冰箱显示板模内注塑工艺及预变形研究

发布时间：2018-08-08 20:07

【摘要】：模内注塑件(IML)因其外观优势,已成为家电行业重要外观显示部件,但是,模内注塑制品也因其极易变形扭曲的工艺缺陷影响制品外观精细化水平,甚至会出现运输、使用过程脱落零部件的问题。本研究主要针对家电的模内注塑制品,通过软件虚拟仿真结合实际试模,统计并分析典型家电模内注塑制品的成形工艺,以及在不同数据下制品的平整度变形。通过CAE软件分析模内注塑制品壁厚、填充过程、保压过程、模具温度、冷却过程,得出模内注塑制品变形理论数据。同时,结合CAE分析的数据进行模具设计,在模具结构设计方案中设计出合理的制品浇口尺寸和位置、冷却系统、顶出系统。模具制造完成后,根据CAE分析的理论数据并结合现场实际情况进行模具调整试制,将制品放置一定时间后测量长度方向和宽度方向变形量,并与CAE软件分析变形数据进行对比,从而得到了预变形验证的数据并进行开模验证。另一方面,本研究还试验并分析了冰箱显示板和异形制品的多个预变形数据,并开模验证了经预变形处理的试验结果,验证了预变形对于改善模内注塑制品翘曲变形重要作用。本研究还提出采用背面加筋位支撑、装配矫正等方式可以控制调整变形。另一方面,预变形的验证虽然已经在冰箱这两款制品上验证成功,但由于这两款制品都属于平板件,对于非平板件制品来讲,弧形方向是否增加预变形数据还需要进一步的研究验证;避免出现带弧度(非平板件)的制品在完全借鉴预变形数据后,因制品回弹尺寸不准确造成装配干涉甚至模具镶块报废的问题。通过本课题研究,初步掌握了制品预变形规律,模内注塑预变形的研究,对于今后家电类模内注塑制品预变形设计数据提供了很好的借鉴和指导。同时,通过预变形的应用明显提升家电类制品外观精细化质量水平,减小模内注塑制品与装配部件之间的装配间隙,提升制品生产达成率,降低部件采购成本。增加制品外观质量市场竞争力。
[Abstract]:Because of its advantages in appearance, (IML) has become an important appearance display part in the household appliance industry. However, because of its easily distorted and distorted process defects, the internal injection molded products will affect the fine appearance level of the products, and even be transported. Problems with shedding parts during use. This research mainly aims at the household appliances injection molding products in the mold, through the software virtual simulation combined with the actual test mold, statistics and analysis of typical household electrical appliances mold injection molding process, as well as under the different data of the product smoothness deformation. The wall thickness, filling process, holding pressure process, mold temperature and cooling process of injection molding products were analyzed by CAE software, and the theoretical data of deformation of injection products were obtained. At the same time, according to the data of CAE analysis, the mold design is carried out, and the reasonable product gate size and position, cooling system and ejection system are designed in the design scheme of die structure. After the mold manufacture is finished, according to the theoretical data of CAE analysis and combined with the actual situation of the field, the mold is adjusted and manufactured. After the products are placed for a certain time, the deformation in the direction of length and width is measured and compared with the deformation data analyzed by CAE software. The data of pre-deformation verification are obtained and the open-die verification is carried out. On the other hand, several pre-deformation data of refrigerator display panel and special-shaped products are tested and analyzed, and the experimental results of pre-deformation are verified by opening mold, which proves that pre-deformation plays an important role in improving the warpage of injection molding products. This study also proposed that the adjustment of deformation can be controlled by means of backside stiffened position support and assembly correction. On the other hand, although the pre-deformation verification has been successfully verified on these two types of refrigerators, since both of these products belong to flat parts, for non-flat products, Whether the arc direction increases the pre-deformation data needs further research and verification; to avoid the occurrence of products with radians (non-plate) after the full use of pre-deformation data, Due to the inaccuracy of springback size, the assembly interference and even the scrap of die insert are caused. Through the research of this subject, we have preliminarily grasped the law of pre-deformation of products and the study of pre-deformation of injection molding in mold, which provides a good reference and guidance for the design data of pre-deformation of in-mold injection molded products of household appliances in the future. At the same time, the application of pre-deformation can obviously improve the fine quality level of household appliances, reduce the assembly gap between injection molding products and assembly parts, improve the production rate of products, and reduce the cost of purchasing parts. Increase product appearance quality market competitiveness.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TM925.21

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