摘要
短纤维增强聚合物(Short fiber reinforced polymer,简称SFRP)是现代复合材料的典型代表之一,本文重点针对SFRP注射和气体辅助注射成型过程的模拟和实验展开了研究,分析了工艺参数对SFRP成型过程和制品质量的影响,实现了工艺参数的优化,为SFRP注射和气体辅助注射工艺设计提供理论意义和指导依据。
1、注射成型中浇口位置模拟研究。采用三维模拟技术对矩形平板和梯形平板的注射成型过程进行模拟,分析了不同浇口位置对SFRP注射成型过程中锁模力、注射压力、纤维取向和塑件变形的影响规律,得出了最佳浇口位置设计方案,为模具的设计提供了指导意义。
2、注射成型工艺参数优化研究。采用Taguchi正交试验设计方法、直观的极差分析法、信噪比分析法对每项评价指标的工艺参数进行优化分析；采用矩阵分析法、遗传算法与径向基神经网络相结合的方法进行多目标函数的工艺参数优化,得到了最佳工艺参数组合形式,指出了纤维含量和熔体温度是影响SFRP注射成型过程的两个最主要的工艺参数,纤维间相互作用系数对纤维取向影响最大。
3、工艺参数和纤维参数对注射成型过程影响模拟。采用三维模拟技术研究了主要工艺参数和纤维参数对注射成型过程中锁模力、注射压力、塑件变形及纤维取向的影响,模拟结果表明：①添加短纤维后聚合物在注射过程中的锁模力和注射压力增大,但制品的变形程度降低。②锁模力、注射压力和塑件变形程度随纤维含量的增加先减小后增大,之后再减小,以纤维含量为20%wt时最小；纤维取向程度也随纤维含量的增大略有增大趋势。③随着熔体温度的升高,熔体黏度减小,流动阻力减小,锁模力和注射压力减小,纤维取向性先增大后减小,变形量呈增大的趋势。④随着纤维相互作用系数的增大,纤维取向程度减小,塑件变形程度呈现先增大后减小的趋势。⑤随着纤维长径比的增大,塑件的变形量先减小,后增大；纤维取向分布状态越明显。⑥随着保压压力的增大,锁模力增大,塑件的变形程度先减小后增大；保压压力对纤维的取向分布基本没有影响。⑦模具温度对SFRP注射成型的影响不明显。
因此,为了获得高质量制品,短纤维含量应控制在20%wt左右,熔体温度、模具温度和保压压力要合理选定。随着熔体温度和模具温度的升高,虽然注射成型的锁模力和注射压力降低,但塑件的变形程度也增大；随着保压压力的增大,注射成型中锁模力增大,但塑件的变形程度先减小后增大；纤维的长径比一般为10～50。
4、工艺参数对气体辅助注射成型过程影响模拟。采用三维模拟技术对SFRP气体辅助注射成型过程进行模拟,得到了气体延迟时间、气体压力、熔体预注射量等对气体辅助注射成型过程中锁模力、注射压力、塑件变形、气体穿透长度和气体时间等的影响及其规律,模拟结果表明：①气体辅助注射中注射压力、锁模力和变形均小于传统的注射成型。②气体在熔体中的穿透过程中形成明显的“气指”现象。③随着气体延迟时间的增大,气体在熔体中的穿透长度和气体时间均增大,而变形程度先减小后增大。④随着气体压力的增大,气体的穿透长度增大,气体时间没有改变,塑件的变形程度先减小后增大。
5、最优工艺参数实验研究。结合纤维取向分布的微观形貌和制品的宏观变形情况,重点研究了纤维含量、熔体温度对制品变形和纤维取向分布的影响规律,实验结果表明：①纤维取向分布存在一定的分层现象,且次表层纤维的取向程度最高,其次是表层纤维,芯层纤维取向程度最低。②纯PP原料注射成型塑件的变形程度较大,其次是含量为30%wt的PP30GF塑件,而PP20GF塑件的变形程度最小。③随着熔体温度的升高,塑件的变形程度呈增大的趋势。通过实验结果与模拟结果比较可知,两者具有较好的一致性,验证了工艺参数对短纤维增强聚合物注射成型的影响规律。
Short fiber reinforced polymer (SFRP) is one of typical represents of modern composites. Simulation and experimental researches of SFRP in injection molding and gas-assisted injection molding are proposed in this paper, the influence of process parameters and the quality of the products in injection molding for SFRP is analyzed, obtained an optimal process parameters for the designing and guiding to SFRP injection molding and gas-assisted injection molding.
1. Simulation of gate location in injection molding. According to the3D simulation technology, simulations of rectangle and trapezoid cross-section plate in injection molding are developed, and the influence of gate location on clamp force, injection pressure, fiber orientation and parts'deformation in injection molding for SFRP is analyzed, the optimum design scheme on gate location is developed, which can provide guidance with mould design.
2. Optimization of process parameters in injection molding. Multiple objective function optimization of process parameters is processed based on Taguchi orthogonal design, range analysis, signal to noise analysis(S/N), matrix analysis and radial basis function neural network combined with genetic algorithm, the optimal combination form of process parameters is obtained and the results show that fiber content and melt temperature are the main parameters, the interaction coefficient of fibers have great influence on the fiber orientation.
3. Simulation of process and fiber parameters in injection molding. The influence of main process and fiber parameters on clamp force, injection pressure, fiber orientation and parts'deformation is investigated, the results show that as follows:①The value of clamp force and injection pressure for SFRP are both more than that of PP in injection molding, and parts' deformation degree of SFRP is significantly less than that of PP.②With fiber content increasing, the maximum value of clamp force, injection pressure and deformation decrease first and then increase, next decrease again, and when fiber content is20%wt, the value of them are the minimum, so the fiber content20%wt is an optimum. Meanwhile, with fiber content increasing, the fiber orientation degree increases.③With melt temperature increasing, melt's viscosity reduces, and the flowing resistance of melt in mould cavity decreases, so the value of clamp force and injection pressure both decrease, but fiber orientation degree increases first and then decreases, while parts' deformation tends to increase.④With the value of fibers interaction coefficient(Ci) increasing, fiber orientation tends to decrease, while part's deformation degree increases first and then decreases.⑤With fiber aspect ratio increasing, part's deformation degree will decreases first and then increases, and the fiber orientation is obvious gradually.⑥With packing pressure increasing, the value of clamp force increases, but part's deformation degree decreases first and then increases.The packing pressure has nearly no effect on fiber orientation.⑦Mould temperature has no obvious influence on SFRP injection molding
In a word, in order to produce high quality products, the fiber content is about20%wt and process parameters of melt temperature, mould temperature and packing pressure are selected reasonably. With melt temperature and mould temperature increasing, both clamp force and injection pressure decrease, but parts' deformation degree increases. With packing pressure increasing, clamp force increases and parts' deformation degree decreases first and then increases. The fiber aspect ratio is10-50generally.
4. Simulation of gas-assisted injection molding. The influence of gas-delay time, gas pressure and melt pre-injection amount on injection pressure, parts'deformation, gas penetration length, gas time is investigated based on simulation of3D technology, the results show as follows:①The injection pressure, clamp force and parts' deformation in gas-assisted injection molding are all less than that of traditional injection molding.②There is an obviously gas-finger phenomenon in gas-assisted injection.③With gas-delay time increasing, both the gas penetration length and gas time increase, but parts'deformation degree decreases first and then increases.④With gas pressure increasing, the gas penetration length increases, and gas time don't vary, but parts' deformation degree decreases first and then increases.
5. Experiment research on optimization of process parameters. Combined fiber orientation microstructures with part's deformation, the effects of fiber content and melt temperature on parts' deformation and fiber orientation are investigated, the results show as follows:①Fiber orientation degree varies in different layers, the fiber orientation degree in the second-surface layer is the highest, next is that in the surface layer, but that in the core layer is the lowest.②The parts'deformation degree of PP is the highest, next is that of PP30GF, and that of PP20GF is the lowest.③With melt temperature increasing, parts'deformation tends to increase. From comparison simulation results with experimental results, it shows that the simulation and experiment results have a good consistency, and they both verify the influence of process parameters on SFRP.
引文
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