汽车门锁注塑工艺优化与模具设计
发布时间：2018-11-05 16:31
【摘要】：随着塑料产品在各个领域的广泛应用,人们对产品的质量要求也不断提升。传统的依据经验进行注塑模具设计和工艺调试的方法,越来越不能满足结构复杂、质量要求高的注塑件生产要求,CAE技术的应用给注塑模具和工艺的开发带来了新的思路,同时能够缩减产品开发周期、节约成本及提高生产效率。本文以某款汽车门锁(POM)为研究对象,运用CAD设计及有限元数值模拟手段对注塑模进行合理设计,并采用数学优化方法对汽车门锁注塑工艺进行优化。本文主要研究内容如下:首先,介绍了车用塑料分类和性能、注塑成型技术,分析了注塑成型中常见的缺陷及改善措施。利用UG软件设计汽车门锁产品,在模具设计过程中借助Moldflow模流分析软件进行注塑成型过程分析,预测各设计方案成型过程中可能存在的缺陷,进而设计出合理的注塑模具结构。本文选取模具温度、熔体温度、冷却时间、保压压力与保压时间这五种工艺参数为设计变量,以翘曲变形量和顶出时体积收缩率为优化质量目标,进行Moldflow数值模拟的正交试验。对试验结果进行极差和方差分析,预测出了变量对目标的影响规律及显著顺序,同时分别得到翘曲变形量和顶出时体积收缩量分别较小的两组工艺参数组合。其次,基于正交试验结果,将翘曲和收缩综合成单一目标来作为综合成型质量的评价指标,建立以上因素不同水平对这个单一目标的灰色关联度模型,进行单一目标寻优。灰色关均值越大,则其对单一目标的影响因子越大,产品的综合质量越好,最后得到最优工艺参数组合。对这一组参数合进行Moldflow验证,结果显示:在塑件翘曲和收缩得到有效控制的前提下,综合成型质量得到了较好的提高,翘曲和收缩达到了兼顾改善的成效。最后,选取保压压力和熔体温度这两个对变形和收缩影响较大的因子作为优化变量,仍以最大变形翘曲和最大顶出体积收缩率为优化目标,利用二阶响应面建立变量和目标之间的非线性映射关系,并将两个目标的响应面等值线进行叠加以寻找最优区域,并得到了精确的最优工艺参数组合(模具温度60℃、熔体温度180.5℃、冷却时间16s、保压压力为注射压力98.75%、保压时间20s)。该组工艺组合的模拟成型结果比灰色关联的效果更好。依据此工艺参数组合进行模具调试,得到了综合质量较佳的汽车门锁塑件,验证了响应面优化法的准确高效性,并为注塑模具开发和塑件质量提高提供了新的途径。
[Abstract]:With the wide application of plastic products in various fields, the quality requirements of products have been improved. The traditional methods of injection mold design and process debugging based on experience can not meet the requirements of injection molding parts with complicated structure and high quality. The application of CAE technology brings new ideas to the development of injection mould and technology. At the same time can reduce product development cycle, cost savings and improve production efficiency. In this paper, a certain automobile door lock (POM) is taken as the research object. The injection molding process is optimized by means of CAD design and finite element numerical simulation, and the mathematical optimization method is used to optimize the injection molding process of the door lock. The main contents of this paper are as follows: firstly, the classification and performance of automotive plastics, injection molding technology, common defects in injection molding and improvement measures are introduced. The automobile door lock product is designed by UG software, and the injection molding process is analyzed by Moldflow mold flow analysis software in the process of mold design. The possible defects in the molding process of each design scheme are predicted, and the reasonable injection mold structure is designed. In this paper, five process parameters, such as die temperature, melt temperature, cooling time, pressure holding pressure and pressure holding time, are selected as design variables, and Moldflow numerical simulation orthogonal experiments are carried out with warpage deformation and volume shrinkage at top out as the optimization quality target. By analyzing the range and variance of the test results, the influence law and significant order of the variables on the target are predicted. At the same time, the combination of two groups of process parameters, which have smaller warpage deformation and smaller volume shrinkage at the top, are obtained respectively. Secondly, based on the results of orthogonal test, warping and shrinkage are combined into a single target to evaluate the quality of the composite molding, and the grey relational degree model of the single target is established at different levels of the above factors, and the single objective optimization is carried out. The larger the grey mean value is, the greater the influence factor on the single target is, and the better the comprehensive quality of the product is. Finally, the optimal combination of process parameters is obtained. The results of Moldflow verification show that the comprehensive molding quality has been improved and the warpage and shrinkage have been improved with the effective control of the warping and shrinkage of the plastic parts. Finally, two factors, pressure holding pressure and melt temperature, which have great influence on deformation and shrinkage, are selected as the optimization variables, and the maximum warpage and the maximum ejection volume shrinkage are still taken as the optimization targets. The nonlinear mapping relationship between variables and targets is established by using the second-order response surface, and the response surface isolines of the two targets are superimposed to find the optimal region, and an accurate combination of the optimal process parameters (die temperature 60 鈩，
本文编号：2312650
[Abstract]:With the wide application of plastic products in various fields, the quality requirements of products have been improved. The traditional methods of injection mold design and process debugging based on experience can not meet the requirements of injection molding parts with complicated structure and high quality. The application of CAE technology brings new ideas to the development of injection mould and technology. At the same time can reduce product development cycle, cost savings and improve production efficiency. In this paper, a certain automobile door lock (POM) is taken as the research object. The injection molding process is optimized by means of CAD design and finite element numerical simulation, and the mathematical optimization method is used to optimize the injection molding process of the door lock. The main contents of this paper are as follows: firstly, the classification and performance of automotive plastics, injection molding technology, common defects in injection molding and improvement measures are introduced. The automobile door lock product is designed by UG software, and the injection molding process is analyzed by Moldflow mold flow analysis software in the process of mold design. The possible defects in the molding process of each design scheme are predicted, and the reasonable injection mold structure is designed. In this paper, five process parameters, such as die temperature, melt temperature, cooling time, pressure holding pressure and pressure holding time, are selected as design variables, and Moldflow numerical simulation orthogonal experiments are carried out with warpage deformation and volume shrinkage at top out as the optimization quality target. By analyzing the range and variance of the test results, the influence law and significant order of the variables on the target are predicted. At the same time, the combination of two groups of process parameters, which have smaller warpage deformation and smaller volume shrinkage at the top, are obtained respectively. Secondly, based on the results of orthogonal test, warping and shrinkage are combined into a single target to evaluate the quality of the composite molding, and the grey relational degree model of the single target is established at different levels of the above factors, and the single objective optimization is carried out. The larger the grey mean value is, the greater the influence factor on the single target is, and the better the comprehensive quality of the product is. Finally, the optimal combination of process parameters is obtained. The results of Moldflow verification show that the comprehensive molding quality has been improved and the warpage and shrinkage have been improved with the effective control of the warping and shrinkage of the plastic parts. Finally, two factors, pressure holding pressure and melt temperature, which have great influence on deformation and shrinkage, are selected as the optimization variables, and the maximum warpage and the maximum ejection volume shrinkage are still taken as the optimization targets. The nonlinear mapping relationship between variables and targets is established by using the second-order response surface, and the response surface isolines of the two targets are superimposed to find the optimal region, and an accurate combination of the optimal process parameters (die temperature 60 鈩，
本文编号：2312650
本文链接：https://www.wllwen.com/shoufeilunwen/boshibiyelunwen/2312650.html
