注塑模浇注系统位置的自动设计

注塑成型可以制作大量具有高精度和复杂型腔形状的制件,其中注塑模浇注系统位置的设定是整个模具设计中关键的一步,它决定了聚合物流动方向和流动平衡性。通过对型腔内前端熔体行为的研究,引入等效流长的概念,建立了单浇注系统位置优化问题。采用遗传算法自动搜索最佳浇注系统位置,使得不同主流动路径的等效流长差异最小,从而获得平衡的充填模式。通过两个算例表明,该方法可以快捷的得到优化的浇注系统位置。     

CAE技术在注塑成型浇注系统优化设计中的应用

注塑模浇注系统是塑料注塑成型模具设计中的关键技术之一,利用CAE软件Moldflow可对不同浇口位置进行流动模拟分析,预测可能存在的气泡和熔接痕的位置,为模具设计人员优化模具设计提供依据,提高一次试模的成功率。并经过实践证明,注塑成型中通过浇注系统位置的优化可以显著提高产品的质量。     

中小型注射模浇注系统断面尺寸的校核

该文主要介绍一种计算中小型注射模普通浇注系统断面尺寸的方法，这种方法是作者通过多年的设计和教学研究摸索出来的，采用这种方法，既可直接用来确定注射模普通浇注系统的主流道，分流道，浇口的断面尺寸，也可用来校核凭经验设计的浇注系统的断面尺寸的正确性，解决一些难以解决的塑料模具设计问题，以达到提高产品质量，缩短模具制造周期的目的。     

CAD/CAE技术在电话机面板注射模设计中的应用

为了优化注射模的设计方法,基于CAD/CAE技术,以电话机面板(下述简称塑件)为例,运用Pro/E软件,设计塑件的三维模型和注射模装配图,运用Moldflow软件,对塑件最佳浇口位置、充填、冷却和翘曲等方面进行模拟分析,并且根据分析结果,确定出浇注系统和冷却系统及注射模的最佳设计方案。结果表明,采用CAD/CAE技术能够为注射模设计及注射工艺参数的优化调整提供依据,及时有效地预防塑件在注射过程中可能出现的问题,可以提高注射模设计质量,并缩短其设计和开发周期。     

多孔复杂型腔塑件注塑模具CAD/CAE数字化研究

在UG中建立了塑件的三维数据图,借助模流分析(Moldflow)软件对塑件注射压力、时间、温度、浇注系统进行计算机辅助工程分析(CAE),确定最优的注射压力、注射时间、模具温度、熔体温度、浇口位置及流道等。优化了注塑工艺参数、注塑模具的设计,确定了最佳的注塑工艺方案,快速成型出优质的塑料制品,提高了模具的质量,缩短了模具的开发周期。     

大型浇注薄壁件的翘曲优化

研究了浇注系统和成型工艺参数对薄壁件翘曲变形的影响,对制件浇注系统进行了优化,再在优化后的浇注系统基础上以模具温度、熔体温度、冷却时间、注射时间、保压压力和保压时间为计算工艺参数,在三维流动分析的研究基础上,对制品缺陷进行了CAE分析,通过采用正交实验法,进行均值分析、极差分析及方差分析,并结合各因素效应曲线图,得出了最优工艺参数组合及各成型工艺参数对翘曲变形影响的主次关系及影响程度。CAE分析与试验结果表明,塑件的翘曲量从1.861mm减少到0.6282mm。     

MoldflowXpress模块在SolidWorks零件结构及模具设计中的应用

MoldflowXpress可根据零件的几何形状、材料、浇注位置进行模拟注射而得出分析结果,演示零件在模具型腔内能否完全填充,智能化地提供塑料零件注射模具制造可行性的建议。这一功能可以使用户通过逼真的动态模拟分析直观了解塑料注入模腔时的流动情况,合理选择模具的注塑位置和塑件的壁厚,优化模具设计及注塑条件的参数设置,提高生产效率,降低零件生产成本。     

基于CAE鼠标浇口与流道平衡设计关系

当鼠标上下盖两个塑料件同时一模注塑成形时,容易产生填充不平衡等缺陷,为了获得良好的鼠标塑件质量,需要对其浇注系统进行优化。用MOLDFLOW先对鼠标的盖面网格进行划分,创建原始浇注系统,进行填充分析并显示结果,从而对原始浇注系统进行优化。通过多次迭代达到收敛要求后,浇口选用堆切式,并确定浇注系统各浇口的具体尺寸。通过优化后对流道进行平衡分析,结果显示充填时间和充填压力均可满足要求,从而说明MOLDFLOW模拟设计鼠标浇注系统可行。     

中小型注射模浇注系统断面尺寸的校核

该文主要是介绍一种计算中小型注射模普通浇注系统断面尺寸的方法.这种方法是作者通过多年的设计和教学研究摸索出来的.采用这种方法,既可直接用来确定注射摸普通浇注系统的主流道、分流道、浇口的断面尺寸;也可用来校核凭经验设计的浇注系统的断面尺寸的正确性,解决一些难以解决的塑料模具设计问题,以达到提高产品质量、缩短模具制造周期的目的.     

基于Moldflow的TPE塑件流动平衡优化设计

根据电动工具把手的结构特点和材料特性,介绍TPE塑件流动平衡的优化过程与设计方法。在结构分析的基础上,利用UG NX和Moldflow软件对塑件三维模型进行前处理,进而进行浇口位置分析、流动平衡初分析;根据前期分析结果修改浇注系统参数,实现了对塑件流动平衡的优化设计。实践证明,基于Moldflow优化后的浇注系统尺寸合理,运行可靠,产品质量稳定。     

A study of gate location optimization of plastic injection molding using sequential linear programming

A gate location is one of the most important design variables controlling the product quality of injection molding. In this paper, the numerical simulation of injection mold filling process is combined with the design optimization method to find the optimum gate location to achieve balanced flow. The objective function is expressed in terms of the difference between the maximum and minimum times of boundary filling. The coordinates of gate are chosen as design variables, and a constraint is employed to limit the clamp force lower than the reference value. The optimization problem is solved with the sequential linear programming algorithm, and design sensitivities are evaluated via the finite difference approximation. Finally, numerical examples are given to demonstrate the effect of proposed methods.     

Moldflow在不对称薄壳注塑件浇口优化设计中的应用

以不对称薄壳手机注塑件为研究对象,运用Moldflow软件对模具浇口进行了优化设计.通过对不同浇口数量和位置进行模拟流动分析,从产品的填充时间、熔接痕和气穴等方面对不同的浇口设计方案进行对比,从而获得了最佳的浇口设计,为同类产品模具浇口的设计提供了合理的依据.     

Micro genetic algorithm based optimal gate positioning in injection molding design

The paper deals with the optimization of runner system in injection molding design. The design objective is to locate gate positions by minimizing both maximum injection pressure at the injection port and maximum pressure difference among all the gates on a product with constraints on shear stress and/or weld-line. The analysis of filling process is conducted by a finite element based program for polymer flow. Micro genetic algorithm (mGA) is used as a global optimization tool due to the nature of inherent nonlinearlity in flow analysis. Four different design applications in injection molds are explored to examine the proposed design strategies. The paper shows the effectiveness of mGA in the context of optimization of runner system in injection molding design.     

基于粘弹本构模型的注射成型充填过程模拟研究

为反映聚合物粘弹属性对注塑产品质量的影响,基于粘弹本构模型,对三维薄壁制件的注射成型充填过程进行了数值模拟研究。针对三维薄壁件,经合理简化假设,建立了其充填成型过程的数学模型,采用不可压缩Leonov粘弹本构模型。采用有限元/有限差分法来求解压力场和温度场,采用控制体积法来实现前沿界面跟踪,采用4阶龙格-库塔方法求解弹性应变张量。以一薄壁圆盘为例,对其注射充填过程中的充填时间及压力、剪切应力和第一法向应力差分布进行了数值模拟。模拟结果与前人的实验结果吻合较好,说明了本文建立的模型和数值方法的有效性及可靠性。     

Injection moulding optimisation of multi-class design variables using a PSO algorithm

Injection moulding optimisation seeks to achieve the highest possible moulding quality under the specified constraints. To this end, the factors (design variables) affecting the moulding quality should be adjusted, including those of process parameters, mould design, part geometry, etc. Past work in this aspect is primarily focused on tuning the process parameters and mould design (e.g., gate location, runner and cooling channel layout), with less attention on the part geometry, and none on them all. To address this problem, this paper presents a PSO (particle swarm optimisation) algorithm for the optimisation of multi-class design variables, such as the part thickness, process parameters (melt temperature, mould temperature, injection time) and gate location. The optimisation is targeted at different aspects of moulding quality, including part warpage, weld lines, air traps, and so on. In applying the PSO algorithm, the paper proposes a modified elite archiving method, which can expedite the convergence speed, hence improving the efficiency of the algorithm. A computer program was developed that automates the steps such as adjusting the part thickness, the injection moulding process parameters and the gate location, activating the CAE software to simulate the injection moulding process, retrieving the simulation results, and evaluating the objective functions. The whole procedure iterates a number of generations by following the search process of the algorithm. A case study was also presented to illustrate as well as to test the proposed methodology, which was demonstrated as both effective and efficient.     

外星轮热挤压模具结构及工艺参数联合多目标优化

针对外星轮热挤压过程模具负载大、填充性能波动的问题, 对关键的模具结构参数（入口斜度,根部圆角,模口圆角）及核心工艺参数（挤压速度,摩擦因数,坯料初始温度,模具预热温度,模具硬度）开展联合优化,以期获得负载和填充性能的平衡。首先应用部分析因试验设计,针对最大成形载荷和填充能力进行主参数效应筛选,对得到的关键因子进行拉丁超立方抽样并对样本点进行有限元模拟。以关键因子为变量、有限元模拟结果为响应,分别建立最大成形载荷和填充能力的径向基函数近似模型。基于上述近似模型,采用线性加权和法将所得近似模型转化为单目标函数,利用粒子群算法进行全局寻优,得到优化的关键结构和工艺参数组合,并通过仿真和生产试验验证了优化结果的正确性。     

GATE TYPE SELECTION BASED ON FUZZY MAPPING

0 INTRODUCTION(Mould conceptual design is the most important phase of mould design. The main characteristic of this phase is a linear flow of design, with minimal number of iteration [1]. The decisions made during this phase are of high level and have a direct influence on performance of the mould and development costs. Within this phase there are many operations that have to be carried out, one of which is gate type selection. Although numerical simulation approach could be used to optim…     

翻转式闸门有限元分析及结构优化设计

为减少在山西中部引黄工程中应用的某翻转式闸门的制造成本,利用ANSYS软件对其进行结构轻量化设计.采用APDL建立该翻转式闸门的参数化有限元模型并对其进行静力分析,通过比较在不同开启角度下闸门所受应力和变形情况,确定出最危险的工况,并在该工况下对闸门模型进行优化分析.优化选择对闸门重量、应力和变形影响较大的参数作为设计...     

Optimization of injection molding process parameters using integrated artificial neural network model and expected improvement function method

In this study, an adaptive optimization method based on artificial neural network model is proposed to optimize the injection molding process. The optimization process aims at minimizing the warpage of the injection molding parts in which process parameters are design variables. Moldflow Plastic Insight software is used to analyze the warpage of the injection molding parts. The mold temperature, melt temperature, injection time, packing pressure, packing time, and cooling time are regarded as process parameters. A combination of artificial neural network and design of experiment (DOE) method is used to build an approximate function relationship between warpage and the process parameters, replacing the expensive simulation analysis in the optimization iterations. The adaptive process is implemented by expected improvement which is an infilling sampling criterion. Although the DOE size is small, this criterion can balance local and global search and tend to the global optimal solution. As examples, a cellular phone cover and a scanner are investigated. The results show that the proposed adaptive optimization method can effectively reduce the warpage of the injection molding parts.