杯座模具设计

1目录摘要·································································错误!未定义书签。绪论·································································错误!未定义书签。第1章设计题目：杯座模具设计·················································3第2章工艺性分析··································································72.1塑料的原材料（ABS）分析·····················································72.2塑件的结构和尺寸精度等级及表面质量分析······························72.3计算塑料制件的体积和质量····················································82.4塑件注塑工艺参数的确定································错误!未定义书签。第3章注塑模具的结构设计·······················································83.1模腔数量的确定·································································83.1.1按注射机的额定锁模力确定型腔数量N1·····························93.1.2注射机注塑量确定型腔数目N2·········································93.2分型面的选择以及型腔的排列方式的确定·······························103.2.1分型面的选择······························································103.2.2确定型腔的排列方式·····················································103.3浇注系统形式和浇口的设计···················································113.4排气结构的设计································································133.5成型零件设计·····································································13第4章模具设计的有关计算························································154.1型腔、型芯工作尺寸计算·································错误!未定义书签。4.2型腔侧壁厚度和底板厚度计算···························错误!未定义书签。4.3模具加热与冷却系统的计算···················································154.4结构与辅助零部件的设计······················································164.5模具闭合高度的确定·······································错误!未定义书签。4.6注塑机有关参数的校核····································错误!未定义书签。第5章塑料模的装配、试模与维修························错误!未定义书签。5.1模具装配······················································错误!未定义书签。5.2试模··················································································165.3试模可能产生的问题及改善措施·············································165.3.1粘着模腔·····································································175.3.2粘着模芯·····································································175.3.3粘着主流道··································································1725.3.4成型缺陷·····································································185.3.5调整措施·····································································19第6章绘制模具总装图····························································19第7章机械加工工艺过程卡······················································20第8章用Pro/E画图的过程······················································248.1用Pro-E画杯座零件的过程···················································258.2用Pro-E画杯座模具的过程···················································258.2.1：加载参照模型·····························································258.2.2：成型零件设计·····························································258.2.3：浇注系统设计及开模···················································258.2.4：模架及其他模具零件设计·············································258.2.5：模具元件后期处理······················································26总结······················································································26致谢······················································································27参考文献················································································283第1章设计题目：杯座模具设计零件图：4设计要求：1．材料2．生产批量3．未注公差取MT5级精度杯座模具工艺方案分析可选方案方案分析结论分型面取A-A面作为分型面，它位于零件截面最大的部位，此分型面是一个曲面，且分型线并不是零件的轮廓曲线合理型腔布局与浇注系统采用一模一件，可以降低模具成本，但不能适应大批量生产的需求，点浇口上端进料，容易保证零件质量。不合理5一模四件对称分布，虽然模具尺寸增大，制造成本有所提高，但生产效率较高，适应大批量生产的需要，点浇口上端进料容易保证零件质量。合理推出结构虽然塑件包紧动模型芯的力不是很大，但因塑件壁很薄，采用顶杆推出容易将塑件顶变形，甚至破坏塑件不合理6将顶杆作成锥面，增大顶出部分的接触面积，可以有效地避免顶出时塑件的变形。合理7第2章工艺性分析2.1塑料的原材料（ABS）分析（1）吸湿性强。成型前须充分干燥要求其含水量小于1％，对于表面光泽要求较高的制品，需长时间干燥。（2）流动性较好（溢边值为0.04mm左右）易于充模，粘度对剪切速率较敏感，同时还与注射温度和注射压力有关，其中注射压力影响较为显著，因此提高流动性要从提高注射压力入手。（3）成型难度大，须采用较高的料温和模温。对于耐热抗冲击性和中抗冲击性制件，应在允许的范围内料温取较大值。（4）精度对之制件影响较大，有破坏ABS橡胶相的倾向，通常ABS在250℃左右变色，270℃开始分解。（5）若制件精度要求较高模温宜采取50～60℃，若制件表面要求具有光泽，模温宜取60～80℃，我们的线圈骨架采用60℃。（5）注射压力应比聚苯乙烯较大，采用螺杆式注塑机料温可取160～220℃，注射压力可取70～90MPa。（6）模具设计过程中注意事项，浇注系统流动阻力应尽可能小，浇口位置及形式应合理并能防止熔接痕的产生，同时要考虑模具制造的经济性和加工的合理性。2.2塑件的结构和尺寸精度等级及表面质量分析从该制品的零件图可知；形状，结构对制件脱模要求较高，但对尺寸大小，产品精度和表面质量要求都不高。此零件壁薄且深，斜度比较大，虽然总体尺寸不大但相对较高，无特殊尺寸要求，零件表面要求较光滑。（1）成型制件的尺寸大小主要取决于塑料原料的流动性和注射时的压力在一定的设备和工艺条件下，流动性较好的塑料品种可以成型较大8的制件，塑料ABS的流动性能较好，适于成型较大的制件。在这里杯座注塑模具的尺寸较小，注塑时的压力要求不太大，一般的注塑压力就能满足。（2）制品的精度等级；塑料制件的尺寸精度主要取决于塑料收缩率的波动和模具制造误差，此处塑料件未注公差，由于该制件的原材料为ABS，而ABS的制件公差等级较低为MT5级，该塑件的精度等级较低。受模具活动部分的影响，取公差值和附加值之和，MT2级取0.05，MT3-5级取0.1。（3）制品的表面质量；塑料制件的精度等级较低，我们所要获得的制件对制品的表面质量除要求无缺陷，毛刺，无特殊要求，一般的模具制造工艺和注塑工艺就能满足要求。（4）制品的形状结构；制品的壁厚均匀为3mm。符合ABS的最小壁厚原则，在制件的交叉处的壁厚较小（0.5mm），在模具的设计和加工过程中要特别注意，防止出现缺陷，由于制件的尺寸较小，ABS的强度较大不需增设加强筋。2.3计算塑料制件的体积和质量计注塑模具的结构设计注塑模的结构设计主要包括：分型面的选择、模具型腔数目的确定、型腔的排列方式、冷却水道布局、模具工作零件的结构设计、侧向分型与抽芯机构的设计、推出机构的设计等内容。3.1模腔数量的确定塑件的生产属大批量生产，宜采用多型腔注塑模具，其型腔个数与注塑机的塑化能力，最大注射量以及合模力等参数有关，此外还受制件精度和生产的经济性等因素影响，有上述参数和因素可按下列方法确定模腔数量；93.1.1按注射机的额定锁模力确定型腔数量N1N1=PCF×A1－AB其中：F注塑机的锁模力NPC型腔内的平均压力mpaA每个制件在分型面上的面积（m㎡）B流道和浇道在分型面上的投影面积（m㎡）B在模具设计前为未知量，根据多型腔模具的流动分析B为（0.2～0.5），常取B=0.35，熔体内的平