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黄河科技学院本科毕业设计（论文）任务书 工 学院 机械 系 材料成型及控制工程 专业 08 级 材料 班学号 080118027 学生 宋长生 指导教师 王宗才 毕业设计（论文）题目 收音机后盖注塑模具设计与制造 毕业设计（论文）工作内容与基本要求（目标、任务、途径、方法，应掌握的原始资料（数据）、参考资料（文献）以及设计技术要求、注意事项等）（纸张不够可加页） 1. 设计目的：（1）综合运用塑料成型材料的基本知识,以塑料成型的基本原理和工艺特点,分析成型工艺对模具的要求；（2）掌握成型设备对模具的要求；（3）掌握成型模具的设计方法,通过毕业设计,使学生具备设计中等复杂程度的模具的能力；（4）培养学生正确的设计思想和分析问题、解决问题的能力，学会运用标准、规范、手册、图表和查阅有关技术资料，培养学生从事模具设计的基本技能。 2. 设计任务：收音机后盖注塑模具设计与制造 3. 设计规格： （1）外形尺寸见附图；（2）材料：ABS；（3）生产纲领：年产10000件 4. 设计内容： 1）塑件的工艺分析以及注射机选择 2）注塑模具的设计,主要包括： （1）型腔数目确定 （2）分型面选择 （3）型腔的布置 （4）浇注系统的设计 （5）排气槽位置的选择 （6）成型零件的设计与加工工艺 （7）脱模机构零件的计算 （8）模具标准零件的选择 （9）冷却系统的设计 （10）塑料模具的材料及热处理 3） 实体设计 （1）所给制品的实体设计 （2）凹凸模实体设计 （3）模具其他零件的实体设计 （4）模具虚拟装配 5. 设计要求： （1）2012年2月10日完成开题报告，文献综述以及文献翻译。 开题报告主要内容包括：调研资料的准备，毕业设计的目的、要求、思路与预期成果；任务完成的阶段内容及时间安排；完成设计所具备的条件因素。 文献综述不少于3000字；文献翻译不少于3000字。查阅文献资料不少于12篇，其中外文资料不少于2篇； （2）2012年3月1日前完成毕业设计方案。 （3）2012年4月10日完成图纸绘制，实体设计和毕业设计说明书初稿。 （4）2012年4月20日完成毕业设计说明书定稿。设计说明书不少于8000字，条理要清晰，格式规范，逻辑性强。 （5）2012年5月1日前上交所有材料（纸质材料和电子档），学院进行答辩资格审查 。2012年5月14日前完成答辩前的修改工作，做好毕业答辩准备。 （6）2012年5月19日-20日院里组织统一毕业答辩。 6. 参考文献： 1 党根茂 骆志斌 李集仁 主编.模具设计与制造.西安：西安电子科技大学出版社，1995.12； 2 许发樾 主编.实用模具设计与制造手册.北京：机械工业出版社，2002.1； 3 塑料模设计手册编写组著.塑料模具设计手册.北京：机械工业出版社； 4 王焕庭 李茅华 徐善国 主编. 机械工程材料.大连理工大学出版社，2000.5； 5 高佩副 主编. 实用模具制造手册. 北京：中国轻工业出版社，1999.3 6 彭建声 秦晓刚 主编. 模具技术问答.北京：机械工业出版社，2000.1 7 陈锡栋，周小玉.实用模具技术手册.机械工业出版社,2001.7 8 付宏生.刘京华.注塑制品与注塑模具设计.化学工业出版社,2003.7； 9 陈万林.实用塑料注射模设计与制造.机械工业出版社2000.10； 10 贾润礼，程志远.实用注塑模具设计手册.中国轻工业出版社,2000.4； 毕业设计（论文）时间： 2012 年 2 月 13 日至 2012 年 5 月 13 日计 划 答 辩 时 间： 2012 年 5 月 19日-20日 专业（教研室）审批意见：审批人（签字）：附图：图1 注塑件尺寸图ORIGINAL ARTICLEModular design applied to beverage-containerinjection moldsMing-Shyan Huang&Ming-Kai HsuReceived: 16 March 2010 /Accepted: 15 June 2010 /Published online: 25 June 2010#Springer-Verlag London Limited 2010Abstract This work applies modular design concepts todesignating beverage-container injection molds. This studyaims to develop a method of controlling costs and time inrelation to mold development, and also to improve productdesign. This investigation comprises two parts: functional-ity coding, and establishing a standard operation procedure,specifically designed for beverage-container injection molddesign and manufacturing. First, the injection mold isdivided into several modules, each with a specific function.Each module is further divided into several structural unitspossessing sub-function or sub-sub-function. Next, dimen-sions and specifications of each unit are standardized and acompatible interface is constructed linking relevant units.This work employs a cup-shaped beverage container toexperimentally assess the performance of the modulardesign approach. The experimental results indicate thatthe modular design approach to manufacturing injectionmolds shortens development time by 36% and reducescosts by 1923% compared with the conventional ap-proach. Meanwhile, the information on modularity helpsdesigners in diverse products design. Additionally, thefunctionality code helps effectively manage and maintainproducts and molds.Keywords Beverage container.Injection mold.Modulardesign.Product family1 IntroductionRecently, growing market competition and increasinglydiverse customer demand has forced competitors toincrease the speed at which they deliver new products tothe market. However, developing a mold for mass produc-tion requires considering numerous factors, includingproduct geometry, dimensions, and accuracy, leading tolong product development time. Introducing modulardesign concepts into product design appears a key meanof facilitating product development, since it increasesdesign flexibility and shortens delivery time 14. Mean-while, a high level of product modularity enhances productinnovativeness, flexibility, and customer services 5.Modularity is to subdivide a complex product intomodules that can be independently created and then areeasily used interchangeably 6, 7. There are three generalfields where modularity could be implemented includingmodularity in design (MID), modularity in use (MIU), andmodularity in production (MIP) 8. MID involves stan-dardizing basic structural units which perform specificfunctions, thus facilitating flexible assembly of variousproducts 9, 10. MID can reveal product structure, namelythe relationship among different products. Related productsare termed product family and include both basic andspecific functions. Developing product families offersbenefits in terms of multi-purpose design and thus reducesproduction costs 11, 12. MIU is consumer-driven decom-position of a product with a view to satisfying the ease ofuse and individually. MIP enables the factory floor to pre-combine a large number of components into modules andthese modules to be assembled off-line and then broughtonto the main assembly line to be incorporated into a smalland simple series of tasks.M.-S. Huang (*):M.-K. HsuDepartment of Mechanical and Automation Engineering andGraduate Institute of Industrial Design,National Kaohsiung First University of Science and Technology,2 Jhuoyue Road, Nanzih,Kaohsiung City 811, Taiwan, Republic of Chinae-mail: mshuang.twInt J Adv Manuf Technol (2011) 53:110DOI 10.1007/s00170-010-2796-yMID has been broadly applied to numerous areas andhas exerted significant effects in terms of cost reduction anddesign diversity 13, 14. However, there is limitedempirical research that has applied modular design tomolds 1518. This study thus aims to reduce molddevelopment time by applying modular design and developa standard operation procedure for designing beverage-container injection molds, which are characterized byscores or even hundreds of components.2 General procedures of designing injection moldsBasically, an injection mold set consists of two primarycomponents, the female mold and the male mold. Themolten plastic enters the cavity through a sprue in thefemale mold. The sprue directs the molten plastic flowingthrough runners and entering gates and into the cavitygeometry to form the desired part. Sides of the part thatappear parallel with the direction of the mold opening aretypically angled slightly to ease rejection of the part fromthe mold. The draft angle required for mold release isprimarily dependent on the depth of the cavity and theshrinkage rate of plastic materials. The mold is usuallydesigned so that the molded part reliably remains on themale mold when it opens. Ejector pins or ejector plate isplaced in either half of the mold, which pushes the finishedmolded product or runner system out of a mold. Thestandard method of cooling is passing a coolant through aseries of holes drilled through the mold plates andconnected by hoses to form a continuous pathway. Thecoolant absorbs heat from the mold and keeps the mold at aproper temperature to solidify the plastic at the mostefficient rate. To ease maintenance and venting, cavitiesand cores are divided into pieces, called inserts. Bysubstituting interchangeable inserts, one mold may makeseveral variations of the same part.General mold design process contains two parts 19:part design and mold design. The part design processcontains five major procedures: defining main pullingdirection, defining core and cavity, calculating shrinkagerate, defining draft angle, and then defining parting line.The mold design process mainly includes choosing a moldbase, positioning the molded part, designing core andcavity, designing components, designing coolant channels,creating returning pin, adding ejector pin, creating gate andrunner, adding locating ring and sprue bushing in sequence.3 Applying modular design for beverage containersThis study applies modular design to beverage-containerinjection molds via a five stage process, as follows: (1)product classification and machine specifications, (2)division of injection molds into modules based on func-tionality, (3) division of individual modules into multipleunits with sub-functions, and the relationship betweendesign and assembly for each unit, (4) standardization ofstructural units, and (5) coding of standard structural units.These individual processes are detailed below.A beverage-container hot-runner injection mold Clamping module Hot-runner module Molding module Ejecting module Guiding module Clamping plate Female mold base Male mold base Manifold Hot-tip bushing Hot tip Female mold insert Cup base female mold insert Male cooling base Male mold insert Air ejector Ejector plate Leader pin Leader pin bushing Fig. 1 Modularity classificationof a beverage-container injectionmold2Int J Adv Manuf Technol (2011) 53:1103.1 Product classification and machine specificationsThis step classifies all of the beverage containers based ontheir geometry and dimensions, and selects the machinewith the most suitable specifications for production. Thereare five major qualifications for an injection moldingmachine, including sufficient mold clamping force, suffi-cient theoretical shot volume, sufficient distance betweentie bars, sufficient range of mold thickness, and sufficientmold clamping stroke.3.2 Division of injection molds into modules basedon functionalityThis step divides a mold set into several modules withindividual functions. The principles of division includegeneral rule, division rule, applicability rule, and inter-change rule. In general rule, modules must contain all thefunctions of beverage-container injection molds. In divisionrule, each functional module must contain at least onefundamental function and each unit must fulfill its ownspecific functions. As to applicability rule, units fulfilling asingle function are preferred. For interchange rule, funda-mental units should be interchangeable among modulesafter dividing molds into product families.3.3 Division of a module into multiple unitswith sub-function and the relationship between designand assembly for each unitFigure 1 illustrates the structure of a beverage-containermold that includes several functional modules. The func-tions of individual modules are further extended to thestructural unit via sub-functions or sub-sub-functions. Thedivided modules include clamping module, hot-runnermodule, molding module, ejecting module, and guidingmodule. The clamping module functions for preciselypositioning individual units and modules on an injectionmolding machine. The hot-runner module is to maintain theflowability of molten plastics via heating. The molding(a)(b)Cup-type container Rectangle shape at cross section Cuboid-shaped mold insert design Round shape at cross sectionCylinder-shaped mold insert designBasin-type container Fig. 3 Design of geometricalstructural unit: a cup-type con-tainer, b basin-type containerCostHighly efficient process Modular mold development process Reduction of working hoursConventional mold development processDuration of conventional molddevelopment processCost down Materials delivery CNC machining Milling Turning Heat treatment EDM Wire cutting Polishing TextureProduct Semi-product TimeDuration of modular mold development process Fig. 2 Comparison of conventional and modular mold developmentprocessesInt J Adv Manuf Technol (2011) 53:1103module controls the geometry and dimensional accuracy ofinjection-molded parts. The ejecting module ejectsinjection-molded parts from the mold cavity. The guidingmodule works for accurately positioning the female andmale molds during mold closing.3.3.1 Geometrical design of structural elementsStandard structural elements are prepared into semi-finishedproducts that fulfill the geometrical outlines of finishedproducts, thus significantly shortening manufacturing molddelivery time. Figure 2 illustrates the comparison betweenthe modularity design mold development process and theconventional process. Standard structural elements are fastto produce since they are pre-manufactured into generalshapes and require minimal manufacturing to yield afinished product.Figure 3 shows the geometrical design of the beveragecontainers examined in this study. The mold insert that bestcorrespondents with the product shape has a simplegeometrical shape. For example, the cylinder and thecuboid represent cup-type and basin-type containers,respectively. The remaining components are modularizedto facilitate their effective integration into a complete set ofinjection molds in a manner similar to stacking playingblocks.(a)(1) Single spiral (2) Double spiral (3) Block plate (4) Fountain (b)(1) Linear shape (2) U shape(3) Multi-segment (4) Block plateFig. 4 Design of cooling sys-tem: a the male portion of themold cooling unit, b the femaleportion of the mold cooling unit4Int J Adv Manuf Technol (2011) 53:1103.3.2 Assembly design of structural unitHundreds of structural elements are involved in newproduct development, each containing numerous dimen-sions. Assembling such a sophisticated system mayfrequently fail because of small mistakes occurring indimensions. This study defines dimensions involvingstructural elements with mutual assembly relationships asunion dimensions. These dimensions are simplified to afool-proofing effect. Procedures for assembling structuralelements are introduced below:(1)Direction of module assemblyTwo lines are used toseparate a mold into four assembly modules. The firstline is the parting line defining the female and malemolds. The second line defines the boundary betweenthe front and rear hot-runner plates. The sequence ofassembly follows the order of male mold, femalemold, front hot-runner plate, and rear hot-runnerplate.(2)Direction of assembly unitsEach unit belonging tothe above-mentioned four assembling modules isassembled in a sequence, namely, confirming theappearance dimensions of injection-molded parts,further confirming the product-related dimensions ofthe mold insert and mold cavity, fixing the moldinsert with the clamping module, identifying thedimension of the hot-runner module using thestructural components of the female mold, calculatingthe precise dimensions of the clamping plates, andfinally selecting the injection molding machinespecifications. The assembling sequence primarilyfollows product, mold insert, clamping plate, andinjection molding machine.3.4 Standardization of structural unitAs for the structural units of beverage-container injectionmolds, the concept of product families is further introducedto increase the commonality and exchangeability amongvarious functional units. Figure 4 illustrates an example ofmutually substitutable cooling systems. Furthermore, Fig. 5shows the design of various ejection systems used forproduct families.3.4.1 Design of cooling systemThe cooling system comprises two units: male moldcooling unit and female mold cooling unit. The male moldcooling unit includes fountain, double spiral, single spiral,(b)Core x 4Ejector plateEjector ring x 4 (a)Line-type L-typeLine-typeL-type air outlet L-type air inletFig. 5 Design of ejector: a airejector, b ejector plateInt J Adv Manuf Technol (2011) 53:1105and block plate types listed in descending sequence ofcooling efficiency. Based on manufacturing cost and cool-ing effect, the double spiral type is prioritized. As to thefemale mold cooling unit, it includes multi-segment, blockplate, U shape, and linear types listed in descendingsequence of cooling efficiency. Based on manufacturingcost and cooling effect, block plate is prioritized.3.4.2 Design of ejection mechanismThe beverage container is normally thin-walled and theideal ejection mechanism is an air ejector, based on thedesirability of preventing damage to injection-molded parts.As for injection molding materials with high shrinkage, theejector plate can be selected to smoothly separate theproducts and mold. The air ejector design incorporates twoair outlets around the mold insert, namely, one L-type outletand one line-type outlet. The air in the L-type outlet entersthe periphery of the mold insert and separates the injection-molded parts from the mold insert. The air in the line-typeoutlet is then injected into the bottom of the parts to ejectthem from the mold cavity. Ejector plate is to push amolded part off a core or out of a cavity mold. It is attachedto a core and moves linearly along leaders.3.5 Coding of standard structural unitsAfter specifying structural unit dimensions, this investiga-tion introduces a coding system to assist in managing thesecomponents and units.3.5.1 Structural unit codesThis study uses three digits to code all of the structural units(Fig. 6a). The first digit is the main function code, whichrepresents product geometry and dimensions, and symbol-izes standardized structural units. The second digit is thesub-function code, which represents materials, and iswidely used in bills of materials (BOM) for structural units.The third digit represents the characteristics of eachstructural unit, and includes the codes for products familiesand dimensions.3.5.2 Product identification complex codeThis code is designed for rapidly searching structural unitswhich are mutually exchangeable during product develop-ment. This code integrates all structural units correlatedwith the manufacture of a specific container, and alsoreveals information on mold geometry and dimensions, andproduct characteristics, as shown in Fig. 6b.Modular design of injection molds Product and unit coding Manufacturing facility analysisConfirmation of product specificationsIs a proper design?YesNoYesNoStructural unit manufacturing Mold assembly and inspection Component drawingList of modular objectsMold testing & mass productionIs inspection OK?Fig. 7 Standard operation procedure for developing beverage-container injection molds(a)(b)Main function - Gemoetry & dimensions1 23Sub function - Materials module codeClamping module Hot-runnermodule Moldingmodule78Characteristic code - Product family & dimensions Injection molding machineProduct classificationEjector typeClamping plateHot-tip bushingFemale moldMale moldFemale mold baseMale mold baseHot tipmanifoldGuiding moduleEjector unit213456910111213Fig. 6 Code of modular functionality: a structural unit codes, bproduct identification complex code6Int J Adv Manuf Technol (2011) 53:1104 Procedure for developing container productsBased on the above-mentioned modular design approach, astandard operation procedure for designing beverage-container injection molds can be generated. Thus, merelyfollowing the procedure can easily design molds for newproducts and identify interchangeable structural units whichcan help effectively manage and maintain products andmolds. Figure 7 shows the standard operation procedure fordesigning beverage-container injection molds. The proce-dure comprises nine steps and is illustrated as follows.Step 1.Confirmation of product specifications: In order toexactly describe the geometry, dimensional accu-racy, and quality characteristics of products, thisstep defines the product with its geometricalcharacteristics, such as width, height, projectionarea, and weight.Step 2.Manufacturing facility analysis: Based on theinformation from Step 1, the most suitable injectionmolding machine is determined by checkingspecifications such as clamping force, shot volume,range of mold thickness, and daylight.Step 3.Modular design of injection molds: Through thedivision of mold function into several functionalmodules, the injection mold of a specific contain-er can be rapidly and easily developed by modulestacking. Modules to be designed include malemold module, female mold module, hot-runnermodule, and others.Step 4.Product and unit coding: Each structural unit isassigned a component code, which is thenintegrated with the product characteristics to yielda product complex identification code. Conse-quently, mutually exchangeable units are availablein the product development stage. Furthermore, No. Title Code Specifications Materials Amount Auxiliary1 Cup-shaped male mold base 6-2-N L450 H450 T60 S55C 1 Heat treatment2 Cup-shaped female mold base 19-2-N L450 H450 T130 S55C 1 Heat treatment3 Clamping plate 3-2-N L450 T50 120 S55C 1 - 4 Manifold 4-2-N L330 H90 T43 SKD61 1 - - 5 Hot tip 2-1-N 14 L90 Beryllium Copper46 Hot-tip bushings 2-3-N 20 L60 FDAC 4 - 7 Cup-shaped male mold insert 19-1-N 150 H130 SUS420 4 - 8 Cooling unit of male mold 19-2-T 90 H130 SDK11 4 Heat treatment9 Cup-shaped base female mold insert 19-1-N 150 H110 SUS420 4 - 10 Cup-shaped female mold insert 19-2-N 130 H20 SKD11 4 Heat treatment11 Leader pin 6-1-15 40 L260 SK3 4 - 12 Leader pin bushing 6-1-21 55 L100 SK3 4 - Fig. 8 BOM of a cup-shapedinjection moldInt J Adv Manuf Technol (2011) 53:1107the code system simplifies mold maintenance andproduct management.Step 5.List of modular objects: According to thestructural specifications from Step 3, all compo-nents of an injection mold are listed in BOM. Forinstance, the BOM of a cup-shaped injectionmold as an example is illustrated in Fig. 8. Thisstep facilitates ease of handling during thesubsequent quotation and production schedulingprocess.Step 6.Component drawing: Since dimensions of struc-tural units are for semi-products, the BOMinformation listed in Step 5 simply is the initialstage of mold design. Thereby, all structural unitsof an injection mold designed for customerrequirement and specification have to be drawnin the format of engineering drawing for engi-neering purposes.Step 7.Structural unit manufacturing: Following theinformation of BOM and component drawinggenerated in Steps 5 and 6, respectively, this stepenables the factory floor to further manufacturethe injection mold.Step 8.Mold assembly and inspection: This step inspectseach unit manufactured in Step 7 to assure moldquality. Based on the assembly drawing of a mold,the location of related modules and structural unitsis accurately assembled. For instance, Fig. 9presents the assembly drawing of a coffee-cupinjection mold, which is used to confirm therelationship of each component.Step 9.Mold testing and mass production: After complet-ing the above eight steps, this final step isperformed to test the mold on the injectionmolding machine and implement mass production.5 Verification and discussionThis study employs a cup-shaped beverage container toexperimentally assess the performance of the modulardesign approach. Since the specification of structural unitsenables preprocessing of the initial unit shape and onlyrequires local preprocessing to obtain precise dimensionsduring mold development, the total mold development timewill be significantly reduced. Table 1 lists mold develop-ment for a cup-shaped container and reveals that the molddevelopment time employing a modular design is some36% less than with the conventional process. Whereas thestandardization of component specifications enabling batchpurchasing of materials which are combined with efficientmanufacturing and design, can reduce total manufacturingcosts. Table 2 lists mold development for a cup-shapedcontainer and reveals that mold manufacturing costs whenemploying a modular design are reduced by 1923%compared with the conventional process. In addition,employing modular design has other advantages such as:1.Increased diversity of customer-oriented design: Modu-lar design of beverage-container injection moldsinvolves dividing a mold into five key functionalmodules and 14 sub-functional structural units. Amutually compatible interface among units is createdvia the specification and standardization of individualstructural units. Moreover, product families with variousfunction structures containing different types of coolingeffects in mold insert cooling unit and different types ofejecting effects in the injection unit are defined. Eachunit type is substitutable, facilitating product assemblyand disassembly, enhancing design flexibility, increasingproducer ability to adapt to market variation, andfulfilling various types of customer demand.Fig. 9 The assembly drawings of a coffee-cup injection mold: a moldinsert, b female mold base8Int J Adv Manuf Technol (2011) 53:1102.Information provision to facilitate rapid product devel-opment: The use of coding system for standardfunctional modules and structural units enables theconstruction of a standard product development proce-dure. This procedure enables designers to quicklyfollow correct design steps and to further completedetailed injection mold design.3.Effective management of the maintenance of productsand molds: The developed coding system enables rapidresponse to repair inquiries by providing availablecomponents that are mutually replaceable from amongunits held in stock. Furthermore, structural units of aproduct and information on product characteristics arecoded using a specialized individual identificationnumber to facilitate new product development.6 ConclusionsThis study applied modular design theory and principles indeveloping beverage-container injection molds. The stan-dard operating procedure for developing mutually substi-tutable standard component mold designs has beendemonstrated. This work only presents a single cup-shapeand basin-shape container injection mold as a researchvehicle for modular design, and yields valid results in termsof saving time and reducing manufacturing costs. Based onthe database of standard structural units constructed forbeverage containers, the application of computer-aideddesign and computer-aided manufacturing can reveal theeffect of modular design. Practical case studies indicate thatthe proposed procedure enables the design of standardTable 2 List of cost savings for a cup-shaped containerStructural unitMaterials discount at batchpurchasing (%)Reduction atmanufacturing time (%)Reduction in designing andother cost (%)Cost saving amongmodular units (%)Clamping plate0.150.440.570.130.260.851.27Manifold0.100.310.620.130.260.851.19Hot-tip bushing0.030.070.260.46Hot tip0.020.070.270.44Female mold base0.280.832.980.150.293.414.11Female mold insert0.170.504.530.160.324.865.36Cup-base mold insert0.0660.310.460.73Cooling unit of male mold0.090.280.380.160.310.630.97Male mold insert0.200.065.640.160.326.006.56Male mold base0.170.521.280.140.281.592.09Summary1.273.8016.461.462.9219.1923.18Table 1 List of manufacturing time savings for a cup-shaped containerStructural unitConventional moldmanufacturing time (h)Modular moldmanufacturing time(h)Saving of modular moldmanufacturing time (h)Percentage of modular moldmanufacturing time (%)Clamping plate86225Manifold38261232Hot-tip bushing65117Hot tip43125Female mold base40291127Female mold insert5216.535.569Cup-base mold insert49.5436.513Cooling unit of malemold44.5386.515Male mold insert56243257Male mold base86225Summary306196.5109.536Int J Adv Manuf Technol (2011) 53:1109components for various products and thus can considerablyreduce working hou
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