小尺寸多型腔塑件充模平衡稳健设计
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摘要
针对多型腔小尺寸塑件充模对成型因素波动敏感,型腔填充不易均衡,传统修模–试模周期长,制约生产率提高的问题,根据前期文献研究成果,定义了多级流道平衡度概念,在正交试验的基础上,基于稳健设计理论,利用灰色关联分析方法,控制多级流道平衡度趋于理想值,并通过关联度方差分析,寻求最佳工艺水平,使设计方案趋于最佳的同时,增强了对成型因素波动的抗干扰性,缩短了试模周期,使生产制程更为可靠。通过Minitab结果预测显示,稳健设计方案各级流道平衡度与理想值关联度非常接近。同时在扰动注射试验中,稳健设计方案抗干扰性明显增强,型腔填充一致性远高于初始方案,显示了多级流道平衡度控制方法的正确性和有效性。
The filling of small size plastic parts with multi-cavity was sensitive to the fluctuation of forming factors,the filling of cavitys was not easy to be balanced,and the cycle of traditional mould modification-trial period was long,which restricted the improvement of productivity. Based on the previous literature,the concept of multi-stage channel equilibrium degree was defined.On the basis of orthogonal experiment,according to the robust design theory,the grey correlation analysis method was used to control the balance degree of multi-level runners to reach the ideal value. Through the variance analysis of correlation degree,the optimum process combination was sought. The design scheme was optimized and the anti-interference ability to the fluctuation of forming factors was enhanced,the test period was shortened,and the production process was more reliable. The results of Minitab prediction show that the correlation degree between the balance degree of all level runners and their ideal values is very close in the robust design scheme. At the same time,in the disturbance injection test,the robustness of the robust design scheme is obviously enhanced,and the consistency of cavity filling is much higher than that of the initial scheme,which shows the correctness and effectiveness of the multi-stage channel balance control method.
The filling of small size plastic parts with multi-cavity was sensitive to the fluctuation of forming factors,the filling of cavitys was not easy to be balanced,and the cycle of traditional mould modification-trial period was long,which restricted the improvement of productivity. Based on the previous literature,the concept of multi-stage channel equilibrium degree was defined.On the basis of orthogonal experiment,according to the robust design theory,the grey correlation analysis method was used to control the balance degree of multi-level runners to reach the ideal value. Through the variance analysis of correlation degree,the optimum process combination was sought. The design scheme was optimized and the anti-interference ability to the fluctuation of forming factors was enhanced,the test period was shortened,and the production process was more reliable. The results of Minitab prediction show that the correlation degree between the balance degree of all level runners and their ideal values is very close in the robust design scheme. At the same time,in the disturbance injection test,the robustness of the robust design scheme is obviously enhanced,and the consistency of cavity filling is much higher than that of the initial scheme,which shows the correctness and effectiveness of the multi-stage channel balance control method.
引文
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[14]蔡厚道.基于响应面和灰色关联分析的汽车滤清器盖注塑工艺多目标优化[J].塑料工业,2017,45(1):48-52.Cai Houdao.Multi-objective optimization of the injection molding of automobile filter cover based on response surface and grey relational analysis[J].China Plastics Industry,2017,45(1):48-52.
[2]杨卫民,谢鹏程,杨高品.注射成型多模腔充填不平衡现象的产生机理(Ⅰ)--模具流道系统中熔体流动行为的研究[J].中国塑料,2004(11):95-101.Yang Weimin,Xie Pengcheng,Yang Gaopin.Mechanism of filling imbalance of plastics injection molding in multi-cavity molds(I)--Study on flow behavior of melt in runner systems of mold[J].China Plastics,2004(11):95-101.
[3]余磊,刘斌,陈静波,等.影响多型腔注射模不平衡充填因素的模拟研究[J].塑料,2011,40(1):109-113.Yu Lei,Liu Bin,Chen Jingbo,et al.Simulation study on factors of imbalance filling in multi-cavities injection mold[J].Plastics,2011,40(1):109-113.
[4]Cardozo D.Three models of the 3D filling simulation for injection molding:A brief review[J].Journal of Reinforced Plastics and Composites,2008,27(18):1 963-1 974.
[5]左向宇,张军华,陈俊萍.基于Moldflow的快速实现一模多腔进料平衡研究[J].模具工业,2013,39(2):46-49.Zuo Xiangyu,Zhang Junhua,Chen Junping.Rapid achievement of feeding balance of multi-cavity mould based on moldflow[J].Die&Mould Industry,2013,39(2):46-49.
[6]杨方洲,杨晓东.基于SIM的多型腔注塑模具流动平衡优化[J].工程塑料应用,2012,40(9):44-47.Yang Fangzhou,Yang Xiaodong.Optimization of balanced flow for multi-cavity injection mold based on SIM[J].Engineering Plastics Application,2012,40(9):44-47.
[7]范杵兰,黄泽雄.注塑模的平衡问题--多型腔模具不平衡充模的解决方案[J].国外塑料,2008,26(12):48-54.Fan Chulan,Huang Zexiong.Balance of injection mold--Solution to unbalanced filling of multi-cavity molding[J].World Plastics,2008,26(12):48-54.
[8]Sreedharan J,Jeevanantham A K.Optimization of injection molding process to minimize weld-line and sink-mark defects using taguchi based grey relational analysis[J].Materials Today:Proceedings,2018,5(5):12 615-12 622.
[9]程锦,谭建荣,余加红.基于TOPSIS的注塑工艺参数多目标稳健优化设计[J].机械工程学报,2011,47(6):27-32.Cheng Jin,Tan Jianrong,Yu Jiahong.Multi-objective robust optimization of injection molding process parameters based on TOPSIS[J].Journal of Mechanical Engineering,2011,47(6):27-32.
[10]孙靖民.机械优化设计[M].北京:机械工业出版社,2012.Sun Jingmin.Mechanical optimal design[M].Beijing:China Machine Press,2012.
[11]吴令云,吴家祺,吴诚鸥,等.MINITAB软件入门--最易学实用的统计分析教程[M].北京:高等教育出版社,2012.Wu Lingyun,Wu Jiaqi,Wu Chengou,et al.Introduction to MINITAB software--The easiest and most practical statistical analysis course[M].Beijing:Higher Education Press,2012.
[12]Pervez H,Mozumder M S.Optimization of injection molding parameters for HDPE/TiO2 nanocomposites fabrication with multiple performance characteristics using the taguchi method and grey relational analysis[J].Materials,2016,9(8):710-718.
[13]黄风立,林建平,钟美鹏,等.基于综合关联度的注塑成型工艺参数多目标稳健设计[J].高分子材料科学与工程,2011,27(3):162-166.Huang Fengli,Lin Jianping,Zhong Meipeng,et al.Multiobjective robust design on craft parameters of plastics injection based on synthesis relation degree[J].Polymeric Materials Science and Engineering,2011,27(3):162-166.
[14]蔡厚道.基于响应面和灰色关联分析的汽车滤清器盖注塑工艺多目标优化[J].塑料工业,2017,45(1):48-52.Cai Houdao.Multi-objective optimization of the injection molding of automobile filter cover based on response surface and grey relational analysis[J].China Plastics Industry,2017,45(1):48-52.