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关键词：: 三通管接头注塑模具设计 17 cad 图纸以及说明书仿单

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摘要

　　塑料注射模具是成型塑料的一种重要工艺装备，通过对液压管路三通塑料模具设计,能够全面的了解塑料模具设计的基本原则、方法.并能较为熟练的使用Proe4.0、AUTOCAD软件进行塑料模具设计,提高自己的绘图能力。为今后从事设计工作打下了坚实的基础。

　　随着现代工业发展的需要，塑料制品在工业、农业、日常生活和军事等各个领域的应用范围越来越广，质量要求也越来越高，中国已经成为全球最大的塑料市场之一，塑料制品产量全球第二。为了做到高质、高效、低成本，从而提高市场占有率，注塑模具的开发、设计、加工与CAD/CAE/CAM技术相结合具有重大意义。

本次主要设计是对液压管路三通注射模的设计, 重点对塑件的成型原理、原料选用和注射技术进行分析。通过根据形状、尺寸、精度及表面质量要求的分析结果，确定所需的模塑成型方案，制品的后加工、分型面的选择、型腔的数目和排列、成型零件的结构、浇注系统等。

关键词：注塑模；模具结构；侧型芯；工艺方案

Abstract

Plastic injection mold is an important technological equipment of plastic forming, based on the hydraulic piping tee plastic mold design, can fully understand the basic principles, methods of plastic mold design. And can be used more skilled Proe4.0, AUTOCAD software for plastic mold design, improve their ability to draw. Engaged in the design for the future work laid a solid foundation.

With the needs of the development of modern industry, plastic products in industry, agriculture, military and other fields of daily life and the application scope is more and more wide, the quality requirements also more and more high, China has become one of the world's largest plastics market, plastic products production in the world's second. In order to achieve high quality, high efficiency, low cost, and improve the market share, injection mold development, design, processing combined with CAD/CAE/CAM technology is of great significance.

The main design is the design of injection mold hydraulic piping tee, focus on the forming principle of plastic parts, raw materials selection and injection technology were analyzed. By according to the shape, size, precision and surface quality requirement analysis, to determine the required molding solutions, products after processing, the choice of the parting surface, cavity number and arrangement, the structure of molding parts, pouring system, etc.

Key words: injection mold; The mold structure; The side core; The processing plan

前言 1

1 研究概况 1

1.1国外研究现状.........................................................................................................1

1.2国内研究现状.........................................................................................................1

2 塑件制品分析 2

2.1 明确制品设计要求 2

2.2 明确制品批量 3

2.3 材料选择及性能 3

2.3.1 材料选择 3

2.4 成型设备 4

2.5 拔模斜度 4

2.6 计算制品的体积和质量 5

2.6.1表面质量的分析 5

2.6.2塑件的体积重量 5

3 注射机及成型方案的确定 6

3.1 注射机的确定 6

3.2 成型方案的确定 6

3.2.1 成型设备的选择 6

3.2.2成型的特点 7

3.2.3成型的原理 7

3.2.4成型过程 7

4 型腔数的确定及分型面的选择 9

4.1 型腔数的确定 9

4.2 分型面的选择 10

4.2.1 分型面的主要选择原则 10

4.3 确定型腔的排列方式 11

4.4 标准模架的选用 11

5 成型零部件的设计与计算 13

5.1 凸模设计 13

5.2 凹模的设计 13

5.3 成型零件工作尺寸的计算 14

5.3.1 模腔工作尺寸的计算 14

6 浇注系统的设计 13

6.1 主流道设计 16

6.2分主流道的设计 16

6.3 浇口的设计 17

6.4 平衡进料 17

6.5冷料穴设计 18

7 排气与冷却系统的设计 13

7.1 冷却系统设计的原则 18

7.2 冷却水路的计算 19

7.3 排气系统的设计 20

8 顶出与抽芯机构的设计 20

8.1 推杆复位装置 20

8.2 抽芯机构的选择 21

8.3 抽芯距的计算 21

8.4斜导柱抽芯的设计 21

8.5滑块的设计 23

8.5侧向分型与抽芯机构三维效果图如下所示： 23

9 导向机构的设计 24

9.1 导向、定位机构的主要功能 24

9.2导向机构的设计 24

9.2.1 导柱的设计 24

10 注塑机与模具各参数的校核 25

10.1 工艺参数的校核 25

10.2 模具安装尺寸的校核 26

10.2.1 喷嘴的校核 26

10.2.2 定位圈尺寸的校核 26

10.2.3 模具外形尺寸的校核 26

10.2.4 模具厚度的校核 26

10.2.5 安装参数的校核 26

10.3 开模行程的校核 27

11 模具安装和试模 27

12 主要成型零件加工工艺 28

13 结论……………………………………………………………… 30

谢辞 32

参考文献 33

前言

　　注射成型也称为注射或注塑，是热塑性塑料的一种重要成型方法。到现在为止，有超过1/3的塑料原材料，是通过注射成型工业加工的，除氟塑料外，几乎所有的热塑性塑料都可以采用此成型方法。它的特点是生产周期短、生产效率高的、易自动化，因此广泛应用于塑料制品的生产。现在塑料成型生产中，塑料制件的质量与塑料成型模具、塑料成型设备和塑料成型工艺密切相关。在这三要素中，塑料成型模具的质量最为关键，他的功能是双重的：赋予塑料熔体以期望的形状、性能、质量；冷却并推出成型的塑件。模具是决定最终产品的性能、规格、形状以及尺寸精度的载体，塑料成型模具是使塑料成型生产过程顺利进行、保证塑料成型质量不可缺少的工艺装备，是体现塑料成型设备高效率、高性能和合理先进塑料成型工艺的具体实施者，也是新产品开发的决定环节。由此可见，周而复始地获得符合技术经济要求及质量稳定的塑料制件，塑料成型模具的优劣是关键，它最能反映出整个塑料成型生产过程的技术含量以及经济效益。因此，注射成型的模具设计制造成为当今社会模具发展的热点,己发展成为热塑性塑料最主要的成型加工方法。

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内容简介：: 编号：毕业设计(论文)外文翻译（原文）学院：专业：学生姓名：学号：指导教师单位：姓名：职称： 2014 年 3 月 9 日第 0 页共 28 页technical note on the characterization of electroformed nickel shells for their application to injection molds aUniversidad de Las Palmas de Gran Canaria, Departamento de Ingenieria Mecanica, Spain AbstractThe techniques of rapid prototyping and rapid tooling have been widely developed during the last years. In this article, electroforming as a procedure to make cores for plastics injection molds is analysed. Shells are obtained from models manufactured through rapid prototyping using the FDM system. The main objective is to analyze the mechanical features of electroformed nickel shells, studying different aspects related to their metallographic structure, hardness, internal stresses and possible failures, by relating these features to the parameters of production of the shells with an electroforming equipment. Finally a core was tested in an injection mold. Keywords: Electroplating; Electroforming; Microstructure; Nickel 1. IntroductionOne of the most important challenges with which modern industry comes across is to offer the consumer better products with outstanding variety and time variability (new designs). For this reason, modern industry must be more and more competitive and it has to produce with acceptable costs. There is no doubt that combining the time variable and the quality variable is not easy because they frequently condition one another; the technological advances in the productive systems are going to permit that combination to be more efficient and feasible in a way that, for example, if it is observed the evolution of the systems and techniques of plastics injection, we arrive at the conclusion that, in fact, it takes less and less time to put a new product on the market and with higher levels of quality. The manufacturing technology of rapid tooling is, in this field, one of those technological advances that makes possible the improvements in the processes of designing and manufacturing injected parts. Rapid tooling techniques are basically composed of a collection of procedures that are going to allow us to obtain a mold of plastic parts, in small or medium series, in a short period of time and with acceptable accuracy levels. Their application is not only included in the field of making plastic injected pieces 1, 2 and 3, however, it is true that it is where they have developed more and where they find the highest output. 第 1 页共 28 页This paper is included within a wider research line where it attempts to study, define, analyze, test and propose, at an industrial level, the possibility of creating cores for injection molds starting from obtaining electroformed nickel shells, taking as an initial model a prototype made in a FDM rapid prototyping equipment. It also would have to say beforehand that the electroforming technique is not something new because its applications in the industry are countless 3, but this research work has tried to investigate to what extent and under which parameters the use of this technique in the production of rapid molds is technically feasible. All made in an accurate and systematized way of use and proposing a working method. 2. Manufacturing process of an injection moldThe core is formed by a thin nickel shell that is obtained through the electroforming process, and that is filled with an epoxic resin with metallic charge during the integration in the core plate 4 This mold (Fig. 1) permits the direct manufacturing by injection of a type a multiple use specimen, as they are defined by the UNE-EN ISO 3167 standard. The purpose of this specimen is to determine the mechanical properties of a collection of materials representative industry, injected in these tools and its coMParison with the properties obtained by conventional tools. Fig. 1. Manufactured injection mold with electroformed core.The stages to obtain a core 4, according to the methodology researched in this work, are the following: (a) Design in CAD system of the desired object.(b) Model manufacturing in a rapid prototyping equipment (FDM system). The material used will be an ABS plastic.(c) Manufacturing of a nickel electroformed shell starting from the previous model that has been coated with a conductive paint beforehand (it must have electrical conductivity).第 2 页共 28 页(d) Removal of the shell from the model.(e) Production of the core by filling the back of the shell with epoxy resin resistant to high temperatures and with the refrigerating ducts made with copper tubes.The injection mold had two cavities, one of them was the electroformed core and the other was directly machined in the moving platen. Thus, it was obtained, with the same tool and in the same process conditions, to inject simultaneously two specimens in cavities manufactured with different technologies. 3. Obtaining an electroformed shell: the equipmentElectrodeposition 5 and 6 is an electrochemical process in which a chemical change has its origin within an electrolyte when passing an electric current through it. The electrolytic bath is formed by metal salts with two submerged electrodes, an anode (nickel) and a cathode (model), through which it is made to pass an intensity coming from a DC current. When the current flows through the circuit, the metal ions present in the solution are transformed into atoms that are settled on the cathode creating a more or less uniform deposit layer. The plating bath used in this work is formed by nickel sulfamate 7 and 8 at a concentration of 400 ml/l, nickel chloride (10 g/l), boric acid (50 g/l), Allbrite SLA (30 cc/l) and Allbrite 703 (2 cc/l). The selection of this composition is mainly due to the type of application we intend, that is to say, injection molds, even when the injection is made with fibreglass. Nickel sulfamate allows us to obtain an acceptable level of internal stresses in the shell (the tests gave results, for different process conditions, not superior to 50 MPa and for optimum conditions around 2 MPa). Nevertheless, such level of internal pressure is also a consequence of using as an additive Allbrite SLA, which is a stress reducer constituted by derivatives of toluenesulfonamide and by formaldehyde in aqueous solution. Such additive also favours the increase of the resistance of the shell when permitting a smaller grain. Allbrite 703 is an aqueous solution of biodegradable surface-acting agents that has been utilized to reduce the risk of pitting. Nickel chloride, in spite of being harmful for the internal stresses, is added to enhance the conductivity of the solution and to favour the uniformity in the metallic distribution in the cathode. The boric acid acts as a pH buffer. The equipment used to manufacture the nickel shells tested has been as follows: Polypropylene tank: 600 mm 400 mm 500 mm in size. Three teflon resistors, each one with 800 W. Mechanical stirring system of the cathode.第 3 页共 28 页 System for recirculation and filtration of the bath formed by a pump and a polypropylene filter. Charging rectifier. Maximum intensity in continuous 50 A and continuous current voltage between 0 and 16 V. Titanium basket with nickel anodes (Inco S-Rounds Electrolytic Nickel) with a purity of 99%. Gases aspiration system.Once the bath has been defined, the operative parameters that have been altered for testing different conditions of the process have been the current density (between 1 and 22 A/dm2), the temperature (between 35 and 55 C) and the pH, partially modifying the bath composition. 4. Obtained hardnessOne of the most interesting conclusions obtained during the tests has been that the level of hardness of the different electroformed shells has remained at rather high and stable values. In Fig. 2, it can be observed the way in which for current density values between 2.5 and 22 A/dm2, the hardness values range from 540 and 580 HV, at pH 4 0.2 and with a temperature of 45 C. If the pH of the bath is reduced at 3.5 and the temperature is 55 C those values are above 520 HV and below 560 HV. This feature makes the tested bath different from other conventional ones composed by nickel sulfamate, allowing to operate with a wider range of values; nevertheless, such operativity will be limited depending on other factors, such as internal stress because its variability may condition the work at certain values of pH, current density or temperature. On the other hand, the hardness of a conventional sulfamate bath is between 200250 HV, much lower than the one obtained in the tests. It is necessary to take into account that, for an injection mold, the hardness is acceptable starting from 300 HV. Among the most usual materials for injection molds it is possible to find steel for improvement (290 HV), steel for integral hardening (520595 HV), casehardened steel (760800 HV), etc., in such a way that it can be observed that the hardness levels of the nickel shells would be within the mediumhigh range of the materials for injection molds. The objection to the low ductility of the shell is compensated in such a way with the epoxy resin filling that would follow it because this is the one responsible for holding inwardly the pressure charges of the processes of plastics injection; this is the reason why it is necessary for the shell to have a thickness as homogeneous as possible (above a minimum value) and with absence of important failures such as pitting. 第 4 页共 28 页Fig. 2. Hardness variation with current density. pH 4 0.2, T = 45 C.5. Metallographic structureIn order to analyze the metallographic structure, the values of current density and temperature were mainly modified. The samples were analyzed in frontal section and in transversal section (perpendicular to the deposition). For achieving a convenient preparation, they were conveniently encapsulated in resin, polished and etched in different stages with a mixture of acetic acid and nitric acid. The etches are carried out at intervals of 15, 25, 40 and 50 s, after being polished again, in order to be observed afterwards in a metallographic microscope Olympus PME3-ADL 3.3/10. Before going on to comment the photographs shown in this article, it is necessary to say that the models used to manufacture the shells were made in a FDM rapid prototyping machine where the molten plastic material (ABS), that later solidifies, is settled layer by layer. In each layer, the extruder die leaves a thread approximately 0.15 mm in diameter which is compacted horizontal and vertically with the thread settled inmediately after. Thus, in the surface it can be observed thin lines that indicate the roads followed by the head of the machine. These lines are going to act as a reference to indicate the reproducibility level of the nickel settled. The reproducibility of the model is going to be a fundamental element to evaluate a basic aspect of injection molds: the surface texture. The tested series are indicated in Table 1. Table 1. Tested series Series pH Temperature (C) Current density (A/dm2) 1 4.2 0.2 55 2.222 3.9 0.2 45 5.563 4.0 0.2 45 10.004 4.0 0.2 45 22.22第 5 页共 28 页Fig. 3 illustrates the surface of a sample of the series after the first etch. It shows the roads originated by the FDM machine, that is to say that there is a good reproducibility. It cannot be still noticed the rounded grain structure. In Fig. 4, series 2, after a second etch, it can be observed a line of the road in a way less clear than in the previous case. In Fig. 5, series 3 and 2 etch it begins to appear the rounded grain structure although it is very difficult to check the roads at this time. Besides, the most darkened areas indicate the presence of pitting by inadequate conditions of process and bath composition. Fig. 3. Series 1 (150), etch 1.Fig. 4. Series 2 (300), etch 2.第 6 页共 28 页Fig. 5. Series 3 (300), etch 2.This behavior indicates that, working at a low current density and a high temperature, shells with a good reproducibility of the model and with a small grain size are obtained, that is, adequate for the required application. If the analysis is carried out in a plane transversal to the deposition, it can be tested in all the samples and for all the conditions that the growth structure of the deposit is laminar (Fig. 6), what is very satisfactory to obtain a high mechanical resistance although at the expense of a low ductibility. This quality is due, above all, to the presence of the additives used because a nickel sulfamate bath without additives normally creates a fibrous and non-laminar structure 9. The modification until a nearly null value of the wetting agent gave as a result that the laminar structure was maintained in any case, that matter demonstrated that the determinant for such structure was the stress reducer (Allbrite SLA). On the other hand, it was also tested that the laminar structure varies according to the thickness of the layer in terms of the current density. Fig. 6. Plane transversal of series 2 (600), etch 2.6. Internal stresses第 7 页共 28 页One of the main characteristic that a shell should have for its application like an insert is to have a low level of internal stresses. Different tests at different bath temperatures and current densities were done and a measure system rested on cathode flexural tensiometer method was used. A steel testing control was used with a side fixed and the other free (160 mm length, 12.7 mm width and thickness 0.3 mm). Because the metallic deposition is only in one side the testing control has a mechanical strain (tensile or compressive stress) that allows to calculate the internal stresses. Stoney model 10 was applied and was supposed that nickel substratum thickness is enough small (3 m) to influence, in an elastic point of view, to the strained steel part. In all the tested cases the most value of internal stress was under 50 MPa for extreme conditions and 2 MPa for optimal conditions, an acceptable value for the required application. The conclusion is that the electrolitic bath allows to work at different conditions and parameters without a significant variation of internal stresses. 7. Test of the injection moldTests have been carried out with various representative thermoplastic materials such as PP, PA, HDPE and PC, and it has been analysed the properties of the injected parts such as dimensions, weight, resistance, rigidity and ductility. Mechanical properties were tested by tensile destructive t

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