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1 Shiou FJ, Chen CH (2003) Determination of optimal ball-burnishing parameters for plastic injection molding steel. Int J Adv Manuf Techno Chao-Chang A. Chen Wen-Tu L Based on the injection mold steel grinding and Based on the injection mold steel grinding and polishing processes automated surfacepolishing processes automated surface treatmenttreatment 1 Introduction Plastics are important engineering materials due to their specific characteristics, such as corrosion resistance, resistance to chemicals, low density, and ease of manufacture, and have increasingly replaced metallic components in industrial applications. Injection molding is one of the important forming processes for plastic products. The surface finish quality of the plastic injection mold is an essential requirement due to its direct effects on the appearance of the plastic product. Finishing processes such as grinding, polishing and lapping are commonly used to improve the surface finish. The mounted grinding tools (wheels) have been widely used in conventional mold and die finishing industries. The 2 geometric model of mounted grinding tools for automated surface finishing processes was introduced in. A finishing process mode of spherical grinding tools for automated surface finishing systems was developed in. Grinding speed, depth of cut, feed rate, and wheel properties such as abrasive material and abrasive grain size, are the dominant parameters for the spherical grinding process, as shown in Fig. 1. The optimal spherical grinding parameters for the injection mold steel have not yet been investigated based in the literature. Fig.1. Schematic diagram of the spherical grinding process In recent years, some research has been carried out in determining the optimal parameters of the ball burnishing process (Fig. 2). For instance, it has been found that plastic deformation on the workpiece surface can be reduced by using a tungsten carbide ball or a roller, thus improving the surface roughness, surface hardness, and fatigue resistance. The burnishing process is accomplished by machining centers and lathes. The main burnishing parameters having significant effects on the surface 3 roughness are ball or roller material, burnishing force, feed rate, burnishing speed, lubrication, and number of burnishing passes, among others. The optimal surface burnishing parameters for the plastic injection mold steel PDS5 were a combination of grease lubricant, the tungsten carbide ball, a burnishing speed of 200 mm/min, a burnishing force of 300 N, and a feed of 40 m. The depth of penetration of the burnished surface using the optimal ball burnishing parameters was about 2.5 microns. The improvement of the surface roughness through burnishing process generally ranged between 40% and 90%. Fig. 2. Schematic diagram of the ball-burnishing process The aim of this study was to develop spherical grinding and ball burnishing surface finish processes of a freeform surface plastic injection mold on a machining center. The flowchart of automated surface finish using spherical grinding and ball burnishing processes is shown in Fig. 3. We began by designing and manufacturing the spherical grinding tool and its alignment device for use on a machining center. The optimal surface spherical grinding parameters were determined by utilizing a Taguchis orthogonal array method. Four factors and three corresponding levels were then chosen for the Taguchis L18 4 matrix experiment. The optimal mounted spherical grinding parameters for surface grinding were then applied to the surface finish of a freeform surface carrier. To improve the surface roughness, the ground surface was further burnished, using the optimal ball burnishing parameters. Fig. 3. Flow chart of automated surface finish using spherical grinding and ball burnishing processes 2 Design of the spherical grinding tool and its alignment device To carry out the possible spherical grinding process of a 5 freeform surface, the center of the ball grinder should coincide with the z-axis of the machining center. The mounted spherical grinding tool and its adjustment device was designed, as shown in Fig. 4. The electric grinder was mounted in a tool holder with two adjustable pivot screws. The center of the grinder ball was well aligned with the help of the conic groove of the alignment components. Having aligned the grinder ball, two adjustable pivot screws were tightened; after which, the alignment components could be removed. The deviation between the center coordinates of the ball grinder and that of the shank was about 5 m, which was measured by a CNC coordinate measuring machine. The force induced by the vibration of the machine bed is absorbed by a helical spring. The manufactured spherical grinding tool and ball-burnishing tool were mounted, as shown in Fig. 5. The spindle was locked for both the spherical grinding process and the ball burnishing process by a spindle-locking mechanism. Fig.4. Schematic illustration of the spherical grinding tool and its adjustment device 6 Fig.5. (a) Photo of the spherical grinding tool (b) Photo of the ball burnishing tool 3 Planning of the matrix experiment 3.1 Configuration of Taguchis orthogonal array The effects of several parameters can be determined efficiently by conducting matrix experiments using Taguchis orthogonal array. To match the aforementioned spherical grinding parameters, the abrasive material of the grinder ball (with the diameter of 10 mm), the feed rate, the depth of grinding, and the revolution of the electric grinder were selected as the four experimental factors (parameters) and designated as factor A to D (see Table 1) in this research. Three levels (settings) for each factor were configured to cover the range of interest, and were identified by the digits 1, 2, and 3. Three types of abrasive materials, namely silicon carbide (SiC), white aluminum oxide (Al2O3, WA), and pink aluminum oxide (Al2O3, PA), were selected and studied. Three numerical values of each factor were determined based on the pre-study results. The L18 orthogonal array was selected to conduct the matrix experiment for four 3-level factors of the spherical grinding process. 7 Table1. The experimental factors and their levels 3.2 Definition of the data analysis Engineering design problems can be divided into smaller-the better types, nominal-the-best types, larger-the-better types, signed-target types, among others 8. The signal-to-noise (S/N) ratio is used as the objective function for optimizing a product or process design. The surface roughness value of the ground surface via an adequate combination of grinding parameters should be smaller than that of the original surface. Consequently, the spherical grinding process is an example of a smaller-the-better type problem. The S/N ratio, , is defined by the following equation: =10 log10(mean square quality characteristic) =10 log10niiyn121 where: yi : observations of the quality characteristic under different noise conditions n: number of experiment After the S/N ratio from the experimental data of each L18 orthogonal array is calculated, the main effect of each factor was determined by using an analysis of variance (ANOVA) technique and an F-ratio test. The optimization strategy of the smaller-the better problem is to maximize , as defined by Eq. 1. Levels that maximize will be selected for the factors that have a significant effect on . The optimal conditions for spherical grinding can then be determined. 4 Experimental work and results The material used in this study was PDS5 tool steel (equivalent to AISI P20), which is commonly used for the molds of large plastic injection products in the field of automobile components and domestic 8 appliances. The hardness of this material is about HRC33 (HS46). One specific advantage of this material is that after machining, the mold can be directly used for further finishing processes without heat treatment due to its special pre-treatment. The specimens were designed and manufactured so that they could be mounted on a dynamometer to measure the reaction force. The PDS5 specimen was roughly machined and then mounted on the dynamometer to carry out the fine milling on a three-axis machining center made by Yang-Iron Company (type MV-3A), equipped with a FUNUC Company NC-controller (type 0M). The pre-machined surface roughness was measured, using Hommelwerke T4000 equipment, to be about 1.6 m. Figure 6 shows the experimental set-up of the spherical grinding process. A MP10 touch-trigger probe made by the Renishaw Company was also integrated with the machining center tool magazine to measure and determine the coordinated origin of the specimen to be ground. The NC codes needed for the ball-burnishing path were generated by PowerMILL CAM software. These codes can be transmitted to the CNC controller of the machining center via RS232 serial interface. Fig.6. Experimental set-up to determine the optimal spherical grinding parameters Table 2 summarizes the measured ground surface roughness 9 alue Ra and the calculated S/N ratio of each L18 orthogonal array sing Eq. 1, after having executed the 18 matrix experiments. The average S/N ratio for each level of the four actors is shown graphically in Fig. 7. Table2. Ground surface roughness of PDS5 specimen Exp. Inner array (control factors) Measured surface roughness value (Ra) Response no A B C D my1 my2 my3 S/N(dB) Mean my_ 1 1 1 1 1 0.35 0.35 0.35 9.119 0.350 2 1 2 2 2 0.37 0.36 0.38 8.634 0.370 3 1 3 3 3 0.41 0.44 0.40 7.597 0.417 4 2 1 2 3 0.63 0.65 0.64 3.876 0.640 5 2 2 3 1 0.73 0.77 0.78 2.380 0.760 6 2 3 1 2 0.45 0.42 0.39 7.530 0.420 7 3 1 3 2 0.34 0.31 0.32 9.801 0.323 8 3 2 1 3 0.27 0.25 0.28 11.471 0.267 9 3 3 2 1 0.32 0.32 0.32 9.897 0.320 10 1 1 2 2 0.35 0.39 0.40 8.390 0.380 11 1 2 3 3 0.41 0.50 0.43 6.968 0.447 12 1 3 1 1 0.40 0.39 0.42 7.883 0.403 13 2 1 1 3 0.33 0.34 0.31 9.712 0.327 14 2 2 2 1 0.48 0.50 0.47 6.312 0.483 15 2 3 3 2 0.57 0.61 0.53 4.868 0.570 16 3 1 3 1 0.59 0.55 0.54 5.030 0.560 17 3 2 1 2 0.36 0.36 0.35 8.954 0.357 18 3 3 2 3 0.57 0.53 0.53 5.293 0.543 Fig.7. Plots of control factor effects The goal in the spherical grinding process is to minimize the surface roughness value of the ground specimen by determining the optimal level of each factor. Since log is a monotone decreasing function, we should maximize the S/N ratio. Consequently, we can determine the optimal level for each factor as being the level that has the highest value of . Therefore, based on the matrix experiment, the optimal abrasive material was pink aluminum oxide; the optimal feed was 50 mm/min; the optimal depth of grinding was 20 m; and the optimal revolution was 18 000 rpm, as shown in Table 3. The optimal parameters for surface spherical grinding obtained from the Taguchis matrix experiments were applied to the surface finish of the freeform surface mold insert to evaluate the surface roughness improvement. A perfume bottle was selected as the 10 tested carrier. The CNC machining of the mold insert for the tested object was simulated with Power MILL CAM software. After fine milling, the mold insert was further ground with the optimal spherical grinding parameters obtained from the Taguchis matrix experiment. Shortly afterwards, the ground surface was burnished with the optimal ball burnishing parameters to further improve the surface roughness of the tested object (see Fig. 8). The surface roughness of the mold insert was measured with Hommelwerke T4000 equipment. The average surface roughness value Ra on a fine-milled surface of the mold insert was 2.15 m on average; that on the ground surface was 0.45 m on average; and that on burnished surface was 0.07 m on average. The surface roughness improvement of the tested object on ground surface was about (2.150.45)/2.15 = 79.1%, and that on the burnished surface was about (2.150.07)/2.15 = 96.7%. Fig.8. Fine-milled, ground and burnished mold insert of a perfume bottle 5 Conclusion In this work, the optimal parameters of automated spherical grinding and ball-burnishing surface finishing processes in a freeform surface plastic injection mold were developed successfully on a machining center. The mounted spherical grinding tool (and its alignment components) was designed and manufactured. The optimal 11 spherical grinding parameters for surface grinding were determined by conducting a Taguchi L18 matrix experiments. The optimal spherical grinding parameters for the plastic injection mold steel PDS5 were the combination of the abrasive material of pink aluminum oxide (Al2O3, PA), a feed of 50 mm/min, a depth of grinding 20 m, and a revolution of 18 000 rpm. The surface roughness Ra of the specimen can be improved from about 1.6 m to 0.35 m by using the optimal spherical grinding conditions for surface grinding. By applying the optimal surface grinding and burnishing parameters to the surface finish of the freeform surface mold insert, the surface roughness improvements were measured to be ground surface was about 79.1% in terms of ground surfaces, and about 96.7% in terms of burnished surfaces. Acknowledgement The authors are grateful to the National Science Council of the Republic of China for supporting this research with grant NSC 89-2212-E-011-059. 毕业设计(论文)开题报告题目：遥控器盒盖塑料模具设计 系 （部）： 机电信息系 专 业： 机械设计制造及其自动化 班 级： 学 生： 学 号： 指导教师： 2012 年 12 月 22 日1.毕业设计（论文）综述（题目背景、研究意义及国内外相关研究情况）11 课题名称遥控器盒盖塑料模具设计1.2 课题研究背景塑料是 20 世纪人类的重大发明，它的发明和广泛使用，在信息工业，通讯工业，航空业，兵器业，船舶业，医学领域中已成为重要材料，并发挥着越来越重要的作用。为人类的物质文明谱写了新的篇章，大大推动了人类社会的进步和繁荣。 塑料材料和塑料制品已经成为人类生活中不可缺少的原材料和用品。随着科学技术的发展，塑料成型方法不断改革和完善，对塑料工业的发展提供了强大的支持，也为现代工业提供了更多的选择空间。模具制造业是我国国民经济基础，也是关键工业。承担了工业中 60%-90%的工业零件，组件和部件的工业加工。 1.3 课题研究的意义 塑料是一种天然合成或者用天然材料改性而得到的，以高分子化合物为基体的固体材料。我国处于经济建设快速发展时期，塑料模具表面光滑，耐水性好，可塑性强，操作简单，模具可以反复使用。而遥控器在人们的生活中已经随处可见，所以完善遥控器的设计是时不我待的，美观，简洁，方便，环保已经是现代的时尚，抽拉式遥控器盒盖也将成为一个大市场，在我国相关政策的引导下，塑料模具行业也会得到更大的发展。 1.4 模具工业在国民经济中的地位 塑料制品是近年来在我国飞速发展的一类加工材料，广泛运用于国民经济的各个领域，模具是制造业的一种基本工艺装备， 它的作用是控制和限制材料 （固态或液态）的流动，使之形成所需要的形体。用模具制造零件以 其效率高，产品质量好，材料消耗低，生产成本低而广泛应用于制造 业中。 模具工业是国民经济的基础工业，是国际上公认的关键工业。模 具生产技术水平的高低是衡量一个国家产品制造水平高低的重要标 志，它在很大程度上决定着产品的质量，效益和新产品的开发能力。 振兴和发展我国的模具工业，正日益受到人们的关注。 、 模具工业既是高新技术产业的一个组成部分， 又是高新技术产业 化的重要领域。模具在机械，电子，轻工，汽车，纺织，航空，航天 等工业领域里，日益成为使用最广泛的主要工艺装备。目前世界模具市场供不应求，模具的主要出口国是美国，日本，法国，瑞士等国家。中国模具出口数量极少，但中国模具钳工技术水 平高，劳动成本低，只要配备一些先进的数控制模设备，提高模具加 工质量，缩短生产周期，沟通外贸渠道，模具出口将会有很大发展。 研究和发展模具技术，提高模具技术水平，对于促进国民经济的发展 有着特别重要的意义。 1.5 各种模具的分类和占有量 模具主要类型有：冲模，锻摸，塑料模，压铸模，粉末冶金模， 玻璃模，橡胶模，陶瓷模等。除部分冲模以外的的上述各种模具都属 于腔型模，因为他们一般都是依靠三维的模具形腔使材料成型。 (1) 冲模：冲模是对金属板材进行冲压加工获得合格产品的工具。冲 模占模具总数的 50以上。按工艺性质的不同，冲模可分为落料模， 冲孔模，切口模，切边模，弯曲模，卷边模，拉深模，校平模，翻孔 模，翻边模，缩口模，压印模，胀形模。按组合工序不同，冲模分为 单工序模，复合模，连续模。 (2) 锻模： 锻模是金属在热态或冷态下进行体积成型时所用模具的总 称。按锻压设备不同，锻模分为锤用锻模，螺旋压力机锻模，热模锻 压力锻模，平锻机用锻模，水压机用锻模，高速锤用锻模，摆动碾压 机用锻模，辊锻机用锻模，楔横轧机用锻模等。按工艺用途不同，锻 模可分为预锻模具， 挤压模具， 精锻模具， 等温模具， 超塑性模具等。 (3) 塑料模：塑料模是塑料成型的工艺装备。塑料模约占模具总数的 35，而且有继续上升的趋势。塑料模主要包括压塑模，挤塑模，注 射模，此外还有挤出成型模，泡沫塑料的发泡成型模，低发泡注射成型模，吹塑模等。 (4) 压铸模：压铸模是压力铸造工艺装备，压力铸造是使液态金属在 高温和高速下充填铸型，在高压下成型和结晶的一种特殊制造方法。 压铸模约占模具总数的 6。 (5) 粉末冶金模：粉末冶金模用于粉末成型，按成型工艺分类粉末冶 金模有：压模，精整模，复压模，热压模，粉浆浇注模，松装烧结模 等。 模具所涉及的工艺繁多，包括机械设计制造，塑料，橡胶加工，金属 材料，铸造（凝固理论） ，塑性加工，玻璃等诸多学科和行业，是一 个多学科的综合，其复杂程度显而易见。 1.6 我国模具技术的现状及发展趋势 20 世纪 80 年代开始，发达工业国家的模具工业已从机床工业中分离出来，并发展成为独立的工业部门，其产值已超过机床工业的产值。改革开放以来，我国的模具工业发展也十分迅速。近年来，每年都以 15的增长速度快速发展。许多模具企业十分重视技术发展。 加大了用于技术进步的投入力度， 将技术进步作为企业发展的重要动力。 此外，许多科研机构和大专院校也开展了模具技术的研究与开发。 模具行业的快速发展是使我国成为世界超级制造大国的重要原因。塑料机械工业的发展趋势与其他工业基本相同，今后主要朝着精密，高质，高性能，节材，低噪与可持续发展的方向发展。其发展的核心和本质上精密技术和高深技术的发展，它的发展驱动力是国民经济对塑料制品在产量上，质量上合品质上的增长需求。产品与技术的发展趋势主要有微型化与大型规格装备的开发，个性化与规模经营的相辅相成，自动化与智能化。1.7 国外模具的发展 国外塑料发展已经有一百多年的历史了，伦敦科学博物馆纪念塑料合成问世百年的展览取名为“可塑性”。早在 1926 年 3 月，美国塑料杂志对塑料也有这样的定义：一种物质的性质，使他成为任何想要的形状，而不像非塑料物质那样需要切凿。目前，国外在塑料以及模具方面有了以下几个注重：1，重于塑料的改性。2，增强高分子的性能。3，多种以上原材料合金。在 21 世纪，国外塑料的领域也是十分广泛：汽车工业，机械工业，电子电器工业，塑料包装工业，航空航天工业，建材工业，农业等。2.本课题研究的主要内容和拟采用的研究方案、研究方法或措施1.主要内容：塑件测绘图、模具装配图、模具零件图、说明书。本设计的基本要求如下： (1) 不少于 3000 字的文献综述； (2) 充分了解塑件结构，绘制 2 维图、3D 图，并完成基本参数的计算及注射机的选用； (3) 确定模具类型及结构，完成模具的结构草图的绘制； (4) 运用 Pro/E 或 AutoCAD 等工具软件辅助设计完成模具整体结构 ； (5) 对模具工作部分尺寸及公差进行设计计算； (6) 对模具典型零件需进行选材及热处理工艺路线分析； (7) 编制模具中典型零件的制造工艺规程卡片； (8) 对设计方案和设计结果进行经济分析和环保分析； (9) 绘制模具零件图及装配图； (10)对模具结构进行三维剖析，输出模具开合结构图； （11）编写设计说明书（所有 3D 图插入说明书中恰当位置） 。2拟定方案：（1）课题名称：遥控器盒盖塑料模具设计（2）材料选择：ABS（3）生产批量：大批量（4）精度要求：中 （5）塑料等级：4 级 方案一：遥控器盒盖的下端面为分型面，采用整体式的直浇道，侧浇口，浇口设在零件的侧面上，手动推出机构脱模，用手动侧向分型方式抽芯。此方案的优点是制造方便，但操作麻烦，生产率低，劳动强度大。方案二：遥控器盒盖的上端面为分型面，采用整体式的直浇道，点浇口，浇口设在分型面的上端面，选用卧式注射机，选用机动推出机