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外文翻译--单一的塑料注塑模具浇口的优化.doc

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外文翻译--单一的塑料注塑模具浇口的优化.doc

SINGLEGATEOPTIMIZATIONFORPLASTICINJECTIONMOLDLIJIQUAN,LIDEQUN,GUOZHIYING,LVHAIYUANDEPARTMENTOFPLASTICITYTECHNOLOGY,SHANGHAIJIAOTONGUNIVERSITY,SHANGHAI200030,CHINAEMAILHUTLI163COMRECEIVEDNOV22,2006;REVISIONACCEPTEDMAR19,2007ABSTRACTTHISPAPERDEALSWITHAMETHODOLOGYFORSINGLEGATELOCATIONOPTIMIZATIONFORPLASTICINJECTIONMOLDTHEOBJECTIVEOFTHEGATEOPTIMIZATIONISTOMINIMIZETHEWARPAGEOFINJECTIONMOLDEDPARTS,BECAUSEWARPAGEISACRUCIALQUALITYISSUEFORMOSTINJECTIONMOLDEDPARTSWHILEITISINFLUENCEDGREATLYBYTHEGATELOCATIONFEATUREWARPAGEISDEFINEDASTHERATIOOFMAXIMUMDISPLACEMENTONTHEFEATURESURFACETOTHEPROJECTEDLENGTHOFTHEFEATURESURFACETODESCRIBEPARTWARPAGETHEOPTIMIZATIONISCOMBINEDWITHTHENUMERICALSIMULATIONTECHNOLOGYTOFINDTHEOPTIMALGATELOCATION,INWHICHTHESIMULATEDANNEALINGALGORITHMISUSEDTOSEARCHFORTHEOPTIMUMFINALLY,ANEXAMPLEISDISCUSSEDINTHEPAPERANDITCANBECONCLUDEDTHATTHEPROPOSEDMETHODISEFFECTIVEKEYWORDSINJECTIONMOLD,GATELOCATION,OPTIMIZATION,FEATUREWARPAGEDOI101631/JZUS2007A1077DOCUMENTCODEACLCNUMBERTQ32066INTRODUCTIONPLASTICINJECTIONMOLDINGISAWIDELYUSED,COMPLEXBUTHIGHLYEFFICIENTTECHNIQUEFORPRODUCINGALARGEVARIETYOFPLASTICPRODUCTS,PARTICULARLYTHOSEWITHHIGHPRODUCTIONREQUIREMENT,TIGHTTOLERANCE,ANDCOMPLEXSHAPESTHEQUALITYOFINJECTIONMOLDEDPARTSISAFUNCTIONOFPLASTICMATERIAL,PARTGEOMETRY,MOLDSTRUCTUREANDPROCESSCONDITIONSTHEMOSTIMPORTANTPARTOFANINJECTIONMOLDBASICALLYISTHEFOLLOWINGTHREESETSOFCOMPONENTSCAVITIES,GATESANDRUNNERS,ANDCOOLINGSYSTEMLAMANDSEOW2000ANDJINANDLAM2002ACHIEVEDCAVITYBALANCINGBYVARYINGTHEWALLTHICKNESSOFTHEPARTABALANCEFILLINGPROCESSWITHINTHECAVITYGIVESANEVENLYDISTRIBUTEDPRESSUREANDTEMPERATUREWHICHCANDRASTICALLYREDUCETHEWARPAGEOFTHEPARTBUTTHECAVITYBALANCINGISONLYONEOFTHEIMPORTANTINFLUENCINGFACTORSOFPARTQUALITIESESPECIALLY,THEPARTHASITSFUNCTIONALREQUIREMENTS,ANDITSTHICKNESSESSHOULDNOTBEVARIEDUSUALLYFROMTHEPOINTVIEWOFTHEINJECTIONMOLDDESIGN,AGATEISCHARACTERIZEDBYITSSIZEANDLOCATION,ANDTHERUNNERSYSTEMBYTHESIZEANDLAYOUTTHEGATESIZEANDRUNNERLAYOUTAREUSUALLYDETERMINEDASCONSTANTSRELATIVELY,GATELOCATIONSANDRUNNERSIZESAREMOREFLEXIBLE,WHICHCANBEVARIEDTOINFLUENCETHEQUALITYOFTHEPARTASARESULT,THEYAREOFTENTHEDESIGNPARAMETERSFOROPTIMIZATIONLEEANDKIM1996AOPTIMIZEDTHESIZESOFRUNNERSANDGATESTOBALANCERUNNERSYSTEMFORMULTIPLEINJECTIONCAVITIESTHERUNNERBALANCINGWASDESCRIBEDASTHEDIFFERENCESOFENTRANCEPRESSURESFORAMULTICAVITYMOLDWITHIDENTICALCAVITIES,ANDASDIFFERENCESOFPRESSURESATTHEENDOFTHEMELTFLOWPATHINEACHCAVITYFORAFAMILYMOLDWITHDIFFERENTCAVITYVOLUMESANDGEOMETRIESTHEMETHODOLOGYHASSHOWNUNIFORMPRESSUREDISTRIBUTIONSAMONGTHECAVITIESDURINGTHEENTIREMOLDINGCYCLEOFMULTIPLECAVITIESMOLDZHAIETAL2005APRESENTEDTHETWOGATELOCATIONOPTIMIZATIONOFONEMOLDINGCAVITYBYANEFFICIENTSEARCHMETHODBASEDONPRESSUREGRADIENTPGSS,ANDSUBSEQUENTLYPOSITIONEDWELDLINESTOTHEDESIREDLOCATIONSBYVARYINGRUNNERSIZESFORMULTIGATEPARTSZHAIETAL,2006ASLARGEVOLUMEPART,MULTIPLEGATESARENEEDEDTOSHORTENTHEMAXIMUMFLOWPATH,WITHACORRESPONDINGDECREASEININJECTIONPRESSURETHEMETHODISPROMISINGFORDESIGNOFGATESANDRUNNERSFORASINGLECAVITYWITHMULTIPLEGATESMANYOFINJECTIONMOLDEDPARTSAREPRODUCEDWITHONEGATE,WHETHERINSINGLECAVITYMOLDORINMULTIPLECAVITIESMOLDTHEREFORE,THEGATELOCATIONOFASINGLEGATEISTHEMOSTCOMMONDESIGNPARAMETERFOROPTIMIZATIONASHAPEANALYSISAPPROACHWASPRESENTEDBYCOURBEBAISSEANDGARCIA2002,BYWHICHTHEBESTGATELOCATIONOFINJECTIONMOLDINGWASESTIMATEDSUBSEQUENTLY,THEYDEVELOPEDTHISMETHODOLOGYFURTHERANDAPPLIEDITTOSINGLEGATELOCATIONOPTIMIZATIONOFANLSHAPEEXAMPLECOURBEBAISSE,2005ITISEASYTOUSEANDNOTTIMECONSUMING,WHILEITONLYSERVESTHETURNINGOFSIMPLEFLATPARTSWITHUNIFORMTHICKNESSPANDELIDISANDZOU1990PRESENTEDTHEOPTIMIZATIONOFGATELOCATION,BYINDIRECTQUALITYMEASURESRELEVANTTOWARPAGEANDMATERIALDEGRADATION,WHICHISREPRESENTEDASWEIGHTEDSUMOFATEMPERATUREDIFFERENTIALTERM,ANOVERPACKTERM,ANDAFRICTIONALOVERHEATINGTERMWARPAGEISINFLUENCEDBYTHEABOVEFACTORS,BUTTHERELATIONSHIPBETWEENTHEMISNOTCLEARTHEREFORE,THEOPTIMIZATIONEFFECTISRESTRICTEDBYTHEDETERMINATIONOFTHEWEIGHTINGFACTORSLEEANDKIM1996BDEVELOPEDANAUTOMATEDELECTIONMETHODOFGATELOCATION,INWHICHASETOFINITIALGATELOCATIONSWEREPROPOSEDBYADESIGNERANDHENTHEOPTIMALGATEWASLOCATEDBYTHEADJACENTNODEEVALUATIONMETHODTHECONCLUSIONTOAGREATEXTENTDEPENDSMUCHONTHEHUMANDESIGNER’SINTUITION,BECAUSETHEFIRSTSTEPOFTHEMETHODISBASEDONTHEDESIGNER’SPROPOSITIONSOTHERESULTISTOALARGEEXTENTLIMITEDTOTHEDESIGNER’SEXPERIENCEDEFINITIONOFFEATUREWARPAGETOAPPLYOPTIMIZATIONTHEORYTOTHEGATEDESIGN,QUALITYMEASURESOFTHEPARTMUSTBESPECIFIEDINTHEFIRSTINSTANCETHETERM“QUALITY”MAYBEREFERREDTOMANYPRODUCTPROPERTIES,SUCHASMECHANICAL,THERMAL,ELECTRICAL,OPTICAL,ERGONOMICALORGEOMETRICALPROPERTIESTHEREARETWOTYPESOFPARTQUALITYMEASURESDIRECTANDINDIRECTAMODELTHATPREDICTSTHEPROPERTIESFROMNUMERICALSIMULATIONRESULTSWOULDBECHARACTERIZEDASADIRECTQUALITYMEASUREINCONTRAST,ANINDIRECTMEASUREOFPARTQUALITYISCORRELATEDWITHTARGETQUALITY,BUTITCANNOTPROVIDEADIRECTESTIMATEOFTHATQUALITYFORWARPAGE,THEINDIRECTQUALITYMEASURESINRELATEDWORKSAREONEOFPERFORMANCESOFINJECTIONMOLDINGFLOWINGBEHAVIORORWEIGHTEDSUMOFTHOSETHEPERFORMANCESAREPRESENTEDASFILLINGTIMEDIFFERENTIALALONGDIFFERENTFLOWPATHS,TEMPERATUREDIFFERENTIAL,OVERPACKPERCENTAGE,ANDSOONITISOBVIOUSTHATWARPAGEISINFLUENCEDBYTHESEPERFORMANCES,BUTTHERELATIONSHIPBETWEENWARPAGEANDTHESEPERFORMANCESISNOTCLEARANDTHEDETERMINATIONOFTHESEWEIGHTINGFACTORSISRATHERDIFFICULTTHEREFORE,THEOPTIMIZATIONWITHTHEABOVEOBJECTIVEFUNCTIONPROBABLYWILLNOTMINIMIZEPARTWARPAGEEVENWITHPERFECTOPTIMIZATIONTECHNIQUESOMETIMES,IMPROPERWEIGHTINGFACTORSWILLRESULTINABSOLUTELYWRONGRESULTSININDUSTRY,DESIGNERSANDMANUFACTURERSUSUALLYPAYMOREATTENTIONTOTHEDEGREEOFPARTWARPAGEONSOMESPECIFICFEATURESTHANTHEWHOLEDEFORMATIONOFTHEINJECTIONMOLDEDPARTSINTHISSTUDY,FEATUREWARPAGEISDEFINEDTODESCRIBETHEDEFORMATIONOFTHEINJECTIONPARTSTHEFEATUREWARPAGEISTHERATIOOFTHEMAXIMUMDISPLACEMENTOFTHEFEATURESURFACETOTHEPROJECTEDLENGTHOFTHEFEATURESURFACEFIG1ΓLH1001WHEREΓISTHEFEATUREWARPAGE,HISTHEMAXIMUMDISPLACEMENTONTHEFEATURESURFACEDEVIATINGFROMTHEREFERENCEPLATFORM,ANDLISTHEPROJECTEDLENGTHOFTHEFEATURESURFACEONAREFERENCEDIRECTIONPARALLELINGTHEREFERENCEPLATFORMEVALUATIONOFFEATUREWARPAGEAFTERTHEDETERMINATIONOFTARGETFEATURECOMBINEDWITHCORRESPONDINGREFERENCEPLANEANDPROJECTIONDIRECTION,THEVALUEOFLCANBECALCULATEDIMMEDIATELYFROMTHEPARTWITHTHECALCULATINGMETHODOFANALYTICGEOMETRYFIG2LISACONSTANTFORANYPARTONTHESPECIFIEDFEATURESURFACEANDPROJECTEDDIRECTIONBUTTHEEVALUATIONOFHISMORECOMPLICATEDTHANTHATOFLSIMULATIONOFINJECTIONMOLDINGPROCESSISACOMMONTECHNIQUETOFORECASTTHEQUALITYOFPARTDESIGN,MOLDDESIGNANDPROCESSSETTINGSTHERESULTSOFWARPAGESIMULATIONAREEXPRESSEDASTHENODALDEFLECTIONSONX,Y,ZCOMPONENTWX,WY,WZ,ANDTHENODALDISPLACEMENTWWISTHEVECTORLENGTHOFVECTORSUMOFWXI,WYJ,ANDWZK,WHEREI,J,KARETHEUNITVECTORSONX,Y,ZCOMPONENTTHEHISTHEMAXIMUMDISPLACEMENTOFTHENODESONTHEFEATURESURFACE,WHICHISCORRELATEDWITHTHENORMALORIENTATIONOFTHEREFERENCEPLANE,ANDCANBEDERIVEDFROMTHERESULTSOFWARPAGESIMULATIONTOCALCULATEH,THEDEFLECTIONOFITHNODEISEVALUATEDFIRSTLYASFOLLOWSWHEREWIISTHEDEFLECTIONINTHENORMALDIRECTIONOFTHEREFERENCEPLANEOFITHNODE;WIX,WIY,WIZARETHEDEFLECTIONSONX,Y,ZCOMPONENTOFITHNODE;Α,Β,ΓARETHEANGLESOFNORMALVECTOROFTHEREFERENCE;AANDBARETHETERMINALNODESOFTHEFEATURETOPROJECTINGDIRECTIONFIG2;WAANDWBARETHEDEFLECTIONSOFNODESAANDBAPPLICATIONANDDISCUSSIONTHEAPPLICATIONTOACOMPLEXINDUSTRIALPARTISPRESENTEDINTHISSECTIONTOILLUSTRATETHEPROPOSEDQUALITYMEASUREANDOPTIMIZATIONMETHODOLOGYTHEPARTISPROVIDEDBYAMANUFACTURER,ASSHOWNINFIG4INTHISPART,THEFLATNESSOFBASALSURFACEISTHEMOSTIMPORTANTPROFILEPRECISIONREQUIREMENTTHEREFORE,THEFEATUREWARPAGEISDISCUSSEDONBASALSURFACE,INWHICHREFERENCEPLATFORMISSPECIFIEDASAHORIZONTALPLANEATTACHEDTOTHEBASALSURFACE,ANDTHELONGITUDINALDIRECTIONISSPECIFIEDASPROJECTEDREFERENCEDIRECTIONTHEPARAMETERHISTHEMAXIMUMBASALSURFACEDEFLECTIONONTHENORMALDIRECTION,NAMELYTHEVERTICALDIRECTION,ANDTHEPARAMETERLISTHEPROJECTEDLENGTHOFTHEBASALSURFACETOTHELONGITUDINALDIRECTIONTHEMATERIALOFTHEPARTISNYLONZYTEL101L30EGF,DUPONTENGINEERINGPOLYMERTHEMOLDINGCONDITIONSINTHESIMULATIONARELISTEDINTABLE1FIG5SHOWSTHEFINITEELEMENTMESHMODELOFTHEPARTEMPLOYEDINTHENUMERICALSIMULATIONITHAS1469NODESAND2492ELEMENTSMPIISTHEMOSTEXTENSIVESOFTWAREFORTHEINJECTIONMOLDINGSIMULATION,WHICHCANRECOMMENDTHEBESTGATELOCATIONBASEDONBALANCEDFLOWGATELOCATIONANALYSISISANEFFECTIVETOOLFORGATELOCATIONDESIGNBESIDESEMPIRICALMETHODFORTHISPART,THEGATELOCATIONANALYSISOFMPIRECOMMENDSTHATTHEBESTGATELOCATIONISNEARNODEN7459,ASSHOWNINFIG5THEPARTWARPAGEISSIMULATEDBASEDONTHISRECOMMENDEDGATEANDTHUSTHEFEATUREWARPAGEISEVALUATEDΓ515,WHICHISAGREATVALUEINTRIALMANUFACTURING,PARTWARPAGEISVISIBLEONTHESAMPLEWORKPIECETHISISUNACCEPTABLEFORTHEMANUFACTURERTHEGREATWARPAGEONBASALSURFACEISCAUSEDBYTHEUNEVENORIENTATION

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