756 直三通注塑模設(shè)計(jì)【全套16張CAD圖+文獻(xiàn)翻譯+說明書】,全套16張CAD圖+文獻(xiàn)翻譯+說明書,756,直三通注塑模設(shè)計(jì)【全套16張CAD圖+文獻(xiàn)翻譯+說明書】,三通,注塑,設(shè)計(jì),全套,16,cad,文獻(xiàn),翻譯,說明書,仿單 課題任務(wù)書 指導(dǎo)教師 學(xué)生姓名 課題名稱 直三通注塑模設(shè)計(jì) 內(nèi)容及任務(wù) 設(shè)計(jì)內(nèi)容：根據(jù)所給的題目及原始數(shù)據(jù)，設(shè)計(jì)出一套注塑模。內(nèi)容包括：該塑料零件注射成型方案設(shè)計(jì)；模具結(jié)構(gòu)設(shè)計(jì)；非標(biāo)模具零件設(shè)計(jì)；成型零件制造工藝編制。 設(shè)計(jì)原始數(shù)據(jù)如下： 1、 Pro/E零件圖,AUTOCAD圖，實(shí)物 2、 塑件尺寸公差按SJ1372-78,3級(jí)（參見塑料模設(shè)計(jì)資料一，表6-6），孔類尺寸為正公差，軸類尺寸為負(fù)公差 3、 角度公差±0.5o 4、 塑膠件表面光亮無劃傷痕跡 5、生產(chǎn)批量為大批大量。 設(shè)計(jì)任務(wù)：學(xué)生在指導(dǎo)教師指導(dǎo)下獨(dú)立完成給定的注塑模設(shè)計(jì)任務(wù)，進(jìn)行調(diào)查研究，選定合理的設(shè)計(jì)方案，進(jìn)行必要的試驗(yàn)、測(cè)試和研究工作，正確繪制工程設(shè)計(jì)圖紙，編寫符合要求的設(shè)計(jì)說明書，翻譯與題目有關(guān)的外文資料。學(xué)生在設(shè)計(jì)工作中，應(yīng)綜合運(yùn)用多學(xué)科的理論、知識(shí)與技能，分析與解決給定的工程設(shè)計(jì)問題。要力爭(zhēng)做到設(shè)計(jì)內(nèi)容的科學(xué)性、設(shè)計(jì)思想的新穎性、設(shè)計(jì)表述的規(guī)范性和設(shè)計(jì)過程的綜合性。 擬達(dá)到的要求或技術(shù)指標(biāo) 1．設(shè)計(jì)總要求： （1）、盡量選用標(biāo)準(zhǔn)模架。 （2）、保證規(guī)定的生產(chǎn)率和高質(zhì)量的塑膠制品的同時(shí)，力求模具成本低、壽命長(zhǎng)。 （3）、設(shè)計(jì)的塑料模必須保證操作維護(hù)安全、方便，與注射機(jī)能夠匹配。 （4）、在能夠生產(chǎn)出性能、特性、質(zhì)量符合要求的前提下，盡量降低制品后加工成本。 （5）、便于搬運(yùn)、安裝、緊固到注射機(jī)上，并且方便、可靠。 （6）、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)。 2、設(shè)計(jì)圖紙 模具總裝圖一張、動(dòng)、定模板、凸模、凹模、定位圈、澆口套、型芯等所有非標(biāo)準(zhǔn)零件圖及電子文件（即*.doc/*.dwg/*.prt/*.asm文件，其中至少要有一張1號(hào)以上計(jì)算機(jī)繪圖）；至少有折合1號(hào)圖幅以上的圖紙用手工繪制。圖幅總量不少于3張零號(hào)圖紙。 3、設(shè)計(jì)說明書（要求不少于1.2萬字，35頁以上） （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）、說明書要求用計(jì)算機(jī)打印出來。 （6）其他要求：寫出不少于400字的中文摘要；至少翻譯一篇本專業(yè)外文文獻(xiàn)（10000個(gè)以上印刷符號(hào)），并附譯文；查閱到10篇以上與題目相關(guān)的文獻(xiàn)。 4、整個(gè)設(shè)計(jì)資料包括：全套圖紙、設(shè)計(jì)計(jì)算說明書、設(shè)計(jì)任務(wù)書、設(shè)計(jì)筆記、畢業(yè)實(shí)習(xí)及畢業(yè)設(shè)計(jì)體會(huì)。 5、自選兩個(gè)重要模具成型零件，編制加工工藝過程卡；編制型腔的數(shù)控加工程序。 6、編制模塑成型工藝卡。 進(jìn)度安排 起止日期 工作內(nèi)容 備注 第1--4周 第5周 第6周 第7周 第8--11周 第12周 第13--14周 第15--16周 第17--18周 1、畢業(yè)設(shè)計(jì)調(diào)研； 2、熟悉設(shè)計(jì)任務(wù)書的具體內(nèi)容，準(zhǔn)備相關(guān)的參考資料； 3、 完成塑料件的設(shè)計(jì)及繪圖工作； 4、 確定模具的設(shè)計(jì)方案； 5、 繪制模具裝配圖及零件圖 6、 編制模具的裝配工藝及主要零件的加工工藝 7、 編制模具成型零件加工工藝過程卡；編制型腔的數(shù)控加工程序；編制模塑成型工藝卡 8、 寫設(shè)計(jì)說明書，翻譯英文資料，做好畢業(yè)答辯的準(zhǔn)備工作。 9、畢業(yè)答辯 主要參考資料 1、國(guó)家標(biāo)準(zhǔn)總局編?！端芰夏?guó)家標(biāo)準(zhǔn)》 中國(guó)標(biāo)準(zhǔn)出版社，1999 2、陳萬林編著《塑料模具設(shè)計(jì)與制作教程》北京希望電子出版社，2000 3、黃健求編《模具制造》 機(jī)械工業(yè)出版社，2001 4、黃毅宏編《模具制造工藝學(xué)》機(jī)械工業(yè)出版社，1996 5、王孝培編《塑料成型工藝及模具簡(jiǎn)明手冊(cè)》機(jī)械工業(yè)出版社，2000 6、陳曉華、王秀英編《典型零件模具圖冊(cè)》機(jī)械工業(yè)出版社，2001 7、翁其金編 《塑料模塑工藝與塑料模設(shè)計(jì)》機(jī)械工業(yè)出版社，1999 8、塑料模具技術(shù)手冊(cè)編委會(huì) 《塑料模具技術(shù)手冊(cè)》機(jī)械工業(yè)出版社，1997 9、孫鳳勤編 《沖壓與塑壓設(shè)備》機(jī)械工業(yè)出版社，1997 10、黃銳編 《塑料工程手冊(cè)》機(jī)械工業(yè)出版社，2000 11、屈華昌編 《塑料成型工藝與模具設(shè)計(jì)》機(jī)械工業(yè)出版社，1995 12、甄瑞麟編《模具制造工藝學(xué)》清華大學(xué)出版社，2005 教研室 意見 年 月 日 系主管領(lǐng)導(dǎo)意見 年 月 日 3 開題報(bào)告 題　　目 直三通注塑模設(shè)計(jì) 學(xué)生姓名 班級(jí)學(xué)號(hào) 專業(yè) 模具工業(yè)是國(guó)民經(jīng)濟(jì)的重要基礎(chǔ)工業(yè)之一。模具是工業(yè)生產(chǎn)中的基礎(chǔ)工業(yè)裝備，是一種高附加值的高精密型集型產(chǎn)品，也是高技術(shù)產(chǎn)業(yè)化的重要領(lǐng)域，其技術(shù)水平的高低以及成為衡量一個(gè)國(guó)家制造業(yè)水平的重要標(biāo)志。 20世紀(jì)80年代以來，國(guó)民經(jīng)濟(jì)高速發(fā)展對(duì)模具工業(yè)提出了越來越高的要求，同時(shí)為模具的發(fā)展提供了巨大的動(dòng)力。這些年來，中國(guó)模具發(fā)展十分迅速，模具工業(yè)一直15%左右的增長(zhǎng)速度快速發(fā)展。振興和發(fā)展中的模具工業(yè)，日益受到人們的重視和關(guān)注。“模具是工業(yè)生產(chǎn)的基礎(chǔ)工業(yè)裝備”已經(jīng)取得了共識(shí)。目前，中國(guó)有17000多個(gè)模具生產(chǎn)廠點(diǎn)，從業(yè)人數(shù)50多萬。在模具工業(yè)的總產(chǎn)值中，沖壓模具約占50%，塑料模具約占33%壓鑄模具約占6%，其他各類模具約占11%。近年來，中國(guó)模具工業(yè)企業(yè)的所有制成分也發(fā)生了變化。除了國(guó)有專業(yè)廠家外，還有集體企業(yè)、合資企業(yè)、獨(dú)資企業(yè)和私營(yíng)企業(yè)，他們都得到了迅速的發(fā)展。許多模具企業(yè)十分重視技術(shù)發(fā)展。加大了用于技術(shù)進(jìn)步的投入力度，將技術(shù)作為企業(yè)發(fā)展的重要?jiǎng)恿?。此外，許多研究機(jī)構(gòu)和大專院校也開展了模具技術(shù)的研究與開發(fā) 中國(guó)塑料模具工業(yè)起步到現(xiàn)在，歷經(jīng)半個(gè)世紀(jì)，有了很大的發(fā)展，模具水平有了較大提高。大型模具方面已能生產(chǎn)48in大屏彩電塑殼注塑模具、6.5kg大容量洗衣機(jī)全套塑料模具以及汽車保險(xiǎn)杠和整體儀表板凳塑料模具，精密塑料模具材料模具方面，已能生產(chǎn)照相機(jī)塑料件模具、多型腔小模齒數(shù)齒輪模具及塑封模具、經(jīng)過多年的努力，在模具CAD/CAE/CAM技術(shù)、模具的電加工和數(shù)控加工技術(shù)、快速成型與快速制模技術(shù)、新型模具材料等方面取得了顯著的進(jìn)步。在提高模具質(zhì)量和縮短模具設(shè)計(jì)制造周期等方面作出了貢獻(xiàn)。 隨著電子、信息等高新技術(shù)的不斷發(fā)展，模具CAD/CAE/CAM正想集成化、三維化、智能化合網(wǎng)絡(luò)方向發(fā)展。模具CAD/CAE/CAM技術(shù)是模具設(shè)計(jì)、制造技術(shù)的發(fā)展方向，模具和工件的檢測(cè)數(shù)字、模具軟件功能集成化、模具設(shè)計(jì)、分析及制造的三維化、模具產(chǎn)業(yè)的逆向工程以及模具軟件應(yīng)用的網(wǎng)絡(luò)化是主趨勢(shì)。 直三通，要求精度不怎么高，所以模具的設(shè)計(jì)可選擇一個(gè)合理的經(jīng)濟(jì)精度，這個(gè)模具需要大批量生產(chǎn)，而且要求效率高質(zhì)量好和壽命長(zhǎng)，這就要求所設(shè)計(jì)的模具材料要有一定的強(qiáng)度剛度和耐磨性。如果只從模具的質(zhì)量考慮采用整體式模具設(shè)計(jì)顯然比組合式模具要好，但這樣會(huì)增加成本，所以我打算用組合式模具，型腔型芯用好材料，同時(shí)組合式模具的排氣良好也是一大優(yōu)點(diǎn)。考慮維修的方便，對(duì)有的型芯采用嵌件式，只對(duì)受力成型部分進(jìn)行熱處理，這樣降低了成本。 要進(jìn)行一副模具的整體設(shè)計(jì)，需要多本參考文獻(xiàn)，不同的參數(shù)需要在不同的文獻(xiàn)上進(jìn)行查閱，如果先不熟悉這些不同的文獻(xiàn)，無疑會(huì)在做設(shè)計(jì)查參數(shù)時(shí)耽誤很多設(shè)計(jì)時(shí)間。比方說要是想進(jìn)行模具流道的設(shè)計(jì)，流道的大小和模架大小的參數(shù)選擇就得查閱《塑料模具設(shè)計(jì)指導(dǎo)》書，這在我們教科書《塑料成型工藝及其模具設(shè)計(jì)》上是沒有的。同樣還有一些其他的數(shù)據(jù)也需查閱不同的文獻(xiàn)。 執(zhí)行方案 1、認(rèn)真分析直三通的cad圖，用proe畫出塑件的三維圖。 2、分析塑件的用途和功能，注意塑件的功能尺寸和配合尺寸、了解ps塑料的性能。 3、分析直三通的分心面，型腔數(shù)量確定以及排列方式的確定。 4、通過理論計(jì)算選擇注塑機(jī)以及工藝參數(shù)校核。 5、對(duì)澆注系統(tǒng)的形式選擇和截面尺寸的計(jì)算。 6、對(duì)成型零件的設(shè)計(jì)及力學(xué)計(jì)算。 7、模架選擇和設(shè)計(jì)、 8、整體分析模具和塑件，看導(dǎo)向機(jī)構(gòu)需不需要另行設(shè)計(jì)、 9、脫模機(jī)構(gòu)的設(shè)計(jì) 10、側(cè)向分析抽芯機(jī)構(gòu)的設(shè)計(jì) 11、溫度調(diào)節(jié)系統(tǒng)的設(shè)計(jì) 12、模具開模合模過程 指導(dǎo)教師批閱意見 指導(dǎo)教師(簽名)： 年 月 日 注射模具設(shè)計(jì)和新型注射成型技術(shù) 塑料注射模具是現(xiàn)在所有塑料模具中使用最廣的模具，能夠成型復(fù)雜的高精度的塑料制品。下面只是粗略介紹一下。 　　 設(shè)計(jì)塑料注射模具首先要對(duì)塑料有一定的了解，塑料的主要成分是聚合物。如我們常說的ABS 塑料便是丙烯腈、丁二烯、苯乙烯三種單體采用乳液、本體或懸浮聚合法生產(chǎn)，使其具有三種單體的優(yōu)越性能和可模塑性，在一定的溫度和壓力下注射到模具型腔，產(chǎn)生流動(dòng)變形，獲得型腔形狀，保壓冷卻后頂出成塑料產(chǎn)品。聚合物的分子一般呈鏈狀結(jié)構(gòu)，線型分子鏈和支鏈型分子認(rèn)為是熱塑性塑料，可反復(fù)加熱冷卻加工，而經(jīng)過加熱多個(gè)分子發(fā)生交聯(lián)反應(yīng)，連結(jié)成網(wǎng)狀的體型分子結(jié)構(gòu)的塑料通常是一此次性的，不能重復(fù)注射加工，也就是所說的熱固性塑料。 　　 既然是鏈狀結(jié)構(gòu)，那塑料的在加工時(shí)收縮的方向也是跟聚合物的分子鏈在應(yīng)力作用下取向性及冷卻收縮有關(guān)，在流動(dòng)方向上的收縮要比其垂直方向上的收縮多。產(chǎn)品收縮也同制品的形狀、澆口、熱脹冷縮、溫度、保壓時(shí)間及內(nèi)應(yīng)力等因素有關(guān)。通常書上提供的收縮率范圍較廣，在實(shí)際應(yīng)用中所考慮的是產(chǎn)品的壁厚、結(jié)構(gòu)及確定注塑時(shí)溫度壓力的大小和取向性。 一般產(chǎn)品如果沒有芯子支撐，收縮相應(yīng)要大些。 塑料注塑模具基本分為靜模和動(dòng)模。 注射模：注射模主要是用來生產(chǎn)熱塑性的零件，盡管有些工藝已經(jīng)發(fā)展為可以用注射模來生產(chǎn)熱固性材料的零件。在從一個(gè)熔化的熔料箱中把熔料注入型腔中，是相當(dāng)難解決在這種情況下熱固性塑料在幾分鐘內(nèi)凝固的問題。注射模的工作原理跟鍛造模十分相似。當(dāng)柱塞向后拉時(shí)，塑料粉末被載入加料斗，還有一定數(shù)量的塑料進(jìn)入了加熱腔。塑料粉末在加熱腔中受到熱力和壓力的作用下熔化。加熱的溫度范圍在265～500華氏度之間。壓力在12000～30000PMa之間作用下，柱塞向前移動(dòng)，把熔化的塑料注入模具的型腔中。由于模具被流通的冷水冷卻，塑料凝固成型，當(dāng)柱塞向后拉出和開模，塑件脫模。注射機(jī)可以設(shè)計(jì)為人工、斗自動(dòng)、全自動(dòng)操作。以每分鐘注射四次的速率，典型注射機(jī)生產(chǎn)的塑件可重達(dá)22盎司，某些注射機(jī)可達(dá)到每分鐘注射六次。除了表面電鍍外， 這類模具的用途與鑄造模相似。注射模的優(yōu)點(diǎn)是：1、 高速注射模適用于大批量生產(chǎn)是可能的; 2、 熱塑性材料的廣泛選擇產(chǎn)生了各種有用的特性。3、 螺紋模具，飛邊，側(cè)孔大的薄壁結(jié)構(gòu)的應(yīng)用成為可能。 成型理論:板料沖壓成形成功機(jī)率著沖壓件形狀的復(fù)雜程度減少而增加,沖壓成形的目的是生產(chǎn)具有一定尺寸,形狀并有穩(wěn)定一致應(yīng)力狀態(tài),甚至無起皺無裂紋的沖壓件. 沖壓有一種至多種成形方式用來成型所需形狀,它們是彎曲,局部成形,拉深,局部成形用來成形,凹陷形狀或凸包,拉深用來成形,啤酒罐之類的沖壓件,隨著沖壓件的形狀越來越復(fù)雜,多種成形方法將會(huì)被用到同一零件的成型中,事實(shí)上,有很多沖壓件上同時(shí)有彎曲,局部成型,拉深模具成型的特征,通常有三種形式的模具,它們是自由成型,局部成形以及拉深形式. 自由成形 自由成形是用的最基本的一種成形材料的成形模具,這類模具只是簡(jiǎn)單地通過一個(gè)沖頭在壓力機(jī)下行過程中把材料“撞擊”進(jìn)入凹模中成形材料。得到的是由無控制材料流動(dòng)導(dǎo)致的應(yīng)罰狀態(tài)的沖壓件，由無約束材料流動(dòng)產(chǎn)生的“松弛金屬區(qū)”的出現(xiàn)，沖壓件尺寸和形狀上趨于不穩(wěn)定。 局部成形 成形工序中用一壓邊圈來控制材料流動(dòng)壓邊圈是置于模具上的一個(gè)多壓裝置，由帶壓邊圈模具成形的沖壓件可分為三部分，它們分別是產(chǎn)品表面，壓邊圈以及連接這兩部分的壁，在凸模一端壁與壁之間的角稱作凸模過渡區(qū)。 凸模模穴理論上是在壁與壓邊圈面的交叉處，凸模被置于凸模穴之中，而壓邊圈被放在凸模穴外凸模的周圍，這種模具還有上面的裝置將壓邊圈與凸模聯(lián)接起來，片料或工序件放到指定位置后壓力機(jī)下行，上模開始接觸片料，壓邊圈在凸模周圍的材料上壓出一些鎖緊臺(tái)階或筋，從防止成形過程中材料從壓邊圈流向凸模部分隨壓邊圈不再發(fā)生作用，材料不斷地變形直到成形為凸模下部成形部分形狀，在壓力機(jī)回程時(shí)，模具做與下行時(shí)相反的動(dòng)作，最后已經(jīng)成形的沖壓件被從模具上移走，就完成了一沖局部成形。 拉深 拉深的得名并不是因?yàn)椴牧显诔尚沃凶冃吻闆r得來，而是因?yàn)樵诶钸^程中材料進(jìn)入拉離壓邊圈表面，直入凸模下面盡管拉深變形產(chǎn)生在拉深模中，但很多局部成形，彎曲模在工作過程中也對(duì)板料進(jìn)行不同程度的拉深變形。 拉深模的工作機(jī)制，與局部成形模具非常類似，不同的是，在拉深模中，壓邊圈部分有特定的地方必須更加嚴(yán)格地控制材料流入凹模量，以防止起皺，拉深模中，控制材料流入是通過成形半月型的拉深筋來代替局部成形中的鎖緊臺(tái)階，一般在直邊部分設(shè)一至三條，以控制這部分的材料流入而在復(fù)雜邊部分少設(shè)或不設(shè)拉深筋，當(dāng)板料工序件放到模具相應(yīng)位置后，拉深的第一個(gè)階段是模具是板料以及壓邊圈的接觸. 毛坯上為考慮到拉深過程中毛坯圓周沿走私方向減少留有的法蘭邊,是所有材料中流動(dòng)最儔的地方,隨著壓力機(jī)滑塊繼續(xù)下行,材料變形流過凹模圓角半徑.板料開始形成與凸模一致的形狀，在拉深的工序中，這部分很少發(fā)生變形。被除數(shù)壓在凹模腔中的空氣由于凸模以及制件的下降而從氣孔中排出。 凸模、凹模的圓角半徑應(yīng)為4-6倍料厚以防止裂紋及起皺 隨著模具繼續(xù)閉合，校形開始發(fā)生，彎過凹模圓角材料，變形成鈑金件的直壁部分，壓邊圈下邊 的材料被拉入凹模并彎過凹模圓部分，考慮到防止材料被拉裂，凹模圓角半徑應(yīng)為4-10個(gè)料厚。毛坯變形情況為周向壓縮么向拉伸，這樣被拉入凹模圓腔中的工序稱為拉深，拉深過程有：摩擦壓縮、拉伸。因此，拉深過程中，壓力機(jī)必須提供足夠大的壓力，以克服拉深過程中的各種抗變形力，如：壓邊圈與毛坯間的靜摩擦力，額外的力也是必須的，用來克服拉深過程中滑支摩擦力?？朔蓧哼吶澾^凹模圓角在后面行程中校直成直壁材料的變形力。在毛坯被拉入凹模沉著凹模半徑變彎，在接下來變形中校直的同時(shí)，壓邊圈部分毛坯被沿周向壓縮。而且沿著圓周半徑方向上壓縮量隨著半徑增大而增大——半徑越大的地方，需壓縮的面積也大，這樣的結(jié)果是壓邊圈部分的材料變厚，而凸模部分的材料因?yàn)楸焕钭儽　Ｔ谟行├钪?，拉深變形使拉深壁變形成卷曲形或弓形。最薄的區(qū)域是沖壓件直壁與圓角過渡部分，因?yàn)檫@部分在拉深過程中拉伸變形最久，受力最大，這里往往也是最容易拉裂的地方，因?yàn)檫@部分的加工硬化少于其它地方。 拉深工序到壓力機(jī)行程下死點(diǎn)結(jié)束，拉深工序結(jié)束后，壓力機(jī)滑塊上行，模具打開，奢力圈在彈性元件作用下，從凸模上卸下包附在凸模上的沖壓件，沖頭下面沒有通氣孔，當(dāng)沖壓件被壓邊圈推起時(shí)，空氣可進(jìn)入。沖壓件離開凸模產(chǎn)生的真空部分如果不設(shè)通氣孔，沖壓件將很難脫出。 計(jì)算機(jī)輔助成型 ????采用計(jì)算機(jī)輔助工程（CAE）對(duì)加工設(shè)計(jì)及分析有助于縮短設(shè)計(jì)周期并可避免代價(jià)昂貴的機(jī)械失誤。商業(yè)性仿真代碼常用于流道上標(biāo)明尺寸，以平衡熔料在流道系統(tǒng)及型腔內(nèi)的流動(dòng)，同時(shí)確定澆口的最佳開設(shè)置和澆口的數(shù)目。計(jì)算注射壓力和合模噸位要根據(jù)不同的加工條件和材料而定。收縮率及翹曲率結(jié)合初始流向也可準(zhǔn)確估算出來。重要的是要使得這種設(shè)計(jì)工具幫助熟練分析人員在某個(gè)設(shè)計(jì)方案或加工研究時(shí)進(jìn)行判斷的操作。結(jié)果必須理解為以研究對(duì)象和加工/材料為前提。當(dāng)考慮采用這種方法準(zhǔn)確輸入數(shù)據(jù)后，可取得巨大的效益。另外，這種分析經(jīng)濟(jì)性可使設(shè)計(jì)周期更短和所需的生產(chǎn)時(shí)間更短。 ????應(yīng)該提醒注意的是，商業(yè)性的CAE程序通常是不可直接使用的。充模仿真可產(chǎn)生有價(jià)值的見識(shí)，但結(jié)果必須重新對(duì)其局限性進(jìn)行重新考慮估計(jì)。應(yīng)用現(xiàn)代計(jì)算機(jī)進(jìn)行注射成型模擬試驗(yàn)，僅限于純粘性流體（不包括粘彈性的熔融塑料）?？深A(yù)測(cè)熔體流入型腔的實(shí)際流動(dòng)速率組成結(jié)構(gòu)和性能公布等，如可進(jìn)行高精度的粘彈性分析。目前所采用的任何其它加工方式都不可能達(dá)到這種先進(jìn)水平，并且最近幾年來，由仿真設(shè)備的工業(yè)界帶頭者和大學(xué)里的研究小組已取得了良好的進(jìn)展。有幾家公司正在努力探索仿真技術(shù)，以求能正確地解釋更多現(xiàn)實(shí)的塑性行為和加工現(xiàn)象。例如，聚合物主鏈的取向?qū)植康奈锢硇阅芎托阅芊植嫉挠绊憽＜庸の锢韺W(xué)是非常復(fù)雜的，而某些粘彈性體現(xiàn)象仍然沒有完全弄清楚，更完善合理的加工方式目前正緩慢形成。這些更強(qiáng)的有力的方式將獲得大大超過目前所設(shè)計(jì)的生產(chǎn)能力。 共注射成型（芯層注射成型） ????采用共注射成型有助于觀察到制件中獨(dú)特的結(jié)構(gòu)。塑料“甲”先注射充入部分型腔，然后塑料：“乙”緊跟著“甲”注射進(jìn)入型腔并保持初始推動(dòng)流動(dòng)壓力場(chǎng)。根據(jù)表皮區(qū)和芯層的尺寸大小，按正確的比例關(guān)系計(jì)量出“甲”和“乙”的用料量，可制得1個(gè)內(nèi)芯層為“甲”外表完全由“乙”包裹的制件。 ????另外，在化妝品應(yīng)用方面，有小部分的表皮“甲”料放在“乙”料之后注射，以使?jié)部诓糠值谋砥つ芡耆]合。用2種不同顏色的樹脂進(jìn)行共注射成型的制件，形成一個(gè)容易區(qū)分的表皮和芯層區(qū)間（認(rèn)識(shí)到所有的注射成型件中存在有類似的表皮和芯層這一點(diǎn)非常重要。）如果沒有先進(jìn)的檢測(cè)技術(shù)，通常難以區(qū)分表皮—芯層的區(qū)域及其分界面。 ????共注射成型并非一門新的工藝技術(shù)。英國(guó)ici公司早在70年代就開始應(yīng)用這一技術(shù)，并取得了包括基礎(chǔ)理論，生產(chǎn)產(chǎn)品及機(jī)器設(shè)備等幾項(xiàng)專利。現(xiàn)普遍采用的ici生產(chǎn)工藝類似“三明治模塑”，由于模塑外層表皮的材料與中間或芯層的材料不同，因此兩種材料必須有一定的相容性，并且芯層材料要求具有可高度輻射、發(fā)泡成型和100%回收利用等性能。選用材料應(yīng)經(jīng)多種選擇比較而定。 共注射成型工藝問世15年后，才真正得以普及推廣。一種采用共注射成型的厚齒輸制作橫截面。 ????表皮材料是非填充尼龍，而芯層材料是玻璃-珠料-填充尼龍。芯層中玻璃珠粒料收縮率極低，具有良好的尺寸穩(wěn)定性。尼龍表皮賦予齒輪齒牙良好的潤(rùn)滑性并避免了珠粒料容易產(chǎn)生的磨蝕問題。 基于共注射成型的基礎(chǔ)理論目前已開發(fā)出幾種新型加工改進(jìn)方法。例如，模內(nèi)“上漆”和氣體輔助模塑成型擴(kuò)大了采用這種工藝的范圍。模內(nèi)上漆加工方法是采用低分子量聚合物作為外層材料，而氣體輔助模塑成型是采用氮?dú)饣蛄硪环N氣體作為芯層（或部分芯層）材料。隨著產(chǎn)品設(shè)計(jì)與生產(chǎn)加工設(shè)備的不斷完善改進(jìn)，將滿足各種新應(yīng)用和新技術(shù)的需求，共注射技術(shù)必將成為富有潛力的工業(yè)化大規(guī)模生產(chǎn)工藝方法。 交變注射成型 ????相比較而言，交變注射是一個(gè)比較新的注射成型選擇參數(shù)。這項(xiàng)技術(shù)的最大難點(diǎn)在于當(dāng)加工條件突然改變時(shí)，對(duì)塑料熔體將呈現(xiàn)出怎樣的變化行為知之甚少。有關(guān)熔體流變學(xué)的基礎(chǔ)知識(shí)，不僅僅是固定的剪切粘度。確切地說，熔體響應(yīng)（粘性和彈性行為）需要表達(dá)的特性，不僅是通常的穩(wěn)態(tài)流動(dòng)速率或剪切速率及溫度，也包括壓力及瞬間流動(dòng)速率。這些特性包括很多內(nèi)容而且十分難于弄清楚。然而，如果在異型材注射方面取得實(shí)質(zhì)性進(jìn)展，將需制訂出多種不同塑料的具體操作規(guī)程。另還需增加通用的累試法，以求得到成熟和精確的控制方法。 在常規(guī)的注射成型中，型腔壁固定不變，某些情況下，還有利用在充模和保壓陷段移動(dòng)模壁?？刹捎?種不同的方法：移動(dòng)型腔壁方向垂直于分模線；旋轉(zhuǎn)或滑動(dòng)型腔壁。在充模階段旋轉(zhuǎn)型芯以增加對(duì)制件尤其是表皮部分分子的變軸取向。通過這種加工工藝，制件的彎曲性能與其它機(jī)械性能得到了極大的提高。聚苯乙飲水杯和聚丙烯注射器就是采用這種加工方法獲得重大改變突破地2個(gè)產(chǎn)品。 Injection mold design and the new-type injekt by shaping technologe The plastic injection mold is in the present all plastics mold，uses the broadest mold, can take shape the complex high accuracy，plastic product. Under only is sketchily introduces. The design plastic injection mold first must have the certain，understanding to the plastic, the plastic principal constituent is a polymer. Like we often said the ABS plastic then is the propylene nitrile, the pyprolylene, the styrene three kind of monomers uses the emulsion, the main body or aerosol gathers the legitimate production,enable it to have three kind of monomers the high performance and may the compression molding, injects under the certain temperature and the pressure to the mold cavity, has the flow distortion, the obtaining cavity shape, after guarantees presses cooling to go against becomes the plastic product. The polymer member assumes the chain shape structure generally, the linear molecule chain and a chain molecule thought is the thermoplastic, may heat up the cooling processing repeatedly, but passes through heats up many members to occur hands over the association response, including forms netted the build molecular structure plastic usually is this, cannot duplicate injects the processing, also is the thermosetting plastics which said. Since is the chain shape structure, that plastic when processing contracts the direction also is with the polymer molecular chain under the stress function the orientation and the cooling contraction related, must be more than in the flow direction contraction its vertical direction in contraction. The product contraction also with the product shape, the runner, the temperature,guarantees presses factor and so on time and internal stress concerns.In the usual book provides the shrinkage scope is broad, considers is product wall thickness, the structure and the determination casts the temperature pressure size when the practical application and the orientation. The common product if does not have the core strut, the contraction correspondingly wants big. The plastic casts the mold basically to divide into the static mold and to move the mold. Injection Molding . Injection molding is principally used for the production of thermolplastic part ,although some progress has been made in developing a method for injection molding some thermosetting materials .The problem of injecting a melted plastic into a mold cavity from a reservoir of melted material has been extremely difficult to solve for thermosetting plastics which cure and harden under such conditions within a few minutes 。The principle of injection molding is quite similar to that of die-casting . Plastic powder is loaded into the feed hopper and a certain amount feeds into the heating chamber when the plunger draws back . This plastic powder under heat and pressure in the heating chamber becomes a fluid. Heating temperatures range from 265 to 500F . After the mold is closed , the plunger moves forward some of the fluid plastic into the mold cavity under pressures ranging from 12000 to 30000 psi . Since the mold is cooled by circulating cold water , the plastic hardens and the part may be ejected when the plunger draws back and the mold opens .Injection-molding machines can be arranged for manual operation, automatic single-cycle operation , and full automatic operation . Typical machines produce molded parts weighing up to 22 ounces at the rate of four shots per minute , and it is possible on some machines to obtain a rate of six shots per minute . The molds used are similar to the dies of a die-casting machine with the exception that the surfaces are chromium-plated . The advantages of injection molding are : 1. A high molding speed adapted for mass production is possible. 2. There is a wide choice of thermoplastic materials providing a variety of useful properties. 3. It is possible to mold threads , undercuts , side holes ,and large thin sections. Forming Theory:The confidence level in successfully forming a sheetmetal stamping increases as the simplicity of the part’s topography increases. The goal of forming with stamping technologies is to produce stampings with complex geometric surfaces that are dimensionally accurate and repeatable with a certain strain distribution, yet free from wrinkles and splits. Stampings have one or more forming modes that create the desired geometries. These modes are bending, stretch forming and drawing. Stretching the sheetmetal forms depressions or embossments. Drawing compresses material circumferentially to create stampings such as beer cans.As the surfaces of the stamping become more complex, more than one mode of forming will be required. In fact, many stampings have bend, stretch and draw features produced in the form die. The common types of dies that shape material are solid form, stretch form and draw. Solid Form The most basic type of die used to shape material is the solid form die. This tool simply displaces material via a solid punch “crashing” the material into a solid die steel on the press downstroke. The result is a stamping with uncontrolled material flow in terms of strain distribution. Since “l(fā)oose metal” is present on the stamping, caused by uncontrolled material flow, the part tends to be dimensionally and structurally unstable. Stretch Form Forming operations that provide for material flow control do so with a blankholder. The blankholder is a pressurized device that is guided and retained within the die set. Stampings formed with a blankholder may be described as having three parts, They are the product surface, blankholder surface and a wall that bridges the two together. The theoretical corner on the wall at the punch is called the punch break. The punch opening is the theoretical intersection at the bottom of the draw wall with the blankholder. The male punch is housed inside the punch opening, whereas the blankholder is located around the punch outside the punch opening. These tools have a one-piece upper member that contacts both the blankholder and punch surfaces. A blank or strip of material is fed onto the blankholder and into location gauges. On the press downstroke, the upper die member contacts the sheet and forms a lock step or bead around the outside perimeter of the punch opening on the blankholder surface to prevent material flow off the blankholder into the punch. The blankholder then begins to collapse and material stretches and compresses until it takes the shape of the lower punch. The die actions reverse on the press upstroke, and the formed stamping is removed from the die. Draw The draw die has earned its name not from the mode of deformation, but from the fact that the material runs in or draws off the blankholder surface and into the punch. Although the draw mode of deformation is present in draw dies, some degree of the stretch forming and bending modes generally also are present. The architecture and operational sequence for draw dies is the same as stretch-form dies with one exception. Material flow off the blankholder in draw dies needs to be restrained more in some areas than others to prevent wrinkling. This is achieved by forming halfmoon-shaped beads instead of lock steps or beads found in stretch-form dies. The first stage of drawing sheetmetal, after the blank or strip stock has been loaded into the die, is initial contact of the die steel with the blank and blankholder. The blank, round for cylindrical shells to allow for a circumferential reduction in diameter, is firmly gripped all around its perimeter prior to any material flow. As the press ram continues downward, the sheetmetal bends over the die radius and around the punch radius. The sheetmetal begins to conform to the geometry of the punch.Very little movement or compression at the blank edge has occurred to this point in the drawing operation. Air trapped in the pockets on the die steel is released on the press downstroke through air vents. The die radius should be between four and 10 times sheet thickness to prevent wrinkles and splits. Straightening of sheetmetal occurs next as the die continues to close. Material that was bent over the die radius is straightened to form the draw wall. Material on the blankholder now is fed into the cavity and bent over the die radius to allow for straightening without fracture. The die radius should be between four and 10 times sheet thickness to prevent wrinkles and splits. The compressive feeding or pulling of the blank circumferentially toward the punch and die cavity is called drawing. The draw action involves friction, compression and tension. Enough force must be present in drawing to overcome the static friction between the blank and blankholder surfaces. Additional force is necessary during the drawing stage to overcome sliding or dynamic friction and to bend and unbend the sheet from the blankholder surface to the draw wall. As the blank is drawn into the punch, the sheetmetal bends around the die radius and straightens at the draw wall. To allow for the flow of material, the blank is compressed. Compression increases away from the die radius in the direction of material flow because there is more surface area of sheetmetal to be squeezed. Consequently, the material on the blankholder surface becomes thicker.The tension causes the draw wall to become thinner. In some cases, the tension causes the draw wall to curl or bow outward. The thinnest area of the sheet is at the punch radius, and gradually tapers thicker from the shock line to the die radius. This is a probable failure site because the material on the punch has been work-hardened the least, making it weaker than the strain hardened material. The drawing stage continues until the press is at bottom dead center. With the operation now complete, the die opens and the blankholder travels upward to strip the drawn stamping off of the punch. Air vents provided in flat or female cavities of the punch allow air to travel under the material as it is lifted by the blankholder. The stamping will have a tendency to turn inside out due to vacuum in the absenceof air vents. Computers Supplementary Shaping Adopt computer assist project( CAE) design and analyse and help and shorten design cycle and prevent cost from expensive mechanical fault processing. Commercial emulations daily to indicate size on flowing one code, melt material flows in flowing dishes of system and type with balance, The figure of offeredding and put bestly and runner defining runner at the same time . Calculate pressure of injecting and shut mould want at different processing terms and material fix by tonnage. And warping rate combine initial to flow into too very accurate to estimate out person who shrink. What is important is and want and make the design tool help and analyse personnel process and go on the operation judged while studying or in a certain plan of design skillfully. Understand at results and can't process in order that it is by research object /materials from prerequisite. After consider adopting this kind of method accurate data-in , can make enormous benefit . In addition, economic make design cycle not to be short and needs produce shorter time the analysis. The one that should point out is, commercial cae procedures usually can't be used directly. It fills and imitate and produce valuable experience but the result must rethink its limitation to estimate again . Use modern computers go on and inject shaping simulated test and limited to pure viscidity fluids only( include the melting plastic of viscoplasticity ). One actual flow form measurable melting body person who flow intoes and performance announce etc. structure by speed, If can carry on the viscoplasticity analysis of high accuracy . At present adopt any other to process way reach this advanced competences, And recent years, at emulation the industrial circle person who take the leads of equipment and the research groups of university already made good progress. Have several a of companies make great efforts and probe emulation technology, in order to be be able to be being explained moulding the sex instinct act and process the phenomenon of more reality correctly. For example, get together on the influence that the orientation of the possessive chain is distributed to some physics performance and performance . Processing physics is very complicated, but some viscoplasticity is embodied too alike to still totally understood , Perfect the rational processing way and taking shape slow at present even more. These stronger strong ways will be exceeded the production capacity that will be designed at present greatly . Inject By Shaping Altogether( inject shaping of at core layers) Adopt and inject shaping help and observe and make one unique structure altogether. " first" of plastic is injected and fill and enter some types first, then the plastic: " second" follow " first" inject person who enter one and keep initial to drive pressure field of flowing closely. At epidermis district and core the sizes of one, measure and publish" first" and the materials quantities of" second" according to correct proportionate relationship, Make one at" first" complete at" second" to make one parcel appearance core each. In addition, in cosmetics application, the material is put after" second" material injecting to have" first" of epidermis of the small part, So that the epidermis of the part of the runner can be totally closed. Inject making one of shaping altogether with the resin of 2 kinds of different colors, form a piece of a layer of blocks of epidermis and core apt to distinguish (Realize inject shaping one as much as all have and have and one very much important this core similar epidermis. )If there is not advanced detection technique, usually difficult to distinguish the epidermis - core area and boundary of layer. Inject shaping a new technology altogether. British ici company began to use this technology in the 1970s early, and had made the basic theory of including, Produce several patents, such as the products and machinery equipment,etc.. Now similar to " mould mould sandwiches" what has been adopted generally ici production technologies,last outer the materials of the epidermis at moulds and in layers is material different on core occasionally, So two a kind of material person who a certain one inclusives, and core require and have high radiations very, issue and steep shaping and retrieve performance of utilizing etc at 100% by layers of material. Should be fixed relatively by the excellent choice to select the material for use. After injecting the shaping technology and come out in 15 altogether, can really just popularize and popularize . One a kind of adoptions inject the thick teeth of shaping fails and produces horizontal cross-section altogether. Material to pack nylon epidermis, and pearl material pack the nylon at - - glass layers of material core. A rate that shrinks material of pearl of glass is extremely low in core one, have good size stabilities. Nylon prevent pearl from grains of material easy problem of denuding that produces by epidermis person who give good and lubricated tooth tooth gear wheel. Already developed several kinds and processed the method of i