开关塑件注塑成型模拟与分析

为提高电钻开关塑件质量,运用CAE软件对塑件进行了填充、流动、冷却及翘曲等数值模拟。分析了注射压力、翘曲变形、熔接纹分布和气穴等情况,优化了保压压力、保压时间,以减小注射缺陷和塑件变形,为模具设计及注射过程工艺参数的设定提供了指导。     

薄壁塑件成型工艺参数优化

利用Moldflow软件对薄壁塑件产生翘曲的原因进行分析,采用正交试验设计方法对塑件成型的注射时间、熔体温度、保压压力、保压时间、冷却时间等工艺参数进行模拟分析,研究各工艺参数对塑件翘曲的影响,从而获得最优工艺参数组合,指导生产。     

微圆柱阵列塑件超声振动注射模设计

以微圆柱阵列塑件为对象,分析了超声振动微注射模的结构设计要点及影响制品成型质量的因素,设计了带有抽真空排气、油加热与水冷却联合控温的超声振动微注射模。通过注射成型试验,获得了质量合格的微圆柱阵列塑件。结果表明,在微注射成型过程中施加超声振动及抽真空排气能够有效提高聚合物熔体充模流动性能和塑件上微结构部分的填充完整性。     

聚合物血管支架注射成型工艺的有限元分析

采用有限元分析的方法,以生物可降解聚合物聚乳酸(PLA)为成型材料,对ART18Z支架注射成型进行模拟分析,探究熔体温度、模具温度和注射压力对支架成型工艺的影响。数值结果表明,塑化阶段熔体温度的升高会提高支架的填充率;填充阶段支架的填充率随着模具温度和注射压力的升高而升高。在保证注射成型质量前提下,注射温度280℃、模具温度90℃和注射压力150MPa为合适的工艺参数。研究成果揭示了不同工艺参数对聚合物血管支架注射成型质量的影响,可为改善血管支架注射成型工艺优化提供指导。     

基于Moldflow的注射成型工艺参数对塑件收缩痕的影响研究

基于Moldflow软件的最佳浇口位置和填充分析功能确定浇口位置和数量,采用正交试验法确定注射成型收缩痕指数较小的最优工艺参数组合,研究了注射成型工艺参数对塑件收缩痕的影响,对不同的工艺参数进行了分析。研究结果表明,熔体温度、模具温度的降低,保压压力和注射时间的增加都能减小收缩痕的影响。     

基于CAE技术的薄壁塑件注射成型分析与工艺优化

以某薄壁塑件面板注射成型为例,介绍应用Moldflow软件进行CAE分析的步骤,通过填充、流动、冷却和翘曲等数值模拟,分析注射压力、翘曲变形、熔接线分布和气穴等情况,优化保压压力、保压时间,以减小注射缺陷和塑件变形,结合分析结果指导模具设计及注射过程工艺参数的设定。     

基于Moldflow的汽车水箱盖注射成型工艺参数优化设计

利用Moldflow软件对汽车水箱盖成型过程进行数值分析,以降低塑件翘曲量为目标,利用正交试验法分析主要成型工艺参数对翘曲变形的影响规律,获得最佳工艺参数组合。研究结果表明:工艺参数对翘曲变形影响程度从大到小依次为保压压力、保压时间、熔体温度、冷却时间、模具温度、注射时间,参数优化后的塑件最大翘曲量为1.148 mm。     

基于MoldFlow和正交实验的电位器盒盖注射成型工艺参数优化分析

针对电位器盒盖注射成型工艺参数不合理的问题,应用MoldFlow和正交实验方法对注射成型工艺参数进行优化设计。首先,分析了管道中熔体的运动状态,得出流量与压力降的关系,为成型参数设计提供参考。其次,比较研究了两种不同的浇口方案,选择了点浇口注射方案,并设定了初始注塑工艺参数。最后,使用正交实验方法优化成型参数,设定翘曲量为正交实验质量指标,选择保压压力、模具表面温度、熔体温度及保压时间4个参数为实验因素,通过优化得出4个成型工艺参数对翘曲量指标影响程度,并得到工艺参数的最佳水平组合。优化后电位器盒盖翘曲量从0.2934mm下降到0.2339mm,减小了20.28%,改善了塑件的翘曲变形问题。     

微圆柱阵列微流控芯片注射成型

以直径为?100μm和?50μm的微圆柱阵列微流控芯片为研究对象,利用单因素试验和正交试验进行充填研究,研究成型工艺参数对微圆柱阵列成型高度及翘曲变形的影响。结果表明,模具温度和注射速度是影响微圆柱阵列成型高度和翘曲变形的主要因素,模具温度对翘曲变形起决定作用;熔体温度和保压压力是次要因素,在保证微圆柱阵列的成型高度,保压压力应减小;充填时间和注射压力对微圆柱阵列成型高度和翘曲变形影响较小,在保证型腔充填完全及注射速度有要求时,充填时间和注射压力应尽量减小。     

基于MoldFlow的塑料箱注射成型CAE分析

通过应用MoldFlow／MPI软件对塑料箱注射模进行CAE综合分析,仿真注射工艺参数如填充时间、气穴、熔接痕、缩痕分析、锁模力曲线和流动前沿温度等来模拟塑件的实际生产过程,显示了MoldFlow技术在模具开发过程中对于优化塑件设计、优化塑料注射模设计和优化注射工艺参数等方面所起到的显著作用。     

吸尘器透明尘杯注塑模设计

运用Moldflow软件对塑件成形进行模流分析,可获得最佳的浇口位置、注射压力、注射时间和保压时间,能降低实际生产中的废品率,同时对模具结构设计进行了详细介绍。经生产实践验证:模具结构合理,动作平稳、可靠。     

U形提手气辅注射成型分析与优化

气辅注射成型参数设置不合理会造成吹穿、气指、缩水、穿透不足等各种成型缺陷.利用Moldflow软件采用正交实验法对提手GAIM的主要工艺参数:熔体温度、注射时间,熔体体积、气体延迟时间、气体注射时间,及压力进行模拟分析,在对每次实验结果进行分析基础上,对成型参数进行进一步优化.采用优化工艺,气体贯通整个提手,产品质量减...     

微小塑料铰链模内装配注射模设计

分析了采用模内装配技术注射成型微小塑料铰链的工艺特点及其所面临的难题,通过优化微小塑料铰链的结构,合理安排塑件的成型顺序以及塑件的浇口位置和分型面,提出了一种能够有效避免模具微细型芯在聚合物熔体高压作用下发生弯曲变形的成型方案。依据这一成型方案和实验室的设备条件,设计了一副能够在单料筒微注塑机上使用的模内装配技术注射成型微小塑料铰链的模具,不仅解决了微小塑料铰链的塑件之间难以产生运动间隙的问题,而且降低了对成型设备的要求。     

Injection molding of micro patterned PMMA plate

A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications, was selected as a model pattern. The prism pattern is 50 μm in pitch and 108° in the vertical angle. The overall size of the plate was 335 mm×213 mm and the thickness of the plate varied linearly from 2.6 mm to 0.7 mm. The prism pattern was firstly machined on the nickel plated core block using micro diamond tool and this machined pattern core was installed in a mold for injection molding of prism patterned plate. Polymethyl methacrylate (PMMA) was used as a molding material. The pressure and temperature of the melt in the cavity were measured at different positions in the cavity and the replication of the pattern was also measured at the same positions. The results show that the pressure or temperature profile through the process depends on the shape and the size of the plate. The replication is affected by the temperature and pressure profiles at the early stage of filling, which is right after the melt reaches the position to be measured.     

Micropatterns of W-Cu composites fabricated by metal powder injection molding

The metal powder injection molding (MIM) process has been applied to fabricate micropatterns of W-Cu composites. A 150μm×150μm×300 μm column array patterned lost plastic mold was used as the mold insert. Several parameters were examined to overcome limitations of lost plastic molding such as low plastic strength, unvented blind hole structure and parting line. Molding temperature was a more dominant factor than molding pressure for the complete filling of feedstock into the micro patterns. The intrinsic defects originating from the lost plastic mold could be eliminated by the re-injection molding of the disc-shaped green part in a vacuum. The final micropatterns of W-Cu composite were fabricated by sintering at 1100°C and 1300°C for 1 h.     

基于Pro/E的挂钩座注射模设计

运用Pro/E软件对塑件成型进行模流分析,可获得最佳的充模注射压力、注射时间和保压时间,能降低实际生产中的废品率,同时对模具结构设计进行详细介绍。经生产实践验证:模具结构合理,动作平稳、可靠,对成型类似塑件的模具设计具有一定的参考作用。     

微器件弯曲成形研究

微器件的市场需求急剧增加,微弯曲成形在微型产品的制造中起着至关重要的作用。尺度效应的影响使得微弯曲成形成为一个全新的领域。阐述了国内外近十多年来微弯曲成形方面尺度效应、晶粒尺寸以及摩擦等基础理论的发展,总结了微弯曲的成形方法、工模材料、成形系统、数值模拟以及成形精度方面的研究,并提出了利用陶瓷纤维制作微弯曲模,压电陶瓷作为驱动器,通过激光辅助加热的微弯曲成形系统。     

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.