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复印机小端盖注塑模具设计[CAD图纸+文档]

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复印机小端盖注塑模具设计

摘　　要

　　　塑料工业是当今世界上增长最快的工业门类之一，而注射模具是其中发展较快的一种。因此，研究注射模具对了解塑料产品的生产过程和提高产品质量有很大意义。

　　　本文主要是设计复印机小端盖的注射模具，论述了注射成型的基本原理，特别是单分型面注射模具的结构设计，详细介绍了注射模具的成型工艺及设备选择、浇注系统、抽芯机构和成型零部件的设计过程，并对模具制造工艺要求做了说明，最后通过CAD软件绘制出模具图。

　　　通过本设计，可以对注射模具有一个初步的认识，注意到设计中的细节问题，了解模具结构及工作原理，系统的复习了大学四年所学的专业知识。

关键词：注射模具；注射成型工艺；模具设计；分型面

Design of injection mould machine small end cover

Abstract

　　　Nowadays plastics industry is to increase one of the quickest industry category in the world, injection mould is to develop quicker among them , therefore studies the injection mould has very big meaning to knowing plastic product procedure of production and raising product quality.

　　　This paper is designed Copier small end cap injection mould , discussed the basal principle injection mould, especially One-surface injection mold design , Have introduced the molding handicraft injecting a mould detailedly、equipment Selection、 feed system、Pulling mechanism and molding part design process, As well as demanded an explanation for mold manufacturing technology, Finally draw out the mould picture by CAD software.

　　　During this design, I can have a preliminary understanding of Injection mould, note the details, know Die structure and operating principle, Review of the professional knowledge of the four-year study .

Key words: injection mould; injection mould process; mould designing;divides the profile

目　　录

1 绪论 1

1.1 题目的背景和意义 1

1.2 国内外模具工业的发展状况 1

1.3 塑料模具发展走势 2

1.4 课题研究的意义及主要研究内容 2

2 复印机小端盖的工艺性分析 4

2.1 塑件的材料与结构分析 4

2.1.1 塑件的体积及质量计算 4

2.1.2 塑件的结构与材料 5

2.2 塑件的尺寸精度及表面质量 7

2.2.1 塑件的尺寸精度 7

2.2.2 塑件的表面质量 7

2.3 工艺性分析 7

3 注塑模具结构设计 8

3.1 分型面的确定 8

3.2 浇口的确定 10

3.3 型腔数目的确定 11

3.4 浇注系统设计 12

3.4.1 主流道 12

3.4.2 分流道 13

3.4.3 浇口的设计 13

3.4.4 浇口套的形式及固定方式 14

3.5 成型零部件设计 14

3.5.1 成型零部件结构设计 15

3.5.2 成型零件工作尺寸计算 18

3.6 导向零件的设计 19

3.7 抽芯机构和顶出机构的设计 21

3.7.1 抽芯机构的设计 21

3.7.2 顶出机构的设计 22

3.8 脱模结构的设计 24

3.8.1 脱模力的计算 24

4 冷却设计及排气系统 26

4.1 冷却水道热传面积 26

4.1.1 塑料传给模具的热量 26

4.1.2 冷却水的体积流量 26

4.1.3 冷却水道热传面积 27

4.2 排气系统的设计 27

5 注射机的选择及校核 28

5.1 选择注射机 28

5.2 注射机的校核 28

5.2.1 注射压力的校核 29

5.2.2 最大注射量的校核 30

5.2.3 锁模力的校核 30

5.2.4 喷嘴尺寸校核 30

5.2.5 注射机固定模板定位孔与模具定位圈的关系 31

5.2.6 模具外形尺寸校核 31

5.2.7 模具的安装紧固 31

5.3 本章小结 31

6 模具材料的选择 32

7 模具装配图及制造工艺 33

7.1 模具装配图 33

7.2 模具制造工艺 35

7 模具可行性分析 36

8.1 本模具的特点 36

8.2 市场效益及经济效益分析 36

9 结论 37

致谢 38

参考文献 39

毕业设计（论文）知识产权声明 40

毕业设计（论文）独创性声明 41

附录 42

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内容简介：: Journal of Mechanical Science and Technology 24 (2010) 145148 /content/1738-494x DOI 10.1007/s12206-009-1126-5 Optimal injection molding conditions considering the core shift for a plastic battery case with thin and deep walls Dong-Gyu Ahn1,*, Dae-Won Kim2 and Yeol-Ui Yoon3 1Department of Mechanical Engineering, Chosun University, Gwang-Ju, 501-751, Korea 2 Incheon Service Division, KITECH, Incheon, 406-840, Korea 3Chun-Bok Injection Mold Inc., Gwang-Ju, 1233-12, Korea (Manuscript Received April 24, 2009; Revised September 21, 2009; Accepted October 12, 2009) Abstract The objective of this paper is to examine the influence of injection molding parameters on the core shift to obtain the optimal injection molding conditions of a plastic battery case with thin and deep walls using numerical analyses and experiments. Unlike conventional injection molding analysis, the flexible parts of the mold were represented by 3-D tetrahedron meshes to consider the core shift in the numerical analysis. The design of experiments (DOE) was used to estimate the proper molding conditions that minimize the core shift and a dominant parameter. The results of the DOE showed that the dominant parameter is the injection pressure, and the core shift de- creases when the injection pressure decreases. In addition, it was shown that the initial mold temperature and the injection time hardly affect the core shift. The results of the experiments showed that products without warpage are manufactured when the injection pressure is nearly 32 MPa. Comparing the results of the analyses with those of the experiments, optimal injection molding conditions were deter- mined. In addition, it was shown that the core shift should be considered to simulate the injection molding process of a plastic battery case with thin and deep walls. Keywords: Optimal injection molding condition; Core shift; Thin and deep walls; Battery case; Design of experiments 1. Introduction One of the recent concerns in the automotive industry is the reduction of overall weight to improve fuel efficiency and re- duce a vehicles environmental impact 1-3. The injection molding process of thinner plastic components allows consid- erable weight savings on the automotive, a significant reduc- tion in production cost, and a shorter cycle time 1. Various studies are actively undertaken in an effort to develop the injec- tion molding process of thin-wall plastic parts 1. High injec- tion pressure and high injection speed are necessary to manu- facture plastic parts with thin and deep walls 4. However, a high injection pressure can give rise to a core shift, which is the spatial deviation of the position of the core during injection molding 5. Shepard et al. found that the mold design and injection molding conditions strongly affect the core shift of the mold 6. Leo et al. reported that the deflection of weak plates in the mold causes variations in the thickness of the product and the over-packing of moldings 7. Bakharev et al. reported that core shift effects in injection molding can be pre- dicted through mold filling simulation coupled with an elastic analysis of the flexible parts of the mold 4. In this paper, the influence of injection molding parameters on the core shift in the injection molding of a plastic battery case with thin and deep walls is examined to estimate an op- timal injection molding condition. The design of experiments is used to estimate a proper molding condition minimizing the core shift, as well as to determine a dominant molding pa- rameter. Several experiments are carried out to obtain an op- timal injection pressure. Comparing the results of numerical analyses with those of the experiments, the optimal injection molding condition is acquired. The effects of the core shift on the quality of the product are also discussed. 2. Numerical analysis and experiments In order to simulate the core shift and injection molding characteristics, a three-dimensional injection molding analysis was performed using the commercial code MPI V6.1. Fig. 1 illustrates the analysis model. The dimensions of the battery case are 164.4 mm (W) 251.4 mm (L) 184.0 mm (H). The maximum and minimum thicknesses of the walls are 2.7 mm and 1.8 mm, respectively. The depth of the walls is 168.7 mm. The runner system consists of a conical sprue with an initial This paper was presented at the ICMDT 2009, Jeju, Korea, June 2009. This paper was recommended for publication in revised form by Guest Editors Sung-Lim Ko, Keiichi Watanuki. *Corresponding author. Tel.: +82 62 230 7043, Fax.: +82 62 230 7234 E-mail address: smartmail.chosun.ac.kr KSME & Springer 2010 146 D.-G. Ahn et al. / Journal of Mechanical Science and Technology 24 (2010) 145148 Table 1. Parameters and their levels for the DOE. Level Parameters 1 2 3 A : Initial mold temperature (oC) 35.0 40.0 45.0 B : injection time (seconds) 1.6 2.2 2.8 C : Injection pressure (MPa) 40.0 35.0 30.0 D : Holding time (seconds) 2.0 3.2 4.4 (a) (b) Fig. 1. Design of the runner system and core: (a) Design of the runner system and product, (b) Meshes for the flexible parts of the core. (a) (b) Fig. 2. Mold for the manufacture of the plastic battery case: (a) Design of the mold, (b) Manufactured mold. diameter of 8 mm and a final diameter of 15 mm, circular runners with diameters of 8 mm, and pin-point gates with diameters of 2 mm. In order to consider the core shift phe- nomenon in the numerical analysis, the flexible parts of the mold and the flow part were represented by 376,674 EA of tetrahedron meshes and 61,098 EA of shell meshes, respec- tively. The injection material was a polypropylene resin. The melting temperature of PP was set at 230 oC. The design of experiments (DOE) was used to quantita- tively examine the influence of injection molding parameters on the core shift. Table 1 shows the injection molding parame- ters and their levels for the L9 (34) orthogonal array. The sig- nal-to-noise (S/N) ratio with the-smaller-the-better characteris- tics was calculated to estimate the proper condition for mini- mizing the core shift. The contribution ratio of each parameter is estimated using Analysis of Variance (ANOVA) to obtain the dominant parameter affecting the core shift. Several experiments were performed using an injection molding machine with 600 tons of clamping force. Fig. 2 shows the design of the mold, as well as the manufactured Table 2. Orthogonal array and results of the numerical analyses. Deformation of flexible parts (mm) # of Exp ABCD F1 F2 F3 F4 F5 F6 1 11110.160.11 0.07 0.14 0.080.23 2 12220.180.09 0.07 0.14 0.080.23 3 13330.130.09 0.05 0.11 0.080.16 4 21230.140.10 0.07 0.13 0.080.18 5 22310.120.09 0.05 0.11 0.080.16 6 23120.140.10 0.07 0.14 0.080.21 7 31320.110.09 0.05 0.10 0.080.15 8 32130.170.10 0.07 0.14 0.080.23 9 33210.150.10 0.07 0.15 0.080.22 Fig. 3. Results of the numerical analysis (Core shift). mold, for the experiments. The dimensions of the mold are 750 mm (W) 700 mm (L) 870 mm (H). The dominant parameter was varied within 10 % of the proposed condition by the DOE to determine the optimal condition. In order to examine the influence of core shift on the simulation of the injection molding process, the results of the experiments are compared to those of the numerical analyses. 3. Results and discussion 3.1 Results of injection molding analysis and DOE Fig. 3 and Table 2 show the results of the injection molding analysis. The flexible parts of the core were deformed in iden- tical directions regardless of the combination of injection molding conditions, as shown in Fig. 3. Fig. 3 and Table 2 show that the deformations of the F1, F5, and F6 parts of the core were greater than 0.1 mm and flexible parts of the core deformed symmetrically. In addition, it was noted that the shifts of the F2 and F3 parts are negligible in comparison with those of other parts. From the results of the injection molding analysis, the S/N and contribution ratios were calculated for the F1, F5, and F6 parts of the core with relatively large core shifts. Fig. 4 and Table 3 show the results of the DOE. In Fig. 4, it can be seen that the S/N ratios of the injection pressure, the holding time, the injection time, and the initial mold tempera- ture are maximized when their values are 30 MPa, 1.6 seconds, 4.4 seconds, and 40 oC, respectively. The S/N ratio of the in D.-G. Ahn et al. / Journal of Mechanical Science and Technology 24 (2010) 145148 147 Table 3. Pure contribution ratios of each injection molding parameter for different flexible parts. Contribution ratio (%) Flexible Parts Injection time Injection Pressure Holding time F1 4.1 56.5 15.8 F4 0.0 99.2 0.2 F6 3.3 73.3 6.3 Mean 2.5 76.3 7.4 (a) (b) Fig. 4. Variation of signal-to-noise ratios according to the levels of injection molding parameters: (a) S/N ratios of injection pressure and holding time, (b) S/N ratios of initial mold temperature and injection time. jection pressure also increases remarkably when the injection pressure decreases, as shown in Fig. 4. Table 3 shows that the mean value of the contribution ratio of the injection pressure is nearly 76.3 % and that the contri- bution ratio of the injection pressure is markedly higher than that of the other parameters. From these results, it was noted that the dominant parameter, which mainly affects the core shift, is the injection pressure. The variation in S/N ratio and the contribution ratio for the injection time and the initial mold temperature are negligible, as shown in Fig. 4 and Table 3. From these results, it was noted that the injection time and the initial mold temperature hardly affect the core shift. 3.2 Results of the experiments Using the results of the DOE, the experimental conditions of injection time, holding time, and initial mold temperature were set at 1.6 seconds, 4.4 seconds, and 40 oC, respectively. The injection pressure was varied in the range of 27-32 MPa. Fig. 5 shows the results of the injection molding experi- Fig. 5. Molded product for different injection pressures: (a) Injection pressure = 30 MPa (Condition proposed by the DOE), (b) Injection pressure = 32 MPa (Optimal condition). (a) (b) Fig. 6. Comparison of the results of numerical analyses and those of the experiments: (a) Thickness distribution of channels, (b) Post- deformation of the molded product. ments. The shortshot did not occur in all experimental condi- tions, as shown in Fig. 5. However, the warpages of the walls of the molded product occurred when the injection pressure was lower than 30 MPa, as shown in Fig. 5(a). This results from the insufficient holding pressure. The warpages of the product walls do not occur when the injection pressure is 32 MPa, as shown in Fig. 5(b). From these results, the optimal injection molding conditions of the tested plastic battery case with thin and deep walls were determined as an injection pres- sure of 32 MPa, an injection time of 1.6 seconds, a holding 148 D.-G. Ahn et al. / Journal of Mechanical Science and Technology 24 (2010) 145148 time of 4.4 seconds, and an initial mold temperature of 40 oC. The results of the experiments were compared to those of the numerical analyses, as shown in Fig. 6. Fig. 6(a) shows that the difference in wall thickness between the analyses and the experiments is reduced from -0.15 mm 0.18 mm to -0.09 mm 0.07 mm when the core shift is considered in the nu- merical analysis. In addition, it was noted that the thickness variation of the walls is properly predicted by the core shift analysis. Fig. 6(b) shows that the core shift appreciably affects the post-deformation pattern of the molded product, and the numerical analysis accounting for the core shift can predict the post-deformation of the product within 0.15 mm of computa- tional accuracy. The results of the numerical analyses show that the injection pressure is reduced from 50.2 MPa to 32.0 MPa when the core shift is considered. This is due to in- creased cavity volume induced by the elastic deformation of the core. Based on the above results, it is noted that injection molding analysis accounting for the core shift can properly simulate the injection molding process of the battery case with thin and deep walls. 4. Conclusions The influence of injection molding parameters on the core shift in the molding of a plastic battery case with thin and deep walls was investigated using numerical analysis and the ex- periment. The elastic deformation of the core was considered to reflect core shift effects on the numerical analysis. Through nu- merical analysis and DOE, it was shown that the injection pressure is the dominant process parameter affecting core shift and that the core shift decreases when the injection pressure decreases. In addi- tion, it was noted that the injection time, the holding time, and the initial mold temperature hardly affect core shift. It was demon- strated through experiments that the molded product without war- pages can be manufactured at an injection pressure of approxi- mately 32 MPa. Comparing the results of the numerical analyses with those of the experiments, the optimal injection molding con- ditions were obtained. In addition, it was shown that the core shift should be considered to accurately simulate the injection molding process of a plastic battery case with thin and deep walls. References 1 R. Spina, Injection moulding of automotive component: comparison between hot runner systems for a case study, J. Mater. Process. Technol. 155-156 (2004) 1497-1504. 2 K. J. Kim, C. W. Sung, Y. N. Baik, Y. H. Lee, D. S. Bae, K. H. Kim and S. T. Won, Hydroforming simulation of high- strength steel cross-mem

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