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第1页附录DEVELOPMENTANDAPPLICATIONOFPLASTICSMOLDINGCAD/CAM/CAESYSTEMYuHuaKongZhenyuAdvancedManufacturingTechnologyCenter,HarbininstituteoftechnologyABSTRACTthispaperdescribesfeaturesofplasticsmoldingCAD/CAM/CAEintegratedsystemandprocessofapplyingthesystemtopractice.DevelopmentandapplicationofIDEASintegrateddesignengineeringsoftwarewereperformedinviewofactualplasticsmolding.TheresultsshowthatplasticsmoldingCAD/CAM/CAEsystemisapracticalandefficienttechniquewhichisworthspreading.KEYWORDSplasticsmoldingCAD/CAM/CAEintegratedIDEAS1.introductionPlasticsmoldingisthemainmethodofproducingplasticsproduct.Itdevelopsinhighspeedbutitshistoryisshort.Plasticsmoldingisalsousedextensively.Accordingtothestatistics,thequantityofplasticsmoldingisabout28ofthatofallmolding,butthetraditionaldesignofplasticsmoldingislowefficient,longperiodicandwasteful.Itcontradictswiththedevelopmentofplasticsindustry.Withthedevelopmentoftechniqueincomputer,numericalcontrolandplasticsfluid,plasticsmoldingCAD/CAM/CAEhasbeenappliedextensivelyatpresent2.plasticsMoldingCAD/CAM/CAEsystem2.1processofplasticsmoldingCAD/CAM/CAETheintegrationofCAD/CAM/CAEchangesthetraditionalmodeofproducingmolding.Fig.1showtheintegratedprocess.第2页Intraditionaldesign,itisrequiredtoproduceactualsolidmoldingtoevaluatetheappearanceandtestthefunctionofproductwhentheproductconstructionisfinished.Bycontrast,inCAD/CAM/CAEsystem,byusingsolidgeometrymodelinguserscandisplaythepictureofproductvividlyongraphicterminal,evaluatetheappearanceandmodelingtechnologythroughobservingthescreen,andneednotproduceactualsolidmodeling.ByusingfiniteFig1processofplasticsmoldingCAD/CAM/CAEElementmethodanalysissoftware,userscanalsotestthemechanicalfunctionsofproduct.ThemainfeatureofCAD/CAMsystemisthegenerationofacommondatabasewhichisusedforalldesignandmanufacturingactivities,soanotherfunctionofgeometrymodelingistoprovidegeometrydataforthefamiliesofplasticsanalysisandgraphicnumericalcontrol,hencetheredundant第3页dataisavoided,andtheefficiencyandprevisionareimproved.Threedimensionalgeometrysolidscanalsobeconvertedintotwodimensionalengineeringdrawing,sodesignerwouldberelaxedfromdraftingandcalculating,concentratedoncreativework..Whenfinishingthepreliminarydesign,userscouldcheckthemoldingtechnologyandtheextentofmoldingconstructionbyusingCAEsoftware,thatistosay,usersshouldsimulatetheprocessofplasticsinjectionbeforethemoldingismanufactured.ThroughtheanalysisofCAEsoftware,allkindsofresultsaregottenineachphaseofplasticsinjection,suchastemperature,pressure,stress,fillingtime,coolingtime,warpageandshrinkage,etc.theseresultsarealsoshownwithabundantmodesofpostprocess.Userscanperformaquantitativeorqualitativeanalysis.Iftherearesomeproblem,thedesigncouldbecorrectincomputer.theinteractionisoperatedbetweenCADandCAEuntilthereasonableresultsaregotten.Notasthetraditionalprocess,themoldingwouldbemodifiedwhenithasbeenmanufacturedifsomethingiswrong,soprocessperiodishortendramatically,andefficiencyandprevisionareimproved.Wheninjectingsimulationisfinished,iftheresultsarereasonable,itshowsthedesignisapplicable.Thenextstepistofinishdetaildesignandmanufacturingtechnology,preparetomanufacture.Recently,thetechniqueofnumericalcontrolNCmakesagreatprogress.TheautomaticallyprogrammedtoolAPTappearedin1960spromotedthedevelopmentofNCtechnologydramatically.APTisalsousedwidelyatpresent,butitalsohassomedefects,suchaslowefficiency,etc.atpresent,thedevelopmentorientationofNCistomergeCADandCAMintoanorganicwhole,soCAD/CAMisaunifiedsoftwaresystem,inwhichtheCADportionisinterfacedinsidethecomputerwiththeCAMsystem.ThereforethetrackofcuttingtooliscreatedwiththemodeofmanmachineinteractionbyusingthegeometrydatafullywhichiscreatedinthephaseofCAD.Nowanewprogrammingtechniquehasbeencomeintousinggraphicnumericalcontrol第4页GNCbasedongraphic.Inthesystem,cuttingtool,workpieceandfixturearedisplayedoncomputerscreenbygeneratinganimation,sothetrackoftoolisoptimumandsafety.Insum,GNCsystemisveryefficientandconvenient.2.2applicationofIDEASsoftwareinpracticeOuradvancedmanufacturingtechnologycenterAMMTECofharbininstituteoftechnologymakesanefforttodevelopintegratedsystemofCAD/CAM/CAE.AMTECwasfoundedin1992.itimportedmanyNCmachinesandlargestyleengineeringsoftwareIDEASintegrateddesignengineeringanalysissoftwarewithwhichequipsIBMRISC6000workstation,sowehavetheconditiontoapplyplasticsmoldingCAD/CAM/CAEsystemtodesign,analysisandmanufacturingofplasticsmolding.IDEASisatypeofsyntheticallyautomaticsoftware.Itintegratesthefunctionsofdesign,drawing,engineeringanalysis,digitalsimulationofplasticsmolding,numericalcontrolprogrammingandtest.Thefamiliesofgeometrymodeling,plasticsanalysisandgraphicnumericalcontrolconstituteaplasticsmoldingCAD/CAM/CAEsystem.Wewoulddesignandmanufactureasetofmoldingwhichproducestheplasticpedalofjettacarproductmaterialisnylon66forthefirstAutomobileWorkofcityofchangchun.Itisdifficultytodesignandmanufacturethemoldingbecausetheshapeofpedalisverycomplicated,sowedecidedtoapplythefamiliesofIDEAStodesign,analysisandNCprogramming.IDEASsolidmodelingisanimportantcomponentofIDEAS.Itsuppliesasetoffunctionaltoolforgeometrymodelinganddetailmechanicaldesign.ThemethodofsolidmodelingisconstructivesolidgeometryCSG.Thestepsareinfollowing1creatingbasicelements,suchascubic,cylinder,sphere,etc.2disposingthebasicelementsbyusingBooleanoperation.Sothecomplicatedgeometrycanbecreated.Usingthesesteps,thethreedimensionalgeometrymodelingofpedalcanbe
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