空调面板注塑模充模流动分析及工艺参数优化

太原理工大学硕士学位论文空调面板注塑模充模流动分析及工艺参数优化姓名：刘丽平申请学位级别：硕士专业：@指导教师：孙桓五20100101ICAECAEMoldflow/MPITaguchiII1Pro/E2/34Taguchi54161024Moldflow/MPITaguchiIIITHEFILLINGFLOWANALYSISOFAIR-CONDITIONINGPANEL’SINJECTIONMOLDANDOPTIMIZATIONOFPROCESSPARAMETERSABSTRACTForovercomingtheshortcomings,thetraditionalapproachisthatthetechnicalandexpertstaffsdeploytheprocessparametersofinjectionmoldingintheselecteddevicethroughcontinuoustesting.Iftheadjustmentsofprocessparameterscannotmeettherequirements,wemustchangesthemolddesign,theuseofmaterialsandequipment.Thismethodrequirestheoperatorwithawealthofpracticalexperience,andtime-consuming,trialmoldcostsarehigh,nolongersuitedtomodernproductionrequirements.Theauthorsimulatetheinjectionprocessofair-conditioningpanelbytheuseofsimulationtestanddosomeresearchworksabouttheforecastofshortcomingsandimprovingthequalityofmoldingintheinjectionprocess,butthechoiceofparametersinvolvedinthousandsofcombinations.Facingtheinnumerablenumberofcombinations,ifthevirtueofexperienceoftrial,itisdifficulttoobtaintheoptimalparameterofmoldingprocess.Inthisstudy,bothorthogonaltestandsimulationresultsintheproductionofacombinationofbeforetheintroductionofCAEtechnology,todetectpotentialproblemsbeforetheyoccur,andanalysisofproblems.FromtheangleoftheadjustmentofIVinjectionparameters,theprocessparameterswereoptimizedandreducethewarpingdeformation.OnunderstandingthetheoreticalbasisofsimulationofCAE,basedonsimulationsoftwareMoldflow/MPIplatformtoair-conditioningpanelpartsasananalysisexample.Fromtwoaspectsofsimulationandparameteroptimizationasastudy,in-depthstudyoftheair-conditioningpanelappearsdefectsintheinjectionmoldingprocess.BytheTaguchimethod,theauthorpresentfivekindsofparametersonthedegreeofinfluenceofthewarpingdeformationandoptimizedtheparameters,proposedcombinationoftheoptimizedparameters.Theauthortesttheresultsonthesimulationoftheoptimizedparametersanddrawaconclusion:optimizedparametersareeffectivetoreducewarpingdeformation.Thereareverypositivepurporttosolvethepracticalproblemsintheproduction.Theauthormainlydoneasfollows:(1)Inordertolaythefoundationformoldflowanalysis,theauthorestablishedanair-conditioningpanel’sthree-dimensionalparametricmodelwithPro/E.(2)Introducedtheair-conditioningpanel’smoldingfillingmechanism,withthefiniteelement/finitedifferencenumericalmethodofinjectionmoldingthree-dimensionalflowanalysistoestablishthemathematicalmodel.(3)Carriedonthefilling,warpingandcoolinganalysis,simulationreachedthefillingtime,injectionpressure,clampingforce,moldtemperatureandmoldingprocessparametersrequired,reachedthecavitationlocation,warpingVdeformationdefectssuchasinjectionmolding,providedareferencefortheadjustmentofprocesslater.(4)Inordertocontrolthewarpingdeformationgoal,withtheTaguchimethodofformingmainlyaffectthequalityoffivefactorswereoptimizedcombinationoffourlevels,by16setofexperimentsreflectingthe1024kindsofallexperimentalcombinationsofinformation,toreceivetheoptimalcombinationofprocessparameters,canbebettertoreducethewarpingdeformation.KEYWORDS:Air-conditioningpanelParametersMoldflow/MPITaguchiDesignWarpingdeformationVI•γQRnρ−υwνµ−FτPPCK•ST•εηeRB−ux−vyαqxKxyKyVIIzKzNS2σnifmfi120CAD/CAE[1],CAE1.11015%[2]1200313.7221/21/334CAD/CAE/CAM51)2)CAD/CAECAD/CAECAD/CAECAD/CAECAD/CAECAD/CAE3DCAE341.2CAD/CAE3CAD/CAECAD/CAEFEACAD/CAE[3-5]1.2.1CAD/CAE,PTCPro/EUGSUG-IISDRCIDEAS3CAD/CAMCVCADDSMATRAEUCLIDDASSAULTCATIADELCAMDUCT,[6]CAE,20607090,MoldflowMFCAE(MF/FLOW)(MF/WARP)(MF/COOL)(MF/STRESS)(MF/GAS)1998(partadviser),20021.2.2CAD/CAE2060CADCAD/CAE70CAD,CAD/CAE207080,90/CAD/CAE,CAE[7]4CAECAE[8]LevelsetLevelSet,[9][10]Hele-Shaw[11][12]CAD/CAE[13-15](1)CAD(2)Internet(3)(4)CAD/CAMGT.CE(Concur-rentEngineering)CAPP(ComputerAidedProcessProgramming)CIMS(ComputerIntegratedManufacturersystem)1.2.351/3[16]CAECAD/CAEMOLDFLOW1.31Pro/E2/34Taguchi5416102461.4CAD/CAE7CAE2.12.1.1[17]4123842.1.2[18]1292.22.2.1122.2.21,10250%60%2.2.31231142.3ABSABS[18]ABSABS6[19]ABS2-1ABS[19]Tab.2-1TheinjectionmoldingprocessparametersofABSABSr/min3060/oC180190200210210230/oC180200/oC5070/Mpa7090/Mpa5070/s35/s1530/s1530/s40702.4122-12-1Fig.2-1Gatingsystem2.4.1α=2οο4~α()2121114dDdDS++=(2-1)132.4.22-2(a)(b)(c)(d)2-2Fig.2-2Commoncross-sectionoffourshunt1dddS442==ππ2-22D=d2()ddDDDS63.4224128421122=+=+=+=ππππππ2-33Dt8π=()ddDttDS02.5281162=+=+=ππ2-4142.4.32.4.42.4.5[20]123456IT82.4.6•γ=132105~105−××s•γ=15410~10−s15•γ=)(3.33nRQπ2-5•γQnR1QθPnQQ=2-6PQcm30.50.8nQnQcm3θs2-22-2nQt[21]Tab.2-2TherelationshipbetweenNominalinjectionvolumenQandinjectiontimetnQ/cm3t/SnQ/cm3t/S601.040005.01251.660005.72502.080006.43502.2120008.05002.5160009.010003.22400010.020004.03200010.630004.66400012.32•γ•γ1•γ=13105−×s2•γ=12105−×s163•γ=15101−×s4•γ=143105~105−××s3mQQQGR/==2-7m2-2nQ=500t=2.52-6PQ=1250cm3•γ=12105−×s2-7mQQG/==1250/6=208.3332-5nR=7.6mm•γ=15101−×s2-5nR=1.3mm2.52-3Fig.2-3ThetotalassemblyofAir-conditioningpanel17,,29,3226,21,57582536,,29,,,42,,50,2.63123451862.719CAEHele-shaw[22]/3.1[23]3.1.1ELLISbird-carreaucross20EILLSBird-carreaucrosscross3.1.2101=⋅∇+