基于Unigraphics软件的汽车内饰件塑料模具设计
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摘要
当今,随着塑料工业的迅速发展,塑料制品在许多工业部门的应用范围越来越广,这就使产品对注塑模具的要求越来越高,传统的注塑模具设计方法已无法适应产品更新换代和提高质量的要求。
本文从国内注塑模CAD/CAE技术与国际先进技术水平的差距和急需解决的问题着手,提出了注塑模集成CAD/CAE的思想,并结合实际注塑模具设计的范例,实现了典型注塑件(哈飞赛马轿车的中央饰罩)注塑模CAD/CAE的集成。
本文重点进行了中央饰罩的三维实体造型、注塑模CAE分析及整套注塑模具的设计。首先,采用UG软件进行注塑件的三维实体造型,针对轿车内饰件的具体外形尺寸,应用基于特征的实体建模和自由形状建模等知识,使用体素特征、扫描特征、成形特征、特征操作、实体冲压等具体的操作步骤逐步生成汽车内饰件,并生成面网格文件。其次,利用仿真软件Moldflow对该注塑件进行充填、流动、冷却、气穴、熔接痕、翘曲等数值模拟。通过对注塑件充型模拟,能够直观的显现出液态塑料在型腔内充型及流动的变化过程,进而比较熔接痕、气穴、翘曲等缺陷,来进行浇注系统的优化设计。最后利用UG软件的Moldwizard模块进行整套注塑模具的设计。
通过该课题的研究,可以直观的再现塑料模具设计的全过程,很好的体现并验证了模具设计的思路,对塑料模具设计企业有一定的指导意义。
With the rapid development of plastic industry, the application of plastic products in many industrial sectors is used more and more widely nowadays. However, conventional design method of plastic mold is not adapted to the requirement of renewal and higher quality of products. So these products require a higher quality of plastic mold.
According to the problems needed to solve urgently and technology gap of CAD/CAE between our nation and foreign countries in the region of plastic mold, this article put forward the integrated idea of CAD/CAE and realize the integrated design of center adorning cover which is one of typical injection product in SaiMa car of Harbin Hafei Motor Co., LTD. This work is finished combined with practical design examples of injection mold.
This article focus on 3D solid modeling of center adorning cover, CAE analysis and complete design of injection mold.
First, 3D solid modeling of injection product should be completed by UG software. Directing towards the particular shape size of the adornment, the modeling and girding file was built by steps of body element feature, scanning feature, figuration feature, feature operation, solid pressing and so on, which was realized by using knowledge of solid modeling and free shape modeling.
Second, numerical simulation of filling, flow, air pocket, fusion trace, and warp were performed with simulation software Mold flow. The filling process and flow transformation of liquid plastic were shown obviously by numerical simulation of filling. Through which we could optimize the casting system and compare the defects and flaws of fusion trace, air pocket and warp.
Finally, complete design of injection mold was performed by Mold wizard
本文从国内注塑模CAD/CAE技术与国际先进技术水平的差距和急需解决的问题着手,提出了注塑模集成CAD/CAE的思想,并结合实际注塑模具设计的范例,实现了典型注塑件(哈飞赛马轿车的中央饰罩)注塑模CAD/CAE的集成。
本文重点进行了中央饰罩的三维实体造型、注塑模CAE分析及整套注塑模具的设计。首先,采用UG软件进行注塑件的三维实体造型,针对轿车内饰件的具体外形尺寸,应用基于特征的实体建模和自由形状建模等知识,使用体素特征、扫描特征、成形特征、特征操作、实体冲压等具体的操作步骤逐步生成汽车内饰件,并生成面网格文件。其次,利用仿真软件Moldflow对该注塑件进行充填、流动、冷却、气穴、熔接痕、翘曲等数值模拟。通过对注塑件充型模拟,能够直观的显现出液态塑料在型腔内充型及流动的变化过程,进而比较熔接痕、气穴、翘曲等缺陷,来进行浇注系统的优化设计。最后利用UG软件的Moldwizard模块进行整套注塑模具的设计。
通过该课题的研究,可以直观的再现塑料模具设计的全过程,很好的体现并验证了模具设计的思路,对塑料模具设计企业有一定的指导意义。
With the rapid development of plastic industry, the application of plastic products in many industrial sectors is used more and more widely nowadays. However, conventional design method of plastic mold is not adapted to the requirement of renewal and higher quality of products. So these products require a higher quality of plastic mold.
According to the problems needed to solve urgently and technology gap of CAD/CAE between our nation and foreign countries in the region of plastic mold, this article put forward the integrated idea of CAD/CAE and realize the integrated design of center adorning cover which is one of typical injection product in SaiMa car of Harbin Hafei Motor Co., LTD. This work is finished combined with practical design examples of injection mold.
This article focus on 3D solid modeling of center adorning cover, CAE analysis and complete design of injection mold.
First, 3D solid modeling of injection product should be completed by UG software. Directing towards the particular shape size of the adornment, the modeling and girding file was built by steps of body element feature, scanning feature, figuration feature, feature operation, solid pressing and so on, which was realized by using knowledge of solid modeling and free shape modeling.
Second, numerical simulation of filling, flow, air pocket, fusion trace, and warp were performed with simulation software Mold flow. The filling process and flow transformation of liquid plastic were shown obviously by numerical simulation of filling. Through which we could optimize the casting system and compare the defects and flaws of fusion trace, air pocket and warp.
Finally, complete design of injection mold was performed by Mold wizard
引文
1 魏凤兰等.工程塑料在农业机械上的应用现状及发展前景.沈阳农业大学学报,2002,33(4):305~308
2 王正远.Practical Handbook of Engineering Plastics. 北京:中国物资出版社,1994,(2):7~9
3 朱芝培.国内外汽车用塑料概况及新的成型方法.化工新材料,2005,26(12):3~7
4 李文耀等.塑料在汽车工业的应用与发展前景.重型汽车,2004,(3):20~22
5 曹文鑫.塑料在汽车工业的应用与发展.国际化工信息,2002, (11): 7~10
6 刘寿华.国内外汽车用塑料的现状和发展前景.现代塑料加工应用,1996,8(6):54~57
7 李熙尹.中国汽车塑料的现状和发展方向.汽车工艺与材料,2000,1:1~2
8 Robert Brown . International Magnesium Association 54th Annual World Conference.light Metal Age,1999:72~73
9 Manzione L T. Applications of Computer-Aided Engineering in Injection Molding Munich: Hanset, 1997:32~33
10 Tadmor Z, et al. Engineering Principles of Plasticating Extrusion. New York: Wiley-Interscience, 1990:76~78
11 朱芝培.国内外汽车用塑料的现状和展望(1).化工新型材料,2001,29(5):12~15
12 朱芝培.国内外汽车用塑料的现状和展望(2).化工新型材料,2001,29(6):5~6
13 朱芝培.国内外汽车用塑料的现状和展望(3).化工新型材料,2001,29(7):24~26
14 王旭.最新塑料成型工艺与模具.上海:上海出版社,1996:4~6
15 刘实骧,于俪.注塑模具的新技术.机械研究与应用,2002,15(1):76~77
16 Robert Brown . International Magnesium Association 54th Annual WorldConference.light Metal Age,1997:72~73
17 赵新,向惠.注塑模具设计中计算机辅助设计应用.山东大学学报,2001,31(4):55~59
18 轩景全,连建设.注塑模具 C AD 技术的基础研究.合成树脂与塑料,2000,17(3):30~32
19 Deck R F , Carnahan R , Vining Retal . Progress in Thixomold- ing.PICSPAC,1996:221~224
20 罗计香.浅析我国模具行业现状及发展趋势和对策.模具技术,2001,(3): 72~78
21 邱建新.模具工业发展趋势综述.CAD/CAM 与制造业信息化,2003,11(3):3~7
22 Paul M.Brulower.Automotive Die Casting Magnesium Reviving up for 21th Century.Die Casting Engineer,1997,41(3):68~70
23 Yong K P.Recent Advances in Semi-solid Metal(SSM)Cast Aluminum and Magnesium Components.PICSPAC,1992:149~158
24 周永泰.模具产品目前水平及今后发展趋势.中国模具工业,2000,(3):39~43
25 K.S.Tong,B.H.Hu.Cavity Pressure Measurements and Process Monitoring for Magnesium Die Casting of a Thin-wall Hand-phone Component to Improve Quality . Journal of Materials Processing Technology , 2002 , 127(2) :238~241
26 孔庆复.计算机辅助设计与制造.哈尔滨工业大学出版社,1997:73~74
27 唐选.塑料模具技术的发展趋势.模型世界,2003,(9):13~14
28 胡行君.推动我国汽车模具业的发展.模具技术,2004,(5):54~59
29 黄春曼,闵好年,张淑珍.中文 Unigraphics NX 模具设计案例教程.冶金工业出版社,2004:1~2
30 宋建军,杜诗文,闫献国.汽车虚拟设计中 UG 的应用.太原重型机械学院学报,2002,23(2):156~157
31 邹浩波,张宇等.基于 UG 的鼠标上盖模腔的 CAD/CAM.现代机械,2005,(6):53~54
32 王晓枫,赵春亮,王亮.基于 UG NX 的型腔零件 3D 建模与 NC 加工.机械工程与自动化,2005,(6):25~26
33 唐春文等.中文 Unigraphics NX 高级应用与实例.北京:冶金工业出版社,2004:15~16
34 张嘉钰,刘永强.Unigraphics 及其应用.河北工业科技,1999,16(2):58
35 Unigraphics Solutions Inc.UG 自由形状特征建模培训教程.北京:清华大学出版社,2002:5~6
36 张冶,洪雷.Unigraphics NX 三维工程设计与渲染教程.北京:清华大学出版社,2004:47~106
37 Unigraphics Solutions Inc.UG 钣金设计培训教程.北京:清华大学出版社,2002:112~113
38 黄汉勇.使用 MOLDFLOW 的分析功能以得到满意的注射方案.机械开发,1996,(1):26~27
39 虞兴翔,管文浩.跨世纪的 MOLDFLOW.模具技术,1998,(4):89~91
40 文劲松,麻向军.塑料成型加工模拟技术及软件应用.计算机辅助工程,2003:(4):57~59
41 张小甫,阎峰云,王翠香等.MoldFlow 和 Plastic Advisor 在注塑成型中的应用.模具技术,2004,(2):14~16
42 黄汉勇.使用 MoldFlow 的分析功能以得到满意的注射方案.计算机应用,2000,(3):25~26
43 于同敏,路全胜,葛东东.影响注塑制品尺寸的因素及控制措施.塑料科技,1994,(3):21~22
44 W.C.Bushko,V.K.Stokes.Solidfication of Thermoviscoelastic Melts.PartⅡ:Effect of Processing Conditions on Shrinkage and Residual Stress. Polymer Engineering and Science,1996,(36):352~364
45 W.C.Bushko,V.K.Stokes.Solidfication of Thermoviscoelastic Melts.PartⅢ:Effect of Molds Temperature Difference on Warpage and Residual Stress.Polymer Engineering and Science,1996,(36):365~377
46 W.C.Bushko,V.K.Stokes.Solidfication of Thermoviscoelastic melts.PartⅣ:Effect of Boundary Conditions on Shrinkage and Residual Stress.Polymer Engineering and Science,1996,(36):658~671
47 T.H.Kwon . Mold Cooling System Design Using Boundary Element Method.ASME Journal of Engineering for Industry,1988,(110):384~394
48 J.C.Lin . Optimum Gate Design of FreeForm Injection Mould using the Abbuctive Network.Advanced manufacturing technology,2001,(17):297~304
49 刘春太,陈静波.注塑成型 CAE 技术的研究进展和发展趋势.郑州工学院学报,1996,(3):115~117
50 文劲松,麻向军.CAD/CAE 软件在注塑模具技术中的应用.模具技术,2003,(5):17~19
2 王正远.Practical Handbook of Engineering Plastics. 北京:中国物资出版社,1994,(2):7~9
3 朱芝培.国内外汽车用塑料概况及新的成型方法.化工新材料,2005,26(12):3~7
4 李文耀等.塑料在汽车工业的应用与发展前景.重型汽车,2004,(3):20~22
5 曹文鑫.塑料在汽车工业的应用与发展.国际化工信息,2002, (11): 7~10
6 刘寿华.国内外汽车用塑料的现状和发展前景.现代塑料加工应用,1996,8(6):54~57
7 李熙尹.中国汽车塑料的现状和发展方向.汽车工艺与材料,2000,1:1~2
8 Robert Brown . International Magnesium Association 54th Annual World Conference.light Metal Age,1999:72~73
9 Manzione L T. Applications of Computer-Aided Engineering in Injection Molding Munich: Hanset, 1997:32~33
10 Tadmor Z, et al. Engineering Principles of Plasticating Extrusion. New York: Wiley-Interscience, 1990:76~78
11 朱芝培.国内外汽车用塑料的现状和展望(1).化工新型材料,2001,29(5):12~15
12 朱芝培.国内外汽车用塑料的现状和展望(2).化工新型材料,2001,29(6):5~6
13 朱芝培.国内外汽车用塑料的现状和展望(3).化工新型材料,2001,29(7):24~26
14 王旭.最新塑料成型工艺与模具.上海:上海出版社,1996:4~6
15 刘实骧,于俪.注塑模具的新技术.机械研究与应用,2002,15(1):76~77
16 Robert Brown . International Magnesium Association 54th Annual WorldConference.light Metal Age,1997:72~73
17 赵新,向惠.注塑模具设计中计算机辅助设计应用.山东大学学报,2001,31(4):55~59
18 轩景全,连建设.注塑模具 C AD 技术的基础研究.合成树脂与塑料,2000,17(3):30~32
19 Deck R F , Carnahan R , Vining Retal . Progress in Thixomold- ing.PICSPAC,1996:221~224
20 罗计香.浅析我国模具行业现状及发展趋势和对策.模具技术,2001,(3): 72~78
21 邱建新.模具工业发展趋势综述.CAD/CAM 与制造业信息化,2003,11(3):3~7
22 Paul M.Brulower.Automotive Die Casting Magnesium Reviving up for 21th Century.Die Casting Engineer,1997,41(3):68~70
23 Yong K P.Recent Advances in Semi-solid Metal(SSM)Cast Aluminum and Magnesium Components.PICSPAC,1992:149~158
24 周永泰.模具产品目前水平及今后发展趋势.中国模具工业,2000,(3):39~43
25 K.S.Tong,B.H.Hu.Cavity Pressure Measurements and Process Monitoring for Magnesium Die Casting of a Thin-wall Hand-phone Component to Improve Quality . Journal of Materials Processing Technology , 2002 , 127(2) :238~241
26 孔庆复.计算机辅助设计与制造.哈尔滨工业大学出版社,1997:73~74
27 唐选.塑料模具技术的发展趋势.模型世界,2003,(9):13~14
28 胡行君.推动我国汽车模具业的发展.模具技术,2004,(5):54~59
29 黄春曼,闵好年,张淑珍.中文 Unigraphics NX 模具设计案例教程.冶金工业出版社,2004:1~2
30 宋建军,杜诗文,闫献国.汽车虚拟设计中 UG 的应用.太原重型机械学院学报,2002,23(2):156~157
31 邹浩波,张宇等.基于 UG 的鼠标上盖模腔的 CAD/CAM.现代机械,2005,(6):53~54
32 王晓枫,赵春亮,王亮.基于 UG NX 的型腔零件 3D 建模与 NC 加工.机械工程与自动化,2005,(6):25~26
33 唐春文等.中文 Unigraphics NX 高级应用与实例.北京:冶金工业出版社,2004:15~16
34 张嘉钰,刘永强.Unigraphics 及其应用.河北工业科技,1999,16(2):58
35 Unigraphics Solutions Inc.UG 自由形状特征建模培训教程.北京:清华大学出版社,2002:5~6
36 张冶,洪雷.Unigraphics NX 三维工程设计与渲染教程.北京:清华大学出版社,2004:47~106
37 Unigraphics Solutions Inc.UG 钣金设计培训教程.北京:清华大学出版社,2002:112~113
38 黄汉勇.使用 MOLDFLOW 的分析功能以得到满意的注射方案.机械开发,1996,(1):26~27
39 虞兴翔,管文浩.跨世纪的 MOLDFLOW.模具技术,1998,(4):89~91
40 文劲松,麻向军.塑料成型加工模拟技术及软件应用.计算机辅助工程,2003:(4):57~59
41 张小甫,阎峰云,王翠香等.MoldFlow 和 Plastic Advisor 在注塑成型中的应用.模具技术,2004,(2):14~16
42 黄汉勇.使用 MoldFlow 的分析功能以得到满意的注射方案.计算机应用,2000,(3):25~26
43 于同敏,路全胜,葛东东.影响注塑制品尺寸的因素及控制措施.塑料科技,1994,(3):21~22
44 W.C.Bushko,V.K.Stokes.Solidfication of Thermoviscoelastic Melts.PartⅡ:Effect of Processing Conditions on Shrinkage and Residual Stress. Polymer Engineering and Science,1996,(36):352~364
45 W.C.Bushko,V.K.Stokes.Solidfication of Thermoviscoelastic Melts.PartⅢ:Effect of Molds Temperature Difference on Warpage and Residual Stress.Polymer Engineering and Science,1996,(36):365~377
46 W.C.Bushko,V.K.Stokes.Solidfication of Thermoviscoelastic melts.PartⅣ:Effect of Boundary Conditions on Shrinkage and Residual Stress.Polymer Engineering and Science,1996,(36):658~671
47 T.H.Kwon . Mold Cooling System Design Using Boundary Element Method.ASME Journal of Engineering for Industry,1988,(110):384~394
48 J.C.Lin . Optimum Gate Design of FreeForm Injection Mould using the Abbuctive Network.Advanced manufacturing technology,2001,(17):297~304
49 刘春太,陈静波.注塑成型 CAE 技术的研究进展和发展趋势.郑州工学院学报,1996,(3):115~117
50 文劲松,麻向军.CAD/CAE 软件在注塑模具技术中的应用.模具技术,2003,(5):17~19
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