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XX设计(XX)任务书毕业设计（论文）题目泡沫灭火器喷嘴的注塑成型工艺及模具设计学生姓名专业班级指导教师姓名职称毕业设计（论文）的基本要求：a. 拟定模具结构形式b. 注塑机型号的确定及参数校核c. 成型零件设计d. 浇注系统设计e. 顶出机构设计f. 冷却系统设计 图纸：模具总装配图；泡沫灭火器喷嘴塑件图 泡沫灭火器喷嘴型腔图；泡沫灭火器喷嘴型芯图g. 设计计算书一份h. 外文翻译（不少于3500单词）课题条件及进度安排：1. 产品名称：泡沫灭火器喷嘴 2. 产品材料POM共需要16周时间完成，时间基本如下：毕业实习，实习报告撰写 3周英文资料下载和翻译 2周资料查询、文献综述及开题报告 3周毕业设计，说明书撰写 7周答辩 1周 指导教师： 20XX 年 3月 5 日ORIGINAL ARTICLEA CAD/CAE-integrated injection mold design systemfor plastic productsIvan Matin&Miodrag Hadzistevic&Janko Hodolic&Djordje Vukelic&Dejan LukicReceived: 27 July 2011 /Accepted: 10 January 2012 /Published online: 25 January 2012#Springer-Verlag London Limited 2012Abstract Mold design is a knowledge-intensive process.This paper describes a knowledge-based oriented, paramet-ric, modular and feature-based integrated computer-aideddesign/computer-aided engineering (CAD/CAE) system formold design. Development of CAx systems for numericalsimulation of plastic injection molding and mold design hasopened new possibilities of product analysis during the molddesign. The proposed system integrates Pro/ENGINEER sys-temwiththe speciallydevelopedmoduleforthecalculationofinjection molding parameters, mold design, and selection ofmold elements. The system interface uses parametric andCAD/CAE feature-based database to streamline the processof design, editing, and reviewing. Also presented are generalstructure and part of output results from the proposed CAD/CAE-integrated injection mold design system.Keywords Molddesign.Numericalsimulation.CAD.CAE1 IntroductionInjection molding process is the most common moldingprocess for making plastic parts. Generally, plastic injectionmolding design includes plastic product design, mold de-sign, and injection molding process design, all of whichcontribute to the quality of the molded product as well asproduction efficiency 1. This is process involving manydesign parameters that need to be considered in a concurrentmanner. Mold design for plastic injection molding aided bycomputers has been focused by a number of authors world-wide for a long period. Various authors have developedprogram systems which help engineers to design part, mold,and selection parameters of injection molding. During thelast decade, many authors have developed computer-aideddesign/computer-aided engineering (CAD/CAE) mold de-sign systems for plastic injection molding. Jong et al. 2developed a collaborative integrated design system for con-current mold design within the CAD mold base on the web,using Pro/E. Low et al. 3 developed an application forstandardization of initial design of plastic injection molds.The system enables choice and management of mold base ofstandard mold plates, but does not provide mold and injec-tion molding calculations. The authors proposed a method-ology of standardizing the cavity layout design system forplastic injection mold such that only standard cavity layoutsare used. When standard layouts are used, their layout con-figurations can be easily stored in a database. Lin at al. 4, 5describe a structural design system for 3D drawing moldbased on functional features using a minimum set of initialinformation. In addition, it is also applicable to assign thefunctional features flexibly before accomplishing the designof a solid model for the main parts of a drawing mold. Thisdesign system includes modules for selection and calculationof mold components. It uses Pro/E modules Pro/Program andPro/Toolkit, and consists of modules for mold selection, mod-ification and design. Deng et al. 6, 7 analyzed developmentof the CAD/CAE integration. The authors also analyzed sys-tems and problems of integration between CAD and CAEsystems for numerical simulation of injection molding andmolddesign.Authorsproposeafeatureontologyconsistingofa number of CAD/CAE features. This feature represents notI. Matin (*):M. Hadzistevic:J. Hodolic:D. Vukelic:D. LukicFaculty of Technical Sciences, Department of ProductionEngineering, University of Novi Sad,Trg Dositeja Obradovica 6,21000 Novi Sad, Serbiae-mail: matiniuns.ac.rsURL: www.ftn.uns.ac.rsInt J Adv Manuf Technol (2012) 63:595607DOI 10.1007/s00170-012-3926-5only the geometric information of plastic part, but also thedesign intent is oriented towards analysis. Part features con-tain the overall product information of a plastic part, wallfeatures, development features (such as chamfer, ribs, boss,hole, etc.), treatment features which contain analysis-relateddesign information and subwall/developed features. Wall anddevelopment features are so called “component features”.Godec et al. 8, 9 developed a CAE system for mold designand injection molding parameters calculations. The system isbased on morphology matrix and decision diagrams. Thesystem is used for thermal, rheological and mechanical calcu-lation, and material base management, but no integration withFig. 1 General structure ofintegrated injection molddesign system for plasticproducts596Int J Adv Manuf Technol (2012) 63:595607commercial CAx software is provided. Huang et al. 10developed a mold-base design system for injection molding.The database they used was parametric and feature-basedoriented. The system used Pro/E for modeling database com-ponents. Kong et al. 11 developed a parametric 3D plasticinjection mold design system integrated with solid works.Other knowledge-basedsystems,suchasIMOLD,ESMOLD,IKMOULD, and IKBMOULD, have been developed forinjection mold design. IMOLD divides mold design into fourmajor steps; parting surface design, impression design, runnersystem design, and mold-base design. The software uses aknowledge-based CAD system to provide an interactiveenvironment, assist designers in the rapid completion of molddesign, and promote the standardization of the mold designprocess. IKB-MOULD application consists of databases andknowledge bases for mold manufacturing. Lou et al. 12developed an integrated knowledge-based system for mold-base design. The system has module for impression calcula-tion, dimension calculation, calculation of the number of moldplatesandselectionofinjectionmachine.ThesystemusesPro/Mold Base library. This paper describes KBS and key technol-ogies, such as product modeling, the frame-rule method, CBS,andthe neural networks.A multilayerneuralnetworkhasbeentrained by back propagation BP. This neural network adoptslength, width, height and the number of parts in the mold asinput and nine parameters (length, width, and height of up anddownset-in,moldbasessidethickness,bottomthicknessofthecore,andcavityplates)asoutput.Moketal.13,14developedanintelligentcollaborativeKBSforinjectionmolds.Mokatel.15 has developed an effective reuse and retrieval system thatcan register modeled standard parts using a simple graphicaluserinterfaceeventhoughdesignersmaynotknowtherulesofregistration for a database. The mold design system was de-veloped using an Open API and commercial CAD/computer-aided manufacturing (CAM)/CAE solution. The system wasapplied to standardize mold bases and mold parts in HyundaiHeavy Industry. This system adopted the method of designediting, which implements the master model using features.The developed system provides methods whereby designerscanregisterthemastermodel,whichisdefinedasafunctionof3D CAD, as standard parts andeffectively reuse standard partseven though they do not recognize the rules of the database.Todic et al. 16 developed a software solution for auto-mated process planning for manufacturing of plastic injec-tion molds. This CAD/CAPP/CAM system does not provideCAE calculation of parameters of injection molding andmold design. Maican et al. 17 used CAE for mechanical,thermal, and rheological calculations. They analyzed phys-ical, mechanical, and thermal properties of plastic materials.They defined the critical parameters of loaded part. Nardinet al. 18 tried to develop the system which would suit allthe needs of the injection molding for selection of the partmoldtechnology system. The simulation results consist ofgeometrical and manufacturing data. On the basis of thesimulation results, part designers can optimize part geome-try, while mold designers can optimize the running and thecooling system of the mold. The authors developed a pro-gram which helps the programmers of the injection moldingmachine to transfer simulation data directly to the machine.Zhou et al. 1 developed a virtual injection molding systembased on numerical simulation. Ma et al. 19 developedstandard component library for plastic injection mold designusing an object-oriented approach. This is an object-oriented, library model for defining mechanical componentsparametrically. They developed an object-oriented moldcomponent library model for incorporating different geo-metric topologies and non-geometric information. Over theyears, many researchers have attempted to automate a wholeFig. 2 Structure of module for numerical simulation of injectionmolding processInt J Adv Manuf Technol (2012) 63:595607597molddesignprocessusingvariousknowledge-basedengineer-ing (KBE) approaches, such as rule-based reasoning (RBR),and case base (CBR) and parametric design template (PDT).Chan at al. 20 developed a 3D CAD knowledge-based-assisted injection mold design system (IKB mold). In theirresearch, design rules and expert knowledge of mold designwere obtained from experienced mold designers and hand-books through various traditional knowledge acquisition pro-cesses. The traditional KBE approaches, such as RBR, CBR,andsimplePDThavebeensuccessfullyappliedtomoldcavityand runner layout design automation of the one product mold.Ye et al. 21 proposed a feature-based and object-orientedhierarchical representation and simplified symbolic geometryapproach for automation mold assembly modeling. Thepreviously mentioned analysis of various systems shows thatauthors used different ways to solve the problems of molddesign by reducing it to mold configurator (selector). Theyused CAD/CAE integration for creating precision rules formold-base selection. Many authors used CAE system fornumerical simulation of injection molding to define parame-tersofinjectionmolding.SeveralalsodevelopedoriginalCAEmodules for mold and injection molding process calculation.However, common to all previously mentioned systems is thelack of module for calculation of mold and injection moldingparameters which would allow integration with the results ofnumerical simulation. This leads to conclusion that there is aneed to create a software system which integrates parametersof injection molding with the result obtained by numericalFig. 3 Forms to define the mold geometryFig. 4 Forms to determine the distance between the cooling channels and mold cavity598Int J Adv Manuf Technol (2012) 63:595607simulation of injection molding, mold calculation, and selec-tion. All this would be integrated into CAD/CAE-integratedinjection mold design system for plastic products.2 Structure of integrated CAD/CAE systemAs is well known, various computational approaches forsupporting mold design systems of various authors use designautomation techniques such as KBE (RBR, CBR, PDT) ordesign optimisation techniques such as traditional (NLP,LP,BB, GBA, IR, HR) or metaheuristic search such as (TS, SA,GA) and other special techniques such as (SPA, AR, ED).The developed interactive software system makes possibleto perform: 3D modeling of the parts, analysis of part designand simulation model design, numerical simulation of injec-tion molding, and mold design with required calculations.The system consists of four basic modules:&Module for CAD modeling of the part&Module for numerical simulation of injection moldingprocessFig. 5 Mold-base selector formsFig. 6 Form for mechanicalmold calculationInt J Adv Manuf Technol (2012) 63:595607599&Module for calculation of parameters of injection mold-ing and mold design calculation and selection&Module for mold modeling (core and cavity design anddesign all residual mold components)The general structure of integrated injection mold designsystem for plastic products is shown in Fig. 1.2.1 Module for CAD modeling of the part (module I)The module for CAD modeling of the part is the firstmodule within the integrated CAD/CAE system. Thismodule is used for generating CAD model of the plasticproduct and appropriate simulation model. The result ofthis module is solid model of plastic part with all necessarygeometrical and precision specifications. Precision speci-fications are: project name, number, feature ID, featurename, position of base point, code number of simulationannealing, trade material name, material grade, part toler-ance, machine specification (name, clamping force, maxi-mal pressure, dimensions of work piece), and number ofcavity. If geometrical and precision specification is speci-fied (given) with product model, the same are used as inputto the next module, while this module is used only togenerate the simulation model.2.2 Module for numerical simulation of injectionmolding process (module II)Module II is used for numerical simulation of injectionmolding process. User implements an iterative simulationprocessfordeterminingthemoldabilityparametersofinjectionmolding and simulation model specification. The structure ofthis module is shown in Fig. 2.After a product model is imported and a polymer isselected from the plastic material database, user selects thebest location for gating subsystem. The database containsrheological, thermal, and mechanical properties of plasticmaterials. User defines parameters of injection molding andpicks the location for the gating subsystem. Further analysesare carried out: the plastic flow, fill time, injection pressure,pressure drop, flow front temperature, presence of weld line,presence of air traps, cooling quality, etc.The module offers four different types of mold flow anal-ysis. Each analysis is aimed at solving specific problems:&Part analysisThis analysis is used to test a known gatelocation, material, and part geometry to verify that a partwill have acceptable processing conditions.&Gate analysisThis analysis tests multiple gate loca-tions and compares the analysis outputs to determinethe optimal gate location.&Sink mark analysisThis analysis detects sink marklocations and depths to resolve cosmetic problemsbefore the mold is built eliminating quality disputes thatcould arise between the molder and the customer.The most important parameters are the following: 22&Part thickness&Flow length&Radius and drafts,&Thickness transitions&Part material&Location of gates&Number of gates&Mold temperature&Melt temperature&Injection pressure&Maximal injection molding machine pressureIn addition to the previously mentioned parameters ofinjection molding, the module shows following simulationresults: welding line position, distribution of air traps, thedistribution of injection molding pressure, shear stressFig. 7 Segment of the mechanical calculation algorithm600Int J Adv Manuf Technol (2012) 63:595607distribution, temperature distribution on the surface of thesimulation model, the quality of filling of a simulationmodel, the quality of a simulation model from the standpointof cooling, and time of injection molding 22, 23. A part ofoutput results from this module are the input data forthe next module. These output results are: materialgrade and material supplier, modulus of elasticity inthe flow direction, modulus of elasticity transverse di-rection, injection pressure, ejection temperature, moldtemperature, melting temperature, highest melting tem-perature thermoplastic, thermoplastic density in liquidand solid state, and maximum pressure of injectionmolding machine. During implementation of iterativeSA procedure, user defines the moldability simulationmodel and the parameters of injection molding. Allresults are represented by different colors in the regionsof the simulation model.2.3 Module for calculation of parameters of injectionmolding and mold design calculation and selection(module III)This module is used for analytical calculations, mold sizing,and its selection. Two of the more forms for determining thedimensions of core and cavity mold plates are shown in Fig. 3.Based on the dimensions of the simulation model andclamping force (Fig. 3) user selects the mold material andsystem calculates the width and length of core and cavityplates. Wall thickness between the mold cavity to the cool-ing channel can be calculated with the following threecriteria: criterion allowable shear stress, allowable bendingstress criterion, and the criterion of allowable angle iso-therms are shown in Fig. 4 22, 24. The system adoptsthe maximum value of comparing the values of wall thick-ness calculated by previously mentioned criteria.Fig. 8 Forms for standard mold plates selectionInt J Adv Manuf Technol (2012) 63:595607601Based on the geometry of the simulation model, userselect shape and mold type. Forms for the selection moldshape, type, and subsystems are shown in Fig. 5. Once thesesteps are completed, user implements the thermal, rheolog-ical, and mechanical calculation of mold specifications. Anexample of one of the several forms for mechanical moldcalculation is shown in Fig. 6.Segment of the algorithm of mechanical calculations isshown in Fig. 7.Where,fmaxmaximal flexure of cavity platefdopallowed displacement of cavity plateelastic deformationminminimal value of shrinkage factorEkmodulus of elasticity of cavity plateGshear modulusSkwall thickness distance measuring betweencavity and waterlinedKTcooling channel diameterAfter the thermal, rheological, and mechanical calcula-tions, user selects mold plates from the mold base. Form forthe selection of standard mold plates is shown in Fig. 8. Thesystem calculates the value of thickness of risers, fixed, andmovable mold plates (Fig. 8). Based on the calculateddimensions, the system automatically adopts the first majorstandard value for the thickness of risers, movable, and fixedmold plate. Calculation of the thickness and the adoption ofstandard values are presented in the form as shown in Fig. 8.The interactive system recommends the required moldplates. The module loads dimensions from the database andgenerates a solid model of the plate. After the plate selec-tion, the plate is automatically dimensioned, material plate isFig. 10 Structure of module IVFig. 9 Forms for mold plate model generation602Int J Adv Manuf Technol (2012) 63:595607assigned, and 3D model and 2D technical drawing aregenerated on demand. Dimensions of mold component (e.g.,fixed plate) are shown in the form for mold plate modegeneration, as shown in Fig. 9.The system loads the plate size required from the moldbase. In this way, load up any other necessary standard moldplatesthatmakeupthemoldsubassembly.Subassemblymoldmodel made up of instance plates are shown in Fig. 10Then get loaded other components of subsystems asshown in Fig. 5. Subsystem for selection other componentsinclude bolts and washers. The way of components selectionare based on a production rules by authors and by company“D-M-E” 25, 26.2.4 Module for mold modeling (core and cavity designand design all residual mold components; module IV)This module is used for CAD modeling of the mold (coreand cavity design). This module uses additional softwaretools for automation creating core and cavity from simula-tion (reference) model including shrinkage factor of plasticsmaterial and automation splitting mold volumes of the fixedand movable plates. The structure of this module is shown inFig. 11.Additional capability of this module consists of softwaretools for:&Applying a shrinkage that corresponds to design plasticpart, geometry, and molding conditions, which are com-puted in module for numerical simulation&Make conceptual CAD model for nonstandard platesand mold components&Design impression, inserts, sand cores, sliders and othercomponents that define a shape of molded part&Populate a mold assembly with standard componentssuch as new developed mold base which consists of D-M-E mold base and mold base of enterprises which usethis system, and CAD modeling ejector pins, screws,and other components creating corresponding clearanceholes&Create runners and waterlines, which dimensions wascalculated in module for calculating of parameters ofinjection molding and mold design calculation andselection&Check interference of components during mold opening,and check the draft surfacesAfter applied dimensions and selection mold compo-nents, user loads 3D model of the fixed (core) and movable(cavity) plate. Geometry mold specifications, calculated inthe previous module, are automatically integrated into thismodule, allowing it to generate the final mold assembly.Output from this module receives the complete mold modelof the assembly as shown in Fig. 15. This module allowsFig. 11 Subassembly model of moldInt J Adv Manuf Technol (2012) 63:595607603modeling of nonstandard and standard mold componentsthat are not contained in the mold base.3 Case studyThe complete theoretical framework of the CAD/CAE-inte-grated injection mold design system for plastic products waspresented in the previous sections. In order to complete thisreview, the system was entirely tested on a real case study.The system was tested on few examples of similar plasticparts. Based on the general structure of the model of inte-grated CAD/CAE design system shown in Fig. 1, theauthors tested the system on some concrete examples. Oneof the examples used for verification of the test model of theplastic part is shown in Fig. 12.The module for the numerical simulation of injectionmolding process defines the optimal location for settinggating subsystem. Dark blue regions indicate the optimalposition for setting gating subsystem as shown in Fig. 13.Based on dimensions, shape, material of the case studyproduct (Fig. 11), optimal gating subsystem location(Fig. 13), and injection molding parameters (Table 1), thesimulation model shown in Fig. 14 was generated.One of the rules for defining simulation model gate fornumerical simulation:IF (tunnel, plastic material, mass) THEN predictiondimension (upper tunnel, length, diameter1, diameter2,radius, angle, etc.)Part of the output results from module II, which are usedin module III are shown in Table 1.Fig. 12 CAD model of the testproductFig. 13 Optimal gating subsystem location in the part604Int J Adv Manuf Technol (2012) 63:595607In module III, the system calculates clamping force F027.9 kN (Fig. 3), cooling channel diameter dKT06 mm,cooling channel length lKT090 mm (Fig. 4). Given theshape and dimensions of the simulation model, square shapeof mold with normal performance was selected as shown inFig. 5. Selected mold assembly standard series: 1,616,length and width of mold housing 156156 mm as shownin Fig. 8. In the segment of calculation shown in Fig. 8,mold design system panel recommends the following moldplates:&Top clamping plate N03-1616-20&Bottom clamping plate N04-1616-20&Fixed mold plate (core plate) N10A-1616-36&Movable plate (cavity plate) N10B-1616-36&Support plate N20-1616-26&Risers N30-1616-46&Ejector retainer plate N40-1616-10&Ejector plate N50-1616-12After finishing the fixed and movable mold plates fromthe standpoint of CAD modeling core and cavity plates,cooling channel, followed by manual selection of othermold standard components such as sprue bush, locatingring, guide pins, guide bush, leading bushing guide, spacerplates, screws (M410, M10100, M1030, M616,M1030, etc.) and modeling nonstandard mold components(if any) ejector pins, ejector holes, inserts etc. A completemodel of the mold assembly with tested simulation model isshown in Fig. 15.Table 1 Part of the outputresults from the module for thenumerical simulation of injec-tion molding processMaterial grade and material supplierAcrylonitrile butadiene styrene 780 (ABS 780),Kumho Chemicals Inc.Max injection pressure100 MPaMold temperature60C ili 40Melt Temperature230CInjection Time0,39 s 0,2 sInjection Pressure27,93 MPaRecommended ejection temperature79CModulus of elasticity, flow direction for ABS 7802,600 MPaModulus of elasticity, transverse direction for ABS 7802,600 MPaPoision ratio in all directions for ABS 7800.38Shear modulus for ABS 780942 MPaDensity in liquid state0.94032 g/cm3Density in solid state1.047 g/cm3Fig. 14 Simulation model ofplastic partInt J Adv Manuf Technol (2012) 63:5956076054 ConclusionThe objective of this research was to develop a CAD/CAEintegrated system for mold design which is based on Pro/ENGINEER system and uses specially designed and devel-oped modules for mold design. This paper presents a soft-ware solution for multiple cavity mold of identical moldingparts, the so-called one product mold. The system is dedi-cated to design of normal types of molds for products whoselength and width are substantially greater than productheight, i.e., the system is customized for special require-ments of mold manufacturers. The proposed system allowsfull control over CAD/CAE feature parameters which ena-bles convenient and rapid mold modification. The describedCAD/CAE modules are feature-based, parametric, based onsolid models, and object oriented. The module for numericalsimulation of injection molding allows the determinationselection of injection molding parameters. The module forcalculation of parameters of injection molding process andmold design calculation and selection improves designFig. 15 Model of the mold assembly with tested simulation model606Int J Adv Manuf Technol (2012) 63:595607faster, reduces mold design errors, and provides geometricand precision information necessary for complete mold de-sign. The knowledge base of the system can be accessed bymold designers through interactive modules so that theirown intelligence and experience can also be incorporatedinto the total mold design. Manufacture of the part confirmsthat the developed CAD/CAE system provides correctresults and proves to be a confident software tool.Future research will be directed towards three main goals.The first is to develop a system for automation of familymold design. Another line of research is the integration withCAPP system for plastic injection molds manufacturingdeveloped at the Faculty of Technical Sciences. Finally,following current trends in this area, a collaborative systemusing web technologies and blackboard architecture shall bedesigned and implemented.References1. Zhou H, Shi S, Ma B (2009) A virtual injection molding systembased on numerical simulation. Int J Manuf Technol 40:2973062. Jong WR, Wu CH, Liu HH, Li MY (2009) A collaborative navi-gation system for concurente mold design. Int J Adv ManufTechnol 40(34):2152253. Low MLH, Lee KS (2003) Application of standardization forinitial design of plastic injection moulds. Int J Prod Res 41:230123244. Lin BT, Chang MR, Huang HL, Liu CHY (2008) Computer-aided structural design of drawing dies for stamping processesbased on functional features