(huán)節(jié)。他們的幾何形狀要求可能相當苛刻。因此一些模芯設計工具的發(fā)展方向基于自動生成模具型芯交互作用是相當有用的。 組裝設計在傳統(tǒng)的CAD/CAM設計系統(tǒng)中模具的實體形狀被當作幾何圖形儲存模型在一個三維空間以邊和面的形式生成。象這樣的一個以嚴密的幾何計算表現(xiàn)的視覺外形可以完成工程分析和模擬。但是這種工作方式不適合設計高層數(shù)據(jù)和產(chǎn) 品的幾何實體外形的關系。 模具設計者更喜歡裝配環(huán)境的設計而不是一種簡單的固體模型環(huán)境。這個方案被 Ye et al 提出。 5、循環(huán)速度的限制因素 在整個循環(huán)期間對轉(zhuǎn)位循環(huán)的影響因素可以分為五個組成部分: (1)機器空循環(huán)時間(這是完成開模、旋轉(zhuǎn)塔臺90 度,閉模和為注射做準備的循環(huán)的時間); (2)陰模充料時間; (3)為避免正冷卻的制件形成凹陷的保壓要求; (4)模內(nèi)冷卻以使模具從保壓期間要求的合模力噸數(shù)中釋壓; (5)在頂出時瓶胚的大量熱造成的表面熱以及熱再生,以避免后續(xù)處理期間制件被刮傷或有粘性。 系統(tǒng)的機器空循環(huán)時間被優(yōu)化。模具不必開那么多,以允許轉(zhuǎn)位旋轉(zhuǎn),象傳統(tǒng)系統(tǒng)為允許機械手進入模具區(qū)所要求的那樣,從而減少了開模和閉模時間。轉(zhuǎn)位速度也比機械手進去,轉(zhuǎn)移制件和機械手再出去快。目前4.3秒的機器空循環(huán)已經(jīng)充分優(yōu)化,改進的余地很小。 如果注射裝置尺寸過小,生成熔體可能是一個限制因素。已經(jīng)在循環(huán)速度低達11.6 秒,用2280 克注射量的0.82IV 樹脂測試過目前120 毫米的螺桿可接受的塑煉能力。這時沒有剩余的滯留時間,這樣循環(huán)將受螺桿性能限制。 充料和保壓時間大約為9 秒?,F(xiàn)正在做試驗以量化最佳的充料速度和保壓外形。 冷卻0.5 秒可以實現(xiàn)模具釋壓,但目前的工藝需要冷卻1.3 秒,循環(huán)目前受到在制件上形成凹陷限制。這受到包裝數(shù)量、保壓壓力和開模的速度的影響。由于轉(zhuǎn)位循環(huán)的冷卻時間非常短,瓶胚遇到陰模壁收縮的時間非常少。正在研究改進這方面的循環(huán)性能的機會。 目前出模時的瓶胚溫度將允許循環(huán)時間遠遠少于13 秒,如果僅這一方面是循環(huán)的限制因素的話。 6、瓶胚設計的考慮因素 根據(jù)最初比較原型系統(tǒng)中使用的瓶胚以及為促進使用轉(zhuǎn)位方法減少轉(zhuǎn)位循環(huán)而對各種瓶胚設計做的試驗。因此,實施一種轉(zhuǎn)位系統(tǒng)而非較傳統(tǒng)的成型方法的決定是由于其他許多考慮因素)轉(zhuǎn)位系統(tǒng)要求四套制件模芯,這樣模芯的復雜性以及由此導致的整個模具成本是選擇的一個因素。其他因素包括生產(chǎn)能力要求、可用的地板面積、資本成本。 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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