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外文翻译--塑料注射模具的并行设计.doc

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外文翻译--塑料注射模具的并行设计.doc

英文原文CONCURRENTDESIGNOFPLASTICSINJECTIONMOULDSASSISTPROFDRAYAYLA/PROFDRPAŞAYAYLAABSTRACTTHEPLASTICPRODUCTMANUFACTURINGINDUSTRYHASBEENGROWINGRAPIDLYINRECENTYEARSONEOFTHEMOSTPOPULARPROCESSESFORMAKINGPLASTICPARTSISINJECTIONMOULDINGTHEDESIGNOFINJECTIONMOULDISCRITICALLYIMPORTANTTOPRODUCTQUALITYANDEFFICIENTPRODUCTPROCESSINGMOULDMAKINGCOMPANIES,WHOWISHTOMAINTAINTHECOMPETITIVEEDGE,DESIRETOSHORTENBOTHDESIGNANDMANUFACTURINGLEADINGTIMESOFTHEBYAPPLYINGASYSTEMATICMOULDDESIGNPROCESSTHEMOULDINDUSTRYISANIMPORTANTSUPPORTINDUSTRYDURINGTHEPRODUCTDEVELOPMENTPROCESS,SERVINGASANIMPORTANTLINKBETWEENTHEPRODUCTDESIGNERANDMANUFACTURERPRODUCTDEVELOPMENTHASCHANGEDFROMTHETRADITIONALSERIALPROCESSOFDESIGN,FOLLOWEDBYMANUFACTURE,TOAMOREORGANIZEDCONCURRENTPROCESSWHEREDESIGNANDMANUFACTUREARECONSIDEREDATAVERYEARLYSTAGEOFDESIGNTHECONCEPTOFCONCURRENTENGINEERINGCEISNOLONGERNEWANDYETITISSTILLAPPLICABLEANDRELEVANTINTODAY’SMANUFACTURINGENVIRONMENTTEAMWORKINGSPIRIT,MANAGEMENTINVOLVEMENT,TOTALDESIGNPROCESSANDINTEGRATIONOFITTOOLSARESTILLTHEESSENCEOFCETHEAPPLICATIONOFTHECEPROCESSTOTHEDESIGNOFANINJECTIONPROCESSINVOLVESTHESIMULTANEOUSCONSIDERATIONOFPLASTICPARTDESIGN,MOULDDESIGNANDINJECTIONMOULDINGMACHINESELECTION,PRODUCTIONSCHEDULINGANDCOSTASEARLYASPOSSIBLEINTHEDESIGNSTAGTHISPAPERPRESENTSTHEBASICSTRUCTUREOFANINJECTIONMOULDDESIGNTHEBASISOFTHISSYSTEMARISESFROMANANALYSISOFTHEINJECTIONMOULDDESIGNPROCESSFORMOULDDESIGNCOMPANIESTHISINJECTIONMOULDDESIGNSYSTEMCOVERSBOTHTHEMOULDDESIGNPROCESSANDMOULDKNOWLEDGEMANAGEMENTFINALLYTHEPRINCIPLEOFCONCURRENTENGINEERINGPROCESSISOUTLINEDANDTHENITSPRINCIPLEISAPPLIEDTOTHEDESIGNOFAPLASTICINJECTIONMOULDKEYWORDSPLASTICINJECTIONMOULDDESIGN,CONCURRENTENGINEERING,COMPUTERAIDEDENGINEERING,MOULDINGCONDITIONS,PLASTICINJECTIONMOULDING,FLOWSIMULATION1INTRODUCTIOINJECTIONMOULDSAREALWAYSEXPENSIVETOMAKE,UNFORTUNATELYWITHOUTAMOULDITCANNOTBEPOSSIBLEHOHAVEAMOULDEDPRODUCTEVERYMOULDMAKERHASHIS/HEROWNAPPROACHTODESIGNAMOULDANDTHEREAREMANYDIFFERENTWAYSOFDESIGNINGANDBUILDINGAMOULDSURELYONEOFTHEMOSTCRITICALPARAMETERSTOBECONSIDEREDINTHEDESIGNSTAGEOFTHEMOULDISTHENUMBEROFCAVITIES,METHODSOFINJECTION,TYPESOFRUNNERS,METHODSOFGATING,METHODSOFEJECTION,CAPACITYANDFEATURESOFTHEINJECTIONMOULDINGMACHINESMOULDCOST,MOULDQUALITYANDCOSTOFMOULDPRODUCTAREINSEPARABLEINTODAY’SCOMPLETIVEENVIRONMENT,COMPUTERAIDEDMOULDFILLINGSIMULATIONPACKAGESCANACCURATELYPREDICTTHEFILLPATTERNSOFANYPARTTHISALLOWSFORQUICKSIMULATIONSOFGATEPLACEMENTSANDHELPSFINDINGTHEOPTIMALLOCATIONENGINEERSCANPERFORMMOULDINGTRIALSONTHECOMPUTERBEFORETHEPARTDESIGNISCOMPLETEDPROCESSENGINEERSCANSYSTEMATICALLYPREDICTADESIGNANDPROCESSWINDOW,ANDCANOBTAININFORMATIONABOUTTHECUMULATIVEEFFECTOFTHEPROCESSVARIABLESTHATINFLUENCEPARTPERFORMANCE,COST,ANDAPPEARANCE2INJECTIONMOULDINGINJECTIONMOULDINGISONEOFTHEMOSTEFFECTIVEWAYSTOBRINGOUTTHEBESTINPLASTICSITISUNIVERSALLYUSEDTOMAKECOMPLEX,FINISHEDPARTS,OFTENINASINGLESTEP,ECONOMICALLY,PRECISELYANDWITHLITTLEWASTEMASSPRODUCTIONOFPLASTICPARTSMOSTLYUTILIZESMOULDSTHEMANUFACTURINGPROCESSANDINVOLVINGMOULDSMUSTBEDESIGNEDAFTERPASSINGTHROUGHTHEAPPEARANCEEVALUATIONANDTHESTRUCTUREOPTIMIZATIONOFTHEPRODUCTDESIGNDESIGNERSFACEAHUGENUMBEROFOPTIONSWHENTHEYCREATEINJECTIONMOULDEDCOMPONENTSCONCURRENTENGINEERINGREQUIRESANENGINEERTOCONSIDERTHEMANUFACTURINGPROCESSOFTHEDESIGNEDPRODUCTINTHEDEVELOPMENTPHASEAGOODDESIGNOFTHEPRODUCTISUNABLETOGOTOTHEMARKETIFITSMANUFACTURINGPROCESSISIMPOSSIBLEORTOOEXPENSIVEINTEGRATIONOFPROCESSSIMULATION,RAPIDPROTOTYPINGANDMANUFACTURINGCANREDUCETHERISKASSOCIATEDWITHMOVINGFROMCADTOCAMANDFURTHERENHANCETHEVALIDITYOFTHEPRODUCTDEVELOPMENT3IMPORTANCEOFCOMPUTERAIDEDINJECTIONMOULDDESIGNTHEINJECTIONMOULDINGDESIGNTASKCANBEHIGHLYCOMPLEXCOMPUTERAIDEDENGINEERINGCAEANALYSISTOOLSPROVIDEENORMOUSADVANTAGESOFENABLINGDESIGNENGINEERSTOCONSIDERVIRTUALLYANDPART,MOULDANDINJECTIONPARAMETERSWITHOUTTHEREALUSEOFANYMANUFACTURINGANDTIMETHEPOSSIBILITYOFTRYINGALTERNATIVEDESIGNSORCONCEPTSONTHECOMPUTERSCREENGIVESTHEENGINEERSTHEOPPORTUNITYTOELIMINATEPOTENTIALPROBLEMSBEFOREBEGINNINGTHEREALPRODUCTIONMOREOVER,INVIRTUALENVIRONMENT,DESIGNERSCANQUICKLYANDEASILYASSESTHESENSITIVITYOFSPECIFICMOULDINGPARAMETERSONTHEQUALITYANDMANUFACTURABILITYOFTHEFINALPRODUCTALLTHESECAETOOLSENABLEALLTHESEANALYSISTOBECOMPLETEDINAMETEROFDAYSOREVENHOURS,RATHERTHANWEEKSORMONTHSNEEDEDFORTHEREALEXPERIMENTALTRIALANDERRORCYCLESASCAEISUSEDINTHEEARLYDESIGNOFPART,MOULDANDMOULDINGPARAMETERS,THECOSTSAVINGSARESUBSTANTIALNOTONLYBECAUSEOFBESTFUNCTIONINGPARTANDTIMESAVINGSBUTALSOTHESHORTENSTHETIMENEEDEDTOLAUNCHTHEPRODUCTTOTHEMARKETTHENEEDTOMEETSETTOLERANCESOFPLASTICPARTTIESINTOALLASPECTSOFTHEMOULDINGPROCESS,INCLUDINGPARTSIZEANDSHAPE,RESINCHEMICALSTRUCTURE,THEFILLERSUSED,MOULDCAVITYLAYOUT,GATING,MOULDCOOLINGANDTHERELEASEMECHANISMSUSEDGIVENTHISCOMPLEXITY,DESIGNERSOFTENUSECOMPUTERDESIGNTOOLS,SUCHASFINITEELEMENTANALYSISFEAANDMOULDFILLINGANALYSISMFA,TOREDUCEDEVELOPMENTTIMEANDCOSTFEADETERMINESSTRAIN,STRESSANDDEFLECTIONINAPARTBYDIVIDINGTHESTRUCTUREINTOSMALLELEMENTSWHERETHESEPARAMETERSCANBEWELLDEFINEDMFAEVALUATESGATEPOSITIONANDSIZETOOPTIMIZERESINFLOWITALSODEFINESPLACEMENTOFWELDLINES,AREASOFEXCESSIVESTRESS,ANDHOWWALLANDRIBTHICKNESSAFFECTFLOWOTHERFINITEELEMENTDESIGNTOOLSINCLUDEMOULDCOOLINGANALYSISFORTEMPERATUREDISTRIBUTION,ANDCYCLETIMEANDSHRINKAGEANALYSISFORDIMENSIONALCONTROLANDPREDICTIONOFFROZENSTRESSANDWARPAGETHECAEANALYSISOFCOMPRESSIONMOULDEDPARTSISSHOWNINFIGURE1THEANALYSISCYCLESTARTSWITHTHECREATIONOFACADMODELANDAFINITEELEMENTMESHOFTHEMOULDCAVITYAFTERTHEINJECTIONCONDITIONSARESPECIFIED,MOULDFILLING,FIBERORIENTATION,CURINGANDTHERMALHISTORY,SHRINKAGEANDWARPAGECANBESIMULATEDTHEMATERIALPROPERTIESCALCULATEDBYTHESIMULATIONCANBEUSEDTOMODELTHESTRUCTURALBEHAVIOUROFTHEPARTIFREQUIRED,PARTDESIGN,GATELOCATIONANDPROCESSINGCONDITIONSCANBEMODIFIEDINTHECOMPUTERUNTILANACCEPTABLEPARTISOBTAINEDAFTERTHEANALYSISISFINISHEDANOPTIMIZEDPARTCANBEPRODUCEDWITHREDUCEDWELDLINEKNOWNALSOKNITLINE,OPTIMIZEDSTRENGTH,CONTROLLEDTEMPERATURESANDCURING,MINIMIZEDSHRINKAGEANDWARPAGEMACHININGOFTHEMOULDSWASFORMERLYDONEMANUALLY,WITHATOOLMAKERCHECKINGEACHCUTTHISPROCESSBECAMEMOREAUTOMATEDWITHTHEGROWTHANDWIDESPREADUSEOFCOMPUTERNUMERICALLYCONTROLLEDORCNCMACHININGCENTRESSETUPTIMEHASALSOBEENSIGNIFICANTLYREDUCEDTHROUGHTHEUSEOFSPECIALSOFTWARECAPABLEOFGENERATINGCUTTERPATHSDIRECTLYFROMACADDATAFILESPINDLESPEEDSASHIGHAS100,000RPMPROVIDEFURTHERADVANCESINHIGHSPEEDMACHININGCUTTINGMATERIALSHAVEDEMONSTRATEDPHENOMENALPERFORMANCEWITHOUTTHEUSEOFANYCUTTING/COOLANTFLUIDWHATSOEVERASARESULT,THEPROCESSOFMACHININGCOMPLEXCORESANDCAVITIESHASBEENACCELERATEDITISGOODNEWSTHATTHETIMEITTAKESTOGENERATEAMOULDISCONSTANTLYBEINGREDUCEDTHEBADNEWS,ONTHEOTHERHAND,ISTHATEVENWITHALLTHESEADVANCES,DESIGNINGANDMANUFACTURINGOFTHEMOULDCANSTILLTAKEALONGTIMEANDCANBEEXTREMELYEXPENSIVEFIGURE1CAEANALYSISOFINJECTIONMOULDEDPARTSMANYCOMPANYEXECUTIVESNOWREALIZEHOWVITALITISTODEPLOYNEWPRODUCTSTOMARKETRAPIDLYNEWPRODUCTSARETHEKEYTOCORPORATEPROSPERITYTHEYDRIVECORPORATEREVENUES,MARKETSHARES,BOTTOMLINESANDSHAREPRICESACOMPANYABLETOLAUNCHGOODQUALITYPRODUCTSWITHREASONABLEPRICESAHEADOFTHEIRCOMPETITIONNOTONLYREALIZES100OFTHEMARKETBEFORERIVALPRODUCTSARRIVEBUTALSOTENDSTOMAINTAINADOMINANTPOSITIONFORAFEWYEARSEVENAFTERCOMPETITIVEPRODUCTSHAVEFINALLYBEENANNOUNCEDSMITH,1991FORMOSTPRODUCTS,THESETWOADVANTAGESAREDRAMATICRAPIDPRODUCTDEVELOPMENTISNOWAKEYASPECTOFCOMPETITIVESUCCESSFIGURE2SHOWSTHATONLY3–7OFTHEPRODUCTMIXFROMTHEAVERAGEINDUSTRIALORELECTRONICSCOMPANYISLESSTHAN5YEARSOLDFORCOMPANIESINTHETOPQUARTILE,THENUMBERINCREASESTO15–25FORWORLDCLASSFIRMS,ITIS60–80THOMPSON,1996THEBESTCOMPANIESCONTINUOUSLYDEVELOPNEWPRODUCTSATHEWLETTPACKARD,OVER80OFTHEPROFITSRESULTFROMPRODUCTSLESSTHAN2YEARSOLDNEEL,1997

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