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外文翻译--大型注塑模具设计仿真工具:2400升固体废弃物集装箱 英文版.pdf

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外文翻译--大型注塑模具设计仿真工具:2400升固体废弃物集装箱 英文版.pdf

AbstractnoUniwandstreetsandprocess©K1.lastprocessasneofwengineering.turesomeUnihasplasticshundredshouseholdelectric,URL09240136/doi10.1016/j.jmatprotec.2005.04.006JournalofMaterialsProcessingTechnology175200615–19AnexampleofsimulationtoolsuseforlargeinjectionmouldsdesignTheCONTENURTM2400lsolidwastecontainerJ.Aisaa,∗,C.Javierrea,J.A.DelaSernabaT.I.I.P.,C.S.I.C.AssociatedUnit,DepartmentofMechanicalEngineering,UniversityofZaragoza,SpainbCONTENURESPA˜NA,S.L.,Pol´ıgonoIndustrialLosAngeles,Getafe,Madrid,SpainLargecontainerswithvolumesabove1100lareusuallyproducedusingproceduressuchasrotomouldingprocess.Thesetechniqueshavepartweightordimensionallimits.T.I.I.P.,injectionmouldingplasticgroupoftheDepartmentofMechanicalEngineeringoftheZaragozaversity,developedwithCONTENURTManewproductunderEuropeannormsforsolidwastecontainersupto2000lvolumetheresultasanewmainbodyupto60kgweightinonepart.ThedesignprocesscombinedseveralCAEtoolsaestheticaldesign,mechanicaldesignrheologicalsimulationand,inlastJune,showedfinalresultandpasseddifferenttests.Nowadays,morethan5000samplesareonthewithoutbasicmodificationsinthemouldmorethan100tonnesweight.Thepaperfocusesonthemethodologyusedtointegratetoolprocessdesignwithproductdefinitioni.e.injectionpressureandclampforceversusthicknessandpartshape.Someparametersaboutcontrolinthisparticularmouldinjectionrate,temperature,viscosity,gatelocation,...aredetailed.2005ElsevierB.V.Allrightsreserved.eywordsCAEdesignContainerInjectionmouldingIntroductionCAEtoolshaveconstitutedanauthenticrevolutionintheyearswithininjectionofthermoplastics.Thesequentialuntilthefinalsolutionincludingseveralsetupssuchdevelopment,testofprototypes,modificationoffigures,wtest,...hasbeenreplacedbyafasteroneconsistingaprocedurewiththedesigner,transformerandfinalclientorkingtogetheronthesamecomputerfilesconcurrentTherefore,thetimingformouldmanufacandcompletionhasbeenreducedenormouslyhowever,interestingadvicesaboutCAEusearedescribedin1.TheWorkshopofInjectionofthePlasticsIndustryoftheversityofZaragozaT.I.I.P.,C.S.I.C.AssociatedUnit,beenworkingwithCAEtoolsoninjectionofthermoformorethan15years,withenormousadvantageforofprojectsmadeindifferentsectorsautomotive,packaging,toys,etc..T.I.I.P.activities∗Correspondingauthor.Emailaddresstiipunizar.esJ.Aisa.www.contenur.com.includedtion,diftheufcollaboratedAssociationtryinjectiontechnologicalorishresearchcascadetechniques2.the–seefrontmatter©2005ElsevierB.V.Allrightsreserved.severalresearchprojectsrheologicalcharacterizasemiautomaticmoulddesign,...workingtogetherwithferentEuropeancompanies.Nevertheless,thisgrouphasalwaysbeenconsciousofnecessitytoarrangesimulationwithprocedureofmanacturenexttothemachine,ofsuchaformthathasbeenanddirectedbytheconstitutionoftheResearchoftheWorkshopofInjectionofthePlasticIndusa.i.T.I.I.P.foundation,whichprovidesservicestothecompanieswithoutaprofitspiritFig.1.ThiscenterhasbeensupportedbyvariousnationalganizationssuchastheAragonsGovernmentandSpanDepartmentofIndustrythroughdifferentprogramsandlinesnewprocesseslikegasassistedtechniquesorinjectionmoulding,newdesigns,processmeasuringusingpressureandtemperaturedevices....TheCONTENURProjectWhen,in1999,thefirstSpanishcompanyinvolvedinmanufactureofcontainersforthecollectionofurban16ProcessingsolidTpiecestestingofwithplasticofalltheplesbigmouldmakandtoandminimummaterial,J.Aisaetal./JournalofMaterialsFig.1.a.i.T.I.I.P.injectionmouldingarea,generalview.remaindersCONTENURSPAIN,S.L.wenttothe.I.I.P.–a.i.T.I.I.P.Grouptoworkjointlyonthedesignofofgreatsizeininjection,thenarrivedthemomentfortherealpossibilitiesoftheseprogramsinthisfield.Themainobjectiveoftheprojectwasthefastmanufacturecontainersofgreatcapacity2400landmoretocompetemarketproductswithweldedmetallicplatesolutionsoronesmadebyrotationalmouldingwiththeinclusionexpensivereinforcementstructures.Obviously,betweenthepiecesthatconstitutedtheset,themainchallengewasmanufactureofasinglepartbucket.Theliteratureshowsseveralpartandmoulddesignexamandfailureadvices2,3,butitisnotpossibletofindplasticpartsupto40kgweightandamistakeinthissizewillhavenoeasysolutiontooltransporttomouldersmanufacturingplantwillbetooexpensive,andtrialerrormethodisnotavailable.Forthedesignofthiselement,thefollowingaspectshadbeconsideredbasicdimensionsagreedwiththeEuropeanNormEN125744unloadingresistancedischargesidesFig.2highimpactresistanceforfunctionalconditionsandlocationparkingareas,forexampleeasilycleaningsurfacesfriendlyaspect,aestheticaldesignminimumcostnotonlyforprocessingandassemblybutalsoforonstreetmaintenancerestrictionoftheclampingforceimposedbytheinstalledpressmachinebigspecialmachineswithlimitedclampingrangebetween5000and10,000tonnespreparedforlabelling,thatistosay,withvisiblefreeandflatspacesmaterialrestrictionssamematerialsusedforotherCONTENURdesigns.Specialmentionrequirestwolimitationsminimumcostmaximumclampingforceundermentionedlimits.Foracost,thicknessisfundamentalbythecostofrawinasmuchasthetimeofmanufacturetherefore,Fig.model,thethejectedstronglyaforcenottechniquesabTResultsMainmm/weightTechnology175200615–192.Boundaryconditionsforunloadingoperation,nonlinearmaterialfiniteelementmodel.costofthemachinederivedapproximatelydependsonsquareofthethickness5.Ontheotherhand,toreducetheclosingforce,theproareaofthepieceandthedistributionofpressuresarerelatedwithpartthicknessnarrowsectionscausedhighinjectionpressure,whichcouldaswellsupposeahighofclosing.Themethodologyapplied,developedbyCastanyetal.,onlyforinjectionmouldingbutalsoforothersimilar6–8,isasgivenbelowDeterminationofthefeasibilityoftheproductclampingforceevaluationandthicknesspartonanagreedbasicgeometrytoadjustdimensionswiththeEuropeannorm.Onlygeneraldesignlines,andnotfunctionaldetails,wereincludedinthisstep.SomebasicresultsareshowninTable1.Theseanalysesweremadewithbasicparametersforgenericmaterialfamily,highdensitypolyethyleneTable2.Foradvancedsteps,calculationsweremadeusingseveraltemperatureconditions.Materialselection,combiningmeltflowindexMFIandmechanicalbehaviour,andinjectionpointlocationsweresimulated,withoutevenknowingthefinalgeometryofthecomponent.Bestresultswerefoundforseveralinjectionpointsarrangedaroundthebottomareainthemainable1forsimpleplasticmodel,firstanalysisusingsimulationtoolsbodythicknesskgMaximuminjectionpressureMPaRequiredclampingforcekN6/5296166,0007/6071122,0008/685594,0009/764474,00010/843559,000ProcessingTComputingMeltInjectionMouldFig.ments.cdJ.Aisaetal./JournalofMaterialsable2parametersforbasicsimulationstemperature◦C240timeatconstantramspeedInseconds20Inpercent50temperature◦C403.Basicline,ProEngineersoftware,beforefinalmouldingarrangebodyofthecontainer.Thiscriteriawasalsoimposedbymouldstructureandpartshape.Analysisofthebodyformandthicknessofthepartcomparingconstructivealternativesitssidewallshapes,metallicelementsofreinforcementand,ifnecessary,inclusionofthetubesinjectedwithgasassistedtechniquestoincreaseinertiaofthesections,etc.,wereconsidered.Obviously,moulddimensionsandthepresenceofundercutssupposedaproblemaddedforthedesignofpieceandmould.Inthisway,semicircularshapeoftheborderTBasicHeightWLengthethegeometrysettlingsoriessetwCompanothertrial1.2.3.Fig.4.SoftwareCMoldplastictemperatureTechnology175200615–1917able3dimensionsfor2400lmainbodymm1600idth14801600oftheuppercontainerwasaharddesignproblemitwasrequiredforfunctionalusebutsupposedanundercutareainvolvingslidesinthemould.Partvolumewasadaptedanddifferentaestheticformsappearedfeasibleconjunctionofthepossiblethicknessbymanufacturewiththethicknessandformsbymechanicalresistance.Inthisstep,finiteanalysis,solid3DdesignandfillingsimulationweremadesimultaneouslyFigs.3and4.ThefinalpartdimensionsareshowninTable3.Withthesebasicmagnitudescalculatedinthesefoursteps,designteamhadaninitialpointforthefinaldrawingofandtheinclusionoftheelementsofdetailslikedownofoutputangles,radios,positionofaccesofthesetcork,skid,etc..Industrialflowanalysiswasindefinitiveway,fixingoptimumpositionsformanifoldorkingtogetherwiththemouldmaker,KyowaIndustrialywithmouldplantsintheUSA,JapanandMexico.ThemainaspectsoftheprocessandtheirsimulationsdetailscannotbepresentedinordertoprotectindusknowhowareModelofthefigurewithgeometriestype2.5D.Locationoftheentrypointstothecavity.Theuseofracetracksforabettercontrolofthefillingwasconsidered,followingrheologicaldesignruleforsimultaneousendoffillingattheendofthecavityavoidingoverpackeffect,especiallyconsideringthebordershapewithsemicircularareas.Optimalconditionsofprocesstheselectionoftemperatureanditsrelationwiththicknessandcyclestronglyconditionedthepermissiblevaluesforthedesign.Valuesbetween210and250◦Cwereevaluated.atejectionandcoolinglineslayout.18ProcessingFig.mould.4.testsislatedbecausegradientscould5.J.Aisaetal./JournalofMaterials5.Realcontainermodelusedfortestingindustrialconditionsin2400lTheadjustmentofthefillingformbymeansofthecorrectprogrammingofspeedsbecameessential.Atconstantspeedprofile,theincreaseofpressuresupposedvaluesofinadmissibleforceofclosingbythelimitationimposedtothedimensionsofthemachine.Inthefinalarrangementforcontainermould,severalramspeedstageswererecommended.ThisprocedurewasexperimentallyvalidatedwithrealusingalreadyexistingsmallerdimensioncontainerFig.5.TypicalramspeedprofilecalculatedwithCAEtechniquesshowninFig.6,butthisfunctioncannotbetranstotheinjectionmachinewithoutpracticalarrangements,hydraulicsystemsarenotabletofollowallthoseexactly.Anyway,around15lessclampingforcebeachievedafterthisoptimisationprocedure.Afterthefillingpossibilitieswerefixed,thiswasverifiedwithanewnumericalmodelbythemouldmakerfromtheinitialideassentbythedesignequipmentandwiththefinalhotrunnersystemdatanecessaryforthemould.Fig.6.Theoreticalramspeedprofilefromcomputerresults.6.detectingofcessing20–25ouslyTechnology175200615–19Fig.7.RealsampleinCONTENURassemblyplant.Thesequentialtechnologywasconsideredasapossibilitywiththepurposeofreducingfillingpressure,butthepracticalarrangement,themaintenanceandpossibleshutdownsunderestimatedtheiruse.Finally,theanalysesofcoolingofthemould,packingandwarpageinducedbytheprocessweredeveloped.Inthisway,differentconstructivematerialswereusedaccordingtotheirthermalconductivity,adjustingcoolinglayoutprovidedbyKyowaIndustrialCompany.Finalmouldweightwashigherthan150,000kgupto150metrictonnes.Actually,morethan6000piecesweremadewithoutanyproblemintheinjection,expulsionorthelifethecomponentingoodconditionFigs.7and8,andproratesaresimilarwithotherexisting1000lcontainerspartsperhour.Othercomponentsweresimultanedesignedand,infact,itwasmorecomplicatedtogetFig.8.Complete2400lwastecontainer,includingallcomponents.

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