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压塑和压铸工艺近年，压塑工艺应用于热固性掺混料，如脲醛塑料、酚醛树脂、环氧树脂、蜜胺树脂和橡胶中。尽管有一些材料可注射成型，但采用压塑工艺仍非常普遍。压铸用材料较压塑用材料要求可塑性更软。许多热固性材料具有高抗冲级（1.0ft一lb）和良好缺口冲击强度的保持性，只有在极限压力下才会流动。 压塑 热固性材料的压塑成型的明显优点是系统简单。将材料置入一加热型腔，保压至所要求团化时间。因工艺过程简单，费用少。添加剂和增强剂无规则，并能得到较好强度。由于无浇口和流道，不浪费材料，模具几乎也不用维修。零件的统一性好，无铸口和流痕，减少了修饰成本。根据制品结构和所用的塑料应用特点，可采用全压式模具、半压式模具和闭模（可参见有关压塑模具方面的文章）。 设备：简单也是压塑设备的主要特点。两半压板结合在一起，加温，加压，将材料制成预定形状。多数压塑过程采用液压操作；也有采用气动操作的。上下两压板在压力之下在4个角柱上上下移动。根据压塑设备的大小，压力一般为201000吨。压板的大小一般为8英寸2到5英尺2. 在加料和固化以后的脱模方面存在不同自动化程度，常用最现代的液压机进行。以前的简单系统有温度控制、压力控制、停压控制和时间控制。现代设备采用更高级的微处理机控制。对于较薄的制品，在板中可用加热筒或带式加热器。对较深的制件，需要用筒形电加热器、蒸汽加热或热油系统加热。有数种用于压塑中的加热体系：用蒸汽加热模温均匀，但加热温度限在350F以下；套筒加热或其它加热（加热盘管、加热带等）比较干净，易于保养，用得比较普及；热油加热，由于加热介质循环稳定，所以加热均匀。现在又有许多新加热方法，热水加热，类似于热油加热，加热介质一水一气体燃烧连续循环，可提供更高的压塑温度。 增强改性高分子材料工业发展迅速，要求压塑工业有新改进。模塑增强塑料用两个模具：阳模（模塞）和阴模（模腔）。当模具充满增强材料时，对模的两半热模具闭合，然后加热、加压固化得到产品。相配合的模具复杂性变化很大，可用铝、塑料或钢制做。 轻质材料制做起来比较便宜，一般用于短期生产如“冷模塑”。冷模塑用室温固化树脂，但仍使用模具和压塑液压机。长期生产用硬化钢模具比较合算，对截坯口可提供较好的剪切性能和优良的光洁度。这些压塑钢模采用机械上适配的截坯口，通常面对合模区。用这种对模的金属模具，其制品表面均匀，光洁度好。闭模工艺用于压塑成型、压铸成型、注射成型及一些可冲压的增强复合材料。 一些热塑材塑料可压塑模塑，但一般还是用预掺混的热固性树脂如BMC（预制整体模塑料）、SMC（片料成型模塑料）、TMC（厚模塑料）、毡片成型等。 毡片成型有时叫湿成型复合材料，在液压机的作用下将增强材料和树脂结合在一起。经常在模中放置毡片，将树脂倾倒在加强材料上。在加压过程中树脂充满模腔时加强材料固定不动。 若制件有严重的异形或斜度，有必要进行预成型。多数毡片和预成型制州在投影面积上需要加150200磅英寸2的模压力。 预掺混料，如SMC，预浸树脂，填料、催化剂和增强料切割成一定大小队片状，再加入热的模具中（一般300400F），在10002000磅英寸2压力下模塑。 用于SMC的较新的压塑设备的总循环周期可少于一分钟（从头到尾）。已经发展了用特殊的液压装置推回压塑机中料筒，自动控制压板的水平度。 增强塑料，如SMC，用金属对模压塑光洁度好，这对制件的表面很重要。在加工时有时出现纤维状的收缩。 用内模涂层的方法可改进表面光洁度。BMC的压塑过程是最老的预掺混后的模塑过程之一。 填料（木屑、矿物料、纤维素等）的掺混混合是在叶片形的混合器中进行的。将一批料装入300400F的模具中在500磅英寸2压力下模塑。因用料廉价，所以原料成本低。不过由于在模塑过程中纤维的定向性降低了机械强度。 高速压塑，即增强热塑性塑料片材的冲压，用途广泛。玻璃毡片和聚丙烯相配合用于可冲压的塑料，其循环周期低于40秒。生坯送至对流炉中加热。加热以后，毛坯放入压塑模具中，这一过程用新的压塑机速度可达1400英寸分钟。以75英寸分钟（比SMC的压塑过程快约3倍）加压进料。根据市场的要求，有些新的可冲压塑料，表面光洁度好，并且具有可涂布性。模塑压力一般1吨英寸2。传统的压塑工艺近几年一直呈增长的趋势。在空间技术和国防方面的应用正在使这种工艺向其难点冲击。 在SMC、BMC、TMC、热塑性片材的冲压、增强材料的掺混和压塑机械方面的发展迅速增长，以适应工业的新要求。 一些先进的掺混料的压塑主要是在空间技术和国防应用方面发展迅速。工具和模具的新概念及高温（达1200F）模塑机，使石墨一碳纤维复合材料得以发展，代替了现有的金属铸件。 高温硅树脂正用作高压介质。复合材料做的片层用于压塑模中。现在，材料和生产成本已使该工艺更加适于空间技术市场，这类硅树脂也很快转向汽车领域。 压铸 在压铸工艺中，热固性树脂料加入一单独的料腔，常叫料槽，然后强制送入一个或多个闭模中进行聚合（固化）。 料道，也叫注道和流道，使物料从料槽流向模腔，进入模腔之前经过限流器或浇口。很多模腔具有单一料槽。料腔中的空气被进来的物料所置换，并通过一特别放置的排气口排出。 当物料置入料槽中时，在一紧凑的测量装置中测料量，然后预热到接近聚合温度。一次只加入足够一次的注塑量。 将预热的原料送出料槽的力再将其送往一注料器，该注料器紧接装在料槽上，以防止从活塞和料槽边之间的缝隙中漏料。通常将密封套卡进注料器以进一步防漏。 料槽、注料器、浇口、流道和模腔的表面维持可使原料迅速固化的一定温度，根据物料性质、模具的设计和制件的几何形状该温度为280380F。 在压铸物达到固化期的终点时，将该次完整的压铸物进行脱模，包括脱除浇口、流道、注道和料槽中形成固化料垫（叫做残料）。 在压铸中，物料的预热很重要。冷料流动缓慢，先进入模腔的料尚未到其终点，即可能聚合。若发生上述情况，产品质量低劣，不仅是外观，也体现于机械性能。有些例外，如一次注射量很少，或一些低粘度的物料。可用加热灯或炉子加热，但有效而常用的方法是用专为塑料模塑制做的介电加热器。 Plastic and pressure die casting process In recent years, the pressure technique used in thermosetting plastic materialmixing ,such as urea-formaldehyde plastics, phenolic resin, epoxy rsin, melamineresin and rubber. In spite of some of the material can be injection moiding, but the use of plastic pressure process is still very common. More pressure die casting material used plastic materials require more malleable soft. Many thermosetting materials with high impact level (1.0ft-1b) and good impact strength of maintaining the gap, only under ertreme pressure will flow. Thermosetting plastic molding material pressure of the obvious advantages of the system is simple. Materials will be placed in a heating cavity, the pressure required by the Mission to time. As a result of the process simple, cost less. Enhancer and additive-free rules, and be able to get a better strength. As the gate and no runner ,not a waste of materials, die almost no maintenance. Parts of unity, and I cast no trace flow and reduce the cost of the modification. According to the structure and products used in the application of the characteristics of can be full-pressure die ,and die-pressure semi-closed mode (can be found in the plastic, plastic mold pressure related articles).Equipment: The pressure is a simple plastic deices the main features . platen combination of the two and a half , heating, pressure, the shape of the target material. Most of the process of plastic used hydraulic pressure to operate; also used pneumatic operation .Tow board up and down under pressure in the 4 corner posts on moving up and down. According to the plastic device the size of the pressure, the pressure is generally 20-1000 tons. The general board for the 8-inch size 2-5 feet 2.In addition, and after curing the release of different aspects of the degree of automation, the most commonly used modern hydraulic machine. The previous system , there is a simple temperature control, pressure control, pressure control and stop-time control. The use of modern equipment, advanced microprocessor control. For thinner products, in the board can be used in heating tube or belt heater. To the deeper parts, the need to use tube-shaped electric heater , heating steam or hot oil heating system. There are several types of plastic used in pressure in the heating system: uniform temperature steam heating mode, but the heating temperature is limited to below 350F;sleeve heating or other heating (heating coil, heating,ect.) relatively clean and easy maintenance, A more universal; thermal heating oil, heating due to the stability of the media cycle, the heat evenly. Now there are many new methods of heating ,hot water heating ,similar to the hot oil heating , water heating a medium for a gas combustion cycle , provides a greater degree of pressure temperature plastic.Polymer modified to enhance rapid industrial development requires a new pressure to improve the plastic industry . Enhanced by two molded plastic mold: mold-yang (side mode) and the negative mold (cavity). When the mold is full of reinforcements, the mode of the hot mold closed two and a half, and then heated, pressurized product to be cured. Along the lines of big changes in the complexity of the mold can be used aluminum, plastic or steel do. Light-weight materials making them less expensive, generally used for the production of short-term such as “cold-molding”.Coll at room temperature with molded resin, but the use of plastic mold and hydraulic pressure. The production of long-term use of hardened steel molds relatively cost-effective, the cut-off billet I can provide better performance and excellent cut finish. These steel pressure module on the use of machinery on the cut-off billet adapter I usually die together in the face area. This mode f metal molds, the products of its uniform surface, a good finish. Closed-mode technology used to pressure plastic molding,die-casting molding, injection and stamping some of the reinforced composites. Some of the thermoplastic plastic materials can be molded plastic pressure, but in general or with pre-mixing of thermosetting resins such as BMC (prefabricated molding as a whole),SMC(film forming material molding),TMC(thick molding),film forming, such as carpet. Carpet wet film forming sometimes called composite molding, in the hydraulic press will strengthen the role of materials and combined with resin. Often placed in the mold in carpet film will be dumped in to strengthen the resin material. Pressure in the process of cavity filled with resin to strengthen the material when fixed. If there are serious parts of the alien or gradient, it is necessary to carry out pre-forming. Most of the film and felt pre-forming system in the projected area of the states need to 150-200 pounds/2 inch of mold pressure. Pre-mixing materials, such as SMC, prepreg resin, filler, and the catalyst size enhance the material cut into a certain team sheet, and then adding the hot mold (in general 300-400 F), 1000-2000 1b/2 inch pressure Under the molding. SMC for the relatively new plastic devices the pressure of the total cycle may be less than one minute (from start to finish). Has developed a special hydraulic device back in the bowl pressure machine, automatic control of the board level degrees. Reinforced plastics, such as SMC, with a metal finish on molded plastic, tjis is very important parts of the surface. Sometimes occur in the processing of fibrous contraction. Model with coating method could improve the surface finish. BMC pressure of the process of plastic is the oldest pre-mixing after one of the molding process. Filling materials (wood, mineral materials, such as celluiose) are mixed in mixing the leaves in the shap of the mixer. Will feed into a group of 300400 F in the mold. In the 500-pound/2 inches under the pressure of molding. As a result of the use of materials for low-cost, the cost of raw materials. However, as in the molding process, the orientation of fiber reduces the mechanical strength. Plastic high-speed pressure, that is, enhanced thermoplastic stamping the sheet, a wide range of uses. Felt piece of glass and polypropylene can be used to match the plastic stamping, the cycle less than 40 seconds. Green sent to the convection heating furnace. Heating, rough pressure into plastic molds, in the process with new pressure machine machine speed up to 1400 inches/minute. To 75 inches/minute (SMC than the pressure of plastic process about 3 times as fast) feed pressure. According to the requirements of the market, some of the new stamping plastics, surface finish, and can be coated with nature. I metric ton of pressure on the general molding/2 inch. Traditional plastic pressure technology in recent years has been on the rise. In the space technology for national defense and the application of this technology is difficult to shock. In the SMC, BMC, TMC, the thermoplastic sheet stamping, reinforcement of the Blending plastic mechanical pressure and the development of the rapid growth of industry in order to meet the new requirements. A number of advanced materials mixing plastic pressure mainly in space technology and applications in the rapid development of national defense. Tools and dies and the new concept of high-temperature (up to 1200 F) molding machine to make a graphite carbon fiber composite materials can be developed to replace the existing metal castings. High temperature silicone is used as a high-pressure media. The composite sheet for the pressure in the mold. Now ,materials and production costs have made the process more suitable for space technology market, this type of silicone is also soon to the area of automobile. In the die-casting process, thermosetting resin material is expected to join a separate chamber, often called trough, and then forced into one or more closed modules for polymerization(curing). Liu, also known as Notes and the road runner, so that the flow of materials from the through cavity into the mold cavity before or after limiting gate. Many cavity with a single through. The air chamber is expected to be the replacement materials come in through a special place of the exhaust emissions. When the materials placed in the trough, in a compact measuring device detected charge, and then warm-up to close to the polymerization temperature. Only by adding a sufficient amount of time the injection. Preheat the raw materials will be sent trough of force and then a note sent to the feeder, the feeder note immediately installed in the trough, so as to prevent the pistons from the trough and gap between the edge of missing material. Taoka is usually closed to inject into the feeder to further leak-proof. Trough, the note feeder, gate, runner and mold cavity on the surface of the material can maintain the rapid solidification of a certain temperature,according to the nature of the materials, mold design and parts of the temperature of 280380 F. In the die-casting material to reach the end of the curing period, the second-casting for a complete release, including the removal gate, runner and injecting Road in trough and the formation of curing pad material (called salvage). In the die-casting, the warm-up material is very important. Cold expected to sloe the flow, first into the cavity of the material to its destination yet, that is likely to polymerization. If it happens, poor product quality, not just the appearance, but also in mechanical properties. Some exceptions, such as injecting a small amount, or some of the low viscosity of the material. Available light or heating stove heating, but an effective and commonly used method is used for making molded plastic dielectric heater. 9华东交通大学理工学院本科生毕业设计任务书题 目：压铸模具设计（气缸盖）_题目来源： 省部级以上 校级 横向 自选题目性质： 理论研究 应用与理论研究 应用研究分 院： _专 业：_班 级：_学 号： _学生姓名： _起讫日期：2009年3月9日_指导老师： 职称：副教授审核日期：_说 明1、毕业设计任务书由指导老师填写，并经分院审定，下达到学。2、学生根据指导老师下达的任务书独立完成开题报告，于3周内提交给知道老师批阅。3、本任务书在毕业设计完成后，与论文一起交给指导老师，作为论文批阅和毕业设计答辩的主要档案资料，是学士学位论文成册的主要内容之一。一、毕业设计的要求和内容（包括原始数据、技术要求、工作要求）确定分型面（有两个以上方案比较），确定浇注系统和排溢系统（有计算或查表），计算型芯、型腔高度和径向尺寸，确定推出机构（和侧向分型与抽芯机构），选择标准模架，并校核模板侧壁和底面厚度，确定加热于冷却系统。确定和校核型腔数目，校核注射量，校核塑件在分型面上的投影面积和锁模力，校核注射压力，校核开模行程，校核模具与注射机安装部分尺寸，校核顶出装置，选择注塑机。二、毕业设计图纸内容及张数1、模具装配图一张，附零件图。2、模具零件图若干张（五张以上）。三、毕业设计实物内容及要求设计图样全部用计算机绘制（二维和三维的，先手绘装配图草图），符合最新制图标准；投影正确，表达完整，布局合理。注重模具结构和装配要求，功能满足，实用可靠。理论分析完整清楚；设计推导简明扼要；计算正确可靠。避免冗长，反对抄袭。四、毕业设计进度计划序号各阶段工作内容起讫日期备注1铸件工艺分析2计算铸件的体积3确定压铸工艺参数4选择压铸机校核5模具结构设计6型芯及型腔计算7画图8编写设计说明书五、主要参考资料压铸成型工艺与模具设计 屈华昌 主编 机械工业出版社 压铸模典型结构图册 压铸技术调查小组 编著 国防工业出版社模具设计与加工速查手册 彭建生 编著 机械工业出版社压铸模具设计手册 编写组 机械工业出版社模具制造手册 编写组 机械工业出版社模具设计基础及模具CAD 李建军 机械工业出版社 执行任务书时间完成毕业设计时间华东交通大学理工学院本科生毕业设计（论文）开题报告题 目：（ 气缸盖）压铸模具设计_分 院： _专 业： _班 级： _学 号： _ 姓 名： _ 指导教师：_ 填表日期：2010年03月19日一、 选题的依据及意义： 近期国外采购商从未间断地到中国考察和选点，国内模具企业加大向外宣传推介的力度，双动的结果是在我国采购压铸模的数量逐年增多。“如何承接好外单？如何才能造到符合不同国家技术标准和要求？”成为近期同行中的热门话题。我国出口的压铸模具目前集中在欧洲、北美、日本、韩国等地，据了解部分企业的出口模具量已占总产值的30%以上。越来越多的优质压铸模飘洋过海，这些模具共同特点是用料考究、制作精良、尺寸精度高、能符合客户标准要求、使用寿命和铸件质量达到或趋近国外先进水平，同时具有明显的价格优势。宁波鑫达模具有限公司为加拿大某公司制作的汽车面板骨架模镶块及赴德的精密压铸模，宁波臻至机械模具有限公司为意大利制造的电机壳模，都因尺寸精确、交货周期短而赢得市场。共立精机（大连）有限公司长期大量为日本和亚洲某国提供模具。此外，公认制造难度大、要求高的大型汽车压铸模，我国无能力出口的记录被改写：2005年一汽铸造模具设备厂出口到加拿大的汽车油底盘压铸模由于价格优势强、设计先进、制作精湛得到外商认可，一再追加定单。广州市型腔模具制造有限公司为多家欧洲大型压铸公司设计与制造了多套汽车压铸模（在1800020000KN压铸机上生产），像桥车离合器、变速箱、油底盘等类模具设计成熟、质量控制严格、准点交付、使用寿命长，得到客户的好评，去年还把电梯梯级压铸模（在2500030000KN压铸机上生产）返供到欧洲。我国大型、复杂、精密的压铸模只进口无出口的历史已经结束，巨大的海外需求将会为各厂家提供更加广阔的市场。二、 国内外研究现状及发展趋势（含文献综述）： 近年来，压铸市场异常活跃，压铸产业的高速增长带来了压铸模具制造工业的一片兴旺。根据中国模具工业协会经营管理委员会编制的全国模具专业厂基本情况统计，压铸模具约占各类模具总产值5%，每年增长速度高达25%。 这几年，各模具厂普遍加大设备投入，提升技术水平和制模能力，模具的质量有了转大的提高。总体来说，中、小型模具的制作完全可以满足国内的需求，大型、复杂、精密的压铸模具依赖进口的状况较大地得到改善；中、低档模具供大于求，大型且要求高的压铸模进口不少；出口的压铸模量年年递增；国内商品化模具总量已经超过一半，自产自用的模具已不再占主导地位。 液压元件及模具各类相关配件品种最齐全和供应最畅通，模架制造、外协机械加工、外协电极制作、热处理协作厂家最为集中。 此外东北的吉林省、辽宁省和西部的四川省、重庆市压铸模的产量也不少。 这几年，压铸模品种、产量、综合设计水平，产品的复杂、精密程度，模具的大型化，以及企业的工装设备，工作环境，加工和检测手段等均有很大提高，应该说是我国有史以来提升最迅速的时期。 但是压铸模的制造总体来说与国外先进工业国家相比差距还很大，大致相当于他们90年代末的水平，模具结构复杂些的还多是步人后尘，以造复制模为主，创新点不多。制造过程中普遍存在质量控制不够严谨、制造精度差些，以及设计时对模具的热平衡分析、冷却系统设置、零件的快换、安装的快捷、生产的安全性等方面考虑欠周全，模具使用时稳定性不高，故障率大。 1.普遍实现了CAD/
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