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固定式管架注塑模具设计及分析【全套CAD图纸和论文】【原创注塑资料】

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固定式 注塑 模具设计 分析 全套 cad 图纸 论文 原创 资料
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摘 要

本文主要介绍了三向侧抽芯的固定式管架注塑模的结构设计，包括塑件工艺的分析，型腔排列的确定，分型面的确定，浇注系统、推出机构和冷却系统的设计，模架的选择，注塑机的选用，以及最重要的成型零部件的设计，侧向抽芯的设计等。根据塑件结构的复杂程度，同时考虑生产效率和批量的要求，采用一模两腔、侧浇口形式的单分型面注射模结构以及斜导柱侧抽机构。在此基础上，借助CAD/CAE技术，利用有限元分析软件完成注射成型模拟，以分析结果辅助该塑件一模多腔的浇注系统设计；借助UG三维软件对整套模具进行模拟装配。


关键词：斜导柱侧抽芯；注射成型；模具设计；CAD/CAE 



ABSTRACT

This paper describes a fixed direction core drawn tube frame injection mold structure design, including the analysis of the process of plastic parts, cavity arranged to determine, the determination of the parting surface, gating system, the introduction of agencies and cooling system design,formwork selection, the selection of the injection molding machine, and most importantly, molded parts of the design, the side core design.According to the complexity of the structure of the plastic parts, taking into account the requirements of the production efficiency and volume, the use of a mold cavity, the side gate in the form of a single parting surface injection mold structure and Bevel Pillar side of the pumping mechanism. On this basis, with the help of CAD / CAE technology, complete injection molding simulation using finite element analysis software to analyze the results assisted the plastic parts of a multi-cavity mold gating system design; With UG three-dimensional software to simulate the entire mold assembly.


Key Words：Bevel Pillar side core；Injection molding；Mold design；CAD/CAE


目 录

1  引 言 1

1.1 概述 1

2 塑件的工艺分析 2

2.1 塑件材料性能分析  材料：PVC-U 2

2.2 塑件结构特征及用途分析 2

2.3 综合分析塑件结构 3

2.4 塑件的Moldflow分析 3

3 模具总体结构设计 6

3.1 确定型腔数目以及排列形式 6

3.2 确定分型面 6

3.3 确定浇注系统结构 8

3.3.1 确定最佳浇口形式及浇口位置、数量 8

3.3.2 流道布置 8

3.4 确定推出机构 9

3.4.1 脱模推出机构的设计原则 9

3.4.2 塑件推出的基本方式 9

3.5 确定导向机构 9

3.6 确定温度调节系统 10

3.6.1加热系统 10

3.6.2冷却系统 10

3.7 确定排气系统 11

3.8 确定模具支撑零件结构 11

4 模具零件结构尺寸设计 12

4.1 初选设备 12

4.1.1 计算塑件体积和重量 12

4.1.2 根据容量初选注射机 12

4.1.3 根据容量初选注射机 12

4.1.4注射机主要参数 12

4.1.5 校核注射机的有关参数 13

4.2 设计浇注系统 13

4.2.1 主流道设计 13

4.2.2 设计计算分流道尺寸 13

4.2.3 设计计算浇口尺寸 14

4.3 设计推出机构 14

4.3.1 推杆推出机构 14

4.3.2 确定推杆位置、形状、尺寸及数量 14

4.3.3 推杆安装、固定及配合 14

4.3.4 推出机构复位方式的确定 14

4.4 动、定模导向机构设计 14

4.5 成型零件工作尺寸的计算 15

4.6 侧向分型抽芯机构的设计 16

4.6.1 抽芯距与抽拔力的计算 16

4.6.2 斜导柱设计 17

4.6.3 侧滑块与导滑槽设计 18

4.6.4 楔紧块的设计 18

4.7 模架的确定和标准件的选用 18

5 注塑机的校核 21

5.1 注射容量的校核 21

5.2 锁模力校核及注射压力校核 21

5.3 成型面积的校核计算 21

5.4 注射压力的校核计算 21

5.5 模高的校核 22

5.6 模具最大尺寸的校核 22

5.7 开模行程的校核 22

结 论 23

致 谢 24

参考文献 25


1  引 言

1.1 概述

塑料是20世纪才发展起来的新材料，目前世界上塑料的体积产量已经赶上和超过了钢材，成为当前人类使用的一大类材料。我国的塑料工业正在飞速发展，塑料制品的应用已深入到国民经济的各个部门。塑料制品的普及应用事毕要求塑料模具得到快速发展。

近年来，我国塑料模具已得到快速发展，主要有如下成果：大型塑料模具已能生产单套重量达到50t 以上的注塑模，精密塑料模具的精度已达到2um，制件精度很高的小模数齿轮模具及达到高光学要求的车灯模具等也已能生产，多腔塑料模具已能生产一模7800 腔的塑封模；高速模具方面已能生产挤出速度达6m/min 以上的高速塑料异型材挤出模具及主型材双腔共挤、双色共挤、软硬共挤、后共挤、再生料共挤出和低发泡钢塑共挤等各种模具。从生产手段上， 模具企业设备数控化率已有较大提高， CAD/CAE/CAM技术的应用面已大为扩展，高速加工及RP/RT 等先进技术的采用已越来越多， 模具标准件使用覆盖率及模具商品化率都已有较大幅度的提高， 热流道模具的比例也有较大提高，内热式或外热式热流道装置得以采用，少数单位采用了具有世界先进水平的高难度针阀式热流道模具，完全消除了制件的浇口痕迹。气体辅助注射技术已成功得到应用。

同时，塑料模具对设计人员的先进设计思维，创新意识的培养也越来越重要，所以掌握叫多的加工技术以及加工工艺是非常必要的。塑料模具的毕业设计在其中发挥了重要的作用，让作为学习塑料模具的学生得到了实践，体会到设计塑料模具的过程，也更加巩固了我们的理论基础与专业知识。了解模具行业，了解塑料模具产品从设计到生产的详细过程。

虽然，塑料模具在国内发展较为迅速，但由于我国模具行业本身起步较晚，相比国外发达国家的模具设计制造水平，我国还存在很大问题，比如说发展不平衡， 产品总体水平较低。工艺装备落后， 组织协调能力差。大多数企业开发能力弱， 创新能力明显不足。供需矛盾一时还难以解决。体制和人才问题的解决尚待时日。

为此，学习、研究塑料模具有其实在意义。通过本次毕业设计，对塑料模具相关知识进行进一步的巩固和学习。通过分析塑料分型面、浇口位置，推件板推出机构等一系列问题，对模具结构进行设计，并结合相关软件的应用，实现了优化模具设计。



2 塑件的工艺分析

2.1 塑件材料性能分析  材料：PVC-U

PVC塑料一般可分为硬质与软质两大类。硬制品中可不加增塑剂，有时加入冲击改性剂以改善其韧性，软制品需加入大量增塑剂。两者均加着色剂、稳定剂、润滑剂等塑料助剂。 结合本次研究的塑件，应选用硬质PVC（PVC-U）。由于塑件是大批量生产，塑件结构带有侧抽芯，所以选择注射成型。


内容简介：
毕 业 设计论文 指 导 记 录 表学院 专业姓名 学号 指导教师计划完成情况日期 写作环节 完成情况及质量选题文献综述外文翻译开题报告初稿二稿定稿答疑及指导记录日期 内 容日期 内 容注：指导教师答疑及指导记录次数不得少于 6 次学生签字 指导教师签字 毕业设计（论文）教师教学质量评价表（学生填写）指导教师姓名 所属学院 评价等级评价项目(分值) 序号 评 价 内 容标准分 优秀 良好 中等 及格 不及 格评价得分1 教师重视毕业设计（论文）指导工作，责任心强，能够经常与学生联系。 10 教学态度（20 分） 2 教师准备工作认真，指导耐心细致，注重言传身教，为人师表。 10 3 及时使学生了解毕业设计（论文）各环节的规范要求。 5 4 毕业设计（论文）题目符合专业培养目标，具有可行性和应用性。 5 5 指导学生合理制定毕业设计（论文）进度计划，并能定期检查学生论文进度情况。 5 6指导教师对毕业设计（论文）的选题、开题报告及设计（论文写作）等各环节和阶段都能认真指导，及时提出修改意见。10 教学内容（30 分）7 指导教师能够认真审阅开题报告和毕业设计（论文） ，书写评阅意见，严格把关。 5 8 因材施教，指导方法得当，学生能够较好的领会教师的指导意见。 10 教学方法及手段（20 分） 9 注重启发学生思维，培养学生的创新意识和分析与解决问题的能力。 10 10 对综合运用专业知识的作用。 5 11 对提高计算机应用能力或新技术应用能力的作用。 5 12 对提高文献资料的搜集和处理方面的作用。 5 教学效果（20 分）13 对提高分析问题和解决问题能力的作用。 5 总体评价（10 分） 14对教师毕业设计（论文）指导工作的总体评价。 10 总 得 分 你对毕业论文（要求）有何要求和建议：填写日期 年 月 日ORIGINAL ARTICLEThermalstructural analysis of bi-metallic conformal coolingfor injection mouldsA. B. M. Saifullah & S. H. Masood & I. SbarskiReceived: 28 July 2011 /Accepted: 21 November 2011 /Published online: 9 December 2011#Springer-Verlag London Limited 2011Abstract In injection moulding process, cooling timegreatly affects the total cycle time. As thermal conductivityis one of the main factors for conductive heat transfer incooling phase of IMP, a cooling channel made by higherthermal conductive material will allow faster extraction ofheat from the molten plastic materials, thus resultingin shorter cycle time and higher productivity. The mainobjective of this paper is to investigate bi-metallic con-formal cooling channel design with high thermal con-ductive copper tube insert for injection moulds.Thermalstructural finite element analysis has been carriedout with ANSYS workbench simulation software for amould with bi-metallic conformal cooling channels andthe performance is compared with a mould with conven-tional straight cooling channels for an industrial plasticpart. Experimental verification has been carried out forthe two moulds using two different types of plastics,polypropylene (PP) and acrylonitrile butadiene styrene,in a mini injection moulding machine. Simulation andexperimental results show that bi-metallic conformalcooling channel design gives better cycle time, whichultimately increases production rate as well as fatiguelife of the mould.Keywords Bi-metallic conformal cooling.Injectionmoulding.Copper tube.Cooling time.Finite elementanalysis1 IntroductionInjection moulding is one of the most important manu-facturing processes available in plastic manufacturingindustries. With the broader use of plastics parts forconsumer products, the injection moulding process(IMP) has been renowned as the most widely used massmanufacturing process. The moulding cycle of IMPconsists of mould closing, injection/holding, cooling,mould opening and product removal stages. In anyinjection moulding cycle, cooling stage is the dominantcomponent, and generally accounts for 50% to 70% ofthe moulding cycle time 1. Thus the production rate isgenerally affected by the cooling channel design in themould. In a typical mould, cooling channel design is themost complex as well as vital factor for economical perfor-mance of injection moulding. The cooling system of aninjection mould can be divided mainly into three categories,cavity cooling, core cooling and sometime cooling of thestripper plate. There are many types of cooling channels thathave been invented by mould designers and researcherssince the invention of injection moulding. Among all typesof cooling channels, straight-drilled cooling channel (SDCC)system is the cheapest and the most popular cooling methodthe injection moulding companies are using. Figure 1 showsthe cross-sectional view of an injection mould with thelocation of SDCC around a plastic part cavity.SDCCs are also used as baffles and bubblers for coolingof cores in the injection moulds. These cooling channels arealso machined using drilling or boring 2, 3. They have astraight flow path and a circular cross-section. Baffles areused for cooling of cores with highly convex geometry 4.In baffle design, holes are first bored to the rear face of thecore, and the lower end of each hole is plugged. The boringsare then interconnected by another hole drilled from a sideA. B. M. Saifullah:S. H. Masood (*):I. SbarskiIndustrial Research Institute Swinburne,Faculty of Engineering and Industrial Sciences,Swinburne University of Technology,Melbourne, Australia 3122e-mail: smasood.auInt J Adv Manuf Technol (2012) 62:123133DOI 10.1007/s00170-011-3805-5face. To ensure that the coolant flows into each hole,blades are fitted in each hole and act as baffles to divertwater to the top of each hole. To achieve more efficientcooling, twisted baffle are applied in practice. Bubbler isanotherpopularmethod used in the core cooling. Bubblersare similar to baffles, but instead of flowing from oneside to the other, the incoming coolant passes through atube fitted in the centre of the hole and returns to theoutlet through the passage in between the tube and thehole. But, it is more expensive 1.There has been significant improvement of coolingchannel design since the innovation of CAD/CAM/CAEand Rapid Tooling (RT) technology. Since early 1980s,mould cooling simulation provided substantial attentionwith different methods to predict the temperature distributionof the mould and part in injection moulding process 59. In1999, Jacobs 10 described the use of conformal coolingchannels in an injection mould insert. In that study, channelswere built by electroformed nickel shells, and finite elementsimulation shows that the conformal cooling channelformed by copper duct bending can increase the uniformityof mould temperature distribution. It can also decrease thecycle time and part distortion. As common injectionmoulding materials, such as steel, have not been includedin his research, the application is only restricted to copper ornickel duct bending. Xu et al.11 in 2001 applied the 3Dprinting process to fabricate injection moulds with conformalcoolingchannelsinside.ChaandPark12 in 2007 describedsome conformal cooling methods, with direct metal lasersintering and spray-formed tooling process. However, theincrease in complexity of part geometries hinders therealization of conformal cooling layout fabrication insome RT processes. Therefore, it is worthwhile to investigatefurther other effective approaches in order to obtain bettercooling performances. One such approach is to use materialswith higher thermal conductivity in injection moulds. Copperis a well-known material with higher thermal conductivitythan steel while its strength is generally lower than steel.Attempts have been made by some researchers to use copperorhighstrengthcopperalloysindiestoallowfasterextractionof heat to reduce cycle time. Kelly et al. 13 in 2011 haveinvestigated the performance of high strength copperalloy mould tool materials in injection moulding withregard to cycle time, part quality and energy consumption incomparison with tool steel. They concluded that copper alloytoolingcanachievesignificantreductionincycletimewithoutaffecting process or part quality. Beal et al. 14 in 2007 haveused the concept of functionally graded materials to developtooling inserts made of copper and steel using selective lasermelting technique. They observed that as copper was addedto tool steel, it provided more efficient heat transfer but ithad less capacity to absorb steel.This research work presents a novel cooling system designinvolving bi-metallic cooling channels in injection moulds,with high thermal conductive copper tube insert (CTI)used to replace conventional straight cooling channel(CSCC). It is expected that a copper tube insert in thechannel will further enhance heat transfer process duringcooling time of injection moulding. Bi-metallic coolingwith CTI can also be used for baffles and bubblers, but itmay be more suitable for plastic parts that do not havecurved surface other than round or fillet, and as a resultsuch cooling channel will maintain equidistance from thecavity surface asshown bydistance x,inFig.1. According toFouriers law of conduction of heat transfer, the distance thatheat is conducting through is inversely proportional to thetotal conduction of heat transfer energy. As a result, uniformheat transfer will take place in the moulding process. Inthis paper, the performance of bi-metallic straight coolingchannel (BSCC) and bi-metallic conformal cooling channel(BCCC), with two different thicknesses of CTI, have beeninvestigatedfor acavitymouldandcoremouldwithbubblers,through thermalstructural finite element analysis, supportedby experimental verification.2 Design of bi-metallic cooling channelsThe part chosen for this study is an injection mouldedplastic canister (0.5 L) made of polypropylene (PP)thermoplastic. Actual mould for this part is of six cavitiesmould, but only single cavity type has been consideredfor this investigation. Figure 2 shows the CAD model ofthe plastic part, which has outer dimensions of 160, 120 and48 mm with wall thickness of 2 mm and the weight of thepart is 69.5 g. Note that the part has curved surfaces at thecorners.Fig. 1 Sectional view of SDCC layout in a mould cavity124 Int J Adv Manuf Technol (2012) 62:123133Figure 3 shows the cavity and core moulds for the plasticpart with CSCC including bubbler cooling in the core.Figure 4a shows the design of BSCC with CTI fitted.Figure 5a shows the design of BSCC with CTI fitted. CTIhas also been used for bubbler system of core in both cases.Two different thicknesses, 2 and 3 mm of CTI, have beenused for BSCC and BCCC. The difference between BSCCand BCCC design is that in case of BSCC, the channels arestraight with no curved corners as shown in Fig. 4b, while incase of BCCC, the channels have curved shape corners,which are conformal with the plastic part corners, and as aresult, these cooling channels maintain same distance fromsurfaces of the plastic part as shown in Fig. 5b. Table 1 givesthe names and abbreviations of five types of coolingchannels that will be used in this study. The outer dimensionsof the single cavity mould are height of 232 mm, diameter of300 mm and the inner diameter of cavity and core coolingchannels are 12 and 15 mm, respectively.3 Thermalstructural finite element analysisThermalstructural FEA of the proposed bi-metallic coolingchannel moulds has been carried out with ANSYS work-bench simulation software to demonstrate that such mouldcan extract faster heat from molten plastic material in injec-tion moulding process, as well to check the robustness andlongevity of the mould with such bi-metallic channels. Inthe analysis, the mould material was taken Stavax Supreme(SS), a stainless steel tool alloy, as recommended by a localmould manufacturer, and the cooling channel insert materialwas high thermal conductive berylliumcopper (BC) alloy,which is capable of transferring heat at a higher rate thansteel. Table 2 shows a comparison of the physical propertiesof SS and CA.ANSYS workbench simulation software is capable ofsimulating both the steady state and transient behaviourwhen subjected to different structural and heat loads. Inthis simulation, transient analysis has been used becausein injection moulding, mould experiences variable tempera-ture, pressure and forces. Automatic meshing (elementsthat are automatically created depending on the physicalstructure) with tetrahedral elements have been used. Finerelevance centre and medium smoothing has been appliedin the meshing.In the simulation process first, the transient thermalanalysis has been carried out in the mould assembly andthen thermal analysis results have been coupled withtransient structural analysis, to calculate equivalent stress(von Mises) in thermal loading conditions. In the mouldingprocess of thermoplastics, three types of heat transfertake place:conduction through mould, convection in thecooling medium and outer surface of the mould, andfinally, radiation heat transfer, which is of very negligibleamount. In this analysis, radiation heat transfer has beenneglected. For thermal analysis, conduction and convec-tion heat flux (heat energy per unit area) have been usedas a boundary condition.Conduction heat transfer energy, which is of vitalimportance in IMP, has been calculated by Eq. 1,asdescribed in 15. This equation which is suitable forsteady-state one-dimensional heat transfer process has beenderived from Fourier conduction heat transfer equation forcomposite material. Though Eq. 1 has been used to calculateconduction heat flux values as an input boundary condition,tabular values of heat flux for different timing of themoulding cycle have been used rather than constantFig. 2 CAD model of plastic canisterFig. 3 Cavity and core with conventional straight cooling channel(CSCC)Int J Adv Manuf Technol (2012) 62:123133 125values to get the transient heat transfer effect in thesimulation process.Conduction heat energy;QCTiC0TwlsksAlckcA1where,ksThermal conductivity of SSkcThermal conductivity of CTIA Cross-sectional area through heat is transferringTWInside surface temperature of CTI.TiTemperature of cavity or core surface interface withplasticlsDistance from cavity or core surface to correspondingCTI outer surfacelcThickness of CTISimilarly, Eq. 2 13 has been used to calculate convectiveheat transfer energy inside the cooling channels surface.Convective heat energy;Qh hcATWC0TC 2where,A Surface area of the cooling channels in contact withflowing fluidTwAverage temperature of the inside surface of CTITCAverage temperature of the coolanthcConvection heat transfer coefficientThe convection heat transfer coefficient hc,has beencalculatedusingEq.3, basedonDittus-Boetler16 correctionequation for forced convective heat transfer by turbulentflow in a circular pipe. These coefficients were calculatedto be 5,397 and 5,709 watt/m2C for core and cavitycooling channels respectively.hc 0:023kDRe0:8Pr0:4310,000Re120,000 and 0.7Pr 120where,hcHeat transfer coefficientk Thermal conductivity of coolant (water)D Diameter of the cooling channelsRe Reynolds NumberPr Prandtl NumberOther thermal boundary conditions are the natural con-vection on the side surface of the cavity mould which isexposed to the air and the channel around the sprue bush, inwhich, air has been passed for additional cooling of spruebush. This additional cooling of sprue bush is necessary as itcarries the hot molten plastic material for injection into themould cavity. Convection co efficient has been used asboundary conditions in these cases, and the values for theseare 5106Watt/mm2C and 6.083103Watt/mm2C asrecorded by local mould manufacturer. So altogether, eleveninput boundary conditions have been used for thermalFig. 4 a Bi-metallic straightcooling channel (BSCC)with copper tube insert (CTI)in core and cavity; b sectionaltop view of cavity mould,showing the orientation ofBSCC in the mouldFig. 5 a Bi-metallic conformalcooling channel (BCCC) withcopper tube insert (CTI) in coreand cavity; b sectional top viewof cavity mould, showing theorientation of BCCC in themould126 Int J Adv Manuf Technol (2012) 62:123133analysis, seven for conduction heat flux (heat flux for SS, RSand BS surfaces for both core and cavity side, and SHSsurface shown in Fig. 6), two for convection heat flux (heatflux for CoCs and CaCS surfaces shown in Fig. 6) and twofor convection coefficient.Figure 6 shows the cross section of the entire mouldassembly, showing different interface surfaces. In order tocalculate different heat fluxes using Eqs. 1 and 2,itisnecessary to know the variable temperature, Tw, Tiand TCat these different surfaces (the interface of plastic andmould cavity, at the interface of cooling channel innersurface and cooling medium), as shown in Fig. 6. To getthese temperature values, a complete injection mouldingflow simulation (cool+flow+pack+warp analysis) has beencarried out separately with Autodesk Moldflow Insight(AMI) software. Flow simulation with AMI, also gives thevalues of the variable injection pressure at different surfaces(surfaces that plastic materials are in contact during injectionmoulding process as shown in Fig. 6) and clamping forces,which will be used as boundary conditions for thermalstructural analysis. For plastic flow analysis with AMI, dualdomain mesh has been used with 9,228 elements, mould andmelt temperature were 50C and 250C respectively, totalcycle time was 20 s (9, 8 and 3 s for injection/hold on,cooling and ejection, respectively), plastic and mouldmaterials were PP and SS stainless tool steel correspond-ingly. Pure water with a temperature of 10C has beenused as coolant. Table 3 shows the temperature values atsix different times (from 0 to 17 s) of the moulding cycle atdifferent interface surfaces of the assembly mould (asshowninFig.6) for the case of CSCC, from AMI flowsimulation. Similar values of temperature have beenobtained for other four cases of bi-metallic cooling channelcase. Values indicate that all four main interfaces cool downgradually during the moulding cycle. Average values ofthe temperature for each surface were taken for heat fluxcalculation using Eqs. 1 and 2. For a particular surface,same temperature values have been taken for core and cavityside because there is not much difference between them.Table 4 shows the heat flux values calculated at differenttimes (0 to 17 s) and used as boundary conditions forvarious interface surfaces for CSCC case. Similar valuesof heat flux have been calculated for other four cases ofbi-metallic cooling channel.Result of transient thermal analysis, which includes thetemperature response over the mould assembly for entirecycle, has been imported in the interface of transientstructural analysis to perform thermalstructural FEAanalysis. For structural analysis, four types of boundaryconditionshavebeenused,whicharefixedsupport(bottomofthe mould), injection pressure, clamping force (top of themould)andthetemperaturefromthethermalanalysis.Table5gives the values of variable clamping forces and injectionpressure for different surfaces for entire cycle, recordedfrom AMI flow simulation.4 Results and DiscussionFrom transient thermal analysis, temperature distributionhas been found for entire mould. Figures 7a, 8 and 9 showthe comparative temperature distribution for all coolingchannel moulds. In case of CSCC, after 1 cycle (20 s),temperature of the mould ranges from a minimum 13C tomaximum 74C (Fig.7a), whereas, for BSCC and BCCCCTI, average minimum to maximum temperature rangesTable 1 Different coolingchannels and their abbreviationsType of cooling channel De
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