注塑件设计与制造品质的同一化研究
摘要
注塑件因其无可替代的可塑性和优良的物理化学性能被广泛应用于制造业,尤其越来越多的被用作产品的主要功能件和外观件。但很多时候因设计之初的盲目、设计同制造的脱节,致使注塑件相关企业在研发的过程中无端的增加了大量的设计变更、模具返工、重复检测等一系列补救成本,拖延了开发进度,耗时耗力却实现不了注塑件的目标品质。相应的,注塑件的低品质会进一步影响到同其关联的产品品质和市场销售。
为了摆脱当前国内制造业国际竞争力弱、整体品质低下的现状,根本之一是提高注塑件品质。本文结合注塑件整个生产过程中的关键技术,就如何使注塑件设计的目标品质同制造的实际品质一致的问题进行了系统化的研究。
本文首先在注塑件传统质量概念的基础之上提出了品质的概念,探讨了注塑件品质同设计和制造品质的关系,提出了注塑件品质评价标准的制定原则。然后,重点以注塑件大体的生产过程为主线,从技术上分析、整合并提炼出各环节工作中确保和提升注塑件设计品质和制造品质的工作流程,可遵循的设计和制造理论、方法、数据和实例。此外,从管理上浅析了便于实现注塑件设计同制造的品质同一化行之有效的措施。最后,以有缺陷的注塑件为实例,反向分析实现设计和制造同一化的具体方法。
本文的指导意义在于使开发人员从一开始就站在较高的角度,全面地考虑注塑件从概念形成到生产制造到报废的全生命周期内各阶段的因素,制定合理的设计品质评价标准,并强调生产中各个环节的协同工作,综合运用设计和制造技术,以最高的效率、最低的成本、最少的失误实现制造品质同设计品质的一致性。
The Injection Molded Parts have been widely used in the manufacturing sector, because of the irreplaceable plasticity and good physical and chemical properties, especially to be used as the increasing number of product’s main functional pieces and appearance pieces. But very often because of the blind design in the beginning, the disjoint of design and manufacture, causing the injection molded Parts-related enterprises unwarranted increase a number of design changes, mold rework, duplication detection series of remedial costs, delays in the development, and time-consuming in the development process, but finally can not achieve the injection molded parts that same as the goal quality. Accordingly, the low-quality injection molded parts will further affect its related products to the same quality and marketing.
To shake off the domestic manufacturing sector’s current state that weakly international competitiveness and overall low quality, the fundamental one is to improve the quality of injection molded parts. The paper combination the key technologies of the injection molded part’s entire production process, on how to make the designed goal quality of injection molded parts Consistent with actual manufacture quality , to make system analysis notes and summarized.
The paper firstly clear the theoretical basis of this research that is concepts of quality of design and quality of manufacture, explore the standards and methods that can measure the quality of the injection molded parts. Then, focus on the whole production process of injection molded parts as the main line, from the technical Perspective to study and review the methods and theories that can make the concept design and the structural design Consistent with the manufacture, make the mold, injection molding, packaging Consistent with the design. Finally, from management Perspective to facilitate the effective measures that can easily achievement the injection molded part’s design quality Consistent with the manufacture quality.
The paper’s guide is to enable developers to start from a higher point standing, comprehensive consideration all stages factors from the concept formation to manufacturing to scrap in injection molded part’s entire life cycle, Comprehensive considered cost, consumer location, function and other factors to determine a reasonable evaluation criteria of design quality, and emphasize all aspects cooperative work in production, integrated use design and manufacturing technology, with the highest efficiency , lowest cost and least errors to make the manufacturing quality with the design quality consistency.
为了摆脱当前国内制造业国际竞争力弱、整体品质低下的现状,根本之一是提高注塑件品质。本文结合注塑件整个生产过程中的关键技术,就如何使注塑件设计的目标品质同制造的实际品质一致的问题进行了系统化的研究。
本文首先在注塑件传统质量概念的基础之上提出了品质的概念,探讨了注塑件品质同设计和制造品质的关系,提出了注塑件品质评价标准的制定原则。然后,重点以注塑件大体的生产过程为主线,从技术上分析、整合并提炼出各环节工作中确保和提升注塑件设计品质和制造品质的工作流程,可遵循的设计和制造理论、方法、数据和实例。此外,从管理上浅析了便于实现注塑件设计同制造的品质同一化行之有效的措施。最后,以有缺陷的注塑件为实例,反向分析实现设计和制造同一化的具体方法。
本文的指导意义在于使开发人员从一开始就站在较高的角度,全面地考虑注塑件从概念形成到生产制造到报废的全生命周期内各阶段的因素,制定合理的设计品质评价标准,并强调生产中各个环节的协同工作,综合运用设计和制造技术,以最高的效率、最低的成本、最少的失误实现制造品质同设计品质的一致性。
The Injection Molded Parts have been widely used in the manufacturing sector, because of the irreplaceable plasticity and good physical and chemical properties, especially to be used as the increasing number of product’s main functional pieces and appearance pieces. But very often because of the blind design in the beginning, the disjoint of design and manufacture, causing the injection molded Parts-related enterprises unwarranted increase a number of design changes, mold rework, duplication detection series of remedial costs, delays in the development, and time-consuming in the development process, but finally can not achieve the injection molded parts that same as the goal quality. Accordingly, the low-quality injection molded parts will further affect its related products to the same quality and marketing.
To shake off the domestic manufacturing sector’s current state that weakly international competitiveness and overall low quality, the fundamental one is to improve the quality of injection molded parts. The paper combination the key technologies of the injection molded part’s entire production process, on how to make the designed goal quality of injection molded parts Consistent with actual manufacture quality , to make system analysis notes and summarized.
The paper firstly clear the theoretical basis of this research that is concepts of quality of design and quality of manufacture, explore the standards and methods that can measure the quality of the injection molded parts. Then, focus on the whole production process of injection molded parts as the main line, from the technical Perspective to study and review the methods and theories that can make the concept design and the structural design Consistent with the manufacture, make the mold, injection molding, packaging Consistent with the design. Finally, from management Perspective to facilitate the effective measures that can easily achievement the injection molded part’s design quality Consistent with the manufacture quality.
The paper’s guide is to enable developers to start from a higher point standing, comprehensive consideration all stages factors from the concept formation to manufacturing to scrap in injection molded part’s entire life cycle, Comprehensive considered cost, consumer location, function and other factors to determine a reasonable evaluation criteria of design quality, and emphasize all aspects cooperative work in production, integrated use design and manufacturing technology, with the highest efficiency , lowest cost and least errors to make the manufacturing quality with the design quality consistency.
引文
[1]申开智、叶淑静等,塑料成型模具,北京:中国轻工业出版社,1982.5~60
[2]付宏生、刘京华,注塑制品与注塑模具设计,北京:化学工业出版社,2003.3~50
[3]廖正品,中国注塑行业基本现状与“十五”期间发展方向,在精密注塑成型技术高级研讨班上的报告,2006.1~6
[4]张国忠、徐万红等,并行工程研究与应用,辽宁工程技术大学学报(自然科学版),2004,01:1~5
[5]徐匡迪,“节约型制造科技前沿”研讨会上的报告,2006. 1~5
[6]傅立丰、张耀宗、刘长红,并行工程的发展及应用,河南科技大学学报,2005,01:1~4
[7]“十一五”期间振兴我国装备制造业的途径与对策的报告,中宏数据库,2006. 1~3
[8]并行工程的研究与实现,第五届中国计算机集成制造系统学术会议(CIMS—China’98)论文集(上册),2006.109—122
[9]2006年中国模具行业投资分析与市场预测报告,2006.1~5
[10]罗继相,浅析我国模具行业现状及发展趋势和对策,模具技术,2001,03: 1~6
[11]边守仁,产品创新设计,北京:北京理工大学出版社,2002.1~50
[12]陈震邦,工业产品造型设计,北京:机械工业出版社,2005.1~30
[13]刘宝顺,产品结构设计,中国建筑工业出版社,2005.5~30
[14]张子成、邢继纲,塑料产品设计,国防工业出版社,2006. 77~83,130~134
[15]洪慎章,实用注塑成型及模具设计,北京:机械工业出版社,2006.65~73
[16]林志航,产品设计与制造质量工程,北京:机械工业出版社,2005.3~10
[17]刘吉昆,产品价值分析,黑龙江科学技术出版社,1997.10~35
[18]王朝晖、刘玉辉,现代制造系统的现状及其发展趋势,冶金设备,2001,03: 1~5
[19]丛伟,价值工程理论在产品优化设计中的应用研究,机械设计与制造,2006,6: 1~5
[20]王红伟、舒大文、朱琦琦,并行工程在注塑模设计与制造中的应用研究, Mould&Die Project,2004,NO.12:1~3
[21]中国模协技术委员会模具评定评述专家组,中国模具工业协会动态信息报81道,第八届国际模展模具先进制造技术评述,2006.2~5
[22] M.J.小戈登(美),塑料制品工业设计,北京:化学工业出版社,2005.1~220
[23]KevinN.Otto,KristinL.Wood(美),产品设计,电子工业出版社,2005.3~58
[24]林秀雄,品质管制,海天出版社,2004.2~15
[25]钟朝蒿(台湾),品质管理大全上下两册,厦门:厦门大学出版社,2005. 2~13
[26]Chen Yuh-Min、Liu Jang-Jong,Cost-efective for injection molding, Robotics and Computer-Integrated manufacturing,1999,(15): 1~4
[27]NI Ke , Value Analysis of Product Design , Robotics and Computer-Integrated manufacturing,2005,(15): 2~6
[28]苟宏,皮具制造业经营管理与品质控制,海天出版社,2005.3~65
[29]季晨,以人性化的思想提高产品品质―浅谈机床PIS形象建设,东华大学学报,2006,(02):1~7
[30]Vawkevae,Seppo(1990),Product Semantics 89.Helsinki,University of Industrial Art.2004,(15): 1~4
[31]唐纳德.高斯、杰拉尔德.温伯格,探索需求---设计前的质量,北京:清华大学出版社,2006.3~24
[32] KevinN.Otto,KristinL.Wood(美),产品设计,电子工业出版社,2005. 67~88
[33]梅强、李文元、赵观兵,新产品开发管理,北京:化学工业出版社,2004.5~45
[34]Tushar H Dani, Rajit Gadh. Creation of concept shape designs via a virtual reality interface. Computer-Aided Design, 1997,29(8): 555~563
[35]邹慧君、王石刚、蔡逆水,基于多层推理机制的机械产品概念设计,计算机辅助设计与图形学学报,1997,9(6):549~553
[36]丁晓东,从人机工程角度谈机械产品的造型设计,机械研究与应用,2005,2(8):2~6
[37]Wallance, R. David, Jakieia, Mark J. Automated Product Concept Design: Unifying Aesthetics and Engineering. IEEE CG&A. 1993, July: 66~75
[38]黄锐,塑料工程手册(上、下),北京:机械工业出版社,2002.3~9
[39]施平,基于神经网络的注塑制品材料选择方法,哈尔滨工业大学学报,2005,03: 2~7
[40]设计课程组,机械设计网络课程,东南大学机械工程学院,网址:http://me.seu.edu.cn/course/mechdesign/netcourse
[41]陈洪武、黄克正、杨波,基于功能表面的产品结构设计自动化研究与实现,机械设计与研究,2004,(03):2~5
[42]金国斌,塑料包装容器设计,北京:化学工业出版社,2003.22~28
[43]徐晓慧、童秉枢,面向装配的产品结构设计模糊评价方法与实现,农业机械学报,2007,02:2~4
[44]吴宗泽、王忠祥、卢颂峰,机械设计禁忌800例,北京:机械工业出版社,2006,69~72
[45]UGS,产品全生命周期管理解决方案在六西格玛设计中的应用,CAD/CAM与制造业信息化,2004,06:1~3
[46]王维、聂冲、赵雯,复杂产品一体化优化设计,计算机仿真,2005,11:1~3
[47]邢静忠、王永岗、陈晓霞,ANSYS 7.0分析实例与工程应用,北京:机械工业出版社,2004. 2~5
[48]何建中,CAE技术在注塑模具设计中的应用,中国西部科技,2007,04:1~3
[49]成都科技大学、北京化工学院、天津轻工业学院合编,塑料成型模具,北京:中国轻工业出版社,1982.3~86
[50]卜建新,塑料模具设计,北京:中国轻工业出版社.1999. 78~96
[51]宋学聪,模具的设计与制造,机械管理开发,2006,06:2~4
[52]赵志伟、张崇才,模具制造缺陷及其防止措施,电加工与模具,2004,05:2~4
[53]奚东,注塑成型中制品的缺陷原因及其对策,塑料科技,2000,03:1~5
[54]许荔珉、李澍、胡炯宇,注塑成型质量缺陷分析,模具技术,2005,No.2: 3~5
[55]陈晓川,并行工程中面向成本的设计(DFC),吉林人民出版,2003.5~9
[56]张国忠、徐万红、黄理清,并行工程研究与应用,辽宁工程技术大学学报(自然科学版),2004,01:2~3
[57]俞昌吉、胡如夫,现代产品开发设计的并行工程技术,机床与液压,200304:2~4
[2]付宏生、刘京华,注塑制品与注塑模具设计,北京:化学工业出版社,2003.3~50
[3]廖正品,中国注塑行业基本现状与“十五”期间发展方向,在精密注塑成型技术高级研讨班上的报告,2006.1~6
[4]张国忠、徐万红等,并行工程研究与应用,辽宁工程技术大学学报(自然科学版),2004,01:1~5
[5]徐匡迪,“节约型制造科技前沿”研讨会上的报告,2006. 1~5
[6]傅立丰、张耀宗、刘长红,并行工程的发展及应用,河南科技大学学报,2005,01:1~4
[7]“十一五”期间振兴我国装备制造业的途径与对策的报告,中宏数据库,2006. 1~3
[8]并行工程的研究与实现,第五届中国计算机集成制造系统学术会议(CIMS—China’98)论文集(上册),2006.109—122
[9]2006年中国模具行业投资分析与市场预测报告,2006.1~5
[10]罗继相,浅析我国模具行业现状及发展趋势和对策,模具技术,2001,03: 1~6
[11]边守仁,产品创新设计,北京:北京理工大学出版社,2002.1~50
[12]陈震邦,工业产品造型设计,北京:机械工业出版社,2005.1~30
[13]刘宝顺,产品结构设计,中国建筑工业出版社,2005.5~30
[14]张子成、邢继纲,塑料产品设计,国防工业出版社,2006. 77~83,130~134
[15]洪慎章,实用注塑成型及模具设计,北京:机械工业出版社,2006.65~73
[16]林志航,产品设计与制造质量工程,北京:机械工业出版社,2005.3~10
[17]刘吉昆,产品价值分析,黑龙江科学技术出版社,1997.10~35
[18]王朝晖、刘玉辉,现代制造系统的现状及其发展趋势,冶金设备,2001,03: 1~5
[19]丛伟,价值工程理论在产品优化设计中的应用研究,机械设计与制造,2006,6: 1~5
[20]王红伟、舒大文、朱琦琦,并行工程在注塑模设计与制造中的应用研究, Mould&Die Project,2004,NO.12:1~3
[21]中国模协技术委员会模具评定评述专家组,中国模具工业协会动态信息报81道,第八届国际模展模具先进制造技术评述,2006.2~5
[22] M.J.小戈登(美),塑料制品工业设计,北京:化学工业出版社,2005.1~220
[23]KevinN.Otto,KristinL.Wood(美),产品设计,电子工业出版社,2005.3~58
[24]林秀雄,品质管制,海天出版社,2004.2~15
[25]钟朝蒿(台湾),品质管理大全上下两册,厦门:厦门大学出版社,2005. 2~13
[26]Chen Yuh-Min、Liu Jang-Jong,Cost-efective for injection molding, Robotics and Computer-Integrated manufacturing,1999,(15): 1~4
[27]NI Ke , Value Analysis of Product Design , Robotics and Computer-Integrated manufacturing,2005,(15): 2~6
[28]苟宏,皮具制造业经营管理与品质控制,海天出版社,2005.3~65
[29]季晨,以人性化的思想提高产品品质―浅谈机床PIS形象建设,东华大学学报,2006,(02):1~7
[30]Vawkevae,Seppo(1990),Product Semantics 89.Helsinki,University of Industrial Art.2004,(15): 1~4
[31]唐纳德.高斯、杰拉尔德.温伯格,探索需求---设计前的质量,北京:清华大学出版社,2006.3~24
[32] KevinN.Otto,KristinL.Wood(美),产品设计,电子工业出版社,2005. 67~88
[33]梅强、李文元、赵观兵,新产品开发管理,北京:化学工业出版社,2004.5~45
[34]Tushar H Dani, Rajit Gadh. Creation of concept shape designs via a virtual reality interface. Computer-Aided Design, 1997,29(8): 555~563
[35]邹慧君、王石刚、蔡逆水,基于多层推理机制的机械产品概念设计,计算机辅助设计与图形学学报,1997,9(6):549~553
[36]丁晓东,从人机工程角度谈机械产品的造型设计,机械研究与应用,2005,2(8):2~6
[37]Wallance, R. David, Jakieia, Mark J. Automated Product Concept Design: Unifying Aesthetics and Engineering. IEEE CG&A. 1993, July: 66~75
[38]黄锐,塑料工程手册(上、下),北京:机械工业出版社,2002.3~9
[39]施平,基于神经网络的注塑制品材料选择方法,哈尔滨工业大学学报,2005,03: 2~7
[40]设计课程组,机械设计网络课程,东南大学机械工程学院,网址:http://me.seu.edu.cn/course/mechdesign/netcourse
[41]陈洪武、黄克正、杨波,基于功能表面的产品结构设计自动化研究与实现,机械设计与研究,2004,(03):2~5
[42]金国斌,塑料包装容器设计,北京:化学工业出版社,2003.22~28
[43]徐晓慧、童秉枢,面向装配的产品结构设计模糊评价方法与实现,农业机械学报,2007,02:2~4
[44]吴宗泽、王忠祥、卢颂峰,机械设计禁忌800例,北京:机械工业出版社,2006,69~72
[45]UGS,产品全生命周期管理解决方案在六西格玛设计中的应用,CAD/CAM与制造业信息化,2004,06:1~3
[46]王维、聂冲、赵雯,复杂产品一体化优化设计,计算机仿真,2005,11:1~3
[47]邢静忠、王永岗、陈晓霞,ANSYS 7.0分析实例与工程应用,北京:机械工业出版社,2004. 2~5
[48]何建中,CAE技术在注塑模具设计中的应用,中国西部科技,2007,04:1~3
[49]成都科技大学、北京化工学院、天津轻工业学院合编,塑料成型模具,北京:中国轻工业出版社,1982.3~86
[50]卜建新,塑料模具设计,北京:中国轻工业出版社.1999. 78~96
[51]宋学聪,模具的设计与制造,机械管理开发,2006,06:2~4
[52]赵志伟、张崇才,模具制造缺陷及其防止措施,电加工与模具,2004,05:2~4
[53]奚东,注塑成型中制品的缺陷原因及其对策,塑料科技,2000,03:1~5
[54]许荔珉、李澍、胡炯宇,注塑成型质量缺陷分析,模具技术,2005,No.2: 3~5
[55]陈晓川,并行工程中面向成本的设计(DFC),吉林人民出版,2003.5~9
[56]张国忠、徐万红、黄理清,并行工程研究与应用,辽宁工程技术大学学报(自然科学版),2004,01:2~3
[57]俞昌吉、胡如夫,现代产品开发设计的并行工程技术,机床与液压,200304:2~4