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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机械科学与技术杂志24 (2010) 145148/content/1738-494xDOI 10.1007/s12206-009-1126-5Optimal injection（最佳注射）molding conditions（成型条件） considering the core shift （型芯的飘动）for a plastic battery case（塑料电池盒）with thin and deep walls（薄壁深腔）具有薄壁深腔的塑料电池盒考虑到其型芯的飘动时，最佳注射模型条件。Dong-Gyu Ahn1,*, Dae-Won Kim2 and Yeol-Ui Yoon31Departmentn.（部；部门；系；科；局）of Mechanical Engineering, Chosun University （朝鲜大学） , Gwang-Ju, 501-751, Korea（韩国）2 Incheon Service Division, KITECH, Incheon, 406-840, Korea3Chun-Bok Injection Mold Inc.（Bok注塑模具有限公司）, Gwang-Ju, 1233-12, Korea(Manuscript Received April 24, 2009; Revised September 21, 2009; Accepted October 12, 2009)（手稿收到2009年4月24日；2009年9月21日修订；2009年10月12日接受） Abstract摘要The objective of this paper is to examine the influence of injection molding parameters（参量；参项；决定因素） on the core shift to obtain the optimal （为了获得最佳）injection molding conditions （注塑条件）of a plastic battery case with thin and deep walls using numerical analyses and experiments（利用数值分析和实验）.这篇文章的目的是利用数值分析和实验的方法来检验型芯移动时对注射模参数的影响以及对薄壁深腔塑料电池盒的最佳注塑条件。Unlike conventional injection molding analysis, the flexible parts(灵活的部件)of the mold were represented（v. 代表；表现；描写） by 3-D tetrahedron （n. 晶体四面体）meshes （n.网孔（ mesh的名词复数）；网状物；陷阱；困境) to consider the core shift in the numerical analysis.与传统的注射成型分析不同，模具的活动部件利用三维四面体网格来表示以数值分析法来考虑型芯移动。The design of experiments (DOE) was used to estimate(估计，估价；判断)the proper molding conditions that minimize (vt. 使减到最少；小看，极度轻视vi. 最小化)the core shift and a dominantparameter（一个重要参数）.DOE（Design of Experiment）试验设计，一种安排实验和分析实验数据的数理统计方法；试验设计主要对试验进行合理安排，以较小的试验规模(试验次数)、较短的试验周期和较低的试验成本，获得理想的试验结果以及得出科学的结论。实验设计(DOE)是用来评估适当的成型条件下,使型芯移动量最小的一个重要参数。The results of the DOE showed that the dominant parameter is the injection pressure, and the core shift decreases when the injection pressure decreases.结果表明,DOE的主要参数是注射压力,当注射压力降低时型芯移动量也在减小。In addition, it was shown that the initial mold temperature and the injection time hardly affect the core shift.此外,研究结果表明,初始模具温度和注射时间几乎不影响型芯移动。The results of the experiments showed that products （n. 产品；商品）without warpage （n. 木翘曲，弯曲） are manufactured （制造，加工）when the injection pressure is nearly 32 MPa.实验的结果表明,当注射压力接近32 MPa时，制造的产品不发生弯曲。Comparing the results of the analyses with those of the experiments, optimal injection molding conditions were determined.分析的结果与实验对比,确定了最佳注射成型条件。In addition, it was shown that the core shift should be considered to simulate（模仿；假装） the injection molding process of a plastic battery case with thin and deep walls.此外,结果表明,模拟注塑一个塑料电池盒薄壁深腔的工艺应考虑型芯移动。Keywords: Optimal injection molding condition; Core shift; Thin and deep walls; Battery case; Design of experiments .关键词:优化注塑条件;型芯飘动;薄和深墙;薄壁深腔;试验设计。1.Introduction One of the recent（adj. 最近的；近代的） concerns（关系；关心；企业）in the automotive industry （汽车工业）is the reduction of overall weight to improve fuel（燃料） efficiency（效率） and reduce a vehicles(车辆) environmental impact 1-3.介绍最近汽车行业中人们普遍关心的问题之一是用减小车辆整体重量来提高燃油效率以及减少车辆对环境产生影响1 - 3。The injection molding process of thinner plastic components allows considerable weight savings on the automotive（汽车）, a significant（显著） reduction in production cost, and a shorter cycle time 1.薄塑料部件注射成型工艺性可以较大的减小汽车的重量，大幅度降低生产成本和缩短生产周期1。Various studies （各种研究）are actively undertaken in an effort to develop the injection molding process of thin-wall plastic parts 1.人们都在积极努力的从事各项研究来开发薄壁塑料件的注塑模工艺1。High injection pressure and high injection speed are necessary to manufacture（制造）plastic parts with thin and deep walls 4.制造生产薄壁深腔的塑料零件必须要使用高喷射压力和高喷射速度4。However, a high injection pressure can give rise（导致） to a core shift,which is the spatial（空间） deviation（偏差） of the position of the core during injection molding 5.然而,一个高喷射压力能增加一个型芯移动,这是型芯在注塑中空间位置的偏差形成的5。Shepard et al. found that the mold design and injection molding conditions strongly affect the core shift of the mold 6.Shepard 等人发现在模具设计和注塑条件强烈影响型芯移动6。Leo et al. reported that the deflection （n. 偏向；挠曲；偏差）of weak（弱） plates (板块）in the mold causes variations in the thickness (厚度)of the product and the over-packing (过度)of moldings (n. 模型制品；线脚)7.Leo 等人报道,模具中强度较差的模板的弯曲会使产品的厚度发生变化7。Bakharev et al. reported that core shift effects in injection molding can be predicted through mold filling simulation coupled with an elastic analysis （弹性分析）of the flexible parts of the mold 4.Bakharev等人报道,可以通过模具填充模拟和易变形模具的零件的弹性分析可事先知道注塑成型时型芯移动的作用情况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 optimal injection molding condition.本文对注射成型参数影响具有薄壁深腔的塑料电池盒考虑到其型芯的飘动时，来评估最佳注射模型条件。The design of experiments is used to estimate a proper molding condition minimizing the core shift, as well as to determine a dominant molding parameter.实验设计是用来评估最小化型芯偏移时适当的成型条件,以及确定主要成型参数。Several experiments are carried out to obtain an optimal injection pressure.多次进行了试验研究用来获得一个理想的喷射压力。Comparing the results of numerical analyses with those of the experiments, the optimal injection molding condition is acquired.最优注塑条件是通过对实验结果进行数值分析对比获得的。The effects of the core shift on the quality of the product are also discussed.探讨研究型芯偏移对产品的质量的影响。2.2。Numerical analysis and experiments In order to simulate the core shift and injection molding characteristics （n. 特性，特征；特色（characteristic的复数）；特质）, a three-dimensional injection molding analysis was performed using the commercial code MPI V6.1.实验和数值分析来模拟型芯偏移的注射成型特点,一个三维的注射成型进行了分析使用MPI V6.1.。Fig. 1 illustrates the analysis model.图1模型分析说明。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.电池盒的尺寸是164.4毫米(W)251.4毫米(L)184.0毫米(H),最大和最小厚度的薄壁分别是2.7毫米和1.8毫米。The depth of the walls is 168.7 mm. The runner system （浇注系统）consists of a conical sprue with an initial diameter of 8 mm and a final diameter of 15 mm, circular runners(圆形通道) with diameters of 8 mm, and pin-point gates（浇口） with diameters of 2 mm. In order to consider the core shift phenomenon （现象）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（壳网格）, respectively.深腔的深度为168.7毫米。浇注系统由一个锥形浇道（初始直径8毫米和最后直径15毫米）,圆形通道的直径8毫米,浇口直径在2毫米。为了考虑型芯移动现象的数值分析,动模的模具和活动部件分别用四面体网格376674 EA和61098 EA壳网格代表。The injection material was a polypropylene resin（聚丙烯树脂）.注射材料是聚丙烯树脂。The melting temperature of PP was set at 230 oC.聚丙烯融化温度设定在230 oC。The design of experiments (DOE) was used to quantitatively （数量上；分量上）examine the influence of injection molding parameters on the core shift.实验设计(DOE)用来定量检查型芯移动对注塑参数的影响。Table 1 shows the injection molding parameters and their levels for the L9 (34) orthogonal array.表1显示了注塑参数的水平幅附图用绘(34)正交阵列表示。The signalto-noise (S/N) ratio with the-smaller-the-better characteristics was calculated to estimate the proper condition for minimizing the core shift.信噪比(S / N)的特点是用计算估算优的条件下最小型芯移动。The contribution（n. 贡献；捐献；投稿）ratio of each parameter（每个参数） is estimated using Analysis of Variance (ANOVA) to obtain the dominant parameter affecting the core shift.用每个参数的贡献比率来估算使用方差分析(ANOVA)获得型芯移动的主要参数影响。Several experiments were performed（执行） using an injection molding machine with 600 tons of clamping force.注射成型机用600吨的夹紧力进行几个实验。Fig. 2 shows the design of the mold, as well as the manufactured mold, for the experiments.图2显示了模具的设计,以及模具的制造,实验。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.模具的尺寸为750毫米700毫米(W)(L)870毫米(H)。主要参数变化在10%的由DOE提出条件来确定最佳条件。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.为了检验型芯移动在模拟注塑工艺中的影响,实验结果用数值分析进行比较。3.Results and discussion 讨论与结果3.1 Results of injection molding analysis and DOE Fig. 3 and Table 2 show the results of the injection molding analysis.3.1 DOE的注射成型结果分析图3和表2注塑分析显示结果。The flexible parts of the core were deformed （变形）in identical directions（方向） regardless of the combination of injection molding conditions, as shown in Fig. 3.在任何注塑条件的组合下动模的型芯的变形方向相同,见图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.图3和表2表明,变形的F1,F5、F6部分的型芯是大于0.1毫米和动模型芯变形对称。In addition, it was noted that the shifts of the F2 and F3 parts are negligible in comparison with those of other parts.此外,他们注意到F2和F3变化的部分相比,是可以忽略不计的其他部分。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.从结果的注塑成型分析、S / N和贡献比率计算的F1,F5、F6部分的型芯与相对较大的型芯偏移。Fig. 4 and Table 3 show the results of the DOE.图4和表3DOE显示结果。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 temperature are maximized (最大化)when their values (n. 价值观念；价值标准)are 30 MPa, 1.6 seconds, 4.4 seconds, and 40 oC, respectively.图4中,可以看到,S / N比率的喷射压力、保温时间、注射时间、初始模具温度是最大的时候,他们的标准分别是是30 MPa,1.6秒,4.4秒,40摄氏度。The S/N ratio of the in jection pressure also increases remarkably （adv. 显著地；非常地；引人注目地） when the injection pressure decreases, as shown in Fig. 4.当注射压力降低S / N比率在注射压力也增加明显,见图4。Table 3 shows that the mean value of the contribution ratio of the injection pressure is nearly 76.3 % and that the contribution ratio of the injection pressure is markedly higher than that of the other parameters.表3显示,平均比例的喷射压力是近76.3%,在比率中的喷射压力明显高于其他参数。From these results, it was noted that the dominant parameter, which mainly affects the core shift, is the injection pressure.从这些结果,指出主要参数,主要影响型芯偏移的,就是注射压力。The variation in ratio and the contribution ratio for the injection time and the initial mold temperature are negligible, as shown in Fig. 4 and Table 3.不同的S/N 注射时间和初始模具温度都可以忽略不计,见图4和表3。From these results, it was noted that the injection time and the initial mold temperature hardly affect the core shift.从这些结果,指出注射时间和初始模具温度几乎没有影响到型芯偏移。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.3.2 DOE实验结果使用结果,实验条件的注射时间、保温时间、初始模具温度分别设定在1.6秒,4.4秒,40摄氏度。The injection pressure was varied in the range of 27-32 MPa.注射压力变化范围在27 - 32 MPa。Fig. 5 shows the results of the injection molding experiments.图5显示了注射成型的实验结果。The shortshot did not occur in all experimental conditions, as shown in Fig. 5.在所有的实验条件中不包括短时间注射,如图5所示。However, the warpages of the walls of the molded product occurred when the injection pressure was lower than 30 MPa, as shown in Fig. 当然,在注射压力低于30 MPa不能制作薄壁易变形的模制产品,见图5(a)。This results from the insufficient（不足）holding pressure.这是保持压力不足的结果。The warpages of the product walls do not occur when the injection pressure is 32 MPa, as shown in Fig. 5(b).当注射压力是32 MPa时薄壁易变形的产品也不能生产,见图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 pressure of 32 MPa, an injection time of 1.6 seconds, a holding time of 4.4 seconds, and an initial mold temperature of 40 oC.从这些结果,塑料电池盒的薄壁深腔优化注塑条件的测试被确定为注射压力32 MPa、注射时间1.6秒,保持时间4.4秒,初始模具温度为40摄氏度。The results of the experiments were compared to those of the numerical analyses, as shown in Fig. 6.实验的结果进行了数值分析比较,见图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 numerical analysis.图6(a)表明,在壁厚之间的差异分析的实验是减少从-0.15 mm 0.18毫米到-0.09毫米 0.07毫米当型芯偏移被认为是在数值分析。In addition, it was noted that the thickness variation of the walls is properly predicted by the core shift analysis.此外,它是指出,厚度变化的深腔是正确预测的型芯偏移分析。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 computational accuracy.图6(b)表明,偏芯偏移略微影响变形期后的模制产品模式,数值分析会计为核心转变可以预测产品的变形期后在0.15毫米的计算精度。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.数值分析的结果表明,当型芯偏移被认为是从注射压力降低到32.0 MPa从50.2 MPa。This is due to increased cavity volume induced by the elastic deformation of the core.这是由于增加了空腔体积引起的弹性变形的型芯。Based on the above results, it is noted that injection molding analysis accounting for（对负有责任；对做出解释；说明的原因）the core shift can properly simulate the injection molding process of the battery case with thin and deep walls.基于上述结果,型芯偏移注塑分析可以正确地模拟电池外壳的薄壁深腔注塑工艺。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 experiment.结论，注射成型对型芯偏移成型的塑料电池盒薄壁深腔的影响参数采用了实验和数值分析。The elastic deformation of the core was considered to reflect core shift effects on the numerical analysis.弹性变形的型芯被认为是反映型芯偏移影响数值分析。Through numerical 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.通过数值分析和DOE显示注射压力是主要过程参数影响型芯偏移,当注射压力降低时型芯偏移减小。In addition, it was noted that the injection time, the holding time, and the initial mold temperature hardly affect core shift.此外,它是指出,注射时间、保压时间、初始模具温度几乎没有影响型芯偏移。It was demonstrated through experiments that the molded product without warpages can be manufactured at an injection pressure of approximately 32 MPa.通过实验证明,一个注射压力约为32 MPa是不可以制造较厚壁厚模制产品。Comparing the results of the numerical analyses with those of the experiments, the optimal injection molding conditions were obtained.比较结果的数值分析与实验,获得了最佳注塑条件。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.此外,结果表明,型芯偏移应该准确地模拟一个塑料电池盒薄壁深腔注塑工艺。References参考文献 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 highstrength steel cross-members in an automotive rear subframe, In

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