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0 Injection Molding CAE Technology 0 Introduction Plastic products from product design to production including molding plastic products design mold design mold manufacturing and injection molding process parameters and several other main areas The traditional injection mold design mainly rely on the designer s experience while the injection molding process is very complex plastic melt flow properties of different and ever changing products and die structure process conditions vary forming various defects mold design often require repeated trial mode maintenance mode can be put into production with little of a successful identify problems not only to re adjust the process parameters or even to modify the plastic products and molds not only time consuming and laborious but also reduces product development time The use of injection molding CAE technology in mold manufacturing prior to simulate injection molding process including filling packing and cooling and the early detection of problems optimize mold design and process conditions set to reduce the number of test mode in order to improve production efficiency has become a injection molding technology is an important direction of development 1 The history of Injection Molding CAE technology Injection Molding CAE technology is based on plastics processing rheology and heat transfer of the basic theory the melt in the mold cavity in the flow heat transfer physics mathematical model using numerical solution method of constructing the theory the use of computer visualization technology image visually simulate the dynamics of the actual shape of the melt filling and cooling process an analysis techniques The 20th century 60 years the United Kingdom the United States and Canada and other countries of the scholars such as JRPearson United Kingdom JFStevenson America MRKamal Canada and KKWang America etc to carry out a series of 1 plastic melt in the mold type cavity flow and cooling of basic research At a reasonable simplification based on 60 years completed a one dimensional flow and cooling analysis programs 70 years to complete the two dimensional cooling analysis programs and 80 years from the injection molding CAE technology has begun to theoretical research into the practical phase launched a three dimensional flow and cooling analysis and the study extended to packing fiber orientation and warpage prediction of molecular and other fields After 90 years carried out into the flow packing cooling and stress analysis the whole process of injection molding processes are integrated research CAE technologies for the injection mold design provides a reliable guarantee that its application is mold design in the history of a major change 2 The role of Injection Molding CAE technology Using traditional methods of design of injection mold design success will rely heavily on the experience of designers but also for complex parts gate position is reasonable or not the location of the exhaust slot settings to determine the location of weld lines and so very difficult Die in delivery will normally take before the test mode after repeated changes until the products have been qualified which inevitably led to the extension of the production cycle and generally difficult to obtain an optimal design and process parameters The use of injection molding CAE technical design mold is not true because of mold design concept stage can make use of CAE technology in injection molding process simulation flow making usually only in the mold tryout phases in order to find problems such as short shots weld lines or holes appear in the surface appearance of parts and other issues have been avoided While helping the designer to complete the balance of the system such as flow channel design exhaust ducts setting rationally determine the injection molding process parameters etc so that usually makes the modification must be repeated tryout to determine structural parameters of the mold die design and process parameters in the conceptual stage able to determine reduce the mold design and manufacturing cycle and improve the mold design quality 2 Therefore the role of injection molding CAE software mainly as follows 1 Optimize design of plastic products Plastic wall thickness gate number and location of the design of flow channel system for the quality of plastic products have a significant impact Depends on the experience of the past designers using manual methods to achieve time consuming effort but the use of CAE technology to quickly design the best products 2 optimize the plastic mold design Can be cavity size gate location and number of flow channel dimensions and cooling systems to optimize the design On the computer simulation test mold mold repair mold and improve quality and reduce the number of actual tryout 3 to optimize injection process parameters Simulation of the injection process and found possible shape defects to determine the best injection pressure clamping force mold temperature melt temperature injection time and cooling time This shows that the injection molding CAE technology in terms of improving productivity reduce mold design and manufacture cycle and to ensure product quality or reduce costs reduce labor intensity and so on have very significant technical advantages and economic significance 3 Injection Molding CAE software types and their details To date a mature business are more injection molding CAE software Moldflow Corporation Moldflow software and AC Tech Inc February 2000 was Moldflow Merger and C Mold software is an excellent representative There are also foreign The TMCONCEPT CADMold Fidap Stirm100 Polyflow and China s Taiwan region Moldex peer software applications are relatively wide and domestic in the Eighth Five Year period began research in this area and now Huazhong University of Technology HSCAE software and Zhengzhou University Z Mold software in China in the leading position Moldflow software is specialized in injection molding CAE software and consulting 3 for Moldflow s range of products the company issued since 1976 the world s first set of injection molding CAE software has been a leading injection molding CAE software market To 2004 Moldflow Injection Molding CAE software in the global market share of over 75 MoldFlow software includes three parts MoldFlow Plastics Advisers product optimization consultant MPA MoldFlow Plastics Insisht injection molding simulation analysis MPI and MoldFlow Plastics Xpert injection molding process control specialists MPX Under normal circumstances the most commonly used MPI is mainly used for injection molding process simulation to get the best number and location of the gate reasonable flow channel system and cooling system and cavity size gate size runner size and cooling systems to optimize the size and the injection molding process parameters may also be optimized Moldflow Software Moldflow analysis techniques can be divided into three kinds namely Midplane Fusion and 3D 4 Moldflow analysis of Midplane Midplane in the surface flow applications began in the 20th century the 80s The grid is a three node triangular element its principle is the 3D geometric model of simplified geometric model of the neutral surface to be created in the model grid the middle of the wall thickness using established simulation analysis of the neutral surface ie to flow in plane to simulate three dimensional solid flow The analysis of technological development has been very mature and stable and the advantages for the analysis of speed and high efficiency Based on the flow of surface flow simulation of injection molding technology software applications the longest widest range But the practice shows that based on the surface flow simulation software in the application of technology that has significant limitations specifically as follows 1 The user must construct a mid surface model Using manual directly from the physical model structure in the surface model is very difficult and often takes a lot of 4 time and can not be converted from other CAD models 2 can not be described in a number of three dimensional features If they can not describe the inertia effect gravitational effects on melt flow which fail to predict jet phenomenon melt the forefront of Quan phenomena 3 The use of CAD phase of the product model and stages of the use of CAE analysis model is not unified so that the inevitable second modeling CAD and CAE systems integration can not be achieved 5 Moldflow s Fusion analysis Fusion double flow analysis technique is based on Moldflow s patented Dual Domain of analysis techniques Fusion launched in 2000 analysis techniques enabling users do not need to extract the neutral surface can be analyzed to overcome the reconstruction of the geometric model thus greatly reducing the burden on the user modeling Grid is also a triangular element and its principle is to mold cavity or the products in the thickness direction is divided into two parts finite element mesh on the surface of the cavity or the products In the flow process the upper and lower surface of the plastic melt at the same time two and to coordinate movement of the simulation shown Clearly Fusion technology the surface of the grid is based on the neutral surface is still not solve the fundamental problem the neutral surface so double sided application of the principle of streaming technologies and methods applied in the surface flow with no difference in the nature the The difference is two sided flow using a series of related algorithms will flow along the surface of the single stranded melts evolved along the upper and lower surface of the coordination of the flow of dual stream Double sided flow of technology s biggest advantage is that the model greatly shorten the preparation time thus greatly reducing the burden on the user modeling will take several hours or even days of the original modeling work reduced to a few minutes Therefore based on double sided flow simulation software technology although the advent of time only a few years but in the world but has a huge user base get the 5 majority of customers for their support and praise But the double sided flow of technology has the following deficiencies 1 The two sided flow of technology does not fundamentally resolve the issue of a neutral face they still can not describe some three dimensional features such as the inertial effect can not describe gravity effect on the melt flow which fail to predict jet phenomenon melt cutting edge Quanyong phenomena 2 the upper and lower surfaces corresponding to the melt flow front there are differences As the upper and lower surface of the grid can not be one correspondence but the grid shape orientation and size can not be completely symmetrical so how the upper and lower surfaces corresponding to the difference between the melt flow front control is within the scope permitted by Difficulties in the implementation of double sided streaming technology 3 melt is only along the upper and lower surface flows in the thickness direction is not to make any treatment lack of realism 6 Moldflow s 3D analysis techniques These two techniques have overlooked the thickness direction of the physical quantity only two dimensional simulation and therefore results are not very precise Moldflow Corporation s 3D 3D analysis technology uses a true three dimensional solid model flow analysis techniques through rigorous theoretical derivation and repeated verification the inertial effect non isothermal flow taking into account factors such as finite element analysis the melt thickness direction of the physical quantity changes will no longer be ignored can be a more comprehensive description of the process of filling flow phenomena so that results of the analysis more realistic conditions applicable to all plastic products Its three dimensional grid is from the four node tetrahedron unit And using the new 3D stereoscopic display technology can quickly model clearly shows that internal and external flow field temperature field stress field and velocity field such as analysis results For the above mentioned results of the analysis can also be used such as bit lines or equipotential surface display so that physical models and external changes in the variables show more 6 clearly the case Moldfiow also offers animation capabilities through 3D animation display plastic melt in the changes in the flow cavity allowing users to more intuitively see the design and manufacturing process may encounter problems But the 3D technology meshing demanding more complex equations to calculate the amount of large long duration and the computational efficiency is low not suitable for short development cycle and need to be repeatedly revised by CAE verification injection mold design Therefore the current penetration rate of the technology is not very high but it will eventually replace the surface flow of technology and double sided streaming technology 7 Development Trend of Injection Molding Injection Molding CAE technology whether in theory or in the application have made great strides but in the following still needs further improvement and development 1 mathematical models numerical algorithms to gradually improve the Injection Molding CAE technology practicality depending on the accuracy of the mathematical model and numerical algorithm accuracy The current commercial simulation software models do not fully consider the physical quantities in the thickness direction of the impact of the software in order to further improve the analysis accuracy and scope to further improve the existing mathematical models and algorithms 2 the whole process of injection molding simulation At present the injection molding simulation software are mainly filling flow packing cooling stress and strain and warpage analysis modules each module was developed based on independent mathematical models these models has been simplified to a large extent ignored of the mutual effects However in view of injection molding process plastic melt filling flow packing and cooling are intertwined and affect each other and therefore filling flow packing and cooling analysis module must be organically combined to carry out coupling analysis in order to comprehensively reflect the real situation of injection molding 7 3 optimization theory and algorithms so that CAE technology active to optimize the design Artificial intelligence technologies such as expert systems and neural networks on the design calculations so that simulation can wisdom to choose the injection molding process parameters product size and cooling to fix the piping layout programs to reduce manual intervention in the program 4 a new method of injection molding simulation analysis of the current In the conventional injection molding technology based on and the development of a number of new injection molding methods such as gas assisted injection thin wall injection molding reaction injection and co injection However no specific methods for these molding simulation software so untapped 5 injection mold CAD CAE CAM integrated and network based The current commercial injection molding CAE software and CAD CAM software data transfer between the mainly rely on the file conversion which easily lead to data loss and errors Therefore in design and manufacturing process to take a single model the establishment of injection mold CAD CAE CAM system a unified database to strengthen the linkages between the three directions of future development In order to meet the development requirements of e commerce this integrated system will achieve different places of the Collaborative Design and virtual manufacturing 8 Conclusion Despite the adoption of a large number of practice has proved in the plastic mold industry the introduction of CAE technology greatly reducing the mold design and manufacturing cycle and improve the life of the mold and manufacturing precision At the same time CAE technologies has also made from the traditional injection mold design experience and skills onto the road of scientific to a certain extent changed the injection mold of traditional production methods but there is no substitute for CAE technology and people s creative work only can serve as a complementary tool 8 to help engineers understand the problems in the program but also difficult to provide a clear improvement program still need to through repeated interactions analysis changes re analysis in order to reflect the experience of the designer s right to die design go the program is designed to determine to a large extent continue to rely on the designer s experience and level 9 注塑模 CAE 技術(shù) 0 引言 塑料產(chǎn)品從產(chǎn)品設(shè)計(jì)到成型生產(chǎn)包括塑料制品設(shè)計(jì) 模具設(shè)計(jì) 模具制造 和注塑工藝參數(shù)選擇等幾個(gè)主要方面 傳統(tǒng)的注塑模具設(shè)計(jì)主要依靠設(shè)計(jì)人員 的經(jīng)驗(yàn) 而注塑成型過程非常復(fù)雜 塑料熔體的流動(dòng)性能千差萬(wàn)別 制品和模 具的結(jié)構(gòu)千變?nèi)f化 工藝條件各不相同 成型缺陷各式各樣 模具設(shè)計(jì)往往需 要反復(fù)的試模 修模才能投入生產(chǎn) 很少有一次成功的 發(fā)現(xiàn)問題后 不僅要 重新調(diào)整工藝參數(shù) 甚至要修改塑料制品和模具 不但費(fèi)時(shí)費(fèi)力 而且降低了 產(chǎn)品的開發(fā)速度 而利用注塑模 CAE 技術(shù)可以在模具制造前 模擬注塑過程 包括充填 保壓及冷卻 并及早發(fā)現(xiàn)問題 優(yōu)化模具設(shè)計(jì)和工藝條件設(shè)定 減少試模次數(shù)以提高生產(chǎn)效率 現(xiàn)已成為注塑加工技術(shù)的一個(gè)重要發(fā)展方向 1 注塑模 CAE 技術(shù)的歷史 注塑模 CAE 技術(shù)是根據(jù)塑料加工流變學(xué)和傳熱學(xué)的基本理論 建立熔體在 模具型腔中的流動(dòng) 傳熱的物理 數(shù)學(xué)模型 利用數(shù)值計(jì)算理論構(gòu)造其求解方 法 利用計(jì)算機(jī)可視化技術(shù)形象 直觀地模擬出實(shí)際成型中熔體的動(dòng)態(tài)填充 冷卻過程的一門分析技術(shù) 20 世紀(jì) 60 年代 英國(guó) 美國(guó)和加拿大等國(guó)的學(xué)者如 J R Pearson 英 J F Stevenson 美 M R Kamal 加 和 K K Wang 美 等開展了一系列有關(guān)塑 料熔體在模具型腔內(nèi)流動(dòng)與冷卻的基礎(chǔ)研究 在合理的簡(jiǎn)化基礎(chǔ)上 60 年代完 成了一維流動(dòng)與冷卻分析程序 70 年代完成了二維冷卻分析程序 80 年代注塑 模 CAE 技術(shù)開始從理論研究進(jìn)入實(shí)用化階段 開展了三維流動(dòng)與冷卻分析并把 研究擴(kuò)展到保壓 纖維分子取向以及翹曲預(yù)測(cè)等領(lǐng)域 進(jìn)入 90 年代后開展了流 動(dòng) 保壓 冷卻和應(yīng)力分析等注塑工藝全過程的集成化研究 CAE 技術(shù)的出現(xiàn) 為注塑模設(shè)計(jì)提供了可靠的保證 它的應(yīng)用是模具設(shè)計(jì) 史上的一次重大變革 2 注塑模 CAE 技術(shù)的作用 10 利用傳統(tǒng)方法設(shè)計(jì)注塑模具 設(shè)計(jì)成功與否將很大程度上依賴設(shè)計(jì)者的經(jīng) 驗(yàn) 而且對(duì)復(fù)雜零件澆口位置的合理與否 排氣槽位置的設(shè)置 熔接線位置的 確定等都十分困難 模具在交付使用之前一般需經(jīng)過反復(fù)試模修改 直到得到 合格的制品為止 從而不可避免地造成了生產(chǎn)周期的延長(zhǎng) 而且一般也難以得 到最優(yōu)的設(shè)計(jì)方案和工藝參數(shù) 而利用注塑模 CAE 技術(shù)設(shè)計(jì)模具則不然 由于 在模具設(shè)計(jì)構(gòu)思階段 可利用注塑模 CAE 技術(shù)進(jìn)行流動(dòng)過程模擬 使得通常只 有在模具試模階段才能發(fā)現(xiàn)的問題 如短射 熔接線或氣孔出現(xiàn)在外觀零件表 面等問題得以避免 同時(shí)幫助設(shè)計(jì)人員完成諸如流道系統(tǒng)的平衡設(shè)計(jì) 排氣槽 的設(shè)置 合理確定注塑工藝參數(shù)等工作 這樣使得通常在必須反復(fù)試模修改而 確定的模具結(jié)構(gòu)參數(shù)和工藝參數(shù)在模具設(shè)計(jì)構(gòu)思階段得以確定 縮短了模具設(shè) 計(jì)制造周期 提高了模具設(shè)計(jì)質(zhì)量 所以注塑模 CAE 軟件的作用主要表現(xiàn)為 1 優(yōu)化塑料制品設(shè)計(jì) 塑料的壁厚 澆口的數(shù)量及位置 流道系統(tǒng)的設(shè)計(jì)等對(duì)于塑料制品的質(zhì)量 有重大影響 以往全憑設(shè)計(jì)者的經(jīng)驗(yàn) 用手工方法實(shí)現(xiàn) 費(fèi)時(shí)費(fèi)力 而利用 CAE 技術(shù) 可快速設(shè)計(jì)出最佳的制品 2 優(yōu)化塑料模具設(shè)計(jì) 可以對(duì)型腔尺寸 澆口位置及數(shù)量 流道尺寸和冷卻系統(tǒng)等進(jìn)行優(yōu)化設(shè)計(jì) 在計(jì)算機(jī)上模擬試模 修模和提高模具質(zhì)量 減少實(shí)際試模次數(shù) 3 優(yōu)化注射工藝參數(shù) 對(duì)注射過程進(jìn)行模擬 發(fā)現(xiàn)可能出現(xiàn)的成型缺陷 確定最佳的注射壓力 鎖模力 模具溫度 熔體溫度 注射時(shí)間和冷卻時(shí)間等 由此可見 注塑模 CAE 技術(shù)無(wú)論在提高生產(chǎn)率 縮短模具設(shè)計(jì)制造周期和 保證產(chǎn)品質(zhì)量 還是在降低成本 減輕勞動(dòng)強(qiáng)度等方面 都具有很大的優(yōu)越性 和重大的技術(shù)經(jīng)濟(jì)意義 3 注塑模 CAE 軟件種類及其簡(jiǎn)介 到目前為止 成熟的商業(yè)注塑模 CAE 軟件比較多 Moldflow 公司的 Moldflow 軟件和 AC Tech 公司 2000 年 2 月 被 Moldflow 公司合并 的 C Mold 軟件是其中的優(yōu)秀代表 另外還有國(guó)外的 11 TMCONCEPT CADMold Fidap Stirm100 Polyflow 和我國(guó)臺(tái)灣地區(qū)的 Moldex 等軟件應(yīng)用也比較廣 而國(guó)內(nèi)在 八五 期間才開始這方面的研究 現(xiàn)在華中 理工大學(xué)的 HSCAE 軟件和鄭州大學(xué)的 Z Mold 軟件在國(guó)內(nèi)處于領(lǐng)先地位 Moldflow 軟件是專業(yè)從事注塑成型 CAE 軟件和咨詢的 Moldflow 公司的系 列產(chǎn)品 該公司自 1976 年發(fā)行了世界上第一套注塑模 CAE 軟件以來 一直主導(dǎo) 注塑模 CAE 軟件市場(chǎng) 至 2004 年 Moldflow 軟件在全球注塑模 CAE 市場(chǎng)的占 有率達(dá) 75 MoldFlow 軟件包括三部分 MoldFlow Plastics Advisers 產(chǎn)品優(yōu)化顧問 MPA MoldFlow Plastics Insisht 注塑成型模擬分析 MPI 和 MoldFlow Plastics Xpert 注塑成型過程控制專家 MPX 一般情況下 最常用 MPI 主要用來對(duì)注塑過程進(jìn)行模擬 從而得到最佳 的澆口數(shù)量與位置 合理的流道系統(tǒng)與冷卻系統(tǒng) 并對(duì)型腔尺寸 澆口尺寸 流道尺寸和冷卻系統(tǒng)尺寸進(jìn)行優(yōu)化 并且還可對(duì)注塑工藝參數(shù)進(jìn)行優(yōu)化 Moldflow 軟件的模流分析技術(shù)可以分為三種 即 Midplane Fusion 和 3D 4 Moldflow 的 Midplane 分析技術(shù) Midplane 中面流 的應(yīng)用始于 20 世紀(jì) 80 年代 其網(wǎng)格是三節(jié)點(diǎn)的三角 形單元 其原理是將 3D 幾何模型簡(jiǎn)化成中性面幾何模型 即將網(wǎng)格創(chuàng)建在模型 壁厚的中間處 利用所建立的中性面進(jìn)行模擬分析 即以平面流動(dòng)來仿真三維 實(shí)體流動(dòng) 此分析技術(shù)發(fā)展至今已相當(dāng)成熟穩(wěn)定 其優(yōu)點(diǎn)為分析速度快 效率 高 基于中面流技術(shù)的注塑流動(dòng)模擬軟件應(yīng)用的時(shí)間最長(zhǎng) 范圍也最廣 但是 實(shí)踐表明 基于中面流技術(shù)的模擬軟件在應(yīng)用中具有很大的局限性 具體表現(xiàn) 為 1 用戶必須構(gòu)造出中面模型 采用手工操作直接由實(shí)體模型 構(gòu)造中面模型十分困難 往往需要花費(fèi)大量的時(shí)間 而且不能從其他 CAD 模型 轉(zhuǎn)換 2 無(wú)法描述一些三維特征 如不能描述慣性效應(yīng) 重力效應(yīng)對(duì)熔體流動(dòng)的影 響 不能預(yù)測(cè)噴射現(xiàn)象 熔體前沿的泉涌現(xiàn)象等 3 由于 CAD 階段使用的產(chǎn)品模型和 CAE 階段使用的分析模型不統(tǒng)一 使二次 12 建模不可避免 CAD 與 CAE 系統(tǒng)的集成也無(wú)法實(shí)現(xiàn) 5 Moldflow 的 Fusion 分析技術(shù) Fusion 雙面流 分析技術(shù)是基于 Moldflow 的獨(dú)家專利 Dual Domain 的分 析技術(shù) 2000 年推出的 Fusion 分析技術(shù) 使得用戶不需要抽取中性面就可以 進(jìn)行分析 克服了幾何模型的重建問題 大大減輕了用戶建模的負(fù)擔(dān) 網(wǎng)格也 是三角形單元 而其原理是將模具型腔或制品在厚度方向上分成兩部分 有限 元網(wǎng)格在型腔或制品的表面產(chǎn)生 在流動(dòng)過程中 上 下兩表面的塑料熔體同 時(shí)并且協(xié)調(diào)地流動(dòng) 顯然 Fusion 技術(shù)的表面網(wǎng)格是基于中性面的 仍無(wú)法解決中性面的根本 問題 所以雙面流技術(shù)所應(yīng)用的原理和方法與中面流所應(yīng)用的沒有本質(zhì)上的差 別 所不同的是雙面流采用了一系列相關(guān)的算法 將沿中面流動(dòng)的單股熔體演 變?yōu)檠厣?下表面協(xié)調(diào)流動(dòng)的雙股流 雙面流技術(shù)的最大優(yōu)點(diǎn)是模型的準(zhǔn)備時(shí)間大大縮短 這樣就大大減輕了用 戶建模的負(fù)擔(dān) 將原來需要幾小時(shí)甚至幾天的建模工作縮短為幾分鐘 因此 基于雙面流技術(shù)的模擬軟件問世時(shí)間雖然只有短短數(shù)年 但在全世界卻擁有了 龐大的用戶群 得到了廣大用戶的支持和好評(píng) 但是雙面流技術(shù)有以下不足 1 由于雙面流技術(shù)沒有從根本上解決中性面的問題 所以還是無(wú)法描述 某些三維特征 如不能描述慣性效應(yīng) 重力效應(yīng)對(duì)熔體流動(dòng)的影響 不能預(yù)測(cè) 噴射現(xiàn)象 熔體前沿的泉涌現(xiàn)象等 2 上 下對(duì)應(yīng)表面的熔體流動(dòng)前沿存在差別 由于上 下表面的網(wǎng)格無(wú) 法一一對(duì)應(yīng) 而且網(wǎng)格形狀 方位與大小也不可能完全對(duì)稱 所以如何將上 下對(duì)應(yīng)表面的熔