塑料制品注塑成型的流变学分析
摘要
注塑成型是塑料制品重要的成型方法,可生产形状复杂、精度要求高的制品。注塑成型是一个相当复杂的物理过程,在注塑成型过程中,聚合物熔体经历了复杂的变形和温度变化,这些与产品的最终性能直接相关。
模流分析是塑料制品注塑成型的一种重要技术手段,它对于优化设计、缩短成型周期、提高产品质量有着重要的意义。本论文以塑料名片格为研究对象,结合实际生产需求,选择PS351为材料,利用Moldflow软件,对一模两腔塑料名片格进行了分析,并对几种流变学粘度模型进行了计算、比较,取得的主要成果如下：
(1)首先通过设计计算得出了塑料名片格各个主要部分的参数,然后在UG/MoldWizard中建立了塑料名片格注塑模具的三维模型。设计了一套完整的模具结构,其中包括型芯、型腔、模架、镶件、滑块、浇注系统和冷却系统等结构的设计。
(2)利用Moldflow/MPI模流分析软件对塑料名片格注塑模具进行了网格划分,设置了分析类型和顺序,选择聚苯乙烯(PS)作为本次分析的材料,并确定了最佳浇口位置,完成分析前处理后对填充过程进行了模拟,对分析结果中的填充时间、压力、流动前沿温度、注塑口压力曲线等做出了分析。
(3)根据不同粘度模型在不同温度下的材料参数得出了Power Law模型、Ellis模型和CIMP模型三种粘度模型剪切粘度-剪切速率曲线,分析得出CIMP粘度模型与Moldflow仿真分析中得到的粘度曲线最为接近,并对剪切粘度的影响因素进行了深入了讨论。
Injection molding is an important method of forming plastic products. It can produce complex shape, high precision products. However, injection molding is a complex physical process. During the injection molding process, the polymer melt is through a complex deformation and temperature changes, and these are directly related to the products ultimate performance.
Flow analysis is injection molding of an important technical means. It has important significance to optimize the design, shortening the molding cycle and improve product quality. Plastic business card was chosen for study in this paper. According as actual production needs, it was selected PS351 for materials, and analyzed a two-cavity plastic cards plastic grid in virtue of Moldflow software. Then it chose several rheological viscosity models to calculate and comparison. Through analysis and comparison, the main achievements are as follows:
(1) In the paper, every main part parameters of the plastic business card has been abtained through the design calculation. Then it has established the plastic business card injection mould three-dimensional model in UG/MoldWizard. It was designed a set of complete mold structure, including the core, the cavity, the mould frame, the inlay, the slide, the gating system and the cooling system structuralism design.
(2) Using the Moldflow/MPI analysis software, the plastic business card injection mould has been carried on the grid mesh, and the analysis type and the order has been established. Polystyrene (PS) was chosen to take this analysis the material in this paper, and the best gate location has been determined. After the pre-treatment process, filling simulation has been finished in the paper, and the results of the packing time, the pressure, the temperature at flow front, the pressure curve at injection location and so on were analyzed.
(3) Based on the material parameters of the different viscosity models at different temperatures of that the Power Law model, Ellis model and the model CIMP three viscosity model shear viscosity-shear rate curve, it has been analyzed that CIMP is better fit to Moldflow simulation. Factors of shear viscosity have been conducted in-depth discussions.
模流分析是塑料制品注塑成型的一种重要技术手段,它对于优化设计、缩短成型周期、提高产品质量有着重要的意义。本论文以塑料名片格为研究对象,结合实际生产需求,选择PS351为材料,利用Moldflow软件,对一模两腔塑料名片格进行了分析,并对几种流变学粘度模型进行了计算、比较,取得的主要成果如下：
(1)首先通过设计计算得出了塑料名片格各个主要部分的参数,然后在UG/MoldWizard中建立了塑料名片格注塑模具的三维模型。设计了一套完整的模具结构,其中包括型芯、型腔、模架、镶件、滑块、浇注系统和冷却系统等结构的设计。
(2)利用Moldflow/MPI模流分析软件对塑料名片格注塑模具进行了网格划分,设置了分析类型和顺序,选择聚苯乙烯(PS)作为本次分析的材料,并确定了最佳浇口位置,完成分析前处理后对填充过程进行了模拟,对分析结果中的填充时间、压力、流动前沿温度、注塑口压力曲线等做出了分析。
(3)根据不同粘度模型在不同温度下的材料参数得出了Power Law模型、Ellis模型和CIMP模型三种粘度模型剪切粘度-剪切速率曲线,分析得出CIMP粘度模型与Moldflow仿真分析中得到的粘度曲线最为接近,并对剪切粘度的影响因素进行了深入了讨论。
Injection molding is an important method of forming plastic products. It can produce complex shape, high precision products. However, injection molding is a complex physical process. During the injection molding process, the polymer melt is through a complex deformation and temperature changes, and these are directly related to the products ultimate performance.
Flow analysis is injection molding of an important technical means. It has important significance to optimize the design, shortening the molding cycle and improve product quality. Plastic business card was chosen for study in this paper. According as actual production needs, it was selected PS351 for materials, and analyzed a two-cavity plastic cards plastic grid in virtue of Moldflow software. Then it chose several rheological viscosity models to calculate and comparison. Through analysis and comparison, the main achievements are as follows:
(1) In the paper, every main part parameters of the plastic business card has been abtained through the design calculation. Then it has established the plastic business card injection mould three-dimensional model in UG/MoldWizard. It was designed a set of complete mold structure, including the core, the cavity, the mould frame, the inlay, the slide, the gating system and the cooling system structuralism design.
(2) Using the Moldflow/MPI analysis software, the plastic business card injection mould has been carried on the grid mesh, and the analysis type and the order has been established. Polystyrene (PS) was chosen to take this analysis the material in this paper, and the best gate location has been determined. After the pre-treatment process, filling simulation has been finished in the paper, and the results of the packing time, the pressure, the temperature at flow front, the pressure curve at injection location and so on were analyzed.
(3) Based on the material parameters of the different viscosity models at different temperatures of that the Power Law model, Ellis model and the model CIMP three viscosity model shear viscosity-shear rate curve, it has been analyzed that CIMP is better fit to Moldflow simulation. Factors of shear viscosity have been conducted in-depth discussions.
引文
1.韩先洪.成型充填过程中非等温非牛顿粘弹性流动数值模拟[D],大连：大连理工大学,2007.
2. L.W. Seow, Y.C. Lam, Optimizing flow in plastic injection molding, Journal of Materials Processing Technology 1997, (72):333-341.
3. J. Fassett, Thin wall molding:differences in processing over standard injection molding, Annual Technical Conference-ANTEC, Conference Proceedings, Vol.1, Soc. of Plastics Engineers, Brookfield, CT, USA,1995,430-433.
4. F. Boitout, J. F. Agassant, M. Vincent, Elastic calculation of residual stresses in injection molding[J], Polymer Processing,1995, (3),237-242.
5. K. M. B. Jansen, D. J. V. Dijk, M. H. Huesselman, Effect of processing conditions on shrinkage in injection molding, Polymer Engineering and Science[J],1998,38(5):838-846.
6. Ming-Chih Huang, Ching-Chih Tai, The effective factors in the warpage problem of an injection-molded part with a thin shell feature, Joural of Material Processing Technology 2001,(110):1-9.
7. N.R. Subramanian, Lin Tingyu (Leon), Yak Aik Seng, Optiming warpage analysis for an optical housing[J], Mechatronics,2005, (15) 111-127.
8.刘华春UG环境下大型注塑模具CAD研究及模流CAE分析[D]昆明：昆明理工大学,2005.
9.陈志新.塑料成型工艺模拟[D],昆明：昆明理工大学,2004.
10.任秉银.模具CAD/CAE/CAM[M],哈尔滨：哈尔滨工业大学出版社,29-37.
11.周大路,何柏林等.Moldflow在注塑模设计中的应用[J],2005,32(8)：26-34.
12.单岩等编著.Moldflow模具分析技术基础[M],北京：清华大学出版社,2005,123-145.
13.王庆历.基于Moldflow注塑制品收缩规律模拟实验研究[D].大连：大连理工大学,2005.
14.王刚、单岩编著.Moldflow模具分析应用实例[M],北京：清华大学出版社2005,52-73.
15.吴其晔、巫静安著.高分子材料流变学[M],北京：高等教育出版社,2002,1-14.
16. Chang Dae Han著,徐僖,吴大诚等译.Rheology in Polymer Processing[M],北京:科学出版社,1985,1-11.
17.巫承德.剪切作用对聚丙烯冷却过程中的高阶结构形成之影响[D],新竹：台湾交通大学,2004.
18.李名洋.平膜物理发泡制程衣架型模具：流动模拟及最佳化设计[D],新竹：台湾交通大学,2006.
19.纪坤宏.模具内的剪切操作对于iPP/PC聚合物射出成型品的材料结构的影响之研究[D],新竹：台湾交通大学,2005.
20.陈英哲.模具内的剪切操作对于PC/ABS聚合物射出成型品的抗拉强度的影响研究[D],新竹：台湾交通大学,2005.
21. HUNG WAI CHI. Flow of Polymer Melts in the Mould in Injection Molding. University of Hong Kong Master [D],1991.
22罗士成.模流分析与射出成型控制参数的优化[D],新竹：台湾交通大学,2006.
23.赖怀恩.导光板成型品质与射出成型过程参数之研究[D],新竹：台湾清华大学,2004.
24.洪继正.覆晶封装底部充填过程之三维CAE分析[D],新竹：台湾清华大学,2000
25.徐金明,张孟喜,丁涛.Matlab实用教程[M],北京：清华大学出版社,北京交通大学出版社,2005,103-146.
26.张威.Matlab基础与编程入门[M],西安：西安电子科技大学出版社,2004,36-78.
27.丁浩.流变学与塑料加工[J],工程塑料应用,1980,(02)：27-39.
28. Willian E. Biles, Timothy J. Gornet, Kenneth Davis, Allen Yi, Computer-Aided Design and rapid tool development in injection molding processes [J], Elsevier Science Ltd.,1995.
29. W. F. Zoetelief, L. F. A. Douven, Jingen Housz, Residual thermal stresses in injection molded products[J], Polymer Engineering and Science.1996,36(14):1886-1896.
30. P. Tantakom, N. R. Schott, "Processing strategies for thin wall injection molding" Processing Annua Technical Conference-ANTEC, Conference Proceedings, Soc. Of Plastics Engineers, Brookfield, CT, USA,1998(1):367-371.
31. K. K. Kabanemi, H. Vaillancount, H. Wang, G. Salloum, Residual stresses, shrinkage and warpage of complex injection molded products:Numerical simulation and experimental validation[J], Polymer Engineering and Science.1998,38(1):21-37.
32.江体乾著.化工流变学[M],上海：华东理工大学出版社,2004.
33.简锯炼.线性高分子溶液之流变性质及其分子量研究[D],台南市：台湾成功大学,2003.
34. S.H.Tang, Y.M. Kong, S.M.Sapuan, R. Samin, S. Sulaiman. Design and Thermal Analysis of Plastic Injection Mould[J]. Materials Processing Technology.2006 (171): 259-267.
35. Zhao Chunhua,B.Eng. Experimental Analysis and Simulation on Injection Molding Melt Temperature[D], Hong Kong:Hong Kong University of Science and Technology.
36. James Mattis, Paul Sheng, William Discipio and Ken Leong. A Framework for Analyzing Energy Efficient Injection Molding Die Design-Electronics and the Environ-ment[J],1996,26(15),56-67.
37.马文琦、孙红镱等编著.塑料成型模拟软件技术基础与应用[M],北京：中国铁道出版社,2006.
38.唐海翔编译.UG注塑模具设计培训教程[M],北京：清华大学出版社,2002.
39.李德群、唐志玉主编.中国模具设计大典[M],南昌：江西科学技术出版社,2002.
40.唐志玉编著.塑料模流变学设计[M],北京：国防工业出版社,1991.
41.陆宁编著.实用注塑模具设计[M],北京：中国轻工业出版社,1997.
42.游正晃著.塑胶机与塑胶模具[M],台北：三民书局出版社,1982.
43.许旭昌.微热压成型之温度模拟与应力分析[D],新竹：台湾交通大学,2006.
44. Yi Yang. Injection Molding Control:from Process to Quality[D], Hong Kong:Hong Kong University of Science and Technology,2004.
45.黄俊伟.压力效应对塑料粘度的影响[D],新竹：台湾成功大学,2002.
2. L.W. Seow, Y.C. Lam, Optimizing flow in plastic injection molding, Journal of Materials Processing Technology 1997, (72):333-341.
3. J. Fassett, Thin wall molding:differences in processing over standard injection molding, Annual Technical Conference-ANTEC, Conference Proceedings, Vol.1, Soc. of Plastics Engineers, Brookfield, CT, USA,1995,430-433.
4. F. Boitout, J. F. Agassant, M. Vincent, Elastic calculation of residual stresses in injection molding[J], Polymer Processing,1995, (3),237-242.
5. K. M. B. Jansen, D. J. V. Dijk, M. H. Huesselman, Effect of processing conditions on shrinkage in injection molding, Polymer Engineering and Science[J],1998,38(5):838-846.
6. Ming-Chih Huang, Ching-Chih Tai, The effective factors in the warpage problem of an injection-molded part with a thin shell feature, Joural of Material Processing Technology 2001,(110):1-9.
7. N.R. Subramanian, Lin Tingyu (Leon), Yak Aik Seng, Optiming warpage analysis for an optical housing[J], Mechatronics,2005, (15) 111-127.
8.刘华春UG环境下大型注塑模具CAD研究及模流CAE分析[D]昆明：昆明理工大学,2005.
9.陈志新.塑料成型工艺模拟[D],昆明：昆明理工大学,2004.
10.任秉银.模具CAD/CAE/CAM[M],哈尔滨：哈尔滨工业大学出版社,29-37.
11.周大路,何柏林等.Moldflow在注塑模设计中的应用[J],2005,32(8)：26-34.
12.单岩等编著.Moldflow模具分析技术基础[M],北京：清华大学出版社,2005,123-145.
13.王庆历.基于Moldflow注塑制品收缩规律模拟实验研究[D].大连：大连理工大学,2005.
14.王刚、单岩编著.Moldflow模具分析应用实例[M],北京：清华大学出版社2005,52-73.
15.吴其晔、巫静安著.高分子材料流变学[M],北京：高等教育出版社,2002,1-14.
16. Chang Dae Han著,徐僖,吴大诚等译.Rheology in Polymer Processing[M],北京:科学出版社,1985,1-11.
17.巫承德.剪切作用对聚丙烯冷却过程中的高阶结构形成之影响[D],新竹：台湾交通大学,2004.
18.李名洋.平膜物理发泡制程衣架型模具：流动模拟及最佳化设计[D],新竹：台湾交通大学,2006.
19.纪坤宏.模具内的剪切操作对于iPP/PC聚合物射出成型品的材料结构的影响之研究[D],新竹：台湾交通大学,2005.
20.陈英哲.模具内的剪切操作对于PC/ABS聚合物射出成型品的抗拉强度的影响研究[D],新竹：台湾交通大学,2005.
21. HUNG WAI CHI. Flow of Polymer Melts in the Mould in Injection Molding. University of Hong Kong Master [D],1991.
22罗士成.模流分析与射出成型控制参数的优化[D],新竹：台湾交通大学,2006.
23.赖怀恩.导光板成型品质与射出成型过程参数之研究[D],新竹：台湾清华大学,2004.
24.洪继正.覆晶封装底部充填过程之三维CAE分析[D],新竹：台湾清华大学,2000
25.徐金明,张孟喜,丁涛.Matlab实用教程[M],北京：清华大学出版社,北京交通大学出版社,2005,103-146.
26.张威.Matlab基础与编程入门[M],西安：西安电子科技大学出版社,2004,36-78.
27.丁浩.流变学与塑料加工[J],工程塑料应用,1980,(02)：27-39.
28. Willian E. Biles, Timothy J. Gornet, Kenneth Davis, Allen Yi, Computer-Aided Design and rapid tool development in injection molding processes [J], Elsevier Science Ltd.,1995.
29. W. F. Zoetelief, L. F. A. Douven, Jingen Housz, Residual thermal stresses in injection molded products[J], Polymer Engineering and Science.1996,36(14):1886-1896.
30. P. Tantakom, N. R. Schott, "Processing strategies for thin wall injection molding" Processing Annua Technical Conference-ANTEC, Conference Proceedings, Soc. Of Plastics Engineers, Brookfield, CT, USA,1998(1):367-371.
31. K. K. Kabanemi, H. Vaillancount, H. Wang, G. Salloum, Residual stresses, shrinkage and warpage of complex injection molded products:Numerical simulation and experimental validation[J], Polymer Engineering and Science.1998,38(1):21-37.
32.江体乾著.化工流变学[M],上海：华东理工大学出版社,2004.
33.简锯炼.线性高分子溶液之流变性质及其分子量研究[D],台南市：台湾成功大学,2003.
34. S.H.Tang, Y.M. Kong, S.M.Sapuan, R. Samin, S. Sulaiman. Design and Thermal Analysis of Plastic Injection Mould[J]. Materials Processing Technology.2006 (171): 259-267.
35. Zhao Chunhua,B.Eng. Experimental Analysis and Simulation on Injection Molding Melt Temperature[D], Hong Kong:Hong Kong University of Science and Technology.
36. James Mattis, Paul Sheng, William Discipio and Ken Leong. A Framework for Analyzing Energy Efficient Injection Molding Die Design-Electronics and the Environ-ment[J],1996,26(15),56-67.
37.马文琦、孙红镱等编著.塑料成型模拟软件技术基础与应用[M],北京：中国铁道出版社,2006.
38.唐海翔编译.UG注塑模具设计培训教程[M],北京：清华大学出版社,2002.
39.李德群、唐志玉主编.中国模具设计大典[M],南昌：江西科学技术出版社,2002.
40.唐志玉编著.塑料模流变学设计[M],北京：国防工业出版社,1991.
41.陆宁编著.实用注塑模具设计[M],北京：中国轻工业出版社,1997.
42.游正晃著.塑胶机与塑胶模具[M],台北：三民书局出版社,1982.
43.许旭昌.微热压成型之温度模拟与应力分析[D],新竹：台湾交通大学,2006.
44. Yi Yang. Injection Molding Control:from Process to Quality[D], Hong Kong:Hong Kong University of Science and Technology,2004.
45.黄俊伟.压力效应对塑料粘度的影响[D],新竹：台湾成功大学,2002.