基于CAE技术的塑料水杯注塑模设计及成型分析

分析了塑料水杯的结构及成形工艺特点,设计了对应的注塑模模具,并利用C A E技术的塑料注射成形软件M oldflow对制件进行了预成形。制件注射过程中气穴较少;温度分布基本合理;熔接痕位置较少,制件冷却相对均衡。综合分析结果表明,模具结构合理,塑件成形质量较好,预成型可较少模具试模、修模次数,降低生产成本。     

一模多用注射模具设计研究

分析降低塑料制件成本的方法,提出为了降低成本,将满足一定条件的几种规格形式的塑料制件用一副模具成型出来,就是一模多用模具;同时研究了一模多用注射模具四种形式的分类及条件,结合生产实例分析模具设计要点,模具巧妙结构特点等。经生产实践证明,在一定的条件下,使用一模多用注射模具可以减少模具数量,降低成本,大大提高企业的市场竞争力。     

玩具汽车前保险杠及楔块组合注塑模设计

针对保时捷911玩具汽车前保险杠和左、右楔块的结构特征,进行了产品成型工艺分析与模具排位设计。根据产品的尺寸结构特征、质量及使用要求,模具采用单分型面、推杆推出以及潜伏式浇口进料注射的总体结构,重点介绍了模具核心元件的结构设计以及浇注系统、冷却系统、推出机构结构形式的选择。通过试模检验,塑件外观光滑、美观,模具动作灵活、可靠。     

矿灯槽盖注射模具设计

针对矿灯槽盖塑料制件的结构特点,设计出不采用复杂的侧抽芯机构,而是采用斜孔特殊成型和成型推杆等结构的注射模具,模具制造容易,成本低,同时介绍注射成型工艺要求.     

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.     

摩擦压边充液拉深模

炼油设备中的一种深矩形盒制件,如图1所示,曾在双动液压机上用普通拉伸模拉伸成形,制件的危险断面处严重变薄,使用寿命短.目前,改在普通四柱液压机上,用摩擦压边的充液拉伸模,一次拉伸成型,制件的壁厚均匀,延长了使用寿命.模具结构如图2所示.把毛坯置于凹模上面定位后,上模部分下行,压边圈9在弹簧13预压力作用下,将液体密封在凹模型腔内.拉伸时,在拉伸力的作用下,聚胺酯橡胶垫10受到挤压,朝着压边圈孔壁径向扩张而产生摩擦,摩擦力约为压边力,其大小与拉伸力保持一定的比例关系.密封在凹模型腔内的液体因被压缩,压力急剧升高,当压     

装饰品注射模设计

分析了装饰品的工艺特点,对制件的成型工艺特点,注射成型条件,模具的设计要点、结构、工作过程作了阐述。试制的装饰品经二次试模成功,塑件质量良好。     

后盖注塑模设计

本文针对儿童玩具手机的后盖设计了其注塑成型的注塑模具结构。该制件结构简单,存在矩形孔和圆形孔、倒扣,因此设计了圆形推杆和推管两种推出机构,以及用斜顶侧抽芯机构。采用一模两腔的型腔布局形式,在XS-ZY-125的注射机上一次注塑成型。     

基于Taguchi试验设计的储箱箱盖注射工艺参数研究

注射成型受众多因素影响,在制件结构和模具结构确定的条件下,通过合理的注射工艺参数,可消除或减少塑件成型中出现的缺陷。针对某企业在试生产一种储物箱箱盖时产生翘曲变形的问题,采用Taguchi试验方法,应用Moldflow对注射过程进行模拟,获得了塑件在熔料温度、模具温度、注射时间和保压压力四因素三水平下成型的翘曲变形量。采用极差分析,比较了不同工艺参数对翘曲变形量的影响程度,得到了优化的工艺参数组合。经试验验证,其效果良好,产品的翘曲变形得到了一定的改善。     

高精度长寿命热固性塑料注射模研制

高精度长寿命热固性塑料注射模研制上海电器公司华一电器厂葛亦麟一、前言我国热固性塑料注射模在６０年代就开始制造和应用，但由于模具结构落后，制造精度低，使用寿命不高，注射成型的热固性塑料件不仅飞边厚、不平度差、而且单件耗电高，因此影响热固性塑料注射成型工...     

Injection molding of polymer micro- and sub-micron structures with high-aspect ratios

This work studies the injection molding characteristics of polymer micro- and sub-micron structures using demonstration mold inserts with micro- and sub-micron channels with high-aspect ratios. The effects of the injection molding parameters on the achievable aspect ratio of the micro- and sub-micron walls were investigated. Additionally, distinctive mold-filling behaviors and resulting defects were observed for various polymers, such as polymethyl methacrylate (PMMA), polypropylene (PP) and high-density polyethylene (HDPE). Experimental results reveal that the mold temperature determines the success of the injection molding of micro- and sub-micron walls. The satisfactory mold temperature for micro-injection molding significantly exceeds that for traditional injection molding. Moreover, the main injection pressure and the main injection time substantially affect the achievable aspect ratio of the micro- and sub-micron walls. Furthermore, unusual flow behaviors occur and poor molding results are obtained when PP and HDPE are used for micro-injection molding.     

Surface microstructure replication in injection molding

In recent years, polymer components with surface microstructures have been in rising demand for applications such as lab-on-a-chip and optical components. Injection molding has proven to be a feasible and efficient way to manufacture such components. In injection molding, the mold surface topography is transcribed onto the plastic part through complex mechanisms. This replication, however, is not perfect, and the replication quality depends on the plastic material properties, the topography itself, and the process conditions. This paper describes and discusses an investigation of injection molding of surface microstructures. The fundamental problem of surface microstructure replication has been studied. The research is based on specific microstructures as found in lab-on-a-chip products and on rough surfaces generated from EDM (electro discharge machining) mold cavities. Emphasis is put on the ability to replicate surface microstructures under normal injection-molding conditions, i.e., with commodity materials within typical process windows. It was found that within typical process windows the replication quality depends significantly on several process parameters, and especially the mold temperature. For the specific microstructures, evidence suggests that step-height replication quality depends linearly on structure width in a certain range.     

Effect of mold temperature on motion behavior of short glass fibers in injection molding process

In injection molding process, the mold temperature can strongly affect the fiber orientation and distribution state in plastic parts. The fiber orientation behavior is discussed, and a model is used to describe the layered structure in injection parts. By studying the injected specimens, the fiber distribution and the layered structure in the part are illustrated and a variation of the fiber distribution along with the increasing of the mold temperatures is also demonstrated. The surface morphologies of the fiber-reinforced specimens at different mold temperatures are analyzed which are used to study the effect of the mold temperature on the fiber motion process of the resultant parts. Results show that in proper mold temperature, the fibers can be completely covered in polymer matrix and the mold temperature can greatly affect the part surface quality.     

注射成型工艺参数对微结构零件复制度的影响

为改善微结构零件的复制度,以具有广泛应用前景的精细微结构零件——微透镜阵列为案例,将制品成型重量作为制品复制度的量化衡量指标,运用单因素实验方法实验研究了注射成型工艺参数（熔体温度、模具温度、注射时间、保压压力、保压时间）对微结构零件制品重量的影响规律。实验结果表明,增加熔体温度和模具温度能使保压压力更有效地通过浇注系统传递到微型腔,增加制品重量;成型重量大的制品,微结构的填充要好于重量轻的制品,微结构零件复制度与成型重量存在对应关系。制品重量可初步评价微结构零件的复制度,研究各工艺参数对制品重量的影响规律对提高微结构零件的复制度有重要意义。     

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。     

Parametric study of injection molding and hot embossing in polymer microfabrication

In recent years, plastics have begun to show great commercial potential especially in manufacturing micro-structured parts. Injection molding and hot embossing are two major microfabrication methods. Replication accuracy was investigated for these two methods. Polymethyl methacrylate (PMMA) was used as the polymer substrate. The mold insert (or master) was fabricated by LIGA-type method. In this study, hot embossing was found to have better replication accuracy for microstructure than injection molding. Experiments were also conducted to study the effects of process parameters on the replication quality.     

Microceramic injection molding of a multilayer micropatterned micropart

Microceramic injection molding (µCIM) has shown great potential in making small-scale intricate near-net-shape parts with the competitive price for mass production. In this study, multi-exposure multi-development UV-Lithographie, Galvanoformung, Abformung (LIGA), µCIM, variothermal temperature control, and Taguchi experimental method are integrated and applied to develop a multilayer micropart with zirconia (ZrO₂) feedstock. With the variothermal temperature control, a 335 μm thickness multilayer micropart having 100 microholes of 21.6 μm in diameter has been successfully molded. Optimization of the molding parameters to achieve high microhole replication quality molding was carried out with Taguchi experimental method. Results from Taguchi experiments reveal that mold temperature (40.9%), back pressure (31.8%), and injection speed (26.8%) contribute most to the replication quality, while ejection temperature has little effect on it. After further sintering processing, the thickness of the part is 200 μm, the final microhole diameter is 17.3 μm and its depth is 35.3 μm while the width of the channel is 38.5 μm and its height is 35.3 μm, and the accumulated aspect ratio of the dual layer structure is 2.95.     

基于Moldflow的魔方中心轴注射分析与优化设计

应用Moldflow软件对魔方中心轴的注射成型过程进行浇口位置、充填、冷却和翘曲等模拟分析。通过在不同注射工艺条件下进行对比分析,确定了注射的最佳工艺参数:充填时间为2 s,注射+冷却时间为8 s,模具温度为40℃,熔体温度为240℃,注射压力为100 MPa。应用UG软件建立了注射模具的实体模型,解决了传统注射模具设计方法存在设计周期长、成本高且质量难以保证等问题。     

CAE与塑料成型质量分析

塑料模具的设计不但采用CAD技术,而且还要采用CAE技术,这是发展的必然趋势。CAE技术提供了从制品设计到生产的完整解决方案。在模具制造之前,CAE技术可以预测塑料熔体在型腔中的整个成型过程,帮助研判潜在的问题,有效地防止问题发生,并能缩短产品的开发周期,降低生产成本。本文从一个生产实例出发,用Moldflow软件对该制品的注射成型方案进行分析比较,从而找到解决制品质量问题的途径。     

A virtual injection molding system based on numerical simulation

CAD and CAE have now become very popular in injection molding development. Integration with virtual reality is a new boost to these fields. This paper presents a research effort targeting the creation of a desktop-based, low-cost and independent virtual injection molding system, which is implemented based on the techniques such as virtual reality, finite element analysis, motion simulation and scientific visualization. With the stereoscopic display of the mold design and motion, the system provides engineers a cohesive view of mold structure and assembly. And by analyzing the numerical CAE results, the possible faults during molding process can also be highlighted. With this integration, the overall system would be a new powerful tool to mimic the real process of injection molding and evaluate various influences from product design to manufacturing, capable, therefore, of improving the moldability and the quality of molded products.