快速模具模塑成形的数值分析及过程智能控制系统的研究
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摘要
快速模具技术因能够很好地响应新产品快速开发的需求，能够解决大量传统加工方法难以甚至不能解决的制造问题，综合经济效益显著，正逐渐成为一种新的生产方式。快速模具模塑成形过程涉及低压注射充模时的流变学问题，双组分高分子材料交联固化的反应动力学问题，反应加工过程中的传热和传质问题，以及过程的智能控制问题等一系列高分子材料反应加工的核心科学问题。本文基于快速模具模塑成形的机理和工艺特点，运用数值分析技术、现代实验技术以及智能控制技术着重研究了制品反应模塑过程影响因素的数值分析方法、工艺参数优化方法以及成形过程的智能控制系统，并进行了大量的实例仿真。本文的研究成果推进和丰富了快速模具模塑成形关键技术的研究，对解决成形过程工艺参数的合理选择及优化、加工过程的智能控制问题具有重要的指导作用。
主要的研究成果归纳如下：
①分析了RT模塑成形的典型工艺过程并归纳了工艺特点；从成形方法、原料体系及充模与固化的物理、化学变化出发，全面分析了RT模塑成形机理；给出了RT模塑成形技术体系，结合控制成形质量的需求阐述并详细分析了工艺参数优化技术、成形过程的数值分析技术及智能控制技术、成形精度控制技术和成形材料的改性技术等RT模塑成形的关键技术。
②分析了RT模塑充模过程的特点及影响充模质量的主要工艺因素，提出了基于数值仿真及正交实验技术的反应模塑充模工艺参数组合优化方法。以模具填充结束时的平均体积转换率和平均剪切速率作为评价指标，通过设计正交仿真实验方案，在定量分析主要工艺参数对充模过程影响程度的基础上，确定最优工艺参数组合。分析实例证明了该方法的实用性和可靠性。该方法的特点是可针对每一具体产品结构进行分析，仿真实验结果直观，可比性强。所采用的实验原始数据来源于经验推荐值，因而对于反应模塑充模工艺参数的优化具有普遍性。
③快速模具低压灌注成形具有热固性材料低压反应注射成形的特点，在充模完成后的数十秒时间内除了化学反应之外，还伴随有快速相分离、氢键化等，体系十分复杂。在分析低压灌注成形特点及影响因素的基础上，建立了分析成
Rapid tooling (RT) technology has being become a new manufacturing mode due to its fast response ability to the market, and good economical benefits. The technology could also solve a lot of problems which can't be done by the traditional techniques. Because there are many behaviors, such as rheology, kinetics, thermodynamics etc., will affect the molding process, the research on these behaviors and their influences to the process is very importment The results of the research could guide to select processing parameters reasonably. In this thesis a comprehensive analysis on rapid tooling and molding process has been made based on the applied experiences. The numerical simulation mothod, modern experiment technology, and intelligent control theory were applied to research the influencing factors of the reactive molding process, parameter optimizing method, and the intelligent control system of molding equipment. A lot of simulations and analyses have been made in order to verifying the results of the research. These results will promote the research of RT, and will help to solve some key problems.
The main contributions in this dissertation are summed up as follows.
(1) By analyzing the typical molding process, some importent technical characteristics are summarized.The principle of rapid tooling and molding are investigated deeply according to the method of molding, material system, and the physical and chemic process. The technical research system is refered, and several issues related to key technologies to RT molding are proposed and detailed discussion including the behavior of rheology with injection process and the method of optimizing technics parameters, kinetics and thermodynamics of molding and the relationship with technics and the qualities of parts, as well as the intelligent control on the molding equipment, etc.
(2) A method of matching the low-pressure injection parameters optimally is presented according to the principle of numerical simulation and orthogonal experiment. The optimal average bulk conversion and average shear rate are selected
主要的研究成果归纳如下：
①分析了RT模塑成形的典型工艺过程并归纳了工艺特点；从成形方法、原料体系及充模与固化的物理、化学变化出发，全面分析了RT模塑成形机理；给出了RT模塑成形技术体系，结合控制成形质量的需求阐述并详细分析了工艺参数优化技术、成形过程的数值分析技术及智能控制技术、成形精度控制技术和成形材料的改性技术等RT模塑成形的关键技术。
②分析了RT模塑充模过程的特点及影响充模质量的主要工艺因素，提出了基于数值仿真及正交实验技术的反应模塑充模工艺参数组合优化方法。以模具填充结束时的平均体积转换率和平均剪切速率作为评价指标，通过设计正交仿真实验方案，在定量分析主要工艺参数对充模过程影响程度的基础上，确定最优工艺参数组合。分析实例证明了该方法的实用性和可靠性。该方法的特点是可针对每一具体产品结构进行分析，仿真实验结果直观，可比性强。所采用的实验原始数据来源于经验推荐值，因而对于反应模塑充模工艺参数的优化具有普遍性。
③快速模具低压灌注成形具有热固性材料低压反应注射成形的特点，在充模完成后的数十秒时间内除了化学反应之外，还伴随有快速相分离、氢键化等，体系十分复杂。在分析低压灌注成形特点及影响因素的基础上，建立了分析成
Rapid tooling (RT) technology has being become a new manufacturing mode due to its fast response ability to the market, and good economical benefits. The technology could also solve a lot of problems which can't be done by the traditional techniques. Because there are many behaviors, such as rheology, kinetics, thermodynamics etc., will affect the molding process, the research on these behaviors and their influences to the process is very importment The results of the research could guide to select processing parameters reasonably. In this thesis a comprehensive analysis on rapid tooling and molding process has been made based on the applied experiences. The numerical simulation mothod, modern experiment technology, and intelligent control theory were applied to research the influencing factors of the reactive molding process, parameter optimizing method, and the intelligent control system of molding equipment. A lot of simulations and analyses have been made in order to verifying the results of the research. These results will promote the research of RT, and will help to solve some key problems.
The main contributions in this dissertation are summed up as follows.
(1) By analyzing the typical molding process, some importent technical characteristics are summarized.The principle of rapid tooling and molding are investigated deeply according to the method of molding, material system, and the physical and chemic process. The technical research system is refered, and several issues related to key technologies to RT molding are proposed and detailed discussion including the behavior of rheology with injection process and the method of optimizing technics parameters, kinetics and thermodynamics of molding and the relationship with technics and the qualities of parts, as well as the intelligent control on the molding equipment, etc.
(2) A method of matching the low-pressure injection parameters optimally is presented according to the principle of numerical simulation and orthogonal experiment. The optimal average bulk conversion and average shear rate are selected
引文
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