薄壁塑件的注射成型数值模拟及模具优化设计研究

重庆理工大学硕士学位论文薄壁塑件的注射成型数值模拟及模具优化设计研究姓名：尚欣申请学位级别：硕士专业：材料加工工程指导教师：@2011-06I“”CAECAEAbstractIIIAbstractInjectionmoldingforthin-wallisanewtechnologywhichdevelopedonthebasisofthetraditionalinjectionmoldingtechnology.Traditionalinjectionmoldingprocessconditionshasnotmettherequirementsoftheformingofthethin-wallplasticinjectionpartsbecausethepolymermeltsinthecavitywithahighcoolingrate.Thepolymerwillcureinashorttime,whichmakestheformingprocesscomplexanddifficult,soitwilldirectlyaffectsthequalityofplasticparts.Forthin-wallplasticparts,warpageisthemajordefectintheinjectionmoldingprocess.Improvingandreducingthewarpageoftheproducts,aswellasoptimizingtheinjectionmoldingprocessparametersandmoldstructurehasbecomethekeyfactorinmanufacturingoftheplasticproducts,soithasattractedtheproductdesigner'sattention.BasedonthecooperationprojectionofDCBrushlessFanofbusairconditioningsystembyChongqingTonadaCo.,LtdandChongqingUniversityofTechnologywemainlytreatthewarpageofthefanbaseasthestudysubject.WeresearchedonthemainprocessparametersbyCAEwhichinfluencedthewarpageoftheproducts.ThroughTaguehiexperiments,weobtainedthebestprocessparameters.Basedonthethebestprocessparameters,weobtainedthewarpageamount.Finally,wefoundthatwarpageisimprovedalot,butitwasstillexistandaffectedtheaccuracyofproductassembly.Inordertomeetwiththecompanyrequirements,weobtaineddeformationcompensationamountbyCAEagain.Theanti-deformedwasappliedtodesignmoldinthepartsofinjection.Wemodifiedthethree-dimensionalmodeloftheplasticpartaccordingtothedeformationcompensationamount.Themoldwasmodifiedtooffsetthewarpageaccordingtothefinalcompensation.Experimentwasmadeontheinjectiondevicebyrationaldesign.Basedonthetheoryofwarpage,weanalyzedtheresultsofexperiment.Severalplasticpartswillbeselectedrandomlyandmeasued.Theresultsshowedthatwarpagedeformationisinthecontrollablerange.Itshowedthatdeformationcompensationwasaneffectwaytodesignmold.CombiningtheCAEanalysiswithmolddesignofdeformationcompensationmethod,thewarpageisgreatlyreducedtheassemblyprecisionofproductsaregreatlyincreasedtheproductioncycleisshortened,andthequalityoftheproductisimproved.Keywords:Thin-wallinjectionmolding;Warpage;Numericalsimulation;Taguehiexperiments;Deformationcompensation(“√”)1.□2.□1111.11.1.11.1.2[1][2]-2TaguchiCAECAE1.2MahishiMaloney[3]L/T(LLengthTThicknessL/T)100150WhettenFasset[3]1mm50cm2-1.8mmT351mm,L/T=195MahishiMaloneyCAECAECAD/CAM[4]CAE131.2.1ChiamingYena,JCLin,AWujengLiaMFHuanga[5]Losch[6]Maloney[7]1mm15.4mm1/4PCABSMoldflowTanktakom[8]1mm50cm2ABSPCMahishi[9]C-MoldJansenetal[10]PSABSPCPBPBT-GF30HDPEHasanKurtaranTuncayErzuntmlu[11]BAMlekusch[12]4BOzcelikTErzurmnlut[l3]TaguehiMoldflow1.2.2S.J.LIAO[14]C-Mold[15][16]Cross-WLF/(l.lmm0.8mm)[17][18]Taguchi15[19]1.31.3.1[20]1.3.2()[21]1[22]6[21][23][24]2[25]()[22]172m[26][23]34[22]()()[21]()[21]81.3.3CAE1.4CAE1CAE2Moldflow3CEA452CAE92CAE2.1CAECAE[27][28]2.1.1()[21](2.1)X(2.2)Y(2.3)Z(2.4)2.1.2()gradpgdtVd−∇+⋅=⋅τρρ)((xzxyxxyzzyyxxxgzyxxzVVyVVxVVtV⋅+∂∂+∂∂+∂∂+∂∂=∂∂+∂∂+∂∂+∂∂⋅ρτττρρ)((yzxyxxyyzyyyxygzyxyzVVyVVxVVtV⋅+∂∂+∂∂+∂∂+∂∂=∂∂+∂∂+∂∂+∂∂⋅ρτττρρ)((zzzyzxzzzyyzxzgzyxzzVVyVVxVVtV⋅+∂∂+∂∂+∂∂+∂∂=∂∂+∂∂+∂∂+∂∂⋅ρτττρρ10[29](2.5)(3.5)TK2∇K}{:(Vρρ∇τ)[29]2.1.3[22]:(2.6)(2.7)2.1.4(SpencerGilmore)PVTSpencerGilmore[22]:V=(2.8)R-T-W-*p-Cohesion*b-}){:()()(2VVTpTTKdtdTCppρρρρ∇+⋅∇∂∂−∇=τρdtdTCpρ)()(VTpTpρρ⋅∇∂∂0)(=⋅+∂∂Vdivtρρ0)()()(=∂⋅∂+∂⋅∂+∂⋅∂+∂∂zVyVxVtzyxρρρρ**)(bppWTR++⋅⋅2CAE112.1.5[24]“”“”“”2.22.2.1CAECAECAE2.1CAECAE[20]CAE[22]1234562.2CAECAE122.1CAE2.22CAE132.2.2ff0fr→0rff1r→1rr→→→−=∆011rrrf2fr→2rf0r→→→−=∆022rrr→∆1rf0f2→∆1r→∆2r→∆2r=-→∆1r→∆2rf0f22-32.32.3CAECAE3CAE143CAE/()()CAD/CAE/CAMMoldflowMoldflowCAEMoldflow()CAEMoldflow[27]1Moldflow2Moldflow3Moldflow3.1,,Pro/ENGINEER5.03.1(a)(b)Pro/ENGINEER5.0AutoCAD2004153.21.8mmPA66+30GF3.1(b)ABCD0.6mm(0.3mm)3.3(a)(b)3.13.212Ra=1.6m30.3mmABDC3CAE163.3MoldflowCAE3.23.2.1PA66+30GF3.13.23.1PA66+30GF(g/cm3)1.30~1.40(%)≤1.5(MPa)≥150(Mpa)≥220(MPa)≥6.5×103(KJ/m2)≥15(°C)≥210(%)30±2%0.2%~1%173.2PA66+30GF/°C220/°C290/°C40/°C90/°C160/Mpa0.5/s-1600003.2.2MPIPro/EHypermeshMoldflowCAEMPICAD1MoldflowCAE,HypermeshHypermeshCAE[30]Hypermesh(3.4)31664Moldflow(3.5)CAE3.4Hypermesh3.53CAE182MPI++MoldflowUltramidB3WG6GP(PA66+30GF)3(1)3.665°C265°C5s++,60s3.6(2)3.73.7(3),:V/P19(4)4(1),(2)(3)(4),(5)(6)(7)3.83.85220603CAE20[26](1)(2)(3)(4)(5)(6)(7)(8)(9)(10)(11)3.98mm1.66m/s,0.05m3/min3.93.2.3CAE121CAE1)MoldflowL=25mmD=10mm8mm[24]h=0.51.5mmb=1.55.0mmL=1.52.5mm0.251.0mm11.3mm6mm,1.36.0mmDD2t,Z1.5~2CAE3(1)13.10(a)(2)23.10(b)(3)23.10(c)(a)1(b)23CAE22(c)33.103.33.3(s)(MPa)(t)(cm3)(cm/s)(mm)1.71141.7349118.6214.8638105.72901.643.26090.3837249.7717.6773106.141.562.51188.16203.389.2618135.231.34Origin8.03.33.11050100150200250321sMPatcm3cm/s(mm)3.1123(1)(2)(3)3.3(4)2)3.12(a)1(b)23CAE24(c)33.12(1)(2)(3)(1)(2)(3)2200~300°C60~80°C(),[31,32](1)(2)()(3)25(4)(5)(6)()(7)()3.43.4/C/C(PS)AS(AS)ABS(PE)(PP)(PA)(POM)(PC)200~250200~260200~260180~250150~250160~260200~300180~220280~32040~6040~6040~6040~6050~7040~6055~6580~12080~1103580()1053.510000()[24]3CAE2610~20Re2300(10~18)3.5d/mmv/m·s1