热成型工艺中车门防撞梁成本优化

本文从介绍热成型工艺的国内外发展历史开始,并对热成型工艺及热成型零件的分类以及热成形生产设备和配套设施进行介绍和详细的成本分析。通过对原材料、开卷落料工艺、热冲压工艺、激光切割工艺、废品损失率、包装运输费、管理利润费等费用进行深入分析,同时结合生产纲领、平均冲次(ASPM)、人工成本、场地/设备分摊投资等因素,利用标准成本控制法得出企业的实际制造成本。通过对设备改造和模具改造,节省激光切割工艺,并降低制造成本费用。     

塑料模具设计及工艺分析

模具是塑料成型加工工艺的一种重要设备,而浇注系统又是注塑模具结构设计中的关键环节,是熔融态塑料进入模具型腔的必经通道。结合注塑模具在机械、电子、航空航天和日常生活等领域的广泛应用,展望了其广阔的发展前景,通过介绍注塑模具在设备生产中的重要性,以及注塑模具浇注系统的结构与设计,综合分析了注塑模具的工艺性,包括温度变化、成型压力、成型时间以及塑件成型不良的原因。     

强制配流型回转式液压振动机在材料成型中的研究

该文介绍了回转式液压脉冲型振动装置的工作原理和构成。通过对振动机应用于粉粒料成型中试验数据的分析,研究振动应用于成型中的最佳工况,将振动与现有成型工艺结合,改造现有设备,提高成型件的质量。实现生产设备小型化,减少设备投资。     

PEEK复合材料及其在风电滑动轴承中的应用

围绕聚醚醚酮(PEEK)复合材料在滑动轴承中的应用，阐述了PEEK材料的耐磨性、耐高温性、材料相容性等综合性能，总结了表面改性、纤维增强、颗粒填充及聚合物共混等改性方法；分析滑动轴承出现胶合、划伤等故障的原因，提出PEEK复合材料摩擦磨损性能研究的必要性；对比PEEK复合材料各成型方法的成型效率、制品强度，分析了注塑成型、热压成型、模压成型、缠绕成型等成型方法的优缺点；基于自润滑聚合物复合材料与金属基底结合机理，对比了采用机械互锁法、化学键法、添加增强体及激光处理获得结合界面的剪切强度；结合PEEK复合材料在压缩机、水泵、磁力泵、高温机械等设备中的应用，探讨了PEEK复合滑动轴承在风电领域应用的可行性，指出后续应以服役性能为目标，结合智能维护、寿命预测等技术，开展PEEK复合滑动轴承的设计与研发。     

焦碳塔现场组对质量控制

介绍了焦碳塔的结构特点，分析了焦碳塔在制造过程中的技术难点，提出了现场分段成型制造时，确保设备纵、环焊缝成型质量的工艺方法。     

纳米塑料发泡板材成型系统的设计与研究

影响发泡塑料制品性能的因素很多,除材料配方外,还与连续挤出成型设备中的螺杆结构、发泡成型模具等主要部件的结构及各区控制温度等工艺参数有关,机电有机结合,合理的结构设计和严格的参数控制是获得合格制品的关键.实验中,调整纳米粒子的含量、调节设备及工艺条件,得到了性能优越的发泡板材.     

精密注射成型影响因素分析探讨

精密注射成型作为一种新的注射成型工艺方法,其特点就是能成型尺寸精度高,而且具备良好的机械、力学性能以及尺寸稳定性的塑料制品.本文从塑料材料、模具设计与制造、成型工艺和成型设备等方面对影响精密注射成型的因素进行了讨论,并给出了相关的解决办法.选择适当的塑料原材料、提高模具设计与制造质量、控制好注塑工艺参数及合理选择注塑成型设备,才能更好地发挥精密注射成型技术在塑料制品成型生产中的作用,成型出高精度、高性能的精密塑料制品.     

异型线材连轧设备结构分析

对冷态金融异型线材连续轧制成型工艺与设备进行了分析，提出一种新型设备结构，具有适用性广泛，精度高，调整方便，重量轻，结构紧凑，造价低廉，占地面积小等优点。     

水压成型技术在飞机副油箱生产中的应用

从水压成型原理、设备结构特点、工艺过程和影响因素分析等4个方面,介绍了水压成型技术在飞机外挂副油箱生产中应用,该成型技术与其他成型技术相比,具有较低廉的成本优势,加工品质稳定可靠,适合于批量生产,是副油箱产品制造必不可少的工艺手段之一,对其他薄壁旋转体件也有一定借鉴作用。     

基于Moldflow的冰箱抽屉侧面变形数值模拟和参数优化

针对冰箱透明长抽屉成型时的质量缺陷——侧面变形,平面度超标问题,基于Moldflow进行了参数建模和网格划分,采用单因素实验分析方法,选取了6个成型工艺参数分组进行了数值分析和参数优化。通过对结果比较和分析,最终得出了一组最优的工艺参数,其中,随着保压时间和冷却时间的延长,侧面变形量明显减小。经生产实践验证了其该组参数的合理性。     

注塑模冷却时间优化设计

针对冷却系统在塑胶模注射成型过程中的重要地位,利用专业模流分析软件MOLDFLOW对注塑抽屉的冷却系统中冷却时间的优化进行了研究。重点介绍了MOLDFLOW软件对模具冷却系统进行计算机模拟分析的过程,主要对模具冷却回路和冷却时间进行了优化设计,获得了高预测质量的产品,进一步说明合理的冷却系统设计对提高产品质量、缩短成型周期、提高生产率和降低能耗提供了有利保证。     

Study of injection molding process simulation and mold design of automotive back door panel

Numerical simulation of the injection molding process of the outer panel of the automotive plastic rear door and mold design is presented here. Computer aided three-dimensional interactive application (CATIA) is employed to design the original automotive steel structure, and the modal and thermodynamic properties of the plastic back door outer panel are changed by changing the different injection materials of the back door outer panel. In order to efficiently design the panels, finite element analysis is used to verify whether the designed parts meet the mechanical properties requirements such as light weight, low fuel consumption, short production cycle, strong modeling design, high corrosion resistance and good recovery, the above main parameters have been evaluated, and the above main parameters are carried out evaluate. To simulate the injection molding process, computer aided engineering (CAE) software such as ANSYS and HyperWorks are used to analyze the back door of the selected material. After the numerical analysis, suitable material is selected, so that the modal and thermodynamic properties of the product could be satisfied as well as improved. Unigraphics NX (UG) is employed to design the convex and concave mold for the injection molding of the automobile’s plastic back door panel. Combined with the characteristics of the parts and the design requirements of the injection mold, the multi-scheme design of the pouring and cooling system is carried out. By comparing the effects of different gating and cooling systems on injection molding, the best gating and cooling system is selected. The artificial fish swarm algorithm is used to optimize the process parameters of the injection molding process, and the best combination of the injection molding process parameters of the outer panel of the rear door of the automobile is obtained.

     

基于Moldflow的魔方中心轴注射分析与优化设计

应用Moldflow软件对魔方中心轴的注射成型过程进行浇口位置、充填、冷却和翘曲等模拟分析。通过在不同注射工艺条件下进行对比分析,确定了注射的最佳工艺参数:充填时间为2 s,注射+冷却时间为8 s,模具温度为40℃,熔体温度为240℃,注射压力为100 MPa。应用UG软件建立了注射模具的实体模型,解决了传统注射模具设计方法存在设计周期长、成本高且质量难以保证等问题。     

Influence of molding conditions on the shrinkage and roundness of injection molded parts

During the plastic injection molding process, one of the biggest challenges is shrinkage which deteriorates the quality of produced parts. To control and reduce this defect, the essential way is to perfectly determine the variables like molding parameters. In this study, the effects of molding parameters including packing pressure, melt temperature, and cooling time on shrinkage and roundness have been investigated experimentally. Also, the relationship among initial molding parameters, the cavity pressure, and mold temperature was investigated. The results of this experimental study and analysis fulfill various requirements of plastic injection molding and clarify the relationship between molding conditions and the overall quality of produced parts. This study illustrated that packing pressure and melt temperature are dominant factors which determine the quality of parts.     

A nondestructive online method for monitoring the injection molding process by collecting and analyzing machine running data

Nondestructive online monitoring of injection molding processes is of great importance. However, almost all prior research has focused on monitoring polymers in molds and damaging the molds. Injection molding machines are the most important type of equipment for producing polymeric products, and abundant information about actual polymer processing conditions can be obtained from data collected from operating machines. In this paper, we propose a nondestructive online method for monitoring injection molding processes by collecting and analyzing signals from injection molding machines. Electrical sensors installed in the injection molding machine, not in the mold, are used to collect physical signals. A multimedia timer technique and a multithread method are adopted for real-time large-capacity data collection. An algorithm automatically identifies the different stages of the molding process for signal analysis. Moreover, ultrasonic monitoring technology is integrated to measure the cavity pressures. Experimental results show that our nondestructive method can continuously monitor the injection molding process in real time and automatically identify the different stages of the molding process. The packing parameters, including the filling-to-packing switchover point and the packing time, can be optimized based on these data. Furthermore, the ultrasonic reflection coefficient and the actual cavity pressure have similar trends, and our technique for measuring the cavity pressure is accurate and effective.     

Mold design and forming process parameters optimization for passenger vehicle front wing plate

The main objective of the present article is to solve the problems of poor molding quality, large warpage, inadequate cooling effect and unsuitable selection of process parameters, in the injection molding process for passenger vehicle front-end plastic wing plate. The thickness and parting surface of the vehicle front-end fender were determined, the injection mold and its cooling system were designed. The relevant process parameters, affecting the product molding quality, were tested, according to orthogonal experimental approach, while their influence on the warpage was obtained, by analyzing the data. Finally, the BP neural network of warpage model was established and globally optimized using genetic algorithm. The optimal parameter combination of the injection molding process was derived as: melt temperature 236 °C, mold temperature 51 °C, cooling time 32 s, packing pressure 97 MPa and packing time 16 s.

     

精密注塑模具的注塑成型模拟

在精密注塑模具设计过程中应用计算机辅助分析的方法模拟注塑成型过程,对保证注塑成型产品的质量,提高生产率有极大的优越性。利用MoldflowPlasticInsight(MPI)软件对精密注塑模具的注塑成型过程进行了模拟,分别介绍了注塑参数、浇注系统和冷却系统的设计过程,比较了两套不同设计方案的注塑成型模拟结果。并对影响翘曲变形的各个因素进行了详细的分析。     

Optimization of injection molding process parameters using integrated artificial neural network model and expected improvement function method

In this study, an adaptive optimization method based on artificial neural network model is proposed to optimize the injection molding process. The optimization process aims at minimizing the warpage of the injection molding parts in which process parameters are design variables. Moldflow Plastic Insight software is used to analyze the warpage of the injection molding parts. The mold temperature, melt temperature, injection time, packing pressure, packing time, and cooling time are regarded as process parameters. A combination of artificial neural network and design of experiment (DOE) method is used to build an approximate function relationship between warpage and the process parameters, replacing the expensive simulation analysis in the optimization iterations. The adaptive process is implemented by expected improvement which is an infilling sampling criterion. Although the DOE size is small, this criterion can balance local and global search and tend to the global optimal solution. As examples, a cellular phone cover and a scanner are investigated. The results show that the proposed adaptive optimization method can effectively reduce the warpage of the injection molding parts.     

A combined analytical hierarchical process (AHP) and Taguchi experimental design (TED) for plastic injection molding process settings

Injection molding process is without doubt a multi-objective process if processing time, productivity, effectiveness, and the multi-criteria quality of the product are taken into consideration. Process settings affect the degree by which these objectives are realized. This work suggests a new proposal for evaluating optimal process settings through the handling of the plastic injection molding process in the same approach as a traditional multi-objective multi-criteria process. In a sense, there are numerous objective functions including cooling time, volumetric shrinkage, warpage, sink marks, residual stresses, and various process settings including temperature, pressure, etc. Within the suggested proposal, the Taguchi experimental design is used to generate a balanced set of experiments to explore the process; then, the finite element software SIMPOE is used to evaluate the behavior of the injection molding at each experimental setting. Analytical hierarchical process is then employed for multiple comparisons of the objectives and experiments as such to give the overall objective weight for each process setting (experiment). Analysis of variance is then used to evaluate the significant factors and the optimal setting of the process. This technique proved effective to obtain compliance between process design and several common manufacturer preferences, although the considered part was not changed.     

超薄塑件注塑成形特性的试验研究与数值模拟

薄壁注塑成形技术具有节约材料、降低成本、减少制品重量和外形尺寸等优点,可促进移动电话等电子产品的迅速发展,特别是超薄塑件的注塑成形技术在微机电领域具有巨大的应用潜力。但随着制品厚度的减小也使注射成形难度加大,填充过程更为复杂,成形特性有待探索。设计制造出可成形超薄塑件的模具,利用正交试验方法(田口方法)进行充模试验和数值模拟技术研究各工艺参数(注射速度、注射压力、熔体温度、注射量和制品厚度等)对超薄塑件注塑成形充模过程的影响。研究结果表明,制品厚度对超薄塑件的填充起决定性作用;注射量及注射速度对超薄塑件注塑成形的填充起主导作用,提高注射速度能大幅度地提高填充率;熔体温度和注射压力相对于注射量和注射速度只起次要作用,但在填充过程中,高的熔体温度和注射压力也是必要的。