应用Taguchi实验设计法最小化ABS注塑制品翘曲变形量

运用Taguchi DOE技术研究了工艺参数对丙烯腈-丁二烯-苯乙烯共聚物(ABS)注塑制品翘曲变形的影响,并获得优化的工艺参数以使制品的翘曲变形量最小。文中以碱性蓄电池盖为例,利用L9(34)正交矩阵进行实验,并采用标准变量分析法(ANOVA)对熔体温度、注射时间、冷却时间、保压压力等工艺参数对制品翘曲变形的影响程度进行了研究,结果表明,在所选工艺参数中,保压压力和熔体温度对翘曲变形的影响程度最大。     

基于稳健设计的电器壳体注塑成型工艺参数优化

将Taguchi稳健设计和CAE模拟技术相结合,应用于注塑工艺参数的优化。以某电器壳体的注塑成型为例,以减小制品的翘曲变形为试验目标,研究模具温度、熔体温度、注射时间、保压压力及浇口位置对注塑件翘曲变形的影响规律,运用变量分析,确定工艺参数对翘曲变形的影响度。     

神经网络技术在注塑成形中的应用

对人工神经网络技术在注塑成形研究中的主要应用和发展概况进行了综述,并将神经网络技术与正交试验设计方法、CAE模拟技术相结合,建立了注塑工艺参数与制品翘曲变形量关系的BP神经网络模型.     

注塑成型工艺中的翘曲变形

在注塑成型过程中不可避免地会产生短射、熔接痕、气穴、飞边、缩痕和翘曲变形等诸多缺陷,而翘曲变形是塑料制件最严重的成型缺陷之一。分析了塑料材料、模具结构和成型工艺条件对注塑制品翘曲变形的影响,指出通过对冷却系统、工艺参数的优化并结合计算机模拟技术,可以改善注塑件的翘曲变形。     

最小化聚丙烯制品沉降斑的注塑工艺优化

基于CAE,通过Taguchi实验分析注塑工艺参数对PP制品沉降斑的影响,找出其中影响较大的因素作为重点关注参数,实现了注塑工艺的优化,改善了制品表面沉降斑,从而明显提高了制品的表面质量。     

基于MPI注塑制品的翘曲变形分析及优化

翘曲变形是注塑制品常见的质量缺陷,阐述了制件翘曲变形的基本理论模型,介绍了翘曲分析流程,以鼠标下盖为例,运用MPI对其进行翘曲变形分析,同时通过优化工艺参数,以达到降低制品的翘曲量的目的,提高产品的成型质量,说明了MPI在注塑模具优化设计中的可靠性与实用性。     

Taguchi试验设计在注射成型工艺参数优化中的应用

采用Taguchi正交试验设计方法,结合有限元分析软件研究工艺参数对注射制品翘曲变形量的影响,获得最优的工艺参数使制品的翘曲变形量最小,以塑料齿轮为研究对象,采用L27(313)正交表进行试验,对试验结果进行级差和方差分析,研究各个参数及参数之间的交互作用对制品翘曲变形量的影响程度,研究发现,填充时间、熔体温度和保压压力的变化对注射制品的翘曲变形量有显著影响。     

基于Moldflow的柜机空调传动齿轮翘曲变形优化方法

基于Moldflow的翘曲优化方法,设计了DOE实验,研究了产品结构尺寸中的筋条料厚、注塑工艺参数中的模温及保压时间对翘曲的影响程度,得到一组最优的参数值.最后通过实际改模验证了方法的准确性,将变形控制在公差范围内,取消了人工整形工艺,提高了制品一致性,降低了成本.     

基于Fluent的塑料注塑模拟分析

塑料注塑成型是一个复杂的物理过程,为了验证工艺参数的合理性和预测制品的质量,建立了塑料注塑成型流动和冷却的数学模型,运用计算流体力学原理,采用了Fluent软件进行塑料注塑模拟,进行流动分析和热分析。整个型坯的注塑速度和熔体温度分布均匀,制品质量较好,使用的注塑工艺参数合理,适用于实际的工程应用。     

基于模糊规则推理的注塑成型缺陷诊断及工艺智能优化

针对注塑成型缺陷成因求解的模糊性与不确定性,综合运用规则推理、模糊推理等人工智能技术,完成了注塑成型缺陷诊断及工艺优化系统的总体结构设计。通过采用规则推理和Mamdani模糊推理分别进行了注塑制品缺陷成因判定和工艺参数智能优化,详细阐述了模糊推理用于优化注塑成型工艺参数的整个过程。基于上述理论及VisualProlog应用平台,采用人工智能系统语言Prolog开发了注塑成型缺陷诊断及工艺优化专家系统,并给出应用实例。结果表明,此系统具备较好的注塑制品缺陷诊断及工艺优化能力,有一定的推广应用前景。     

注射压缩工艺参数对厚壁塑件成形质量的影响

为探究注射压缩工艺参数对厚壁塑件成形质量影响,以表面缩痕指数为指标,选择注射压缩工艺中的熔体温度、模具温度、压力机打开距离、等待时间、压缩时间、压缩力和压机速度7个工艺参数作为分析因素,运用Moldflow软件进行正交实验,得到各工艺参数对指标的影响程度;然后对前5个主要参数作单因素实验研究,获得各参数对塑件表面缩痕指数、翘曲变形及体积收缩率等指标的影响趋势,并结合实际对该厚壁模型的成形工艺参数进行了合理的优化,使各指标值大大降低。     

Influence of processing parameters on quality factors of one-shot hybrid structures made by RTM

This paper is dealing with the influence of processing parameters for manufacturing of steel–carbon-fiber-reinforced-plastic (CFRP) hybrid plates by using the one-shot-hybrid resin-transfer-moulding (OSH-RTM) process. A design of experiments study was carried out. The quality of the manufactured parts was quantified by the bending modulus, the apparent interlaminar shear strength (ILSS), the maximum deflection and the density of the CFRP. The following changeable processing parameters were chosen: mould temperature, resin temperature, change in mass flow and maximum injection pressure. It is shown that the mould temperature and the change in mass flow show significant impact on the flexural modulus, density and maximum deflection of the plate while there is no significant impact on the apparent ILSS. Furthermore, the interaction between the mould temperature and resin temperature is having an influence on the flexural modulus and density.     

水辅助注塑制品残余壁厚影响因素仿真分析

残余壁厚是衡量水辅助成型制品质量的重要指标,研究工艺参数对残余壁厚的影响规律对生产工艺具有重要指导意义。基于流体体积法,应用计算流体力学（CFD）计算软件分析了工艺参数对水辅助注塑三维弯管残余壁厚的影响。仿真分析中为了完整描述熔体黏度在实际成型中的变化,利用软件中的用户定义功能（UDF）完成对熔体黏度模型的定义。模拟分析表明：注水速率与熔体注射量是影响水管件成型质量的主要因素。提高注水速率,使得短时间内有更多熔体被推向前方,形成更小的残余壁厚。提高熔体注射量会降低水体穿透空间,得到的水管件残余壁厚更大。另一方面,本次模拟分析中诸如注水温度、模具温度、熔体温度等因素对残余壁厚影响并不大。     

Warpage of injection-molded thermoplastics parts: Numerical simulation and experimental validation

A mathematical model and the integrated simulation program for predicting part warpage, which arises during injection molding of thermoplastic polymers, were developed. To build the model, the finite element method (FEM) was used and the theory of shells, represented as an assembly of flat elements formed by combining the constant strain triangular element and the discrete Kirchhoff triangular element, was applied. This shell theory is well suited for thin injection molded products of complex shape. Furthermore, in this work, experimental research on flat plates was performed to study the effect of the plastic material, the mold structure, and certain key processing parameters on warpage. The investigated processing parameters include injection pressure, packing pressure, injection time, packing time, cooling time, and melting temperature. Different examples were presented to examine the developed simulation software, and results predicted from the simulation program were verified in the above experiments and showed reasonable accuracy compared with experiment data.     

Optimization of mechanical properties of recycled plastic products via optimal processing parameters using the Taguchi method

The large amount of plastic products presently produced necessitates recycling and reuse of these non-biodegradable materials. However, the degradation in the mechanical properties of products made from recycled plastic is a major drawback that limits their use. This study aims to improve the mechanical properties of products made from recycled plastic by utilizing the Taguchi optimization method, instead of coupling the products with additives. By adopting L₉ Taguchi OA, products made from various compositions of virgin and recycled plastic are produced by injection moulding. Four controllable factors (i.e., melt temperature, packing pressure, injection time, and packing time), each at three levels, are tested to determine the optimal combination of factors and levels in the manufacturing process. By determining the optimal combination of factors and levels, the appropriate blending ratio of virgin and recycled plastic can be evaluated from the mechanical performance exhibited by the compound. The effects of the optimal processing parameters and the addition of recycled plastic in various compositions on the mechanical properties and melt flow index of the produced parts are also investigated. The results reveal that the product made of 25% recycled polypropylene (PP) and 75% virgin PP exhibits a better flexural modulus compared to the virgin form. The same product exhibits a 3.4% decrease in flexural strength. The degradation in mechanical properties of products produced from recycled plastic can be improved by optimizing the influence processing parameters during the manufacturing process.     

基于缩痕最小的注塑件成形工艺参数优化设计

针对汽车手制动檐口在注塑过程中出现的缩痕问题,借助Moldflow软件模拟其注射成型过程,得到了基于注塑件表面缩痕最小的最佳浇口位置、数量、模具温度和熔体温度等工艺参数。据此进行模具设计,可缩短模具开发周期,提高产品质量和企业竞争力。     

降低塑料直尺残留应力的优化分析

针对塑料直尺注射成型容易产生翘曲变形的问题,对其注射成型过程进行了优化分析,以降低注射成型中塑件的模内残留应力,提高塑件质量。采用正交优化方法和Minitab统计分析软件,将塑件的模内残留应力作为优化目标、对成型过程中影响塑件模内残留应力的模具温度、熔体温度、注射速率、保压压力与注射压力比和保压时间等5个工艺参数进行了优化分析。在此基础上,选取熔体温度、注射速率和保压时间这3个对优化目标有显著影响的工艺参数进行了二次优化,得到最优组合。最后进行试验,验证了数值模拟的合理性和优化分析的有效性。     

基于UV-LIGA技术的导光板微结构注射模型芯制作工艺研究

介绍了基于UV-LIGA技术的导光板微结构注射成型工艺过程,对注射模型芯制作关键工艺进行了分析与研究,在优选关键制备环节工艺参数的基础上,制作了带有微结构的导光板镍型芯,并通过在精密注塑机上设置温度250℃、注射速度85 mm/s、保压压力80 MPa、保压时间7 s、模具温度80℃、冷却时间30 s的注射工艺参数,成功注射出了PMMA导光板微结构,微结构表面光滑,形貌理想。     

精密工业配件的注射成型模拟

采用CAE技术对工业配件精密焊丝盘的注射成型工艺过程进行了计算机动态模拟,研究了不同充填时间、压力、注射温度和模具温度对焊丝盘边沿翘曲变形的影响规律,从而提出了优化模具冷却系统的方案和加工工艺参数     

手机电池盖的CAE翘曲变形分析

注塑产品的翘曲是由于塑料的体积收缩、结晶和分子定向所引起的变形现象。以目前应用广泛的CAE软件MPI／warpage为工具详尽地分析了手机电池盖的翘曲变形情况，指出了的翘曲变形原因，并结合产品的分析结果对产品的精密注塑提出了相应的改进方案。