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MJZ02-096@遥控器面板注塑模具设计,机械毕业设计全套
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河南理工大学万方科技学院 本科毕业设计(论文)中期检查表 指导教师: 李章东 职称: 副教授 所在院(系): 机械与动力工程系 教研室(研究室): 机制教研室 题 目 遥控器面板注塑模具设计 学生姓名 丁东东 专业班级 万方 07 机制 2 班 学号 0720150089 一、选题质量: 1.遥控器面板注塑模具设计 符合本专业的培养目标,能够体现综合训练要求。 2.题目难易程度中等偏上。 3.设计说明 书的设计与计算部分难度中等但工作量较大。 4.此题目直接与现实中的生产相关,设计此模具设计 可以直接与工厂生产相连,产 生效益;此题目为创新型题目,可培养 学生的研究精神。 二、开题报告完成情况: 按时 完成 nts 2 三、阶段性成果: 1.完成开题报告 2.设计说明书计算部分草稿完成 3.完成 AutoCAD 的部分图纸草绘 4.完成国外文献的翻译 四、存在主要问题: 1.图纸设计需要查资料,因此进展缓慢 2.设计计算工作量稍大,特别是需要校核部分 五、指导教师对学生在毕业实习中,劳动、学习纪律及毕业设计(论文)进展等方面的评语 指导教师: (签名) 年 月 日 nts河南理工大学 万方科技学院 本科毕业设计(论文)开题报告 题目名称 遥控器面板注塑模具设计 学生姓名 丁东东 专业班级 万方 07 机制二班 学号 0720150089 一、 选题的目的和意义: 模具是工业生产中使用极为广泛的基础工艺装备。在汽车、电机、仪表、电子、通信、家电和轻工业等行业中, 60% 80%的零件都要依据模具成形,并且随着近年来这些行业的迅速发展,对模具的要求越来越迫切,精度要求越来越高结构要求也越来越复杂。模具已广泛应用于电机电器产品、电子和计算机产品、仪表、家用电器、汽车、军械、通用机械等产品的 生产中。 本课题要求设计遥控器面盖的注塑模具,注塑成型是现代塑料工业中的一种重要的加工方法 注塑模具由于其 专用性和独一性,在设计时主要考虑到工厂现有的设备情况、产品的生产批量及模具的寿命。这遥控器面盖为批量生产,但由于该塑料制件尺寸比较小,模具的结构相对比较简单,模具制造成本比较底,在生产时主要考虑到模具寿命尽量要高,所以对模具材料提出了较高的要求。遥控面盖是一个外形件,尺寸精度要求不高,但对外层的表面粗糙度要求比较高,因此在设计时在能顺利成型出塑料制品的情况下,对模具型腔的表面抛光工艺要求比较高。 从总体 结构上来看,该制件是一个尺寸较小,壁厚较薄,整体结构比较简单的塑料件。由于壁厚较薄,脱模时如果受力不均则易会产生变形从而出现制品缺陷,因此对脱模机构及冷却系统的设计要求较高。 按照现今注塑模具设计的总体趋势,注塑模具的设计已很少使用手工绘图或完全由二维软件来进行设计,且模具标准件已在注塑模具设计中大量采用。 因此本课题将采取使用模具二维软件 CAD 和三维软件 Pro/E 综合使用来进行模具的结构设计,且在模具设计的过程中综合考虑模具制造工艺及注塑成型工艺 。 nts 2 二、 国内外研究综述: 塑料工业是当今世界上增长最快的工业 门类之一,而注塑模具是其中发展较快的种类,因此,研究注塑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。工业发展水平的不断提高,工业产品更新速度加快,对模具的要求越来越高,尽管改革开放以来,模具工业有了较大发展,但无论是数量还是质量仍满足不了国内市场的需要, 目前满足率只能达到 70%左右。造成产需矛盾突出的原因,一是专业化、标准化程度低,除少量标准件外购外,大部分工作量均需模具厂去完成。加工企业管理的体制上的约束,造成 模具制造周期长,不能适应市场要求。二是设计和工艺技术落后,如模具 CAD/CAM 技术 采用不普遍,加工设备数控化率低等,亦造成模具生产效率不高、周期长。总之,是拖了机电、 轻工等行业发展的后腿。 模具按国家标准分为十大类,其中冲压模、塑料模占模具用量的主要部分。按产值统计,我国目前冲压占 50%-60%,塑料模占 25-30。国外先进国家对发展塑料模很重视,塑料 模比例一般占 30%-40%。国内模具中,大型、精密、复杂、长寿命模具比较低,约占 20%左右,国外为 50%以上。我国模具生产企业结构不合理,主要生产模具能力集中在各主机厂的 模具分厂 (或车间 )内,模具商品化率低,模具自产自用比例高达 70%以上。国外, 70%以上 是商品化的。 注塑成型是现代塑料工业中的一种重要的加工方法 ,模具是现代化工业生产的重要工艺装备,被称为 “工业之母 ”。而塑料模具又是在整个模具工业中的一枝独秀,发展极为迅速。世界上注塑模的产量约占塑料成型模具总产量的 50 %以上 ,尤其是家电盒型注塑产品需求量不断增加,注塑成型能一次成型形状复杂、尺寸精确的制品 ,适合高效率、大批量的生产方式 ,以发展成为热塑性塑料和部分热固性塑料最主要的成型加工方法 ,注塑模具的设计与制造主要依赖于设计者的经验和技师的制造技艺 ,一般需要经过反复 调试和修模才能正式投入生产 ,这种传统 的生产方式不仅使产品的生产周期延长 ,生产成本增加 ,而且难以保证产品的质量,要解决这些问题 ,必须以科学分析的方法 ,研究各个成型过程的关键技术,塑料注塑成型是一个复杂的加工与物理过程 ,为实现注塑产品的更新换代 ,提高企业的竞争能力 ,必须进行注塑模具设计与制造及成型过程分析的 CAD/ CAM/ CAE 集成技术的研究国外注塑模 CAD/ CAM/ CAE 技术研究的成果有关统计数据表明 :采用注塑模 CAD/ CAE/CAM 技术能使设计时间缩短 50 %,制造时间缩短 30 %,成本下降 10 %,塑 料节省 7 % 注nts 3 塑模计算机模拟技 术正朝着与 CAD/ CAE 无缝整体集成化方向发展 ,注塑 CAD 所构造的几何模型为实现注塑模 CAE 技术提供了基本的几何拓扑信息和特征信息 ,注塑模 CAE 的目标是通过对塑料材料性能的研究和注射成型工艺过程的模拟和分析 ,为塑料制品的设计、材料选择、模具设计、注射成型工艺的制定及注射成型工艺过程的控制提供科学依据 。 现时国际上占主流地位的注射模 CAD 软件有 Pro/E、 I-DEAS、UG、 SolidWorks 等;结构分析软件有 MSC、 Analysis 等;注射过程数值分析 软件有MoldFlow 等;数控加工 软件有 MasterCAM、 Cimatron 等 .现代模具生产中采用集特种加工设备为一体的数控加工中心加工型腔零件,减少工序间的衔接环节,减少多次装夹定位造成的误差,减少经手人员的数量,质量和周期由计算机数据处理人员控制,尽可能避免人为失误,使得生产周期和成本估算的精确性大大提高,生产质量也得到保证。 目前注塑模设计方法比较多,但是最常用的设计步骤如下: ( 1)了解设计任务 ( 2)塑件的结构工艺性分析 ( 3)分型面及浇注系统的设计 ( 4)模具设计方案论证 ( 5)主要零部件的设计计算 ( 6)成型设备的校核计算 ( 7)绘制模具装配图 ( 8)绘制零件图 ( 9)编写设计计算说明书 三、 毕业设计(论文)所用的主要技术与方法: 1.基本设计思路 塑件注塑成型工艺分析:做出零件的三维造型,对塑件进行结构工艺性分析,分析塑件塑料的成型工艺性及确定注塑成型工艺参数。 注射机型号的选择:初选注射机并确定注射成型的工艺参数,注射机相关计算的校核和成型设备。 模具结构设计方案论证:分型面的选择、浇注系统的设计方案选择、成型部分及其零件设计、排溢系统设计、脱模机构的设计、冷却系统的设计,模体与支撑连接零件的结构。 nts 4 遥控器面盖模具相关结构设计的 计算,主要包括浇注系统的计算、成型零件的结构设计和计算、脱模方面的计算以及冷却系统的相关设计计算,模架的确定和标准件的选用和成型设备的校核计算。 2.拟采用的途径(研究手段) 主要采用模具 CAD/CAM/CAE 等软件来进行模具的设计,在模具设计过程中要综合考虑到模具制造工艺以及注塑成型工艺,主要包括: ( 1)根据遥控面盖技术要求进行相关的计算、分型面的设计、确定型腔和型芯、模具结构的详细设计、塑料充填过程分析等几个方面。 ( 2)利用 PRO/E 或者 UG 确定分型面,生成上下模腔和模芯,进行侧抽芯机构的设计,再进 行流道、浇口以及冷却水管的布置。 ( 3)利用 PRO/E 的 EMX4.1 来自动生成模板、标准模架及模具标准零件,并将PRO/E 生成总装图转换 .dwg 扩展名的图,再用 Autocad 编辑出正确清晰的 2D 总装图。 四、 主要参考文献与资料获得情况: 1 武良臣 ,吕宝占 互换性与技术测量 北京邮电出版社 2009 2 莫亚林,侯守明工程图学中国电力出版社 2007 3彭建生,模具设计与加工速查手册机械工业出版社 2005 4 塑料模设计手册编写组 塑料模设计手册 第二版 北京 : 机械工业出版社 ,1994 5 彭建生,秦晓刚模具技术问答机械工业出版社 2000 6 鄂大辛 ,成型工艺与模具设计北京理工大学出版社 2007 7 马金骏 , 塑料模具设计 北京:中国科学出版社, 1985 nts 5 五、 毕业设计(论文)进度安排(按周说明) 第一周,收集资料 第二周,进行部分数据计算并撰写论文大纲 第三周,撰写毕业设计论文 第四周,运用 AutoCAD 设计部分零件图与装配图 六、 指导教师审批意见: 指导教师: (签名) 年 月 日 ntsDOI 10.1007/s00170-004-2374-2ORIGINAL ARTICLEInt J Adv Manuf Technol (2006) 28: 370378C.L. Li K.M. Yu Y.H. LeeAutomatic datum dimensioning for plastic injection mould designand manufacturingReceived: 7 May 2004 / Accepted: 10 August 2004 / Published online: 20 April 2005 Springer-Verlag London Limited 2005Abstract Datum dimensioning (or ordinate dimensioning) tech-nique is very popular in plastic injection mould drawings wherethe location dimensions of a large number of hole features mustbe specified in the drawings of the mould plates. Although com-mercial CAD/CAM systems provide semi-automatic tools to as-sist the designer in the dimensioning process, it is still a verytedious process, as the user has to specify the location of each di-mension tag. This paper reports a completely automatic methodwhere optimal placements of the dimension tags can be deter-mined. The method employs dynamic programming technique tooptimize the dimension process with respect to several criteriathat can be selected by the user. The method has been imple-mented and incorporated into a commercial CAD/CAM system,and examples are given to illustrate the important features of theprogram.Keywords Automatic dimensioning Datum dimensioning Dynamic programming Optimal dimensioning Ordinate dimensioning1 IntroductionCAD/CAM systems are now widely used in the plastic injec-tion mould-making industry. Many companies are using a solidmodeling system to design the injection mould. They use a CADsystem to model not only the core and cavity inserts of the mould(which are the most important components that form the im-pression of the mould), but also all other components in theC.L. Li (a117) Y. H . L e eDepartment of Manufacturing Engineering and Engineering Management,City University of Hong Kong,Tat Chee Avenue, Kowloon, Hong KongE-mail: meclli.hkTel.: +8-52-27888432Fax: +8-52-27888423K.M. YuDepartment of Industrial and Systems Engineering,The Hong Kong Polytechnic Universityentire mould assembly. With the advance in Internet technologyand the recent development of Internet-enabled CAD, the de-sign information of the injection mould can be communicatedelectronically between the product engineer (who designs theplastic part) and the tooling engineer (who designs the injectionmould), even though they may be located in different geographicregions of the world. While flow of design information betweenproduct design and tooling design are communicated effectivelythrough an electronic means, the communication of manufac-turing information to the shop floor is done by both electronicand traditional techniques. Computer Numerical Control (CNC)machining toolpath or inspection instructions can be generateddirectly from the CAD/CAM system and downloaded througha network to the CNC controller for the machining or inspectionoperations. However, set-up instructions for a particular machin-ing job may be specified in an engineering drawing. Moreover,not all machining tasks are done using CNC machine tools. Sometraditional machining processes, such as drilling and grinding,are done using conventional machine tools because of cost con-sideration. Conventional engineering drawings are thus still play-ing an important role in communicating engineering informationto the shop floor. The orthographic projections in engineeringdrawings can be generated automatically from the CAD modelof the parts. Automatic tools for dimensioning of the parts arealso provided by many commercial CAD systems. However, aspointed out by Chen et al. 1, those automatic dimensioningtools are not able to generate dimensions according to the draw-ing standards and engineering practices adopted in the shop floor.In the specific application of injection mould design, datumdimensioning (or ordinate dimensioning) of hole features areused extensively. Figure 1 shows a typical detail drawing that canbe found on the shop floor of a mould making company. Shownin the figure are the hole features and datum dimensions whichare used to specify the locations of the holes. It can be seenthat the dimensions are very crowded and it is a tedious task tomanually adjust the placement of all the datum dimensions. Thequality of the final fully-dimensioned drawing thus depends verymuch on the experience of the draftsman who produces the draw-ing. The purpose of this research is to develop a tool that cannts371Fig. 1. Use of datum dimensioning in a drawing of a plastic injection mould partgenerate the datum dimensions automatically from a given partof the injection mould. The resulting dimensions must satisfytwo obvious requirements: first, that no two dimension tags mayoverlap; and second, that a dimension tag be placed as close aspossible to the feature being dimensioned. The key issue in thisresearch is to develop a method that can optimize the placementof the datum dimensions.2 Related workWhile dimensioning and tolerancing are two closely related pro-cesses in specifying the size and location information of thefeatures in a mechanical part or an assembly, most of the pastresearch work has focused on tolerancing. The major researchissues in tolerancing are representation, analysis and synthesis.Tolerancing representation is concerned with the incorporationof tolerance information into a product modeling scheme. Exam-ples include the solid offset approach developed by Requicha 2,the feasibility space approach proposed by Turner 3, and theTTRS by Desrochers and Clement 4. More detailed review canbe found in Roy et al. 5 and Yu et al. 6. Tolerance analy-sis aims to determine the combined effect of part tolerances onthe assembly tolerance. It can be used to verify the functional-ity of a design given known or assumed variations of individualpart dimensions. Examples of technique in tolerance analysis in-clude Monte Carlo simulation 7 and the direct linearizationmethod 8. The main objective of tolerance synthesis or tol-erance allocation is to allocate part tolerances based on givenfunctional requirements of the assembly. Recently, Islam 9 re-ported a concurrent engineering approach to address this prob-lem. Based on a systemic analysis of the functional requirementsfrom different customer requirements and the technical require-ments from engineering considerations, a methodology for ex-tracting dimensional requirements is developed. A software pro-totype FDT 10 is also developed for supporting the implemen-tation of the methodology. FDT provides tools for representingthe functional requirements, dimensions, tolerances and processcapability into a functional requirement/dimensions matrix. Thefunctional equations captured in the matrix are then separatedinto groups, and each group is then solved using a solution strat-egy specific to the functional requirement and the tolerancingproblem involved. More detailed review in tolerance analysis andsynthesis can be found in Roy et al. 5, Ngoi and Ong 11 andHong and Chang 12.Several methods have been developed for generating dimen-sions automatically from the CAD model of a part. Yuen etal. 13 reported an early attempt in automatic dimensioning ofparts represented in Constructive Solid Geometry (CSG) solidmodeling technique. Points from planar faces and axes of cylin-ders are extracted from the solid model. The coordinates of thepoints are arranged in a tree structure to generate linear dimen-sions in the three principal directions. A simple technique fordiametric and radial dimensions was also reported. Other earlyworks in automatic dimensioning have been summarized by Yuet al. 6. Recently, Chen et al. 1, 14 reported a more in-depthstudy of automatic dimensioning. Their method analyzed di-mension redundancy, determined dimensioning schemes that arespecific to feature patterns, selected appropriate views for spec-ifying the dimension, and determined the appropriate locationof the dimension using an expert system approach 15. The ex-pert system analyses the geometry and topology of the featureto be dimensioned, and determined a position for placing thedimension based on a set of rules that is relevant to the cur-rent dimensioning feature. With the placement of one dimension,a forbidden region is constructed so that all subsequent dimen-sions will not be placed in this region. This avoids overlap orintersection between two dimensions.nts372A limitation in the existing approach for the placement ofthe dimension is due to the sequential nature of the method.For example, in Chens 1, 14 method the features to be dimen-sioned are prioritized, and the positions of the dimensions aredetermined one after another. The approach is not appropriatefor determining the placement of datum dimensions, especiallywhen the dimensions are very crowded, as in the case of injectionmould plates. This is because the placement of one datum di-mension may have an effect on the placement of another dimen-sion that may be located far away from the current dimension.This paper reports our work in solving the placement problemin datum dimensioning. The major contribution of our work isthe development of a new method that determines the optimalplacement of each datum dimension. Using the dynamic pro-gramming approach to optimization, this new method overcomesthe limitation of the sequential approach used in the existingmethod.3 Basic characteristic of datum dimensioningIn datum dimensioning, the location of a feature is specifiedby the horizontal and vertical distances from the reference lo-cation of the feature and a reference datum. The default formof datum dimension is shown in Fig. 2a. When the vertical dis-tance between two features to be dimensioned is less than thedimension tag size (i.e. the sum of the dimension text heightand the minimum spacing between adjacent dimension texts),Fig. 2. Basic characteristics of datum dimensioningthe alternative forms shown in Fig. 2b are required.1The di-mension tags are shifted upward or downward from the defaultlocation to prevent overlap. As shown in Fig. 2c, the shiftingof the dimension tag is achieved by breaking the single exten-sion line of the dimension into three segments: two horizontalsegments which are connected by one inclined segment. The ex-tent to which a dimension tag can be shifted is governed bythree parameters: (i) the dogleg angle , which is the angle be-tween the inclined segment and the horizontal segments of thedimension line; (ii) the margin distance m between the dimen-sion text and the part boundary; and (iii) the location (xfi, yfi) ofthe feature fi. The two extreme positions (i.e. the uppermost pos-ition ymaxiand lowermost position ymini) of the dimension tag aregiven by:ymaxi= yfi+(xfi+m) tan ymini= yfi(xfi+m) tan (1)4 Automatic datum dimensionThe objective of the automatic datum dimensioning system is tofind an optimal position for each datum dimension. The processconsists of two phases of operation: the preparation phase andthe optimization phase. In the preparation phase, major param-eters that facilitate the optimization process will be established.Feasibility for placing the dimensions for all the features usingthe given dogleg angle, margin offset and dimension tag sizewill also be tested. In the optimization phase, a dynamic pro-gramming approach is used. The dimension tag locations can beoptimized with respect to different sets of criteria, including theminimization of the shift of every dimension from their defaultlocations, or maximization of the use of the default form as muchas possible.4.1 The preparation phaseThe features to be dimensioned are first grouped into one ormore feature sets. For each feature in a feature set, there existat least one other feature in the set such that the vertical dis-tance between them is less than the dimension tag size. In otherwords, the features in a feature set cannot be dimensioned usingthe default form exclusively without overlap between adjacentdimension tags. Instead, at most one feature can use the de-fault form while all others require the use of the alternativeform. The set of dimension tags associated with a feature setis called a dimension block. The configuration of a dimensionblock refers to the forms and locations of each datum dimen-sion within the dimension block. For each position of a dimen-sion block, its configuration is uniquely defined. Figure 3 showstwo feature sets and their dimension blocks at two differentconfigurations.1To simplify the explanation of the technique, only vertical dimensionsplaced on the left hand side of the part are discussed. The method developedis general and can be applied to the other sides of the part.nts373Fig. 3. Feature sets and different con-figurations of dimension blocksDefinition 1: Validity of a configuration. A configuration of a di-mension block is valid if there is no overlap between any dimen-sion tags in the dimension block, and each dimension tag lieswithin its extreme positions.The configurations of the dimension blocks shown in Fig. 3bare valid. Two examples of invalid configuration are shown inFig. 4. The configuration shown in Fig. 4a is invalid because twoof the dimension tags overlap. For the configuration shown inFig. 4b, the extension line of the dimension tag 14.00 is at itslowermost position, while the required position for the dimen-sion tag is beyond this lowermost position.Fig. 4. Invalid configurations of a dimension blockFig. 5. Dimension block at extreme configurationsDefinition 2: Extreme configurations. There are two extremeconfigurations: the uppermost and lowermost configurations.A dimension block is at its uppermost (lowermost) configurationif the dimension block is valid and is at a position such that anyother higher (lower) position results in an invalid configuration.The extreme configurations of a dimension block diare denotedby Ymaxiand Ymini.Figure 5a shows a dimension block at its uppermost config-uration. It cannot move further upward because the dimensiontag 29.5 is at its highest position. Figure 5b shows a dimen-sion block at its lowermost configuration. It cannot move fur-nts374ther downward because the dimension tag 14.00 is at its lowestposition.The extreme configurations of a dimension block are the twoimportant parameters that will be used by the optimization pro-cess. They are also useful in testing whether it is feasible todimension all the features without any overlap between the di-mension tags. It is observed that two properties are useful indeveloping a method to determine the extreme configurations.Property 1:. For a dimension block at its uppermost (lowermost)configuration, at least one of its dimension tags is at its upper-most (lowermost) position.Property 2:. A dimension block has a valid configuration if andonly if it has extreme configurations.Property 1 can be proved by contradiction. Assume that a di-mension block is at its uppermost (lowermost) configuration, andnone of its dimension tags are at their uppermost (lowermost)positions. Since all the dimension tags are not at their uppermost(lowermost) positions, they can all be moved upwards (down-wards) simultaneously by the same amount until any one of themreaches its uppermost (lowermost) position. As all dimensiontags are moved simultaneously by the same amount, the dimen-sion tags do not overlap, and thus the resulting configurationis still valid and at a higher (lower) position than its originalconfiguration. This violates the assumption that the original con-figuration is the uppermost (lowermost) configuration.Property 2 can be verified directly. Given a valid configura-tion, the dimension block is moved upward (downward) until oneor more of its dimension tags reach its uppermost (lowermost)position. Since all the dimension tags are moved simultaneouslyby the same amount, overlap does not occur. Moreover, the di-mension block cannot be moved upwards (downwards) any fur-ther without invalidating the configuration because at least oneof its dimension tags is at its uppermost (lowermost) position.According to Definition 2, the resulting configuration is thus theuppermost (lowermost) configuration. On the other hand, it is ob-vious that if a dimension block has extreme configurations, thenit has a valid configuration because the extreme configurationsare, by definition, valid.Property 1 indicates that the extreme configurations of a di-mension block can be obtained by investigating the extreme pos-itions of the dimension tags in the block. The configuration ofa dimension block can be specified by yi, i = 1, 2,.,n,whereyiis the location of the dimension tag of the ith feature in thefeature set fi.Thisassumesthat fi are arranged in ascend-ing order by their vertical positions (i.e. yfi yfjif i j). Then,to avoid overlap between dimension tags, the location of the ithdimension tag is given by:yi= (i 1)SIZE + y1; n i 2(2)where SIZE is the dimension tag size and y1is the location of thedimension tag for the first feature ( f1)oftheset.y1is also usedas the reference location of the dimension block.For a configuration to be valid, all dimension tags must liebelow its own uppermost position given by Eq. 1. That is:ymaxi yiand thusymaxi (i 1)SIZE + y1The above relationship must be satisfied by all i. Therefore, thehighest allowable value for y1is given by:Miniymaxi(i 1)SIZE (3)with the y1value given by Eq. 2, and one or more yiequal toymaxi. All other yiare less than its ymaxi. Since no other largervalue of y1results in a configuration that satisfies ymaxi yi,theresulting configuratio
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