群腔热流道PET瓶坯注塑模设计与CAE分析
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摘要
群腔PET注塑模是PET瓶包装企业适应市场需求,提高PET瓶产量和质量,降低成本的主要举措。本文首先对不同腔数的PET瓶坯注塑模具,进行制品结构设计分析,确定PET材料的合理加工工艺,并进行非自然平衡式热流道系统流变学平衡设计。其次,利用ANSYS计算模拟热流道板温度场,包括其单板加热,注塑加工过程温度场;测试验热流道板温度及热膨胀,提出热流道分析的有效方式;此外,还利用专业的模流软件Moldflow分析非平衡式多型腔(如12、28、32等)的充填、流动、保压及冷却情况,预测设计中的缺陷;根据分析,设计注塑模(以数值模拟结果为参考),并进行试模检验。最后,对群腔热流道PET瓶坯注塑模进行CAE分析,得到以下结论:
(1)在PET瓶坯的轻量化设计中,设计了半圆、抛物线、锥形瓶坯制品方案,通过MPI分析得出采用抛物线型瓶坯设计方案比较理想并且节省物料;
(2)非平衡式浇注系统在群腔注塑模中是可行的,可通过流道平衡法或浇口平衡法进行平衡设计;
(3)热流道热损失影响模具注塑过程的稳定性,通过分析温度场,计算加热功率,优化加热管和热电偶的布置,可实现热流道系统热平衡;
(4)预测注塑生产中可能出现制品缺陷是注塑模CAE应用的重点,进行注塑填充、流动、保压与冷却分析,改进注塑工艺,改善冷却效果,可提高试模的成功率。
The design of multi-cavity can reduce the number of injection equipment,reduce costs and improve producion efficiency.In this paper, we firstly design the product structure on different numbers cavities PET bottle injection molds,determine the reasonable PET materials processing,and design rheological balance of unnatural balanced hot runner system.And then we use ANSYS to simulate the hot runner temperature field, including its single board heating, injection molding processing temperature; Test the temperature and thermal expansion of runner plate, advance the effective way to make hot runners analysis.In addition,we use professional mold flow software Moldflow to analysis the filling, flow, packing and cooling conditions of non-equilibrium multi-cavity (such as 12,28,32, etc.),and forecasts the defects on design.Design a reasonable option (reference numerical simulation results), to test mold test according to the analysis.At last,through the CAE analysis on multi-cavity hot runner PET bottles injection mold, we get these following conclusions:
(1) Designed semi-circular, parabolic preform and cone preform products, through the MPI analysis we obtained Parabolic preform design is most reasonable and materials saving in the PET preform lightweight design;
(2) Unbalance gating system is feasible in multi-cavity injection mold, balance design can be done by flow balance method or the gate balance method;
(3) Heat loss influence the stability of the process in hot runner injection mold, and hot runner system can achieve thermal equilibrium by analyzing the temperature field, calculating heating power,optimizat optimally arranging heat pipe and heating power, thermocouple
(4) Forecasting product defects which may appear is a focus of Injection Molding CAE applications.Analysising the injection molding situactions of filling, flow, packing and cooling,improving the injection molding process, making better the cooling effect, can improve the success rate of test mode.
(1)在PET瓶坯的轻量化设计中,设计了半圆、抛物线、锥形瓶坯制品方案,通过MPI分析得出采用抛物线型瓶坯设计方案比较理想并且节省物料;
(2)非平衡式浇注系统在群腔注塑模中是可行的,可通过流道平衡法或浇口平衡法进行平衡设计;
(3)热流道热损失影响模具注塑过程的稳定性,通过分析温度场,计算加热功率,优化加热管和热电偶的布置,可实现热流道系统热平衡;
(4)预测注塑生产中可能出现制品缺陷是注塑模CAE应用的重点,进行注塑填充、流动、保压与冷却分析,改进注塑工艺,改善冷却效果,可提高试模的成功率。
The design of multi-cavity can reduce the number of injection equipment,reduce costs and improve producion efficiency.In this paper, we firstly design the product structure on different numbers cavities PET bottle injection molds,determine the reasonable PET materials processing,and design rheological balance of unnatural balanced hot runner system.And then we use ANSYS to simulate the hot runner temperature field, including its single board heating, injection molding processing temperature; Test the temperature and thermal expansion of runner plate, advance the effective way to make hot runners analysis.In addition,we use professional mold flow software Moldflow to analysis the filling, flow, packing and cooling conditions of non-equilibrium multi-cavity (such as 12,28,32, etc.),and forecasts the defects on design.Design a reasonable option (reference numerical simulation results), to test mold test according to the analysis.At last,through the CAE analysis on multi-cavity hot runner PET bottles injection mold, we get these following conclusions:
(1) Designed semi-circular, parabolic preform and cone preform products, through the MPI analysis we obtained Parabolic preform design is most reasonable and materials saving in the PET preform lightweight design;
(2) Unbalance gating system is feasible in multi-cavity injection mold, balance design can be done by flow balance method or the gate balance method;
(3) Heat loss influence the stability of the process in hot runner injection mold, and hot runner system can achieve thermal equilibrium by analyzing the temperature field, calculating heating power,optimizat optimally arranging heat pipe and heating power, thermocouple
(4) Forecasting product defects which may appear is a focus of Injection Molding CAE applications.Analysising the injection molding situactions of filling, flow, packing and cooling,improving the injection molding process, making better the cooling effect, can improve the success rate of test mode.
引文
[1]范杵兰.2009热流道技术最新发展[J].国外塑料.2009.12:54-56
[2]刘浪潮.浅析塑料注塑模热流道技术[J].科技资讯.2008,11:1-3
[3]王建华,徐佩弦编著.注射模的热流道技术[M].北京:机械工业出版社.2005:11
[4]陈剑玲,刘廷华.热流道技术的发展和应用概况[M].模具工业.2003,8:32-36
[5]治明编译.热流道的新设计和新机遇[J].国外塑料.2008,26(6):72-73
[6]马国亭.模具热流道技术应用与选择[J].模具制造.2005,2:59-63
[7]舒世常,彭圣辉.160腔高精度热流道注射模具的设计[J].工程塑料应用.1989,4:34—37
[8]苏娟华,曹津.PET瓶坯热流道注射模流道直径的优化设计[J].洛阳工学院学报.2000,21(4):89—91
[9]柴再胜,宋振彪,闫柏郁等.利用CAE软件优化流道设计[J].吉林化工学院学报.2004,21(2):73—76
[10]徐佩弦,王建华.注射模热流道的传热损失和加热计算[J].模具工业.2005,2:41-45
[11]魏汝梅.热流道模具的加热试验[J].模具工业,1990,(9):34-36
[12]金振刚,刘延华,王涛.热流道系统温度场的数值模拟[J].模具工业.2003,6:51—54.
[13]金振钢.注塑热流道温度场的数值模拟[D],四川:四川大学,高分子材料.2002
[14]曾志敏.注塑模热流道结构设计及其温度场模拟.[D].昆明:昆明理工大学,材料加工工程.2007
[15]傅永华著.有限元分析基础[M].武汉:武汉大学出版社.2003
[16]濮仲佳. CAE技术在铝合金轮毂开发中的应用研究[D].上海:上海交通大学.2007
[17]郭鹏.基于CAE的垂直循环立体车库结构设计研究[D].山东:山东大学,2007
[18] Chen X,Lam Y.C.,Li D.Q.Analysis of thermal residual stress in piastic injection molding[J].Journal of Materials Processing Tachnology 101,2000:275-280
[19] Li C.S, Shen Y.K.Optimum Design of Runner system Balancing In Injection Molding[J].International Communications in Heat and Mass Transfer.1995,22(2):179-188
[20] Huang Ching-Chin,Tai.The Effective Factors in The Warpage Problem of an Injection-molded Part With a Thin Shell Feature[J].journal of Masterials ProcessingTechnology110(2001):1-9.
[21] Ming-Hung Tsai, Keng-Liang Ou,Chiung-Fang Huang. Study on micro-injection molding of light guiding plate by numerical simulation[J]. International Communications in Heat and Mass Transfer 35 (2008):1097-1100.
[22] Bunch Michael J,Shoemaker Jay.Runner Sizing and Balancing for Injection Molding Using Computer Analysis[J].Molding the Futre-In Tooling and Deaign. 1992,3:169-192
[23] Nagaoka Shinchi,Hirota Tomoo,Togawa Yoshiki.New Method of Designing Runner System for Injection Mold Using CAO Technique.Annual Twchnical Conference-ANTEC[J].Conference Proceedings.2004,3:3438-3442
[24] Koszkul J,Jnabialek J.Viscosity models in simulation of the filling stage of the injection molding process[J].Journal of Materials Processing Technology 157-158 (2004):183–187
[25] Babur Ozcelik,Ibrahim Sonat.Warpage and structural analysis of thin shell plastic in the plastic injection molding[J].Materials and Design.30(2009):367-375
[26]王家惠.CAE模拟分析在注射成型缺陷预测中的应用[D].昆明:昆明理工大学,机械制造及自动化.2003
[27]徐佩弦,王建华.注射模热流道的传热损失和加热计算[J].模具工业.2005,2:41-45.
[28]左大平,张益华,苪玉龙.MPI注射成型数值分析的实验验证[J].模具工业.2006,32(6):14—16
[29]陈静波,申长雨,横井俊秀.多型腔注射模充填不平衡试验.机械工程学报.2007,43(10):170-174
[30]徐小青.基于Pro/E和Moldflow的显示器外壳注射模具设计[J].塑料工业.2005,33(12):26—28
[31]赖鹏,彭响方,陈己明.Moldflow冷却分析在注塑模具中的应用[J].塑料工业.2007,35(6):29—31
[32] [美]J.P.博蒙特,R.内格尔,R.舍曼,黄汉雄,王喜顺等译.成功的注射成型加工、设计和模拟[M].化学工业出版社,2009:1
[33]刘来英主编.注塑成型工艺[M].北京:机械工业出版社.2005
[34]林师沛编著.塑料加工流变学及其应用[M].北京,国防工业出版社,2008
[35]韩春燕.瓶级聚酯切片质量及加工性能研究[D].苏州:苏州大学,材料工程.2005
[36]王恩鑫.聚酯塑料PET瓶的开发与应用[J].橡塑资源利用.2006,1:19-22
[37]刘士杰.注拉吹技术生产PET小瓶成型工艺探讨[J].2001年中国工程塑料加工及棋具技术研讨会论文集:78-79
[38]杨始堃.聚酯瓶问题分析(二)[J].聚酯工业.2005,18(2):1-5
[39]杨占尧,王高平.热流道注射模热流道板的设计[J].模具工业.2006,32(9):49-52
[40]张维合编著.注塑模具设计实用教程[M].北京:化学工业出版社.2007.9:180-189
[41]刘保臣,杨晓东,申长雨.热流道板设计与制造[J].模具工业.2007,33(10):52-55成型加工专业,2002
[42]唐志玉著.大型注塑模具设计技术原理与应用[M].北京:化学工业出版社.2004
[43]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
[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[J].模具技术.2007,6:50-53
[45]陈礼编.热工基础[M].北京.高等教育出版社.2005.22
[46]邹继强编.塑料模具设计参考资料汇编[M].北京.清华出版社.2005.9
[47]徐江,赵其兴,袁晓华等.ANSYS在混凝土拱坝温度场仿真计算中的应用[J].水利规划与设计.2008,8:75-79
[48]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[J].机械设计与制造.2009,9:21-23
[49] Prosenjit Santraa,Vijay Bedakihalea, Tata Ranganathb. Thermal structural analysis of SST-1 vacuum vessel and cryostat assembly using ANSYS[J]. Fusion Engineering and Design. 2009,84: 1708–1712
[50]蒋存波,金利,牛秦洲等.基于微处理器的热流道模具精密温控仪研制[J].2004,24(2):235-240
[51] Huang T.C.Improving flow balance during filling a multi-cavity mold with moldified runner systems.International Processing[J],2008,4(23):363-369.
[2]刘浪潮.浅析塑料注塑模热流道技术[J].科技资讯.2008,11:1-3
[3]王建华,徐佩弦编著.注射模的热流道技术[M].北京:机械工业出版社.2005:11
[4]陈剑玲,刘廷华.热流道技术的发展和应用概况[M].模具工业.2003,8:32-36
[5]治明编译.热流道的新设计和新机遇[J].国外塑料.2008,26(6):72-73
[6]马国亭.模具热流道技术应用与选择[J].模具制造.2005,2:59-63
[7]舒世常,彭圣辉.160腔高精度热流道注射模具的设计[J].工程塑料应用.1989,4:34—37
[8]苏娟华,曹津.PET瓶坯热流道注射模流道直径的优化设计[J].洛阳工学院学报.2000,21(4):89—91
[9]柴再胜,宋振彪,闫柏郁等.利用CAE软件优化流道设计[J].吉林化工学院学报.2004,21(2):73—76
[10]徐佩弦,王建华.注射模热流道的传热损失和加热计算[J].模具工业.2005,2:41-45
[11]魏汝梅.热流道模具的加热试验[J].模具工业,1990,(9):34-36
[12]金振刚,刘延华,王涛.热流道系统温度场的数值模拟[J].模具工业.2003,6:51—54.
[13]金振钢.注塑热流道温度场的数值模拟[D],四川:四川大学,高分子材料.2002
[14]曾志敏.注塑模热流道结构设计及其温度场模拟.[D].昆明:昆明理工大学,材料加工工程.2007
[15]傅永华著.有限元分析基础[M].武汉:武汉大学出版社.2003
[16]濮仲佳. CAE技术在铝合金轮毂开发中的应用研究[D].上海:上海交通大学.2007
[17]郭鹏.基于CAE的垂直循环立体车库结构设计研究[D].山东:山东大学,2007
[18] Chen X,Lam Y.C.,Li D.Q.Analysis of thermal residual stress in piastic injection molding[J].Journal of Materials Processing Tachnology 101,2000:275-280
[19] Li C.S, Shen Y.K.Optimum Design of Runner system Balancing In Injection Molding[J].International Communications in Heat and Mass Transfer.1995,22(2):179-188
[20] Huang Ching-Chin,Tai.The Effective Factors in The Warpage Problem of an Injection-molded Part With a Thin Shell Feature[J].journal of Masterials ProcessingTechnology110(2001):1-9.
[21] Ming-Hung Tsai, Keng-Liang Ou,Chiung-Fang Huang. Study on micro-injection molding of light guiding plate by numerical simulation[J]. International Communications in Heat and Mass Transfer 35 (2008):1097-1100.
[22] Bunch Michael J,Shoemaker Jay.Runner Sizing and Balancing for Injection Molding Using Computer Analysis[J].Molding the Futre-In Tooling and Deaign. 1992,3:169-192
[23] Nagaoka Shinchi,Hirota Tomoo,Togawa Yoshiki.New Method of Designing Runner System for Injection Mold Using CAO Technique.Annual Twchnical Conference-ANTEC[J].Conference Proceedings.2004,3:3438-3442
[24] Koszkul J,Jnabialek J.Viscosity models in simulation of the filling stage of the injection molding process[J].Journal of Materials Processing Technology 157-158 (2004):183–187
[25] Babur Ozcelik,Ibrahim Sonat.Warpage and structural analysis of thin shell plastic in the plastic injection molding[J].Materials and Design.30(2009):367-375
[26]王家惠.CAE模拟分析在注射成型缺陷预测中的应用[D].昆明:昆明理工大学,机械制造及自动化.2003
[27]徐佩弦,王建华.注射模热流道的传热损失和加热计算[J].模具工业.2005,2:41-45.
[28]左大平,张益华,苪玉龙.MPI注射成型数值分析的实验验证[J].模具工业.2006,32(6):14—16
[29]陈静波,申长雨,横井俊秀.多型腔注射模充填不平衡试验.机械工程学报.2007,43(10):170-174
[30]徐小青.基于Pro/E和Moldflow的显示器外壳注射模具设计[J].塑料工业.2005,33(12):26—28
[31]赖鹏,彭响方,陈己明.Moldflow冷却分析在注塑模具中的应用[J].塑料工业.2007,35(6):29—31
[32] [美]J.P.博蒙特,R.内格尔,R.舍曼,黄汉雄,王喜顺等译.成功的注射成型加工、设计和模拟[M].化学工业出版社,2009:1
[33]刘来英主编.注塑成型工艺[M].北京:机械工业出版社.2005
[34]林师沛编著.塑料加工流变学及其应用[M].北京,国防工业出版社,2008
[35]韩春燕.瓶级聚酯切片质量及加工性能研究[D].苏州:苏州大学,材料工程.2005
[36]王恩鑫.聚酯塑料PET瓶的开发与应用[J].橡塑资源利用.2006,1:19-22
[37]刘士杰.注拉吹技术生产PET小瓶成型工艺探讨[J].2001年中国工程塑料加工及棋具技术研讨会论文集:78-79
[38]杨始堃.聚酯瓶问题分析(二)[J].聚酯工业.2005,18(2):1-5
[39]杨占尧,王高平.热流道注射模热流道板的设计[J].模具工业.2006,32(9):49-52
[40]张维合编著.注塑模具设计实用教程[M].北京:化学工业出版社.2007.9:180-189
[41]刘保臣,杨晓东,申长雨.热流道板设计与制造[J].模具工业.2007,33(10):52-55成型加工专业,2002
[42]唐志玉著.大型注塑模具设计技术原理与应用[M].北京:化学工业出版社.2004
[43]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
[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[J].模具技术.2007,6:50-53
[45]陈礼编.热工基础[M].北京.高等教育出版社.2005.22
[46]邹继强编.塑料模具设计参考资料汇编[M].北京.清华出版社.2005.9
[47]徐江,赵其兴,袁晓华等.ANSYS在混凝土拱坝温度场仿真计算中的应用[J].水利规划与设计.2008,8:75-79
[48]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[J].机械设计与制造.2009,9:21-23
[49] Prosenjit Santraa,Vijay Bedakihalea, Tata Ranganathb. Thermal structural analysis of SST-1 vacuum vessel and cryostat assembly using ANSYS[J]. Fusion Engineering and Design. 2009,84: 1708–1712
[50]蒋存波,金利,牛秦洲等.基于微处理器的热流道模具精密温控仪研制[J].2004,24(2):235-240
[51] Huang T.C.Improving flow balance during filling a multi-cavity mold with moldified runner systems.International Processing[J],2008,4(23):363-369.