In an injection moulding process, the parallelism b et ween the tie bars of the injection moulding machine is very important as it will affect the mould closing and clamping system. In recent years, more and more ho t...In an injection moulding process, the parallelism b et ween the tie bars of the injection moulding machine is very important as it will affect the mould closing and clamping system. In recent years, more and more ho t runner systems are being applied in the moulding industry to save material and decrease the losses of injection pressure. Heat transfer from hot runner system from the fixed half which is secured in the fix machine platen could transmit s o much heat that it may cause high temperature differential between the machine fix platen and moving platen. This will cause the tie bar to become unparallel. Part quality will be compromised and the wear of the tie bar will be excessive. Overhaul of the tie bar may be necessary after a short period of time which is c ostly. This raises the need to analyze the heat transfer from the hot runner sys tem to the machine fix platen and the methods of isolating or minimizing the hea t transfer. In this case study, a photo lens article mould was used. The mould w as built with a direct hot runner nozzle system. Heat conduction from hot runner and machine screw to machine fix platen were studied based on either using high temperature heat insulating plate put in placed between the mould and the mould ing machine fix platen or drill cooling channels in the front mould clamping pla te. The high temperature insulator is very costly as it is made out of glass re inforced polymer composite material. Experimental results were obtained and anal yzed to find the best method to minimize the unwanted heat transfer using the ch eapest and most effective method.展开更多
In an injection moulding process, the mould cooling s ystem is very important as an efficient and uniform cooling effect can improve b oth the productivity and part quality. Due to the complexity of the process, muc h...In an injection moulding process, the mould cooling s ystem is very important as an efficient and uniform cooling effect can improve b oth the productivity and part quality. Due to the complexity of the process, muc h research on the mould cooling analysis and cooling design optimization has bee n focused on the core and the cavity, excluding other systems of injection mould s. However, the runner system introduces a considerable amount of heat into the mould. In recent years, more and more hot runner systems are being applied in th e moulding industry to save material and decrease losses of injection pressure. This raises the need to include the hot runner system in the cooling analysis. I n this paper, a photo frame part was studied. The mould was built with a hot run ner system. Two thermal sensors were installed: one measures the temperature of lateral surface of hot runner nozzle; the other measures the plastic temperature from the core side. A pressure sensor was also installed to measure the pressur e of the core impression. Cooling analysis was performed using ABAQUS, ananalysi s software based on the Finite Element Method (FEM). The assembly including core , cavity and plastic part was modeled. Heat conduction from hot runner to cavity and from polymer melt to the mould and force convection on the cooling channel surfaces were studied. The natural convection between the ambient air and the ex terior mould surface was ignored. The simulations were adjusted with the experim ental results to find out the heat input from hot runner and its influence on mo uld cooling. Finally, the optimal cooling design and optimal injection condition were obtained.展开更多
The finite element analysis and the optimum design of aluminum profile extrusion mould were investigated using the ANSYS software and its parameterized modeling method. The optimum dimensions of the mould were obtaine...The finite element analysis and the optimum design of aluminum profile extrusion mould were investigated using the ANSYS software and its parameterized modeling method. The optimum dimensions of the mould were obtained. It is found that the stress distribution is very uneven, and the stress convergence is rather severe in the bridge of the aluminum profile extrusion mould. The optimum height of the mould is 70.527 mm, and the optimum radius of dividing holes are 70.182 mm and 80.663 mm. Increasing the height of the mould in the range of 61.282 mm to 70.422 mm can prolong its longevity, but when the height is over 70.422 mm, its longevity reduces.展开更多
The effects of process parameters in rapid heat cycle moulding （RHCM） on parts warpage were investigated. A vehicle-used blue-tooth front shell （consisting of ABS material） was considered as a part example manufac...The effects of process parameters in rapid heat cycle moulding （RHCM） on parts warpage were investigated. A vehicle-used blue-tooth front shell （consisting of ABS material） was considered as a part example manufactured by RHCM method. The corresponding rapid heat response mould with an innovational conformal heating/cooling channel system and a dynamic mould temperature control system based on the Jll-W-160 type precise temperature controller was proposed. During heating/cooling process, the mould was able to be heated from room temperature to 160 ~C in 6 s and then cooled to 80 ~C in 22 s. The effects of processing conditions in RHCM on part warpage were investigated based on the single factor experimental method and Taguchi theory. Results reveal that the elevated mould temperature reduces unwanted freezing during the injection stage, thus improving mouldability and enhancing part quality, whereas the overheated of mould temperature will lead to defective product. The feasible mould temperature scope in RHCM should be no higher than 140 ~C, and the efficient mould temperature scope should be around the polymer heat distortion temperature. Melt temperature as well as injection pressure effects on warpage can be divided into two stages The lower stage gives a no explicit effect on warpage whereas the higher stage leads to a quasi-linear downtrend. But others affect the warpage as a V-type fluctuation, reaching to the minimum around the heat distortion temperature. Under the same mould temperature condition, the effects of process parameters on warpage decrease according to the following order, packing time, packing pressure, melt temperature, injection pressure and cooling time, respectively.展开更多
With the rapid development of information and multi me dia technologies, the demand for the optical plastic aspheric elements used in o pto-electronic devices, camera, optical disc and projector lens etc. has been i n...With the rapid development of information and multi me dia technologies, the demand for the optical plastic aspheric elements used in o pto-electronic devices, camera, optical disc and projector lens etc. has been i ncreased rapidly in the recent years. The key technologies of fabrication of asp heric plastic lens are the design and manufacturing moulds, selection of proper injection moulding equipment, and optimization of injection moulding parameters etc. In this paper, the effect of injection pressure, moulding temperature, cool ing time and injection speed on the surface profile of the lenses during injecti on and holding process is investigated. Surface quality of plastic lenses is mea sured by Talysurf Texture Measuring System. The experimental results showed that the injection pressure and moulding temperature are important parameters compar ing to cooling time and injection speed. A bit change of injection pressure or m oulding temperature will affect the property of the surface profile. Either incr easing injection pressure or mould temperature can achieve less shrinkage. Other wise, a lower injection pressure will produce more shrinkage, more air traps and a lower mould temperature results greater warp and higher shrinkage. The dynami c process of injection for optical plastic lenses is simulated by 3D Moldflow pl astic Insight software (MPI). The MPI will help us to optimize injection mouldin g parameters.展开更多
Cristobalite SiO2 can be obtained from the fused silica ceramic waste of ploysilicon plant, due to the phase conversion of fused silica to cristobalite during the process of polysilicon ingot. Cristobalite powder mate...Cristobalite SiO2 can be obtained from the fused silica ceramic waste of ploysilicon plant, due to the phase conversion of fused silica to cristobalite during the process of polysilicon ingot. Cristobalite powder materials with high purity are manufactured by milling the discarded waste above. Thermal expansion rate of the cristobalite and gypsum bonding moulds were studied, which show that the thermal expansion of the cristobalite phase transition could effectively compensate for the shrinkage of the gypsum at the temperature between 200 ℃ and 400 ℃. Casting experiments with copper alloy show that the cristobalite can improve the thermal performance of moulds for precise casting of jewelry.展开更多
The characteristic of metallographic structure of the SnSb alloy moulds is that hard particles are distributed on the soft metal matrix. Great difference of the hard particles and the soft metal matrix’hardness makes...The characteristic of metallographic structure of the SnSb alloy moulds is that hard particles are distributed on the soft metal matrix. Great difference of the hard particles and the soft metal matrix’hardness makes moulds’polishing become difficult. When a rigid grindstone is used to polish the surface of the SnSb alloy mould, the hard abrasives fall off and are embed in the soft matrix of SnSb alloy and while the process, the grinding chips are able to block the gap on the grindstone surface and enable the grindstone to blunt, which brings about the polished area on the surface of the mould is seriously squeezed and deformed and the crystal lattice of SnSb alloys is seriously distorted, and the work hardening takes place. At the same time, the rigid grindstone is easy to scratch the surface of the SnSb alloy mould. Owing to the above reasons, it is difficult to reduce surface roughness and improve the surface quality of SnSb alloy moulds. Taking use of the CAD/CAM technique and the complex processing of combining electrolyzing polishing and mechanical polishing with the magnetic force, mould’s polishing automation is realized on the numerical control machine tool. This complex processing is finished under a comprehensive action as the following: 1. Electrolyzing polishing action Under the electric field, the electrolyte between the elastic grind wheel and the mould is ionized, which electrolyzes the metal of the mould’s surface. The electrolyzing speed of convex peak on the mould’s surface is faster than that of concave valley, which levels the mould’s surface. 2. Mechanical Polishing action During electrolyzing, a dense passive film of low hardness is formed on the mould’s surface. While polishing, soft grinding wheel scraps the passive film on the conven peak easily, and the new metal surface is exposed, then, a new passive film is formed again, going round and round, the conven peak on the mould’s surface is leveled quickly. 3. Magnetic force action The charged particles in electric field will be acted by the Lorentz force in magnetic field. The field plays a stirring part on electrolyte and reduces electrochemical polarization and concentration polarization, and accelerates the electrochemical reaction. The complex polishing process is not only of high efficiency, but also of good surface quality and provides a good effective method for the non-ferrous metal polishing. When the mould is polished, a speed-raising tool system is used and it can increase the grinding wheel spindle’s speed up to five times. This paper describes the SnSb alloy moulds’polishing steps, grinding wheel speed-raising tool system, polishing principle and the results.展开更多
Today, the time-to-market for plastic products ar e getting shorter, thus the lead-time for making the injection mould is decreasin g. There is potential in timesavings in the mould design stage because the design pro...Today, the time-to-market for plastic products ar e getting shorter, thus the lead-time for making the injection mould is decreasin g. There is potential in timesavings in the mould design stage because the design process that is repeatable for every mould design can be standardized. T he preliminary work of any final plastic injection mould design is to always pro vide an initial design of the mould assembly for product designers (customers) p rior to receiving the final product CAD data. Traditionally and even up till no w, this initial design is always created using 2D CAD packages. The information used for the initial design is based on the technical discussion checklist, in which most mould makers have their own standards. This checklist is also being used as a quotation since the most basic information of the mould in the particu lar project is being recorded in it. The basic information in this checklist in cludes the number of cavities, the type of mould base to be used, the moulding m achine to be used for the moulding, the type of gating system, the type of resin material used and its shrinkage value etc. Information on special requirements such as the number of sliders or lifters to be used is also listed in the check list. At this stage, there is still no information on the cooling and ejection design since they are greatly dependent on the final product CAD data. This res earch focuses on the methodology of providing the initial design in 3D solid bas ed on the technical discussion checklist, which takes the role of the overall st andard template since every sub-design has its own standard template. An examp le of a sub-design that has its own standard template is the cavity layout desi gn. The cavity layout for plastic injection moulds can be designed by controlli ng the geometrical parameters using a standardization template. The standardiza tion template for the cavity layout design consists of configurations for the po ssible layouts. Each configuration of the layout design has its own layout desi gn table of all the geometrical parameters. This standardization template is pr e-defined in the layout design level of the mould assembly design. This ensure s that the required configuration can be loaded into the mould assembly design v ery quickly without having the need to redesign the layout. This makes it usefu l for technical discussions between the product designers and mould designers pr ior to the manufacture of the mould. Changes can be made to the 3D cavity layou t design immediately during the discussions thus the savings in time and avo idance of miscommunications.展开更多
On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is ...On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is an ardent task due to its warpage, induced by the high specific grinding energy (2～10 J/mm 3). Therefore, coolant is often used to avoid thermal damage, obtai n better surface integrity and to prolong wheel life. However coolant, the incomp ressibility media introduce high forces at the grinding zone creating dimensiona l as well as shape instability. In view of these situations chilled air was ap plied in place of conventional coolant. The chilled air is produced using a two -stage vapor compression refrigeration cycle with characteristics of: temperatu re -35 ℃, pressure 0.2～0.3 MPa and flow rate 0.4 m 3/min. Also traces of eco - oil mist that encompass the chilled air are supplied to the grinding zone. B oth chilled air and eco-oil mist are applied through two independent paths of a specially designed twin compartment nozzle for maximizing the penetration. This paper investigates the grinding characteristics of mold insert which is closer to M2 tool steel (component widely used in connector industries) when using chil led air as coolant media. Grinding experiments were conducted using a vitrified bond CBN wheel (B91N100V) and a surface grinder. Initial study was focussed on establishing the most suita ble clamping method for the thin mold insert. FEM analysis and grinding experime nt studies were performed to quantitatively analyze the clamping induced deflect ion. Waviness value (W t) of (24～62) μm was achieved for resin clampi n g whereas (4～8) μm, (4～6) μm were achieved for magnetic and wax clamping res pe ctively. Wax clamping is predominantly used in all the grinding experiments that characterize the grinding process, which use chilled air as the coolant media. Between 0.15 to 0.9 mm 3/mm.s of specific material removal rate, ground sur face temperature of mold insert was increased from 0.3 ℃ to 59.7 ℃ for chi lled air. For the similar grinding conditions with the coolant fluid an increase from 0.9 ℃ to 14.4 ℃ was recorded. With increase of specific material removal rate from 0.15 to 0.65 mm 3/mm.s, F t/F n ratio was increased from (0.2 to 0.4), (0.6 to 1.67) for wet coolant and chilled air respectively. Despite of high F t/F n ratio and ground surface temperature, chilled air method has shown a surface waviness, W t from (2 to 5.6) μm. Microstructure examination of chilled air produced ground surface was comparable to those of using coolant fluids. Surface finish, R a of (0.45～0.7) μm was achieved for mold insert . This work will enable to have clear understanding about the quantitative influe nce of chilled air as well as the clamping method against the surface waviness o f thin mold insert.展开更多
Obtaining the optimal values of the parameters for th e design of a required mould and the operation of the moulding process are diffi cult, this is due to the complexity of product geometry and the variation of pla s...Obtaining the optimal values of the parameters for th e design of a required mould and the operation of the moulding process are diffi cult, this is due to the complexity of product geometry and the variation of pla stic material properties. The typical parameters for the mould design and mouldi ng process are melt flow length, injection pressure, holding pressure, back pres sure, injection speed, melt temperature, mould temperature, clamping force, inje ction time, holding time and cooling time. This paper discusses the difficulties of using the current computer aided optimization methods to acquire the values of the parameters. A method that is based on the concept of genetic algorithm is proposed to overcome the difficulties. The proposed method describes in details on how to attain the optimal values of the parameters form a given product geom etry.展开更多
With the use of multimedia which combines the use o f text, sound, images, motion video and animation, it is more efficient for studen ts to learn mould design interactively. A program is created using several multi m...With the use of multimedia which combines the use o f text, sound, images, motion video and animation, it is more efficient for studen ts to learn mould design interactively. A program is created using several multi media software to simulate the mechanism of moulding processes in order to let s tudents understand the concept of mould design. In addition, students can even access the program through the Internet. Therefore, the software is defined as Multimedia and Internet Technology (MIT) program. The MIT program consists of four sections: (i) simulation of mould mechanisms, ( ii) cooling system, (iii) material information and (iv) games for tutorials. Sec tion One covers the basic operations of different types of moulds such as two-p late mould, three-plate mould, split mould, side-core mould and mould with und ercuts. Section Two introduces different types of cooling systems such as bubble r, baffle, cooling circuits, etc. Section Three provides some useful material in formation for mould design. Section Four contains games of matching mould compon ents, mould design problem finding and multiple choice questions to test student s how much they understand mould design concept. Multimedia is highly effective particularly in teaching and learning. It changes the nature of learning itself. It makes reading dynamic by giving words an impo rtant new dimension. It allows students to see, hear and do simultaneously, thus significantly reducing average learning time. Furthermore, through cooperative learning on Internet, students can access the program, share data or search info rmation anytime anywhere. Therefore, Multimedia and Internet Technology is one o f the vital aspects to speed up the realization of information age in society.展开更多
文摘In an injection moulding process, the parallelism b et ween the tie bars of the injection moulding machine is very important as it will affect the mould closing and clamping system. In recent years, more and more ho t runner systems are being applied in the moulding industry to save material and decrease the losses of injection pressure. Heat transfer from hot runner system from the fixed half which is secured in the fix machine platen could transmit s o much heat that it may cause high temperature differential between the machine fix platen and moving platen. This will cause the tie bar to become unparallel. Part quality will be compromised and the wear of the tie bar will be excessive. Overhaul of the tie bar may be necessary after a short period of time which is c ostly. This raises the need to analyze the heat transfer from the hot runner sys tem to the machine fix platen and the methods of isolating or minimizing the hea t transfer. In this case study, a photo lens article mould was used. The mould w as built with a direct hot runner nozzle system. Heat conduction from hot runner and machine screw to machine fix platen were studied based on either using high temperature heat insulating plate put in placed between the mould and the mould ing machine fix platen or drill cooling channels in the front mould clamping pla te. The high temperature insulator is very costly as it is made out of glass re inforced polymer composite material. Experimental results were obtained and anal yzed to find the best method to minimize the unwanted heat transfer using the ch eapest and most effective method.
文摘In an injection moulding process, the mould cooling s ystem is very important as an efficient and uniform cooling effect can improve b oth the productivity and part quality. Due to the complexity of the process, muc h research on the mould cooling analysis and cooling design optimization has bee n focused on the core and the cavity, excluding other systems of injection mould s. However, the runner system introduces a considerable amount of heat into the mould. In recent years, more and more hot runner systems are being applied in th e moulding industry to save material and decrease losses of injection pressure. This raises the need to include the hot runner system in the cooling analysis. I n this paper, a photo frame part was studied. The mould was built with a hot run ner system. Two thermal sensors were installed: one measures the temperature of lateral surface of hot runner nozzle; the other measures the plastic temperature from the core side. A pressure sensor was also installed to measure the pressur e of the core impression. Cooling analysis was performed using ABAQUS, ananalysi s software based on the Finite Element Method (FEM). The assembly including core , cavity and plastic part was modeled. Heat conduction from hot runner to cavity and from polymer melt to the mould and force convection on the cooling channel surfaces were studied. The natural convection between the ambient air and the ex terior mould surface was ignored. The simulations were adjusted with the experim ental results to find out the heat input from hot runner and its influence on mo uld cooling. Finally, the optimal cooling design and optimal injection condition were obtained.
文摘The finite element analysis and the optimum design of aluminum profile extrusion mould were investigated using the ANSYS software and its parameterized modeling method. The optimum dimensions of the mould were obtained. It is found that the stress distribution is very uneven, and the stress convergence is rather severe in the bridge of the aluminum profile extrusion mould. The optimum height of the mould is 70.527 mm, and the optimum radius of dividing holes are 70.182 mm and 80.663 mm. Increasing the height of the mould in the range of 61.282 mm to 70.422 mm can prolong its longevity, but when the height is over 70.422 mm, its longevity reduces.
基金Project(20122BAB206014)supported by National Natural Science Foundation of ChinaProject(51365038)supported by the Natural Science Foundation of Jiangxi Province,ChinaProject(GJJ13068)supported by the Science and Technology Program of Educational Committee of Jiangxi Province,China
文摘The effects of process parameters in rapid heat cycle moulding （RHCM） on parts warpage were investigated. A vehicle-used blue-tooth front shell （consisting of ABS material） was considered as a part example manufactured by RHCM method. The corresponding rapid heat response mould with an innovational conformal heating/cooling channel system and a dynamic mould temperature control system based on the Jll-W-160 type precise temperature controller was proposed. During heating/cooling process, the mould was able to be heated from room temperature to 160 ~C in 6 s and then cooled to 80 ~C in 22 s. The effects of processing conditions in RHCM on part warpage were investigated based on the single factor experimental method and Taguchi theory. Results reveal that the elevated mould temperature reduces unwanted freezing during the injection stage, thus improving mouldability and enhancing part quality, whereas the overheated of mould temperature will lead to defective product. The feasible mould temperature scope in RHCM should be no higher than 140 ~C, and the efficient mould temperature scope should be around the polymer heat distortion temperature. Melt temperature as well as injection pressure effects on warpage can be divided into two stages The lower stage gives a no explicit effect on warpage whereas the higher stage leads to a quasi-linear downtrend. But others affect the warpage as a V-type fluctuation, reaching to the minimum around the heat distortion temperature. Under the same mould temperature condition, the effects of process parameters on warpage decrease according to the following order, packing time, packing pressure, melt temperature, injection pressure and cooling time, respectively.
文摘With the rapid development of information and multi me dia technologies, the demand for the optical plastic aspheric elements used in o pto-electronic devices, camera, optical disc and projector lens etc. has been i ncreased rapidly in the recent years. The key technologies of fabrication of asp heric plastic lens are the design and manufacturing moulds, selection of proper injection moulding equipment, and optimization of injection moulding parameters etc. In this paper, the effect of injection pressure, moulding temperature, cool ing time and injection speed on the surface profile of the lenses during injecti on and holding process is investigated. Surface quality of plastic lenses is mea sured by Talysurf Texture Measuring System. The experimental results showed that the injection pressure and moulding temperature are important parameters compar ing to cooling time and injection speed. A bit change of injection pressure or m oulding temperature will affect the property of the surface profile. Either incr easing injection pressure or mould temperature can achieve less shrinkage. Other wise, a lower injection pressure will produce more shrinkage, more air traps and a lower mould temperature results greater warp and higher shrinkage. The dynami c process of injection for optical plastic lenses is simulated by 3D Moldflow pl astic Insight software (MPI). The MPI will help us to optimize injection mouldin g parameters.
文摘Cristobalite SiO2 can be obtained from the fused silica ceramic waste of ploysilicon plant, due to the phase conversion of fused silica to cristobalite during the process of polysilicon ingot. Cristobalite powder materials with high purity are manufactured by milling the discarded waste above. Thermal expansion rate of the cristobalite and gypsum bonding moulds were studied, which show that the thermal expansion of the cristobalite phase transition could effectively compensate for the shrinkage of the gypsum at the temperature between 200 ℃ and 400 ℃. Casting experiments with copper alloy show that the cristobalite can improve the thermal performance of moulds for precise casting of jewelry.
文摘The characteristic of metallographic structure of the SnSb alloy moulds is that hard particles are distributed on the soft metal matrix. Great difference of the hard particles and the soft metal matrix’hardness makes moulds’polishing become difficult. When a rigid grindstone is used to polish the surface of the SnSb alloy mould, the hard abrasives fall off and are embed in the soft matrix of SnSb alloy and while the process, the grinding chips are able to block the gap on the grindstone surface and enable the grindstone to blunt, which brings about the polished area on the surface of the mould is seriously squeezed and deformed and the crystal lattice of SnSb alloys is seriously distorted, and the work hardening takes place. At the same time, the rigid grindstone is easy to scratch the surface of the SnSb alloy mould. Owing to the above reasons, it is difficult to reduce surface roughness and improve the surface quality of SnSb alloy moulds. Taking use of the CAD/CAM technique and the complex processing of combining electrolyzing polishing and mechanical polishing with the magnetic force, mould’s polishing automation is realized on the numerical control machine tool. This complex processing is finished under a comprehensive action as the following: 1. Electrolyzing polishing action Under the electric field, the electrolyte between the elastic grind wheel and the mould is ionized, which electrolyzes the metal of the mould’s surface. The electrolyzing speed of convex peak on the mould’s surface is faster than that of concave valley, which levels the mould’s surface. 2. Mechanical Polishing action During electrolyzing, a dense passive film of low hardness is formed on the mould’s surface. While polishing, soft grinding wheel scraps the passive film on the conven peak easily, and the new metal surface is exposed, then, a new passive film is formed again, going round and round, the conven peak on the mould’s surface is leveled quickly. 3. Magnetic force action The charged particles in electric field will be acted by the Lorentz force in magnetic field. The field plays a stirring part on electrolyte and reduces electrochemical polarization and concentration polarization, and accelerates the electrochemical reaction. The complex polishing process is not only of high efficiency, but also of good surface quality and provides a good effective method for the non-ferrous metal polishing. When the mould is polished, a speed-raising tool system is used and it can increase the grinding wheel spindle’s speed up to five times. This paper describes the SnSb alloy moulds’polishing steps, grinding wheel speed-raising tool system, polishing principle and the results.
文摘Today, the time-to-market for plastic products ar e getting shorter, thus the lead-time for making the injection mould is decreasin g. There is potential in timesavings in the mould design stage because the design process that is repeatable for every mould design can be standardized. T he preliminary work of any final plastic injection mould design is to always pro vide an initial design of the mould assembly for product designers (customers) p rior to receiving the final product CAD data. Traditionally and even up till no w, this initial design is always created using 2D CAD packages. The information used for the initial design is based on the technical discussion checklist, in which most mould makers have their own standards. This checklist is also being used as a quotation since the most basic information of the mould in the particu lar project is being recorded in it. The basic information in this checklist in cludes the number of cavities, the type of mould base to be used, the moulding m achine to be used for the moulding, the type of gating system, the type of resin material used and its shrinkage value etc. Information on special requirements such as the number of sliders or lifters to be used is also listed in the check list. At this stage, there is still no information on the cooling and ejection design since they are greatly dependent on the final product CAD data. This res earch focuses on the methodology of providing the initial design in 3D solid bas ed on the technical discussion checklist, which takes the role of the overall st andard template since every sub-design has its own standard template. An examp le of a sub-design that has its own standard template is the cavity layout desi gn. The cavity layout for plastic injection moulds can be designed by controlli ng the geometrical parameters using a standardization template. The standardiza tion template for the cavity layout design consists of configurations for the po ssible layouts. Each configuration of the layout design has its own layout desi gn table of all the geometrical parameters. This standardization template is pr e-defined in the layout design level of the mould assembly design. This ensure s that the required configuration can be loaded into the mould assembly design v ery quickly without having the need to redesign the layout. This makes it usefu l for technical discussions between the product designers and mould designers pr ior to the manufacture of the mould. Changes can be made to the 3D cavity layou t design immediately during the discussions thus the savings in time and avo idance of miscommunications.
文摘On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is an ardent task due to its warpage, induced by the high specific grinding energy (2～10 J/mm 3). Therefore, coolant is often used to avoid thermal damage, obtai n better surface integrity and to prolong wheel life. However coolant, the incomp ressibility media introduce high forces at the grinding zone creating dimensiona l as well as shape instability. In view of these situations chilled air was ap plied in place of conventional coolant. The chilled air is produced using a two -stage vapor compression refrigeration cycle with characteristics of: temperatu re -35 ℃, pressure 0.2～0.3 MPa and flow rate 0.4 m 3/min. Also traces of eco - oil mist that encompass the chilled air are supplied to the grinding zone. B oth chilled air and eco-oil mist are applied through two independent paths of a specially designed twin compartment nozzle for maximizing the penetration. This paper investigates the grinding characteristics of mold insert which is closer to M2 tool steel (component widely used in connector industries) when using chil led air as coolant media. Grinding experiments were conducted using a vitrified bond CBN wheel (B91N100V) and a surface grinder. Initial study was focussed on establishing the most suita ble clamping method for the thin mold insert. FEM analysis and grinding experime nt studies were performed to quantitatively analyze the clamping induced deflect ion. Waviness value (W t) of (24～62) μm was achieved for resin clampi n g whereas (4～8) μm, (4～6) μm were achieved for magnetic and wax clamping res pe ctively. Wax clamping is predominantly used in all the grinding experiments that characterize the grinding process, which use chilled air as the coolant media. Between 0.15 to 0.9 mm 3/mm.s of specific material removal rate, ground sur face temperature of mold insert was increased from 0.3 ℃ to 59.7 ℃ for chi lled air. For the similar grinding conditions with the coolant fluid an increase from 0.9 ℃ to 14.4 ℃ was recorded. With increase of specific material removal rate from 0.15 to 0.65 mm 3/mm.s, F t/F n ratio was increased from (0.2 to 0.4), (0.6 to 1.67) for wet coolant and chilled air respectively. Despite of high F t/F n ratio and ground surface temperature, chilled air method has shown a surface waviness, W t from (2 to 5.6) μm. Microstructure examination of chilled air produced ground surface was comparable to those of using coolant fluids. Surface finish, R a of (0.45～0.7) μm was achieved for mold insert . This work will enable to have clear understanding about the quantitative influe nce of chilled air as well as the clamping method against the surface waviness o f thin mold insert.
文摘Obtaining the optimal values of the parameters for th e design of a required mould and the operation of the moulding process are diffi cult, this is due to the complexity of product geometry and the variation of pla stic material properties. The typical parameters for the mould design and mouldi ng process are melt flow length, injection pressure, holding pressure, back pres sure, injection speed, melt temperature, mould temperature, clamping force, inje ction time, holding time and cooling time. This paper discusses the difficulties of using the current computer aided optimization methods to acquire the values of the parameters. A method that is based on the concept of genetic algorithm is proposed to overcome the difficulties. The proposed method describes in details on how to attain the optimal values of the parameters form a given product geom etry.
文摘With the use of multimedia which combines the use o f text, sound, images, motion video and animation, it is more efficient for studen ts to learn mould design interactively. A program is created using several multi media software to simulate the mechanism of moulding processes in order to let s tudents understand the concept of mould design. In addition, students can even access the program through the Internet. Therefore, the software is defined as Multimedia and Internet Technology (MIT) program. The MIT program consists of four sections: (i) simulation of mould mechanisms, ( ii) cooling system, (iii) material information and (iv) games for tutorials. Sec tion One covers the basic operations of different types of moulds such as two-p late mould, three-plate mould, split mould, side-core mould and mould with und ercuts. Section Two introduces different types of cooling systems such as bubble r, baffle, cooling circuits, etc. Section Three provides some useful material in formation for mould design. Section Four contains games of matching mould compon ents, mould design problem finding and multiple choice questions to test student s how much they understand mould design concept. Multimedia is highly effective particularly in teaching and learning. It changes the nature of learning itself. It makes reading dynamic by giving words an impo rtant new dimension. It allows students to see, hear and do simultaneously, thus significantly reducing average learning time. Furthermore, through cooperative learning on Internet, students can access the program, share data or search info rmation anytime anywhere. Therefore, Multimedia and Internet Technology is one o f the vital aspects to speed up the realization of information age in society.
