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关键词：: 时尚艺术板凳注塑模具设计 17 cad 图纸以及说明书仿单

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摘要

注塑成型工艺已经在我国的农业、工业、制造业、国防及日常生活等方面广泛的运用。为了探究注塑成型工艺的生产过程及其模具的设计制造过程，本次毕业设计参考相关书籍，结合生活实际，对整套注塑模具的生产设计过程进行详细探究。

本文将对塑料板凳的注塑模具设计，详细描述了整套模具的设计过程。主要内容包括塑件的基本介绍、塑件的结构及成型工艺分析、材料的选择及成型工艺、注射机的选择及校核、模具的工作及结构原理、浇注系统的设计、成型零件的设计、侧向分型抽芯机构的设计、合模导向机构的设计、温度调节系统的设计、排气系统的设计、推出机构的设计等。在正确的分析材料的特点和塑件的工艺特点后，运用三维软件对塑件和模具的设计，制造及质量进行分析；运用CAXA软件绘制完整的模具装配图和其主要零件图。此次设计综合运用多中专业基础知识、如模具设计与制造基本理论、机械设计、材料成型基础、塑性成型工艺、计算机基础技术、模具CAD/CAM等。

通过对整个模具设计的过程，进一步加深对注塑成型工艺的了解，同时也巩固了对成型工艺的类型、结构、工作原理等的理论知识，以及在实践中总结并掌握模具设计的关键要点及其设计方法。

关键词: 成型工艺；设计；制造；塑料

Abstract

Injection molding process has been widely used in China's agricultural、 industrial、 manufacturing、defense and other aspects of daily life. In order to explore the injection molding process and mold production process design and manufacturing process, this graduation design reference books, combined with real life, the production of injection molds for the entire design process detailed inquiry.

This article will bench plastic injection mold design, detailed description of the entire mold design process. The main contents include a basic introduction to plastic parts, design selection and verification, working principle and structure of the mold, pouring system structure and plastic parts molding process analysis, choice of materials and molding process, injection machine, forming part of the design, side parting pulling mechanism design, design-oriented organization designed to mold temperature control system, the design of the exhaust system, the introduction of design institutions. After the characteristics and process characteristics of plastic parts correct analysis of the material, the use of three-dimensional software for plastic parts and mold design, manufacturing and quality analysis; using CAXA software to draw a complete mold assembly drawing and its major parts diagram. The design of the integrated use of multi-professional knowledge, such as mold design and manufacture of basic theory, mechanical design, material forming the basis of the plastic molding process, basic computer technology, tooling CAD / CAM and so on.

Key points through the entire mold design process, and further deepen their understanding of the injection molding process, but also to consolidate the process of forming the type, structure and operating principles of the theory of knowledge, as well as summary and master mold design and in practice.

Keywords: Molding process; design; making; plastic.

引言 1

1 塑件的基本介绍 2

1.1 塑件3D建模 2

1.2 塑件名称 2

1.3 塑件材料 2

1.4 塑件前景 3

1.5 塑件总体要求 3

2 塑件的结构及工艺性分析 4

2.1 塑件结构分析 4

2.2 塑件的工艺性分析 4

2.3 开模方向 4

2.4 脱模斜度 5

2.5 收缩率 5

2.6 表面粗糙度 5

2.7 塑件壁厚 6

2.8 圆角 6

3 材料的选择与工艺参数 7

3.1 材料的选择及其性能 7

3.2 塑件的成型工艺 8

4 注射机的选择及校核 10

4.1 注射机的相关参数 10

4.2 注射机的选择 11

4.3 锁模力的校核 11

4.4 开模行程的校核 12

5 模具的工作及结构原理说明 13

5.1 模具的工作原理 13

5.2 模具的结构说明 13

6 浇注系统的设计 15

6.1 浇注系统的设计要求 15

6.2 型腔的数目及分布 15

6.3 双分型面的选择与设计 16

6.4 主流道的设计 17

6.5 分流道的设计 18

6.6 冷料穴的设计 19

6.7 浇口的设计 19

7 成型零部件的设计 21

7.1 凹模的设计 21

7.2 凸模的结构设计 22

7.3 成型零部件尺寸的设计 22

8 侧向分型抽芯机构的设计 25

8.1 斜导柱的倾角 25

8.2 斜导柱直径设计 25

8.3 斜导柱长度的设计 26

8.4 滑块的设计 26

8.5 导滑槽的设计 27

8.6 楔紧块的设计 27

8.7 滑块定位的设计 27

9 合模导向机构的设计 28

9.1 导柱、导套的设计 28

10 温度调节系统的设计 30

10.1 温度调节系统的设计要求 30

10.2 冷却回路的设计 30

11 排气系统的设计 31

12 推出机构的设计 32

12.1 顶出力的计算 32

12.2 凝料推出机构的设计 33

13 支撑零部件设计 34

14 常见问题及其解决办法 35

14.1 熔接痕产生的原因及解决办法 35

14.2 充模不力产生的原因及解决办法 35

14.3 弯曲变形产生的原因及解决办法 35

结论 37

谢辞 38

参考文献 39

引言

随着我国工业技术的飞跃性发展，模具在我国国民经济的各个领域中发挥越来越大的作用，享有着“工业之母”的美称。模具制造是指通过注塑、压铸和锻压等方式得到所需的各种产品或工件，一个设计合理的塑件往往能够代替几个传统金属构件。利用塑性材料独有的特性，一次注塑成型往往就可以得到非常复杂的形状，所带来的实际应用效果非传统工艺所能相比。模具的生产与制造融合了多项高精密技术为一体，既是高新技术产品，又是高新技术载体。采用模具成型工艺，运用高新技术控制对所需的塑件进行加工生产，不仅可以提高生产时效，保质保量。而且还能减少生产线对材料的过度依赖，压缩了生产成本，更好的获取经济效益。

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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A METHODOLOGY FOR THE DESIGN OF EFFECTIVE COOLING SYSTEM IN INJECTION MOULDINGInt J Mater Form (2010) Vol. 3 Suppl 1:13 16DOI10.1007/s12289-010-0695-2Springer-VerlagFrance2010ABSTRACTIn thermoplastic injection molding, part quality and cycle time depend strongly on the cooling stage. Numerous strategies have been investigated in order to determine the cooling conditions which minimize undesired defects such as war page and differential shrinkage. In this paper we propose a methodology for the optimal design of the cooling system. Based on geometrical analysis, the cooling line is defined by using conformal cooling concept. It defines the locations of the cooling channels. We only focus on the distribution and intensity of the fluid temperature along the cooling line which is here fixed. We formulate the determination of this temperature distribution, as the minimization of an objective function composed of two terms. It is shown how this two antagonist terms have to be weighted to make the best compromise. The expected result is an improvement of the part quality in terms of shrinkage and war page.KEYWORDS: Inverse problem；heat transfer；injection molding ；Cooling design1. INTRODUCTIONIn the field of plastic industry, thermoplastic injection molding is widely used. The process is composed of four essential stages: mould cavity filling, melt packing, solidification of the part and ejection. Around seventy per cent of the total time of the process is dedicated to the cooling of the part. Moreover this phase impacts directly on the quality of the part 1 2. As a consequence, the part must be cooled as uniformly as possible so that undesired defects such as sink marks, warpage, shrinkage, thermal residual stresses are minimized. The most influent parameters to achieve these objectives are the cooling time, the number, the location and the size of the channels, the temperature of the coolant fluid and the heat transfer coefficient between the fluid and the inner surface of the channels. The cooling system design was primarily based on the experience of the designer but the development of new rapid prototyping process makes possible to manufacture very complex channel shapes what makes this empirical former method inadequate. So the design of the cooling system must be formulated as an optimization problem.1.1 HEAT TRANSFER ANALYSISThe study of heat transfer conduction in injection tools is a non linear problem due to the dependence of parameters to the temperature. However thermo physical parameters of the mould such as thermal conductivity and heat capacity remain constant in the considered temperature range. In addition the effect of polymer crystallization is often neglected and thermal contact resistance between the mould and the part is considered more often as constant. The evolution of the temperature field is obtained by solving the Fouriers equation with periodic boundary conditions. This evolution can be split in two parts: a cyclic part and an average transitory part. The cyclic part is often ignored because the depth of thermal penetration does not affect significantly the temperature field 3.Many authors used an average cyclic analysis which simplifies the calculus, but the fluctuations around the average can be comprised between 15% and 40% 3.The closer of the part the channels are, the higher the fluctuations around the average are. Hence in that configuration it becomes very important to model the transient heat transfer even in stationary periodic state. In this study, the periodic transient analysis of temperature will be preferred to the average cycle time analysis. It should be noticed that in practice the design of the cooling system is the last step for the tool design. Nevertheless cooling being of primary importance for the quality of the part, the thermal design should be one of the first stages of the design of the tools.1.2 OPTIMIZATION TECHNIQUES IN MOULDINGIn the literature, various optimization procedures have been used but all focused on the same objectives. Tang et al. 4 used an optimization process to obtain a uniform temperature distribution in the part which gives the smallest gradient and the minimal cooling time.Huang 5 tried to obtain uniform temperature distribution in the part and high production efficiency i.e. a minimal cooling time. Lin 6 summarized the objectives of the mould designer in 3 facts. Cool the part the most uniformly, achieve a desired mould temperature so that the next part can be injected and minimize the cycle time.The optimal cooling system configuration is a compromise between uniformity and cycle time. Indeed the longer the distance between the mould surface cavity and the cooling channels is, the higher the uniformity of the temperature distribution will be 6. Inversely, the shorter the distance is, the faster the heat is removed from the polymer. However non uniform temperatures at the mould surface can lead to defects in the part. The control parameters to get these objectives are then the location and the size of the channels, the coolant fluid flow rate and the fluid temperature. Two kinds of methodology are employed. The first one consists in finding the optimal location of the channels in order to minimize an objective function 4 7. The second approach is based on a conformal cooling line.Lin 6 defines a cooling line representing the envelop of the part where the cooling channels are located. Optimal conditions (location on the cooling and size of the channels) are searched on this cooling line. Xu et al. 8 go further and cut the part in cooling cells and perform the optimization on each cooling cell.1.3 COMPUTATIONAL ALGORITHMSTo compute the solution, numerical methods are needed. The heat transfer analysis is performed either by boundary elements 7 or finite elements method 4.The main advantage of the first one is that the number of unknowns to be computed is lower than with finite elements. Only the boundaries of the problem are meshed hence the time spent to compute the solution is shorter than with finite elements. However this method only provides results on the boundaries of the problem. In this study a finite element method is preferred because temperatures history inside the part is needed to formulate the optimal problem. To compute optimal parameters which minimize the objective function Tang et al. 4 use the Powells conjugate direction search method. Mathey et al. 7 use the Sequential Quadratic Programming which is a method based on gradients. It can be found not only deterministic methods but also evolutionary methods.Huang et al. 5 use a genetic algorithm to reach the solution. This last kind of algorithm is very time consuming because it tries a lot of range of solution. In practice time spent for mould design must be minimized hence a deterministic method (conjugate gradient) which reaches an acceptable local solution more rapidly is preferred.2 METHODOLOGY2.1 GOALSThe methodology described in this paper is applied to optimize the cooling system design of a T-shaped part (Figure 1). This shape is encountered in many papers so comparison can easily be done in particularly with Tang et al. 4.Based on a morphological analysis of the part, two surfaces 1 and 3 are introduced respectively as the erosion and the dilation (cooling line) of the part (Figure 1). The boundary condition of the heat conduction problem along the cooling line 3 is a third kind condition with infinite temperatures fixed as fluid temperatures. The optimization consists in finding these fluid temperatures. Using a cooling line prevents to choose the number and size of cooling channels before optimization is carried out. This represents an important advantage in case of complex parts where the location of channels is not intuitive. The location of the erosion line in the part corresponds to the minimum solidified thickness of polymer at the end of cooling stage so that ejectors can remove the part from the mould without damages.Figure 1 : Half T-shaped geometry2.2 OBJECTIVE FUNCTIONIn cooling system optimization, the part quality should be of primarily importance. Because the minimum cooling time of the process is imposed by the thickness and the material properties of the part, it is important to reach the optimal quality in the given time. The fluid temperature impacts directly the temperature of the mould and the part, and for turbulent fluid flow the only control parameter is the cooling fluid temperature. In the following, the parameter to be optimized is the fluid temperature and the determination of the optimal distribution around the part is formulated as the minimization of an objective function S composed of two terms computed at the end of the cooling period (Equation (1). The goal of the first term S1 is to reach a temperature level along the erosion of the part. 3 CONCLUSIONSIn this paper, an optimization method was developed to determine the temperature distribution on a cooling line to obtain a uniform temperature field in the part which leads to the smallest gradient and the minimal cooling time. The methodology was compared with those found in the literature and showed its efficiency and benefits. Notably it does not require specifying a priori the number of cooling channels. Further work will consist in deciding a posteriori the minimal number of channels needed to match the solution given by the optimal fluid temperature profile.An integrated framework for die and mold cost estimation using design features and tooling parametersReceived: 5 August 2003 / Accepted: 6 January 2004 / Published online: 2 February 2005Springer-Vela London Limited 2005AbstractTooling is an essential element of near net shape manufacturing processes such as injection molding and die casting, where it may account for over 25% of the total product cost and development time, especially when order quantity is small. Development of rapid and low cost tooling, combined with a scientist approach to mold cost estimation and control, has therefore become essential. This paper presents an integrated methodology for die and mold cost estimation, based on the concept of cost drivers and cost moodier. Cost drivers include the geometric features of cavity and core, handled by analytical cost estimation approach to estimate the basic mold cost. Cost moodier include tooling parameters such as parting line, presence of side core(s), surface texture, ejector mechanism and die material, contributing to the total mold cost. The methodology has been implemented and tested using 13 industrial examples. The average deviation was 0.40%. The model is edible and can be easily implemented for estimating the cost of a variety of molds and dies by customizing the cost moodier using quality function deployment approach, which is also described in this paper.Keywords：Cost estimation; Die casting; Injection molding; Quality function deployment。1 IntroductionProduct life cycles today are typically less than half of those in the 1980s, owing to the frequent entry of new products with more features into the market. Manufacturing competitiveness is measured in terms of shorter lead-time to market, without scribing quality and cost. One way to reduce the lead-time is by employing near net shape (NNS) manufacturing processes, such as injection molding and die casting, which involve fewer steps to obtain the desired shape. However, the tooling (die or mold), which is an essential element of NNS manufacturing, consumes considerable resources in terms of cost, time and expertise.A typical die casting die or plastic injection mold is made in two halves: moving and axed which butt together during mold ling and move apart during part ejection. The construction of a typical cold chamber pressure die casting die is shown in Fig. 1.The main functional elements of the die and mold include the core and cavity, which impart the desired geometry to the incoming melt. These may be manufactured as single blocks or built-up with a number of inserts. The secondary elements include the feeding system, ejection system, side core actuators and fasteners. The feeding system comprising of spree bush, runner, gate and overawe enables the town of melt from machine nozzle to mold cavity. The ejector mechanism is used for ejecting the molded part from the core or cavity. All the above elements are housed in a mold base set, comprising of support blocks, guides and other elements. Part-specie elements, including core and cavity and feeding system are manufactured in a tool room. Other elements are available as standard accessories from vendors. Mold assembly and functional trials are conducted by experienced toolmakers in consultation with tool designers.Fig. 1. Construction of a typical pressure diecasting dieThe tooling industry is presently dominated by Japan, Germany, USA, Canada, Korea, Taiwan, China, Malaysia, Singapore and India. The major users of tooling include automobiles, electronics, consumer goods and electrical equipment sectors. Plastic molds account for the major share of tooling industry. About 60% of tool rooms belong to small and medium scale industries worldwide 1. The tooling requirement is over US$ 600 million per year in India alone, with an annual growth rate of over 10% during the last decade. In India, the share of different types of molds and dies is: plastic molds 33%, sheet metal punches and dies 31%, die casting dies 13%, jigs mold cost was estimated using linear regression analysis.To summarize, cost similarity and cost functions (cost factors) are the two sets of methods for estimating the mold cost.In the rest set, similarity between a new mold and a previous mold developed in the tool rooms is used as a reference. Intuitive and analogical methods fall under this category. In the widely used intuitive method, the cost appraiser may not be in a position to identify all the risk factors and to quantify many of them. The analogical method can be successfully used for estimating the cost of die bases and other secondary elements where grouping is much easier. However, in the case of functional elements (core and cavity), grouping becomes a difficult task as their geometry, machining sequence and tolerance greatly vary with product design.In the second set of methods, the dependency between the mold cost and its drivers are expressed in mathematical functions. Analytical method, activity based costing, feature based method and parametric costing methods falls under this category. While analytical methods are well established for estimating the machining cost of simple parts, they are difficult to apply in die and mold manufacturing because of their geometric complexity. Similarly, feature based cost estimation is difficult to apply because the current feature recognition and classification algorithms cannot handle freeform surfaces present in most of the dies and molds,

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