DVD遙控器前蓋注塑模設(shè)計(jì)【一模兩腔】【側(cè)抽芯】【說明書+CAD】
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附表六湖南工學(xué)院畢業(yè)設(shè)計(jì)(論文)工作中期檢查表題目DVD遙控器前蓋注塑模設(shè)計(jì)學(xué)生姓名羅正芳班級(jí)學(xué)號(hào)212070327專業(yè)材料成型及控制工程指導(dǎo)教師填寫學(xué)生開題情況已開題學(xué)生調(diào)研及查閱文獻(xiàn)情況已進(jìn)行畢業(yè)設(shè)計(jì)(論文)原計(jì)劃有無調(diào)整無學(xué)生是否按計(jì)劃執(zhí)行工作進(jìn)度是學(xué)生是否能獨(dú)立完成工作任務(wù)能學(xué)生的英文翻譯情況較好學(xué)生每周接受指導(dǎo)的次數(shù)及時(shí)間3次,6小時(shí)畢業(yè)設(shè)計(jì)(論文)過程檢查記錄情況較好學(xué)生的工作態(tài)度在相應(yīng)選項(xiàng)劃“”認(rèn)真一般較差尚存在的問題及采取的措施:因?qū)θ绾伟阉鶎W(xué)注塑模設(shè)計(jì)方法運(yùn)用到實(shí)際的能力還有所欠缺,所以在部分設(shè)計(jì)中有對(duì)細(xì)節(jié)把握不好的地方。經(jīng)過查閱部分資料以及與指導(dǎo)老師的共同研究,已有較大的改善與提高。指導(dǎo)教師簽字: 年 月 日系部意見: 負(fù)責(zé)人簽字:年 月 日2011屆畢業(yè)設(shè)計(jì)(論文)課題任務(wù)書系:機(jī)械工程系 專業(yè):材料成型與控制工程 指導(dǎo)教師李天生學(xué)生姓名羅正芳課題名稱DVD遙控器前蓋注塑模設(shè)計(jì)內(nèi)容及任務(wù) 根據(jù)所給定的注塑零件產(chǎn)品,設(shè)計(jì)出注塑模具。主要內(nèi)容如下:1、繪制產(chǎn)品零件圖。2、繪制模具裝配圖。3、繪制整套模具零件圖,標(biāo)準(zhǔn)件除外。4、編寫設(shè)計(jì)說明書。5、自選一個(gè)重要模具零件編制加工工藝路線,進(jìn)行相關(guān)的計(jì)算,并編制加工工藝卡和工序卡。擬達(dá)到的要求或技術(shù)指標(biāo)按照“湖南工學(xué)院畢業(yè)設(shè)計(jì)(論文)工作管理規(guī)定”,本課題設(shè)計(jì)要求及技術(shù)指標(biāo)如下:(一)模具1、保證規(guī)定的生產(chǎn)率和高質(zhì)量產(chǎn)品的同時(shí),力求成本低、壽命長(zhǎng)。2、模具結(jié)構(gòu)設(shè)計(jì)合理,工藝性好,具有一定的創(chuàng)新性。3、操作安全、方便,易于維修,便于管理。4、在保證模具強(qiáng)度前提下,注意外形美觀,各部分比例協(xié)調(diào)。(二)設(shè)計(jì)圖紙1、模具繪圖布局合理,視圖完整、清晰,各項(xiàng)內(nèi)容符合標(biāo)準(zhǔn)要求。2、設(shè)計(jì)圖紙應(yīng)符合學(xué)校的要求,不少于3張零號(hào)圖紙的結(jié)構(gòu)設(shè)計(jì)圖、裝配圖和零件圖,其中應(yīng)包含一張以上用計(jì)算機(jī)繪制的具有中等難度的1號(hào)圖紙,同時(shí)至少有折合1號(hào)圖幅以上的圖紙用手工繪制。(三)設(shè)計(jì)說明書1、資料數(shù)據(jù)充分,并標(biāo)明數(shù)據(jù)出處。2、計(jì)算過程詳細(xì)、完全。3、公式的字母含義應(yīng)標(biāo)明,有時(shí)還應(yīng)標(biāo)注公式的出處。4、內(nèi)容條理清楚,按步驟書寫。5、說明書按照學(xué)校的有關(guān)規(guī)定,編寫不少于12000字的設(shè)計(jì)說明書,同時(shí)上交電子文檔。(四)其他要求1、查閱到10篇以上與題目相關(guān)的文獻(xiàn)2、翻譯一篇本專業(yè)外文文獻(xiàn)(10000個(gè)以上印刷符號(hào)),并附譯文。進(jìn)度安排起止日期工作內(nèi)容備注2011年2月 5月1周(2、212、28)4周(2、283、25)2周(3、284、10)2周(4、114、24)1周(4、255、1)5周(5、26、3)1周(6、66、10)完成畢業(yè)設(shè)計(jì)的選題和開題報(bào)告;進(jìn)行畢業(yè)實(shí)習(xí)及調(diào)研;進(jìn)行工藝及結(jié)構(gòu)設(shè)計(jì);繪制裝配圖和零件圖;對(duì)整個(gè)設(shè)計(jì)進(jìn)行合理性檢查; 撰寫設(shè)計(jì)說明書及畢業(yè)答辯的準(zhǔn)備;畢業(yè)設(shè)計(jì)答辯。主要參考資料1伍先明.塑料模具設(shè)計(jì)指導(dǎo)M .國(guó)防工業(yè)出版社,20062許發(fā)樾.實(shí)用模具設(shè)計(jì)與制造手冊(cè)M .北京:機(jī)械工業(yè)出版社,20013劉彩英.塑料模具設(shè)計(jì)手冊(cè)M .機(jī)械工業(yè)出版社,20024徐佩弦.塑料制品與模具設(shè)計(jì)M .中國(guó)輕工業(yè)出版社,20015機(jī)械工業(yè)職業(yè)鑒定指導(dǎo)中心M .機(jī)械制圖.機(jī)械工業(yè)出版社,20006高佩福.實(shí)用模具制造技術(shù)M .輕工業(yè)出版社,19997孟少農(nóng).機(jī)械加工工藝手冊(cè)M .機(jī)械工業(yè)出版社,19918林清安.Pro/Engineer Wildfire 2.0 模具設(shè)計(jì)M .北京大學(xué)出版社,2004.9葉久新.塑料制品成型及模具設(shè)計(jì)M .湖南科學(xué)技術(shù)出版社,200510中國(guó)機(jī)械工程學(xué)會(huì).中國(guó)模具設(shè)計(jì)大典(第二卷)M .江西科學(xué)技術(shù)出版社,200311張建鋼等.數(shù)控技術(shù)M .華中科技大學(xué)出版社,200012胡蓉,PRO/E在模具中的應(yīng)用J .機(jī)械工程與自動(dòng)化200513梅紅吹,余拔龍,淺談塑料模具CAD/CAM設(shè)計(jì)與制造工藝J .中國(guó)科技信息,200514朱福順,王鵬程,郭勝利,模具材料及其發(fā)展概況J .內(nèi)蒙古石油化工,200515楊俊秋,淺談塑料模具畢業(yè)設(shè)計(jì)J.模具制造,2005,(7)教研室意見年 月 日系主管領(lǐng)導(dǎo)意見年 月 日附表五湖南工學(xué)院畢業(yè)設(shè)計(jì)(論文)開題報(bào)告 題目DVD遙控器前蓋注塑模設(shè)計(jì)學(xué)生姓名羅正芳班級(jí)學(xué)號(hào)212070327專業(yè)材料成型及控制工程一、 選題的目的和意義:塑料制品在日常社會(huì)中得到廣泛利用,模具技術(shù)己成為衡量一個(gè)國(guó)家產(chǎn)品制造水平的重要標(biāo)志之一。國(guó)內(nèi)注塑模在質(zhì)與量上都有了較快的發(fā)展。但是與國(guó)外的先進(jìn)技術(shù)相比,我國(guó)還有大部分企業(yè)仍然處于需要技術(shù)改造、技術(shù)創(chuàng)新、提高產(chǎn)品質(zhì)量、加強(qiáng)現(xiàn)代化管理以及體制轉(zhuǎn)軌的關(guān)鍵時(shí)期。關(guān)于全國(guó)塑料加工業(yè)區(qū)域分布,珠三角、長(zhǎng)三角的塑料制品加工業(yè)位居前列,浙江、江蘇和廣東塑料模具產(chǎn)值在全國(guó)模具總產(chǎn)值中的比例也占到70。現(xiàn)在,這3個(gè)省份的不少企業(yè)已意識(shí)到塑模業(yè)的無限商機(jī),正積極組織模具產(chǎn)品的開發(fā)制造。塑料制品在汽車、機(jī)電、儀表、航天航空等國(guó)家支柱產(chǎn)業(yè)及與人民日常生活相關(guān)的各個(gè)領(lǐng)域中得到了廣泛的應(yīng)用。塑料制品成形的方法雖然很多,但最主要的方法是注塑成形,世界塑料模具市場(chǎng)中塑料成形模具產(chǎn)量中約半數(shù)是注塑模具。目前,我國(guó)模具生產(chǎn)廠點(diǎn)約有3萬(wàn)多家,從業(yè)人數(shù)80多萬(wàn)人。2005年模具出口7.4億美元,比2004年的4.9億美元增長(zhǎng)約50,均居世界前列。2006年,我國(guó)塑料模具總產(chǎn)值約300多億元人民幣,其中出口額約58億元人民幣。除自產(chǎn)自用外,市場(chǎng)銷售方面,2006年中國(guó)塑料模具總需求約為313億元人民幣,國(guó)產(chǎn)模具總供給約為230億元人民幣,市場(chǎng)滿足率為73.5%。在我國(guó),廣東、上海、浙江、江蘇、安徽是主要生產(chǎn)中心。廣東占我國(guó)模具總產(chǎn)量的四成,注塑模具比例進(jìn)一步上升,熱流道模具和氣輔模具水平進(jìn)一步提高。注塑模具在量和質(zhì)方面都有較快的發(fā)展,我國(guó)最大的注塑模具單套重量己超過50噸,最精密的注塑模具精度己達(dá)到2微米。制件精度很高的小模數(shù)齒輪模具及達(dá)到高光學(xué)要求的車燈模具等也已能生產(chǎn),多腔塑料模具已能生產(chǎn)一模7800腔的塑封模,高速模具方面已能生產(chǎn)擠出速度達(dá)6m/min以上的高速塑料異型材擠出模具及主型材雙腔共擠、雙色共擠、軟硬共擠、后共擠、再生料共擠出和低發(fā)泡鋼塑共擠等各種模具。在CAD/CAM技術(shù)得到普及的同時(shí), CAE技術(shù)應(yīng)用越來越廣,以 CAD/CAM/CAE一體化得到發(fā)展,模具新結(jié)構(gòu)、新品種、新工藝、新材料的創(chuàng)新成果不斷涌現(xiàn),特別是汽車、家電等工業(yè)快速發(fā)展,使得注塑模的發(fā)展迅猛?;诂F(xiàn)狀并結(jié)合本學(xué)校教學(xué)特色,選用固體膠底座注塑模設(shè)計(jì)作為我這次畢業(yè)設(shè)計(jì)的題目。二、國(guó)內(nèi)外研究綜述注塑模具在量和質(zhì)方面都有較快的嘔,我國(guó)最大的注塑模具單套重醏己超過5 噸,最精密的注塑模具精度己達(dá)到2微米。制件精度很高的小模數(shù)齒輪模具及達(dá)到高光學(xué)要求的車燈模具等也已能生產(chǎn),多腔塑料模具已能生產(chǎn)一模7800腔的塑封模,高速模具方面已能生產(chǎn)擠出速度達(dá)6m/min以上的高塑料異型材擠模具及主型材雙腔共擠、叄色共擠、硬共擠、后共擠、生料共擠出和低發(fā)泡鋼塑共擠等各種模具。在CAD/CAM技術(shù)得到普半的同時(shí), CAE技術(shù)應(yīng)用越敥越廣,以 CA/CAM/CAE一體化得發(fā)展,模具斠結(jié)構(gòu)新品種、新工藝、新的新成果不攭?,F(xiàn),爹別是汽車、家電等工業(yè)快速發(fā)展,伖泈塑模的發(fā)展迅猛。整體來看我國(guó)塑料模具論昏在量上,蟘是在質(zhì)量、技昭和能力等方面都有很大誅,但國(guó)搑經(jīng)濟(jì)發(fā)屑的需求、世先水帳相比,差趝僅很大。一些大型、精、復(fù)雜、長(zhǎng)壽命的高檔模具每年仍需大量進(jìn)叡。在總量應(yīng)摂同時(shí),一些低偑料模具卻供迃于求市圚獰爭(zhēng)激烈,還有一些術(shù)含量不夢(mèng)高嚄嚴(yán)檔塑斉具也有供迅于桂的趨。分析:未敥我國(guó)注塑模行業(yè)的發(fā)展趨勢(shì) 據(jù)業(yè)內(nèi)人士分未來內(nèi)外棈塑樁發(fā)展勢(shì)包4丟方面: 1、大力提高注塑模開發(fā)能力。將開發(fā)工作盡量往前推,直至介入到模具用戶的產(chǎn)品開發(fā)中去,甚至在尚無明確用戶對(duì)象之前進(jìn)行開發(fā),變被動(dòng)為主動(dòng)。目前,電視機(jī)和顯示器外殼、空調(diào)器外殼、摩托車塑件等已采用這種方法,手機(jī)和電話機(jī)模具開發(fā)也已開始嘗試。這種做法打破了長(zhǎng)期以來模具廠只能等有了合同,才能根據(jù)用戶要求進(jìn)行模具設(shè)計(jì)的被動(dòng)局面。2、注塑模具從依靠鉗工技藝轉(zhuǎn)變?yōu)橐揽楷F(xiàn)代技術(shù)。隨著模具企業(yè)設(shè)計(jì)和加工水平的提高,注塑模具的制造正在從過去主要依靠鉗工的技藝轉(zhuǎn)變?yōu)橹饕揽考夹g(shù)。這不僅是生產(chǎn)手段的轉(zhuǎn)變,也是生產(chǎn)方式的轉(zhuǎn)變和觀念的上升。這一趨勢(shì)使得模具的標(biāo)準(zhǔn)化程帶不斷捐高緦模偷精庢趈來越高,生產(chǎn)周期越來越短,鉗工比例越來越低,最終促進(jìn)了模具工丒整體水平不斷提鋘。目前我國(guó)已10多個(gè)國(guó)家級(jí)高新技術(shù)企業(yè),約200個(gè)省市級(jí)高新技術(shù)企業(yè)。與此趨勢(shì)相適應(yīng),生產(chǎn)模具的主要骨干力量從技藝型人才逐昐轉(zhuǎn)變?yōu)榧夹g(shù)型人才是必然要求。3、模具生產(chǎn)正在向信息化迅速發(fā)嘔。在息社會(huì)中,作為一高水平的現(xiàn)代模具企業(yè),單單只是CAD.CAM的應(yīng)用已遠(yuǎn)遠(yuǎn)不夠。目前許多企業(yè)已經(jīng)采用了CAE、CAT、PDM、CAPP、KBE、KBS、RE、CIMS、ERP等技術(shù)及其它先進(jìn)制造技術(shù)和虛擬網(wǎng)絡(luò)技術(shù)等,這些都是信息化的表現(xiàn)。向信息化方向發(fā)展這一趨向已成為行業(yè)共識(shí)。4、注塑模向更廣的范圍發(fā)展。隨著人類社會(huì)的不斷進(jìn)步,模具必然會(huì)向更廣泛的領(lǐng)域和更高水平發(fā)展。現(xiàn)在,能把握機(jī)遇、開拓市場(chǎng),不斷發(fā)現(xiàn)新的增長(zhǎng)點(diǎn)的模具企業(yè)和能生產(chǎn)高技術(shù)含量模具企業(yè)的業(yè)務(wù)很是紅火,利潤(rùn)水平和職工收入都很好。因此,模具企業(yè)應(yīng)把握這個(gè)趨向,不斷提高綜合素質(zhì)和國(guó)際競(jìng)爭(zhēng)力。隨著市場(chǎng)的發(fā)展,塑料新材料及多樣化成型方式今后必然會(huì)不斷發(fā)展,因此對(duì)模具的要求也越來越高。為了滿足市場(chǎng)需要,未來的塑料模具無論是品種、結(jié)構(gòu)、性能還是加工都必將有較快發(fā)展。超大型、超精密、長(zhǎng)壽命、高效模具;多種材質(zhì)、多種顏色、多層多腔、多種成型方法一體化的模具將得到發(fā)展。更高性能及滿足特殊用途的模具新材料將會(huì)不斷發(fā)展,隨之將產(chǎn)生一些特殊的、更為先進(jìn)的加工方法。各種模具型腔表面處理技術(shù),如涂覆、修補(bǔ)、研磨和拋光等新工藝也會(huì)不斷得到發(fā)展。三、 畢業(yè)設(shè)計(jì)(論文)所用的主要技術(shù)與方法:隨著計(jì)算機(jī)技術(shù)的發(fā)展,注塑模的設(shè)計(jì)方法已經(jīng)由傳統(tǒng)的手工繪圖設(shè)計(jì)逐步向計(jì)算機(jī)輔助設(shè)計(jì)(CAD)方向發(fā)展,給注塑模生產(chǎn)帶來了深刻的變革。此次畢業(yè)設(shè)計(jì)題目主要是基于AutoCAD的技術(shù)與方法進(jìn)行設(shè)計(jì)。1、調(diào)研DVD遙控器前蓋注塑模的造型結(jié)構(gòu)特征及對(duì)注塑零件的工藝性分析。2、注塑工藝的總體方案的分析和確定,然后進(jìn)行排樣設(shè)計(jì)和工藝計(jì)算。3、進(jìn)行模具關(guān)鍵結(jié)構(gòu)的方案設(shè)計(jì),制定初步模具關(guān)鍵結(jié)構(gòu)設(shè)計(jì)方案,繪制產(chǎn)品草圖。4、進(jìn)行DVD遙控器前蓋注塑模結(jié)構(gòu)設(shè)計(jì),繪制正規(guī)DVD遙控器前蓋注塑模零件設(shè)計(jì)圖紙。5、選擇合理的注塑設(shè)備,并對(duì)設(shè)備進(jìn)行校核。6、編制模具中主要零件的制造工藝方案和加工方法。7、撰寫設(shè)計(jì)說明書,所有設(shè)計(jì)文檔、資料的整理、收尾、答辯。四、 主要參考文獻(xiàn)及資料獲得情況1伍先明.塑料模具設(shè)計(jì)指導(dǎo)M .國(guó)防工業(yè)出版社,20062許發(fā)樾.實(shí)用模具設(shè)計(jì)與制造手冊(cè)M .北京:機(jī)械工業(yè)出版社,20013劉彩英.塑料模具設(shè)計(jì)手冊(cè)M .機(jī)械工業(yè)出版社,20024徐佩弦.塑料制品與模具設(shè)計(jì)M .中國(guó)輕工業(yè)出版社,20015機(jī)械工業(yè)職業(yè)鑒定指導(dǎo)中心M .機(jī)械制圖.機(jī)械工業(yè)出版社,20006高佩福.實(shí)用模具制造技術(shù)M .輕工業(yè)出版社,19997孟少農(nóng).機(jī)械加工工藝手冊(cè)M .機(jī)械工業(yè)出版社,19918林清安.Pro/Engineer Wildfire 2.0 模具設(shè)計(jì)M .北京大學(xué)出版社,2004.9葉久新.塑料制品成型及模具設(shè)計(jì)M .湖南科學(xué)技術(shù)出版社,200510中國(guó)機(jī)械工程學(xué)會(huì).中國(guó)模具設(shè)計(jì)大典(第二卷)M .江西科學(xué)技術(shù)出版社,200311張建鋼等.數(shù)控技術(shù)M .華中科技大學(xué)出版社,200012胡蓉,PRO/E在模具中的應(yīng)用J .機(jī)械工程與自動(dòng)化200513梅紅吹,余拔龍,淺談塑料模具CAD/CAM設(shè)計(jì)與制造工藝J .中國(guó)科技信息,200514朱福順,王鵬程,郭勝利,模具材料及其發(fā)展概況J .內(nèi)蒙古石油化工,200515楊俊秋,淺談塑料模具畢業(yè)設(shè)計(jì)J.模具制造,2005,(7)五、畢業(yè)設(shè)計(jì)(論文)進(jìn)度安排(按周說明)第5-6周 收集并整理相關(guān)資料第7-8周 研究資料、編寫開題報(bào)告第9-10周 完成畢業(yè)設(shè)計(jì)論文的初稿 第11-12周 根據(jù)指導(dǎo)教師意見,修改和完善論文第13-14周 進(jìn)一步完善論文,定稿并裝訂成冊(cè)第15-17周 準(zhǔn)備畢業(yè)答辯,提交論文指導(dǎo)教師批閱意見 指導(dǎo)教師(簽名): 年 月 日注:可另附A4紙摘要隨著現(xiàn)代工業(yè)的迅猛發(fā)展, 注塑成型在機(jī)械、電子、航空航天工業(yè)、生物領(lǐng)域及日用品生產(chǎn)中所占的比例越來越大。本次設(shè)計(jì)的是DVD遙控器前蓋塑料模具,制件的結(jié)構(gòu)決定了該模具必須同時(shí)使用側(cè)抽芯。設(shè)計(jì)過程整體采用現(xiàn)代先進(jìn)的模具加工制造方法和強(qiáng)大的Pro/Engineer Wildfire 2.0模具設(shè)計(jì)軟件相結(jié)合,在保證設(shè)計(jì)質(zhì)量的同時(shí)設(shè)計(jì)速度也有提高,設(shè)計(jì)思路及要求符合現(xiàn)代模具設(shè)計(jì)的潮流和未來的發(fā)展方向。 關(guān)鍵詞: 注塑成型;塑料模具;遙控器;側(cè)抽芯ABSTRACTWith the rapid development of industry, the mould plastics shapings covers more and more in mechanical industry, electronics industry, spaceflight industry,biological field and production of daily necessities. This remote controler front cover of DVD molding die must include special slide pull structure because the structure of the product. This design is the integration of modern advanced mould process manufacturing approach and powerfull Pro/Engineer Wildfire 2.0 mold design,not only the design quality is assured but also heightened the design speed. The thought and requirement of this design accord to the trend of contemporary mold design and its future of development direction. Keywords: Mould plastics shaping;Injiectiong mold die;Remote controller;Slide pull structureMinimizing manufacturing costs for thin injection molded plastic components1. IntroductionIn most industrial applications, the manufacturing cost of a plastic part is mainly governed by the amount of material used in the molding process. Thus, current approaches for plastic part design and manufacturing focus primarily on establishing the minimum part thickness to reduce material usage. The assumption is that designing the mold and molding processes to the minimum thickness requirement should lead to the minimum manufacturing cost.Nowadays, electronic products such as mobile phones and medical devices are becoming ever more complex and their sizes are continually being reduced. The demand for small and thin plastic components for miniaturization assembly has considerably increased in recent years.Other factors besides minimal material usage may also become important when manufacturing thin plastic components. In particular, for thin parts, the injection molding pressure may become significant and has to be considered in the first phase of manufacturing.Employing current design approaches for plastic parts will fail to produce the true minimum manufacturing cost in these cases.Thus, tackling thin plastic parts requires a new approach, alongside existing mold design principles and molding techniques.1.1 Current researchToday, computer-aided simulation software is essential for the design of plastic parts and molds. Such software increases the efficiency of the design process by reducing the design cost and lead time 1. Major systems, such as Mold Flow and C-Flow, use finite element analysis to simulate the filling phenomena, including flow patterns and filling sequences. Thus, the molding conditions can be predicted and validated, so that early design modifications can be achieved. Although available software is capable of analyzing the flow conditions, and the stress and the temperature distribution conditions of the component under various molding scenarios, they do not yield design parameters with minimum manufacturing cost 2,3. The output data of the software only give parameter value ranges for reference and leaves the decision making to the component designer. Several attempts have also been made to optimize the parameters in feeding 47, cooling 2,8,9, and ejection These attempts were based on maximizing the flow ability of molten material during the molding process by using empirical relation ships between the product and mold design parameters. Some researchers have made efforts to improve plastic part quality by Reducing the sink mark 11 and the part deformation after molding 12, analyzing the effects of wall thickness and the flow length of the part 13, and analyzing the internal structure of the plastic part design and filling materials flows of the mold design 14. Reifschneider 15 has compared three types of mold filling simulation programs, including Part Adviser, Fusion, and Insight, with actual experimental testing. All these approaches have established methods that can save a lot of time and cost. However, they just tackled the design parameters of the plastic part and mold individually during the design stage. In addition, they did not provide the design parameters with minimum manufacturing cost. Studies applying various artificial intelligence methods and techniques have been found that mainly focus on optimization analysis of injection molding parameters 16,17. For in-stance He et al. 3 introduced a fuzzy- neuro approach for automatic resetting of molding process parameters. By contrast , Helps et al. 18,19 adopted artificial neural networks to predict the setting of molding conditions and plastic part quality control in molding. Clearly, the development of comprehensive molding process models and computer-aided manufacturing provides a basis for realizing molding parameter optimization 3 , 16,17. Mok et al. 20 propose a hybrid neural network and genetic algorithm approach incorporating Case-Based Reasoning (CBR) to derive initial settings for molding parameters for parts with similar design features quickly and with acceptable accuracy. Moks approach was based on past product processing data, and was limited to designs that are similar to previous product data. However, no real R&D effort has been found that considers minimizing manufacturing costs for thin plastic components. Generally, the current practical approach for minimizing the manufacturing cost of plastic components is to minimize the thickness and the dimensions of the part at the product design stage, and then to calculate the costs of the mold design and molding process for the part accordingly, as shown in Fig. 1.The current approach may not be able to obtain the real minimum manufacturing cost when handling thin plastic components.1.2Manufacturing requirements for a typical thin plastic component As a test example, the typical manufacturing requirements for a thin square plastic part with a center hole, as shown in Fig. 2, are given in Table 1.Fig.1. The current practical approachFig.2. Test example of a smallplastic component Table1. Customer requirements for the example component2. The current practical approachAs shown in Fig.1, the current approach consists of three phases: product design, mold design and molding process parameter setting. A main objective in the product design is to establish the physical dimensions of the part such as its thickness, width and length. The phases of molded sign and molding subsequently treat the established physical dimensions as given inputs to calculate the required details for mold making and molding operations.When applying the current practical approach for tackling the given example, the key variables are handled by the three phases as follows:Product design* Establish the minimum thickness (height) HP, and then calculate the material cost. HP is then treated as a predetermined input for the calculation of the costs of molddesign and molding operations. HP Mold design* Calculate the cooling time for the determined minimumthickness HP in order to obtain the number of mold cavities required. The mold making cost is then the sum of the costs to machine the: Depth of cutting (thickness) HPNumber of cavitiesRunner diameter DRGate thickness HG Molding process* Determine the injection pressure Pin, and then the cost of power consumptionl Determine the cooling time t co, and then the cost of machine operations. The overall molding cost is the sum of the power consumption cost and machine operating cost.The total manufacturing cost is the sum of the costs of plastic material, mold making and molding operations. Note that, in accordance with typical industry practice, all of the following calculations are in terms of unit costs.2.1 Product design This is the first manufacturing phase of the current practical approach. The design minimizes the thickness HP of the plastic component to meet the creep loading deflection constraint , Y (1.47mmafter1yearofusage),and to minimize plastic material usage cost Cm. Minimizing HP requires 21:Figure 3 plots changes in HP through Eqs.1 and 2.The graphs show that the smallest thickness that meets the 1.47mm maximum creep deflection constraint is 0 .75mm,with a plastic material cost of $0.000483558/unit and a batch size of 200000 units. This thickness will be treated as a given input for the subsequent molded sign and molding process analysis phases. 2.2Mold design2.2.1 Determination of cooling timeThe desired mold temperature is 25 C. The determined thickness is 0.75mm. Figure 4 shows the cooling channels layout following standard industry practices. The cooling channel diameter is chosen to be 3mm for this example.From 22, the cooling time t co:And the location factor, BysolvingEqs.3and4, and substituting HP =0.75mm and the given values of the cooling channel design parameters, the cooling time (3.1s) is obtained.The cycle time t cycle, given by E q. 5, is proportional to the molding machine operating costs, and consists of injection time (t in), ejection time (t e j), dry cycle time (t d c), and cooling time (t c o). 2.2.2 Determination of the number of mold cavities In general, the cost of mold making depends on the amount of machining work to form the required number of cores/cavities, runners, and gates. The given example calls for a two-plate mold Fig.3. Deflection and plastic materials costs versus part thickness Fig.4. Cooling channel layout that does not require undercut machining. Therefore, the ma chining work for cutting the runners and gates is proportional to the work involved in forming the cores/cavities and need not be considered. In the example, mold making cost Cmm is governed by (n, HP).Generally, the minimum number of cavities, Nmin, is chosen to allow for delivery of the batch of plastic parts on time圖3 。 After substitutionwhich is rounded To n =3,since the mold cannot contain 2.64 cavities. The machine operation capacity and the lead-time of production in the example are given as 21.5h/d and 21d, respectively. Moreover, as mentioned in the previous section, the cycle time is directly proportional to the part thickness HP. A curve of batch size against thickness is plotted in Fig. 5. As shown, at HP =0.75mm, the production capability (batch size) is 242470units.Thus the production capability of n =3 is larger than the required lot size (200000units).For simplicity, the time taken for machining the depth of a thin component is treated as a given constant and added to the required time t CC for making a cavity insert. The C mm can then be calculated by n as expressed 12.3Molding process In the molding process, the cycle cost and power consumption cost are used to establish the molding operations cost as described in the following sections.Fig.5. Mold making cost versus part thickness2.3.1 Cycle costThe cycle cost C is defined as the labor cost for molding machine operations. The calculation of cycle cost, given by E q. 8, mainly depends on the cycle time and number of mold cavities For the example, the value of labor cost per hour, L, is given as $1.19/h. Also, Cp can be calculated, as t cycle =20.1sand n = 3 when HP = 0.75mm, as found earlier. And so Cp =$0.0022147/unit.2.3.2 Power consumption costTypically,within the operating cycle of a molding machine,maximum power is required during injection. Hence, longer injection times and higher injection pressures increase the power consumption cost.For the purposes of this example, an injection time of tin =0.5sisselectedand applied for the molding process。The required hydraulic power PH, power consumption E i, and cost CPC for injection can be found from the followingexpressions 23In E q. 9, 0.8 is the mechanical advantage of the hydraulic cylinder for power transmission during molding, and the resulting electric power cost of CE = HK$1.0476/kWh is given in E q. 11. To find CPC, the sum of the required injection pressures Pin in the feeding system and cavity during molding need to be found.Required injection pressures. Based on the mold layout design, the volume flow rate Q in the sprue is equal to the overall flow rate, and the volume flow rate in each primary and secondary runner will be divided by the separation number, Ni,according to:The volume flow rate in a gate and cavity equals to that of the runner connecting to them. Tan 24 derived simplified modelsFor filling circular and rectangul a r channels that can be employed for the feeding system design in this study 1. Sprue and runner (circular channel)The pressure drop of sprue and runner is express e d a s:2. Cavity and gate (rectangular channel)The pressure drop of cavity and gate is expressed as: Further, the temperature-dependent power law viscosity model can be defined as: Based on the values of the volume flow rate and consistency index m (T) for each simple unit, the pressure drop P can be found by using E q s. 12to15. Thus, the required filling pressure is the sum of pressure drops P in the sprue, primary runner, secondary runner, gate, and cavity: Required power consumption. Given the shape and dimensions of the part and feeding channel, the pressure drops of the sprue , runner, gate , and cavity are obtained through the calculation froE q s. 12 to 15, and are substituted into E q. 16. The required injection pressure Pin is calculated and substituted into the E q. 9.Combining E q s. 10 and 11, the power consumption cost CPC is calculated and depends on the variation of injection pressure, which is indirectly affected by the thickness of product as shown in the following E q .17. After substitution, this becomes: Then the molding costAfter calculation, C molding = $0.0022147/unit+$0.003755/unit,when HP =0.75mm, n =3.2.4Remarks on the current practical approach Based on Esq. 8 to 18 it can be shown that as the part thickness,Hp, increases, the necessary injection pressure Fig.6. Molding process cost versus thickness consumption cost) decreases but the cycle time (and thus labor cost) increases and so there is a minimum total molding process cost, as shown in Fig.6 for the example in this study. As can be seen the minimum molding process cost is Hp =2.45mm.If the test example part thickness, Hp, were increased from0.75 to 2.45mm, the plastic material cost is increased by230.1%; however, the total molding process cost decreases by20.6% to $0.004741/unit. Moreover, the total manufacturing cost for the part falls by9.54%, a saving of $0.0001174/unit.Thus, applying the current practical approach does not give the true minimum manufacturing cost. The current practical approach mainly focuses on minimizing the thickness of the part to reduce the plastic material usage and achieve shorter cooling times. When the part is thin, higher injection pressures are needed during the molding process, which substantially increases the molding process costs and consequently shifts the true minimum manufacturing cost for the part away from the minimum thickness solution.3 The proposed approachTo overcome the shortcoming of the current practical approach, a concurrent approach is proposed for minimizing the manufacturing cost for plastic parts made by injection molding.3.1Framework of the proposed approachThree parallel phases of product design, mold design, and molding process setting are undertaken for the proposed approach showninFig.7. The parallel phases handle individual cost functions for material cost, molding cost, and mold making cost, Which add to yield the total manufacturing cost . The product shape and dimensions (the possible range of thicknesses) are considered as the main design inputs at the beginning of design phase, as shown in Fig. 7.The proposed approach will provide a possible solution by considering the three phases simultaneously. The outputs are options for combinations of the thickness of the part , the number of mold cavities , and the minimum manufacturing cost that meet all the given requirements.Fig.8. Creep deflection and plastic material cost versus thicknessFig.9. Mold making cost versus part thickness (n =18) 3.5 Molding phaseThe molding process cost is the sum of cycle cost and power consumption cost. Each number of mold cavities has its own curve of molding cost as shown in Fig. 10. Each curve is inversely proportion to the thickness of the plastic component. The lowest point of the curve is the minimum cost. Usually, when the curve has no sharp turning point and asymptotes, it means that enlarging the thickness cannot reduce molding cost very much.If the thickness of product is increased, lower injection pressure is required during molding, thus the power consumption cost is reduced, but the cycle time is lengthened and the cycle cost is increased.As in Fig. 10, assuming an eight cavity mold, the thickness of the plastic part should be less than 2.81mm, with minimum molding cost lessthan$0.00475676/unit.mold3.6Determination of manufacturing costAs discussed, the results obtained in sections 3.3, 3.4, and 3.5 can be combined to yield a total manufacturing cost that is the summation of the part design, mold making, and molding process costs. Eight different curves have beendrawninFig.11, for the different numbers of mold cavities. The minimum manufacturing cost is obtained from the lowest point among the eight curves in this study. From Fig.11, the thickness of the plasticFig.10. Molding process cost versus part thickness (n =18):Fig.11. Manufacturing cost versus part thickness (n =18) component is 1.44mm, with minimum manufacturing cost of $0.00843177/unit and n =3.The lowest manufacturing cost is obtained after inputting all values of thickness and numbers of cavities with in the allowable range, 0.01mm to 6mm and 1 to 8, respectively.Table2. Comparison of results for the different approaches3.7 Comparison of the approachesThe results for the current and proposed approaches are summarized in Table 2.When the thickness is increased from 0.75 to 1.44mm, the plastic material cost increases by 92%, but reduces total manufacturing cost by 72.4%. An improvement of 85.9% for the creep deflection is also obtained in the functional design. Further, with the 1.44mm papt thickness, 4.5% less elecpric power is splt.4 ConchusionsThe problems o& the cu2rent apprkaCh to optimize the designparameters for a smahl plastic part, its mold and the corresponding molding process for the Mhnimization of the mnufactuping cksts have beej investacated. A new aroach to o6ercnme dhe problems hac been proposed and tested. ThE relatinnshIps betweel power consumption and thickness of smaLD plastic parts for design And molding have been cat up. The criteria for the propos%d approac to muf!cture a smahl plas4ic part wIth minilum manufactTring cost hAve been discussed and v%rifIed by a tesd ex!mplE. In cknclusion, the proposed approach will ensure that the minimum cost solution can be obtained wheN manu&a#turing 3lald pl!st)c parts.盡量少生產(chǎn)成本的超薄注塑成型塑斉聨1前言在多數(shù)工業(yè)應(yīng),塑撙零件的生產(chǎn)成本,主要集中在材撙成型的模具上。因此曮前使唨多的辦就是降低偑料聨件的厚度,以減少材料使用。假設(shè)設(shè)計(jì)模成型過程的最厚度要求昏圍導(dǎo)致制造的最成。如今電子產(chǎn)品如移動(dòng)電話和醫(yī)療論備正變得越捥越復(fù)雜,尺寸正在不減小。在挀近幾年小而薄的塑撙部件需求已大為加除了最低限度的贈(zèng)用其他方镢也可能成為唟產(chǎn)超蒄塑憑郠件的重要因特是對(duì)于制造薄來說,在第一階段的注塑壓力尤丸重要。如果采用目瘄設(shè)計(jì)方法鼌在這些薄件中,塑料部件將無法制造最伎成本。因此,處理超薄塑料零件,需要一種斐的方法,以適岔現(xiàn)有的模具設(shè)莡原則和成工藝。1.1目前的研究狀況如仂,電腦輔模拏軟件是模關(guān)設(shè)計(jì)必可少的組成部分。這種軟件,增加了設(shè)計(jì)的效率減少設(shè)謡成本和時(shí)間 1 。主要系統(tǒng),如模具流和C -流量使用有限元分析模擬充填現(xiàn)葡,包括流動(dòng)模式和填補(bǔ)序列。因此成型條件可以預(yù)測(cè)和驗(yàn)證,以使早朗設(shè)計(jì)的修改是可以實(shí)現(xiàn)的雖然現(xiàn)有的轪件能夠分枀流量條件三應(yīng)力和溫度分布狀況,他們梡有產(chǎn)生最的制造成本瘄設(shè)讁參數(shù) 2,3 。輸出數(shù)據(jù)的軟件只能提供參數(shù)范圍,以供設(shè)計(jì)師參考和決策。多次嘗試乗取得了優(yōu)化的參數(shù) 4-7 ,冷卻系統(tǒng) 0,8,9 ,并凍饋 10 Y 。這些嘗試在礎(chǔ)上最大虐度限制了熔融材料在成壓過程中使甠的經(jīng)驗(yàn)與船舶之間的品模的設(shè)計(jì)廠數(shù)。一些究人員已作出努力,為了搹善塑料零件質(zhì)量通過減少縮水 11 和部分變形后成型 12 ,分朐影響壁厚和流動(dòng)長(zhǎng)度的一部分K 13 ,分掐了內(nèi)部結(jié)構(gòu)的塑料零件的設(shè)計(jì)和充填料流動(dòng)的模設(shè)計(jì) 14 。 Reifschneider 15 揔較三種米喋的充型模擬程序,包括胨分顧問,融吀,和Ansight ,實(shí)虅實(shí)驗(yàn)敋試。所有這些已建立的方,可以節(jié)省大量的時(shí)間和成本。焆而他們只解決了設(shè)覡參數(shù)的塑料銀件和模具單獨(dú)在設(shè)計(jì)階段。此,他們還沒有懐供的設(shè)計(jì)卂數(shù)與最制造成本。研究人智能應(yīng)焨各秉方法和技術(shù)已被發(fā)現(xiàn),主要集中在優(yōu)刖分析的注參數(shù) 16,17 。用于莫乃光等。 3 介紹亄糊神經(jīng)自動(dòng)復(fù)位的方法成型工藝參數(shù)。瓸比義下,莫乃光人。 18,19 通過人工神經(jīng)網(wǎng)絡(luò)預(yù)測(cè)的設(shè)繕?biāo)芰铣尚蜅l仦的一部分中的質(zhì)量控制成型。顯然,制定全面昄成型過稃模型電腦輇助制造提供了基礎(chǔ)妞現(xiàn)成型參數(shù)優(yōu)化 3,16,17 U 。莫乃光等人 20 提出了一種淳合神經(jīng)網(wǎng)絡(luò)和遺傳算法璄刞法納入基于案例推理( CBR的)店到初步設(shè)厚成型參的部分有類似的設(shè)計(jì)特點(diǎn)迅速,準(zhǔn)確。莫的辦法是據(jù)過去嚄產(chǎn)品處理數(shù)據(jù),并僅限于設(shè)計(jì),類似以前的產(chǎn)品數(shù)據(jù)。然而緦考慮到盡臏兏少生產(chǎn)戀本的塑料部仴,撡真正璄被R&D努力研發(fā)所發(fā)掰。一般說,目前璄切合實(shí)際的辦法是盡量減少生產(chǎn)成本的塑料胨件匨產(chǎn)品設(shè)計(jì)階段盡量?jī)笇ê穸群蛥蚀绲牟糠?,然后?jì)算出的贙用,模具誶計(jì)與成型過程的一部分,如圖1中顯示。目前的做法在處理塑料部件時(shí)可能無法取得實(shí)際最低制造成本。1.2生產(chǎn)要求一個(gè)典型的塑料部分作為測(cè)試的例子,典型的生產(chǎn)要求薄平方米塑料零件的中心孔,所顯示的圖。 2 ,載于表1 。圖1 。目前切實(shí)可行的辦法圖2 。試驗(yàn)的例子,一個(gè)小塑料元件表1 。客戶的需求為榜樣部分2目前切實(shí)可行的辦法在圖1所示,目前的辦法包括三個(gè)階段:產(chǎn)品設(shè)計(jì),模具設(shè)計(jì)和成型工藝參數(shù)的設(shè)置。一個(gè)主要目標(biāo)的產(chǎn)品設(shè)計(jì)是建立在物理尺寸的一部分,如它的厚度,寬度和長(zhǎng)度。各階段的模塑成型和隨后簽署和處理建立物理尺寸作為給出的投入來計(jì)算所需的詳細(xì)資料和成型模具制造業(yè)務(wù)當(dāng)申請(qǐng)目前切實(shí)可行的辦法解決給定的例子,關(guān)鍵的變數(shù)是由三個(gè)階段處理如下:產(chǎn)品設(shè)計(jì)l 確定的最小厚度(高度) ,然后計(jì)算材料成本。HP則視為預(yù)先輸入的計(jì)算費(fèi)用的模具設(shè)計(jì)和
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