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塑料斜齿轮旋转脱螺纹注塑模具设计【三维UG零件】【18张CAD图纸和说明书】

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关键词：: 塑料齿轮旋转螺纹罗纹注塑模具设计三维 ug 零件 18 cad 图纸以及说明书仿单

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摘要

伴随着全球性经济发展，新技术革命浪潮不断的突破与发展，跨越性的技术发展已经成为推动世界经济增长的重要因素。市场经济的不断繁荣，极大地促进了对体积小，工业产品的品种多，低成本，高品质的方向发展。为了提高生产周期的市场竞争力的核心产品的要求越来越高，开发周期短，因此对各种产品的制造的关键技术及设备，模具的要求也越来越严格和苛刻的。

模具是基础工业之一。随着市场经济全球化趋势和各种高新技术的迅猛发展，快速经济模具被赋予了新的内涵和新的任务，种类的激增，促使快速经济制模材料向着多品种系列化迈进，不断促使工艺有新突破和发展。鉴于商品经济的快速发展，产品换代更新的加速，以及市场竞争愈发激烈，都愈发高的刺激着快速经济制模技术朝着短周期、低成本、高质量及高制造精度等方向发展。鉴于它能够使企业获得更大的市场，创造更大显著的经济效益，因此愈发受到企业家的垂青以及获得相关领导部门的政策资金的支持。鉴于快速发展的高新技术以及各种技术的综合运用，未来必定会产生新型节能省材的快速制模技术来适应社会生产中差异化需求。

此次毕业设计是对塑料斜齿轮注塑模具设计，难点在于实现自动旋转脱螺纹功能。本设计有两大亮点，一是使用齿轮齿条传动机构来实现测抽芯，二是用轴承使型腔旋转来实现脱螺纹设计。因模具中有多处需要配合，可能使模具在制造和装配方面有些难度。

关键词：模具；斜齿轮；结构设计；注射模；型腔

Abstract

With the global economic development, new technology revolution continued breakthroughs and development, leapfrog technology development has become an important factor in promoting world economic growth . Continued prosperity of the market economy , which greatly promoted to small, multi- variety of industrial products , low-cost , high-quality direction. In order to enhance the core products in the market competitiveness of the production cycle, and increasingly demanding shorter development cycle , and therefore the key to the manufacture of various products, technology and equipment - mold requirements are increasingly stringent and demanding .

Mold is one of the basic industries . With the rapid development of economic globalization and a variety of high-tech markets , rapid economic mold was given a new meaning and a new task , the type of surge , prompting rapid economic modeling material moving toward multi- variety series , continue to promote technology breakthroughs and development. Given the rapid development of the commodity economy , accelerate the upgrading products , and market more competitive , are increasingly high to stimulate rapid economic modeling techniques towards short-cycle , low-cost , high-quality and high manufacturing precision direction. Given its ability to enable enterprises to gain a larger market , creating greater significant economic benefits , and therefore increasingly favored by the entrepreneurs and access to funding to support policies related to the leadership department. Given the rapid development of high-tech and comprehensive use of various technologies , the future will certainly generate new energy-saving materials for rapid tooling technology to meet the social needs of the difference in production .

??The graduation project is a plastic injection mold design helical gear , the difficulty lies off the automatic rotation of the threaded function. This design has two bright spots , one using rack and pinion mechanism to achieve measured Pulling , two bearings so that the cavity is rotated to achieve the de- thread design . Because there are many die with blood , may cause some difficulty in mold manufacturing and assembly areas .

Keyword: mold ; bevel wheel; structural design;plastics injection mold; cavity

引言 1

1 塑件（斜齿轮）的分析 3

1.1 塑件（ABS）的三维模型 3

1.2 塑料的基础知识与应用 4

1.3 ABS塑料 4

1.3.1塑料ABS的基本概念 4

1.3.2塑料ABS的特性 5

1.3.3塑料ABS的成型特性及成型条件 6

1.3.4塑料ABS的成型条件 6

1.4 塑件结构工艺性要求的了解及分析 7

1.5 脱模斜度［1］ 7

1.6 塑件的壁厚［1］ 7

1.7 圆角 8

2 注射机的选择 9

3 型腔数目的决定 10

4 成型零件设计 12

4.1 确定型腔壁厚 12

4.2 动模板厚度的计算 12

4.3 分型面的确定［1］ 13

4.4 排气系统的设计 13

4.5 成型零件的结构设计 14

4.5.1成型凹模的结构设计 14

4.5.2成型凸模的结构设计 14

4.5.3型腔尺寸计算 14

5 浇注系统设计 18

5.1 主浇道（浇口套）的设计 18

5.2 浇口的设计［1］ 20

5.3 定位圈的选择 20

6 模具温度调节系统的设计 21

6.1 模具温度调节对塑件质量的影响 21

6.2 加热系统的设计 21

6.3 冷却系统设计 21

7 脱模机构的设计 22

7.1 推管脱模机构设计 22

7.2 内螺纹抽芯脱模机构的设计 22

7.2.1螺纹型芯的设计 22

7.2.2传动齿条的设计 24

8 复位机构的设计和选择 26

8.1 弹簧的选用［4］ 26

8.2 弹簧的分布形式 27

9 合模导向机构的设计 28

9.1 导向机构的功用 28

9.2 导向机构的选用［5］ 28

10 型芯与侧型芯脱模力的计算 29

10.1 型芯脱模力的计算 29

10.2 侧抽芯力计算 29

11 模具的闭模高度和开模行程验算 30

12 模具其它零件的设计 31

13 标准件的选择［5］ 32

14 模具的总装图以及运动顺序、及其特点 33

15 模具的安装、调试 34

16 工艺卡片 35

16.1 塑件成型工艺卡 35

16.2 机械加工工艺卡 36

16.2.1浇口套定位圈机械加工工艺卡 36

16.2.2定模板机械加工工艺卡 37

16.2.3垫块机械加工工艺卡 38

结论 39

谢辞 40

参考文献 41

引言

模具是一种重要的工业产品的生产技术和设备，是国民经济的基础，被冠以现代“工业之母”。现代生产中，模具因其加工效率高，互换性，节约了材料，所以广泛应用。作为一个蓬勃发展的行业，在整个模具塑料模具发展很快。作为制造行业的一个后起之秀，它以它独特的优势而被广泛应用，极大地促进了塑料工业的质的发展。

（一）、我国塑料模具的发展现状

模具是现代工业生产的重要工艺装备。依工业技术的飞跃式发展，依靠模具来进行加工在国民经济的各领域中愈发常见。

随着塑料工业的迅速发展，效率高，自动化程度高，寿命长和高精密模具的设计和制造是关注未来的重点。例如电视机外壳、空调机零件、洗衣机内缸、电冰箱、灯座、周转箱等模具。世界上的一些工业化国家，其工业产值已超过机床工业的模具，其增长率也超过了机床，汽车，电子等行业。在这些国家，模具工业已成为国民经济的基础工业之一。美国工业界称“模具工业是美国工业的基石”，日本模具协会称“模具是促进社会富裕的动力”。什么东西既具有自己的价值通过同一模具为社会创造了巨大的经济效益和社会效益。

一流的模具设计理念、高质量的制造水平、上等的材料、合理的加工工艺和现代化管理及成型设备等都是制造优质模具不可获缺的。一副优质的模具可以重复上百万次成型，这是和上面所陈述的因素分不开的。纵观国内外同行情况，注塑成型技术发展趋势大致有以下几个方面：

（1）CAD/CAE/CAM技术在模具设计与制造中的应用；

（2）模具制造对工业领域的推动发展；

（3）开发模具逆向工程，创新模具的快测技术；

（4）开发上等的模具材料和对其表面进行特殊处理；

（5）提升模具标准化水平，用模块化实现模具的重组；

（6）模具的模块化、集成化、精密化。

塑料模具在我国的发展很快。塑料模的设计制造、CAD/CAE/CAM技术、CAPP技术，已有不少的企业及研究机构在开发及应用。在设计及制造技术上与一流水准相比有一定的不足。专用模具钢的种类少少、标准化程度不高、质量尚不稳定等问题还在困扰着我国模具行业；模具的商品化、系列化及规模化能力还有不少改进及提升的空间；CAD、CAM、Flow Cool等软件应用程度不是很高；提高模具的设计与制造水平是增加国际核心竞争能力比不可少的。

近些年来，伴随着模具综合技术的提升，模具产品也更加复杂、精密，模具制造成本和周期也在缩短。

（二）、研究此项目的内容、目的和意义

通过计算机数据模拟和仿真对塑料注射模具的设计思路和制造过程进行有效的评估和预测，并且可改善模具的结构设计并快速制得样品，便于赢得客户，争取定单，从而扩大市场及占有率；此外还降低返厂率，缩短生产周期，节省材料和费用，进而很大幅度地降低了模具的生产成本。

此项目针对的内容和要求:

（1）拟定斜齿轮塑件的成型工艺，选用合理的成型设备。

（2）合理的模具设计结构。必要时可依模具要求对塑件图纸进行适当的修改。

（3）长使用寿命、高强度，高耐磨性是模具配件必不可少的。?

（4）经济性好、便于制造是模具制造需要考虑的。

（5）确定零件尺寸及形状，选择合理的结构。

（6）高效率、高可靠性、高自动化程度是模具设计制造的精髓。

研究此项目的目的与意义:

（1）选择合适的塑料及成型工艺。

（2）通过对产品质量分析，改进模具的工艺及结构设计。

（3）将模具设计融合到CAD/CAM/CAE的运用中去。

（4）提高分析和解决问题的能力，改进我们的学习与创新发展。

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动模垫板A2.gif

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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 38 页Incorporating Manufacturability Considerations during Design of Injection Molded Multi-Material Objects Ashis Gopal Banerjee, Xuejun Li, Greg Fowler, Satyandra K. Gupta1 Mechanical Engineering Department and The Institute for Systems Research University of Maryland, College Park, MD 20742, U.S.A. ABSTRACT The presence of an already molded component during the second and subsequent molding stages makes multi-material injection molding different from traditional injection molding process. Therefore, designing multi-material molded objects requires addressing many additional manufacturability considerations. In this paper, we first present an approach to systematically identifying potential manufacturability problems that are unique to the multi-material molding processes and design rules to avoid these problems. Then we present a comprehensive manufacturability analysis approach that incorporates both the traditional single material molding rules as well as the specific rules that have been identified for multi-material molding. Our analysis shows that sometimes the traditional rules need to be suppressed or modified. Lastly, for each of the new manufacturability problem, this paper describes algorithms for automatically detecting potential occurrences and generating redesign suggestions. These algorithms have been implemented in a computer-aided manufacturability analysis system. The approach presented in this paper is applicable to multi-shot and over molding processes. We expect that the manufacturability analysis techniques presented in this paper will help in decreasing the product development time for the injection molded multi-material objects. Keywords: Automated manufacturability analysis, generation of redesign suggestions, and multi-material injection molding. 1 INTRODUCTION Over the last few years, a wide variety of multi-material injection molding (MMM) processes have emerged for making multi-material objects, which refer to the class of objects in which different portions are made of different materials. Due to fabrication and assembly steps being performed inside the molds, molded multi-material objects allow significant reduction in assembly operations and production cycle times. Furthermore, the product quality can be improved, and the possibility of manufacturing defects, and total manufacturing costs can be reduced. In MMM, multiple different materials are injected into a multi-stage mold. The sections of the mold that are not to be filled during a molding stage are temporally blocked. After the first injected material sets, then one or 第 1 页共 38 页more blocked portions of the mold are opened and the next material is injected. This process continues until the required multi-material part is created. Nowadays, virtually every industry (e.g., automotive, consumer goods, toys, electronics, power tools, appliances) that makes use of traditional single-material injection molding (SMM) process is beginning to use multi-material molding processes. Some common applications include multi-color objects, skin-core arrangements, in-mold assembled objects, soft-touch components (with rigid substrate parts) and selective compliance objects. Typical examples of each class of application are shown in Fig. 1. There are fundamentally three different types of multi-material molding processes. Multi-component injection molding is perhaps the simplest and most common form of MMM. It involves either simultaneous or sequential injection of two different materials through either the same or different gate locations in a single mold. Multi-shot injection molding (MSM) is the most complex and versatile of the MMM processes. It involves injecting the different materials into the mold in a specified sequence, where the mold cavity geometry may partially or completely change between sequences. Over-molding simply involves molding a resin around a previously-made injection-molded plastic part. Each of the three classes of MMM is considerably different. Each specific MMM process requires its own set of specialized equipment; however, there are certain equipment requirements that are generally the same for all types of MMM. Techniques described in this paper are applicable to over-molding and multi-shot molding.Currently only limited literature exists that describes how to design molded multi-material objects. Consequently very few designers have the required know-how to do so. Consider an example of a two piece assembly consisting of part A and part B to be produced by multi-material molding. In fact, many new users believe that if part A and part B meet the traditional molding rules then assembly AB will also be moldable using multi-material molding. By moldable we mean that the assembly (or part) can be molded using one or more MMM (or SMM) processes such that basic functional and aesthetic requirements for the part or assembly are satisfied and the mold cavity shape can be changed (i.e. mold can be opened, pieces may be removed or inserted and then mold can be closed) without damaging the mold pieces. However, this notion is not always correct. Fig. 2 shows an assembly to be molded by MMM. In this case, both parts can be individually molded without any problem. However, molding them as an assembly using over-molding process leads to manufacturability problems. After molding the inner part in the first stage, it is not possible to carry out second stage molding as the injected plastic will flow over the inner part and damage the surfaces of the already molded component. This emphasizes the need for developing new design rules that are specific to addressing manufacturability problems encountered in multi-material molding. Detection of this problem and corresponding redesign suggestion will be described in sub-section 5.3.On the other hand, there are molded multi-material assemblies where at least one of the parts would have not been moldable as an individual piece using traditional molding. However, this part can be molded when done as a part of the assembly. Fig. 3 highlights such a case. Although application of traditional plastic injection molding rules would have concluded that component B cannot be manufactured, it is possible to mold 第 2 页共 38 页assembly AB by choosing an appropriate molding sequence. For example, in this case we first need to mold part A and then mold part B using overmolding operation.The reason why MMM appears to be significantly different from SMM can be explained as follows. The part that has been molded first (component A) acts as the “mold piece” during the second molding stage. Thus, a plastic mold piece is present in addition to the metallic mold pieces during this molding stage. Hence, this second stage is fundamentally different in nature from conventional single-material injection molding. Fig. 4 illustrates this condition by depicting the two molding stages in rotary platen multi-shot molding. Although the shape of the core remains identical in both the stages, the cavity shape changes and already molded component A acts as an additional “mold piece” in the second shot. Moreover, the first stage part that acts as plastic “mold piece” is not separated from the final assembly. This forces us to avoid applying some of the traditional molding design rules on certain portions of the gross shape of the overall object also referred as gross object. By gross object, we mean the solid object created by the regularized union of the two components. That is why, simply ensuring that the first stage part and the gross shape are moldable do not solve this problem either. Fig. 5 illustrates this fact; blindly checking all the faces of the gross object for presence of undercuts leads us to wrongly conclude that it cannot be molded. In reality, this is not the case and we should only test the faces that need to be demolded (i.e., separated from the mold pieces) during that molding stage while determining a feasible molding sequence.Based on the above discussion, we conclude that a new approach needs to be developed to analyze manufacturability of molded multi-material objects. In the current paper we only consider manufacturability problems arising due to the shape of the components and the gross object. Fig. 6 shows an example where undercuts create problems; they need to be eliminated in order to form a feasible molding sequence. The gross object shown in that figure cannot be made by any MMM process, because neither of the two components is moldable due to the presence of deep, internal undercuts. Slight redesign of component A enables us to carry out MMM operation component A can be injected first and then component B, provided they have similar melting points or A melts at a higher temperature than B. Section 3 systematically derives five such new manufacturability problems that arise in multi-material molding from the state transition diagram representing the process flow.The next task in developing a systematic manufacturability analysis methodology is to develop a detailed approach for applying these new rules. A comprehensive approach to outline how and when the new multi-material molding design rules need to be applied and traditional single material molding rules have to be applied, modified or suppressed has been proposed in Section 4. Finally, algorithms have been presented to detect violations of such rules and generate feasible redesign suggestions in Section 5. All the algorithms have been implemented in a computer-aided manufacturability analysis system. We conclude this paper by stating its contributions and limitations in Section 6.第 3 页共 38 页2 RELATED RESEARCH A wide variety of computational methods have emerged to provide software aids for performing manufacturability analysis Gupt97a, Vlie99. Such systems vary significantly by approach, scope, and level of sophistication. At one end of the spectrum are software tools that provide estimates of the approximate manufacturing cost. At the other end are sophisticated tools that perform detailed manufacturability analysis and offer redesign suggestions. For analyzing the manufacturability of a design, the existing approaches can be roughly classified into two categories. In direct approaches Ishi92, Rose92, Shan93, shape-based rules are used to identify infeasible design attributes from direct inspection of the design description. In indirect or plan-based approaches Gupt95, Gupt97b, Gupt98, Haye89, Haye94, Haye96, the first step is to generate a manufacturing plan, and then to evaluate the plan in order to assess the manufacturability of design. This approach is useful in domains where there are complex interactions between manufacturing operations.Several leading professional societies have published manufacturability guidelines for molded plastic parts to help designers take manufacturability into account during the product design phase Bake92, Truc87. Poli Poli01 has also described qualitative DFM rules for all the major polymer processing processes including injection molding, compression molding and transfer molding. Moreover, companies such as General Electric Gene60 have generated their own guidelines for the design of plastic parts. Such guidelines show examples of good and bad designs. It is left to the designers discretion to apply them as and when necessary. Basically, there are two types of guidelines. The first type deals with manufacturability issues, whereas the second type deals with part functionality. We will only cover the first type of guidelines here. They are listed as follows.a) Fillets should be created and corners should be rounded so that the molten plastic flows smoothly to all the portions of the part. Use of radii and gradual transitions minimize the degree of orientation associated with mold filling, thereby resulting in uniform mold flow Mall94. Moreover, this also avoids the problem of having high stress concentration. Fig. 7 shows an example of how part design needs to be altered to get rid of sharp corners. b) The parting line must be chosen carefully so that “parting” and metal “shut-off” flashes can be minimized. Typically, flashes (solidified leakages of plastic material) occur along the parting line, where the mold pieces come in direct contact with each other. Fig. 8 illustrates how the stiffening ribs on a part have to be redesigned in order to change the location of the parting line. This consequently changes the flash formation position. In the first case, flashes run all along the part, destroying the part quality. However, they occur on the top surface of the part in the second design, and hence can be easily removed later on. c) Thin and uniform section thickness should be used so that the entire part can cool down rapidly at the same rate. Thick sections take a longer time to cool than thin sections. For example, in the first part shown in Fig. 9, the thicker, hotter sections of the molding will continue to cool and shrink more than the thinner sections. This will result in a level of internal stress in the portions of the part where the wall thickness changes. These 第 4 页共 38 页residual, internal stresses can lead to warpages and reduced service performances. If possible, the part must be redesigned to eliminate such thickness variations altogether. Otherwise, tapered transitions can be used to avoid residual stresses, high stress concentrations and abrupt flow transitions during mold filling. Whenever feasible, wall section thickness must be reduced by coring out sections of the molding, and by using ribs to compensate for the loss in stiffness of a thinner part Mall94. d) Side actions (side cores, split cores, lifters etc.) must be used to create undercut features on the part or the part should be redesigned to eliminate undercut features. Fig. 10 shows an example of a plastic part, whose undercut region cannot be molded by any side action. A simple redesign shown in this figure solves this problem. e) Draft angles need to be imparted to vertical or near-vertical walls for ease of removal of the part from the mold assembly. Fig. 11 shows that incorrect draft angles make it impossible to eject the part. Tapering the side walls inward (towards the core side) resolves this issue satisfactorily. Drafting also reduces tool and part wear considerably sliding friction as well as scuffing or abrasion of the outer (cavity) faces of the part are eliminated to a large extent. Typically, the required draft angle ranges from a fraction of a degree to several degrees and depends on a lot of parameters such as depth of draw, material rigidity, surface lubricity and material shrinkage Mall94. Computational work in the field of manufacturability analysis of injection molded parts mainly focuses on two different areas. The first area deals with demoldability of a single material part. The demoldability of a part is its ability to be ejected easily from the mold assembly (core, cavity and side actions) when the mold opens. Deciding if a part is demoldable is equivalent to deciding if there exists a combination of main parting direction, side cores and split cores such that the criterion of demoldability is satisfied. Chen et al. Chen93 describe a visibility map based approach to find a feasible parting direction that minimizes the number of side cores. Hui Hui97 describes a heuristic search technique for selecting a combination of main parting, core and insert directions. Approaches based on undercut-feature recognition have also been developed Gu99, Fu99, Lu00, Yin01. The basic idea behind these approaches is to find potential undercuts on the part using feature recognition techniques. Each type of feature has its own set of candidate parting directions. The optimal main, parting direction is then chosen on the basis of some evaluation functions.Ahn et al. Ahn02 describe mathematically sound algorithms to test if a part is, indeed, moldable using a two-piece mold (without any side actions) and if so, to obtain the set of all such possible parting directions. Building on this, Elber et al. Elbe05 have developed an algorithm based on aspect graphs to solve the two-piece mold separability problem for general free-form shapes, represented by NURBS surfaces. McMains and Chen McMa04 have determined moldability and parting directions for polygons with curved (2D spline) edges. Recently, Kharderkar et al. Khar05 have presented new programmable graphics hardware accelerated algorithms to test the moldability of parts and help in redesigning them by identifying and graphically displaying undercuts. Dhaliwal et al. Dhal03 described exact algorithms for computing global accessibility cones for each face of a polyhedral object. Using these, Priyadarshi and Gupta Priy04 developed algorithms to design multi-piece molds. Other notable work in the area of 第 5 页共 38 页automated multi-piece mold design includes that by Chen and Rosen Chen02, Chen03.The second area of active work deals with the simulation of molten, plastic flow in injection molding process. Many commercial systems are available to help designers in performing manufacturability analysis. Also, finite element analysis software like ANSYS, ABAQUS, FEMLAB etc. can be used to predict and solve some problems, such as whether the strength of some portion of the part is adequate. Since these types of problems arising during multi-material injection molding are the same as those experienced in case of single material molding, appropriate commercial packages can be used to overcome them.3 IDENTIFYING SOURCES OF MOLDING PROBLEMS Many different reasons can contribute to manufacturability problems during MMM. These reasons include material incompatibility, interac

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