遥控器后盖的注塑模具设计-抽芯塑料注射模含12张CAD图带开题
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遥控器
注塑
模具设计
塑料
注射
12
CAD
开题
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遥控器后盖的注塑模具设计-抽芯塑料注射模含12张CAD图带开题,遥控器,注塑,模具设计,塑料,注射,12,CAD,开题
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CONCURRENTDESIGNOFPLASTICSINJECTIONMOULDSAbstractTheplasticproductmanufacturingindustryhasbeengrowingrapidlyinrecentyears.Oneofthemostpopularprocessesformakingplasticpartsisinjectionmoulding.Thedesignofinjectionmouldiscriticallyimportanttoproductqualityandefficientproductprocessing.Mould-makingcompanies,whowishtomaintainthecompetitiveedge,desiretoshortenbothdesignandmanufacturingleadingtimesofthebyapplyingasystematicmoulddesignprocess.Themouldindustryisanimportantsupportindustryduringtheproductdevelopmentprocess,servingasanimportantlinkbetweentheproductdesignerandmanufacturer.Productdevelopmenthaschangedfromthetraditionalserialprocessofdesign,followedbymanufacture,toamoreorganizedconcurrentprocesswheredesignandmanufactureareconsideredataveryearlystageofdesign.Theconceptofconcurrentengineering(CE)isnolongernewandyetitisstillapplicableandrelevantintodaysmanufacturingenvironment.Teamworkingspirit,managementinvolvement,totaldesignprocessandintegrationofITtoolsarestilltheessenceofCE.TheapplicationofTheCEprocesstothedesignofaninjectionprocessinvolvesthesimultaneousconsiderationofplasticpartdesign,moulddesignandinjectionmouldingmachineselection,productionschedulingandcostasearlyaspossibleinthedesignstage.Thispaperpresentsthebasicstructureofaninjectionmoulddesign.Thebasisofthissystemarisesfromananalysisoftheinjectionmoulddesignprocessformoulddesigncompanies.Thisinjectionmoulddesignsystemcoversboththemoulddesignprocessandmouldknowledgemanagement.Finallytheprincipleofconcurrentengineeringprocessisoutlinedandthenitsprincipleisappliedtothedesignofaplasticinjectionmould.Keywords:Plasticinjectionmoulddesign,Concurrentengineering,Computeraidedengineering,Mouldingconditions,Plasticinjectionmoulding,Flowsimulation1.IntroductionInjectionmouldsarealwaysexpensivetomake,unfortunatelywithoutamoulditcannotbepossiblehohaveamouldedproduct.Everymouldmakerhashis/herownapproachtodesignamouldandtherearemanydifferentwaysofdesigningandbuildingamould.Surelyoneofthemostcriticalparameterstobeconsideredinthedesignstageofthemouldisthenumberofcavities,methodsofinjection,typesofrunners,methodsofgating,methodsofejection,capacityandfeaturesoftheinjectionmouldingmachines.Mouldcost,mouldqualityandcostofmouldproductareinseparableIntodayscompletiveenvironment,computeraidedmouldfillingsimulationpackagescanaccuratelypredictthefillpatternsofanypart.Thisallowsforquicksimulationsofgateplacementsandhelpsfindingtheoptimallocation.Engineerscanperformmouldingtrialsonthecomputerbeforethepartdesigniscompleted.Processengineerscansystematicallypredictadesignandprocesswindow,andcanobtaininformationaboutthecumulativeeffectoftheprocessvariablesthatinfluencepartperformance,cost,andappearance.2.InjectionMouldingInjectionmouldingisoneofthemosteffectivewaystobringoutthebestinplastics.Itisuniversallyusedtomakecomplex,finishedparts,ofteninasinglestep,economically,preciselyandwithlittlewaste.Massproductionofplasticpartsmostlyutilizesmoulds.Themanufacturingprocessandinvolvingmouldsmustbedesignedafterpassingthroughtheappearanceevaluationandthestructureoptimizationoftheproductdesign.Designersfaceahugenumberofoptionswhentheycreateinjection-mouldedcomponents.Concurrentengineeringrequiresanengineertoconsiderthemanufacturingprocessofthedesignedproductinthedevelopmentphase.Agooddesignoftheproductisunabletogotothemarketifitsmanufacturingprocessisimpossibleortooexpensive.Integrationofprocesssimulation,rapidprototypingandmanufacturingcanreducetheriskassociatedwithmovingfromCADtoCAMandfurtherenhancethevalidityoftheproductdevelopment.3.ImportanceofComputerAidedInjectionMouldDesignTheinjectionmouldingdesigntaskcanbehighlycomplex.ComputerAidedEngineering(CAE)analysistoolsprovideenormousadvantagesofenablingdesignengineerstoconsidervirtuallyandpart,mouldandinjectionparameterswithouttherealuseofanymanufacturingandtime.Thepossibilityoftryingalternativedesignsorconceptsonthecomputerscreengivestheengineerstheopportunitytoeliminatepotentialproblemsbeforebeginningtherealproduction.Moreover,invirtualenvironment,designerscanquicklyandeasilyassesthesensitivityofspecificmouldingparametersonthequalityandmanufacturabilityofthefinalproduct.AlltheseCAEtoolsenablealltheseanalysistobecompletedinameterofdaysorevenhours,ratherthanweeksormonthsneededfortherealexperimentaltrialanderrorcycles.AsCAEisusedintheearlydesignofpart,mouldandmouldingparameters,thecostsavingsaresubstantialnotonlybecauseofbestfunctioningpartandtimesavingsbutalsotheshortensthetimeneededtolaunchtheproducttothemarket.Theneedtomeetsettolerancesofplasticparttiesintoallaspectsofthemouldingprocess,includingpartsizeandshape,resinchemicalstructure,thefillersused,mouldcavitylayout,gating,mouldcoolingandthereleasemechanismsused.Giventhiscomplexity,designersoftenusecomputerdesigntools,suchasfiniteelementanalysis(FEA)andmouldfillinganalysis(MFA),toreducedevelopmenttimeandcost.FEAdeterminesstrain,stressanddeflectioninapartbydividingthestructureintosmallelementswheretheseparameterscanbewelldefined.MFAevaluatesgatepositionandsizetooptimizeresinflow.Italsodefinesplacementofweldlines,areasofexcessivestress,andhowwallandribthicknessaffectflow.Otherfiniteelementdesigntoolsincludemouldcoolinganalysisfortemperaturedistribution,andcycletimeandshrinkageanalysisfordimensionalcontrolandpredictionoffrozenstressandwarpage.TheCAEanalysisofcompressionmouldedpartsisshowninFigure1.TheanalysiscyclestartswiththecreationofaCADmodelandafiniteelementmeshofthemouldcavity.Aftertheinjectionconditionsarespecified,mouldfilling,fiberorientation,curingandthermalhistory,shrinkageandwarpagecanbesimulated.Thematerialpropertiescalculatedbythesimulationcanbeusedtomodelthestructuralbehaviourofthepart.Ifrequired,partdesign,gatelocationandshrinkageandwarpagecanbesimulated.Thematerialpropertiescalculatedbythesimulationcanbeusedtomodelthestructuralbehaviourofthepart.Ifrequired,partdesign,gatelocationandprocessingconditionscanbemodifiedinthecomputeruntilanacceptablepartisobtained.Aftertheanalysisisfinishedanoptimizedpartcanbeproducedwithreducedweldline(knownalsoknitline),optimizedstrength,controlledtemperaturesandcuring,minimizedshrinkageandwarpage.Machiningofthemouldswasformerlydonemanually,withatoolmakercheckingeachcut.ThisprocessbecamemoreautomatedwiththegrowthandwidespreaduseofcomputernumericallycontrolledorCNCmachiningcentres.SetuptimehasalsobeensignificantlyreducedthroughtheuseofspecialsoftwarecapableofgeneratingcutterpathsdirectlyfromaCADdatafile.Spindlespeedsashighas100,000rpmprovidefurtheradvancesinhighspeedmachining.Cuttingmaterialshavedemonstratedphenomenalperformancewithouttheuseofanycutting/coolantfluidwhatsoever.Asaresult,theprocessofmachiningcomplexcoresandcavitieshasbeenaccelerated.Itisgoodnewsthatthetimeittakestogenerateamouldisconstantlybeingreduced.Thebadnews,ontheotherhand,isthatevenwithalltheseadvances,designingandmanufacturingofthemouldcanstilltakealongtimeandcanbeextremelyexpensive.Manycompanyexecutivesnowrealizehowvitalitistodeploynewproductstomarketrapidly.Newproductsarethekeytocorporateprosperity.Theydrivecorporaterevenues,marketshares,bottomlinesandshareprices.Acompanyabletolaunchgoodqualityproductswithreasonablepricesaheadoftheircompetitionnotonlyrealizes100%ofthemarketbeforerivalproductsarrivebutalsotendstomaintainadominantpositionforafewyearsevenaftercompetitiveproductshavefinallybeenannounced(Smith,1991).Formostproducts,thesetwoadvantagesaredramatic.Rapidproductdevelopmentisnowakeyaspectofcompetitivesuccess.Figure2showsthatonly37%oftheproductmixfromtheaverageindustrialorelectronicscompanyislessthan5yearsold.Forcompaniesinthetopquartile,thenumberincreasesto1525%.Forworld-classfirms,itis6080%(Thompson,1996).Thebestcompaniescontinuouslydevelopnewproducts.AtHewlett-Packard,over80%oftheprofitsresultfromproductslessthan2yearsold!(Neel,1997)Figure1Importanceofnewproduct(Jacobs,2000)Withtheadvancesincomputertechnologyandartificialintelligence,effortshavebeendirectedtoreducethecostandleadtimeinthedesignandmanufactureofaninjectionmould.Injectionmoulddesignhasbeenthemainareaofinterestsinceitisacomplexprocessinvolvingseveralsub-designsrelatedtovariouscomponentsofthemould,eachrequiringexpertknowledgeandexperience.Leeet.al.(1997)proposedasystematicmethodologyandknowledgebaseforinjectionmoulddesigninaconcurrentengineeringenvironment.4.ConcurrentEngineeringinMouldDesignConcurrentEngineering(CE)isasystematicapproachtointegratedproductdevelopmentprocess.Itrepresentsteamvaluesofco-operation,trustandsharinginsuchamannerthatdecisionmakingisbyconsensus,involvingallperspectivesinparallel,fromtheverybeginningoftheproductlife-cycle(Evans,1998).Essentially,CEprovidesacollaborative,co-operative,collectiveandsimultaneousengineeringworkingenvironment.Aconcurrentengineeringapproachisbasedonfivekeyelements:（1）.process（2）.multidisciplinaryteam（3）.integrateddesignmodel（4）.facility（5）.softwareinfrastructureFigure2Methodologiesinplasticinjectionmoulddesign,a)Serialengineeringb)ConcurrentengineeringIntheplasticsandmouldindustry,CEisveryimportantduetothehighcosttoolingandlongleadtimes.Typically,CEisutilizedbymanufacturingprototypetoolingearlyinthedesignphasetoanalyzeandadjustthedesign.Productiontoolingismanufacturedasthefinalstep.Themanufacturingprocessandinvolvingmouldsmustbedesignedafterpassingthroughtheappearanceevaluationandthestructureoptimizationoftheproductdesign.CErequiresanengineertoconsiderthemanufacturingprocessofthedesignedproductinthedevelopmentphase.Agooddesignoftheproductisunabletogotothemarketifitsmanufacturingprocessisimpossible.IntegrationofprocesssimulationandrapidprototypingandmanufacturingcanreducetheriskassociatedwithmovingfromCADtoCAMandfurtherenhancethevalidityoftheproductdevelopment.Foryears,designershavebeenrestrictedinwhattheycanproduceastheygenerallyhavetodesignformanufacture(DFM)thatis,adjusttheirdesignintenttoenablethecomponent(orassembly)tobemanufacturedusingaparticularprocessorprocesses.Inaddition,ifamouldisusedtoproduceanitem,therearethereforeautomaticallyinherentrestrictionstothedesignimposedattheverybeginning.Takinginjectionmouldingasanexample,inordertoprocessacomponentsuccessfully,ataminimum,thefollowingdesignelementsneedtobetakenintoaccount:（1）geometry; draftangles,Nonre-entrantsshapes, nearconstantwallthickness, complexity,splitlinelocation,andsurfacefinish,（2）materialchoice;（3）rationalisationofcomponents(reducingassemblies);（4）.cost.Ininjectionmoulding,themanufactureofthemouldtoproducetheinjection-mouldedcomponentsisusuallythelongestpartoftheproductdevelopmentprocess.Whenutilisingrapidmodelling,theCADtakesthelongertimeandthereforebecomesthebottleneck.Theprocessdesignandinjectionmouldingofplasticsinvolvesrathercomplicatedandtimeconsumingactivitiesincludingpartdesign,moulddesign,injectionmouldingmachineselection,productionscheduling,toolingandcostestimation.Traditionallyalltheseactivitiesaredonebypartdesignersandmouldmakingpersonnelinasequentialmanneraftercompletinginjectionmouldedplasticpartdesign.Obviouslythesesequentialstagescouldleadtolongproductdevelopmenttime.Howeverwiththeimplementationofconcurrentengineeringprocessintheallparameterseffectingproductdesign,moulddesign,machineselection,productionscheduling,toolingandprocessingcostareconsideredasearlyaspossibleinthedesignoftheplasticpart.Whenusedeffectively,CAEmethodsprovideenormouscostandtimesavingsforthepartdesignandmanufacturing.Thesetoolsallowengineerstovirtuallytesthowthepartwillbeprocessedandhowitperformsduringitsnormaloperatinglife.Thematerialsupplier,designer,moulderandmanufacturershouldapplythesetoolsconcurrentlyearlyinthedesignstageoftheplasticpartsinordertoexploitthecostbenefitofCAE.CAEmakesitpossibletoreplacetraditional,sequentialdecision-makingprocedureswithaconcurrentdesignprocess,inwhichallpartiescaninteractandshareinformation,Figure3.Forplasticinjectionmoulding,CAEandrelateddesigndataprovideanintegratedenvironmentthatfacilitatesconcurrentengineeringforthedesignandmanufactureofthepartandmould,aswellasmaterialselectionandsimulationofoptimalprocesscontrolparameters.QualitativeexpensecomparisonassociatedwiththepartdesignchangesisshowninFigure4,showingthefactthatwhendesignchangesaredoneatanearlystagesonthecomputerscreen,thecostassociatedwithisanorderof10.000timeslowerthanthatifthepartisinproduction.Thesemodificationsinplasticpartscouldarisefrommouldmodifications,suchasgatelocation,thicknesschanges,productiondelays,qualitycosts,machinesetuptimes,ordesignchangeinplasticparts.Figure3Costofdesignchangesduringpartproductdevelopmentcycle(Rioset.al,2001)Attheearlydesignstage,partdesignersandmouldershavetofinalisepartdesignbasedontheirexperienceswithsimilarparts.Howeverasthepartsbecomemorecomplex,itgetsratherdifficulttopredictprocessingandpartperformancewithouttheuseofCAEtools.Thusforevenrelativelycomplexparts,theuseofCAEtoolstopreventthelateandexpensivedesignchangesandproblemsthatcanariseduringandafterinjection.Forthesuccessfulimplementationofconcurrentengineering,theremustbebuy-infromeveryoneinvolved.5.CaseStudyFigure5showstheinitialCADdesignofplasticspartusedforthesprinklerirrigationhydrantleg.Oneoftheessentialfeaturesofthepartis
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