基于加热细胞单元的电热变模温注塑模具加热系统设计

硕士学位论文(学术型)论文题目：基于加热细胞单元的电热变模温注塑模具加热系统设计作者姓名 指导教师 学科专业 机械工程 所在学院 机械工程学院 提交日期 2016 年 4 月浙江工业大学硕士学位论文（学术型）基于加热细胞单元的电热变模温注塑模具加热系统设计作者姓名：XXX指导教师：XXX( 教授)、XXX( 副教授)浙江工业大学机械工程学院2016 年 4 月Dissertation Submitted to Zhejiang University of Technologyfor the Degree of MasterDesign for Heating System of Electrical Rapid Heat Cycle Molding Mold based on Heating Cell UnitCandidate: XXXAdvisor: XXX, XXXCollege of Mechanical EngineeringZhejiang University of TechnologyApr 2016浙江工业大学学位论文原创性声明本人郑重声明：所提交的学位论文是本人在导师的指导下，独立进行研究工作所取得的研究成果。除文中已经加以标注引用的内容外，本论文不包含其他个人或集体已经发表或撰写过的研究成果，也不含为获得浙江工业大学或其它教育机构的学位证书而使用过的材料。对本文的研究作出重要贡献的个人和集体，均已在文中以明确方式标明。本人承担本声明的法律责任。作者签名： 日期： 年 月 日学位论文版权使用授权书本学位论文作者完全了解学校有关保留、使用学位论文的规定，同意学校保留并向国家有关部门或机构送交论文的复印件和电子版，允许论文被查阅和借阅。本人授权浙江工业大学可以将本学位论文的全部或部分内容编入有关数据库进行检索，可以采用影印、缩印或扫描等复制手段保存和汇编本学位论文。本学位论文属于(请在以下相应方框内打 “” ) 保密，在_年解密后适用本授权书。 不保密。作者签名： 日期： 年 月 日导师签名： 日期： 年 月 日浙江工业大学硕士学位论文（学术型）I基于加热细胞单元的电热变模温注塑模具加热系统设计摘 要快速变模温注塑成型(Rapid Heat Cycle Molding，以下 简称 RHCM)技术，可以有效地改善注塑制品的熔接痕、浮纤、表面粗糙、光泽度差等质量缺陷，是一种新型的注塑成型技术。本文以电热变模温注塑成型(Electrical Rapid Heat Cycle Molding，以下简称ERHCM)模具为研究对象，在进行加热过程模具型腔表面的热响应规律分析的基础上对模具加热系统的设计做了研究和探讨，以达到快速均匀地加热模具型腔表面的目的。本文的主要研究工作与成果如下：1. ERHCM 注塑模具热平衡分析及关键结构设计。基于传热学基本理论，对ERHCM 注塑模具加热过程进行热传递分析，建立热平衡分析方程，理论推导获得提高模具加热效率的方法。结合传统注塑模具设计基本准则和 RHCM 注塑成型工艺原理分析，提出 ERHCM 模具结构特别是加热系统关键部位的设计准则。2. ERHCM 注塑模具热响应分析。对 ERHCM 注塑模具的传热过程进行有限元温度场模拟，在 ERHCM 注塑模具的热响应规律和特点分析的基础上提出了加热细胞单元这一理念，同时阐述了模具热响应效率的两个评价指标所代表的含义。基于加热细胞单元，评估了模具材料、模具结构和加热元件等因素对模具加热效率和温度均匀性的影响，分析讨论提高 ERHCM 注塑成型工艺加热效率和改善加热均匀性具体措施。3. 提出了一种 ERHCM 注塑模具加热系统设计方法。基于随形加热冷却系统设计思想，将复杂的 ERHCM 注塑模具的加热系统简化成多个加热细胞单元，结合热响应分析计算、BP 神经网络、多目标优化和多属性决策技术获得单个加热细胞单元的最佳设计参数，再将其映射到整个模具结构体来完成整个 ERHCM 注塑模具加热系统设计。在此过程中，以中心复合试验法(CCD)进行试验规划，运用所开发的 ERHCM 注塑模具辅助分析程序进行热响应分析，基于分析结果建立了加热时间以及加热完成后温差的BP 神经网络模型，以加热效率和加热后型腔表面温度均匀性为优化目标，结合 NSGA-II 多目标优化方法和基于熵值权重法的 TOPSIS 多属性决策技术获得单个加热细胞单元的最佳设计参数。4. 开发了具有人机交互中文界面的 ERHCM 注塑模具热响应辅助分析程序，有助于设计者对于 ERHCM 注塑模具加热系统设计参数的修改，提高了设计效率。摘 要II论文的相关研究成果完善了 RHCM 注塑成型工艺的理论体系，为 ERHCM 注塑模具加热系统的设计提供了合理的指导原则，具有较强的工程和实用意义。关键词：快速变模温注塑成型，ERHCM，模具温度场，多目标优化，加热系统设计浙江工业大学硕士学位论文（学术型）IIIDesign for Heating System of Electrical Rapid Heat Cycle Molding Mold based on Heating Cell UnitABSTRACTThe Rapid Heat Cycle Molding (RHCM) technique is a new injection molding technology developed recently, which can effectively eliminate surface quality defects of plastic part, such as welding line, floating fiber, rough surface, poor glossiness, and so on.In this paper, an Electrical Rapid Heat Cycle Molding (ERHCM) mold was applied for studying thermal response analysis. In order to heat mold cavity surface rapidly and uniformly, the thermal response of mold cavity surface and how to design the heating system were studied. The main research work and conclusions are as follows:1. The thermal balance analysis and key structure design. Based on the heat transfer theory， the heat transfer for ERHCM mold was analyzed and the thermal balance equations during heating stage was established. Then, some efficient ways to improve the mold heating efficiency was obtained. According to the traditional injection mold design theory and RHCM process principle, the design guidelines for heating system of ERHCM mold were proposed.2. Thermal response analysis of ERHCM mold. ERHCM mold heating process was simulated by using ANSYS software, and the characteristics of mold thermal response were investigated. Then, the heating cell unit was proposed, and the meaning of the two evaluation index for thermal response efficiency of ERHCM mold was intuitively elaborated. Based on heating cell unit, the effect of mold materials, mold structure, and heating element on heating efficiency and temperature uniformity of the mold cavity surface was investigated and some efficient ways to improve the mold heating efficiency and heating uniformity was discussed.3. An efficient design method for heating system of ERHCM mold was proposed. First, the heating system of ERHCM mold was simplified as multiple heating cell units for thermal response analysis based on conformal design theory. Then, a strategy consisting of thermal ABSTRACTIVresponse analysis, neural network, multi-objective optimization and multiple-attribute decision-making technique was applied to obtain the optimized heating cell unit. Finally, the modified heating cell unit was then mapped into the entire mold to finish the heating system design of ERHCH mold. During this design process, the central composite design (CCD) method was employed in factorial experiments. In order to obtain experimental data, a thermal response aided analysis program of ERHCM mold was developed. Subsequently, a response surface using back propagation neural network (BPNN) was formed on the ground of initial finite element experiments. Then, combing Non-dominated sorting genetic algorithm II (NSGA-II) and the technique for order preferenceby similarity to ideal solution (TOPSIS) based on entropy-based weight, in which the required heating time and mold cavity surface temperature difference are the objective functions, the optimized heating cell unit for ERHCM mold was obtained. 4. This developed thermal response aided analysis program can provide a fast and efficient way for heating system design of ERHCM mold and hence shorten the mold development cycle time.The related research results perfect the the