本地窗口塑料注塑模具三维设计系统.docx
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本地窗口塑料注塑模具三维设计系统.docx
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本地窗口塑料注塑模具三维设计系统
JournalofMaterialsProcessingTechnology139(2003)81–89
AWindows-native3Dplasticinjectionmolddesignsystem
Abstract
3Dsolid-modelingrevolutionhasreachedthedesignmainstream.Whilehigh-end3Dsolid-modelingsystemshavebeenonengineers’workstationatlargeaerospace,consumerproducts,andautomobilecompaniesforyears,manysmallercompaniesarenowmakingtheswitchfromworkstationstoPC.OnereasonfortheshiftisthattheflexibilityandadvancementofWindows-native/NThasletsoftwaredeveloperscreateapplicationsthatareaffordableandeasytouse.High-endusersarefindingthatmid-rangesolidmodelers,suchasSolidWorks,havemettheirneeds.
SolidWorkswaschosenastheplatformduetotheWindows-nativedesignenvironment,powerfulassemblycapabilities,ease-of-use,rapidlearningcurve,andaffordableprice.AWindows-native3DplasticinjectionmolddesignssystemhasbeenimplementedonanNTthroughinterfacingVisualC++codeswiththecommercialsoftware,SolidWorks99andAPI.Thesystemprovidesadesignerwithaninteractivecomputer-aideddesignenvironment,whichcanbothspeedupthemolddesignprocessandfacilitatestandardization.
Keywords:
Plasticinjectionmold;Windows;CAD;Parting
1.Introduction
Withthebroaderuseofplasticspartsinawideproductrange,fromconsumerproductstomachinery,carsandairplanes,theinjectionmoldingprocesshasbeenrecognizedasanimportantmanufacturingprocess.Themolddesignprocessisgenerallythecriticalpathofanewproductdevelopment.Conventionally,molddesignhasalwaysbeenamuch“mystified”art,requiringyearsofexperiencebeforeonecanberelativelyproficientinit.Duetotheinitialdifficultyinlearningthisart,lessandlesspeoplearebenefitingfromtheexperienceandknowledgeoftheexpertsinthisfield.Tochangethecurrentsituation,onewayistouseacomputer-aideddesign(CAD)system.
CADasaneverydaytermhasgrowntoabroadrangeofcapabilitiesandhasapplicationsinfieldsrangingfromeducationforschoolteachingtothree-dimensionalmechanicaldesign.Atthepresenttime,mostCADsystemsprovideonlythegeometricmodelingfunctionsthatfacilitatethedraftingoperationsofmolddesign,anddonotprovidemolddesignerswiththenecessaryknowledgetodesignthemolds.Thus,much“add-on”software,e.g.IMOLD®,havebeendevelopedonhigh-level3Dmodelingplatformstofacilitatethemolddesignprocesses.Suchanarrangementisadvantageousinmanyways.The3Dmodelingplatformprovidesplug-insoftwarewithalibraryoffunctionsaswellasanestablisheduserinterfaceandstyleofprogramming.Asaresult,thedevelopmenttimeforthese“add-ons”issignificantlyreduced.
IMOLD(intelligentmolddesign)[1]isaknowledgebasedsoftwareapplication,whichrunsontheUnigraphicsSolidWorksplatformandiscarriedoutbyusingtheUserFunctionprovided.ItisavailableontheUNIXandwindowsoperationsystem.Foryears,molddesignengineershavehadtodealwithtwodifferentsystems,UNIXandPC.Theformeriswidelyusedinengineeringapplicationswhilstthelatterisusedmainlyinsmallandmediumcompanies.Engineersalsoneedtoruncorporateofficeapplicationssuchaswordprocessing,spreadsheets,andprojectmanagementtools,butthesewerenotontheirUNIXworkstations.
Fortunately,theremarkabledevelopmentofcomputertechnologyinthelastdecadehasprovidedawaytochangethissituation.Themostsignificantchangehasbeenintheareaofcomputerhardware,i.e.theactualelectroniccomponentsassociatedwithdataprocessing,informationstorage,anddisplaytechnology,intermsofbothspeedandmemory.Thesehaveresultedinthemoreefficientuseofthesolid-modelingfunctionsinaPC-basedCAD/CAMsystem.Withtheincreasedavailabilityofsophisticated,low-costsoftwareforWindows,moreandmoreengineersareusingPCapplicationstogettheirjobsdone.ThusthedevelopmentofanewmolddesignapplicationbasedontheWindowsplatformsisinhighdemand.
High-endusersarefindingthatmid-rangesolidmodelers,suchasSolidWorks,havemettheirneeds.DevelopedfromthebeginningasanativeWindowsapplication,SolidWorksisoneofthe3DmechanicaldesignsoftwaresforWindows.Itsuniquecombinationofproduction-levelpower,ease-of-use,andaffordabilityisunmatched.SolidWorks99,theseventhmajorreleaseofthecompany’smechanicaldesignsoftwareforWindowsNT,Windows98andbeyondprovidesanincreasedpowerandfunctionalityinafullyintegratedsolidmodeler.Familiarconventionssuchaspoint-and-click,drag-and-drop,cut-and-paste,andseamlessdatasharingwithotherWindowssoftwareleadtoproductivitygains.Theease-of-usewithoutextensivetrainingandataffordablepricingenablescompaniestoinstallthesystemoneveryengineer’sdesktop.Oneofitsapplicationsisformolddesignintheplasticsindustry.Thislatestapplicationtechnologyhasaddedanentirelynewdimensiontothemolddesignprocess.
2.Injectionmolddesign
Injectionmoldingusestemperature-dependentchangesinmaterialpropertiestoobtainthefinalshapesofdiscretepartstofinishornear-finishdimensionsthroughtheuseofmolds.Inthistypeofmanufacturingprocess,liquidmaterialisforcedtofillandsolidifyinsidethecavityofthemold[2].
Firstly,thecreationofamoldmodelrequiresadesignmodelandacontainingbox.Thedesignmodelrepresentsthefinishedproduct,whereasthecontainingboxrepresentstheoverallvolumeofthemoldcomponents.
Injectionmolddesigninvolvesextensiveempiricalknowledge(heuristicknowledge)aboutthestructureandthefunctionsofthecomponentsofthemold.Thetypicalprocessofanewmolddevelopmentcanbeorganizedintofourmajorphases:
productdesign,moldabilityassessment,detailedpartdesign,insert/cavitydesign,anddetailedmolddesign.
InPhase0,aproductconceptispulledtogetherbyafewpeople(usuallyacombinationofmarketingandengineering).TheprimaryfocusofPhase0istoanalyzethemarketopportunityandstrategicfit.InPhaseIthetypicalprocess-relatedmanufacturinginformationisthenaddedtothedesigntoproduceadetailedgeometry.Theconceptualdesignistransformedintoamanufacturabilityonebyusingappropriatemanufacturinginformation.InPhaseIIthepartingdirectionandpartinglineslocationareaddedtoinspectthemoldability.Otherwise,thepartshapeisagainmodified.InPhaseIII,thepartgeometryisusedtoestablishtheshapeofthemoldcoreandcavitythatwillbeusedtoformthepart.Generallyshrinkageandexpansionsneedtobeconsideredsothatthemoldingwillbethecorrectsizeandshapeattheprocessingtemperature.Gates,runners,overflows,andventsalsoneedtobeadded.Theassociationbetweengeometricdataandpartinginformationiscriticalatthispoint.PhaseIVisrelatedtotheoverallmechanicalstructureofthemoldincludingtheconnectionofthemoldtotheinjectionmachine,amechanismsforfilling,cooling,andforejectionandmoldassembly.
3.Methodology
Forthereasonsdescribedabove,SolidWorks99hasbeenusedastheplatformforthenewmolddesignapplication.Fig.1showsaWindows-native3DinjectionmolddesignsystemcomparedwithIMOLD.Users’applicationscanbecreatedandrunasastandaloneexefileorasaUserDLLorExtensionDLLinSolidWorks.TheSolidWorksAdd-InManagerallowsuserstocontrolwhichthirdpartysoftwareisloadedatanytimeduringtheirSolidWorkssession.Morethanonepackagecanbeloadedatonce,andthesettingswillbemaintainedacrossSolidWorkssessions.
Fig.1.Relationshipamonguserapplications,SolidWorks,UnigraphicsandParasolid.
3.1.SolidWorks
SolidWorksrecentlyemergedasoneofthe3DproductdesignsoftwareforWindows,providingoneofthemostpowerfulandintuitivemechanicaldesignsolutioninitsclass.InSolidWorks,partsarecreatedbybuildinga“basefeature,”andaddingotherfeaturessuchasbosses,cuts,holes,fillets,orshells.Thebasefeaturemaybeanextrusion,revolution,sweptprofile,orloft.Tocreateabasefeature,sketchatwo-dimensionalgeometricprofileandmovetheprofilethroughspacetocreateavolume.Geometrycanbesketchedonconstructionplanesoronplanarsurfacesofparts.
Feature-basedsolid-modelingprogramsaremakingtwo-dimensionaldesigntechniquesobsolete.However,Unix-basedsolid-modelingsoftwareisexpensive.WiththeintroductionofSolidWorksforMicrosoftWindows,thecostislessthanthepriceofearlierdimensiondrivensolid-modelingprograms[3].
3.2.Parasolidasa3Dkernel
SolidWorksusesParasolidasa3Dkernel.Parasolidkernelmodelingtoolkit,isrecognizedasaworld’sleading,production-provencoresolidmodeler.Designedasanexactboundary-representationsolidmodeler,Parasolidprovidesrobustsolid-modeling,generalizedcellularmodelingandintegratedsurface/sheetmodelingcapabilitiesandisdesignedforeasyintegrationintoCAD/CAM/CAEsystemstogiverapidtimetomarket.Itsextensivefunctionalityissuppliedasalibraryofroutineswithanobject-orientedprogramminginterface.Itisessentiallyasolidmodeler,whichcanbeusedto[4]:
(i)buildandmanipulatesolidobjects;(ii)calculatemassandmomentsofinertia,andperforminterferencedetection;(iii)outputtheobjectsinvariouspictorialways;(iv)storetheobjectsinsomesortofdatabaseorarchiveandretrievethemlater;and(v)supportfreeformsurfaces.
3.3.API[5]
TheSolidWorksapplicationprogramminginterface(API)isanOLEprogramminginterfacetoSolidWorks.TheAPIcontainshundredsoffunctionsthatcanbecalledfromVisualBasic,VBA(Excel,Access,etc.),C,C++,orSolidWorksmacrofiles
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