透明塑料板件注射压缩成型工艺的模拟研究

华中科技大学硕士学位论文透明塑料板件注射-压缩成型工艺的模拟研究姓名：李毅超申请学位级别：硕士专业：材料加工工程指导教师：张宜生2011-01-11IIIIIIAbstractWiththerapiddevelopmentofpolymerengineering,largetransparentpolymerpartsarewidelyusedinautomobileandaerospaceindustries,forexample,thefabricationofcarglassesandlargetransparentaeroplanecoverings.Duetotheiruniqueapplications,theyshouldhavegoodmechanicalandopticalqualities.However,howtodesignfitproceduretoproducesuchhigh-qualityproductsisagreatconcern.Earlierresearchturnedoutthatwhentraditionalinjectionmoldingisusedtomakesuchlargetransparentpolymerparts,non-uniformdistributionofpressure,temperatureandfiberflowlineontheproductmaygiverisetoresidualstressduringthemoldingprocessandbringaboutunequalshrinkageondifferentpointsoftheproduct,especiallyedgeandangleareas,aftermoldingisdone,asaresultbringdefectslikewarpandbirefringencewhichwillmakenegativeimpactsonthemechanicalandopticalqualityoftheproduct.Tosolvetheproblem,animprovedInjection-CompressionMolding(ICM)isbeennoticed,especiallyontheaspectsofmoldingprocessanalysisandparameteroptimization.Comparedwithinjectionmolding,ICMallowsmoldtomove,addingacompressionstageattheendoftheinjectprocess.Thisextraworkhelpstocontrolthevariationofpolymertemperatureandpressure,andeliminatetheproblemofresidualstressandunevenshrinkageonroot.AsthelatestartonICMinChina,littleinformationhasbeenobtainedonICMinareaslikeparametervariation,utilityofICMandnoticing,whichareofgreatvaluetobeusedtodesignprocedureforspecificpartsmaking.Usingcomputer-basednumericalsimulationtechnique,baseonnonlinearnumericalalgorithm,thispaperusesmulti-physicscalculationmethodtosimulateICMonplateswithdifferentgeometricstructuresthoroughly,andcompareditsresultswithonesdonebytraditionalinjectionmolding.Followingconclusionsareobtained:ThereisaconsistentpressuredistributioninthemoldwhenICMisdone.Besides,IVthevelocityofcompression,thestartinggapbetweenthetwomoldsandtheswitchtimebetweeninjectionandcompressionperiodaffectthepressurecurveonthecorrespondentaspectsofamplitude,variationintensityandphase.Comparedwithinjectionmolding,ICMcangreatlyreducetheshrinkageofthefinalproduct.Inaddition,lengthofthefiberflowlineandtemperaturecanaffecttheshrinkageoftheproduct.Shorterfiberflowline,moreeventemperaturedistributioncanleadtolowerandmoreevenshrinkagedistribution.ICMisnotfittoproduceproductswithrandomgeometries.Forpartswithirregulargeometricstructures,thepileupeffectcausedbytheunsteadyflowofpolymeratcornerandnon-uniformcrosssectionofthecavitycanbringunequalstretchoffiberflowline,makingnegativeaffecttotheproductquality.SoitismorepreferabletouseICMtofabricateproductwithsymmetricgeometricstructure.Keywords:Injection-compressionmolding;Multiphysics;Numericalsimulation;Fiberflowline;Shrinkage(“”)::111.11.1.15mm2mm1985FTP1997NGTJSFF221-12200312T-381-120LFAPCChemicalVaporDepositionCVDTaberHazeNitton1-2aCCD3ab1-2CAD/CAEPMMA1DVD/VCD243451.1.21.21.2.1F.A.Martin20602080801-3123461-312345671.2.2SatoSpector1995KitamuraEngelKrauss-MaffeiBatten-feldEngel-DuoSE-DUSummererKrauss-Maffei7SummererBattenfeldInMouldPressingIMPmore1-41-5IMPmoreHM200001.2.3KazmerBickertonWirthGauvin(CRTM)Chang1-41-58MoonKooKangRTM1-6a1-6ba9)1-6Walbran1-7Tekscan1-7Khondker10PPPP1.2.4FanKazmerChenHele-ShawCVFEMChang1-8CCD1-9a1-9b111-8ab1-9RTMRTMShojaeiRICMFEMCVDarcy12(randomunidirectionalbidirectionalfiberreinforcements)1-10ShojaeiRTMhSnabcd1-101.3131422.1-2.1.1Non-NewtonianFlowPowerLawPowerlaw1nm-η=γmnn1PowerLawPseudoplasticn1PowerLawDilatantn=1PowerLawNewtonianFluidCarreauCarreau(1)22()[1()]n-∞0∞η=η+η-η+λγ?0?8nCross010*()()1()nTPTP-η,ηγ,,=ηγ+τ&&t??00(,)exp()exp()bTTPBPTη=⋅⋅β15BTbßTb?0ß?0Cross-WLF010*()()1()nTPTP-η,ηγ,,=ηγ+τ&&*101*2()(,)exp[]()ATTTPDATT-η=⋅-+-*23()TPDDP=+~223AADP=+n?0γ&A1A2D1D2D3A1A2*τ2.1.2Polycarbonate22-4-PCPC2-1PCPCPCGELexanPCPCLexanMR52AC16777LexanGLX2-2PCLexanSP7602PVTPCPC1.58695.1%PCPC200302-1PC2-12-12-2PCPC%8789%1.5931J/m8001000M70%0.41381420.7g/cm31.210-4/K1.2172.22.2.1(Level-setMethod)00.51⎧⎪Φ=⎨⎪⎩F=01F=12F=0.5F..[(1)]utddΦ∇Φ+∇Φ=γ∇ε∇Φ-Φ-Φ∇ΦeF01?F2.2.2Navier-StokesN-SZZZ18..[(())]nTuuupIuutddρ+ρ∇=∇-+η∇+∇+σκδ0uvwxyzdddddd++=uvwKxyzdddddd++=zzVKHVt=-⋅..[(1)]utddΦ∇Φ+∇Φ=γ∇ε∇Φ-Φ-Φ∇Φ22w2()()pTTTTCuvkhTTtxyzdddddd∂ρ++=+ηγ+-∂&uvwxyz?p?sKCpkhTwγ&VzH??Cpk121ρ=ρ+ρρ⋅Φ121κ=κ+κκ⋅Φ121η=η+ηη⋅Φ121ppppCCCC=+⋅ΦCross-WFL0101()n-*ηη=ηγ+τ&POLYCARBONATESPCCalibre510019n=0.4681?2=1131.4*τ=503660PaCp2=1789J/kg*Kk2=0.25W/m*KD1=3.67e11Pa*sT*=417.15KA1=26.415A2=51.6Kh=29W/m*K?1=1.2kg/m3?1=1e-5Pa*sCp1=1000J/kg*Kk1=0.03W/m*KTw=373.15K2.2.3333310v331VVS100%100%V--=×=×VTait-PVT0(,)()[1ln(1)](,)()tPVTPVTCVTPBT=-++56tTbbP=+1250125()()()()()mmtsstbbTbTTVTbbTbTT+-⎧=⎨+-⎩345345exp[()]()()exp[()]()mmtsstbbTbTTBTbbTbTT--⎧=⎨--⎩78590()(,)exp[()]()tttTTVTPbbTbbPTT⎧=⎨--⎩VT,PPTV0TC0.0894BTTtb5=414.07Kb6=3.867e-7K/Pab1m=b1s=0.0008m3/kgb2m=4.5e-7m3/kgb2s=1.75e-7m3/kgb3m=2.13e8Pab3s=3.16e8Pab4m=0.0041/Kb4s=0.0031/Kb7=b8=b9=02.32-3202-3Navier-StrokesN-SLevel-Set21COMSOL3.52-42-42.4ComsolMultiphysicsTait-PVT2.5PCttinj?NoYesttcom?NoYesStop1222333.13.1.13-1400mm×300mm×10mm3-13-13.1.23-23-3F01Tw243.1.31H