A CAD/CAE-integrated injection mold design system for plastic products

Mold design is a knowledge-intensive process. This paper describes a knowledge-based oriented, parametric, modular and feature-based integrated computer-aided design/computer-aided engineering (CAD/CAE) system for mold design. Development of CAx systems for numerical simulation of plastic injection molding and mold design has opened new possibilities of product analysis during the mold design. The proposed system integrates Pro/ENGINEER system with the specially developed module for the calculation of injection molding parameters, mold design, and selection of mold elements. The system interface uses parametric and CAD/CAE feature-based database to streamline the process of design, editing, and reviewing. Also presented are general structure and part of output results from the proposed CAD/CAE-integrated injection mold design system.     

基于模拟的注塑工艺分析设计集成系统的开发

将模具设计、制造和注塑工艺作为模具设计开发过程中的三个重要因素 ,提出了在模具设计阶段并行地进行注塑工艺方案设计的思想。开发了一套基于 C- MOL D系统的注塑工艺方案设计系统 ,该系统是基于并行设计思想 ,集成了 CAD和注塑过程 CAE分析系统部分信息的新平台 ,为在模具设计阶段进行注射工艺方案的并行设计和在注射工艺方案设计阶段进行工艺方案评价提供了一个集成环境     

CAE技术在注塑成型浇注系统优化设计中的应用

注塑模浇注系统是塑料注塑成型模具设计中的关键技术之一,利用CAE软件Moldflow可对不同浇口位置进行流动模拟分析,预测可能存在的气泡和熔接痕的位置,为模具设计人员优化模具设计提供依据,提高一次试模的成功率。并经过实践证明,注塑成型中通过浇注系统位置的优化可以显著提高产品的质量。     

Virtual plastic injection molding based on virtual reality technique

Virtual reality (VR), as a new technology, is integrated with software systems for engineering, design, and manufacturing. The integration has given a new impetus to the field of computer-aided engineering. This paper presents a research effort aimed at creating a virtual plastic injection molding (VPIM) environment, which is designed and implemented based on techniques such as VR, multidiscipline simulation, and scientific visualization. The VPIM system includes two parts: designing in VPIM and evaluation in VPIM. It is the first system to scrutinize virtual prototype mock-ups of new products, machines and production processes in interactive graphic simulation. During the evaluating phase, coupled to appropriate computer-based reasoning and decision-support tools and driven by data from the real manufacturing environment, a realistic impression of the process of plastic injection molding and manufacture can be achieved and can be changed interactively, and it is possible to thoroughly examine the planned system and eventually detect and remove any defects and inadequacies. The construction approach and key techniques (FEA, virtual assembly, stereoscopic display, a triangulated boundary-representation of an approximating polyhedron, collision detection, etc.) of the system are described in detail. The overall system is a powerful new approach for highly relevant industrial application of VPIM which focuses on the construction and assessment of alternate manufacturing sequences and mold design in an early design stage. Improvement of the design and manufacturing process will lead to better design and reduced development time and cost.     

CAE与塑料成型质量分析

塑料模具的设计不但采用CAD技术,而且还要采用CAE技术,这是发展的必然趋势。CAE技术提供了从制品设计到生产的完整解决方案。在模具制造之前,CAE技术可以预测塑料熔体在型腔中的整个成型过程,帮助研判潜在的问题,有效地防止问题发生,并能缩短产品的开发周期,降低生产成本。本文从一个生产实例出发,用Moldflow软件对该制品的注射成型方案进行分析比较,从而找到解决制品质量问题的途径。     

基于Moldflow对突变壁厚塑件的注塑成型优化方案的研究

利用Mold flow/MPI技术对摩托车外壳进行CAE注塑模拟分析,预测了成型过程中的填充流动情况,并对型腔的填充时间、压力分布、锁模力大小等进行计算分析,掌握了翘曲变形产生的原因。根据注塑模拟分析结果优化了浇口、冷却系统设计方案和成型工艺参数,使模具设计更趋合理。优化后的成型方案用于实际生产,缩短了试模周期。     

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CAE技术的电子琴上盖塑件的熔接痕缺陷优化研究

利用注塑模CAE技术对电子琴上盖的注塑过程进行分析,并结合产生的熔接痕缺陷,对电子琴盖板的浇口位置、数量进行了详细的分析,最后得出比较优化的参数设置,进而注塑出品质较好的电子琴盖板.     

基于MPI的注塑成型分析

介绍了注塑CAE软件-MPI(Moldflow Plastics Insight)的应用流程和方法,应用MPI软件进行制件注塑成型过程模拟分析,优化模具浇注系统、冷却系统和注射成型工艺方案,为生产优质塑料制件提供理论指导.     

光学塑料透镜注射成型关键技术的研究

传统的塑料模具设计及注射成型工艺参数对经验的依赖性较强,难以满足高精度光学塑料元件的成型需求.采用CAD/CAE技术对光学塑料透镜注射成型的充模及保压过程进行了计算机动态模拟,研究了不同注射温度、压力、时间和保压温度、压力、时间对透镜面形质量的影响规律.     

天文望远镜底座注塑成型模拟

针对注塑成型过程中,影响注塑质量因素多的问题,运用CAE技术,对某型号天文望远镜底座进行注塑成型模拟,预测可能出现的缺陷,得出一组经过CAE分析优化的数据应用于实际生产,缩短模具的试模时间,获得合格的产品.     

Integrated simulation of the injection molding process with stereolithography molds

Functional parts are needed for design verification testing, field trials, customer evaluation, and production planning. By eliminating multiple steps, the creation of the injection mold directly by a rapid prototyping (RP) process holds the best promise of reducing the time and cost needed to mold low-volume quantities of parts. The potential of this integration of injection molding with RP has been demonstrated many times. What is missing is the fundamental understanding of how the modifications to the mold material and RP manufacturing process impact both the mold design and the injection molding process. In addition, numerical simulation techniques have now become helpful tools of mold designers and process engineers for traditional injection molding. But all current simulation packages for conventional injection molding are no longer applicable to this new type of injection molds, mainly because the property of the mold material changes greatly. In this paper, an integrated approach to accomplish a numerical simulation of injection molding into rapid-prototyped molds is established and a corresponding simulation system is developed. Comparisons with experimental results are employed for verification, which show that the present scheme is well suited to handle RP fabricated stereolithography (SL) molds.     

冰箱冷冻室抽屉注塑模CAE分析

针对某冰箱冷冻室抽屉的结构特点及成型规律，在模具制造之前，结合选用的材料和设备，经过冷冻室抽屉模型导入、网格划分、成型设备参数输入、原料选择、注射速度初步设定等步骤，在计算机上进行填充、流动、冷却等CAE分析，确定了理想的浇口位置，设计了其冷却系统，结合成型工艺窗口分析模块，预测了能够生产合格产品的成型工艺条件范围。     

基于Pro/E的扣板模具设计与制造

文章叙述了扣板塑件的注射成型工艺分析,扣板模具的Pro/E模具设计、模具的虚拟装配干涉检测,模具零件加工工艺分析,复杂模具零件的数控加工程序的自动生成、加工仿真等。     

基于Moldflow与正交试验法的注塑参数优化

在塑料产品的开发过程中,涉及到塑料模具进行注塑,注塑模具开发方案确定后,最重要的就是如何选择注塑参数。注塑参数可以在注塑机上直接进行试生产来调试,但必须是模具制造出来之后才能进行,对场地和设备均有要求,而且在试模过程中会浪费一定的塑料原材料。本文采用正交试验法对注塑参数进行优化,利用Moldflow软件的模具CAE技术对正交试验过程各种取值情况进行验证,并对最终优化组合进行验证,检验正交试验的正确性。确定翘曲变形量为实验指标,以注射温度、模具温度、充填时间、冷却时间、保压时间为变量的5因素,取各自允许取值范围进行4均分得到4水平,形成一个5因素4水平的正交试验矩阵设计实验,找出KDC-1型电磁断路器塑料壳体充填优化组合,通过在Moldflow的验证,及时反映了该正交试验结果是正确的注塑参数最优组合。     

面向虚拟制造的塑料注射成形CAE模拟

虚拟制造是塑件及模具计算机辅助设计技术的发展方向,为了有效地将CAE集成到塑料注射件的虚拟制造系统中,建立了基于表面模型的智能CAE分析系统。通过引入表面模型取代传统的“中性层”模型,使CAE与CAD的集成成为可能,并突破了原有CAE软件的建模瓶颈。将人工智能和专家系统技术充分应用到CAE分析中,指导用户设计初始方案、评价分析结果并在此基础上优化设计,提高了CAE的应用价值和使用效率。     

基于CAE分析的塑件3D制造技术的研究

为提高塑件生产质量,研究了CAE技术应用于注射模设计,论述了该技术的优点和意义;结合具体塑件,在浇注、冷却系统确定的前提下,CAE分析能够模拟注射过程,以流动、冷却和翘曲分析为例,分析结果以3D彩图形式给出,形象直观.通过应用CAE分析克服了以往只有在试模中才会发现的问题,缩短模具设计、制造周期,优化了注射模设计,提升了塑件质量.     

CAE技术在注塑产品中的应用

应用CAE软件Moldflow对充电器底座进行流动模拟分析,发现产品成型存在欠注.在分析了欠注产生原因的基础上,通过优化充电器底座结构,以及调整模具温度、熔体温度、注射时间、保压压力和时间等注塑工艺参数,解决了欠注问题,同时改善了翘曲变形,保证了注塑产品的成型质量.     

大型注塑模浇注系统设计研究

大型模具在制造设计等方面与普通的中小注塑模具相比没有很大的区别，而且用CAE分析可以很好地解决模具制造中遇到的一些如成本高等问题，并且提高了大型注塑模具开发的成功率。     

薄壁注塑件翘曲的正交分析及优化

分析了注塑制件翘曲的原因,采用著名的CAE软件Moldnow与正交试验方法,对不同工艺条件下的注塑成型过程进行模拟分析并对正交实验数据进行极差分析,确定注射时间、保压压力、保压时间、冷却时间、熔体温度、模具温度以及冷却液温度等注塑成型工艺参数对制件翘曲变形的影响程度,得出最优的注塑成型工艺参数组合,并以一薄壁导光板对该工艺组合方案进行模拟验证与实际注塑实验验证。