薄壁气体辅助注塑件气体穿透过程的研究

基于气体穿透实验技术的研究分析，针对气体辅助注射成形中气体穿透气道的复杂过程，对薄壁气辅注塑件沿圆形截面气道穿透推进并形成模壁表层熔体的充模流动过程进行了研究。通过引入合理的简化和假设，建立了反映充模流动压力梯度、材料性能、表层熔体厚度比、非牛顿指数等影响因素的计算穿透速度和时间的数学方程．对气体注射压力、熔体温度、非牛顿指数影响气体穿透充模过程进行了实例数值模拟研究。结果表明，增大气体注射压力，其气体穿透方向所形成的表层熔体厚度比值也增大，降低熔体注射温度和非牛顿指数会增大气体穿透的壁厚值，其值接近国外试验测定值，也比较符合实际的气辅注射成形工艺结果。     

水辅助注射成型充模流动的仿真与分析

基于现有气体辅助注射成型充模流动模型、非定常流场数学方程和湍流模型,突破未考虑高雷诺数水相区湍流特性、小尺度薄壁建模、初始化壁厚的人为影响以及未考虑熔体前沿喷注效应等局限,建立水辅助注射成型充模流动的仿真模型。比较湍流模型,分析水辅成型多相分层流动界面不稳定现象。针对主要工艺控制参数进行仿真分析。结果表明:结晶性塑料随熔体温度升高、延迟时间缩短、水注射入口流速增大,残留壁厚减小,随延迟时间增加、熔体温度降低和水注射流量的增大,负载压力升高,与水辅成型试验结果相吻合。延迟时间对负载压力影响有限,延迟时间和水注射入口流速对残留壁厚影响显著,且水辅成型负载的压力流量耦合特性明显。由此提出以成型效果为目标的水压系统压力控制优化,是改进水辅成型工艺的重要思路。     

气体辅助注射成型模拟软件的原理及应用

基于塑料熔体流动和气体穿透的数学模型,研制出气体辅助注射成型流动模拟软件并成功地应用于实际生产。     

金属粉末注射成形充模过程数学模型研究

详细阐述了金属粉末注射成形的充模机理,假定了喂料熔体为混合均匀、不可压缩的非牛顿流体,充模流动为层流,依据流体力学和热力学知识,建立了完整的金属粉末注射成形充模过程数学模型,为金属粉末注射成形计算机模拟求解奠定了基础.     

全三维注塑成形流动模拟有限元模型的研究

注塑制品往往具有复杂的几何形状，存在着壁厚的差异。三维流动模型比二维模型能更准确地模拟出熔体充模流动的情况。提出了一种基于全三维模型的注塑成形流动模拟的数学模型和数值实现方法，把速度和压力同次插值的方法成功地应用到三维注塑模拟的计算中，采用三维控制体积追踪塑料熔体的流动前沿，在温度场计算中，全面考虑了对流项在各个方向的影响，使模型的适用范围更广，结果更准确。在此基础上开发了相应的软件，可以计算熔体充模过程中的压力场、速度场和温度场等。实验验证和算例分析说明了三维流动模型的有效性。     

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。     

聚合物气体辅助挤出中气体流动对熔体截面的影响

将聚合物熔体和低速热空气均视作不可压流体,针对一聚苯乙烯（PS）片材的全气体辅助挤出,建立了描述其气体-熔体两相分层流动的三维有限元模型,采用黏弹应力分离法（EVSS）和非协调流线迎风法（SU）等有限元方法,利用PolyFlow求解器对气体辅助流道中气体和熔体流动进行了计算,分析了熔体截面变化的规律及原因。研究结果表明：气体辅助流道内,气体对熔体有拖曳作用;沿挤出方向,熔体速度逐渐增大,而截面积逐渐减小,都在口模出口面上达到极值,同时截面形状有微小改变;口模出口面上熔体沿挤出方向的速度随入口气体体积流率的增大而近似线性增大,熔体截面积则近似线性减小。     

基于Ｆｌｕｅｎｔ的中间摆臂注射成型工艺参数优化

基于 ＣＦＤ计算流体力学计算软件Ｆｌｕｅｎｔ,把金属粉末注射成形过程看作空气、粉末以及粘结剂的多相流动成形过程。根据模腔注射成形的经验公式所得工艺参数设置相关边界条件并设计正交试验,对汽车发动机中间摆臂注射成形的充模过程进行三维数值模拟,基于试验结果来分析各个实验参数及其交互作用对产品质量的影响,从而为注射成形产品缺陷产生的原因提供直观分析方法,以实现 ＣＡＥ技术对实际生产的指导作用。     

[成形过程仿真优化与集成计算材料工程]注射成形熔体喷射的三维模拟及消除对策研究

为了探寻塑料注射成形过程中熔体喷射的消除对策,采用高精度离散格式追踪熔体流动前沿,基于有限体积法离散控制方程,发展了三维数值算法。与实验结果对比发现：所发展算法能有效模拟壁厚为4 mm的长方体型腔内的两种喷射演化模式以及厚壁型腔内的熔体喷射及其演化过程;小壁厚型腔内熔体的屈曲呈二维折叠演化,厚壁型腔内熔体的屈曲呈三维缠绕演化;重力对厚壁型腔内的喷射演化产生影响。通过增大剪切速率即改变熔体流动速度大小或者流动方向能有效消除或抑制喷射现象,并且用两个数值算例论证了该观点。     

小浇口进行注射成型加工时的优点

浇口是浇注系统中很关键的一段料流通道,除了主流道型浇口外,大多数浇口都是浇注系统中截面积最小的部位,其数值一般只有分流道截面积的3％-9％。对于服从牛顿流动规律的塑料熔体来说,由于其黏度与切变速率无关,大的浇口截面积可以降低流动阻力,提高熔体流速,这对于充模和成型质量都比较有利。而对于绝大多数不服从牛顿流动规律的塑料熔体,采用减小浇口截面积,却经常有可能使熔体切变速率增大,由于剪切热作用,将会导致熔体的表观粘度大幅度下降反而有可能比大截面浇口更有利于充模。至于采用小浇口成型时因增大流动阻力所引起的压力降,可在一定的范围内用提高注射压力的方法来补偿。一般来讲,采用小浇口进行注射成型时,具有以下优点。     

汽车把手件气辅成型气指缺陷影响因素分析

在气体辅助成型工艺中,常常遇到一种缺陷是“气指”,气泡穿过气道形成指状分支,严重的“气指”会降低注塑件的强度,造成气辅成型技术的失败,或者不能发挥气辅成型技术的优势。为了消除或减少这种缺陷的产生,本文采用数值模拟方法和正交试验方法对气辅成型制品“气指”缺陷进行了研究。研究了对“气指”缺陷影响最重要的6个工艺参数：熔体短射量、气体注射延迟时间、气体注射压力 、模具温度、熔体温度以及气体注射时间对气辅成型制品“气指”缺陷的影响关系。结果表明,影响“气指”最重要的工艺参数依次是气体注射延迟时间、熔体温度和气体注射压力。因此优先选择合理的延时,熔体温度和注气压力参数尤为重要,为控制气指行为建议在相同熔体温度下适当延长气体注射延迟时间。     

Computing gas/melt free interface of gas-assisted injection molding

A solution was put forward to predicate the flow pattern of gas penetration in gas-assisted injection molding. The differential equations that governed the flow field and gas/melt free-interface evolution were analyzed and discretized by Galerkin finite element method, and the free interface was located by the volume of fluid method. The gas was assumed as a fluid phase of constant density and viscosity instead of being simply treated as boundary conditions. The non-Newtonian property of polymer melt was characterized by Carreau model with four parameters. As a case study, different kinds of gas channel were modeled. The gas/melt free interface was captured. The gas front velocity and the pressure of gas/melt front were also computed. The edge shape of gas channel was discussed, which are helpful for the design of gas-assisted injection molding.     

Three-dimensional numerical simulation for plastic injection-compression molding

Compared with conventional injection molding, injection-compression molding can mold optical parts with higher precision and lower flow residual stress. However, the melt flow process in a closed cavity becomes more complex because of the moving cavity boundary during compression and the nonlinear problems caused by non-Newtonian polymer melt. In this study, a 3D simulation method was developed for injection-compression molding. In this method, arbitrary Lagrangian- Eulerian was introduced to model the moving-boundary flow problem in the compression stage. The non-Newtonian characteristics and compressibility of the polymer melt were considered. The melt flow and pressure distribution in the cavity were investigated by using the proposed simulation method and compared with those of injection molding. Results reveal that the fountain flow effect becomes significant when the cavity thickness increases during compression. The back flow also plays an important role in the flow pattern and redistribution of cavity pressure. The discrepancy in pressures at different points along the flow path is complicated rather than monotonically decreased in injection molding.     

Simulations of gas penetration in thin plates designed with a semicircular gas channel during gas-assisted injection molding

Numerical simulations and experimental studies concerning gas and melt flows during gas-assisted injection molding of a thin plate designed with a gas channel of semicircular cross section were conducted. Distribution of the skin melt thickness along the gas penetration path was measured. Melt and gas flows in a gas channel of semicircular cross section were approximated by a model which uses a circular pipe of equivalent diameter superimposed on the thin plate. An algorithm based on the control-volume/finite-element method combined with a particle-tracing scheme using a dual-filling-parameter technique was utilized to predict both melt front and gas front advancements during the mold filling process. Simulated distribution of gas penetration shows reasonably good coincidence with the experimental observations.     

The selection of the optimal design parameters applied to the gas-assisted injection mould of an L-shape plates design

This study examined the finite element and abductive network method applied to thegas-assisted injection mould (GAIM). From these models, the effect of the GAIM condition includes the melt formation by percent volume filled, the base-plane thickness, and the ratio of L-shape plane thickness. The L-shape plane can reduce by about 50 per cent the expense of materials, reduce the injection cycle time, and increase the L-shape structure. In order to select the optimal design parameters to minimize the warp of a GAIM, the experimental design method and abductive network were used. These methods were applied to create an efficient model with functional nodes. Once the GAIM parameters were developed, this network was used to predict GAIM warp accurately. A simulated annealing (SA) optimization algorithm with a performance index was then applied to the neural network for searching the optimal GAIM parameters, obtaining a more satisfactory result compared to the corresponding finite element verification.     

气辅成型中高压气体射流扩散特征分析

通过试验研究和理论分析,研究了气辅成型工艺中气体穿透聚合物熔体的扩散特征。结果表明,在气体注射点近区,气体对聚合物熔体冲击程度较大,呈现出复杂流动形态及扩散特征;当气泡穿透到离注气点一定距离后才趋于均匀;在气泡末端,由于气体的二次穿透作用而使气泡变得细而长。研究结果对于气辅工艺开发和气辅模具设计有重要指导意义。     

Diagnosis of the behavior characteristics of natural gas jet

We analyzed natural gas fuel (Methane, CH₄) jet at STP (standard temperature and pressure) using a commercial program, ANSYS CFX release 11.0, and compared the results with experimental ones obtained by using shadowgraph method. The combined MCM(multicomponent model) and k-? turbulence model is used in the simulation. Injection pressure is selected as a main parameter in both experimental and numerical study. In the analysis, longer jet tip penetration was measured each time after start of injection for high injection pressure. Also, the process of mixture formation before combustion was examined by comparing the experimental and the numerical results on the behavior of jet and ambient gas flow. It was found that the experimental and the numerical results are consistent with each other. Further, the use commercial CFX program for the analysis of the macro jet behavior characteristics such as jet tip penetration, and flow of ambient gas can be recommended. In particular, in the analysis of the jet development process it is important to investigate the mixture formation by the interaction between the injected fuel and ambient gas.     

气体辅助注塑成型技术及其模具 CAE

全面介绍了气体辅助注塑成型技术的概念、先进性和该项技术的适用范围。对气体辅助成型的设计原理及气体填充方法作了阐述,介绍了气体辅助注塑模具的计算机辅助工程分析。     

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.