潜栅凸轮衬套塑料注射模的设计与分析Word文件下载.docx
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潜栅凸轮衬套塑料注射模的设计与分析Word文件下载.docx
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ScienceDirect
MaterialsToday:
Proceedings2(2015)2083–2093
4thInternationalConferenceonMaterialsProcessingandCharacterisation(ICMPC2015)
DesignandAnalysisofPlasticInjectionMouldforCAMBUSHwithSubmarineGate
MohdJamsheeda*MdAaqibRahmanbM.AMoyeedcG.M.SayeedAhmedd
aAssistantProfessors,Dept.ofMechanicalEngineering,VIFcollegeofEngineeringandtechnology.AssistantProfessorsb,MechanicalEngineering.NawabshahAlamKhancollegeofEngineering,cAssistantProfessorsDept.ofMechanicalEngineering,NawabshahAlamKhancollegeofEngineering.,
dSeniorAssistantProfessors,Dept.ofMechanicalEngineering,M.J.CollegeofEngineeringandtechnology,
Abstract
©
2014TheAuthors.ElsevierLtd.Allrightsreserved.
Selectionandpeer-reviewunderresponsibilityoftheconferencecommitteemembersofthe4thInternationalconferenceonMaterialsProcessingandCharacterization
ThisPaperfocusedonDesignandAnalysisofanautomaticplasticinjectionmouldforproductionofCAMBUSH.CamBushisusedasaindexingdeviceinON/OFFLoadTapchangerdeviceofhighvoltagetransformerandservesastheconnectorbetweentheindexingheadandthepowerchanginggears.Aninjectionmouldisatoolwhichisusedforproductionofplasticcomponentsinlargenumbersinashortspanoftime.ModelingindonebyusingUnigraphics(NX7.5)andAutoDeskMouldflowPlasticInsightisuseforMouldflowAnalysisforCAMBUSHfillingrate,coolingsystemlocationandLocationofsubmarinegate.ThemouldingtoolconsistsoftheTopplate,Cavityplate,Coreplate,Spacerblocks,EjectorplateandtheBottomplate.Inthissixcorepinsandsixejectorpinsareprovidedoninjectionmouldbecausetherequiredcambushhassixindexingholes.ThematerialuseisOilHardenedNon-shrinkingSteel(OHNS)forthecoreandcavity,andEN353fortheTieRod,guidebushes,corepins,ejectorpins,locatorringandthespruebushandMildSteelforotherplatesareselected.Theelementsofinjectionmouldingtoolhasdesignedandanalyzed.SubmarinegateandBafflecircularholecoolingsystemhasprovidedinthemouldingtooltoincreasetheproductivityandgoodsurfacefinish.TherequiredNylon-66Cambushcomponentwillproducedwiththismouldingtoolwiththevariousparametersofinjectionmouldingmachine.
Keywords:
PlasticInjectionMould,CAMBUSH,MouldFloeAnalysis
1.Introduction
Nowaday’splasticareoccupyingavitalroleintheday-to-daylife.Itisnotatallcanexaggeration,ifwesaythatthereisnofieldintowhichplastichavenotsteppedinrightfromthemanufacturingatapintothatofaspacecraft.Atthemiddleof19thcentury,plasticsstartaleadingroleinthematerialandinourlife.Corrosionresistancearesomeoftheaspectsthroughwhichplasticsareevenbecomingsuperiorstometalsandattainedanelevatedrateofpreferenceineverybranchofmanufacturing.Rightfromtheemergencyofplasticstheyareundergoingdrasticinvariousaspectslikedesignofplasticproduct,manufacturingprocessingthenintestingfieldsandnow,becauseoffruitfuleffortsofmanypeopleatlastthecameinworkthroughmanuallabor,butwithhelpofartificialintelligencethatis,withsoftwarepackagelikeCAD/CAM.Becauseofhighstrengthofweightratio,improvechemicalandtemperatureresistance,inherentpropertiesofbeingbaththermalandcorrosionresistance,transparencyhavemadethemamaterialchoice.Plasticconsumelessenergyduringformationandcanbeprofitablyrecycled.TodayplasticsarereplacingthemetalslikeBrass,Copper,CastIron,Steeletc.PlasticscanbeclassifiedaccordingtomanufacturingmethodsintomaingroupsThosewhichsoftenwhenheatedandsolidifiesoncooling.Theseareknownas“Thermoplastic”andThosewhichhardenwhenheatedasaresultofchemicalchange.TheseareknownasThermosettingorDuroplasticmaterial”Selectionofparticularmaterialfortheproductisanotherimportantfactor.Thisisparticularlyverynecessaryfortheproduct
Correspondingauthor.Tel.:
+919701574596E-mailaddress:
drgmsa786@.
2214-7853©
2015PublishedbyElsevierLtd.
Selectionandpeer-reviewunderresponsibilityoftheconferencecommitteemembersofthe4thInternationalconferenceonMaterialsProcessingandCharacterization.
doi:
10.1016/j.matpr.2015.07.203
determination.Itshouldcapableofwithstandingstressesacteduponitaswell.Eachmaterialhasitsownpropertiesandattributes.Somematerialsarebetterinhighenvironmentandextremelyabrasionresistance.Thedifficultpartistofindamaterialthatwillcomeclosetofulfillingtheentirerequirementofthepurpose.Somaterialshouldbesoversatilethatitsuitsalltheconsiderationandrequirementofourproduct.Afterconsideringallthesepoint’smaterialmustbeselectedsuitableenoughtosatisfyalltheseconditions.
2.PlasticCamBushforTransformer
TheobjectiveofthepaperistodesignandAnalysistheinjectionmouldtoolforacambushofanHighvoltagetransformer.CamBushisusedasaindexingdeviceinON/OFFLoadTapchangerdeviceofhighvoltagetransformerandservesastheconnectorbetweentheindexingheadandthepowerchanginggears.TheindexingheadisconnectedtothegearbymeansoftheshaftwhichisattachedwiththeCamBush.Thecambushhastwotailends,onesideispressfittedtotheindexingcrankcircleandtheothersideisfittedtothedrivingmechanism.Eachholehasdifferentdrivingmechanism,whentheindexingcirclerotatesandthecrankpinengagedinthefirstholethefirstdrivingmechanismturnson.Thedifferenttypeofpowerisobtainedbymeansofchangingtheindexposition.Cambushservesastheconnectorbetweencrankcircleandthegears.Itisprovidedinthepowerchangingindexingmechanism.Theindexingcrankcirclehasmanyindexingholes,butthemechanismhas6drive,sothecambushwith6holesisprovidedinbetweenthecrankcircle,speedindicatorwheelandtheshaftwhichisintersectedincenterandconnectedtothegears.ThisCAMBUSHisgenerallymadewithPolystyrene,Nylon6andPVC.DuetohighvoltageregulatingapplicationthisCamBushbecomesheatedupandwearoff.Duetorepeatedlyapplyingpressurebyregulatingit,itbecomesdamage.
Fig.1CambushSolidModelandAssembly
Plasticsareman-madematerials.Theyarelessbrittlethanglass,yettheycanbemadeequallytransparentandsmooth.Theyarelightweightandatthesametimepossessgoodstrengthandrigidity.Theyresistcorrosionandtheactionofchemicals.Theycanbeeasilymoldedtodifferentshapes.CommonlyusedthermoplasticmaterialsarePolystyrene,Nylon6,P.V.C,Polypropyleneetc.Mouldmakingisanimportantroleinplasticsindustriesbecausetherelatedproductsconstitutemorethan70%ofthecomponentsinconsumerproducts.Injectionmouldingisacomplexbuthighlyefficientmeansofproducingalargevarietyofthermoplasticproductsandhasmanyadvantages,suchasshortproductioncycles,excellentsurfacesoftheproducts,andhasnosecondaryoperations,goodresultsinmouldingofcomplicatedshapes.Thedesignandfabricationofinjectionmouldingtoolforcomplexplasticproductsisplayawiderroletomeettheindustrialdemandespeciallyinplasticindustries.Hence,thereisademandintheindustryforplasticinjectionmouldingtechniquescapableofproducingplasticparts.Literaturereviewrevealsthatthereisalackofresearchondesignandmanufacturingofinjectionmouldingtoolforcomplicatedplasticcomponents.Hence,thisprojectfocusedondesignandAnalysisofInjectionmouldingtoolwithbaffletypecoolingchannelandsubmarinegateforcambush.
3.InjectionMouldingProcess
Itisamanufacturingprocessforproducingpartsbyinjectingliquidmoltenmaterialintoamould.Injectionmouldingcanbeperformedwithahostofmaterials,includingMetals,Glasses,Elastomers,ConfectionsandmostcommonlyThermoplasticandThermosettingpolymers.Materialforthepartisfedintoaheatedbarrel,mixed,andforcedintoamouldcavitywhereitcoolsandhardenstotheconfigurationofthecavity.Afteraproductisdesigned,usuallybyanindustrialdesigneroranengineer,mouldsaremadebyamouldmaker(ortoolmaker)frommetal,usuallyeithersteeloraluminum,andprecision-machinedtoformthefeaturesofthedesiredpart.Injectionmouldingiswidelyusedformanufacturingavarietyofparts,fromthesmallestcomponentstoentirebodypanelsofcars.Thepart,thedesiredshapeandfeaturesofthepart,thematerialofthemould,andthepropertiesofthemouldingmachinemustallbetakenintoaccount.TheversatilityofinjectionmouldingisfacilitatedbythisbreadthofdesignconsiderationsandpossibilitiesInjectionmoldingutilizesaramorscrew-typeplungertoforcemoltenplasticmaterialintoamoldcavity;
thissolidifiesintoashapethathasconformedtothecontourofthemold.Itismostcommonlyusedtoprocessboththermoplasticandthermosettingpolymers,withtheformerbeingconsiderablymoreprolificintermsofannualmaterialvolumesprocessed.
Fig2:
ModelofInjectionMouldingProcess
Injectionmoldingconsistsofhighpressureinjectionoftherawmaterialintoamoldwhichshapesthepolymerintothedesiredshape.Moldscanbeofasinglecavityormultiplecavities.Inmultiplecavitymolds,eachcavitycanbeidenticalandformthesamepartsorcanbeuniqueandformmultipledifferentgeometriesduringasinglecycle.Moldsaregenerallymadefromtoolsteels,butstainlessandaluminummoldsaresuitableforcertainapplications.Aluminummoldstypicallyareill-suitedforhighvolumeproductionorpartswithnarrowdim
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