薄壁注塑件翘曲影响因素分析及优化研究进展

分析了薄壁注塑成型翘曲变形产生的原因,介绍了几种优化算法的基本原理及特点。重点讨论了薄壁注塑件翘曲变形的模具优化设计和工艺参数优化方法。注塑模具优化设计主要通过保证流动平衡来间接实现翘曲优化。注塑工艺参数优化是减少翘曲的可行而有效的途径,影响翘曲最主要的工艺参数是保压压力、注射速率及模具温度。总结了注塑工艺参数优化的几种方法,对“代理模型”翘曲优化进行分析,步进式代理模型能更好地提高计算效率。     

面向绿色注塑加工的工艺耦合参数设计优选方法

为提高产品加工过程的绿色性能,提出一种基于耦合推广正交算法的工艺参数优选方法。利用正交实验在解决单目标优化问题中的优势,提出基于工艺参数耦合强度关系的推广正交算法,用小生境演化繁殖后代,以实现多绿色性能指标优化。将该方法运用到注塑加工工艺参数设计中,选择面向绿色性能指标的注塑加工工艺参数,确定相互间的耦合强度关系以及注塑加工过程的多项绿色性能指标,建立注塑加工绿色设计模型。以某风机盖注塑加工为例验证了所提方法的可行性。     

两种神经网络在注塑产品工艺参数确定中的应用

汽车外饰件的塑料化趋势对注塑模成型质量提出了更高要求.为解决传统CAE方法需多次试验才能得到较优工艺的缺点,以一汽车观后镜为研究对象,建立了基于人工神经网络的从注塑工艺参数到注塑翘曲量的非线性映射关系,并对比了两种经典的前馈神经网络(BP网络和RBF网络)的学习能力,从而实现用神经网络模型代替CAE软件获得注塑翘曲量.研究结果表明,该方法能有效地缩短优化工艺参数的时间,提高了工艺设计效率.     

基于遗传算法的注塑工艺优化设计

在一般注塑CAE模块中 ,对给定的塑料件输入一定的工艺条件如分型面、注射温度、模具温度等参数可得到熔体流动图、气穴位置、熔接痕等分析结果 ,但不能实现工艺条件的优化。介绍了一种利用CAE模块产生的数据 ,通过遗传算法进行注塑工艺优化的方法。     

基于BP神经网络的连接器注塑工艺参数多目标优化

为提高连接器注塑工件质量,获得最优的连接器注塑工艺参数,设计一种基于BP神经网络的连接器注塑工艺参数多目标优化方法。利用方差分析法获得对试验结果有显著影响的参数,进而得到更全面的信息。建立相应工艺参数优化模型,并添加多层级的结构;建立BP神经网络集预测模型,映射工艺参数与质量指标的非线性关系,利用预补偿法最终实现工艺参数优化及误差补偿。在相同的测试环境之下,对比于传统优化补偿测试组,新型的优化补偿组所得出的翘曲平均值较低。测试结果证明：新型优化补偿组处理效果更佳,具有一定的应用价值。     

基于遗传算法的注塑工艺优化设计

在一般注塑CAE模块中，对给定的塑料件输入一定的工艺条件如分型面、注射温度、模具温度等参数可得到熔体流动图、气穴位置、熔接痕等分析结果，但不能实现工艺条件的优化。介绍了一种利用CAE模块产生的数据，通过遗传算法进行注塑工艺优化的方法。     

注塑产品工艺参数的计算机管理

介绍了一个注塑工艺参数管理软件的实际开发过程.随着工艺参数记录的增加,可将此作为以后开发注塑工艺参数专家系统的知识库,实现注塑工艺参数的智能给定.     

模内层压模具动态温度控制系统的设计实现

介绍一种模内层压注塑模具的动态温度控制系统,系统基于CPLD、FPGA构建了可靠、独立和快速的测控平台,并通过优化的PID策略,实现了模温的精确测量与控制.模内层压注塑工艺采用动态温度控制,提高了产品品质和生产效率.     

基于MPI的注塑成型分析

介绍了注塑CAE软件-MPI(Moldflow Plastics Insight)的应用流程和方法,应用MPI软件进行制件注塑成型过程模拟分析,优化模具浇注系统、冷却系统和注射成型工艺方案,为生产优质塑料制件提供理论指导.     

工艺参数对平板微小器件注塑翘曲的影响

对显著影响平板微小器件注塑成型的翘曲现象进行了研究.为了减少翘曲量,以带十字微沟槽的微流控芯片的基片为研究对象,研究了注塑工艺涉及的工艺参数.从注塑残余应力角度分析了翘曲变形的产生机理与演化过程.然后,以数值仿真和工艺实验为手段,建立了平板微小器件翘曲的测量方法.设计加工了基于硅型芯的注塑模具,以翘曲测量方法为基础,利用正交试验获得了最优注塑工艺参数.最后,通过极差分析法定量分析工艺参数对翘曲的影响.实验显示,通过工艺优化获得的最小翘曲量为141 μm,工艺参数对翘曲的影响由大到小依次为:保压时间、模具温度、保压压力、熔体温度、冷却时间.该研究成果为平板微小器件注塑工艺提供了参考依据.     

滑雪板底板注射模设计

介绍在卧式注射机上生产滑雪板底板,底板中间层的不锈钢片采用嵌件方式进行生产,一方面保证了产品的质量,另一方面减少了装配,保证了产品的外观。金属嵌件注射模的生产一般在立式注射机上进行,较少使用卧式注射机,如何设计在卧式注射机上生产的金属嵌件注射模,要考虑的问题很多,就不锈钢嵌件在模具中的定位问题、注射成型工艺、顶出结构系统等注射生产中涉及到的内容进行论述交流。     

Multi-characteristic optimization of wax patterns in the investment casting process using grey–fuzzy logic

The present investigation focuses on optimizing the injection process parameters with multiple performance characteristics in the investment casting process using the orthogonal array with grey–fuzzy logics. A grey–fuzzy reasoning grade obtained from the grey–fuzzy logics analysis is used as a performance index to determine the optimal injection process parameters. The selected injection process parameters are injection temperature, injection time, and injection pressure, while the considered performance characteristics are linear shrinkage and surface finish. The response table, response graph, and analysis of variance are used to find the optimal setting and the influence of injection process parameters on the multiple performance characteristics. The results of confirmation experiments reveal that grey–fuzzy logics can effectively acquire an optimal combination of the process parameters. Hence, quality of wax patterns in the investment casting process can be significantly improved through this approach.     

A computational system for process design of injection moulding: Combining blackboard-based expert system and case-based reasoning approach

The process design of injection moulding involves the selection of the injection moulding machine, mould design, production scheduling, cost estimation, and determination of injection moulding parameters. Expert system approaches have been attempted to derive the process solution for injection moulding in the past few years. However, this approach has been found to be incapable of determining the injection moulding parameters owing to the difficulty in setting the moulding parameters. In addition, the existing expert systems for process design lack the proper architecture for organising a heterogeneous knowledge source. In this paper, the combination of a blackboard-based expert system and case-based reasoning approach is introduced to make up the deficiencies of the existing expert-system approach to the process design, from which a computational system for process design of injection moulding, named CSPD, was developed and described. CSPD first derives the process solution including the selection of injection moulding machine and mould base, tooling cost, and processing cost estimation, and production scheduling based on the blackboard-based expert-system approach. It is then followed by the determination of the injection moulding parameters based on the case-based reasoning approach and the previously derived partial solution.     

基于模拟的注塑工艺分析设计集成系统的开发

将模具设计、制造和注塑工艺作为模具设计开发过程中的三个重要因素 ,提出了在模具设计阶段并行地进行注塑工艺方案设计的思想。开发了一套基于 C- MOL D系统的注塑工艺方案设计系统 ,该系统是基于并行设计思想 ,集成了 CAD和注塑过程 CAE分析系统部分信息的新平台 ,为在模具设计阶段进行注射工艺方案的并行设计和在注射工艺方案设计阶段进行工艺方案评价提供了一个集成环境     

塑料注射模具的并行设计方法

塑料制品注射成型属于一次成型工艺 ,传统的串行模具设计和制造方式 ,造成了对设计经验的过分依赖和模具返修率的提高 ,本文举例介绍了基于流动模拟技术的注射模并行设计方法 ,说明了 CAE对模具结构设计和相关注塑工艺的指导作用。     

A Hybrid Neural Network and Genetic Algorithm Approach to the Determination of Initial Process Parameters for Injection Moulding

Determination of the initial process parameters for injection moulding is highly skilled task and is based on a skilled operator's "know-how" and intuitive sense acquired through long-term experience rather than on a theoretical and analytical approach. In the face of global competition, the current trial-and-error practice is inadequate. In this paper, a hybrid neural network and genetic algorithm approach is described to determine a set of initial process parameters for injection moulding. A hybrid neural network and genetic algorithm system for the determination of initial process parameter settings for injection moulding based on the proposed appraoch was developed and validated. The preliminary validation test of the system has indicated that the system can determine a set of initial process parameters for injection moulding quickly from which good quality moulded parts can be produced without relying on experienced moulding personnel.     

修复如新下基于RP和MC的故障注入样本生成

由于测试性虚拟试验可有效弥补测试性实物试验的不足,但同时也对故障注入样本生成提出新的要求.在可修系统修复如新假设下,提出一种基于更新过程理论和蒙特卡罗仿真的故障注入样本模拟生成方法.首先分析指出修复如新假设下可修系统的故障发生过程是随机过程,并用更新过程描述修复如新下可修系统的故障发生过程;然后,基于统计仿真实验中的蒙特卡罗方法,对事后维修模式下的故障发生过程进行抽样,实现故障注入样本的模拟生成;最后,以某稳定跟踪平台上的陀螺和运动控制器为案例进行实验.由于考虑了多种寿命分布类型,模拟生成的故障样本在样本量和样本结构上符合实际情况,所提出的方法能有效指导修复如新和事后维修情况下测试性虚拟验证试验中的故障注入.     

A computational system for process design of injection moulding: Combining a blackboard-based expert system and a case-based reasoning approach

Process design of injection moulding involves the selection of the injection moulding machine, mould design, production scheduling, cost estimation, and determination of injection moulding parameters. An expert system approach has been used to derive the process solution for injection moulding over the past few years. However, this approach is found to be incapable of determining the injection moulding parameters owing to the fragile nature of the knowledge for setting the moulding parameters. In addition, the existing expert systems for process design lack proper architecture for organising heterogeneous knowledge sources. In this paper, the combination of a blackboard-based expert system and a case-based reasoning approach is introduced to eliminate the deficiency of the existing expert-system approach to process design, from which a computational system for the process design of injection moulding, named CSPD, has been developed. CSPD first derives the process solution including the selection of the injection moulding machine and the mould base, tooling cost, processing cost estimation, and production scheduling based on the blackboard-based expert-system approach. It is then followed by the determination of the injection moulding parameters based on the case-based reasoning approach and the previously derived partial solution.     

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。     

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。