精密注射成型若干关键问题的研究
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摘要
近年来，“精密化、高效化、轻薄化”作为未来注射成型技术发展的方向得到了广泛的研究。本文中研制了一套用于精密注射成型可视化研究的装置，建立了精密注射成型中一模多腔“H”型流道中不平衡充填现象的流动模型，利用可视化技术从熔体流动行为和温度参数分布两方面直观且全面的揭示了不平衡充填现象的产生机理。提出了一种采用超磁致伸缩材料制作前端控制式超高速注射成型的新方法，研制了高速精密注射机专用的磁致伸缩位移传感器。研究中开展的主要工作如下：
1．注射充模可视化实验平台的研制及应用
研制了一套注射充模可视化实验装置。利用该可视化装置研究了注射速度及重力作用对于熔体流动行为的影响。观察并记录了典型成型缺陷产生过程，包括喷射与蛇形流动、缩痕、气泡等，提出了解决这些成型缺陷的方法。
2．建立一模多腔不平衡流动理论模型，运用可视化及CAE模拟技术揭示不平衡充填现象的产生机理
建立了“H”型流道中由于熔体截面温度分布不匀而造成不平衡流动的熔体流动模型，指出剪切生热对于流道中熔体截面温度分布的影响明显，不均衡的温度分布结果是造成不平衡充填的最终原因。利用“H"型流道中熔体充填过程的静态和动态可视化实验结果以及熔体温度参数变化结果直观而全面揭示了充填不平衡现象的产生机理。提出了一种不修改模具流道结构就可明显改善不平衡充填结果的“两步注射法”。研究结果为完善一模多腔不平衡充填过程的CAE模拟提供了依据。
3．提出一种基于超磁致伸缩材料的超高速注射成型新方法
为解决传统超高速注射成型中螺杆作为执行元件在高应答性和控制精度上的局限，提出了一种通过在注射螺杆前端设置一个具有高响应速度、可灵敏控制的喷嘴，注射之前关闭喷嘴，预先对熔体进行压缩，通过控制喷嘴开关状态和开启量来释放熔体实现超高速注射的新方法。引入稀土超磁致伸缩材料来制作具有高响应速度、可灵敏控制的电磁阀，用于控制喷嘴的开关状态和开启量大小。这种基于超磁致伸缩材料的超高速注射新方法在国内外文献中没有报道。
4．前端控制式超高速注射成型关键部件的研制及相关实验研究
提出了可控喷嘴用超磁致伸缩微位移驱动器的设计理论和方法，通过理论分析计算优化了驱动线圈和控制电路的设计。发明了一种基于杠杆原理将多级杠杆叠加的位移传递和放大机构，制造了超磁致伸缩位移驱动器实验样机。
采用不同材料对前端控制式超高速注射成型中喷嘴开启量、注射压力、注射速度之间的关系进行研究。实验结果表明，在压力恒定的条件下，可通过控制喷嘴开启量大小获得不同的注射充填速度。实验结果为探索超高速注射成型规律，建立相应的控制方法提供了基础。
5．磁致伸缩位移传感器的研制及性能研究
研制了精密注射机专用的高精度磁致伸缩位移传感器。在现行高速精密注射机上分别将磁尺和电子尺用于注射机螺杆位移测量，针对螺杆预塑化量、螺杆转速、注塑速度和熔体背压四个相关工艺参数设定不同参数值采用正交实验法进行实验。结果表明，磁尺相对于电子尺具有更高的计量精度，并能得到更高的制品重量重复精度。磁尺受外界参数变化的影响更小，工作过程更稳定。研究结果从高精度计量方面为提高精密注塑机重复精度提供了一种可行方案。
Precision, high efficiency, and thin-wall injection molding, as the development trend of conventional injection molding, were widely studied in recent years. In this paper, a set of visualization device was designed and manufactured. A model of imbalance filling of precision injection molding in multi-cavity mold with "H" pattern runner system was established. The imbalance filling mechanism was clarified thoroughly by the visualization experimental results of melt flow behavior and the measurement results of melt temperature. A new method of ultra high speed injection molding based on giant magnetostrictive materials was proposed. A specific magnetostrictive displacement transducer used for high speed precision injection molding machine was developed. The main research results are as followed.
1. Development and application of visualization experimentaldevice for injection molding
A set of visualization experimental device was developed. Theinfluence of injection molding speed and gravity on melt flow behaviorwere studied with the visualization device. The generation processes of several typical injection molding defects, such as jetting and snake flow, sink mark and bubble, were directly observed and recorded. The methods of improving these defects were proposed.
2. Establishment and clarification of the model of imbalance filling mechanism in multi-cavity mold with "H" pattern runner system
On the basis of the theory analyzing, the model of imbalance filling mechanism in multi-cavity mold with "H" pattern runner system was supposed. It is clarified that the mechanism of imbalance filling results from dissymmetrical temperature distribution on the cross-section of runner, which is strongly influenced by the shear heat and the cooling process in the runner. The imbalance filling mechanism was clarified thoroughly by the visualization experimental results of melt flow behavior and the measurement results of melt temperature. The method of improving imbalance filling named "two-step" process was proposed.
3. A new method of ultra high speed injection molding
The conventional injection molding machine to implement ultra high speed injection molding was restricted by the controlling response and precision of screw advance. Therefore, a new type of injection system with a quick response nozzle based on giant magnetostrictive materials (GMM) is proposed in this paper. The injection system is capable of implementing ultra high speed injection molding through controlling port width of nozzle, meanwhile, melts with sufficient pre-compress potential energy under under constant injection molding pressure with a hydraulic accumulator system. The method of implementing ultra high speed injection molding is never reported in the literatures.
4. Development and experimental study of the key parts of foreside control ultra high speed injection molding
The designing theories and methods of microdisplacement actuator for controllable nozzle based on GMM are proposed. The designing process of such components as microdisplacement transfer and amplifier mechanism, driving coil and control circuitry is presented particularly. Furthermore, a new type of multilevel lever mechanism was invented to transfer and magnify output microdisplacement. A sample of microdisplacement actuator based on GMM manufactured.
The influence of nozzle port opening width parameter on injection speed under different injection pressures was investigated in this paper. As a result, it was found that injection speed could be increased through varying nozzle port opening width under keeping constant injection pressure. The results obtained from this study are valuable for establishment of control theory of foreside-control high speed injection molding.
5. Development and experimental study of magnetostrictive displacement transducer
A magnetostrictive displacement transducer special for precision injection molding was developed. Both potentiometer and magnetostrictive displacement sensor used to measure the displacement of screw. The influence of such parameters as preform and speed of screw, injection speed and back pressure was studied with orthogonal experiment method. The results showed that the higher measurement precision and higher repeatability of products can be obtained by adopting magnetostrictive displacement transducer. And magnetostrictive displacement transducer is less impacted by surrounding environment factors. The research results provide a solution method for improving precision injection molding repeatability.
1．注射充模可视化实验平台的研制及应用
研制了一套注射充模可视化实验装置。利用该可视化装置研究了注射速度及重力作用对于熔体流动行为的影响。观察并记录了典型成型缺陷产生过程，包括喷射与蛇形流动、缩痕、气泡等，提出了解决这些成型缺陷的方法。
2．建立一模多腔不平衡流动理论模型，运用可视化及CAE模拟技术揭示不平衡充填现象的产生机理
建立了“H”型流道中由于熔体截面温度分布不匀而造成不平衡流动的熔体流动模型，指出剪切生热对于流道中熔体截面温度分布的影响明显，不均衡的温度分布结果是造成不平衡充填的最终原因。利用“H"型流道中熔体充填过程的静态和动态可视化实验结果以及熔体温度参数变化结果直观而全面揭示了充填不平衡现象的产生机理。提出了一种不修改模具流道结构就可明显改善不平衡充填结果的“两步注射法”。研究结果为完善一模多腔不平衡充填过程的CAE模拟提供了依据。
3．提出一种基于超磁致伸缩材料的超高速注射成型新方法
为解决传统超高速注射成型中螺杆作为执行元件在高应答性和控制精度上的局限，提出了一种通过在注射螺杆前端设置一个具有高响应速度、可灵敏控制的喷嘴，注射之前关闭喷嘴，预先对熔体进行压缩，通过控制喷嘴开关状态和开启量来释放熔体实现超高速注射的新方法。引入稀土超磁致伸缩材料来制作具有高响应速度、可灵敏控制的电磁阀，用于控制喷嘴的开关状态和开启量大小。这种基于超磁致伸缩材料的超高速注射新方法在国内外文献中没有报道。
4．前端控制式超高速注射成型关键部件的研制及相关实验研究
提出了可控喷嘴用超磁致伸缩微位移驱动器的设计理论和方法，通过理论分析计算优化了驱动线圈和控制电路的设计。发明了一种基于杠杆原理将多级杠杆叠加的位移传递和放大机构，制造了超磁致伸缩位移驱动器实验样机。
采用不同材料对前端控制式超高速注射成型中喷嘴开启量、注射压力、注射速度之间的关系进行研究。实验结果表明，在压力恒定的条件下，可通过控制喷嘴开启量大小获得不同的注射充填速度。实验结果为探索超高速注射成型规律，建立相应的控制方法提供了基础。
5．磁致伸缩位移传感器的研制及性能研究
研制了精密注射机专用的高精度磁致伸缩位移传感器。在现行高速精密注射机上分别将磁尺和电子尺用于注射机螺杆位移测量，针对螺杆预塑化量、螺杆转速、注塑速度和熔体背压四个相关工艺参数设定不同参数值采用正交实验法进行实验。结果表明，磁尺相对于电子尺具有更高的计量精度，并能得到更高的制品重量重复精度。磁尺受外界参数变化的影响更小，工作过程更稳定。研究结果从高精度计量方面为提高精密注塑机重复精度提供了一种可行方案。
Precision, high efficiency, and thin-wall injection molding, as the development trend of conventional injection molding, were widely studied in recent years. In this paper, a set of visualization device was designed and manufactured. A model of imbalance filling of precision injection molding in multi-cavity mold with "H" pattern runner system was established. The imbalance filling mechanism was clarified thoroughly by the visualization experimental results of melt flow behavior and the measurement results of melt temperature. A new method of ultra high speed injection molding based on giant magnetostrictive materials was proposed. A specific magnetostrictive displacement transducer used for high speed precision injection molding machine was developed. The main research results are as followed.
1. Development and application of visualization experimentaldevice for injection molding
A set of visualization experimental device was developed. Theinfluence of injection molding speed and gravity on melt flow behaviorwere studied with the visualization device. The generation processes of several typical injection molding defects, such as jetting and snake flow, sink mark and bubble, were directly observed and recorded. The methods of improving these defects were proposed.
2. Establishment and clarification of the model of imbalance filling mechanism in multi-cavity mold with "H" pattern runner system
On the basis of the theory analyzing, the model of imbalance filling mechanism in multi-cavity mold with "H" pattern runner system was supposed. It is clarified that the mechanism of imbalance filling results from dissymmetrical temperature distribution on the cross-section of runner, which is strongly influenced by the shear heat and the cooling process in the runner. The imbalance filling mechanism was clarified thoroughly by the visualization experimental results of melt flow behavior and the measurement results of melt temperature. The method of improving imbalance filling named "two-step" process was proposed.
3. A new method of ultra high speed injection molding
The conventional injection molding machine to implement ultra high speed injection molding was restricted by the controlling response and precision of screw advance. Therefore, a new type of injection system with a quick response nozzle based on giant magnetostrictive materials (GMM) is proposed in this paper. The injection system is capable of implementing ultra high speed injection molding through controlling port width of nozzle, meanwhile, melts with sufficient pre-compress potential energy under under constant injection molding pressure with a hydraulic accumulator system. The method of implementing ultra high speed injection molding is never reported in the literatures.
4. Development and experimental study of the key parts of foreside control ultra high speed injection molding
The designing theories and methods of microdisplacement actuator for controllable nozzle based on GMM are proposed. The designing process of such components as microdisplacement transfer and amplifier mechanism, driving coil and control circuitry is presented particularly. Furthermore, a new type of multilevel lever mechanism was invented to transfer and magnify output microdisplacement. A sample of microdisplacement actuator based on GMM manufactured.
The influence of nozzle port opening width parameter on injection speed under different injection pressures was investigated in this paper. As a result, it was found that injection speed could be increased through varying nozzle port opening width under keeping constant injection pressure. The results obtained from this study are valuable for establishment of control theory of foreside-control high speed injection molding.
5. Development and experimental study of magnetostrictive displacement transducer
A magnetostrictive displacement transducer special for precision injection molding was developed. Both potentiometer and magnetostrictive displacement sensor used to measure the displacement of screw. The influence of such parameters as preform and speed of screw, injection speed and back pressure was studied with orthogonal experiment method. The results showed that the higher measurement precision and higher repeatability of products can be obtained by adopting magnetostrictive displacement transducer. And magnetostrictive displacement transducer is less impacted by surrounding environment factors. The research results provide a solution method for improving precision injection molding repeatability.
引文
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