鼠標(biāo)下蓋的注塑模具設(shè)計-抽芯塑料注射模含NX三維及12張CAD圖帶開題、模流
鼠標(biāo)下蓋的注塑模具設(shè)計-抽芯塑料注射模含NX三維及12張CAD圖帶開題、模流,鼠標(biāo),注塑,模具設(shè)計,塑料,注射,nx,三維,12,十二,cad,開題,模流
開題報告
學(xué)生姓名
學(xué) 號
專 業(yè)
指導(dǎo)教師
姓名
職 稱
所在系部
課題來源
自擬課題
課題性質(zhì)
模具設(shè)計制造
課題名稱
鼠標(biāo)底座注射模設(shè)計
畢業(yè)設(shè)計的內(nèi)容和意義?
1． 主要內(nèi)容：
1、利用圖書館、網(wǎng)絡(luò)等資源，查閱和應(yīng)用相關(guān)模具設(shè)計資料。
2、通過測量，運用三維軟件Pro/E完成產(chǎn)品三維造型設(shè)計。
3、根據(jù)塑件的質(zhì)量、重量和生產(chǎn)成本，確定型腔數(shù)量，選擇注塑機(jī)型號并對注塑機(jī)的參數(shù)進(jìn)行校核。
4、應(yīng)用MPI軟件對塑料制件進(jìn)行澆注系統(tǒng)、排氣系統(tǒng)、冷卻系統(tǒng)的設(shè)計進(jìn)行優(yōu)化，確定方案。
5、通過對塑件的整體結(jié)構(gòu)工藝性分析，進(jìn)行塑件分析計算，進(jìn)行成型零部件、側(cè)向抽芯機(jī)構(gòu)、推出機(jī)構(gòu)、導(dǎo)向機(jī)構(gòu)的設(shè)計。
6、根據(jù)塑料熔體的熱學(xué)性能、型腔形狀及布置，進(jìn)行模溫調(diào)節(jié)系統(tǒng)的設(shè)計。
7、繪制裝配圖和零件圖，撰寫設(shè)計說明書。
8、根據(jù)塑料熔體的熱學(xué)性能、型腔形狀及布置，進(jìn)行模溫調(diào)節(jié)系統(tǒng)的設(shè)計。
9、完成一篇與專業(yè)有關(guān)的外文翻譯，要求語句通順，含義準(zhǔn)確。
2．畢業(yè)設(shè)計的意義：
隨著塑料工業(yè)的飛速發(fā)展，人們對塑料制品質(zhì)量要求越來越高，而且產(chǎn)品更新快、價格越來越低、市場競爭越趨激烈。在這種情況下，要求模具交貨期短、質(zhì)量好、價格低。顯然，傳統(tǒng)的人工設(shè)計、手工作坊的生產(chǎn)方式已不能適應(yīng)工業(yè)發(fā)展的需要。為了在市場經(jīng)濟(jì)的殘酷競爭中取勝，跟上產(chǎn)品更新?lián)Q代的速度，模具制造業(yè)不得不采用新技術(shù)、新工藝以解決傳統(tǒng)技術(shù)存在的問題。為提高塑料注射模的質(zhì)量、縮短模具的設(shè)計和制造周期，發(fā)達(dá)的工業(yè)國家從20世紀(jì)80年代中期已廣泛使用計算機(jī)對注射模進(jìn)行輔助設(shè)計CAD(ComputerAideDesign)，輔助制造CAM(ComputerAided Manufacture)，并對模具設(shè)計的各個環(huán)節(jié)進(jìn)行定量計算和數(shù)值分析CAE (Computer Aided Engineering)，使產(chǎn)品的質(zhì)量得到保證，大大縮短了新產(chǎn)品的開發(fā)周期。
文獻(xiàn)綜述
塑料工業(yè)是當(dāng)今世界上增長最快的工業(yè)門類之一，掌握塑料產(chǎn)品的生產(chǎn)過程對提高產(chǎn)品質(zhì)量有很大意義。在機(jī)械制造業(yè)中，隨著全球市場競爭的日益激烈，各企業(yè)都力求以最好質(zhì)量、最低成本、最快速度將產(chǎn)品推向市場，計算機(jī)模擬技術(shù)得以充分用用。在傳統(tǒng)模具設(shè)計制造過程中，模具制造完畢后要進(jìn)行多次試模、修模。反復(fù)的修模會造成模具內(nèi)部品質(zhì)的變化，導(dǎo)致整副模具.性能降低，從而使最終塑料制品質(zhì)量不能達(dá)到標(biāo)準(zhǔn)。而使用計算機(jī)輔助技術(shù)不僅可提高一次性試模的成功率，而且還可以使模具在質(zhì)量、性能及成本上都有很大程度的提高。通過本次設(shè)計掌握先進(jìn)軟件技術(shù)，用專業(yè)分析軟件moldflow和軟件EMX4.1來縮短設(shè)計周期，提高一次性試模的成功率。本設(shè)計還通過電熱毯開關(guān)的注塑模具設(shè)計，了解注塑模具制造特點和新興注射成型技術(shù)對模具制造的新要求，分析注塑模具制造技術(shù)中的幾個關(guān)鍵問題。
模具具有明顯的效益擴(kuò)大作用，用模具生產(chǎn)出來的最終產(chǎn)品價值，往往是模具自身價值的幾十倍，幾百倍，甚至更多。用模具生產(chǎn)制件所具備的高精度、高復(fù)雜程度、高一致性，高生產(chǎn)率和代消耗，是其他加工方法所不能比擬的。注塑模具的發(fā)展日新月異，掌握注塑模具設(shè)計及其專業(yè)分析軟件，對未來的注塑模具設(shè)計市場有著不可估量的意義，對個人今后的事業(yè)有著不同尋常的意義。
文獻(xiàn)綜述
研究內(nèi)容
參考文獻(xiàn)
[1] 王剛，單巖.MOLDFLOW模具分析應(yīng)用實例[M].北京：清華大學(xué)出版社，2005
[2] 陳立亮.材料加工CAD/CAE/CAM技術(shù)基礎(chǔ)[M]. 北京：機(jī)械工業(yè)出版社，2007
[3]王剛，單巖.MOLDFLOW模具分析應(yīng)用基礎(chǔ)[M].北京：清華大學(xué)出版社，2005
[4]屈華昌.塑料成型工藝與模具設(shè)計[M].第2版.北京：高等教育出版社，2007
[5]馬文琦，孫紅鐿.塑料成型模擬軟件技術(shù)基礎(chǔ)與應(yīng)用[M].北京：中國鐵道出版社，2006
[6]黃虹.塑料成型加工與模具[M]. 北京：化學(xué)工業(yè)出版社，2004
[7]李志剛.中國模具設(shè)計大典（第一卷）[M].南昌：江西科學(xué)技術(shù)出版社，2003
[8]B.H.Lee，B.H.Kim.Optimization of part wall thicknesses to reduce warpage of injection一molded parts based on the modified complex method[J].Polymor-plastics technology engineering，1995，34(5):793
[9]B.H.Lee，B.H.Kim.Automated design for the runner systerm of injection molds based on packing simulation [J].Polymer-plastics technology engineering，1996，35(l):147
[10]B.H.Lee，B.H.Kim.Automated selection of gate location based on desired quality of injection-molded part[J].Polymer-plastics technology engineering，1996，35(2):253
[11]B.H.Lee，B.H.Kim.Variation of part wal1 thicknesses to reduce warpage of injection-molded part:robust design against process variability[J].Polymer-plastics technology engineering，1997，36(5):791
1． 設(shè)計、研究思路：
1、通過測量，應(yīng)用Pro/E軟件對產(chǎn)品進(jìn)行三維造型設(shè)計。應(yīng)用MPI軟件對塑料制件進(jìn)行澆注系統(tǒng)、排氣系統(tǒng)、冷卻系統(tǒng)的設(shè)計進(jìn)行優(yōu)化。
2、通過對塑料制件結(jié)構(gòu)工藝分析，論證并確定模具設(shè)計方案，用AutoCAD等軟件繪制裝配圖和零件圖。要求總體設(shè)計方案合理，零件設(shè)計正確，結(jié)構(gòu)表達(dá)完整清楚，標(biāo)準(zhǔn)正確規(guī)范。
2．課題研究的主要內(nèi)容：
注塑模具的proe設(shè)計、分析, 包括初期的建模以及根據(jù)產(chǎn)品模型進(jìn)行模具分型面的設(shè)計、確定型腔和型芯、模具結(jié)構(gòu)的詳細(xì)設(shè)計、塑料充填過程分析等幾個方面。利用proe軟件進(jìn)行三維建模并在此基礎(chǔ)上很容易地確定分型面, 生成上下型腔和型芯, 再進(jìn)行流道、澆口以及冷卻水管的布置等。然后需要導(dǎo)出二維cad圖紙 并撰寫說明書。
研究內(nèi)容
3．解決的關(guān)鍵問題
1、零件結(jié)構(gòu)工藝性分析。
2、選擇分型面與型腔布置。
3、確定澆注系統(tǒng)。
4、溢流排氣系統(tǒng)的設(shè)計。
5、脫模方式的設(shè)計。
6、側(cè)抽機(jī)構(gòu)的設(shè)計。
7、模具零件的結(jié)構(gòu)設(shè)計。
8、模具調(diào)溫系統(tǒng)的設(shè)計。
9、模具裝配圖的設(shè)計
4．預(yù)期成果
（1）該塑料件模具技術(shù)要求一份、訂料表文件一份；
（2）開題報告一份、外文翻譯資料一份；
（3）3D開模圖一份；
（4）2D裝配圖一份和零件圖若干份（不少于3張A0圖紙）；
（5）畢業(yè)論文一份；
（6）熔體模擬流動分析，優(yōu)化模具設(shè)計結(jié)構(gòu)報告；
研究計劃
第1-四周：查閱，收集與整理與課題相關(guān)工程設(shè)計資料。
第五周：撰寫開題報告。
第六周：測繪塑料件，用PRO/E造出三維模型，繪出塑料件的零件圖。應(yīng)用MPI軟件對塑料制件進(jìn)行澆注系統(tǒng)、排氣系統(tǒng)、冷卻系統(tǒng)的設(shè)計進(jìn)行優(yōu)化，確定方案。
第七周：分析塑件的結(jié)構(gòu)工藝性，論證并確定摸具設(shè)計方案第一階段。
第八周：完成摸具的全部設(shè)計方案。
第九周：繪制草圖，繪制總裝配圖。
第十周：繪制總裝配圖。
第十一周：繪制總裝配圖。
特色與創(chuàng)新
本次設(shè)計采用moldflow對塑件進(jìn)行模擬分析，這樣避免的后期模具制造完成后，塑件的成型缺陷，而且該模具設(shè)計我們采用的潛伏式澆口，這樣就避免了在塑件留下澆注痕跡。
指導(dǎo)教師
意 見
指導(dǎo)教師簽名：
2015年 1 月 21 日
教研室意見
主任簽名：
2015 年 1 月 22日
學(xué)院（系部）意見
教學(xué)院長（主任）簽名：
2015年 1 月 23日
畢業(yè)答辯班級：XXX設(shè)計者：XXX 指導(dǎo)老師:XXX 鼠標(biāo)底座模具設(shè)計緒論本次設(shè)計的是一種鼠標(biāo)下蓋的注塑模具設(shè)計，結(jié)構(gòu)特點突出，具有側(cè)孔，需要做側(cè)向抽芯結(jié)構(gòu)，采用斜頂抽芯結(jié)構(gòu)，該塑料件分型面為曲面分型面，所以該模具結(jié)構(gòu)復(fù)雜。本題目要求學(xué)生具有較強(qiáng)的模具設(shè)計能力及創(chuàng)新能力，并熟練運用AutoCAD等軟件進(jìn)行計算機(jī)繪圖，會查閱相關(guān)設(shè)計資料及手冊，進(jìn)行必要的計算。通過MOLDFLOWMPI模具分析技術(shù)從理論上對產(chǎn)品設(shè)計方案在注塑成型過程進(jìn)行數(shù)值模擬，通過有關(guān)計算結(jié)果的分析，預(yù)測塑料件結(jié)構(gòu)可能出現(xiàn)的缺陷，利用MPI分析結(jié)果，合理設(shè)計模具澆注系統(tǒng)和冷卻系統(tǒng)，消除缺陷。塑料模設(shè)計零件名稱：鼠標(biāo)底座生產(chǎn)批量：中批量 一 塑件的工藝性分析性能典型值外觀無色至微黃色透明液體分子量（粘均）2500040000密度g/cm31.20吸水性0.13馬丁溫度120熱變形溫度（1.82Mpa），134玻璃化溫度，149熱分解溫度，340線膨脹系數(shù)，K-16C10-57C10-5燃燒性自熄氧指數(shù)31.5表面電阻率，1C1015體積電阻率，M1.5C1014介電強(qiáng)度，KV/mm22介電常數(shù)，1MHZ2.9介質(zhì)損耗角正切，1MHZ7C10-31.塑件的原材料分析一 塑件的工藝性分析工藝參數(shù)數(shù)值料筒溫度，/前部270300中部270300后部240280噴嘴溫度，/270300模具溫度，/70110注射壓力，/Mpa60140螺桿轉(zhuǎn)速，/rmin-130120螺桿背壓，/Mpa010成形周期，/s/注射1 25冷卻540制品熱處理溫度，/110制品熱處理時間，h0.52一 塑件的工藝性分析 3.塑件表面質(zhì)量分析 該塑件要求外觀美觀,色澤鮮艷,上表面沒有斑點及印痕,而下表面沒有較高的尺寸和粗糙度要求4.塑件的結(jié)構(gòu)工藝性分析 該塑件的尺寸較小,整體結(jié)構(gòu)較簡單,卻帶有曲面特征,根據(jù)塑件的工作要求和表面特征及材料性能,故選一般精度精度等級五級.二 確定成型設(shè)備選擇1.1.計算塑件的體積和質(zhì)量計算塑件的體積和質(zhì)量 塑件體積：V15cm 塑件密度：根據(jù)有關(guān)手冊查得=1.2K3所以，塑件的重量為：M=V=18g2.2.計算澆注系統(tǒng)的體積計算澆注系統(tǒng)的體積V總=1.2nV塑=36cmV=V總/0.8=45cm 根據(jù)塑件形狀及尺寸要求采用一模兩件的模具結(jié)構(gòu),參考模具設(shè)計手冊初選注射機(jī)：XSZY125。二 確定成型設(shè)備選擇項目XS-ZY125結(jié)構(gòu)形式臥理論注射容量/cm3125螺桿（柱塞）直徑/mm42注射壓力/Mpa119鎖模力/KN900拉桿內(nèi)間距/mm260290移模行程/mm300最大模具厚度/mm300最小模具厚度/mm200噴嘴球半徑/mm14噴嘴口孔徑/mm3三 moldflow分析3.1產(chǎn)品網(wǎng)格劃分3.2最佳澆口的分析3.3型腔的布局和設(shè)計3.4澆注系統(tǒng)的設(shè)計四 注射模的結(jié)構(gòu)設(shè)計1.分型面的選擇 在選擇分型面時,根據(jù)分型面的選擇原則,考慮不影響其外觀質(zhì)量以及成型后能順利脫模取出塑件,設(shè)計分型如下圖所示四 注射模的結(jié)構(gòu)設(shè)計2.型腔數(shù)目的確定及型腔的排列該塑件采用一模兩腔的結(jié)構(gòu)3.澆注系統(tǒng)的設(shè)計1)主流道的設(shè)計根據(jù)選用的XS-ZY-125型號注射機(jī)的相關(guān)尺寸得 噴嘴前端孔徑：d=4mm；噴嘴前端球面半徑：R=12mm；根據(jù)模具主流道與噴嘴的關(guān)系 取主流道球面半徑：R=13mm；取主流道小端直徑：d=5mm；3.澆注系統(tǒng)的設(shè)計2)分流道的設(shè)計分流道選用圓形截面：直徑D=6mm 流道表面粗糙度Ra=1.6um四 注射模的結(jié)構(gòu)設(shè)計3.澆注系統(tǒng)的設(shè)計3)澆口的設(shè)計 根據(jù)澆口的位置選擇要求，盡量縮短流動距離，避免熔體破裂現(xiàn)象引起塑件的缺陷，澆口應(yīng)開設(shè)在塑件壁厚處,不影響外觀質(zhì)量等要求,選用潛伏式澆口四 注射模的結(jié)構(gòu)設(shè)計.推出機(jī)構(gòu)的設(shè)計采用推桿推出，推桿截面為圓形，推桿推出動作靈活可靠，推桿損壞后也便于更換。推桿的位置選擇在脫模阻力最大的地方，塑件各處的脫模阻力相同時需均勻布置，以保證塑件推出時受力均勻，塑件推出平穩(wěn)和不變形。根據(jù)推桿本身的剛度和強(qiáng)度要求，采用四根推桿推出。推桿裝入模具后，起端面還應(yīng)與型腔底平齊或搞出型腔0.050.1cm.四 注射模的結(jié)構(gòu)設(shè)計5標(biāo)準(zhǔn)模架的選擇由于制件外圍尺寸為6111221，采用一模2腔結(jié)構(gòu)，經(jīng)過以上設(shè)計我們可以確定型腔的尺寸為12031545，按照一般的要求。模架的尺寸型腔尺寸+260，模架動模板的厚度型芯厚度+（2030），模架定模板的厚度型腔厚度+（2030）。本塑件采用潛伏式澆口注射成型，根據(jù)其結(jié)構(gòu)形式，選擇CI型模架。CI-2545-A70-B70-C80五 模具設(shè)計凸凹模斜頂2d裝配圖3d裝配圖謝 謝 觀 看！
外文翻譯
Injection Molding CAE Technology
0 Introduction
Plastic products from product design to production, including molding plastic products design, mold design, mold manufacturing and injection molding process parameters and several other main areas. The traditional injection mold design mainly rely on the designer's experience, while the injection molding process is very complex, plastic melt flow properties of different and ever-changing products and die structure, process conditions vary, forming various defects, mold design often require repeated trial-mode, maintenance mode can be put into production, with little of a successful, identify problems, not only to re-adjust the process parameters, or even to modify the plastic products and molds, not only time-consuming and laborious, but also reduces product development time . The use of injection molding CAE technology in mold manufacturing prior to simulate injection molding process (including filling, packing and cooling) and the early detection of problems, optimize mold design and process conditions set to reduce the number of test mode in order to improve production efficiency, has become a injection molding technology is an important direction of development.
1 The history of Injection Molding CAE technology
Injection Molding CAE technology is based on plastics processing rheology and heat transfer of the basic theory, the melt in the mold cavity in the flow, heat transfer physics, mathematical model, using numerical solution method of constructing the theory, the use of computer visualization technology image, visually simulate the dynamics of the actual shape of the melt filling and cooling process, an analysis techniques.
The 20th century, 60 years, the United Kingdom, the United States and Canada and other countries of the scholars, such as JRPearson (United Kingdom), JFStevenson (America), MRKamal (Canada) and KKWang (America), etc. to carry out a series of plastic melt in the mold-type cavity flow and cooling of basic research. At a reasonable simplification, based on 60 years completed a one-dimensional flow and cooling analysis programs, 70 years to complete the two-dimensional cooling analysis programs, and 80 years from the injection molding CAE technology has begun to theoretical research into the practical phase, launched a three-dimensional flow and cooling analysis and the study extended to packing, fiber orientation and warpage prediction of molecular and other fields. After 90 years carried out into the flow, packing, cooling and stress analysis, the whole process of injection molding processes are integrated research.
CAE technologies, for the injection mold design provides a reliable guarantee that its application is mold design in the history of a major change.
2 The role of Injection Molding CAE technology
It shows the design of injection molds using traditional methods and the use of injection molding CAE technical design features and differences in mold. It can be seen using traditional methods of design of injection mold design success will rely heavily on the experience of designers, but also for complex parts gate position is reasonable or not, the location of the exhaust slot settings, to determine the location of weld lines and so very difficult. Die in delivery will normally take before the test mode after repeated changes, until the products have been qualified, which inevitably led to the extension of the production cycle, and generally difficult to obtain an optimal design and process parameters. The use of injection molding CAE technical design, mold is not true, because of mold design concept stage, can make use of CAE technology in injection molding process simulation flow, making usually only in the mold tryout phases in order to find problems, such as short shots, weld lines or holes appear in the surface appearance of parts and other issues have been avoided. While helping the designer to complete the balance of the system, such as flow channel design, exhaust ducts, setting, rationally determine the injection molding process parameters, etc., so that usually makes the modification must be repeated tryout to determine structural parameters of the mold die design and process parameters in the conceptual stage able to determine, reduce the mold design and manufacturing cycle and improve the mold design quality.
Therefore, the role of injection molding CAE software, mainly as follows:
(1) Optimize design of plastic products
Plastic wall thickness, gate number and location of the design of flow channel system for the quality of plastic products have a significant impact. Depends on the experience of the past, designers using manual methods to achieve, time-consuming effort, but the use of CAE technology to quickly design the best products.
(2) optimize the plastic mold design
Can be cavity size, gate location and number of flow channel dimensions and cooling systems to optimize the design. On the computer simulation test mold, mold repair mold and improve quality and reduce the number of actual tryout.
(3) to optimize injection process parameters
Simulation of the injection process and found possible shape defects, to determine the best injection pressure, clamping force, mold temperature, melt temperature, injection time and cooling time.
This shows that the injection molding CAE technology in terms of improving productivity, reduce mold design and manufacture cycle and to ensure product quality, or reduce costs, reduce labor intensity and so on, have very significant technical advantages and economic significance.
3 Injection Molding CAE software types and their details
To date, a mature business are more injection molding CAE software, Moldflow Corporation Moldflow software and AC-Tech, Inc. (February 2000, was Moldflow Merger) and C-Mold software is an excellent representative; There are also foreign The TMCONCEPT, CADMold, Fidap, Stirm100, Polyflow and China's Taiwan region Moldex-peer software applications are relatively wide; and domestic in the "Eighth Five-Year" period began research in this area, and now Huazhong University of Technology HSCAE software and Zhengzhou University, Z -Mold software in China in the leading position.
Moldflow software is specialized in injection molding CAE software and consulting for Moldflow's range of products, the company issued since 1976, the world's first set of injection molding CAE software, has been a leading injection molding CAE software market. To 2004, Moldflow Injection Molding CAE software in the global market share of over 75%.
MoldFlow software includes three parts: MoldFlow Plastics Advisers (product optimization consultant, MPA), MoldFlow Plastics Insisht (injection molding simulation analysis, MPI), and MoldFlow Plastics Xpert (injection molding process control specialists, MPX).
Under normal circumstances, the most commonly used MPI, is mainly used for injection molding process simulation to get the best number and location of the gate, reasonable flow channel system and cooling system, and cavity size, gate size, runner size and cooling systems to optimize the size and the injection molding process parameters may also be optimized.
Moldflow Software Moldflow analysis techniques can be divided into three kinds, namely, Midplane, Fusion and 3D [2-3].
4 Moldflow analysis of Midplane
Midplane (in the surface flow) applications began in the 20th century, the 80s. The grid is a three-node triangular element, its principle is the 3D geometric model of simplified geometric model of the neutral surface (to be created in the model grid the middle of the wall thickness), using established simulation analysis of the neutral surface, ie to flow in plane to simulate three-dimensional solid flow. The analysis of technological development has been very mature and stable, and the advantages for the analysis of speed and high efficiency. The simulation shown in Figure 3.
Based on the flow of surface flow simulation of injection molding technology, software applications, the longest, widest range. But the practice shows that, based on the surface flow simulation software in the application of technology that has significant limitations, specifically as follows:
(1) The user must construct a mid-surface model. Using manual directly from the physical model structure in the surface model is very difficult and often takes a lot of time and can not be converted from other CAD models.
(2) can not be described in a number of three-dimensional features. If they can not describe the inertia effect, gravitational effects on melt flow, which fail to predict jet phenomenon, melt the forefront of Quan phenomena.
(3) The use of CAD phase of the product model and stages of the use of CAE analysis model is not unified, so that the inevitable second modeling, CAD and CAE systems integration can not be achieved.
5 Moldflow's Fusion analysis
Fusion (double flow) analysis technique is based on Moldflow's patented Dual Domain of analysis techniques. Fusion launched in 2000, analysis techniques, enabling users do not need to extract the neutral surface can be analyzed, to overcome the reconstruction of the geometric model, thus greatly reducing the burden on the user modeling. Grid is also a triangular element, and its principle is to mold cavity or the products in the thickness direction is divided into two parts, finite element mesh on the surface of the cavity or the products. In the flow process, the upper and lower surface of the plastic melt at the same time two and to coordinate movement of the simulation shown .
Clearly, Fusion technology, the surface of the grid is based on the neutral surface is still not solve the fundamental problem the neutral surface, so double-sided application of the principle of streaming technologies and methods applied in the surface flow with no difference in the nature, the The difference is two-sided flow using a series of related algorithms, will flow along the surface of the single-stranded melts evolved along the upper and lower surface of the coordination of the flow of dual-stream.
Double-sided flow of technology's biggest advantage is that the model greatly shorten the preparation time, thus greatly reducing the burden on the user modeling, will take several hours or even days of the original modeling work reduced to a few minutes. Therefore, based on double-sided flow simulation software technology, although the advent of time, only a few years, but in the world but has a huge user base, get the majority of customers for their support and praise.
But the double-sided flow of technology has the following deficiencies:
(1) The two-sided flow of technology does not fundamentally resolve the issue of a neutral face, they still can not describe some three-dimensional features, such as the inertial effect can not describe gravity effect on the melt flow, which fail to predict jet phenomenon, melt cutting-edge Quanyong phenomena.
(2) the upper and lower surfaces corresponding to the melt flow front there are differences. As the upper and lower surface of the grid can not be one correspondence, but the grid shape, orientation and size can not be completely symmetrical, so how the upper and lower surfaces corresponding to the difference between the melt flow front control is within the scope permitted by Difficulties in the implementation of double-sided streaming technology.
(3) melt is only along the upper and lower surface flows, in the thickness direction is not to make any treatment, lack of realism.
6 Moldflow's 3D analysis techniques
These two techniques have overlooked the thickness direction of the physical quantity, only two-dimensional simulation, and therefore results are not very precise. Moldflow Corporation's 3D (3D) analysis technology uses a true three-dimensional solid model flow analysis techniques, through rigorous theoretical derivation and repeated verification, the inertial effect, non-isothermal flow, taking into account factors such as finite element analysis, the melt thickness direction of the physical quantity changes will no longer be ignored, can be a more comprehensive description of the process of filling flow phenomena, so that results of the analysis more realistic conditions, applicable to all plastic products. Its three-dimensional grid is from the four-node tetrahedron unit. And using the new 3D stereoscopic display technology, can quickly model clearly shows that internal and external flow field, temperature field, stress field and velocity field such as analysis results. For the above-mentioned results of the analysis can also be used such as bit lines or equipotential surface display, so that physical models and external changes in the variables show more clearly the case, Moldfiow also offers animation capabilities, through 3D animation display plastic melt in the changes in the flow cavity, allowing users to more intuitively see the design and manufacturing process may encounter problems.
But the 3D technology, meshing demanding, more complex equations to calculate the amount of large, long duration and the computational efficiency is low, not suitable for short development cycle and need to be repeatedly revised by CAE verification injection mold design. Therefore, the current penetration rate of the technology is not very high, but it will eventually replace the surface flow of technology and double-sided streaming technology.
7 Development Trend of Injection Molding
Injection Molding CAE technology, whether in theory or in the application have made great strides, but in the following still needs further improvement and development [4-5]:
(1) mathematical models, numerical algorithms to gradually improve the
Injection Molding CAE technology, practicality, depending on the accuracy of the mathematical model and numerical algorithm accuracy. The current commercial simulation software models do not fully consider the physical quantities in the thickness direction of the impact of the software in order to further improve the analysis accuracy and scope to further improve the existing mathematical models and algorithms.
(2) the whole process of injection molding simulation
At present, the injection molding simulation software are mainly filling, flow, packing, cooling, stress and strain and warpage analysis modules, each module was developed based on independent mathematical models, these models has been simplified to a large extent, ignored of the mutual effects. However, in view of injection molding process, plastic melt filling, flow, packing and cooling are intertwined and affect each other and, therefore, filling, flow, packing and cooling analysis module must be organically combined to carry out coupling analysis, in order to comprehensively reflect the real situation of injection molding.
(3) optimization theory and algorithms, so that CAE technology "active" to optimize the design
Artificial intelligence technologies, such as expert systems and neural networks on the design calculations, so that simulation can "wisdom" to choose the injection molding process parameters, product size and cooling to fix the piping layout programs to reduce manual intervention in the program.
(4) a new method of injection molding simulation analysis of the current
In the conventional injection molding technology, based on and the development of a number of new injection molding methods, such as gas-assisted injection, thin wall injection molding, reaction injection and co-injection . However, no specific methods for these molding simulation software, so untapped.
(5) injection mold CAD / CAE / CAM integrated and network-based
The current commercial injection molding CAE software and CAD, CAM software, data transfer between the mainly rely on the file conversion, which easily lead to data loss and errors. Therefore, in design and manufacturing process to take a single model, the establishment of injection mold CAD / CAE / CAM system, a unified database to strengthen the linkages between the three directions of future development. In order to meet the development requirements of e-commerce, this integrated system will achieve different places of the "Collaborative Design" and "virtual manufacturing."
8 Conclusion
Despite the adoption of a large number of practice has proved, in the plastic mold industry, the introduction of CAE technology, greatly reducing the mold design and manufacturing cycle and improve the life of the mold and manufacturing precision. At the same time, CAE technologies has also made from the traditional injection mold design experience and skills onto the road of scientific, to a certain extent, changed the injection mold of traditional production methods, but there is no substitute for CAE technology and people's creative work, only can serve as a complementary tool to help engineers understand the problems in the program, but also difficult to provide a clear improvement program, still need to through repeated interactions (analysis - changes - re-analysis) in order to reflect the experience of the designer's right to die design go, the program is designed to determine to a large extent continue to rely on the designer's experience and level.
注塑模CAE技術(shù)
引言
塑料產(chǎn)品從產(chǎn)品設(shè)計到成型生產(chǎn)包括塑料制品設(shè)計、模具設(shè)計、模具制造和注塑工藝參數(shù)選擇等幾個主要方面。傳統(tǒng)的注塑模具設(shè)計主要依靠設(shè)計人員的經(jīng)驗，而注塑成型過程非常復(fù)雜，塑料熔體的流動性能千差萬別，制品和模具的結(jié)構(gòu)千變?nèi)f化，工藝條件各不相同，成型缺陷各式各樣，模具設(shè)計往往需要反復(fù)的試模、修模才能投入生產(chǎn)，很少有一次成功的，發(fā)現(xiàn)問題后，不僅要重新調(diào)整工藝參數(shù)，甚至要修改塑料制品和模具，不但費時費力，而且降低了產(chǎn)品的開發(fā)速度。而利用注塑模CAE技術(shù)可以在模具制造前，模擬注塑過程（包括充填、保壓及冷卻）并及早發(fā)現(xiàn)問題，優(yōu)化模具設(shè)計和工藝條件設(shè)定，減少試模次數(shù)以提高生產(chǎn)效率，現(xiàn)已成為注塑加工技術(shù)的一個重要發(fā)展方向。
注塑模CAE技術(shù)的歷史
注塑模CAE技術(shù)是根據(jù)塑料加工流變學(xué)和傳熱學(xué)的基本理論，建立熔體在模具型腔中的流動、傳熱的物理、數(shù)學(xué)模型，利用數(shù)值計算理論構(gòu)造其求解方法，利用計算機(jī)可視化技術(shù)形象、直觀地模擬出實際成型中熔體的動態(tài)填充、冷卻過程的一門分析技術(shù)。
20世紀(jì)60年代，英國、美國和加拿大等國的學(xué)者如J.R.Pearson(英)、J.F.Stevenson（美）、M.R.Kamal(加)和K.K.Wang(美)等開展了一系列有關(guān)塑料熔體在模具型腔內(nèi)流動與冷卻的基礎(chǔ)研究。在合理的簡化基礎(chǔ)上，60年代完成了一維流動與冷卻分析程序，70年代完成了二維冷卻分析程序，80年代注塑模CAE技術(shù)開始從理論研究進(jìn)入實用化階段，開展了三維流動與冷卻分析并把研究擴(kuò)展到保壓、纖維分子取向以及翹曲預(yù)測等領(lǐng)域。進(jìn)入90年代后開展了流動、保壓、冷卻和應(yīng)力分析等注塑工藝全過程的集成化研究。
CAE技術(shù)的出現(xiàn)，為注塑模設(shè)計提供了可靠的保證，它的應(yīng)用是模具設(shè)計史上的一次重大變革。
注塑模CAE技術(shù)的作用
比較利用傳統(tǒng)方法設(shè)計注塑模具和利用注塑模CAE 技術(shù)設(shè)計模具的特點和差異。從中可以看出利用傳統(tǒng)方法設(shè)計注塑模具，設(shè)計成功與否將很大程度上依賴設(shè)計者的經(jīng)驗，而且對復(fù)雜零件澆口位置的合理與否，排氣槽位置的設(shè)置、熔接線位置的確定等都十分困難。模具在交付使用之前一般需經(jīng)過反復(fù)試模修改，直到得到合格的制品為止，從而不可避免地造成了生產(chǎn)周期的延長，而且一般也難以得到最優(yōu)的設(shè)計方案和工藝參數(shù)。而利用注塑模CAE技術(shù)設(shè)計模具則不然，由于在模具設(shè)計構(gòu)思階段，可利用注塑模CAE 技術(shù)進(jìn)行流動過程模擬，使得通常只有在模具試模階段才能發(fā)現(xiàn)的問題，如短射，熔接線或氣孔出現(xiàn)在外觀零件表面等問題得以避免。同時幫助設(shè)計人員完成諸如流道系統(tǒng)的平衡設(shè)計，排氣槽的設(shè)置，合理確定注塑工藝參數(shù)等工作，這樣使得通常在必須反復(fù)試模修改而確定的模具結(jié)構(gòu)參數(shù)和工藝參數(shù)在模具設(shè)計構(gòu)思階段得以確定，縮短了模具設(shè)計制造周期、提高了模具設(shè)計質(zhì)量。
所以注塑模CAE軟件的作用主要表現(xiàn)為：
（1）優(yōu)化塑料制品設(shè)計
塑料的壁厚、澆口的數(shù)量及位置、流道系統(tǒng)的設(shè)計等對于塑料制品的質(zhì)量有重大影響。以往全憑設(shè)計者的經(jīng)驗，用手工方法實現(xiàn)，費時費力，而利用CAE技術(shù)，可快速設(shè)計出最佳的制品。
（2）優(yōu)化塑料模具設(shè)計
可以對型腔尺寸、澆口位置及數(shù)量、流道尺寸和冷卻系統(tǒng)等進(jìn)行優(yōu)化設(shè)計。在計算機(jī)上模擬試模、修模和提高模具質(zhì)量，減少實際試模次數(shù)。
（3）優(yōu)化注射工藝參數(shù)
對注射過程進(jìn)行模擬，發(fā)現(xiàn)可能出現(xiàn)的成型缺陷，確定最佳的注射壓力、鎖模力、模具溫度、熔體溫度、注射時間和冷卻時間等。
由此可見，注塑模CAE技術(shù)無論在提高生產(chǎn)率、縮短模具設(shè)計制造周期和保證產(chǎn)品質(zhì)量，還是在降低成本、減輕勞動強(qiáng)度等方面，都具有很大的優(yōu)越性和重大的技術(shù)經(jīng)濟(jì)意義。
注塑模CAE軟件種類及其簡介
到目前為止，成熟的商業(yè)注塑模CAE軟件比較多，Moldflow公司的Moldflow軟件和AC-Tech公司（2000年2月，被Moldflow公司合并）的C-Mold軟件是其中的優(yōu)秀代表；另外還有國外的TMCONCEPT、CADMold、Fidap、Stirm100、Polyflow和我國臺灣地區(qū)的Moldex等軟件應(yīng)用也比較廣；而國內(nèi)在“八五”期間才開始這方面的研究，現(xiàn)在華中理工大學(xué)的HSCAE軟件和鄭州大學(xué)的Z-Mold軟件在國內(nèi)處于領(lǐng)先地位。
Moldflow軟件是專業(yè)從事注塑成型CAE軟件和咨詢的Moldflow公司的系列產(chǎn)品，該公司自1976年發(fā)行了世界上第一套注塑模CAE軟件以來，一直主導(dǎo)注塑模CAE軟件市場。至2004年，Moldflow軟件在全球注塑模CAE市場的占有率達(dá)75%。
MoldFlow軟件包括三部分：MoldFlow Plastics Advisers（產(chǎn)品優(yōu)化顧問，MPA）、 MoldFlow Plastics Insisht（注塑成型模擬分析，MPI）和 MoldFlow Plastics Xpert（注塑成型過程控制專家，MPX）。
一般情況下，最常用MPI，主要用來對注塑過程進(jìn)行模擬，從而得到最佳的澆口數(shù)量與位置，合理的流道系統(tǒng)與冷卻系統(tǒng)，并對型腔尺寸、澆口尺寸、流道尺寸和冷卻系統(tǒng)尺寸進(jìn)行優(yōu)化，并且還可對注塑工藝參數(shù)進(jìn)行優(yōu)化。
Moldflow軟件的模流分析技術(shù)可以分為三種，即Midplane、Fusion和3D[2-3]。
Moldflow的Midplane分析技術(shù)
Midplane（中面流）的應(yīng)用始于20世紀(jì)80年代。其網(wǎng)格是三節(jié)點的三角形單元，其原理是將3D幾何模型簡化成中性面幾何模型（即將網(wǎng)格創(chuàng)建在模型壁厚的中間處），利用所建立的中性面進(jìn)行模擬分析，即以平面流動來仿真三維實體流動。此分析技術(shù)發(fā)展至今已相當(dāng)成熟穩(wěn)定，其優(yōu)點為分析速度快、效率高。
基于中面流技術(shù)的注塑流動模擬軟件應(yīng)用的時間最長、范圍也最廣。但是實踐表明，基于中面流技術(shù)的模擬軟件在應(yīng)用中具有很大的局限性，具體表現(xiàn)為： (1) 用戶必須構(gòu)造出中面模型。采用手工操作直接由實體模型構(gòu)造中面模型十分困難，往往需要花費大量的時間，而且不能從其他CAD模型轉(zhuǎn)換。
(2) 無法描述一些三維特征。如不能描述慣性效應(yīng)、重力效應(yīng)對熔體流動的影響，不能預(yù)測噴射現(xiàn)象、熔體前沿的泉涌現(xiàn)象等。
(3) 由于CAD階段使用的產(chǎn)品模型和CAE階段使用的分析模型不統(tǒng)一，使二次建模不可避免，CAD與
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