高精度碳纤维反射器制造技术

碳纤维复合材料制件在雷达产品中的应用越来越广,文中介绍了一种获得毫米波高精度反射器的先进工艺方案。首先设计研制高精度母模和碳纤维复合材料模具,然后以该高精度复合材料模具为基础,筛选高性能、成型工艺性好的碳纤维预浸料,通过铺层设计、工艺参数优化等手段,采用热压罐法成型出高精度的碳纤维反射器,之后利用先进的真空镀膜金属化方法对反射器进行金属化。最后获得的Φ400 mm反射器的型面精度为0.039 mm,达到了毫米波的精度要求,其重量仅0.9 kg,较原铝反射器减重80%以上。     

一种快速制作栅格天线的新型解决方案

文中以一种树脂基碳纤维复合材料栅格天线反射面的制作成型为研究对象,详细阐述了该反射面成型后脱模模具工装的设计及成型方案。该栅格反射面所使用的主要材料为东丽公司的T700,基体为3234树脂体系。通过对复合材料模具的设计制作及使用、复杂复合材料制品二次脱模等方面的研究,提出了用球墨铸铁及碳纤维复合材料制造模具、采用真空袋热压罐成型工艺的新型解决方案。结果表明：与传统金属模具相比,在较大温差下复合材料模具具有尺寸精度更稳定、制作更简便、重量更轻等优势;利用复合材料过渡模具实现栅格反射面二次脱模可以大大提高生产效率。该方法对此类栅格反射面的制作具有指导意义。     

碳纤维喇叭天线制造工艺研究

喇叭天线是雷达系统中重要的功能件,碳纤维材料由于具有金属材料不具备的某些优异性能,在雷达系统中的应用越来越广泛。文中介绍了一种碳纤维喇叭天线的制造工艺过程,对喇叭天线原型结构的工艺改进设计满足碳纤维材料热压罐成型工艺和成型模具设计要求;成型模具结构设计满足零件尺寸精度、脱模以及零件批量生产要求;碳纤维喇叭天线表面金属化达到了金属层致密、均匀、光顺以及导电率指标。通过以上工艺过程研究,制造出满足指标要求的碳纤维喇叭天线,可为此类碳纤维喇叭天线制造提供工艺借鉴。     

一种高承载碳纤维复合材料机架的制造技术

碳纤维复合材料机架是为某特种飞机任务电子系统研制的电子设备安装平台,具有自重小、承载大、环境适应性要求高的特点。文中对高承载碳纤维复合材料机架的高精度制造和装配技术进行了研究。就机架的结构特点,分析了多种成型工艺方案,选择了合适的工艺方法,并在工装设计、零件成型、胶铆装配等方面进行了深入研究和实践。通过力学环境适应性试验验证,成型的机架性能稳定,满足设计和使用要求。目前,该机架已完成设计定型和交付,并实现了批量生产。     

碳纤维复合材料深腔壳体成型模设计

碳纤维复合材料深腔壳体零件成型后,由于冷却收缩,零件会紧紧包住成型模块,造成难脱模、易变形等问题。文中结合碳纤维复合材料的性能特点,针对这些问题进行了具体的工艺成型技术分析,设计了一种镶拼式锥面结构成型模块,利用开模工具分解模块。该脱模方式操作简单可靠。模具材料选用加工性好、尺寸稳定性高、膨胀系数与碳纤维复合材料最为接近的QT-500。制造出的零件表面平滑,尺寸稳定,精度高。该模具的设计较好地解决了深腔壳体类零件脱模难的问题,同时也为同类零件的生产制造提供了一种比较新颖的成型设计方法。     

热压罐成型框架式模具温度场分析

模具成型型面的温度均匀性对复合材料制件的成型精度具有重要影响。某大尺寸高平面度复合材料蜂窝夹层板构件利用热压罐工艺成型,模具为大型框架结构模具。文中采用有限元数值模拟方法,利用Simcenter12.0 软件对该大型框架结构模具热压罐成型工艺过程的温度场特性进行了模拟分析,模拟值与试验值误差小于10%,证明了模拟方法的准确性。模拟结果表明：成型固化工艺参数设置合理,模具型面温度均匀性较好,金属边框对模具的整体温度场影响较大;模具在热压罐内的位置在所设定的2.1 m 范围内沿长度方向移动对模具温度场的影响可以忽略。     

碳纤维汽车顶盖模压成型模具设计开发

针对奇瑞某车型顶盖零件,通过分析其结构特性,优化设计开发出碳纤维材质零件。结合湿法模压成型工艺技术特点及成型节拍要求(5min/件),设计开发碳纤维顶盖模具。通过理论分析,优化模具加热系统、冷却系统等关键部位,最终开发出涵盖两个下模的顶盖模具。在试模过程中,出现零件顶出困难问题,通过对模具进行修正(即在下模增加两处油缸气门,破真空吹气),试制出合格零部件,节拍控制在5min以内,表明模具结构与工艺可靠。     

插座面板注射模设计

通过对插座面板的结构、尺寸和成型要求进行分析,确定了合理的模具结构.文中阐述了模具中的分型面、型腔与流道的布置、脱模机构与冷却机构、斜顶机构的结构设计,介绍了模具的工作过程.该模具采用一模四腔的结构.     

碳纤维机载电磁屏蔽机箱制造工艺研究

某机载电磁屏蔽机箱对重量的控制要求严苛,因此采用碳纤维复合材料制造该机箱。文中论述了该碳纤维机载电磁屏蔽机箱的制造工艺过程,即对该整体成型机箱的制造工艺流程进行了介绍,并对模具设计、铺层设计、金属预埋件精确定位、表面金属化等关键技术进行了详细讨论。与相同结构的铝制机箱相比,该碳纤维机箱的质量减轻了约30%,并通过了电磁屏蔽性能测试以及振动、盐雾、湿热、温度冲击等环境适应性试验验证,完全满足设计和使用要求。     

Ka波段天线反射面板成型技术

介绍了铝合金高精度天线面板的成型技术,分析了关键技术和工艺装备,论述了采用"拉伸 负压"成型技术加工高精度Ka波段天线面板的工艺过程并成功运用在工程实践中.     

树脂基碳纤维复合材料栅格天线反射面制造技术

介绍了树脂基碳纤维复合材料(CFRP)栅格天线反射面的制造技术.纤维采用日本东丽公司的T700,基体为3234树脂体系,采用球墨铸铁制造模具,真空袋热压罐成型工艺.通过认真的工艺研究,突破了模具设计与制造、铺层设计、成型工艺等关键技术,制造的栅格天线反射面栅格条宽度和厚度均匀,外表光洁,型面精度高,满足了设计要求.     

数理统计在模具生产制程能力分析中的应用

用数理统计精确度指标CPK对模具生产的制程能力进行分析.按照CPK值将模具的制程能力划分为5个等级,并以5个尺寸的32组抽样数据为例,得出CPK等级在A级时,模具生产的准确性和精密度较高,可以生产出优质产品,无需对模具和成型工艺参数做任何修改;当CPK等级不在A级时,结合准确度和精密度的情况,给出了相应的模具及成型工艺参数的整改方案.     

超长、高精度铝蜂窝隔板制造技术研究

介绍了高精度铝蜂窝夹层结构隔板的研制概况,详细叙述了铝蜂窝夹层结构板成型过程中的变形控制技术,以及超长铝蜂窝夹层结构板的高精度加工方法。     

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.

     

UG在注塑模具设计与加工中的应用

当前模具制造业正处于一个品种繁多的大量生产状态,以适应国内外市场迅速变化的要求。数控技术及CAD/CAM技术的迅速发展使传统的模具设计与制造方式发生了根本性变化。现结合实际注塑模具的设计与加工阐述UG在注塑模具中的应用。它的应用可大大缩短模具的交付时间,为企业降低生产成本提供一个有效的手段。     

An affordable injection-molded precision hybrid glass–polymer achromatic lens

This paper describes the development of an affordable precision hybrid glass–polymer achromatic doublet fabricated by microinjection molding. This hybrid lens can be used to correct chromatic aberration by combining a flint and a crown glass. Specifically, polycarbonate was selected as the flint glass with higher dispersion and N-BK7 was selected for lower dispersion crown glass. Microinjection molding was utilized to apply the aspherical polycarbonate layer directly onto the N-BK7 glass lens’ surface in this study for its capabilities of precision microfeature replication and mass production. In addition, finite element-based numerical simulation for molding process was employed to assist the design to improve the manufacturability. To ensure high precision in the fabricated hybrid lens, mechanical alignment features were created on the mold inserts to position the finished polymer lens along with the insert that housed the glass lens. The mold inserts’ surfaces were diamond-turned to optically finished without polishing. It was demonstrated in this study that with properly designed manufacturing processes, an integrated hybrid glass–polymer lens could be fabricated without further mechanical alignment. Lastly, the optical performance of the hybrid lens was verified by focal shift evaluation.     

A framework of a concurrent process planning system for mold manufacturing

This paper presents a research on the development of a computer-based framework that supports concurrent mold manufacturing process planning. The practical goal of this research is three-fold: (1) to develop a systematic and concurrent mold manufacturing process planning model, (2) to develop a computer-based mold manufacturing process planning system based on the concurrent model, and (3) to develop knowledge bases to assist in concurrent type of mold manufacturing process planning that accommodates mold development concerns, as well as the requirements of the products. The approach of this work includes steps of (1) modeling and reengineering concurrent mold manufacturing process planning, (2) analysis of system functional requirements, (3) system framework design, and (4) system modeling and implementation. The results of this research will facilitate the rationalization and automation of the mold development process planning, thus improving the efficiency and quality, and also reducing the cost of molding product and process development.