完整版注塑模具外文翻译定稿毕业设计论文.docx
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完整版注塑模具外文翻译定稿毕业设计论文.docx
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完整版注塑模具外文翻译定稿毕业设计论文
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Integratedsimulationoftheinjectionmoldingprocesswithstereolithographymolds
AbstractFunctionalpartsareneededfordesignverificationtesting,fieldtrials,customerevaluation,andproductionplanning.Byeliminatingmultiplesteps,thecreationoftheinjectionmolddirectlybyarapidprototyping(RP)processofinjectionmoldingwithRPdemonstratedmanytimes.Whatismissingisthefundamentalunderstandingofandtheinjectionmoldingprocess.Inaddition,numericalsimulationtechniquesmolding.Butallcurrentsimulationpackagesforconventionalinjectionmoldingarenolongerapplicabletothisnewtypeofinjectionmolds,mainlybecausethepropertyofthemoldmaterialchangesgreatly.Inthispaper,anintegratedapproachtoaccomplishanumericalsimulationofinjectionmoldingintorapid-prototypedmoldsisestablishedandacorrespondingsimulationsystemisdeveloped.Comparisonswithexperimentalresultsareemployedforverification,whichshowthatthepresentschemeiswellsuitedtomoldingNumericalsimulationRapidprototyping
1Introduction
Ininjectionmolding,thepolymermeltattocreatethe
injectionmolddirectlybyarapidprototyping(RP)process.Byeliminatingmultiplesteps,thismethodoftoolingaproductionmaterial.ThepotentialofintegratinginjectionmoldingwithRPtechnologiesdemonstratedmanytimes.ThepropertiesofRPmoldsareverydifferentfromthoseoftraditionalmetalmolds.Thekeydifferencesarethepropertiesofthermalconductivityandelasticmodulus(rigidity).Forexample,thepolymersusedinRP-fabricatedstereolithography(SL)moldsonethousandththatofanaluminumtool.InusingRPtechnologiestocreatemolds,theentiremolddesignandinjection-moldingprocessparametersneedtobemodifiedandoptimizedfromtraditionalmethodologiesduetothecompletelydifferenttoolmaterial.However,thereisstillnotafundamentalunderstandingofandtheinjectionmoldingprocessparameters.Onecannotobtainreasonableresultsbysimplychangingafewmaterialpropertiesincurrentmodels.Also,usingtraditionalapproacheswhenmakingactualpartsmaybegeneratingsub-optimalresults.Sothereisadireneedtostudytheinteractionbetweentherapidtooling(RT)processandmaterialandinjectionmolding,soastoestablishthemolddesigncriteriaandtechniquesforanRT-orientedinjectionmoldingprocess.
Inaddition,computersimulationisaneffectiveapproachforpredictingthequalityofmoldedparts.CommerciallyavailablesimulationpackagesofthetraditionalinjectionmoldingprocessprogramsforconventionalinjectionmoldingarenolongerapplicabletoRPmolds,becauseofthedramaticallydissimilartoolmaterial.Forinstance,inusingtheexistingsimulationsoftwarewithaluminumandSLmoldsandcomparingwithexperimentalresults,thoughthesimulationvaluesofpartdistortionarereasonableforthealuminummold,resultsareunacceptable,withtheerrorexceeding50%.Thedistortionduringinjectionmoldingisduetoshrinkageandwarpageoftheplasticpart,aswellasthemold.Forordinarilymolds,themainfactoristheshrinkageandwarpageoftheplasticpart,whichismodeledaccuratelyincurrentsimulations.ButforRPmolds,thedistortionofthemoldneglectedincurrentmodels.Forinstance,[3]usedasimplethree-stepsimulationprocesstoconsiderthemolddistortion,which.
Inthispaper,basedontheaboveanalysis,anewsimulationsystemforRPmoldsisdeveloped.Theproposedsystemfocusesonpredictingpartdistortion,whichisdominatingdefectinRP-moldedparts.ThedevelopedsimulationcanbeappliedasanevaluationtoolforRPmolddesignandprocessoptimization.Oursimulationsystemisverifiedbyanexperimentalexample.
AlthoughmanymaterialsareavailableforuseinRPtechnologies,weconcentrateonusingstereolithography(SL),theoriginalRPtechnology,tocreatepolymermolds.TheSLprocessusesphotopolymerandlaserenergytobuildapartlayerbylayer.UsingSLtakesadvantageofboththecommercialdominanceofSLintheRPindustryandthesubsequentexpertisebasethatdevelopedforcreatingaccurate,andform-fitstudieswithverylimitedfunctionalapplications.However,thenewergenerationstereolithographicphotopolymersofthemoldingprocess
2.1Methodology
InordertosimulatetheuseofanSLmoldintheinjectionmoldingprocess,aniterativemethodisproposed.Differentsoftwaremodulesdevelopedandusedtoaccomplishthistask.ThemainassumptionisthattemperatureandloadboundaryconditionscausesignificantdistortionsintheSLmold.Thesimulationstepsareasfollows:
1Thepartgeometryismodeledasasolidmodel,whichistranslatedtoafilereadablebytheflowanalysispackage.
2Simulatethemold-fillingprocessofthemeltintoaphotopolymermold,whichwilloutput
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