SD30渔具旋臂盖的塑料注塑模具设计【说明书+CAD】
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摘要塑料保险杠取代金属保险扛是汽车行业的发展趋势，但是塑料保险杠的设计目前仍采用传统的模具设计方法。因此本文针对轿车前保险杠的制品结构，采用华塑CAE(HSCAE)软件对轿车保险杠注射模的型腔压力、熔体温度及流动前沿进了优化分析及模拟，同时对保险杠注射模的主要参数进行了校核。研究结果表明本文采用的设计方法可以极大提高保险杠注射模设计开发的效率。关键词保险杠 注射模 热流道 CAE1 前言 随着汽车上业的发展，全金属保险杠越来越不适应现代汽车在轻量化、高机能化以及与车体造型一体化等方面的要求，尤其在轿车、轻型车上，有用塑料保险杠取代全金属保险杠的趋势。作为钢铁件的替代产品，汽车塑料保险杠以其造型美观，重量轻，易于成型，耐腐蚀，成本低，综合机械性能良好，且容易实现规模化生产等优点在汽车行业占据了一席之地。目前，我国轿车。微型车、轻型车等生产厂家正在逐步实现该产品的更新换代。2 轿车前保险杠几何结构分析 图1所示零件为马自达轿车前保险杠，零件壁厚3.5mm，通常要求制件表面光滑无缺陷，对其外形精度没有过高要求。如图1所示，保险杠形状为马鞍形，长1925mm，宽715mm，高538mm，平均壁厚为3.5mm。椭圆形灯孔左右各一，中间为通风栅格，内侧加强筋若干。尾部有内侧卷曲，因此，需要采用内侧抽芯。1 前言 随着汽车上业的发展，全金属保险杠越来越不适应现代汽车在轻量化、高机能化以及与车体造型一体化等方面的要求，尤其在轿车、轻型车上，有用塑料保险杠取代全金属保险杠的趋势。作为钢铁件的替代产品，汽车塑料保险杠以其造型美观，重量轻，易于成型，耐腐蚀，成本低，综合机械性能良好，且容易实现规模化生产等优点在汽车行业占据了一席之地。目前，我国轿车。微型车、轻型车等生产厂家正在逐步实现该产品的更新换代。2 轿车前保险杠几何结构分析图1所示零件为马自达轿车前保险杠，零件壁厚3.5mm，通常要求制件表面光滑无缺陷，对其外形精度没有过高要求。如图1所示，保险杠形状为马鞍形，长1925mm，宽715mm，高538mm，平均壁厚为3.5mm。椭圆形灯孔左右各一，中间为通风栅格，内侧加强筋若干。尾部有内侧卷曲，因此，需要采用内侧抽芯。 保险杠材料要求在较宽的温度范围内刚性好，耐冲击性能好，尺寸稳定性好，耐溶剂性好，涂装性能好。丙烯综合什能较好，故在此选用聚丙烯(改性)作为保险杠材料。所设计保险杠模具特点为：模具外形尺寸大(2400mm700mm11OOmm)、体积重(2540t)，结构复杂，类似为一个中等程度的工作母机；模具浇注系统为热流道，需要电加热；型腔、型芯冷却系统复杂，型腔与浇注系统的热流道相互矛盾；制品顶出系统复杂，常用液压、机械联合顶出，并采用机械手自动取出制品；制品尺寸大，浇注系统常为冷，热流道相结合。3 CAE优化分析在对轿车前保险杠注射模的总体结构、使用功能控制及模具结构的具体设计(包括浇注系统成型零件和导向装置、测向分型抽芯机构、模温控制装置等的设计)进行全面设定的基础上，采用华中科技大学国家模具重点实验室开发的HSCAE(华塑CAE)软件进行优化及动态模拟分析，从而改变了过去那种单靠人为经验来设计模具浇口位置及尺寸，需要多次试模反复修改，才能最后设计定型和制造模具的落后方法。该课题的开展，将会极大地减少设计人员反复估算饶口尺寸的繁杂劳动，加速我国对大型轿车注射模设计、制造及产品牛产系列化的进程。 塑料注射成型时，塑料在型腔中的流动和成型，与材料的性能、塑件的形状尺寸、成型温度、成型速度成型压力、成型时间、模腔表面情况和模具设计等一系列因素有关。CAE优化分析就是利用计算机高速运算功能，综合考虑各种因数，得出流动场、温度场、压力场、剪切应力场等模拟结果，从而评定所用方案的优劣。这里使用华中科技大学模具国家重点实验室开发的HSCAE5.0软件进行优化分析。流动场分析结果如图2所示，其流动是平衡的，结合后面熔结痕分析结果说明浇口开设是合理的。温度场分结果如图3所示，结束时温差比较大，可能原因是此模具采用热流道技术，而CAE分析结果按冷流道汁算得出。若出现注射结束时不同位置的温差太大，就很难获得均匀的冷却，不同的温度将导致聚合体的密度和性能都发生着改变，这样会产生翘曲。同时可能会产生较大的因温差引起的残余应力。压力场结果如图4所示，因为热流道原因，出现轻度压力不是现象。若出现压力不足现象应考虑以下因素：材判流动性不够；制品过大而零件壁厚很薄；流道长度过长；需要分级注射。剪切应力场结果如图画所示，应力场均匀，不会产生喷现象。CAE优化分析时必须考虑到分析时所用STL，文件没有坐标，不能精确定位，会人为引入流动不平衡因数。大型注射模常用热流道或冷、热流道结合技术与CAE分析假定的冷流道有很大区别，这也给分析带来很大误差。4 保险杠大型注射模热流道设计在设计大型塑件模具浇注系统时，既要保证型腔充满，又要减少因系统设计不当给制品带来的缺陷。特大型塑件常采用多级分流道。多点同时浇注方案。复杂的浇注系统在提高塑件质量的同时也使设计的难度增加。因此，浇注系统的设计是设计大型注射横的关键之一。 本次没计采用热流道技术，这项新技术的开发乃是注射模的一次重大改革。它的应用不仅缩短了成型周期、提高了生产效率，同时也节省了原料。在大型模具设计中，热流道系统设计应用愈来愈广，特别是热流道模具，它是大型模具的发展方向。 下面就热流道模具加以讨沦。热流道模贝之所以得到广泛应用，是因为它具有以下独特优点：缩短成型周期，一般可达30-40；避免回收大量回头料从而节省原料，降低成本；由于严格控制温度，因此提高了制品质量，保证了制品的尺寸精度和强度；热流道有利于压力传递，从而可以降低注射压力；缩短开模行程，有利于保护模具，延长模具使用寿命；无需修剪料把，节省工时和人力；缩短制模周期，制品成本降低，在一般情况下生产成本降低16。 根据CAE分析结果，采用AutoCAD软件进行二维模具设计，本模具设计为单型腔，热流道、9点进浇、内侧抽芯等技术。合模过程由两矩形导滑块导向，最后由锥面定位锁紧。模具总长2000mm，宽1200mm，高1440mm，模具结构总图如图6所示。二维模具设计的基本步骤如下：(1) 绘制制品二维结构图，确定好分型面，浇口的位置及尺寸大小。(2) 采用金属零件包围制品内外表面。(3) 设置浇注系统、合模导向机构、顶出系统、加热冷却系统。(4) 按动、定模分型面绘制左右动定模的方位图。(5) 在动、定模视图中分别表示出相关零件的装配坐标位置。(6) 采用另一个视图表达未完整主视图的相关内容。(7) 在主视图下方绘出制品图，并标注产品的尺寸。(8) 标注零件序号，并列出零件明细表中的材料、件数、热处理等技术要求。(9) 在总装图中写山技术要求及模具的动作原理.5 大型注射模主要参数校核(1)加热流道板的热功率计算。热流道板相当于延伸了注塑机喷嘴，使得熔料流程大为缩短，有利于熔料的填充。但是采用热流道浇注系统需配备精碗的模具温度控制器，以防止熔料温度过高而烧焦。加热管功率一般凭经验按每kg热流道板需0.1-O.15kW估算，也叫按下式进行计算(2)型芯、型腔的加热冷却系统。 模温是影响制品质量及成型效率的一个重要因素。在使用了热流道的模具中，一方面热流道需要加热而另一方面模具需要冷却。且由于此模具体积巨大模具开始工作时模温低，需要预热，工作一段时间后模温上升超过规定温度时又需要冷却。聚丙烯(PP)的成型温度在160-260，其模具温度应控制在5565。大型注射模最好用自来水冷却，比较经济，冷却水孔直径一般在8-12mm。 大型注射模加热装置一般为电加热棒加热，它有方便、易控制等优点，但必须防止局部过热。(3)型腔侧壁厚度计算。理论分析与实践证明，大型模具的刚度是中要问题，而强度足次要问题。故成型件尺寸应以满足刚度条件为前提，聚丙烯所允许挠曲量在0.03-0.04mm。将侧壁看作是受均布载荷的固定梁模型，由挠度公式可推出允许最小侧壁厚度：对于此保险杠模具:(4)动模垫板问受力变形计算，方法原理同侧壁校核，允许最大挠曲量一般取0.05mm。一般对大型注射模还需进行制品对型芯包紧力的计算及顶出力的校核；连接螺钉顶出杠强度校核等。可参见注时模设计手册。6 结束语 设计保险杠大型注射模应注意的问题： (1)应认真分析产品几何结构，选择好分型面；CAE优化分析选择浇口形式、大小、数目及进浇位置。 (2)确定产品所用原材料常需要流动性好(即熔体流动指数大的塑料)、有利充模；好的机械力学特性，能保证轿车在冲击下不变形、有弹性回复；耐恶劣环境气候变化而不变形(翘曲)。(3)大型或特大型注射模设计应考虑使用热流道或冷、热流道相结合的浇注系统。(4)加热、冷却是大型注射模设计需要解决的一对矛盾。(5)大型注射模顶出系统一般很复杂，常需要机械液压联合顶出。Abstract that the plastic safety bar substitutes metal being sure shouldering is that automobileindustry developing trend, but plastic safety bar design adopt the tradition design for die and mould method at present still. Therefore the main body of a book type cavity pressure , the forward position melting experiencing and observing the temperature and being on the move adopt China tomould the CAE (HSCAE) software injecting a model to saloon safety bar have entered the mainparameter optimizing analysis and the simulation , injecting a model at the same time to the safety bar specifically for saloon front safety bar products structure, having carried out the core ofschool. Study result indicates the main body of a book the design procedures adopting can beimmense raising a safety bar injecting a model designing development efficiency.Keyword safety bar injection model heat current says CAE1 preface mounts development of job with the automobile, entire the more and more unadaptable metal safety bar Hyundai Motor request in the field of make light of quantization , high enginery-rization and unifying with car body model and so on, the plastic safety bar especially useful on the saloon , light vehicle, substitutes entire metal safety bar trend. And as iron and steel piece of replacement product, the plastic safety bar makes light of an automobile with whose attractive appearance , weight , molding , be able to bear corrosion , cost low , synthetical mechanical performance are easily fine, scale-rization childbirth easy to come true waits for merit to have occupied a space for one person in automobile industry. At present, our country saloon. That minitype vehicle , light vehicle etc. produces a manufacturer is realizing the renovation and upgrade being a products turn step by step.2 saloon front safety bars geometries structural analysisPicture what 1 shows a part is a Mazda saloon front safety bar, part wall thickness 3.5 mms, generally, had demanded a request to make piece of surface nothing defect glossy , do not had to its external form accuracy. 715 mms, are 538 mms taller than if picture what 1 shows , the safety bar form are shape of a saddle , 1925 long mms , width, average wall thickness is 3.5 mms. The ellipse light hole controls every one, centre is the grid being ventilated , reinforce a tendon on the inner side some. The tail assembly has inner side to curl , needs to adopt inner side to take a core out therefore.Safety bar material requires that stiffness is easy to be able to bear within broader temperature range, pounding a function well , the dimension stability is able to bear the function of menstruum easy to spread dress well,well. The miscellaneous energy propylene is synthesized is fairly good , is safety bar material therefore selecting and using polypropylene (change nature) here.Designed that the safety bar mould characteristic is: Mould external form dimension big (2400 mms X 700 mms X 11 OOmm) , volume duplicate each other (25 40 ts) , structure is complicated , are similar with for a medium degree machine tool; Mould teeming system is that heat current says , needs an electrical heating; The type cavity , core cooling system are complicated , the type cavity and systematic heat current of teeming contradict mutually; And take place products top system is complicated , hydraulic pressure in common use , machinery unity support out, adopt machine hand to take out products voluntarily; The products dimension is big , teeming system is often cold, heat current combines each other.3 CAE optimize analysisOn injecting model population structure to saloon front safety bar , using a function to control (the design reaching architectural designing including pouring the system molding part and the guiding device , measuring to being allotted a type taking core organization , the model temperature out a control device) concretely and so on of mould carrying out the basis setting up all round, has adopt the development country of Huazhong University of Science an Technology mould priority laboratory HSCAE (China moulds CAE) software to carry out the optimization and the development simulation analysis , has changed thereby that depended solely on the location and dimension coming to design the mould running gate artificial experience in the past, Require that many times tries a modelRelapse revises , ability designs finally the method getting into form and making the mould falling behind. Should the problem carrying out, with course that can cut down the seriation designing that the personnel estimates that complication giving a mouth extra a dimension works , acceleration our country designs that to large-scale saloon injection model , fabrication and the product cattle produce again and again tremendously.Plastic form dimension , the molding temperature , molding speed molding pressure , molding time , model cavity moulding a piece with the material function in flow and molding , in type cavity, surface a series of factor such as condition and design for die and mould is relevant when plastic injection molding. CAE optimizes analysis being to make use of the computer high speed arithmetic function , to consider the various factor synthetically , reach field , the temperature , pressure being on the move , shear strain waiting to simulate result, appraise what be used a scheme superior or inferior rank thereby. Use the development HSCAE5.0 of Huazhong University of Science an Technology mould country priority laboratory software to carry out optimization analysis here。The field being on the move analyses result if pursuing what 2 shows , that the running gate establishes its the explanation being on the move being balanced , forming trace analysing result combining with melting later is rational.The temperature is allotted if result pursuing what 3 shows, the difference in temperature is comparatively big when being over , possibility cause is that this mould adopt heat current to say technology, but analytical result of CAE finally reaches according to cold runner juice. Inject the very big , right away very difficult to gain homogeneous difference in temperature cooling being unlike location when being over if appearing, the different temperature the density and function leading to the polymerization body is changed being happening , this may produce buckling. May possibly produce remains strain that bigger reason difference in temperature arouses at the same time.Pressure bears fruit if pursuing what 4 shows , making light of degree pressure because of heat current says that cause, appears is not phenomenon. If pressure appears, the insufficient phenomenon should consider the following factor: (1) material be sentenced to flowability insufficient; (2) products is too big but part wall thickness is very infertile; The runner length is too long (3) The runner length is too long; (4) require that classification gets a shot.Shear strain finally gushing phenomenon if what picture shows , strain come into being homogeneous incapable。CAE optimization analytical now and then must think arrive at analytical now and then used STL, document not coordinate, unable accurate fix position, meeting artificial introduction be on the move unbalance factor. Large-scale injection model heat current in common use is say or cold, heat current says that the cold runner linking technology with CAE analysing assumption has very big differences , this to bring very big error to very big error analysis also.4 Heat current designs large-scale safety bar injection modelsDuring the period of the system designing that heavy section moulds piece of mould teeming, now that want the guarantee type cavity be full of, will fall off again designing the defect not should be brought about by products because of system. The super-huge type moulds a document often adopt multistep to shunt saying. The multiple spot pours a scheme at the same time. That complicated teeming system moulds piece of mass simultaneous in rise also makes the degree of difficulty designing that increase by. Therefore, pouring systematic design is one of the horizontal key designing that heavy section gets a shot.Have not been a significant reformation adopt heat current to say that the technology , this new technique exploitation are indeed to be to inject a model originally time. Not only, its application has shortened the molding period , has improved an efficacy, have economized at the same time also raw material. In large-scale design for die and mould, heat current says that system designs that application is broader and broader , heat current says that mould , it are large-scale mould development direction especially.With regard to heat current, the mould gets men at the lower levels additionally fall to. Heat current says that model cowry gets extensive use , is unique merit because of it has the following: Shorten the molding period , the sort but amount to 30%- 40%; Avoid reclaiming a great quantity turning about to expect economizing raw material , cost reduction thereby; Products dimension accuracy and intensity having controlled the temperature since strict , having improved the products mass, guarantee therefore; Pressure beneficial to saying transfers heat current to, can reduce injection pressure thereby; Shorten the model route or distance of travel , life time beneficial to protecting a mould , prolonging a mould open; Need not trim material with economizing the working hour and manpower,; Shorten the moulding period , products cost reducing , produce Cheng under ordinary circumstances。Analyse result according to CAE , adopt the AutoCAD software to carry out two-dimensional design for die and mould, design for die and mould is a Shan type cavity , heat current says that 9 oclock enters technologies such as irrigating , taking a core out on the inner side. Agree well with model process leading smooth piece guiding from two rectangles, locking fixing position finally from the conic surface. Mould cabinet minister 2000 mms , width 1200 mms , 1440 high mms, if mould structure general view pursuing what 6 shows.Fundamental two-dimensional design for die and mould step as follows：(1)Draw two-dimensional structural drawing of products, ascertain location and dimension size easy to be allotted type face , the running gate. (2) adopt the metal part to surround products inside and outside outside. (3) sets up teeming system , closes model guiding organization , is equivalent to system out , heats cooling system. (4) draws a retinue moving bearing picture fixing a model face to face according to moving , fixing a model be allotted a type. (5) expresses out relevance part assembling coordinate location respectively in moving , fixing model view. (6)adopt another view to express not entire front view relevance content.7) dimensions drawing out products picture, and marking a product on the down part in front view. (8) marks the part serial number , standing side by side out specification such as material ,numbers heat treatment in part detail list. (9) write mountain specification and the mould action principle in general dress picture.5 The main large-scale injection model parameter is proofreaded(1) heats the unnatural thermal power of Liudao secretly scheming against. Heat current says that board has been equal to extending injection machine spray nozzle , will do melt expecting that technological process shortens extremely , beneficial to melting material filling. But adopt heat current to say that teeming system needs allocating the mould temperature controller being skill in a bowl, to prevent from melting expecting that the temperature is excessive but charring. Like heating pipe power, heat current says that board needs 0.1-O let experience push down every kg. Estimate , also call 15 kW to press down style being in progress secretly scheming against (2) cores , type cavity warmup cooling system.The model temperature is a key factor affecting products mass and molding efficiency. In the mould having used heat current to say, on one hand, heat current needs to heat but the another aspect mould needs to cool down. And when exceeding the regulation temperature since the model temperature requires that the period of time queen model temperature preheating , working rises low when this enormous mould volume mould begins to work, need to cool down. The polypropylene (PP) molding temperature is in 160 C- 260 C, whose mould temperature should be in 55 C under the control of 65 C. Use running water to cool down , parallel large-scale best injection model economy, the chilled water hole diameter is just like in phi8-phi12mm.The large-scale injection model heats the device sort for the electrical heating stick heats , it has merit such as convenient , easy to control, but guards against part be obliged to hotness.(3) type cavity oblique tones wall thickness secretly schemes against.Theoretical analysis and practice are testified, large-scale mould stiffness is middle want problem, but the intensity is fully secondary questions. Therefore the molding document dimension responds to satisfy stiffness, condition are allowed bend amounts by the premise , polypropylene in 0.03-0.04mm. Oblique tones wall look upon as being to accept the fixed beam model spreading loading equally , to may debut a
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