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电吹风外壳注塑模的设计【优秀】【word+11张CAD图纸全套】【注射塑料模具类】【毕设】

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关键词：: 电吹风吹风机外壳吹风机注塑模注射模塑料模具

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电吹风外壳模具设计

吹风机外壳的注塑模设计

电吹风外壳注塑模的设计【含全套CAD图纸】【优秀】【word+11张CAD图纸全套】【注射塑料模具类】【毕业设计】

【带任务书+开题报告+选题审批表+中期检查表+实习报告+外文翻译】【51页@正文23500字】【详情如下】【需要咨询购买全套设计请加QQ1459919609】.bat

2.3注射成型外文文献翻译.doc

中期检查.doc

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任务书.doc

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动模板.dwg

定模座板.dwg

定模板.dwg

实习报告.doc

开题报告.doc

推件板.dwg

推杆固定板和推杆垫板.dwg

电吹风外壳.dwg

电吹风外壳模具设计正文.doc

装配图.dwg

选题审题表.doc

任务书

1、本毕业设计（论文）课题应达到的目的：

①　掌握塑料模具的相关知识

②　了解注塑模具的设计方法

③　阅读大量模具设计相关文献，能独立翻译外语资料

④　初步学会CAD绘图和Pro/e等软件的三维造型

⑤　结合查找的资料与自己的设计，能撰写设计说明书

2、本毕业设计（论文）课题任务的内容和要求（包括原始数据、技术要求、工作要求等）：

1)本课题应完成的主要内容有：

①收集阅读大量资料，完成文献翻译和文献综述；

②电吹风面壳三维造型；

③由三维模型设计出上下模；

④完成模架的设计；

⑤设计模具整体结构；

⑥生成上下模及部分模架构件的工程图。

2)本课题应完成的主要要求有：

①设计的模具及注塑件的质量寿命达到要求；

②模具及其组成系统结构合理，经济性好；

③模具装配方便，零件结构合理，加工可行；

④出图数量跟质量达到要求；

毕业设计（论文）任务书

3、对本毕业设计（论文）课题成果的要求（包括毕业设计论文、

图表、实物样品等）：

1.开题报告：包括任务书，文献综述，实习报告与外文翻译跟中期检查表等。

2.出图：①电吹风外壳三维造型；②由三维模型设计出上下模；

③设计模具整体结构；④生成上下模及部分模架构件的工程图；

3. 注射模设计说明书

4、主要参考文献：

1、何满才　Pro/ENGINEER模具设计与Mastercam数控加工　人民邮电出版社

2、单泉、陈砚、阚虎等　Pro/ENGINEER Wildfire3.0中文版模具设计专家指导教程　

机械工业出版社

3、凯德. 精通Pro/Engineer中文野火版模具设计[M]. 北京：中国青年出版社.2007.

4、张磊、谢龙汉 Pro/ENGINEER Wildfire4.0 模具设计视频精讲人民邮电出版社

5、胡仁喜、康士廷 Pro/Engineer Wildfire5.0中文版模具设计从入门到精通机械工业出版社

6 张鲁阳.《以工程思维为主线组织教学内容.再谈模具专业材料学课程改革》

[J].机械工业高教研究 2001.7

7 陈志刚.《塑料模具设计》[M].北京机械工业出版社 2002.

8 吴兆祥.《模具材料及表面处理》[M].北京机械工业出版社 2003.

9 屈华昌．塑料成型工艺与模具设计．北京机械工业出版社．2003．

10 李德群.唐志玉．《中国模具设计大典》．江西科学技术出版社．2003．1．

11 塑料模设计手册编写组．《塑料模设计手册》．北京机械工业出版社．1982．12．3．

12 姜勇．《AutoCAD2006基础培训教程》．人民邮电出版社．2006．3．

13 伍先明等编著．《塑料模具设计指导》[M]．国防工业出版社，2006．

14 邹强主编．《塑料模具设计参考资料汇编》[M]．清华大学出版社， 2005．

15 邹玉堂编著．《Pro/ENGINEER实用教程》[M]．机械工业出版社，2005．

16 杨占尧自柳主编．《塑料模具典型结构设计实例》．化工公业出版社，2008

17 申开智主编.《塑料成型模具（第二版）》中国轻工业出版社 2009

18 丁浩主编.《塑料加工基础》上海科技出版社 1998

毕业设计（论文）任务书

5、本毕业设计（论文）课题工作进度计划

起止日期工作内容

第1~3周了解相关知识、完成实习调研，作开题报告

第4、5周完成模具结构设计，包括凸凹模具、模架的三维造型

第6、7周完成相关的零件图、装配图。中期检查

第8~10周撰写毕业设计说明书

第11、12周完善相关资料、答辩

摘要

模具现在已经成为工业发展的基础，而塑料模占模具总量的比例达到35%~40%，塑料成型模具的应用在各类模具的应用中占有领先地位。注射成型是塑料成型的一种重要方法，它主要适用于热塑性塑料的成型，可以一次成型形状复杂的精密塑件。本课题就是电吹风外壳作为设计模型，将注射模具的相关知识作为依据，阐述塑料注射模具的设计过程。

通过对电吹风外壳成型工艺的分析，本人设计了一副一模两腔的塑料模具。模具中决定塑件几何形状和尺寸的零部件称为成型零件，包括上模板、上模芯、下模板、下模芯、下模镶件等的设计与加工工艺过程。设计成型零部件时，应根据塑料的特性、塑件的结构和使用要求，确定型腔的总体布局，选择分型面，确定脱模方式，设计浇注系统、排溢系统。然后进行成型零部件的结构设计，计算成型零部件的工作尺寸，对关键的成型零部件进行强度和刚度校核。然后运用Pro/E软件完成电吹风外壳模具的整体设计；最后应用Pro/E中的塑料顾问模块（Plastic Advisor），对塑料制品进行注射仿真分析。

关键词：注射成型；电吹风外壳；一模两腔；Pro/E。

Abstract

The?design?of?the?Cd-rom?shell?injection?mould?Abstract?Mould?has?become?the?foundation?for?industrial?development?,and?plastic?moulds?account?for?the??Proportion?of?the?total?35%~40%,plastic?mould?used?in?the?application?of?various?types?of?mould?occupies?a?leading?position?.Injection molding is an important method of plastic molding. It mainly suits thermoplastic molding which can be used to shape a precision plastic part in one time. My topic is to explain the design process of the plastic injection mold on the basis of the injection mold-related knowledge, taking the hair dryer enclosure as a design model.

Through analysis of the hair dryer shell molding process, I designed a double-cavity plastic mould. Those parts that deciding the geometrical shape and dimensions of the plastic mold are known as molded parts, including the design and machining process of the upper plate, the upper mold core, the lower plate, the lower mold core, and the inserting of lower mold.While designing molding components, based on the characteristics of plastic, plastic parts of the structure and use requirements, the overall layout of the cavity, the joint face, the stripping methods, design of gating system, exhaust system should be determined. Then structure of molded parts are designed, the working size of the molded parts is calculated, the key molded parts are checked for strength and rigidity. Then use Pro / E software to complete the overall design hair dryer shell mold; and finally the plastic module consultant (Plastic Advisor) in Pro / E is applied for plastic injection simulation analysis.

Key word: Injection molding; hair dryer shell; double-cavity mold; Pro / E.

摘要

Abstract

第一章绪论

1.1塑料模具业的现状1

1.2常见的塑料成型模具1

1.3注射模具的发展趋势2

第二章塑料成型工艺

2.1塑料制品的结构和工艺性能设计3

2.2注塑成型工艺过程5

2.3注塑成型设备6

第三章电吹风外壳注射模设计

3.1注射模具分类及典型结构 13

3.2电吹风外壳模具的结构设计 16

3.3注射模具与注射机的关系 26

第四章电吹风外壳模具三维设计

4.1Pro/e模具设计过程简介32

4.2EMX模架设计34

第五章电吹风外壳注射仿真分析

5.1 Plastic Advisor的简介38

5.2塑料顾问模块的进入38

5.3 分析功能应用 39

5.4 分析结果 41

第六章小结43

致谢44

参考文献45

第一章绪论

1.1塑料模具业的现状

随着工业发展水平的不断提高，工业产品更新的速度越来越快，对模具的要求也越来越高。改革开放以来，模具工业的发展有了较大发展，但无论数量和质量都仍满足不了市场的需要，目前满足率只能达到百分之七十左右，造成产需矛盾突出的原因，异世专业化、标准化程度低，除了少数标准件外购外，大部分工作量都需要模具厂去完成，因此造成模具制造周期长，不能适应市场的要求。二是设计和工艺技术落后，如模具CAD/CAM技术采用不普遍，加工设备数控化程度低，亦造成模具生产效率不高周期长。总之，是拖了机电，轻工业的后退，因此对模具设计的研究的目的和意义在于能够更好的认识模具工业在国民经济中的重要性。因为利用模具成型零件的方法，是一种少切削乃至无切削打的多工序重合的生产方法，采用模具成型的工艺替代传统工艺，可以大大提高成产率、保证零件质量、节约材料、降低生产成本，从而提高经济效益。因此，德国把模具称为“金属加工中的帝王”，把模具工业称为“关键工业”，美国把模具称为“美国工业的基石”，把模具工业视为“不可估量的工业”，在罗马尼亚则更为直接：“模具就是黄金”。可见模具工业在国民经济中重要地位。我国对模具工业的发展也十分重视，早在1989年3月颁布的《关于当前国家产业政策要点的决定》中，就把模具技术的发展作为机械行业的首要任务。人们对产品要求其独具个性，特别是一些生活用品，不仅要求它要实用，还要求它外观漂亮，美丽的外观以及产品的环保性吸引着每个人的眼球。

目前，吹风机的样式越来越多，外观也越来越复杂。因而模具的要求也越来越高，设备也更先进，制造工艺也比以前要更有难度。在这样的市场中要有立足之地，对我们设计人员是一个相当大的考验，设计人员必须多掌握几种软件。设计出来的东西要有创新才行，这样才不会被淘汰。

1.2常见的塑料成型模具

按照成型方法的不同，可以划分出对应不同工艺要求的塑料加工模??具类型，主要有注射成型模具、挤出成型模具、吸塑成型模具、高发泡聚苯乙烯成型模具等。下面具体介绍的是本课题采用的塑料注射模具。

1.2.1塑料注射模具?

它主要是热塑性塑料件产品生产中应用最为普遍的一种成型模具，塑料注射成型模具对应的加工设备是塑料注射模具对应的加工设备是塑料注射成型机，塑料首先在注射机底加热料筒内受热熔融，然后在注射机的螺杆或柱塞推动下，经注射机喷嘴和模具的浇注系统进入?模具型腔，塑料冷却硬化成型，脱模得到制品。其结构通常由成型部件、浇注系统、导向部件、推出机构、调温系统、排气系统、支撑部件等部分组成。制造材料通常采用塑料模具钢模块，常用的材质主要为碳素结构钢、碳素工具钢、合金工具钢，高速钢等。注射成型加工方式通常只适用于热塑料品的制品生产，用注射成型工艺生产的塑料制品十分广泛，从生活日用品到各类复杂的机械，电器、交通工具零件等都是用注射模具成型的，它是塑料制品生产中应用最广的一种加工方法。?

1.3注射模具的发展趋势

近年来，模具增长十分迅速，高效率、自动化、大型、微型、精密、高寿命的模具在整个模具产量中所占的比重越来越大。从模具设计和制造角度来看，模具的发展趋势可分为以下几个方面：?加深理论研究?在模具设计中，对工艺原理的研究越来越深入，模具设计已经有经验设计阶段逐渐向理论技术设计各方面发展，使得产品的产量和质量都得到很大的提高。高效率、自动化?大量采用各种高效率、自动化的模具结构。高速自动化的成型机械配合以先进的模具，对提高产品质量，提高生产率，降低成本起了很大的作用。?大型、超小型及高精度?由于产品应用的扩大，于是出现了各种大型、精密和高寿命的成型模具，为了满足这些要求，研制了各种高强度、高硬度、高耐磨性能且易加工、热处理变形小、导热性优异的制模材料。?革新模具制造工艺?在模具制造工艺上，为缩短模具的制造周期，减少钳工的工作量，在模具加工工艺上作了很大的改进，特别是异形型腔的加工，采用了各种先进的机床，这不仅大大提高了机械加工的比重，而且提高了加工精度。?标准化?开展标准化工作，不仅大大提高了生产模具的效率，而且改善了质量，降低了成本。

第二章塑料成型工艺

塑料成型是将塑料原材料转变为所需形状和性能的塑件的一门工程技术。在设计模具时不仅要了解塑料制作的技术要求和注射成型的工艺过程，还必须了解注射机的技术规范，以保证设计的模具与使用的注射机相适应。

其中，塑料注塑成型，又称注射成型，是目前塑料加工中最普遍采用的方法之一，除用于热塑性塑料成型外，近年来，也用于部分热固性塑料的成型加工。注塑成型生产效率高、易于实现机械化和自动化、并能制造外形复杂、尺寸精确的塑料制品，大约60%～70%的塑料制件用此方法生产。

2.1塑料制品的结构和工艺性能设计

2.1.1塑件结构形状

制品的整体外形尺寸与塑料的流动性有关。在注射成型与传递成型中，当塑料流动性能差时（如玻璃纤维或石棉纤维增强塑料）以及制品壁厚较薄时，其整体外形尺寸不能设计过大。此外，整体外形尺寸受到成型设备的制约。

2.1.2塑件材料选择

结合电吹风外壳壁薄的特点，本课题选流动性较好的材料：丙烯腈-丁二烯-苯乙烯共聚物（ABS）。ABS的密度和收缩率见表2-1。

2.1.3物料性能

1.综合性能较好,冲击强度较高,化学稳定性,电性能良好.

2.与372有机玻璃的熔接性良好,制成双色塑件,且可表面镀铬,喷漆处理。

3.有高抗冲、高耐热、阻燃、增强、透明等级别，柔韧性好。

4.适于制作一般机械零件,减磨耐磨零件,传动零件和电讯零件。

2.1.4成型性能

无定形料,流动性中等,吸湿大,必须充分干燥,表面要求光泽的塑件须长时间预热干燥80-90度,3小时。宜取高料温,高模温,但料温过高易分解。对精度较高的塑件,模温宜取50-60度,对高光泽.耐热塑件,模温宜取60-80度。冷却速度快，模具宜加热，应选用耐磨钢。

2.1.5塑料制件的结构工艺性

要想获得合格的塑料制件，除合理选用塑件的原材料外，还必须考虑塑件的结构工艺性。塑件的结构工艺性与模具设计有直接关系，只有塑件结构设计满足成型

工艺要求，才能设计出合理的模具结构，以防止成型时产生气泡、缩孔、凹陷及开裂等缺陷，达到提高生产率和降低成本的目的。塑件结构工艺性设计的主要内容包括：尺寸和精度、表面粗糙度、塑件形状、壁厚、脱模斜度、加强筋、支承面、圆角、孔、螺纹、齿轮、嵌件、文字、符号及标记等。

下面重点介绍一下脱模斜度，壁厚，制品的精度和粗糙度等四个方面

1、脱模斜度

查表2-2可知ABS型腔的脱模斜度为，型芯的脱模斜度为。

2、壁厚

塑料制品的壁厚对制品质量有至关重要的影响。壁厚过后，不但用料多，成本高还容易产生气泡、缩化、凹陷等缺陷，而且冷却时间长生产效率低（对热塑性塑料制品而言）。壁厚过薄，成型困难，流动阻力大，尤其是大型制品和形状复杂制品。

制品最小壁厚的确定原则：（1）脱模时受顶出零件的推力不变形；（2）能承受装配时紧固力。壁厚因制品大小和塑料品种的不同而异。热塑性塑料制品的最小壁厚可达到0.25mm，但一般在（0.6~0.9）mm之间。常用壁厚为（2~4）mm。

本课题电吹风外壳的壁厚为2.25mm。

3、制品的精度

影响制品精度的因素较多。首先是模具的制造精度和模具的磨损量，其次是成型工艺条件的变化所引起的塑料收缩率的波动。另外，成型后的实效率变化和模具结构形式对尺寸精度也有一定的影响。因此，对塑料制品的精度要求不能过高，应在保证使用性能的情况下，尽可能选用低精度等级。

本课题采用一般精度MT3，对应公差为0.55mm。

参考文献

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内容简介：: 2.3注射成型2.31注射成型注塑主要用于生产热塑性塑料零件，也是最原始的方法之一。目前注塑占所有塑料树脂消费量的30%。典型的注塑成型产品“塑料杯、容器、外壳、工具手柄、旋钮、电气和通信组件(如电话接收器)、玩具、和水暖配件。聚合物熔体由于其分子量具有很高的粘度；它们不能像金属液在重力的条件下倒进模,必须在高压力下注入模具。因此,金属铸造的力学性能是由模具壁传热的速度决定，同时也决定了在最终铸件的晶粒尺寸和晶粒取向, 高压注射成型过程中熔体的注射剪切力产生的主要原因是材料最后的分子取向。力学性能影响成品都是因为在模具里的注塑条件很冷却条件。注塑已应用于热塑性塑料和热固性材料,发泡部分,也已被修改过用于展现注射成型（RIM）反应过程，其中有两个部分组成，一种是热固性树脂体系，另一种是聚合物快速注射模具。然而大多数注射成型是热塑性塑料,后面的讨论集中于这样的模型。一个典型的注塑周期或序列由五个阶段组成 (见图2 - 1): 注射或模具填充; (2) 包装或压缩;(3) 保持;(4) 冷却;(5)部分排除物图2 - 1注射成型过程塑料颗粒（或粉末）被装入进料斗并通过注塑缸上的开口在那里它们被旋转螺杆结转。螺杆的旋转使颗粒处于高压下加上受热缸壁使它们融化。加热温度范围从265到500F。随着压力的增大,旋转螺丝被迫向后,直到积累了足够的塑料可以进行注射。注射活塞(或螺钉)迫使熔融塑料从料桶通过喷嘴、浇口和流道系统,最后进入模腔。在注射过程中,熔融塑料充满模具型腔。当塑料接触冷模具表面,它迅速凝固(冻结)产生皮肤层。由于核心仍在熔融状态,塑料流经核心来完成填充。一般的，该空腔被注入期间填充到95?98。然后成型工艺转向了填充的阶段。型腔填充后，熔融塑料开始冷却。由于冷却塑料会收缩产生缺陷，如缩孔、气泡，而且空间存在不稳定性。所以被迫实行空穴用来补偿收缩、添加塑料。一旦模腔被填充，压力应用熔体防止腔内熔融塑料会流进浇口。压力必持续到浇口部分就凝固了。该过程可以分成两个步骤（填充和保持）或者可能在一个步骤中（保持或第二级）所涵盖。在填充过程中，熔体被用于收缩的填充压力补偿压入型腔中。保持过程中，压力只是防止聚合物熔体的倒流。保持阶段结束后冷却阶段开始。在冷却过程中，部分在模具持有指定期间。冷却阶段的持续时间主要取决于材料的性质和厚度。通常，该部分的温度必须冷却到低于材料的脱模温度。在冷却部件，这台机器塑性熔化在下一个周期。聚合物受剪切作用以及电热丝的能量。一旦开枪，塑化停止。这应该是在冷却阶段结束之前。然后将模具开启，一部分被排出。2.3.2注塑模具注塑模具的多种多样的设计、复杂程度和大小作为它们的生产部分。功能热塑性塑料模具，基本上是传授理想的形状，然后进行聚合物注射件的冷却。一种模具是由两组部件组成：（1）型腔和型芯（2）空腔和型芯的安装。模塑部件的尺寸和重量限制了模腔的数量并且还决定了所要求的设备的能力。考虑成型工艺，模具必须设计的安全地吸收由于夹紧。注塑。脱模带来的力。同时，浇口和流道的设计必须允许有效流动和统一的模具型腔填充。图2-2示出了一个典型的注塑模具。模具主要由两部分组成：一个部分精止不动的（模腔板），在那边熔融聚合物被注入，另一部分可以移动（型心板）在截止面上或喷射器的注塑设备上。两个半模之间的分离线被称为分型线。注射的材料是通过中央进料通道，称为浇口。物料位于锥形流道，便于套管在打开的模具中释放模具材料。在多数模具、物料聚合物熔体助长了流道系统，通过一个浇口流向每个模具型腔。核心板的主要核心。主要的核心的目的是建立内部部分的配置。核心目的是建立内部结构。核心板具有备份或支撑板，支撑板是由支柱所支撑的，这个支柱是作为喷射器壳体的u型结构为人所知，它由后部夹持板和隔块组成。此U形结构是用螺栓固定在核心板，它为起模行程也就是脱模行程提供了空间。在凝固过程中该部分围绕主芯收缩，使模具打开时，第二部分和浇道一起被移动的半模进行。随后，中央喷射器被激活时，使顶出板向前移动，导致顶出杆可以推动这部分远离核心。两个半模设置有冷却通道，通过该冷却通道，水被循环以吸收由热塑性聚合物熔体输送到模具的热量。模腔还采用精细的通风口（0.02?0.08毫米5毫米）的，以确保填充过程中没有空气残留。注塑模具现在在使用中有六种基本类型。它们是：（1）双板模具，（2）三板模，（3）热浇道模，（4）绝缘热浇道模，（5）热歧管模具，以及层叠模具。图。 2-3和图2-4说明了这六种基本类型的注塑模具。图2 - 2注塑模具 1 - 顶杆2 - 推板3 - 导套4 - 导柱5 - 顶杆底板6钩料杆销 7推回针8针限制9导柱10 - 导柱11腔板 12 - 浇口套13塑料工件14芯图2-3这说明三者的六种基本类型的注塑模具 (1) 两板注射模具（2）三板注塑模（3）热流道模具见图. 2-4其他三种型。图2-4这说明三者的六种基本类型的注塑模具（1）绝缘热流道注塑模具（2）热歧管注塑模具（3）堆叠式注塑模具见图.2-3对于其他三种类型。1两板模一种双板模具由两个板与腔和型芯安装在任一模版上.板被固定到压板上。移动一半的模具通常含有推出结构和浇道系统。所有注塑模具的基本设计有这样的设计理念。两板模具是最合乎逻辑的类型对于一些需要使用那些需要很大浇口零件的工具来说。2三板模具这种类型的模具是由三块板组成：（1）固定或流道板是连接到静止的滚筒，通常包含浇道和半流道，（2）中间板或模腔板，包含一半道和浇口，允许在开模时浮动，（3）移动板或受力板塑造和推出系统部分切除塑造的部分。当通道开始打开，中间板和可动板一起移动，从而释放浇道和流道系统和去浇口的成型部件。这种类型的模具的设计能够分隔流道系统和部件当模具打开时。这种模具的设计可以使用点浇口浇注系统。3 .热流道模具在注射成型的过程中，流道保持热量以保证熔融塑料是流体状态，在任何时候。实际上这是一个无浇道成型工艺而且有时被称为是相同的。在无流道模具中，流道包含在一个独立的板上。热流道模具类似三板注塑模具，除了模具流道的部分在成型周期打不开。加热流道板与其余的冷模隔热。除了加热板是为了流道设计，模具剩余部分是一个标准两板模。无流道成型较传统浇道式成型有很多优点。没有成型的副产物（浇口，流道，或主流道）被处理掉或循环再使用，没有从主流到分离。周期时间是成型部分被冷却，从模具中顶出。在这个系统中，一个均匀的熔体温度可以从注射模具型腔的汽缸达到的。4绝缘热流道模具这是一个变化的保温模具。在这种类型的模具中，流道的外表面材料是绝缘体的优质材料。在绝热模具中，成型材料铸造成型仍然通过保持热量。有时一个分料梭和热探测器需要更多的灵活性。这种类型的模具多腔中心浇口部分是理想的。、5.热流道模具这是一个变化的保温流道模具。在热流道模具中，流道是加热的而不是流道板。这是通过使用一个电子嵌入探针完成的。 6.堆叠模具堆叠注塑模具，顾名思义就是多个两板模具放置一起。这种结构也可以用于三板模具和保温流道模具。堆叠两模板的构造重点提出一个单一通道要求比同样数量的模具减少一般夹紧压力。这个方法有时候被称为“二级成型”。2.3.3成型机1.传统注塑机在这个过程中,塑料颗粒或颗粒注入机料斗并注入加热缸腔内。然后柱塞压缩材料,迫使它逐步通过加热缸的温度区域,在那里它被分料梭分散的很薄。分料梭安装在缸的中心，目的是为了加快塑料中心的加热质量。分料梭也可从内部加热处理使塑料内外都加热。材料从加热缸流动通过一个管口进入模具。这个管口是缸和和模具的分割点,它是用来防止产生压力导致物质泄漏。模具是关闭了有夹钳一端的机器。对于聚苯乙烯,夹钳上两到三吨的压力要用于材料和系统的每一寸空间。传统的柱塞机是唯一可以产生杂色部件的注塑机,其他类型的完全将塑料材料融合在一起,只会产生一种颜色。2.柱塞式预塑机这台机器使用一个分料梭加热器来预塑塑料颗粒。融化阶段后,液体塑料是被排入一个存放腔内，直到可以进入模具。这种类型的机器生产速度比传统的机器快,由于成型室是在冷却时不断释放能量。由于注射柱塞作用于流体材料,在颗粒压缩时没有压力损失。这允许更大的部件有更大的投影面积。它其余的特性与传统单活塞注射机相同。图2 - 5演示了一个柱塞式预塑机。3.螺杆式预塑机这种注射机用挤出机塑化塑料材料。车削螺杆向挤压机内表面供料。将挤出机熔融、塑化的材料移动到另一个存放腔,然后从那里被注射柱塞挤入模具。使用螺旋有以下优点:(1)塑性材料能更好的融合和受力;(2)流动材料更硬，热敏感材料能流动;(3)颜色变化可以在更短的时间内处理(4)模制品受更小的压力。4.往复式螺杆注塑机这种类型的注塑机在加热室处采用卧式挤压机。塑料材料由于螺杆的旋转被推进挤压机管道。随着材料通过加热筒与螺杆时,它正在从颗粒变成塑料熔融状态。在往复式螺杆注塑机中,热量传递到模塑料的热量是由螺杆之间的摩擦传导和挤压机管道壁。材料移动时,螺杆又回到极限状态,这种状态是决定材料在压力机管道前的体积的。这时,与典型压力机的相似之处结束了。在材料注入模具时,螺杆向前移动，重新塑造管道中的材料。在这台机器中，螺杆的角色既是一个柱塞又是一个螺杆。在模型浇口部分已经凝固不能回流时，螺杆开始旋转回程，走下一圈。图2-5是一个往复式螺杆注塑机。这种注塑方法有几个优点。它能使热敏材料更有效地塑化，使颜色融合更快,材料的温度通常更低，整个循环时间也更短。2.3 Injection Molds2.3.1 Injection MoldingInjection molding is principally used for the production of thermoplastic parts, and it is also one of the oldest. Currently injection-molding accounts for 30% of all plastics resin consumption.Typical injection-molded products are cups, containers, housings, tool handles, knobs, electrical and communication components (such as telephone receivers), toys, and plumbing fittings.Polymer melts have very high viscosities due to their high molecular weights; they cannot be poured directly into a mold under gravity flow as metals can, but must be forced into the moldunder high pressure. Therefore while the mechanical properties of a metal casting are predominantly determined by the rate of heat transfer from the mold walls, which determines the grain size and grain orientation in the final casting, in injection molding the high pressure during the injection of the melt produces shear forces that are the primary cause of the final molecularorientation in the material. The mechanical properties of the finished product are therefore affected by both the injection conditions and the cooling conditions within the mold.Injection molding has been applied to thermoplastics and thermosets, foamed parts, and has been modified to yield the reaction injection molding (RIM) process, in which the twocomponents of a thermosetting resin system are simultaneously injected and polymerize rapidly within the mold. Most injection molding is however performed on thermoplastics, and the discussion that follows concentrates on such moldings.Chapter 2 Plastics Molds A typical injection molding cycle or sequence consists of five phases (see Fig. 2-1): （1）Injection or mold filling;(2) Packing or compression;(3) Holding;(4) Cooling;(5) Part ejection.Plastic pellets (or powder) are loaded into the feed hopper and through an opening in the injection cylinder where they are carried forward by the rotating screw. The rotation of the screw forces the pellets under high pressure against the heated walls of the cylinder causing them to melt. Heating temperatures range from 265 to 500 F. As the pressure builds up, the rotating screw is forced backward until enough plastic has accumulated to make the shot. The injection ram (or screw) forces molten plastic from the barrel, through the nozzle, sprue and runner system,and finally into the mold cavities. During injection, the mold cavity is filled volumetrically.When the plastic contacts the cold mold surfaces, it solidifies (freezes) rapidly to produce the skin layer. Since the core remains in the molten state, plastic flows through the core to complete mold filling. Typically, the cavity is filled to 95%98% during injection.Then the molding process is switched over to the packing phase. Even as the cavity is filled,the molten plastic begins to cool. Since the cooling plastic contracts or shrinks, it gives rise to defects such as sink marks, voids, and dimensional instabilities. To compensate for shrinkage,addition plastic is forced into the cavity. Once the cavity is packed, pressure applied to the melt prevents molten plastic inside the cavity from back flowing out through the gate. The pressure must be applied until the gate solidifies. The process can be divided into two steps (packing and holding) or may be encompassed in one step (holding or second stage). During packing, melt forced into the cavity by the packing pressure compensates for shrinkage. With holding, the pressure merely prevents back flow of the polymer melt.After the holding stage is completed, the cooling phase starts. During cooling, the part is held in the mold for specified period. The duration of the cooling phase depends primarily on the material properties and the part thickness. Typically, the part temperature must cool below the materials ejection temperature.While cooling the part, the machine plasticates melt for the next cycle. The polymer is subjected to shearing action as well as the condition of the energy from the heater bands. Once the shot is made, plastication ceases. This should occur immediately before the end of the cooling phase. Then the mold opens and the part is ejected.2.3.2 Injection MoldsMolds for injection molding are as varied in design, degree of complexity, and size as are the parts produced from them. The functions of a mold for thermoplastics are basically to impart the desired shape to the plasticized polymer and then to cool the molded part.A mold is made up of two sets of components: (1) the cavities and cores, and (2) the base in which the cavities and cores are mounted. The size and weight of the molded parts limit the number of cavities in the mold and also determine the equipment capacity required. From consideration of the molding process, a mold has to be designed to safely absorb the forces of clamping, injection, and ejection. Also, the design of the gates and runners must allow for efficient flow and uniform filling of the mold cavities.Fig.2-2 illustrates the parts in a typical injection mold. The mold basically consists of two parts: a stationary half (cavity plate), on the side where molten polymer is injected, and a moving half (core plate) on the closing or ejector side of the injection molding equipment. The separating line between the two mold halves is called the parting line. The injected material is transferred through a central feed channel, called the sprue. The sprue is located on the sprue bushing and is tapered to facilitate release of the sprue material from the mold during mold opening. In multicavity molds, the sprue feeds the polymer melt to a runner system, which leads into each mold cavity through a gate.The core plate holds the main core. The purpose of the main core is to establish the inside configuration of the part. The core plate has a backup or support plate. The support plate in turn is supported by pillars against the U-shaped structure known as the ejector housing, which consists of the rear clamping plate and spacer blocks. This U-shaped structure, which is bolted to the core plate, provides the space for the ejection stroke also known as the stripper stroke. During solidification the part shrinks around the main core so that when the mold opens, part and sprue are carried along with the moving mold half. Subsequently, the central ejector is activated,the ejector plates to move forward so that the ejector pins can push the part off the core.Both mold halves are provided with cooling channels through which cooled water is circulated to absorb the heat delivered to the mold by the hot thermoplastic polymer melt. The mold cavities also incorporate fine vents (0.02 to 0.08 mm by 5 mm) to ensure that no air is trapped during filling.There are six basic types of injection molds in use today. They are: (1) two-plate mold; (2)three-plate mold, (3) hot-runner mold; (4) insulated hot-runner mold; (5) hot-manifold mold; and（6）stacked mold. Fig. 2-3 and Fig. 2-4 illustrate these six basic types of injection molds.1. Two-Plate MoldA two-plate mold consists of two plates with the cavity and cores mounted in either plate.The plates are fastened to the press platens. The moving half of the mold usually contains the ejector mechanism and the runner system. All basic designs for injection molds have this design concept. A two-plate mold is the most logical type of tool to use for parts that require large gates.2. Three-Plate MoldThis type of mold is made up of three plates: (1) the stationary or runner plate is attached to the stationary platen, and usually contains the sprue and half of the runner; (2) the middle plate or cavity plate, which contains half of the runner and gate, is allowed to float when the mold is open; and (3) the movable plate or force plate contains the molded part and the ejector system for the removal of the molded part. When the press starts to open, the middle plate and the movable plate move together, thus releasing the sprue and runner system and degating the molded part.This type of mold design makes it possible to segregate the runner system and the part when the mold opens. The die design makes it possible to use center-pin-point gating.3. Hot-Runner MoldIn this process of injection molding, the runners are kept hot in order to keep the molten plastic in a fluid state at all times. In effect this is a runnerless molding process and is sometimes called the same. In runnerless molds, the runner is contained in a plate of its own. Hot runner molds are similar to three-plate injection molds, except that the runner section of the mold is not opened during the molding cycle. The heated runner plate is insulated from the rest of the cooled mold. Other than the heated plate for the runner, the remainder of the mold is a standard two-plate die.Runnerless molding has several advantages over conventional sprue runner-type molding.There are no molded side products (gates, runners, or sprues) to be disposed of or reused, and there is no separating of the gate from the part. The cycle time is only as long as is required for the molded part to be cooled and ejected from the mold. In this system, a uniform melt temperature can be attained from the injection cylinder to the mold cavities.4. Insulated Hot-Runner MoldThis is a variation of the hot-runner mold. In this type of molding, the outer surface of the material in the runner acts like an insulator for the melten material to pass through. In the insulated mold, the molding material remains molten by retaining its own heat. Sometimes a torpedo and a hot probe are added for more flexibility. This type of mold is ideal for multicavity center-gated parts.5. Hot-ManifoldThis is a variation of the hot-runner mold. In the hot-manifold die, the runner and not the runner plate is heated. This is done by using an electric-cartridge-insert probe.6. Stacked MoldThe stacked injection mold is just what the name implies. A multiple two-plate mold is placed one on top of the other. This construction can also be used with three-plate molds and hot-runner molds. A stacked two-mold construction doubles the output from a single press and reduces the clamping pressure required to one half, as compared to a mold of the same number of cavities in a two-plate mold. This method is sometimes called “two-level molding”.2.3.3 Mold Machine1. Conventional Injection-Molding MachineIn this process, the plastic granules or pellets are poured into a machine hopper and fed into the chamber of the heating cylinder. A plunger then compresses the material, forcing it through progressively hotter zones of the heating cylinder, where it is spread thin by a torpedo. The torpedo is installed in the center of the cylinder in order to accelerate the heating of the center of the plastic mass. The torpedo may also be heated so that the plastic is heated from the inside as well as from the outside.The material flows from the heating cylinder through a nozzle into the mold. The nozzle is the seal between the cylinder and the mold; it is used to prevent leaking of material caused by the pressure used. The mold is held shut by the clamp end of the machine. For polystyrene, two to three tons of pressure on the clamp end of the machine is generally used for each inch of projected area of the part and runner system. The conventional plunger machine is the only type of machine that can produce a mottle-colored part. The other types of injection machines mix the plastic material so thoroughly that only one color will be produced.2. Piston-Type Preplastifying MachineThis machine employs a torpedo ram heater to preplastify the plastic granules. After the melt stage, the fluid plastic is pushed into a holding chamber until it is ready to be forced into the die. This type of machine produces pieces faster than a conventional machine, because the molding chamber is filled to shot capacity during the cooling time of the part. Due to the fact that the injection plunger is acting on fluid material, no pressure loss is encountered in compacting the granules. This allows for larger parts with more projected area. The remaining features of a piston-type preplastifying machine are identical to the conventional single-plunger injection machine. Fig. 2-5 illustrates a piston or plunger preplastifying injection molding machine.3. Screw-Type Preplastifying MachineIn this injection-molding machine, an extruder is used to plasticize the plastic material. The Chapter 2 Plastics Molds 41turning screw feeds the pellets forward to the heated interior surface of the extruder barrel. The molten, plasticized material moves from the extruder into a holding chamber, and from there is forced into the die by the injection plunger. The use of a screw gives the following advantages:(1) better mixing and shear action of the plastic melt; (2) a broader range of stiffer flow and heatsensitive materials can be run; (3) color changes can be handled in a shorter time, and (4)fewer stresses are obtained in the molded part.4. Reciprocating-Screw Injection MachineThis type of injection molding machine employs a horizontal extruder in place of the heating chamber. The plastic material is moved forward through the extruder barrel by the rotation of a screw. As the material progresses through the heated barrel with the screw, it is changing from the granular condition to the plastic molten state. In the reciprocating screw, the heat delivered to the molding compound is caused by both friction and conduction between the screw and the walls of the barrel of the extruder. As the material moves forward, the screw backs up to a limit switch that determines the volume of material in the front of the extruder barrel. It is at this point that the re- semblance to a typical extruder ends. On the injection of the material into the die, the screw moves forward to displace the material in the barrel. In this machine, the screw performs as a ram as well as a screw. After the gate sections in the mold have frozen to prevent backflow, the screw begins to rotate and moves backward for the next cycle. Fig.2-5 shows a reciprocating-screw injection machine.There are several advantages to this method of injection molding. It more efficiently plasticizes the heat-sensitive materials and blends colors more rapidly, due to the mixing action of the screw. The material heat is usually lower and the overall cycle time is shorter.2.1计算机辅助设计和计算机辅助CAD/CAM 纵观人类工业社会的历史,许多发明获得了专利，整个新技术也逐渐形成。惠特尼的通用零件的思路,瓦特的蒸汽机和福特的流水线不仅是几个少数的发展阶段而且是人类工业的几个重要的发展阶段。正如我们所知的任何一个这样的发展都影响了制造业并且在历史的挂钩中赢得了这些个体应得的承认。或许单个的发展影响制造业更快，而影响比先前技术更大的是数字电脑。自从电脑技术出现以来,制造业人员一直希望自动化设计过程和使用数据库开发自动制造过程。计算机辅助设计/计算机辅助制造(CAD/CAM),当成功执行,应该消除存在于设计和生产部件之间的传统屏障。 CAD/CAM 意味着用电脑进行设计和制造过程。因为 CAD/CAM 的出现其他方面也发展起来：l 计算机图形CGl 电脑辅助工程CAEl 电脑辅助设计和绘图设计CADDl 计算机辅助工艺规划CAPP 这些附带条件是指包括解答 11 项具体方面的 CAD / CAM 的概念而 CAD / CAM 本身就是一个更广泛平台,它是在生产的自动化和集成的核心。CAD/CAM 成功的一个关键目标是创建可以用来产品的数据当成功实施的产品设计的发展数据库。CAD/CAM 致力于一个在设计和生产部件分享通用的数据库的公司。交互式计算机图形学(ICG)在 CAD/CAM 扮演一个重要角色，虽然 ICG 用途上,设计师冲洗被设计的产品的一个图表图象,当存放电子上组成图表图象的数据。图表图象在二维可以被提出二维(2-D)三维(3-D)或者固体格式化。ICG 图象被修建使用这样基本的几何字符象点、线、圈子和曲线。一旦生成,这些图象可以容易地被编辑和被操作用各种各样的方式包括扩大、减少、自转和运动。 lCG 系统有三个主要成份,1)硬件,包括计算机和各种各样的外围设备; 2)软件,包括系统的计算机程序和技术指南; 3)设计师,最重要三个组分。ICG 系统的典型的硬件构造包括一个电脑,一个显示终端、磁盘的一个驱动器单位，一个硬盘或者两个; 并且输入-输出设备例如键盘，绘图器和打印机。这些设备,与软件一起，是现代工具设计师用以开发和提供他们的设计的。 ICG 系统能通过允许人的设计师集中提高设计过程于设计过程的智力方面，例如概念化和做出基于评断的决定。计算机执行它更好地适合，例如数据的各种各样的反复操作数学演算、存贮与检索，和各种各样的反复操作比如交叉涂画。 2.11CAD/CAM 的基本原理 CAD/CAM 的基本原理类似于制造业以前证明技术为基础的提高。它来源于一个需要不断提高生产率，质量和反过来的竞争力。还有其他原因，可能使公司从手工流程转换为 CAD / CAM 的。l 提高生产力l 质量更好l 更好的沟通l 共同的数据库与制造l 降低建造成本原型l 更快的响应客户 2.12 CAD/CAM 的历史发展 CAD/CAM 的历史发展在计算机科技的发展之后紧密跟随了和对应了 ICG 技术的发展。使得 CAD/CAM 的重大发展在 20 世纪 50 年代和 60 年代初期末期开始了。最先发展的是在麻省理工学院(MIT)进行的刀具控制程序自动编制系统(APT)计算机程式语言。 APT 的目的是将数字控制器部分方案的开发进行简化。它是为此计划被使用的第一种计算机语言。APT 语言代表了主要步往制造过程的自动化。在 CAD/CAM 的历史中的另一重大发展在 APT 之后紧密跟随了，也被开发在 MIT，一个项目被称之为草图项目。这个项目，Ivan Sutherland 诞生了 ICG 的概念。草图项目是第一个计算机在实时中被用于生成和操作在 CRT 中显示的图表图象。在 20 世纪 60 年代和 70 年代的剩下的人中，CAD 继续被开发，多家厂商提出了自己的名字生产和销售生产全套 CAD 系统。这是一个完整的系统方案包括硬，软件，销售和维修培训。这些早期的系统被大型机和小型机左右。因此,它们太昂贵一直不能实现大规模被中小型制造业接受。在 20 世纪 70 年代末之前微型计算机在 CAD/CAM 的更加一步的发展中最终将扮演一个重要角色变得日益清晰。然而早期的微型计算机没有配置为 ICG 需要的处理能力、记忆能力或者图表能力。结果,早期尝试在微型计算机附近配置 CAD/CAM 系统的尝试失败了。在 1983 IBM 介绍了 IBM PC第一个有处理能力、记忆能力和图表能力可被用于 CAD/CAM 的微型计算机。这使得了 CAD/CAM 供营商的数量的迅速增量。截止到 l989 安装CAD/CAM 设施的数量的微型计算机等于安装在大型机和小型机上的数量。 2.13 CAD 到 CAM 接口使用 CAD/CAM，设计和制造之间的真正的接，是他们分享的共同的数据库。这是 CAD/CAM 精华。手工设计和制造，工程师审阅在设计，起草生产图纸和其他文件传达设计的每步，生产人员使用图画开发处理计划，车间人员负责实际上的生产。与旧方法相比,直到设计和起草人员完成他们的工作，生产人员都没有看到它。设计和起草部门做他们的工作，把计划再扔过墙再让制造部门做他们的工作。这种做法导致沟通的不畅通以及制造部分与设计部分的脆弱关系。其结果是生产力的损失。使用 CAD/CAM,生产人员可以尽快进入创建的数据的设计阶段。在任何一点在设计过程中，他们可以调用数据库中的信息并使用它。因为数据分享从开始到结束，所以当设计成到准备生产时没有一点吃惊。当设计师创造时数据库和起草者提供的设计，使生产人员也成为项目的一部分。生产人员生产产品的任何需要都被包含在一个共同的数据库里。数学模型，图形图像，用料清单，零件清单，尺寸，从区位尺寸到公差规格和原材料明细表都包含数据库。2.1 Computer-aided Design and Computer-aided Manufacturing(CAD/CAM) Throughout the history of our industrial society ,many invention have been patented and whole new technologies have evolved .Whitney is concept of interchangeable parts ,Watts steam engine,and Ford is assembly line are but a few developments that are most noteworthy during our industrial period . Each of these developments has impacted manufacturing as we know it,and has earned these individuals deserved recognition in 0ur history hooks. Perhaps the single development that has impacted manufacturing more quickly and significantly than any previous technology is the digital computer. Since the advent 0f computer technology, manufacturing professionals have wanted to automate the design process and use the database developed therein for automating manufacturing processes. Computeraided design,computer-aided manufacturing (CAD/CAM),when successfully implemented, should remove the “wall” that has traditionally existed between the design and manufacturing components . CAD/CAM means using computers in the design and manufacturing processes. Since the advent of CAD/CAM other terms have developed:l Computer graphics(CG)l Computeraided engineering(CAE)l Computer-aided design and drafting(CADD)l Computer aided process planning(CAPP) These spin-off terms a11 refer to specific aspects of the CAD/CAM concept CAD/CAM itself is a broader,more inclusive term. It is at the heart of automated and integrated manufacturing. A key goal of CAD/CAM is to produce data that can be used in manufacturing a product while developing the database for the design of that product When successfully implemented, CAD/CAM involves the sharing of a common database between the design and manufacturing components of a company, Interactive computer graphics (ICG) plays an important role in CAD/CAM, Though the use of ICG, designers develop a graphic image of the product being designed while storing the data that electronically make up the graphic image. The graphic image can be presented in a two-dimensional (2-D) , three-dimensional(3-D),or solids format. ICG image are constructed using such basic geometric characters as points, lines, circles, and curves. Once created, these images can be easily edited and manipulated in a variety of ways including enlargements,reductions, rotations, and movements. An lCG system has three main components :1 ) hardware, which consists of the computer and various peripheral devices; 2) software, which consists of the computer programs and technical manuals for the system ; and 3) the human designer, the most important of the three components. A typical hardware configuration for an ICG System include a computer,a display terminal, a disk drive unit for floppy diskettes, a hard disk, or both; and input/output devices such as a keyboard,plotter, and printer. These devices, along with the software, are the tools modern designers use to develop and document their designs. The ICG systems could enhance the design process by allowing the human designer to focus on the intellectual aspects of the design process, such as conceptualization and making judgment-based decisions. The computer performs tasks for which it is better suited, such as mathematical calculations, storage and retrieval of data and various repetitive operations such as crosshatching.2.1.1 Rationale for CAD/CAM The rationale CAD/CAM is similar to that used to justify any technology-based improvement in manufacturing . It grows out of a need to continually improve productivity,Quality and in turn competitiveness. There are also other reasons why a company might make a conversion from manual processes to CAD/CAM:l increased productivityl better qualityl better communicationl common database with manufacturingl reduced prototype construction costsl faster response to customers2.12 Historical Development of CAD/CAM The historical development of CAD/CAM has followed close behind the development of computer technology and has paralleled the development of ICG technology. The significant developments leading to CAD/CAM began in the late 1950s and early 1960s. The first of these was the development, at Massachusetts Institute of Technology (MIT),of the Automatically Programmed Tools (APT) computer programming language. The purpose of APT was to simplify the development of parts programs for numerical control machines. It was the first computer language to be used for this purpose. The APT language represented a major step toward automation of manufacturing processes. Another significant development in the history of CAD/CAM followed close behind APT, also developed at MIT, was called the Sketchpad project. With this project, Ivan Sutherland gave birth to the concept of ICG. The Sketchpad project wa

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