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喷墨打印机盒盖注塑模具设计【10张CAD图纸和说明书】

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关键词：: 喷墨打印机盒盖注塑模具设计 10 cad 图纸以及说明书仿单

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摘要

本设计为打印机盒盖注塑模的设计。设计中采用一模一腔，浇口采用点胶口，分型面选在截面最大处，塑件成型后利用推杆将成型制品从动模上推出，回程时利用复位杆复位。

设计中需要对塑件的尺寸进行计算，确定尺寸精度，然后进行注射机的初步选取。以及对注塑机的浇注系统、成型零件的结构、成型零件的尺寸、脱模推出机构、排气系统、温度调节系统进行了设计与计算。并且对注射机参数进行校核，包括模具闭合厚度、模具安装尺寸、模具开模行程、注射机的锁模力等。各个参数都满足要求后才能确定注射机的型号。

在设计过程中，为了更清楚的表达模具的内部结构，因此附有动模镶块、定模镶块、定模推板的二维零件图和模具三维爆炸图。

关键词：打印机盒盖；分型面；浇口；工艺分析

Ink jet printer cover injection mold design

Abstract

This design is the design of injection mould for the cabinet. The design uses two mold cavity, type of the sprue is latent gate, the parting surface is chosen in the maximum section of the plastics. After plastics are molded， molding products are driven by putting from dynamic model,then using reset stem returned.

In the design ,The need to calculate the size design, determine the size precision, the preliminary selection and the injection machine. And the injection molding machine of gating system, forming part of the structure, forming part of the size, mold release mechanism, exhaust system, temperature control system design and calculation. And to check the injection machine parameters, including the thickness of mold closing, mold installation size, mold opening stroke, the clamping force injection molding machine etc.. All the parameters meet the requirements to determine the type of injection machine.

In the design process, in order to express more clearly the internal structure of the mold, so a moving die insert, fixed die insert, the fixed mould push plate 2D part drawing and 3D map explosion.

Keywords：?Cabinet;Parting;surface;Runner;Process analysis

主要符号表

额定锁模力

模腔压力

安全系数

最小模具厚度

最大模具

塑件尺寸误差

塑料的最大收缩率

塑料的最小收缩率

塑件尺寸

塑料的平均收缩率

塑料的公差

模具制造公差

型腔许用变形量

型腔材料的弹性模量

型腔材料的需用压力

脱模斜度

摩擦系数

脱模力

推杆长度系数

总脱模力

应力

屈服极限

1 绪论……………………………………………………………………………1

1.1 题目背景………………………………………………………………………1

1.2 题目国内外相关研究情况……………………………………………………1

1.2.1 国内研究的情况…………………………………………………………1

1.2.2 国外研究情况……………………………………………………………2

1.3中国与国外先进技术的差距…………………………………………………2

1.4塑料模具发展走势……………………………………………………………2

2 产品分析……………………………………………………………………4

2.1 塑件分析……………………………………………………………………4

2.1.1结构分析…………………………………………………………………4

2.1.2尺寸精度分析……………………………………………………………5

2.1.3 塑件厚度检测……………………………………………………………5

2.1.4 表面质量分析……………………………………………………………5

2.2 塑件材料选择………………………………………………………………6

2.2.1 物理性能…………………………………………………………………6

2.2.2 ABS的主要性能指标…………………………………………………6

2.2.3 ABS成型塑件的主要缺陷及消除措施…………………………………6

3 拟定模具结构形式及注射机的初步选择………………………………7

3.1 分型面位置的确定…………………………………………………………7

3.1.1模具的分型面…………………………………………………………7

3.1.2 分型面的确定…………………………………………………………7

3.2 塑件相关计算……………………………………………………………8

3.2.1塑件相关计算…………………………………………………………9

3.3 型腔数量的确定…………………………………………………………10

3.4 初步选择注塑机…………………………………………………………11

4 浇注系统的设计……………………………………………………………13

4.1浇注系统 ……………………………………………………………………13

4.1.1浇注系统的作用………………………………………………………13

4.1.2 浇注系统布置…………………………………………………………13

4.2 浇注系统设计…………………………………………………………13

4.2.1 浇口套的设计…………………………………………………………13

4.2.2 浇注系统的设计………………………………………………………16

4.2.3 分流道与浇口…………………………………………………………17

4.3 浇口设计……………………………………………………………………18

4.3.1 浇口的类型………………………………………………………………18

4.3.2 浇口的位置 ……………………………………………………………18

5 成型零件的工作尺寸计算……………………………………………20

5.1 成型零件工作尺寸的计算………………………………………………20

6 成型零件结构设计…………………………………………………………24

6.1 PRO/E中的模具模块设计………………………………………………24

6.1.1 凹模结构设计……………………………………………………………25

6.1.2 凸模结构设计…………………………………………………………25

7导向机构设计………………………………………………………………27

7.1导向机构………………………………………………………………………27

7.1.1 导柱…………………………………………………………………27

7.1.2 导套………………………………………………………………………28

7.1.3 导柱与导套的配用………………………………………………………29

7.1.4 导柱布置…………………………………………………………………30

7.2 定位装置…………………………………………………………………30

7.2.1 拉杆………………………………………………………………………30

7.3 尼龙开闭器装置……………………………………………………………30

8 脱模推出机构的设计………………………………………………………32

8.1 在设计脱模推出机构是应遵循下列原则…………………………………32

8.2 脱模力的计算……………………………………………………………32

8.3 推出机构设计……………………………………………………………32

8.3.1 推杆布置…………………………………………………………………32

8.3.2推杆结构及固定………………………………………………………33

8.3.3 推杆强度交核……………………………………………………………33

8.4 拉料机构…………………………………………………………………34

9 排气系统设计……………………………………………………………36

10 温度调节系统设计………………………………………………………37

10.1 对温度调节系统的要求…………………………………………………37

10.2 冷却系统设计……………………………………………………………37

10.2.1 冷却回路的布置………………………………………………………37

10.2.1 设计原则………………………………………………………………37

10.2.2 冷却时间的确定…………………………………………………38

10.3 模具冷却系统的计算…………………………………………………39

11 注塑机的校核………………………………………………………………40

11.1 最大注塑量的校核………………………………………………………40

11.2 锁模力的校核 ……………………………………………………………40

11.3 喷嘴尺寸校核……………………………………………………………40

11.4 定位圈尺寸校核……………………………………………………………41

11.5 模具外形尺寸校核………………………………………………………41 11.6 模具厚度校核……………………………………………………………41

11.7 模具安装尺寸校核………………………………………………………41

11.8 开模行程的校核……………………………………………………………41

12 模具工作过程……………………………………………………………43

12.1 模具总体结构………………………………………………………………43

12.2 开合模动作…………………………………………………………………45

13 模具可行性分析…………………………………………………………46

13.1 本模具的特点……………………………………………………………46

13.2 市场效益及经济效益分析…………………………………………………46

结论……………………………………………………………………………… 47致谢…………………………………………………………………………… 48

参考文献……………………………………………………………………… 49

毕业设计（论文）知识产权声明…………………………………………… 50

毕业设计（论文）独创性声明………………………………………… 51

附录………………………………………………………………………………52

1 绪论

1.1 题目背景

近年来,我国塑料模具业发展相当快，目前，塑料模具在整个模具行业中约占30%左右，而在整个塑料模具市场以注塑模具需求量最大。随着模具制造行业的发展，许多企业开始追求提高产品质量及生产效率,缩短设计周期及制造周期,降低生产成本，最大限度地提高模具制造业的应变能力等目标。新兴的模具CAD技术很大程度上实现了企业的愿望。近年来，CAD技术的应用越来越普遍和深入, 大大缩短了模具设计周期, 提高了制模质量和复杂模具的制造能力[][1]。

全部文件.jpg

塑件图.jpg

装配图.jpg

总装配图+主要零件图共10张.jpg

字数统计.jpg

内容简介：: ORIGINAL ARTICLE A scaffolding architecture for conformal cooling design in rapid plastic injection moulding K. M. Au &K. M. Yu Received: 4 August 2005/Accepted: 25 March 2006/Published online: 8 June 2006 # Springer-Verlag London Limited 2006 Abstract Cooling design of plastic injection mould is important because it not only affects part quality but also the injection moulding cycle time. Traditional injection mould cooling layout is based on a conventional machining process. As the conventional drilling method limits the geometric complexity of the cooling layout, the mobility of cooling fluid within the injection mould is confined. Advanced rapid tooling technologies based on solid free- form fabrications have been exploited to provide a time- effective solution for low-volume production. In addition, research has made attempts to incorporate conformal cooling channel in different rapid tooling technologies. However,the coolingperformance doesnotmeet the mould engineers expectations. This paper proposes a novel scaffold cooling for the design of a more conformal and hence more uniform cooling channel. CAD model for constructing the scaffolding structure is examined and cooling performances are validated by computer-aided engineering (CAE) and computer fluid dynamics (CFD) analysis. Keywords Conformalcooling . Scaffolding . Rapidtooling . Plasticinjectionmoulding 1 Background on cooling channel design in plastic injection mould In recent years, rapid prototyping and tooling 1 pro- cesses have found widespread use in speeding up tooling production. These processes greatly reduce the manufac- turing cost and the lead time required for tool produc- tion. Figure 1 illustrates the difference between traditional tooling production and contemporary rapid tooling fabrication. 1.1 Conventional cooling channel in plastic injection mould The use of conventional cooling channel 2 allows coolant or water to circulate within the injection mould, removing the heat by dissipation. It is the most common method of controlling mould temperature. The channel is formed by hole-drilling in various sizes as close as possible to the actual moulding area of the cavity sets. Figures 2 and 3 illustrate the conventional cooling channel in the injection mould. According to the part dimensional accuracy re- quired, the drilled holes are always machined using boring tool or drilling machine. The side wall of the mould is plugged and coolant is directed into cross bores and changed in direction. The freeform geometric cavity is surrounded by a straight-line cooling pattern. This will cause uneven cooling in the mould part. The uneven cooling will result in a tendency of several mould defects occurrence and increase the cooling time. A more accept- able cooling method is performed by the coolant flows in a pattern that closely matches the geometry of the part being moulded. 2 Conformal cooling channel in rapid soft tooling formed by copper duct Conformal cooling 4 is defined as the cooling channels that conform to the surface of the mould cavity (or core) for effectively transferring the heat from the mould cavity to Int J Adv Manuf Technol (2007) 34:496515 DOI 10.1007/s00170-006-0628-x K. M. Au : K. M. Yu(*) Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Hong Kong, Peoples Republic of China e-mail: mfkmyu.hkthe coolant channel. The term conformal means that the geometry of the cooling channel follows the mould surface geometry. The aim is to maintain a steady and uniform cooling performance for the moulding part. Figures 4 and 5 illustrate the geometries of the different conformal cooling channels. From experimental results by several researchers, the injection mould cooling performance after utilizing confor- mal cooling channels can offer nearer uniform temperature distribution within the mould than the traditional cooling method. Heat can be evenly transferred or dissipated through the conformal cooling channel. Figures 6 and 7 illustrate the conformal cooling channel of direct AIM prototype tooling, designed by 3D Systems in 1997 5. However, the geometry of the copper duct can only partially follow the shape of the moulding part. It cannot provide a true uniform temperature distribution in the injection mould. The bending of the copper duct is limited by its diameter, mechanical strength and the size of the moulding part. Further bending of the copper duct will damage the cooling channel. It is worth to focus on the relationship between the geometry of the moulding surface and the cooling channel. The technique shown in Figs. 6 and 7 is proposed to realize the conformal cooling channel with better cooling performance. Besides, properties like thermal conductivity and coeffi- cient of thermal expansion are important in the rapid tooling process. Thermal conductivity is the quantity of heat transmitted through a distance in a direction normal to a surface with a certain area due to a temperature difference. An increase in thermal conductivity of the mould shortens the time required to cool down the moulding part. As epoxy is the material having low thermal conductivity, aluminium filler is added or mixed with epoxy.On the contrary,the coefficientofthermal expansion is the fractional change in dimension (or length) of a material for a unit change in temperature. The value decreases when aluminium filled compounds are added. Aluminium filled epoxy have a better dimensional stability than unfilled epoxy for injection moulding in RT. Table 1 indicates the coefficient of linear thermal expansion and thermal conductivity of various metal filled epoxies. Fig. 1 Difference in time between traditional and concurrent rapid tooling fabrications Fig. 2 Configuration of an injection mould with conventional cooling channel (side view) Fig. 3 Configuration of conventional cooling channel with coolant circulation 3 Int J Adv Manuf Technol (2007) 34:496515 4972.1 Related works in injection mould cooling channel design via RT techniques The advancement of SFF gives rise to the production of injection mould with intricate cooling channel geometry. RapidtoolingbasedonSFFtechnologyincludesRapidTool, SL, SLS or rapid casting, 8 etc. They provide significant advantages to plastic injection mould manufacturing. Much research has focused on improving the geometric design of the cooling channel via RT technologies. In 2001, Xu 9 studied injection mould with complex cooling channels based on SFF processes. He described the conformal cooling layout that can be realized with substantial improvements in part quality and productivity. He presented a modular and systematic technique for the design of cooling layouts by using 3DP. He suggested the decomposition of the injection moulded surface into definite controllable parts, called cooling zones. Then the cooling zones with the system of cooling layouts are further divided into definite cooling cells for analysis with the assistance of six design rules or constraints. He demon- strated his methodology via application to complex core and cavity for injection moulding. Figure 8 shows the green part of an injection mould with conformal cooling system design made by MITs 3D printing 9. Li 10 studied a new design synthesis approach with the use of a feature-recognition algorithm to optimize the cooling system of a complex shape plastic part at the initial designstage.Theplasticpart modelisdividedfromintegral domain into simpler shape features. Then the individual shape feature is matched with its corresponding cooling design layout to form the mould cavity. This design synthesis technique can offer uniformity in mould temper- ature distribution. The ineffective computation time and complexity in domain part subdivision may give rise to some technical problems during the mould design process. Figure 9 illustrates the proposed conformal cooling design based on feature recognition algorithm. In 1999, Jacobs 11 described the use of conformal cooling channels in an injection mould insert. The channels arebuiltby electroformed nickelshells.From finite element simulation, the conformal cooling channel formed by copper duct bending can increase the uniformity of mould temperature distribution. It can also decrease the cycle time and part distortion. As common injection moulding materials, such as steel, have not been included in his research, the application is only restricted to copper or nickel duct bending. Schmidt 12 investigated and generated a series of design of experiments in an attempt to evaluate and measure the benefits of conformal cooling for injection moulding. He presented an overview of the mould design methodology, cooling channel simulation and analysis, and tool production through MITs 3D Printing process. The simulation results show that conformal cooling can reduce both cycle and cooling times, and in part shrinkage. However, the mechanical strength, thermal stress of mould material and other mould defects are not taken into consideration in this work. Figure 10 illustrates the Fig. 4 Conformal cooling channel in cavity side Fig. 5 Location of conformal cooling channel 6 Fig. 6 Conformal cooling channel formed by copper duct 5 Fig. 7 Bending of cooling duct evenly around the cavity wall (surrounding the ejector pin) 498 Int J Adv Manuf Technol (2007) 34:496515comparison between conventional and conformal cooling design for cooling simulation. Ferreira 13 attempted to use rapid soft tooling technology for plastic injection moulding. His work integrates rapid tooling with a composite material of aluminium-filled epoxy. The mould is cooled by conformal cooling channels. With the assistance of a decision matrix algorithm, a proper choice of materials and processes can be selected. The cooling layouts of the soft tooling are inserted with a bending copper duct before the epoxy filling process. However, in reality, the geometries of the cooling layouts are not fully conformed to the model. The cooling and moulding performance are affected directly with the rough metal mould surface finish. Mould defects such as flash,weldline,sinkmarksandlow backpressure appeared and cannot be avoided. Figure 11 shows the soft RT mould with conformal cooling channel. From the above review, much research has attempted to apply SFF technologies to the design of conformal cooling channel. However, the increase in complexity of part geometries hinders the realization of conformal cooling layout fabrication in some RT processes. It is worthwhile to investigate further a more effective approach in order to obtain better cooling performances. 3 RapidTool fabrication with conformal cooling design RT, such as RapidTool process 14 by 3D systems, has successfullyappliedtotheproductionofprototypeinrecent years. Figures 12 and 13 indicate the workflow of the RapidTool process for tooling fabrication. The application of RT for injection mould fabrication can assess to complex metal-type prototype more rapidly than other contemporary rapid prototyping technologies. As mould cooling is one of the limiting factors in the injection-moulding cycle, cooling channel design in RT is important for controlling the production time and quality. 3.1 Laminated steel tooling (LST) Laminated steel tooling (LST) 15 is a process that is employed to produce a laminated tool made of sheets of steel from laser-based cutting technology. The process is based on sequentially combining sheets of steel layer by layer with high-strength brazed joints for the laminated injection-mould fabrication. The advantage of LST is the production of tools that have dimensional accuracy com- parable to injection moulding. The technology can give rise to produce complex geometric configuration within the injection mould. However, LST moulds are used only for low melting thermoplastics and are not appropriate for the injection-moulding process with thermosetting plastics or high-temperature glass fibre. The layered manufacturing feature of LST is capable of fabricating injection moulds insertion of conformal cooling channels into any shape or position required. Figure 14 shows the hot platening process for LST production. 3.2 RapidTool RapidTool is a proprietary process from 3D Systems (formerly from DTM) based on selective laser sintering of LaserForm powder (thermoplastic coated steel powder) and subsequent bronze infiltration. Conformal cooling channels can be incorporated into the moulds, which last for hundreds of thousands of shots of common plastic. Table 1 Mechanical properties of various metal-filled epoxies 7 Epoxy for casting resins and compounds Unfilled Silica- filled Aluminium- filled Coefficient of linear thermal expansion, (10 6 /C) 4565 2040 5.5 Coefficient of thermal conductivity, (W/(m K) 4.5 1020 1525 Fig. 8 Green parts of an injection mould with conformal cooling channel design made by MITs 3D Printing 9 Fig. 9 Conformal cooling design based on a feature-recognition algorithm 10 Int J Adv Manuf Technol (2007) 34:496515 4993.3 Copper polyamide Like RapidTool, the Copper Polyamide process is now available from 3D Systems and uses a mixture of bronze and polyamide powders and conformal cooling channels can be incorporated into the moulds. 3.4 Direct metal laser sintering (DMLS) EOSs DMLS process utilizes specially developed machines and multi-component metal powders (mixture of bronze or steel with nickel). The SLS process is used for sintering, but no bronze infiltration is needed. Figure 15 shows the core and cavity of inserts with conformal cooling channel designed by EOS. 3.5 Direct AIM (accurate, clear, epoxy solid-injection mould) The advancement in rapid prototyping provides the capa- bility for the development of rapid tooling for injection moulding via 3D Systems stereolithography (SL). In the SL process, a photo-curable epoxy formed resin is solidified by exposing to a UV laser beam. In order to further improve thermal conductivity, copper channels or aluminium shots can be added to the low-melt alloy mix. The proposed design of cooling channel limits the consistencyofthemouldsurfaceforheattransfer.Figure16 shows the cross section of an injection mould assembly by the SL technique. 3.6 ProMetal ProMetal is an application of MITs Three Dimensional Printing Process to the fabrication of injection moulds. The ProMetal system creates metal parts by selectively binding metal powders layer by layer. It uses a wide area inkjet head to deposit a liquid binder onto the metal powders. The final metal mould is obtained by sintering and bronze infiltration similar to RapidTool of 3D Systems. Figure 17 shows the design of the cooling channel that can be located on any position within the mould. 4 Proposed model of porous scaffold architecture for an injection mould Scaffold technique 1620 has been widely used in the medical, bio-technological and architectural disciplines. It can offer a desirable three-dimensional interconnectivity with tough mechanical strength. The dimension can be accurately controlled by the highly repeatable solid free- form fabrication processes. The design and fabrication of various complex geometries with a porous network can be performed by various RP&T processes. Figure 18 shows a porous structure formed by the assembly of scaffold elements. A mechanical and chemical feasible three- dimensional porous scaffold architecture can be fabricated. The maturity and high resolution of various RP and RT techniques allow scaffold architectural model to be devel- oped in various applications. 4.1 Possible methods for the design of a cooling passageway The use of rapid tooling technologies offers a compact fabrication of a complex 3D model. With the purpose of enabling the production of a cooling passageway con- formally, this section outlines the surface offsetting method for the approximation of automatic design of cooling Fig. 10 Comparison between conventional and conformal cooling design for cooling simulation 12 Fig. 11 Soft RT mould with conformal cooling channel 13 500 Int J Adv Manuf Technol (2007) 34:496515passageway with the scaffolding technique. Firstly, spatial occupancy enumeration is used to approximate the array of the whole conformal cooling passageway with scaffolding elements.Figure 19showsthe flowchartof scaffold cooling surface approximation. a) Formulation and numerical solution of conformal cool- ing passageway formed by mould surface offsetting. Offsetting method is widely applied in various applica- tions. In theory, surface offsetting 21 is defined as the locus of points that are at constant distance d along the normal from the original surface. The offset surface r 0 (u) of a parametric surface r(u) can be expressed by Eq. (1) r 0 u r u dn u 1 Here, the surface of the mould cavity is under surface offset. The intention is to define the geometric approximation of cooling passageway with a specific offset distance d. The new offset surface will identify the location of the cooling passageway of the mould cavity. The new offset surface is then offset again with a specific distance to form the layout and size of cool

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