注塑模随形冷却水道设计与制造技术概述

在采用注塑模制造注塑件的过程中,注塑的冷却阶段是一个涉及热力学与流体力学的复杂过程,直接影响到注塑件的制造质量与生产效率。随着市场对注塑件质量要求的提高,针对注塑模随形冷却水道的设计及其快速成形制造技术的研究逐渐成为国内外的热门课题。介绍了注塑模随形冷却水道的概念、产生及其意义;对目前国内外随形冷却水道关键技术的研究进行了综述;结合国内外现状,指出了随形冷却水道设计及其快速成形制造技术的发展趋势。     

热冲压模具冷却水道随形分布算法及实现

在热冲压生产中，模具的冷却和冲压件质量密切相关，冷却效果越好，冲压件的随形冷却水道冷却效率越高、模面温度均匀性越好。冷却水道的设计需要考虑水道的分布间距及其随形程度，有较高的设计难度。因此，基于NXOPEN二次开发技术，在NX8.5平台上开发了一套热冲压模具随形冷却水道设计系统。采用线性近似约束优化算法优化水道起点和终点位置，保证了水道分布的均匀性；采用离散点集凸包算法及角度扫描拟合方法，计算出适合深钻加工的随形水道走向，并自动完成水道的绘制，大大地缩短了人工水道设计的时间，提高了效率。     

塑料弹夹注塑模具的设计

介绍了塑料弹夹的结构特点,在此基础上设计了塑料弹夹注塑模具.塑料弹夹注塑模具采用增材制造方式制作随形冷却水路,随形冷却水路按照冷却功效分为塑件内部冷却、塑件外部及筋板冷却两部分.塑料弹夹注塑模具的型腔采用两个镶块组合的结构,避免在开模时与随形冷却水路产生干涉.塑料弹夹注塑模具结构简单可靠、布置合理,可以有效提高塑料弹夹的生产效率.     

计算机辅助技术在注塑成型冷却模块设计中的应用

注塑成型工艺是一种高分子复合材料高效加工技术,目前,此项技术已成为国内外塑料制造业的重要工艺方法之一。注塑模具冷却模块的设计优异性直接关系到模具的冷却效率和冷却效果,进而影响产品的成型质量以及生产效率。虽然传统注塑模具冷却模块的结构相对简单,但冷却效率较低,其热机械性能已经逐渐无法满足现阶段生产要求。以随形冷却方法核心理念,简述了注塑模具冷却模块的性能对塑料零件生产的影响,对比了传统模具和随形冷却模具的结构。并选择以塑料桶件为研究对象,在一个统一连续的方式下快速地降低塑件的温度,冷却过程中不从模具中取出,直到冷却充分后取出注塑件。并以基于有限元分析平台的动态结构-热耦合分析技术为工具,分别分析了随形冷却通道的管路直径D、匝数N和桶件与冷却通道距离L对冷却时间t的影响,比较了传统注塑模具和随形冷却模具的冷却时间和等效应力,对有关于随形冷却模块的结构参数分析过程对其模具对应结构的设计具有一定的指导性意义。     

基于正交试验的汽车挡板塑件注塑模具冷却系统的优化分析

以汽车挡板注塑模具冷却水道水孔直径、相邻冷却水道水孔间距及冷却水道模具表面距离为实验参数,利用正交实验对模壁温差进行模拟分析。验证得出水孔间距对模具的冷却效果影响最为明显,通过优化分析,使得冷却系统的冷却效果较为理想,使得模具的温差均匀,能提升塑件的产量和合格率。可得到冷却水道最佳的工艺组合为:冷却水道水孔直径10mm、相邻冷却水道水孔间距140mm、冷却水道模具表面距离30mm。     

注射模冷却系统中的CAE技术应用

因塑件所用塑料的性能、塑件的结构以及成型工艺参数不同,注射模对其冷却系统的要求也不相同.塑料注射模冷却系统的设计不但关系到塑件质量而且也关系到注射成型生产效率.以碗厨上盖塑料制件为倒,阐述了CAE技术在注射成型冷却系统中的应用与模拟分析,并根据冷却分析的结果提出了相应的优化方案,最终获得了良好的冷却效果.     

双L环200L大型物料桶模具设计与分析

以大型中空制品:双L环200L大型物料桶为基础,利用solidworks三维CAD/CAE/CAM软件完成其模具设计及冷却水道分析。借助solidworks模具设计功能完成双L环200L大型物料桶的拔模分析、分型面创建、切削分割,从而获得模腔主题。在模腔主题的基础上利用软件的三维建模功能完成制品的主模设计、上子模设计、下子模设计、导向设计。最后利用solidworks flow Simulation流体与热耦合插件对模具冷却水道进行有限元分析,检验冷却水道设计是否合理、满足模具的冷却效率和制品生产的周期要求。     

中厚高强度钢板热冲压冷却速率的研究

对中厚高强度钢板U形件进行创新型研究,通过对两种不同冷却系统的热冲压模具所得到的U形件进行冷却速率研究,发现带水浴池冷却系统模具得到的U形件平均冷却速率显著大于带冷却管道冷却系统模具得到的U形件的平均冷却速率、且U形件温差较小,很好地解决了中厚板料在热成形过程中因板料厚度大而平均冷却速率减小、板料淬火不均匀温差大影响热冲压件力学性能等问题,同时大大缩短了淬火时间,提高生产效率。     

电话听筒浇注和冷却系统的设计及CAE分析

分析了电话听筒的结构和成型工艺;针对听筒塑件前壳与后盖配对生产、壁薄和表面质量要求高等特点,运用MFI软件对听筒塑件前壳与后盖进行浇口位置分析选取;设计了注塑模具的浇注系统和冷却系统,并对听筒塑件进行了流动分析、冷却系统分析和翘曲变形分析;得到了回路冷却液温度、回路管壁温度和达到顶出温度的时间。结果表明:听筒塑件翘曲变形主要发生在听筒前壳,由收缩不均匀引起,其变形量为2.339 0mm,冷却和取向引起的变形量接近于0,为电话听筒注塑模具浇注系统与冷却水道排布设计提供了理论依据。     

高炉冷却壁冷却水管设计探讨

高炉冷却壁的水管设计对提高其冷却性能有重要作用。鉴于此,通过数值模拟计算了高炉冷却壁在各种水管布置方式下水管半径对最高温度和最大热应力的影响,对比分析了同等冷却水流量下冷却壁内布置不同水管数时的最高温度和最大热应力。研究结果表明:冷却壁最高温度和最大热应力随水管半径的增加显著减小,但水管半径的增大会使冷却水流量大幅增加,并且冷却水管半径过大会造成冷却壁机械强度降低;同等冷却水流量下,增加冷却水管数可以增加冷却水与壁体的总接触面积从而增强冷却效果,冷却壁最高温度和最大热应力随水管数的增加而显著减小。     

Manufacture of an injection mould with rapid and uniform cooling characteristics for the fan parts using a DMT process

The aims of the present study is to manufacture an injection mould with a pair of conformal cooling channels in each blade of the mould for a plastic fan part via laser-aided direct metal tooling (DMT) process to achieve both rapid and uniform cooling characteristics. The features of the design and the manufacturing process for the injection mould as well as the characteristics of the manufactured mould were discussed. Three-dimensional injection moulding analyses were performed to obtain a proper design of the conformal cooling channels. Injection moulding experiments were carried out to investigate the practical applicability of the fabricated mould and the influence of the cooling time on the qualities of the moulded product. The results of the experiments showed that a plastic fan part with superior qualities can be fabricated from the designed mould when the cooling time is 13 s. The efficiency of the designed mould was examined through a comparison of the product from the newly designed mould and that from a previously designed mould with linear cooling channels in terms of product qualities as well as the cooling and cycle times. The results of the comparison showed that the newly designed mould can remarkably reduce the positional error distributions and the eccentricity of the moulded product. In addition, it was shown that the cooling and cycle times of the designed mould can be shortened to 35.0 % and 25.7 % of those of the previously designed mould, respectively.     

Thermal–structural analysis of bi-metallic conformal cooling for injection moulds

In injection moulding process, cooling time greatly affects the total cycle time. As thermal conductivity is one of the main factors for conductive heat transfer in cooling phase of IMP, a cooling channel made by higher thermal conductive material will allow faster extraction of heat from the molten plastic materials, thus resulting in shorter cycle time and higher productivity. The main objective of this paper is to investigate bi-metallic conformal cooling channel design with high thermal conductive copper tube insert for injection moulds. Thermal–structural finite element analysis has been carried out with ANSYS workbench simulation software for a mould with bi-metallic conformal cooling channels and the performance is compared with a mould with conventional straight cooling channels for an industrial plastic part. Experimental verification has been carried out for the two moulds using two different types of plastics, polypropylene (PP) and acrylonitrile butadiene styrene, in a mini injection moulding machine. Simulation and experimental results show that bi-metallic conformal cooling channel design gives better cycle time, which ultimately increases production rate as well as fatigue life of the mould.     

A scaffolding architecture for conformal cooling design in rapid plastic injection moulding

Cooling design of plastic injection mould is important because it not only affects part quality but also the injection moulding cycle time. Traditional injection mould cooling layout is based on a conventional machining process. As the conventional drilling method limits the geometric complexity of the cooling layout, the mobility of cooling fluid within the injection mould is confined. Advanced rapid tooling technologies based on solid freeform fabrications have been exploited to provide a time-effective solution for low-volume production. In addition, research has made attempts to incorporate conformal cooling channel in different rapid tooling technologies. However, the cooling performance does not meet the mould engineer’s expectations. This paper proposes a novel scaffold cooling for the design of a more conformal and hence more uniform cooling channel. CAD model for constructing the scaffolding structure is examined and cooling performances are validated by computer-aided engineering (CAE) and computer fluid dynamics (CFD) analysis. An erratum to this article can be found at     

基于CAE技术的电视机视窗注塑模冷却系统多方案优化

针对冷却系统在塑料制品注射模成型过程中的重要地位,利用专业模流分析软件MOLDFLOW对塑件冷却系统进行了优化设计.以某型号电视机视窗为例,介绍了MOLDFLOW软件对其冷却系统进行计算机模拟分析的过程,优化了模具冷却回路和冷却时间,从而获得高预测质量的产品,降低了生产成本,对生产具有一定的指导意义.     

细长塑件的冷却及模具设计

阐述细长塑件注射模具冷却系统的设计方法,重点介绍该模具细长型芯的冷却。     

注塑模冷却时间优化设计

针对冷却系统在塑胶模注射成型过程中的重要地位,利用专业模流分析软件MOLDFLOW对注塑抽屉的冷却系统中冷却时间的优化进行了研究。重点介绍了MOLDFLOW软件对模具冷却系统进行计算机模拟分析的过程,主要对模具冷却回路和冷却时间进行了优化设计,获得了高预测质量的产品,进一步说明合理的冷却系统设计对提高产品质量、缩短成型周期、提高生产率和降低能耗提供了有利保证。     

CAE技术在注射模设计中的应用

通过一个带有锥度的长方桶形塑料制品的注射模设计的例子，介绍了利用CAE技术确定浇注系统、冷却系统的方法，提出了一种减少省时高效的模具设计方法。     

Design of U-shape milled groove conformal cooling channels for plastic injection mold

Besides the solid free-form fabrication technology, milling operation is an alternative applicable method to make complex cooling channels conform to the surface of the mold cavity. This paper presents the U-shape milled groove conformal cooling channels and proposes the design optimization process in order to obtain an optimal cooling channels’ configuration and target mold temperature. The relation between the cycle averaged thermal behavior of the mold cavity and the two-dimensional configuration of cooling channels was first investigated thoroughly by an analytical method. Design of experiment and 2D simulation were done to obtain the mold wall temperature and to check the feasibility of the analytical method. The optimization process of the free-form conformal cooling channels is based on the combination of both analytical method and 3D CAE simulation. The analytical step relies on explicit mathematic formulas, so it can approach the neighboring optimal solution quickly. Subsequently, the three-dimensional heat transfer simulation is applied to fine-tune the optimization results. A case study for a plastic car fender was investigated to verify the feasibility of the proposed method. The results show that conformal cooling channel gives a uniform cooling, reducing the cooling time and increasing the molded part’s quality with less effort of plastic designers and high computational efficiency.     

基于UG的内螺纹瓶盖注塑模设计

UG MoldWizard是UG系统的一个独立的智能化设计注射模具的模块,它运用知识嵌入的基本理念,按照注射模具设计过程的一般顺序来实现模具设计的整个过程.在本次内螺纹瓶盖的设计中,充分体现UG在注塑模设计中的高效和快捷.通过对内螺纹瓶盖工艺分析,巧妙地采用镶块成型内螺纹和项出塑件,从而简化模具结构.并对模架、浇注系统...