PET瓶胚注塑模具热流道关键技术研究及应用
|
摘要
热流道技术是国家制造业大力发展而迫切需求的一项新技术,采用该技术可减少制品废料、缩短成型周期、提高制品精度。本文基于数值模拟技术将流动平衡和热平衡集成应用于瓶胚注塑模具热流道设计,构建了PET瓶胚注塑模具热流道设计流程并应用于工厂实际生产。
第一章,阐述了课题背景以及注塑模具的发展现状和热流道技术的研究现状,引出课题研究目的和意义,提出本文的研究内容与总体框架。
第二章,分析了PET材料的流变特性及力学模型,阐述了PET材料的加工工艺性,并结合Mold Flow软件,给出了PET材料的粘度-剪切速率曲线图。对注塑工艺采用的模具和成形设备进行了相应的说明。为随后的流动平衡设计奠定了理论基础和验证实践。
第三章,基于PET材料特性及工艺加工性能,结合热流道系统原理,对热流道结构设计进行了分析说明,讨论了针对PET瓶胚注塑模具热流道的不同流动平衡方式,实现了基于Mold Flow软件的流动平衡数值模拟分析流程。
第四章,进行了基于有限元技术的热流道系统热平衡计算,给出了热流道系统的热规划及加热功率的计算方法,并实现了基于ANSYS软件的热流道系统温度场分析,为热流道系统的热平衡状态提供了技术支撑。
第五章,基于娃哈哈集团公司596ml纯净水瓶热流道项目,结合CAE分析结果,比较了所设计的四种不同热流道结构设计方案,再利用热平衡的计算分析结果,选择了最优方案。最后通过工厂生产进行了应用验证。
第六章,对本文的研究工作进行了总结,介绍了PET瓶胚注塑模具热流道设计进一步研究展望。
Hot runner is a new technology which has urgent demand in manufacturing industry with which can bring less waste, shorter production cycle and better manufacturing precision. In this thesis, the author made a deep research on hot Runner system which is based on the integration discussion and study of CAE technology and completed a PET project for hot runner design.
In chapter 1, current development of injection mold and the application of hot runner were presented. Based on the analysis of existing problems about Hot Runner key technology, the research aim and the main frame of this dissertation were put forward.
In chapter 2, the models of PET material were introduced. The forming procedure and process design based on PET were put forward. On the basis of this theory, the power law model of PET material was adopted and methodically fitted. The general concept of process design was also represented according to the flow theory.
In chapter 3, the structure of Hot Runner system was discussed. Hot runners were designed by commercial software Moldflow. These were including with balance and non-natural balance runners.
In chapter 4, the method of heat transfer calculating on a hot runner was presented. The principle of the base was presented, and the detail process of calculation was illustrated.
In chapter 5, a workshop project example was given. In which, four design of hot runner were evaluated through CAE and HT calculations and based on these results, one optimized design manifold was standing out.
In chapter 6, the research work is summarized and the future work of this research was given.
第一章,阐述了课题背景以及注塑模具的发展现状和热流道技术的研究现状,引出课题研究目的和意义,提出本文的研究内容与总体框架。
第二章,分析了PET材料的流变特性及力学模型,阐述了PET材料的加工工艺性,并结合Mold Flow软件,给出了PET材料的粘度-剪切速率曲线图。对注塑工艺采用的模具和成形设备进行了相应的说明。为随后的流动平衡设计奠定了理论基础和验证实践。
第三章,基于PET材料特性及工艺加工性能,结合热流道系统原理,对热流道结构设计进行了分析说明,讨论了针对PET瓶胚注塑模具热流道的不同流动平衡方式,实现了基于Mold Flow软件的流动平衡数值模拟分析流程。
第四章,进行了基于有限元技术的热流道系统热平衡计算,给出了热流道系统的热规划及加热功率的计算方法,并实现了基于ANSYS软件的热流道系统温度场分析,为热流道系统的热平衡状态提供了技术支撑。
第五章,基于娃哈哈集团公司596ml纯净水瓶热流道项目,结合CAE分析结果,比较了所设计的四种不同热流道结构设计方案,再利用热平衡的计算分析结果,选择了最优方案。最后通过工厂生产进行了应用验证。
第六章,对本文的研究工作进行了总结,介绍了PET瓶胚注塑模具热流道设计进一步研究展望。
Hot runner is a new technology which has urgent demand in manufacturing industry with which can bring less waste, shorter production cycle and better manufacturing precision. In this thesis, the author made a deep research on hot Runner system which is based on the integration discussion and study of CAE technology and completed a PET project for hot runner design.
In chapter 1, current development of injection mold and the application of hot runner were presented. Based on the analysis of existing problems about Hot Runner key technology, the research aim and the main frame of this dissertation were put forward.
In chapter 2, the models of PET material were introduced. The forming procedure and process design based on PET were put forward. On the basis of this theory, the power law model of PET material was adopted and methodically fitted. The general concept of process design was also represented according to the flow theory.
In chapter 3, the structure of Hot Runner system was discussed. Hot runners were designed by commercial software Moldflow. These were including with balance and non-natural balance runners.
In chapter 4, the method of heat transfer calculating on a hot runner was presented. The principle of the base was presented, and the detail process of calculation was illustrated.
In chapter 5, a workshop project example was given. In which, four design of hot runner were evaluated through CAE and HT calculations and based on these results, one optimized design manifold was standing out.
In chapter 6, the research work is summarized and the future work of this research was given.
引文
[1]王建华,徐佩弦编著,注射模的热流道技术,北京：机械工业出版社,2005：11-12
[2]陈剑玲,刘廷华,热流道技术的发展和应用概况,模具工业,2003,(8)：32-36
[3]李彦文,注塑模热流道技术的发展及未来发展趋势探究,技术研发.2011,18(9)：124
[4]王勖成,有限单元法,北京：清华大学出版社,2003
[5]傅永华,有限元分析基础,武汉：武汉大学出版社,2003
[6]崔健,刘光烨,CAE技术在塑料注塑中的应用和发展,现代塑料加工应用,1999,(3)：26-29
[7]李德群,国外注射模CAD/CAE/CAM发展概况,模具工业,1994,(9)：47-53
[8]张春吉,唐跃,CAD/CAE在塑料模具设计中的应用,塑料科技,2004,(1)：20-21
[9]Broyer E, Cutfinger C, Tadmor Z, Transaction of the Society of Rheology,1975, (3): 423
[10]Carl Kirkland. Runnerless Metal Molding Molds. Injection Molding Metals & Ceramics, June 1999
[11]G Brunettia, B Golobb. A feature-based approach towards an integrated product model including conceptual design information. Computer-Aided Design.2000, (30):877-887
[12]Ming-Hung Tsai, Keng-Liang Ou, Chiung-Fang Huang, Study on micro-injection molding of light guiding plate by numerical simulation. International Communications in Heat and Mass Transfer,2008, (35):1097-1100.
[13]Koszkul J, Jnabialek J, Viscosity models in simulation of the filling stage of the injectionmolding process. Journal of Materials Processing Technology,2004, (157-158): 183-187
[14]Babur Ozcelik, Ibrahim Sonat, Warpage and structural analysis of thin shell plastic in the plastic injection molding. Materials and Design.2009 (30):367-375
[15]Clovis R.Maliska, Joao Flavio V.de Vasconcellos. An Unstructured Finite Volume Procedure For Simulating With Moving Fronts. Comput. Methods Appl. Mech. Engrg., 2000(182):401-420
[16]Guy Courbebaisse, David Garcia. Shape Analysis And Injection Molding Optimization. Computational Materials Science,2002(25):547-553
[17]Wipoo Sriseubasai. Dynamic Viscosity Purging of A Hot Runner Manifold. University of Massachusetts Lowell.2008
[18]Feng P E, Chen Y, Pan S X, et al. Genetic engineering and conceptual design. In:Culley A eds, Design methods for Performance and sustainability, the 13th International Conference on Engineering Design, Glasgow, UK,2001, London:Imeche,2001: 235-242
[19]X.Chen, Y.C.Lam, D.Q.Li. Analysis of thermal residual stress in plastic injection molding, Journal of Materials Processing Technology,2000(101):275-280
[20]L.Kong, J.Y.H.Fuh. A Windows-native 3D Plastic Injection Mold Design System. Journal of Materials Processing Technology,2003(139):81-89
[21]左太平,张益华,芮玉龙,MPI注射成型数值分析的实验验证,模具工业,2006,32(6)：14-16
[22]徐小青,基于Pro/E和Moldflow的显示器外壳注射模具设计,塑料工业,2005,33(12)：26-28
[23]赖鹏,彭响方,陈已明,Moldflow冷却分析在注塑模具中的应用,塑料工业,2007,35(6)：29-31
[24]唐明真.群腔热流道PET瓶坯注塑模设计与CAE分析：[学位论文],广州,华南理工大学硕士学位论文,2010.
[25]杨占尧,王高平,热流道注射模热流道板的设计,模具工业,2006,32(9)：49-52
[26]陈静波,陆宜清,祁东霞,多型腔注塑模的流动平衡计算与分析[J].工程塑料应用, 2004,32(9)：54-57
[27]王恩鑫,聚酯塑料PET瓶的开发与应用,橡塑资源利用,2006,(1)：19-22
[28]邹继强编,塑料模具设计参考资料汇编,北京：清华出版社,2005.9
[29]张维合编著,注塑模具设计实用教程,北京：化学工业出版社,2007,(9)：180-189
[30]刘来英主编,注塑成型工艺,北京：机械工业出版社,2005
[31]刘保臣,杨晓东,申长雨,热流道板设计与制造,模具工业.2007,33(10)：52-55
[32]唐志玉著,大型注塑模具设计技术原理与应用,北京：化学工业出版社,2004
[33]林师沛编著,塑料加工流变学及其应用,北京：国防工业出版社,2008
[34]张杰,注塑级塑料粘性模型研究,塑料工业,1995(3)：39-41
[35]Richard G. Griskey, Polymer Process Engineering, Chapman and Hall,1995,19
[36]John S. Hsu and Dr. Dean Reber, Method for Effective Color Change in Extrusion Blow Molding Accumulator Heads, In ANTEC 1998 Plastics:Annual Technical Conference: Plastics on My Mind,1998,1:Processing
[37]李学锋,塑料模设计及制造,北京：机械工业出版社,2002
[38]钱泉森,塑料成型工艺及模具设计,济南：山东科技出版社,2004
[39]翁其金,塑料模塑成型技术,北京：机械工业出版社,2000
[40]马国亭,模具热流道技术应用与选择,模具制造,2005(2)：59-63
[41]柴再胜,宋振彪,闫柏郁等,利用CAE软件优化流道设计,吉林化工学院学报,2004,21(2)：73-76
[42]苏娟华,注射模热流道喷嘴加热功率的计算,洛阳工学院学报,1995(04)：21-24
[43]魏汝梅,周玉华,热流道注射模喷嘴设计及热平衡分析,模具工业,1995(05)：35-37
[44]陈耀武,赵良知,黄锦强,基于Pro/E与ANSYS的一模多腔模具热分析,模具技术,2007(6)：50-53
[45]金振刚,刘延华,王涛,热流道系统温度场的数值模拟,模具工业,2003(6)：51-54
[46]徐佩弦,王建华,注射模热流道的传热损失和加热计算,模具工业,2005(2)：41-45
[47]陈仁杰,华保祥,刘怀文等,热流道板的热平衡及温度场的有限元分析,机械设计 与制造,2009(9)：21-23
[2]陈剑玲,刘廷华,热流道技术的发展和应用概况,模具工业,2003,(8)：32-36
[3]李彦文,注塑模热流道技术的发展及未来发展趋势探究,技术研发.2011,18(9)：124
[4]王勖成,有限单元法,北京：清华大学出版社,2003
[5]傅永华,有限元分析基础,武汉：武汉大学出版社,2003
[6]崔健,刘光烨,CAE技术在塑料注塑中的应用和发展,现代塑料加工应用,1999,(3)：26-29
[7]李德群,国外注射模CAD/CAE/CAM发展概况,模具工业,1994,(9)：47-53
[8]张春吉,唐跃,CAD/CAE在塑料模具设计中的应用,塑料科技,2004,(1)：20-21
[9]Broyer E, Cutfinger C, Tadmor Z, Transaction of the Society of Rheology,1975, (3): 423
[10]Carl Kirkland. Runnerless Metal Molding Molds. Injection Molding Metals & Ceramics, June 1999
[11]G Brunettia, B Golobb. A feature-based approach towards an integrated product model including conceptual design information. Computer-Aided Design.2000, (30):877-887
[12]Ming-Hung Tsai, Keng-Liang Ou, Chiung-Fang Huang, Study on micro-injection molding of light guiding plate by numerical simulation. International Communications in Heat and Mass Transfer,2008, (35):1097-1100.
[13]Koszkul J, Jnabialek J, Viscosity models in simulation of the filling stage of the injectionmolding process. Journal of Materials Processing Technology,2004, (157-158): 183-187
[14]Babur Ozcelik, Ibrahim Sonat, Warpage and structural analysis of thin shell plastic in the plastic injection molding. Materials and Design.2009 (30):367-375
[15]Clovis R.Maliska, Joao Flavio V.de Vasconcellos. An Unstructured Finite Volume Procedure For Simulating With Moving Fronts. Comput. Methods Appl. Mech. Engrg., 2000(182):401-420
[16]Guy Courbebaisse, David Garcia. Shape Analysis And Injection Molding Optimization. Computational Materials Science,2002(25):547-553
[17]Wipoo Sriseubasai. Dynamic Viscosity Purging of A Hot Runner Manifold. University of Massachusetts Lowell.2008
[18]Feng P E, Chen Y, Pan S X, et al. Genetic engineering and conceptual design. In:Culley A eds, Design methods for Performance and sustainability, the 13th International Conference on Engineering Design, Glasgow, UK,2001, London:Imeche,2001: 235-242
[19]X.Chen, Y.C.Lam, D.Q.Li. Analysis of thermal residual stress in plastic injection molding, Journal of Materials Processing Technology,2000(101):275-280
[20]L.Kong, J.Y.H.Fuh. A Windows-native 3D Plastic Injection Mold Design System. Journal of Materials Processing Technology,2003(139):81-89
[21]左太平,张益华,芮玉龙,MPI注射成型数值分析的实验验证,模具工业,2006,32(6)：14-16
[22]徐小青,基于Pro/E和Moldflow的显示器外壳注射模具设计,塑料工业,2005,33(12)：26-28
[23]赖鹏,彭响方,陈已明,Moldflow冷却分析在注塑模具中的应用,塑料工业,2007,35(6)：29-31
[24]唐明真.群腔热流道PET瓶坯注塑模设计与CAE分析：[学位论文],广州,华南理工大学硕士学位论文,2010.
[25]杨占尧,王高平,热流道注射模热流道板的设计,模具工业,2006,32(9)：49-52
[26]陈静波,陆宜清,祁东霞,多型腔注塑模的流动平衡计算与分析[J].工程塑料应用, 2004,32(9)：54-57
[27]王恩鑫,聚酯塑料PET瓶的开发与应用,橡塑资源利用,2006,(1)：19-22
[28]邹继强编,塑料模具设计参考资料汇编,北京：清华出版社,2005.9
[29]张维合编著,注塑模具设计实用教程,北京：化学工业出版社,2007,(9)：180-189
[30]刘来英主编,注塑成型工艺,北京：机械工业出版社,2005
[31]刘保臣,杨晓东,申长雨,热流道板设计与制造,模具工业.2007,33(10)：52-55
[32]唐志玉著,大型注塑模具设计技术原理与应用,北京：化学工业出版社,2004
[33]林师沛编著,塑料加工流变学及其应用,北京：国防工业出版社,2008
[34]张杰,注塑级塑料粘性模型研究,塑料工业,1995(3)：39-41
[35]Richard G. Griskey, Polymer Process Engineering, Chapman and Hall,1995,19
[36]John S. Hsu and Dr. Dean Reber, Method for Effective Color Change in Extrusion Blow Molding Accumulator Heads, In ANTEC 1998 Plastics:Annual Technical Conference: Plastics on My Mind,1998,1:Processing
[37]李学锋,塑料模设计及制造,北京：机械工业出版社,2002
[38]钱泉森,塑料成型工艺及模具设计,济南：山东科技出版社,2004
[39]翁其金,塑料模塑成型技术,北京：机械工业出版社,2000
[40]马国亭,模具热流道技术应用与选择,模具制造,2005(2)：59-63
[41]柴再胜,宋振彪,闫柏郁等,利用CAE软件优化流道设计,吉林化工学院学报,2004,21(2)：73-76
[42]苏娟华,注射模热流道喷嘴加热功率的计算,洛阳工学院学报,1995(04)：21-24
[43]魏汝梅,周玉华,热流道注射模喷嘴设计及热平衡分析,模具工业,1995(05)：35-37
[44]陈耀武,赵良知,黄锦强,基于Pro/E与ANSYS的一模多腔模具热分析,模具技术,2007(6)：50-53
[45]金振刚,刘延华,王涛,热流道系统温度场的数值模拟,模具工业,2003(6)：51-54
[46]徐佩弦,王建华,注射模热流道的传热损失和加热计算,模具工业,2005(2)：41-45
[47]陈仁杰,华保祥,刘怀文等,热流道板的热平衡及温度场的有限元分析,机械设计 与制造,2009(9)：21-23