灌水器精密注塑模具设计理论与方法
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摘要
滴灌是先进的现代农业灌溉方法,灌水器的设计与制造是滴灌技术的核心,获取高质量、高精度灌水器的关键要依靠精密注塑模具和精密注塑工艺。然而人们在进行精密注塑模具的设计时未能考虑模具设计、模具制造以及注塑工艺之间的密切联系,这一串行的设计模式导致了模具设计周期冗长、模具返修率高、注塑件精度难以获得保障等问题。为解决这一问题,本文提出了一种基于并行设计的精密注塑模具设计方法。
首先分析现行注塑模串行设计缺点的基础上,给出了精密注塑模具并行设计流程。这一流程以模具设计为中心,以CAE和CAM为重要手段,能够最大限度地协调塑件设计、模具设计、模具制造、塑件生产各个环节的设计工作。由于各个设计环节并行进行,各环节之间密切联系,大大减少了设计问题出现的可能,节约了修改、反复的时间和成本,提高了设计的效率和准确度。
紧接着讨论了注塑模设计的两大关键部分——浇注系统和冷却系统的设计。推导出了多型腔浇注系统流动平衡的数学模型,给出了模型的求解方法,并开发出了浇注系统设计专用模块。并引入随形冷却技术,利用选择性激光烧结间接制造内置随形冷却水道的注塑模具,能够使模具温度均匀稳定,提高注塑模的冷却效果,获得质量更好的塑件;减少冷却时间,缩短注塑周期,使注塑效率更高。提出了随形冷却水道的设计思想,总结出了随形冷却水道的设计规则。同时结合SLS成功烧结出内置随形冷却水道的香盒注塑模并生产出合格的注塑件产品。
最后讨论了注塑工艺参数对注塑件精度和质量的影响,通过CAE模拟技术,可以获得合理的注塑工艺参数。
Drip is an advanced modern agriculture irrigation method, the design and manufacture of emitter is the core of drip technology, the key that obtains high quality and accuracy emitter is depend on precise injection mold and precise injection process. However, when we carried on the design of precise injection mold, the close contact among mold design, mold manufacture and injection process are neglected. This string design mode caused a series of problems, such as: long design period, frequent modification and the injection parts’accuracy hard to acquire a guarantee. In order to resolve this problem, this paper provides a new precise injection mold design method which is based on concurrent design.
Firstly,on the foundation of analyzing the disadvantage of string design of precise injection mold, we give out a concurrent design flow. In this flow, mold design process should be regarded as a center of the whole design cycle, CAE and CAM should be taken as important tools. It can harmonize the design among part design, mold design, mold manufacture and parts produce. Because of all design links are carried on parallel, their contact are too close, which decrease the possibility of design problems appeared, economize the time and cost of modify and iterative, promote the design efficiency and accuracy.
Next, we discuss the runner system and cooling system design, two key parts of mold design. We deduce the mathematics model of mutli-cavity injection mold runner system’s flow balance; give out the method to solve this model. At last, a program about runner system design was developed. Introduce the conformal cooling technology, and manufacture the injection mold with conformal cooling channels via in-direct Selective Laser Sinter (SLS), offering the substantial improvement in the control of mold temperature to keep it in steady state, improvement the uniform and efficient cooling of parts and the resulting quality of parts produced, influencing both the rate of the process and the injection cycle time. We advanced the design idea and rules of conformal cooling channels. Uses the core inserts with conformal cooling channels induce the design rules for the design of cooling system for mold based on SLS technology.
Lastly, we discuss the factors influence the quality of injection parts. Passed CAE imitation, we can obtain a group of process parameters for parts’product.
首先分析现行注塑模串行设计缺点的基础上,给出了精密注塑模具并行设计流程。这一流程以模具设计为中心,以CAE和CAM为重要手段,能够最大限度地协调塑件设计、模具设计、模具制造、塑件生产各个环节的设计工作。由于各个设计环节并行进行,各环节之间密切联系,大大减少了设计问题出现的可能,节约了修改、反复的时间和成本,提高了设计的效率和准确度。
紧接着讨论了注塑模设计的两大关键部分——浇注系统和冷却系统的设计。推导出了多型腔浇注系统流动平衡的数学模型,给出了模型的求解方法,并开发出了浇注系统设计专用模块。并引入随形冷却技术,利用选择性激光烧结间接制造内置随形冷却水道的注塑模具,能够使模具温度均匀稳定,提高注塑模的冷却效果,获得质量更好的塑件;减少冷却时间,缩短注塑周期,使注塑效率更高。提出了随形冷却水道的设计思想,总结出了随形冷却水道的设计规则。同时结合SLS成功烧结出内置随形冷却水道的香盒注塑模并生产出合格的注塑件产品。
最后讨论了注塑工艺参数对注塑件精度和质量的影响,通过CAE模拟技术,可以获得合理的注塑工艺参数。
Drip is an advanced modern agriculture irrigation method, the design and manufacture of emitter is the core of drip technology, the key that obtains high quality and accuracy emitter is depend on precise injection mold and precise injection process. However, when we carried on the design of precise injection mold, the close contact among mold design, mold manufacture and injection process are neglected. This string design mode caused a series of problems, such as: long design period, frequent modification and the injection parts’accuracy hard to acquire a guarantee. In order to resolve this problem, this paper provides a new precise injection mold design method which is based on concurrent design.
Firstly,on the foundation of analyzing the disadvantage of string design of precise injection mold, we give out a concurrent design flow. In this flow, mold design process should be regarded as a center of the whole design cycle, CAE and CAM should be taken as important tools. It can harmonize the design among part design, mold design, mold manufacture and parts produce. Because of all design links are carried on parallel, their contact are too close, which decrease the possibility of design problems appeared, economize the time and cost of modify and iterative, promote the design efficiency and accuracy.
Next, we discuss the runner system and cooling system design, two key parts of mold design. We deduce the mathematics model of mutli-cavity injection mold runner system’s flow balance; give out the method to solve this model. At last, a program about runner system design was developed. Introduce the conformal cooling technology, and manufacture the injection mold with conformal cooling channels via in-direct Selective Laser Sinter (SLS), offering the substantial improvement in the control of mold temperature to keep it in steady state, improvement the uniform and efficient cooling of parts and the resulting quality of parts produced, influencing both the rate of the process and the injection cycle time. We advanced the design idea and rules of conformal cooling channels. Uses the core inserts with conformal cooling channels induce the design rules for the design of cooling system for mold based on SLS technology.
Lastly, we discuss the factors influence the quality of injection parts. Passed CAE imitation, we can obtain a group of process parameters for parts’product.
引文
[1] 杨培岭,雷显龙.滴灌用灌水器的发展及研究.节水灌溉,2000,(3):17~18
[2] 韩权利,赵万华,丁玉成.滴灌用灌水器的现状及分析.节水灌溉,2003,(1):17~18
[3] 范兴科,吴普特,朱献文等.滴灌产品的激光快速成型技术.灌溉排水学报,2003,22(5):35~37
[4] 黄兴法,李光永.地下滴灌技术的研究现状与发展.农业工程学报,2002,18(2):176~181
[5] 魏青松,史玉升,董文楚等.精密滴灌灌水器快速响应开发方法研究.农业机械学报,2006(已录用)
[6] 史玉升,魏青松,鲁俊等.农业节水产品(灌水器)低成本快速开发方法研究.节水灌溉,2004,(5):31~32
[7] 魏青松,史玉升,鲁俊等.滴灌灌水器低成本快速开发理论与方法研究.农业工程学报,2005,21(2):17~21
[8] 鲁俊,史玉升,魏青松等.滴灌灌水器精密注塑模具设计与开发.中国农村水利水电,2005,(7):1~3
[9] 王建和,史玉升,魏青松等.灌水器注塑模浇注系统计算机辅助设计.农业机械学报,2006 (已录用)
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[3] 范兴科,吴普特,朱献文等.滴灌产品的激光快速成型技术.灌溉排水学报,2003,22(5):35~37
[4] 黄兴法,李光永.地下滴灌技术的研究现状与发展.农业工程学报,2002,18(2):176~181
[5] 魏青松,史玉升,董文楚等.精密滴灌灌水器快速响应开发方法研究.农业机械学报,2006(已录用)
[6] 史玉升,魏青松,鲁俊等.农业节水产品(灌水器)低成本快速开发方法研究.节水灌溉,2004,(5):31~32
[7] 魏青松,史玉升,鲁俊等.滴灌灌水器低成本快速开发理论与方法研究.农业工程学报,2005,21(2):17~21
[8] 鲁俊,史玉升,魏青松等.滴灌灌水器精密注塑模具设计与开发.中国农村水利水电,2005,(7):1~3
[9] 王建和,史玉升,魏青松等.灌水器注塑模浇注系统计算机辅助设计.农业机械学报,2006 (已录用)
[10] 奚永生编著.精密注塑模具设计.北京:中国轻工出版社,1997
[11] 李岐新.精密注塑成型模具的设计要点.机电元件,1997,17(2):35~41
[12] [日]白石顺一郎著.注塑成形模具.许鹤峰译.北京:烃加工出版社出版,1989
[13] Sun YF, Lee KS, Nee AYC. The Application of U Shape Milled Grooves for Cooling of Injection Moulds. Proceedings of the Institution of Mechanical Engineers(PartB):Journal of Engineering Manufacture,2002,216(12):1561~1573
[14] Leopold Kiernicki, James W.Mciginley, Philip W.Schofield. Method and Apparatus for Precision Injection Molding. US Patent:US6277308 B1,2001
[1] 杨培岭,雷显龙.滴灌用灌水器的发展及研究.节水灌溉,2000,(3):17~18
[2] 韩权利,赵万华,丁玉成.滴灌用灌水器的现状及分析.节水灌溉,2003,(1):17~18
[3] 范兴科,吴普特,朱献文等.滴灌产品的激光快速成型技术.灌溉排水学报,2003,22(5):35~37
[4] 黄兴法,李光永.地下滴灌技术的研究现状与发展.农业工程学报,2002,18(2):176~181
[5] 魏青松,史玉升,董文楚等.精密滴灌灌水器快速响应开发方法研究.农业机械学报,2006(已录用)
[6] 史玉升,魏青松,鲁俊等.农业节水产品(灌水器)低成本快速开发方法研究.节水灌溉,2004,(5):31~32
[7] 魏青松,史玉升,鲁俊等.滴灌灌水器低成本快速开发理论与方法研究.农业工程学报,2005,21(2):17~21
[8] 鲁俊,史玉升,魏青松等.滴灌灌水器精密注塑模具设计与开发.中国农村水利水电,2005,(7):1~3
[9] 王建和,史玉升,魏青松等.灌水器注塑模浇注系统计算机辅助设计.农业机械学报,2006 (已录用)
[10] 奚永生编著.精密注塑模具设计.北京:中国轻工出版社,1997
[11] 李岐新.精密注塑成型模具的设计要点.机电元件,1997,17(2):35~41
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