虚拟塑料注塑成型教学系统

塑料注射成型技术的发展与注射模具设计人员需求的增长十分迅速，模具设计人员学习必要的塑料成型基本原理是掌握注射模具设计方法的现实需要。该文在虚拟现实（VR）技术的基础上，结合基于三维模型的注塑成型FEA技术、面向对象的编程技术和OpenGL图形库，研究并实现了沉浸式、交互式的虚拟塑料注射成型教学仿真系统（VPIM），提出了立体成像算法，给出了模拟注射成型过程运动仿真的方法，借助VR外设及通过建立知识化、数字化、可视化、现实化的教学平台来提高设计人员的学习效率、学习兴趣及对问题理解的深入程度。     

基于CAD/CAE的卡扣模具快速设计与优化

为提高塑料卡扣模具设计的速度,利用ImageWare对塑料卡扣进行点云数据处理、特征线网格划分和曲面重构;将重构的塑料卡扣模型导入UG,借助UG的曲面修复功能缝合不连续的曲面,并以STL格式保存;利用UG的Mold Wizards模具设计模块,根据已保存的STL格式卡扣模型建立模具装配模型,设计分型面,生成模具成型零件的三维实体模型;用Moldflow/MPI进行塑料卡扣注射成型分析.结果表明采用优化后的模具设计参数与实验结果基本吻合。     

An Internet-based intelligent design system for injection moulds

The rapid growth of Internet and information technologies in recent years provides a solution to support and facilitate collaborative product developments among different geographically distributed enterprises. An effective and feasible tool to aid the collaborative development of injection moulds can be realized by developing an Internet-based mould design system as one of the modules of a collaborative product development system. This paper presents a prototype Internet-based intelligent design system for injection moulds. The architecture of the system consists of an interactive KB mould design system embedded in an Internet environment. A Java-enabled solution together with artificial intelligence techniques is employed to develop such a networked interactive CAD system. In this system, the computational module, the knowledge base module and the graphic module for generating mould features are integrated within an interactive CAD-based framework. The knowledge base of the system would be accessed by mould designers through interactive programs so that their own intelligence and experience could also be incorporated with the total mould design. The approach adopted both speeds up the design process and facilitates design standardization which in turn increases the speed of mould manufacture. A practical case study is presented to illustrate the operations of the Internet-based mould design system.     

Modeling of multi-connected porous passageway for mould cooling

Cooling channel design in the plastic injection moulding process is of paramount importance to the performance of the mould, influencing the quality of the parts being produced and productivity of the process. However, cooling channel design is usually limited to relatively simple configurations as well as conventional machining processes, such as straight-line drilling, and milling, etc. The cooling performance may not meet the expectations of the mould engineers.This paper proposes an alternative design method for a conformal cooling passageway with multi-connected porous characteristics based on the duality principle. The proposed method can provide a more uniform cooling performance between the mould plate and the conformal cooling passageway than the existing conformal cooling channel design. Injection mould defects like warpage or hot spots can be avoided.In this study, a 3D mould plate model was offset negatively and the location of the proposed multi-connected porous cooling passageway was identified. The negatively offset model was decomposed into a finite number of cubical cells via the sub-boundary spatial enumerated cell decomposition. Then a duality relationship between the primal and the dual graphs was developed. This provided the preliminary layout of the multi-connected porous passageway for the coolant flow in multiple directions. The cooling channel axis design of the multi-connected porous passageway, illustrated by the skeleton from the dual graph, was created. Following a Boolean difference operation, the proposed multi-connected porous cooling passageway inside the mould plate was able to be generated and fabricated with the aid of rapid tooling technologies. A real-life case study for the design of a multi-connected porous cooling passageway was implemented and examined. The effects of coolant flow and cooling performances, analyzed by computational fluid dynamics simulation, were validated.     

应用于片上系统中低功耗IP核设计的自适应门控时钟技术

门控时钟技术一直以来是降低芯片动态功耗的有效方法.文章结合片上系统(SoC)的结构特性和设计特点,分析已有的各种门控时钟技术的优缺点,指出这些缺点是SoC设计中的严重障碍,随后抽象出IP核工作模型,提出了仅用非常简单的逻辑就可以方便应用于IP核的自适应门控时钟技术.这种技术在不影响性能的前提下,可以根据IP核的应用状况自动开关时钟,不但可以降低动态功耗,还可以结合门控电源技术降低漏电功耗.对一款真实SoC中浮点IP核的改造实验表明,在不降低性能的前提下,可以平均降低62.2%的动态功耗,同时理论上平均降低70.9%的漏电功耗.     

Case-based retrieval of 3-dimensional shapes for the design of metal castings

This paper describes research into retrieval based on 3-dimensional shapes for use in the metal casting industry. The purpose of the system is to advise a casting engineer on the design aspects of a new casting by reference to similar castings which have been prototyped and tested in the past. The key aspects of the system are the orientation of the shape within the mould, the positions of feeders and chills, and particular advice concerning special problems and solutions, and possible redesign. The main focus of this research is the effectiveness of similarity measures based on 3-dimensional shapes. The approach adopted here is to construct similarity measures based on a graphical representation deriving from a shape decomposition used extensively by experienced casting design engineers. The paper explains the graphical representation and discusses similarity measures based on it. Performance measures for the CBR system are given, and the results for trials of the system are presented. The competence of the current case-base is discussed, with reference to a representation of cases as points in an n-dimensional feature space, and its principal components visualization. A refinement of the case base is performed as a result of the competence analysis and the performance of the case-base before and after refinement is compared.     

Discrete cost optimization of composite floor system using social harmony search model

This paper presents a social harmony search algorithm model for the cost optimization of composite floor system with discrete variables. The total cost function includes the costs of concrete, steel beam and shear studs. The design is based on AISC load and resistance factor design specifications and plastic design concepts. Here, six decision variables are considered for the objective function. In order to demonstrate the capabilities of the proposed model in optimizing composite floor system designs, two design examples taken from the literature are studied. It is shown that use of the presented model results in significant cost saving. Hence, it can be of practical value to structural designers. Also the proposed model is compared to the original harmony search, its recently developed variants, and other meta-heuristic algorithms to illustrate the superiority of the present method in convergence and leading to better solutions. In order to investigate the effects of beam spans and loadings on the cost optimization of composite floor system a parametric study is also conducted.     

Plastic injection mould cooling system design by the configuration space method

The cooling system of an injection mould is very important to the productivity of the injection moulding process and the quality of the moulded part. Despite the various research efforts that have been directed towards the analysis, optimization, and fabrication of cooling systems, support for the layout design of the cooling system has not been well developed. In the layout design phase, a major concern is the feasibility of building the cooling system inside the mould insert without interfering with the other mould components. This paper reports a configuration space (C-space) method to address this important issue. While a high-dimensional C-space is generally required to deal with a complex system such as a cooling system, the special characteristics of cooling system design are exploited in the present study, and special techniques that allow C-space computation and storage in three-dimensional or lower dimension are developed. This new method is an improvement on the heuristic method developed previously by the authors, because the C-space representation enables an automatic layout design system to conduct a more systematic search among all of the feasible designs. A simple genetic algorithm is implemented and integrated with the C-space representation to automatically generate candidate layout designs. Design examples generated by the genetic algorithm are given to demonstrate the feasibility of the method.     

Runner sizing in multiple cavity injection mould by non-dominated sorting genetic algorithm

Runner system is important in the plastic injection moulding as it affects the part quality and the material costs. The layout of the runners for a multiple non-identical cavity mould is geometrically imbalance. Even for a multiple identical cavity mould, the layout can be imbalance due to various reasons. This paper presents an approach to balance the flow by adjusting the runner sizes. Runner size determination is a multiobjective optimisation problem. The non-dominated sorting genetic algorithm is adopted for determining the runner sizes. Multiple objective functions including runner balancing, part quality in terms of warpage and runner volume are incorporated into the algorithm. The moulding conditions affecting the mould cavity filling are also determined due to their sensitivity to runner sizes. This runner sizing approach is suitable for the geometric imbalance mouldings and family mouldings.     

Artificial intelligence based system to improve the inspection of plastic mould surfaces

Plastic industry is today in a constant growth, demanding several products from other segments, which includes the plastic moulds, used mainly in the injection moulding process. This paper presents a methodology for the surface evaluation of plastic moulds, aiming the automation of the polishing surface analysis. Provided that this type of analysis by traditional procedures can be slow and expensive, the development of automatic system could lead to considerable improvements regarding the speed and reliability of information. The starting point of the evaluation procedure is the image generated by the laser light scattered over the sample mould surface that could be captured and analysed by image processing and artificial intelligence techniques. The results showed that the proposed system is able to mapping and classifying several damages over the polished surface and could be an alternative to reduce efficiently the costs and the spending time in mould surface inspection tasks.     

基于CAD的注塑模具设计与仿真研究

研究了基于CAD技术的注塑模具设计流程,并对模具的工艺参数进行了分析和优化,具体采用CAD注塑模集成系统实现。完成了最优工艺参数方案的确定,通过UG的CAE分析模块的应用并以模拟结果为依据完成了对注塑件应力应变分布情况的分析,应力最大值及位置通过实验对比完成确定,为模具结构的优化方案提供参考。最佳注塑制品工艺参数通过分析相关工艺参数获取,并以音箱零件为例,对注塑模具型腔设计方法进行了探讨。     

基于Pro/engineer的折叠夹板注塑模虚拟装配及模流仿真

利用Pro／engineer对折叠夹板进行产品及注塑模的参数化设计及虚拟装配。检测模具开模时的干涉情况;同时,仿真注射时的模流过程,实现在设计模具时就确切了解塑料在型腔中的充填和流动情况,预测折叠夹板产品质量,从而优化了模具的设计流程,减少了设计周期。     

基于采矿CAD的硐室参数绘图系统设计及实现

CAD系统因其本身具有许多长处,得到了工程设计人员的广泛使用。但它只能处理图形的几何信息,真正具有工程实际意义的图形拓扑信息和参数约束信息均被抛弃了。为了保留更多的图形信息以及让工程设计人员更方便地进行硐室图形的绘制,文中根据采矿CAD图形的特点,把要绘制的硐室图形进行参数化分析,并通过编程调用采矿CAD的接口实现了硐室图形的自动绘制系统。此系统能根据用户输入的参数自动生成硐室的二维和三维图形,这大大减少了设计人员的工作量,提高了设计效率,也有利于计算机辅助设计的进一步发展。     

计算机辅助模拟注射模充模过程

在注射成形过程中 ,塑料熔体的流动状况是决定塑件质量的重要因素 ,运用注射成形流动模拟软件可以准确模拟塑料熔体的整个充模过程 ,优化塑料熔件的流动场 ,以找到最合适的浇注系统及尺寸。     

Cost-effective design for injection molding

It is commonly agreed that a large proportion of the ultimate product cost is determined at product design stage. Therefore, a cost-effective design cannot be obtained unless all cost issues are resolved at early design stage. Therefore, instead of performing cost estimation after design, research presented in this paper aims to provide on-line cost evaluation and advisory to help product designers avoid cost-ineffective design. The objective can be obtained by (1) identifying factors that might affect product cost at each product design stage, (2) developing a design for cost effectiveness methodology that accommodates the concepts of concurrent engineering, and (3) developing a computer-based design for cost effectiveness system based on the proposed methodology. In this research, we focus on injection molding product design due to the advantages of injection molding process, such as high production rates, excellent quality and accuracy of the parts, and very long mold life. This paper first reviews and characterizes the conventional molding product development process with an emphasis on the identification of cost factors. Based on the results of process characterization, a cost model is developed, which depicts the relationships between cost factors and product development activities, as well as their relationships with product geometry. According to the product life cycle activities and the cost model, a design for cost effectiveness process is proposed. The process and the cost model are then employed for the development of a computer-based product design for cost effectiveness as one of the module of an integrated design for injection molding environment.     

Automation in the design of EDM electrodes

Plastic parts, especially those designed for consumer electronics products, are becoming more compact and freeform in shape. This requires the construction of compact and delicate geometric features in the injection moulds that produce these parts. It is now common practice to employ electric discharge machining (EDM) whenever the conventional machining process fails to machine such delicate features. Although CAD/CAM systems are widely used in mould design and manufacturing, and specific commercial CAD/CAM systems that are customized for injection mould applications are also available, there are still no intelligent CAD tools that address the specific requirements of EDM electrode design. The aim of this research is to develop an intelligent CAD tool that supports EDM electrode design. This CAD tool uses a new technique that recursively splits the EDM region into sub-regions until machinable electrodes can be constructed. The CAD tool has been implemented and integrated into a commercial CAD/CAM system, and 40 different real designs has been used to test its capability in handling a wide variety of geometric shapes. Performance data show that the efficiency of the design process can be improved by at least 50%, with a potential to achieve 85% through improved implementation and further research.     

Equivalent transfer function method for PI/PID controller design of MIMO processes

In this paper, a novel engineering oriented control system design method for multivariable processes is presented. By employing the concepts of energy transmission ratio and effective relative gain, an equivalent transfer function matrix for closed loop control system can be obtained. Based on the equivalent transfer function matrix, both off-diagonal decoupling controllers and main loop diagonal controllers can be easily designed using the existing PI/PID tuning rules. The main advantages of the method are that: (1) the overall control system performance is better compared with the existing decoupling control methods; (2) it is very simple which can be easily understood and implemented by field control engineers; and (3) the control system is robust, it can still work with satisfactory performance even under significant model mismatches. Several multivariable industrial processes with different interaction characteristics are employed to demonstrate the simplicity and effectiveness of the design method.     

注塑模图形的参数化设计方法

基于 Auto CAD2 0 0 0的软件包 Object ARX,建立注塑模图形库和图形约束的参数化设计方法 ,可以简化注塑模具设计 ,提高模具质量 ,缩短模具制造周期 ,易于维护和管理。     

基于加权数据通路的RTL级低功耗SoC设计

低功耗是SoC设计与评估的重要技术指标之一,现利用加权数据通路,提出一种新的低功耗SoC设计方法。该算法首先利用程序切片技术提取RTL级数据通路,然后采用贝叶斯网络训练获得各数据通路的权重(使用频率),以形成加权数据通路,最后根据各路径权值控制门控信号的产生,对权值小的通路优先插入门控逻辑或合并门控逻辑,从而有效降低系统功耗。实验结果表明,该算法与已有ODC低功耗算法相比功耗平均下降8. 38%,面积开销平均减少6.8%,同时数据通路的简化也使得算法计算负荷大幅下降。     

A CBR system for injection mould design based on ontology: A case study

Case-based reasoning (CBR) often shows significant promise for improving the effectiveness of design support in mould design, which is a domain strong in practice but poor in theory. However, existing CBR systems lack semantic understanding, which is important for intelligent knowledge retrieval in design support system. This hinders the application of CBR in injection mould design. In order to develop an intelligent CBR system and meet the need of design support for injection mould design, this paper integrates ontology technology into a CBR system by constructing domain ontology as case-base with a new method, in which two means of acquisition are combined, one is acquiring ontology from existing ontologies, the other from established engineering knowledge resources, and proposing a new semantic retrieval method as the first grade case retrieval. Numerical measurement is also employed as the second grade case retrieval, which adopts various methods to calculate different types of attribute values. A case is executed to illustrate the use of proposed CBR system, then a lot of experiments are organized to evaluate its performance and the result shows that the proposed approach outperforms existing CBR systems.