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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

ABSTRACTNOUNIWANDSTREETSANDPROCESSK1LASTPROCESSASNEOFWENGINEERING”TURESOMEUNIHASPLASTICSHUNDREDSHOUSEHOLDELECTRIC,URL09240136/DOI101016/JJMATPROTEC200504006JOURNALOFMATERIALSPROCESSINGTECHNOLOGY175200615–19ANEXAMPLEOFSIMULATIONTOOLSUSEFORLARGEINJECTIONMOULDSDESIGNTHECONTENURTM2400LSOLIDWASTECONTAINERJAISAA,∗,CJAVIERREA,JADELASERNABATIIP,CSICASSOCIATEDUNIT,DEPARTMENTOFMECHANICALENGINEERING,UNIVERSITYOFZARAGOZA,SPAINBCONTENURESPA˜NA,SL,POLIGONOINDUSTRIALLOSANGELES,GETAFE,MADRID,SPAINLARGECONTAINERSWITHVOLUMESABOVE1100LAREUSUALLYPRODUCEDUSINGPROCEDURESSUCHASROTOMOULDINGPROCESSTHESETECHNIQUESHAVEPARTWEIGHTORDIMENSIONALLIMITSTIIP,INJECTIONMOULDINGPLASTICGROUPOFTHEDEPARTMENTOFMECHANICALENGINEERINGOFTHEZARAGOZAVERSITY,DEVELOPEDWITHCONTENURTMANEWPRODUCTUNDEREUROPEANNORMSFORSOLIDWASTECONTAINERSUPTO2000LVOLUME;THERESULTASANEWMAINBODYUPTO60KGWEIGHTINONEPARTTHEDESIGNPROCESSCOMBINEDSEVERALCAETOOLSAESTHETICALDESIGN,MECHANICALDESIGNRHEOLOGICALSIMULATIONAND,INLASTJUNE,SHOWEDFINALRESULTANDPASSEDDIFFERENTTESTSNOWADAYS,MORETHAN5000SAMPLESAREONTHEWITHOUTBASICMODIFICATIONSINTHEMOULDMORETHAN100TONNESWEIGHTTHEPAPERFOCUSESONTHEMETHODOLOGYUSEDTOINTEGRATETOOLPROCESSDESIGNWITHPRODUCTDEFINITIONIEINJECTIONPRESSUREANDCLAMPFORCEVERSUSTHICKNESSANDPARTSHAPESOMEPARAMETERSABOUTCONTROLINTHISPARTICULARMOULDINJECTIONRATE,TEMPERATURE,VISCOSITY,GATELOCATION,AREDETAILED2005ELSEVIERBVALLRIGHTSRESERVEDEYWORDSCAEDESIGN;CONTAINER;INJECTIONMOULDINGINTRODUCTIONCAETOOLSHAVECONSTITUTEDANAUTHENTICREVOLUTIONINTHEYEARSWITHININJECTIONOFTHERMOPLASTICSTHESEQUENTIALUNTILTHEFINALSOLUTIONINCLUDINGSEVERALSETUPSSUCHDEVELOPMENT,TESTOFPROTOTYPES,MODIFICATIONOFFIGURES,WTEST,HASBEENREPLACEDBYAFASTERONECONSISTINGAPROCEDUREWITHTHEDESIGNER,TRANSFORMERANDFINALCLIENTORKINGTOGETHERONTHESAMECOMPUTERFILES“CONCURRENTTHEREFORE,THETIMINGFORMOULDMANUFACANDCOMPLETIONHASBEENREDUCEDENORMOUSLY;HOWEVER,INTERESTINGADVICESABOUTCAEUSEAREDESCRIBEDIN1THEWORKSHOPOFINJECTIONOFTHEPLASTICSINDUSTRYOFTHEVERSITYOFZARAGOZATIIP,CSICASSOCIATEDUNIT,BEENWORKINGWITHCAETOOLSONINJECTIONOFTHERMOFORMORETHAN15YEARS,WITHENORMOUSADVANTAGEFOROFPROJECTSMADEINDIFFERENTSECTORSAUTOMOTIVE,PACKAGING,TOYS,ETCTIIPACTIVITIES∗CORRESPONDINGAUTHOREMAILADDRESSTIIPUNIZARESJAISAWWWCONTENURCOMINCLUDEDTION,DIFTHEUFCOLLABORATEDASSOCIATIONTRYINJECTIONTECHNOLOGICALORISHRESEARCHCASCADETECHNIQUES2THE–SEEFRONTMATTER2005ELSEVIERBVALLRIGHTSRESERVEDSEVERALRESEARCHPROJECTSRHEOLOGICALCHARACTERIZASEMIAUTOMATICMOULDDESIGN,WORKINGTOGETHERWITHFERENTEUROPEANCOMPANIESNEVERTHELESS,THISGROUPHASALWAYSBEENCONSCIOUSOFNECESSITYTOARRANGESIMULATIONWITHPROCEDUREOFMANACTURENEXTTOTHEMACHINE,OFSUCHAFORMTHATHASBEENANDDIRECTEDBYTHECONSTITUTIONOFTHERESEARCHOFTHEWORKSHOPOFINJECTIONOFTHEPLASTICINDUSAITIIPFOUNDATION,WHICHPROVIDESSERVICESTOTHECOMPANIESWITHOUTAPROFITSPIRITFIG1THISCENTERHASBEENSUPPORTEDBYVARIOUSNATIONALGANIZATIONSSUCHASTHEARAGON’SGOVERNMENTANDSPANDEPARTMENTOFINDUSTRYTHROUGHDIFFERENTPROGRAMSANDLINESNEWPROCESSESLIKEGASASSISTEDTECHNIQUESORINJECTIONMOULDING,NEWDESIGNS,PROCESSMEASURINGUSINGPRESSUREANDTEMPERATUREDEVICESTHECONTENURPROJECTWHEN,IN1999,THEFIRSTSPANISHCOMPANYINVOLVEDINMANUFACTUREOFCONTAINERSFORTHECOLLECTIONOFURBAN16PROCESSINGSOLIDTPIECESTESTINGOFWITHPLASTICOFALLTHEPLESBIGMOULDMAKANDTOANDMINIMUMMATERIAL,JAISAETAL/JOURNALOFMATERIALSFIG1AITIIPINJECTIONMOULDINGAREA,GENERALVIEWREMAINDERSCONTENURSPAIN,SLWENTTOTHEIIP–AITIIPGROUPTOWORKJOINTLYONTHEDESIGNOFOFGREATSIZEININJECTION,THENARRIVEDTHEMOMENTFORTHEREALPOSSIBILITIESOFTHESEPROGRAMSINTHISFIELDTHEMAINOBJECTIVEOFTHEPROJECTWASTHEFASTMANUFACTURECONTAINERSOFGREATCAPACITY2400LANDMORETOCOMPETEMARKETPRODUCTSWITHWELDEDMETALLICPLATESOLUTIONSORONESMADEBYROTATIONALMOULDINGWITHTHEINCLUSIONEXPENSIVEREINFORCEMENTSTRUCTURESOBVIOUSLY,BETWEENTHEPIECESTHATCONSTITUTEDTHESET,THEMAINCHALLENGEWASMANUFACTUREOFASINGLEPARTBUCKETTHELITERATURESHOWSSEVERALPARTANDMOULDDESIGNEXAMANDFAILUREADVICES2,3,BUTITISNOTPOSSIBLETOFINDPLASTICPARTSUPTO40KGWEIGHTANDAMISTAKEINTHISSIZEWILLHAVENOEASYSOLUTIONTOOLTRANSPORTTOMOULDER’SMANUFACTURINGPLANTWILLBETOOEXPENSIVE,ANDTRIALERRORMETHODISNOTAVAILABLEFORTHEDESIGNOFTHISELEMENT,THEFOLLOWINGASPECTSHADBECONSIDEREDBASICDIMENSIONSAGREEDWITHTHEEUROPEANNORMEN125744;UNLOADINGRESISTANCEDISCHARGESIDESFIG2;HIGHIMPACTRESISTANCEFORFUNCTIONALCONDITIONSANDLOCATIONPARKINGAREAS,FOREXAMPLE;EASILYCLEANINGSURFACES;FRIENDLYASPECT,AESTHETICALDESIGN;MINIMUMCOSTNOTONLYFORPROCESSINGANDASSEMBLYBUTALSOFORONSTREETMAINTENANCE;RESTRICTIONOFTHECLAMPINGFORCEIMPOSEDBYTHEINSTALLEDPRESSMACHINEBIGSPECIALMACHINESWITHLIMITEDCLAMPINGRANGEBETWEEN5000AND10,000TONNES;PREPAREDFORLABELLING,THATISTOSAY,WITHVISIBLEFREEANDFLATSPACES;MATERIALRESTRICTIONSSAMEMATERIALSUSEDFOROTHERCONTENURDESIGNSSPECIALMENTIONREQUIRESTWOLIMITATIONSMINIMUMCOSTMAXIMUMCLAMPINGFORCEUNDERMENTIONEDLIMITSFORACOST,THICKNESSISFUNDAMENTALBYTHECOSTOFRAWINASMUCHASTHETIMEOFMANUFACTURE;THEREFORE,FIGMODEL,THETHEJECTEDSTRONGLYAFORCENOTTECHNIQUESABTRESULTSMAINMM/WEIGHTTECHNOLOGY175200615–192BOUNDARYCONDITIONSFORUNLOADINGOPERATION,NONLINEARMATERIALFINITEELEMENTMODELCOSTOFTHEMACHINEDERIVEDAPPROXIMATELYDEPENDSONSQUAREOFTHETHICKNESS5ONTHEOTHERHAND,TOREDUCETHECLOSINGFORCE,THEPROAREAOFTHEPIECEANDTHEDISTRIBUTIONOFPRESSURESARERELATEDWITHPARTTHICKNESSNARROWSECTIONSCAUSEDHIGHINJECTIONPRESSURE,WHICHCOULDASWELLSUPPOSEAHIGHOFCLOSINGTHEMETHODOLOGYAPPLIED,DEVELOPEDBYCASTANYETAL,ONLYFORINJECTIONMOULDINGBUTALSOFOROTHERSIMILAR6–8,ISASGIVENBELOWDETERMINATIONOFTHEFEASIBILITYOFTHEPRODUCTCLAMPINGFORCEEVALUATIONANDTHICKNESSPARTONANAGREEDBASICGEOMETRYTOADJUSTDIMENSIONSWITHTHEEUROPEANNORMONLYGENERALDESIGNLINES,ANDNOTFUNCTIONALDETAILS,WEREINCLUDEDINTHISSTEPSOMEBASICRESULTSARESHOWNINTABLE1THESEANALYSESWEREMADEWITHBASICPARAMETERSFORGENERICMATERIALFAMILY,HIGHDENSITYPOLYETHYLENETABLE2FORADVANCEDSTEPS,CALCULATIONSWEREMADEUSINGSEVERALTEMPERATURECONDITIONSMATERIALSELECTION,COMBININGMELTFLOWINDEXMFIANDMECHANICALBEHAVIOUR,ANDINJECTIONPOINTLOCATIONSWERESIMULATED,WITHOUTEVENKNOWINGTHEFINALGEOMETRYOFTHECOMPONENTBESTRESULTSWEREFOUNDFORSEVERALINJECTIONPOINTSARRANGEDAROUNDTHEBOTTOMAREAINTHEMAINABLE1FORSIMPLEPLASTICMODEL,FIRSTANALYSISUSINGSIMULATIONTOOLSBODYTHICKNESSKGMAXIMUMINJECTIONPRESSUREMPAREQUIREDCLAMPINGFORCEKN6/5296166,0007/6071122,0008/685594,0009/764474,00010/843559,000PROCESSINGTCOMPUTINGMELTINJECTIONMOULDFIGMENTSCDJAISAETAL/JOURNALOFMATERIALSABLE2PARAMETERSFORBASICSIMULATIONSTEMPERATURE◦C240TIMEATCONSTANTRAMSPEEDINSECONDS20INPERCENT50TEMPERATURE◦C403BASICLINE,PROENGINEERSOFTWARE,BEFOREFINALMOULDINGARRANGEBODYOFTHECONTAINERTHISCRITERIAWASALSOIMPOSEDBYMOULDSTRUCTUREANDPARTSHAPEANALYSISOFTHEBODYFORMANDTHICKNESSOFTHEPARTCOMPARINGCONSTRUCTIVEALTERNATIVESITSSIDEWALLSHAPES,METALLICELEMENTSOFREINFORCEMENTAND,IFNECESSARY,INCLUSIONOFTHETUBESINJECTEDWITHGASASSISTEDTECHNIQUESTOINCREASEINERTIAOFTHESECTIONS,ETC,WERECONSIDEREDOBVIOUSLY,MOULDDIMENSIONSANDTHEPRESENCEOFUNDERCUTSSUPPOSEDAPROBLEMADDEDFORTHEDESIGNOFPIECEANDMOULDINTHISWAY,SEMICIRCULARSHAPEOFTHEBORDERTBASICHEIGHTWLENGTHETHEGEOMETRYSETTLINGSORIESSETWCOMPANOTHERTRIAL123FIG4SOFTWARECMOLDPLASTICTEMPERATURETECHNOLOGY175200615–1917ABLE3DIMENSIONSFOR2400LMAINBODYMM1600IDTH14801600OFTHEUPPERCONTAINERWASAHARDDESIGNPROBLEM;ITWASREQUIREDFORFUNCTIONALUSEBUTSUPPOSEDANUNDERCUTAREAINVOLVINGSLIDESINTHEMOULDPARTVOLUMEWASADAPTEDANDDIFFERENTAESTHETICFORMSAPPEAREDFEASIBLECONJUNCTIONOFTHEPOSSIBLETHICKNESSBYMANUFACTUREWITHTHETHICKNESSANDFORMSBYMECHANICALRESISTANCEINTHISSTEP,FINITEANALYSIS,SOLID3DDESIGNANDFILLINGSIMULATIONWEREMADESIMULTANEOUSLYFIGS3AND4THEFINALPARTDIMENSIONSARESHOWNINTABLE3WITHTHESEBASICMAGNITUDESCALCULATEDINTHESEFOURSTEPS,DESIGNTEAMHADANINITIALPOINTFORTHEFINALDRAWINGOFANDTHEINCLUSIONOFTHEELEMENTSOFDETAILSLIKEDOWNOFOUTPUTANGLES,RADIOS,POSITIONOFACCESOFTHESETCORK,SKID,ETCINDUSTRIALFLOWANALYSISWASINDEFINITIVEWAY,FIXINGOPTIMUMPOSITIONSFORMANIFOLDORKINGTOGETHERWITHTHEMOULDMAKER,KYOWAINDUSTRIALYWITHMOULDPLANTSINTHEUSA,JAPANANDMEXICOTHEMAINASPECTSOFTHEPROCESSANDTHEIRSIMULATIONSDETAILSCANNOTBEPRESENTEDINORDERTOPROTECTINDUSKNOWHOWAREMODELOFTHEFIGUREWITHGEOMETRIESTYPE25DLOCATIONOFTHEENTRYPOINTSTOTHECAVITYTHEUSEOFRACETRACKSFORABETTERCONTROLOFTHEFILLINGWASCONSIDERED,FOLLOWINGRHEOLOGICALDESIGNRULEFORSIMULTANEOUSENDOFFILLINGATTHEENDOFTHECAVITYAVOIDINGOVERPACKEFFECT,ESPECIALLYCONSIDERINGTHEBORDERSHAPEWITHSEMICIRCULARAREASOPTIMALCONDITIONSOFPROCESSTHESELECTIONOFTEMPERATUREANDITSRELATIONWITHTHICKNESSANDCYCLESTRONGLYCONDITIONEDTHEPERMISSIBLEVALUESFORTHEDESIGNVALUESBETWEEN210AND250◦CWEREEVALUATEDATEJECTIONANDCOOLINGLINESLAYOUT18PROCESSINGFIGMOULD4TESTSISLATEDBECAUSEGRADIENTSCOULD5JAISAETAL/JOURNALOFMATERIALS5REALCONTAINERMODELUSEDFORTESTINGINDUSTRIALCONDITIONSIN2400LTHEADJUSTMENTOFTHEFILLINGFORMBYMEANSOFTHECORRECTPROGRAMMINGOFSPEEDSBECAMEESSENTIALATCONSTANTSPEEDPROFILE,THEINCREASEOFPRESSURESUPPOSEDVALUESOFINADMISSIBLEFORCEOFCLOSINGBYTHELIMITATIONIMPOSEDTOTHEDIMENSIONSOFTHEMACHINEINTHEFINALARRANGEMENTFORCONTAINERMOULD,SEVERALRAMSPEEDSTAGESWERERECOMMENDEDTHISPROCEDUREWASEXPERIMENTALLYVALIDATEDWITHREALUSINGALREADYEXISTINGSMALLERDIMENSIONCONTAINERFIG5TYPICALRAMSPEEDPROFILECALCULATEDWITHCAETECHNIQUESSHOWNINFIG6,BUTTHIS“FUNCTION”CANNOTBETRANSTOTHEINJECTIONMACHINEWITHOUTPRACTICALARRANGEMENTS,HYDRAULICSYSTEMSARENOTABLETOFOLLOWALLTHOSEEXACTLYANYWAY,AROUND15LESSCLAMPINGFORCEBEACHIEVEDAFTERTHISOPTIMISATIONPROCEDUREAFTERTHEFILLINGPOSSIBILITIESWEREFIXED,THISWASVERIFIEDWITHANEWNUMERICALMODELBYTHEMOULDMAKERFROMTHEINITIALIDEASSENTBYTHEDESIGNEQUIPMENTANDWITHTHEFINALHOTRUNNERSYSTEMDATANECESSARYFORTHEMOULDFIG6THEORETICALRAMSPEEDPROFILEFROMCOMPUTERRESULTS6DETECTINGOFCESSING20–25OUSLYTECHNOLOGY175200615–19FIG7REALSAMPLEINCONTENURASSEMBLYPLANTTHESEQUENTIALTECHNOLOGYWASCONSIDEREDASAPOSSIBILITYWITHTHEPURPOSEOFREDUCINGFILLINGPRESSURE,BUTTHEPRACTICALARRANGEMENT,THEMAINTENANCEANDPOSSIBLESHUTDOWNSUNDERESTIMATEDTHEIRUSEFINALLY,THEANALYSESOFCOOLINGOFTHEMOULD,PACKINGANDWARPAGEINDUCEDBYTHEPROCESSWEREDEVELOPEDINTHISWAY,DIFFERENTCONSTRUCTIVEMATERIALSWEREUSEDACCORDINGTOTHEIRTHERMALCONDUCTIVITY,ADJUSTINGCOOLINGLAYOUTPROVIDEDBYKYOWAINDUSTRIALCOMPANYFINALMOULDWEIGHTWASHIGHERTHAN150,000KGUPTO150METRICTONNESACTUALLY,MORETHAN6000PIE

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