外文翻译注塑模具设计的一种智能型腔设计系统.docx
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外文翻译注塑模具设计的一种智能型腔设计系统.docx
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外文翻译注塑模具设计的一种智能型腔设计系统
InternationalJournalofCAD/CAMVol.2,No.1,pp.69~75(2002)
AnIntelligentCavityLayoutDesignSystemforInjectionMoulds
WeigangHuandSyedMasood*
IndustrialResearchInstituteSwinburne(IRIS),SwinburneUniversityofTechnology,Hawthorn,Melbourne,Australia3122
AbstractThispaperpresentsthedevelopmentofanIntelligentCavityLayoutDesignSystem(ICLDS)formultiplecavity
injectionmoulds.Thesystemisintendedtoassistmoulddesignersincavitylayoutdesignatconceptdesignstage.The
complexitiesandprinciplesofcavitylayoutdesignaswellasvariousdependenciesininjectionmoulddesignareintroduced.
Theknowledgeincavitylayoutdesignissummarizedandclassified.Thefunctionality,theoverallstructureandgeneral
processofICLDSareexplained.Thepaperalsodiscussessuchissuesasknowledgerepresentationandcase-basedreasoning
usedinthedevelopmentofthesystem.Thefunctionalityofthesystemisillustratedwithanexampleofcavitylayoutdesign
problem.
Keywords:
Intelligentdesign,cavitylayoutdesign,injectionmoulddesign,case-basedreasoning,designsupportsystem
1.Introduction
Inmanufacturing,theinjectionmouldingisoneofthemostwidelyusedproductionprocessesforproducingplasticpartswithhighproductionrateandlittleornofinishingrequiredonplasticproducts.Theprocessconsistsofinjectingmoltenplasticmaterialfromahotchamberintoaclosedmould,allowingtheplastictocoolandsolidifyandejectingthefinishedproductfromthemould.Foreachnewplasticproduct,theinjectionmouldingmachinerequiresanewinjectionmould.Designandmanufactureofinjectionmouldisatimeconsumingandexpensiveprocessandtraditionallyrequireshighlyskilledtoolandmouldmakers.Aninjectionmouldconsistsofseveralcomponents,whichincludemouldbase,cavities,guidepins,asprue,runners,gates,coolingwaterchannels,supportplates,slidesandejectormechanism[1].Designofmouldisalsoaffectedbyseveralotherfactorssuchaspartgeometry,mouldmaterial,partinglineandnumberofcavitiespermould.Withtheadvancesincomputertechnologyandartificial
intelligence,effortshavebeendirectedtoreducethecostandleadtimeinthedesignandmanufactureofaninjectionmould.Injectionmoulddesignhasbeenthemainareaofresearchsinceitisacomplexprocessinvolvingseveralsub-designsrelatedtovariouscomponentsofthemould,eachrequiringexpertknowledgeandexperience.Moulddesignalsoaffectstheproductivity,mouldmaintenancecost,manufacturabilityofmould,andthequalityofthemouldedpart.Mostoftheworkinmoulddesignhasbeendirectedtotheapplicationofexpertsystems,knowledgebasedsystemsandartificialintelligencetoeliminateorsupplementthevastamountofhumanexpertiserequiredintraditionaldesignprocess.KruthandWillems[2]developedanintelligentsupportsystemforthedesignofinjectionmouldsintegratingcommercialCAD/CAM,arelationaldatabaseandanexpertsystem.Leeet.al.[3]proposedasystematicmethodologyandknowledgebaseforinjectionmoulddesigninaconcurrentengineeringenvironment.RaviwongseandAllada[4]developedaneuralnetworkbaseddesignsupporttooltocomputethemouldcomplexityindextohelpmoulddesignerstoassesstheirproposedmoulddesignonmouldmanufacturability.KwongandSmith[5]developedacomputationalsystemfortheprocessdesignofinjectionmouldingbasedontheblackboard-basedexpertsystemandthecase-basedreasoningapproach,whichincludesmoulddesign,productionscheduling,costestimationanddeterminationofinjectionmouldingparameters.Brittonet.al.[6]discussedtheinjectionmoulddesignfromafunctionalperspectiveusingfunctionaldesignknowledgeandanumberofknowledgelibraries.Moket.al.[7]developedaninteractiveknowledge-basedCADsystemforinjectionmoulddesignincorporatingcomputational,knowledgeandgraphicmodules.Severalstudieshavealsobeenmadeonimprovingthedesignofspecificcomponentsofaninjectionmould.Onget.al.[8]developedaknowledge-basedandobjectoriented
approachforthedesignofthefeedsystemforinjectionmoulds,whichcanefficientlydesignthetype,locationandsizeofagatingsysteminthemould.Iraniet.al.[9]alsodevelopedasoftwaresystemforautomaticdesignofgatingandrunnersystemsforinjectionmouldsandprovideevaluationofgatingdesignbasedonspecifiedperformanceparameters.Neeet.al.[10]
proposedamethodologyfordeterminationofoptimal.partingdirectionsininjectionmoulddesignbasedonautomaticrecognitionandextractionofundercutfeatures.ChenandChou[11]developedalgorithmsforselecting
apartinglineinmoulddesignbycomputingtheundercutvolumesandminimisingthenumberofundercuts.ParkandKwon[12]workedonthedesignofcoolingsystemsininjectionmouldsandproposedanoptimaldesignbasedonthermalanalysisanddesignsensitivityanalysisofthecoolingstageoftheinjectionmouldingprocess.Lin[13]workedontheuseofgatesizeandgatepositionasthemajorparametersforsimulatedinjectionmould
performanceprediction.Oneareaininjectionmoulddesign,whichhas
receivedlittleattention,isthedesignofcavitylayoutinamultiplecavityinjectionmould.Cavitylayoutdesignaffectsthewholeprocessofinjectionmouldingdirectly,sinceitisoneofthemostimportantphasesinmould
designprocess.Considerationofcavitylayoutdesignininjectionmouldatconceptdesignstagewillimprovethequalityofinjectionmouldedproductsbecauseitisassociatedwiththedeterminationofmanykeyfactorsaffectingthedesignandqualityofmould.Suchfactorsincludenumberofcavities;partingline;typeofmould;typeandpositionofgate;runnersystem;coolingsystemandejectionsystem.Someofthesefactorsaredifficulttobuildastruemathematicalmodelsforanalysisanddesign.Thispaperpresentsthedevelopmentofadesignsupportsystem,calledIntelligentCavityLayoutDesignSystem(ICLDS),formultiple-cavityinjectionmouldsbasedonknowledgebasedandobjectorientedapproaches.Itusesthecase-basedandruled-basedreasoninginarrivingatthelayoutsolution[14].Itisbasedonthecommercialsoftwaresystemnamed“RETE++”,whichisanintegrateddevelopmentplatformforcustomerstodeveloptheirownknowledge-basedsystems[15].Theobjectiveistomakefulluseofavailabletechniquesin
artificialintelligenceinassistingmoulddesignersatconceptdesignstage.
2.CavityLayoutDesigninInjectionMoulds
Currentpracticeforinjectionmoulddesign,especiallycavitylayoutdesign,dependslargelyondesigners’experiencesandknowledge.Itwouldthereforebedesirabletouseknowledgeengineering,artificialintelligenceandintelligentdesigntechniquesingeneratinganacceptablecavitylayoutdesignininjectionmouldaccuratelyandefficiently.Inmoulddesign,mostofpatternsofcavitylayoutandrulesandprinciplesofcavitylayoutdesign
canalsobeeasilyrepresentedintheformofknowledge,whichcanbeusedinmostofknowledge-baseddesignsystems.thecriteriatoselectthesuitablelayoutpatternfordesignaremainlydependentonworkingenvironments,
conditionsandrequirementsofcustomerandaremainlybasedondesigner’sskillandexperience.Tomakeachoiceofcontradictoryfactorswillrelyobviouslyondesigner’sknowledgeandexperiences.Itisrathersuitable
forintelligentdesigntechniquestobeusedinsystemsdesignedforsuchsituations,especiallyforroutineorinnovationdesign.Designofinjectionmouldmainlyinvolvesconsiderationofdesignofthefollowingelementsorsub-systems:
(1)mouldtype
(2)numberofcavities
(3)cavitylayout
(4)runnersystem
(5)ejectorsystem
(6)coolingsystem
(7)venting
(8)mountingmechanism
Mostoftheelementsareinter-dependentsuchthatitisvirtuallyimpossibletoproduceameaningfulflowchartcoveringthewholemoulddesignprocess.Obviously,ininjectionmoulddesign,itisdifficultfordesignertomonitoralldesignparameters.Cavitydesignandlayoutdirectlyaffectsmostofotheractivities.Theapplicationofadvancedknowledgebasedtechniquestoassistdesignerincavitylayoutdesignatconcept
designstagewillgreatlyassistinthedevelopmentofacomprehensivecomputer-aidedinjectionmoulddesignandmanufacturingsystem.Higherthenumberofcavitiesofmould,highertheproductivityoftheinjectionmould.Butthismayleadtodifficultieswithissuessuchasbalancingthe
runnersorproductswiththecomplicatedcavityshapes,whichinturnmayleadtoproblemsofmouldmanufacturability.Itisalsopossiblethatthenumberofcavitiesandthepatternofcavitylayoutwillinfluencethedeterminationofpartingline,typeofgate,positionofgate,runnersystemandcoolingsystem.Mostofthemainactivitiesofmoulddesignarethereforelinkedtocavitylayoutdesign.Thecavitylayoutdesignproblemthereforedependsuponanumberoffunctionalitiesoftheoverallmoulddesignsystem,whichincludes:
(1)definitionofdesignspecificationsincluding
analysisanddescriptionofcharacteristicsof
(2)determinationofmouldtype
(3)determinationofnumberofcavities
(4)determinationoforientationofproduct
(5)determinationofrunnertypeandrunner
configuration
(6)determinationoftypeandpositionofgate
(7)cavitylayoutconceptualdesign
(8)evaluationofejectionability,manufacturing
abilityandeconomicperformances
(9)determinationofcoolingsystem
(10)graphicresultsdisplayandoutput
3.StructureofICLDSandtheDesignProcess
ThestructureoftheIntelligentCavityLayoutDesignSystem(ICLDS)isbasedoncase-basedreasoningandruled-based
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