220型復合管螺旋式脫模裝置設計-15t螺旋式電工絕緣管脫模裝置【含7張CAD圖帶開題報告-獨家】.zip
220型復合管螺旋式脫模裝置設計-15t螺旋式電工絕緣管脫模裝置【含7張CAD圖帶開題報告-獨家】.zip,含7張CAD圖帶開題報告-獨家,220,復合管,螺旋式,脫模,裝置,設計,15,電工,絕緣,CAD,開題,報告,獨家
-資料來源：
文章名：Modern Mold Manufacturing
書刊名：《English for Die & Mould Design and Manufacturing》
作 者：劉建雄 王家惠 廖丕博 主編
出版社：北京大學出版社，2002
章 節(jié)：Chapter 6 Modern Mold Manufacturing
文 章 譯 名： 計算機輔助設計與制造
21
Chapter 7 CAD/CAM/CAE
7.1 The Computer in Die Design
The term CAD is alternately used to mean computer aided design and computer aided drafting. Actually it can mean either one or both of these concepts, and the tool designer will have occasion to use it in both forms.
CAD computer aided design means using the computer and peripheral devices to simplify and enhance the design process. CAD computer aided drafting means using the computer and peripheral devices to produce the documentation and graphics for the design process. This documentation usually includes such things as preliminary drawings, working drawings, parts lists, and design calculations.
A CAD system, whether taken to mean computer aided design system or computer aided drafting system, consists of three basic components: (1) hardware, (2) software, and (3) users. The hardware components of a typical CAD system include a processor, a system display, a keyboard, a digitizer, and a plotter. The software component of a CAD system consists of the programs which allow it to perform design and drafting functions. The user is the tool designer who uses the hardware and software to simplify and enhance the design process.
The broad-based emergence of CAD on an industry-wide basis did not begin to materialize until the 1980’s. However, CAD as a concept is not new. Although it has changed drastically over the years, CAD had its beginnings almost thirty years ago during the middle 1950’s. Some of the first computers included graphics displays. Now a graphics display is an integral part of every CAD system.
Graphics displays represented the first real step toward bringing the worlds of tool design and the computer together. The plotters depicted in figure, represented the next step. With the advent of the digitizing tablet in the early 1960’s, CAD hardware as we know it today began to take shape. The development of computer graphics software followed soon after these hardware developments.
Early CAD systems were large, cumbersome, and expensive. So expensive, in fact,
only the largest companies could afford them. During the late 1950’s and early 1960’s, CAD was looked on as an interesting, but impractical novelty that had only limited potential in tool design applications. However, with the introduction of the silicon chip during the 1970’s, computers began to take their place in the world of tool design.
Integrated circuits on silicon chips allowed full scale computers to be packaged in small consoles no larger than television sets. These “mini-computers” had all of the characteristics of full scale computers, but they were smaller and considerably less expensive. Even smaller computers called microcomputers followed soon after.
The 1970’s saw continued advances in CAD hardware and software technology. So much so that by the beginning of the 1980’s, making and marketing CAD systems had become a growth industry. Also, CAD has been transformed from its status of impractical novelty to its new status as one of the most important inventions to date. By 1980, numerous CAD systems were available ranging in sizes from microcomputer systems to large minicomputer and mainframe systems.
7.2 CAD/CAM
7.2.1 CAD
Computer-aided design/computer-aided manufacturing (CAD/CAM) refers to the integration of computers into the design and production process to improve productivity. The heart of the CAD/CAM system is the design terminal and related hardware, such as computer, printer, plotter, paper tape punch, a tape reader, and digitizer. The design is constantly monitored on the terminal until it is completed. A hard copy can be generated if necessary. A computer tape or other control medium containing the design data guides computer-controlled machine tools during the manufacturing, testing, and quality control.
The software for CAD/CAM is a collection of computer programs stored in the system to make the various hardware components perform specific tasks. Examples of software are programs developed to generate a NC tool path, to assemble a bill of materials, or to create nodes and elements on a finite element model. Some of these software packages are referred to as software modules and can be classified into four categories: (1) operating systems, (2) general-purpose programs, (3) application programs, and (4) user programs. Although there are other kinds of software, these are sufficient for an explanation of the complexities in developing a CAD/CAM system.
Operating systems are programs written for a specific computer or class of computers. For convenient and efficient operation, programs and data are available in the system’s memory. The operating system is especially concerned with the input/output (I/O) devices like displays, printers, and tape punches. In most cases the operating system is supplied with the computer.
Although it may be argued that there are no general-purpose programs as such, some are more general than others. An example is a graphics program written in a high-level language like FORTRAN that allows the generation of geometric entities such as lines, circles, and parabolas and a combination of these to make designs. These designs may range from printed circuits to drill jigs and fixtures.
Application programs are developed for a special or specific purpose. The first language for specialized application was Automatically Programmed Tools (APT) in 1956. APT was deve- loped to ease the job of NC programmers in developing input to NC machine tools, as illustrated in Fig. 7-1. Other examples of application programs, relative to CAD/CAM, are programs developed specifically for the generation of finite element mesh and flat pattern development or “unbending” of sheet metal parts. These programs are uUser programs in CAD/CAM are highly specialized packages for creating specific outputs. For example, a user program may automatically design a gear after the user inputs certain parameters like the number of teeth, pitch diameter, and so on. Another program may calculate optimum feeds and speeds, given cutter information, material, depth of cut, and so on. These programs are often developed by the user from a software module furnished by the supplier of general-purpose software. Not all CAD/CAM software packages have these user programs, even though considerable savings can be achieved with them.
1. Computer Graphics
The computer graphics system accumulates and stores physically related data identifying the precise location, dimensions descriptive text, and other properties of every design element. The design-related data help the user-operator perform complex engineering analysis, generate bills of materials, produce reports, and detect design inconsistencies before the part reaches manufacturing.
With computer graphics two-dimensional drawings can be made into three-dimensional wire frames and solid models.
2. Wire Frames
The simple wire frame plot is the least expensive form of geometrically displaying a model. It is useful to verify the basic properties of a shape and continuity of the model. However, when a complex model is developed, wire frame displays become inadequate. Solid models eliminate most of the problems of the wire frame.
3. Solid Modeling
There are three basic techniques for generating solid models: constructive solid geometry (CSG), boundary representation (B-Rep), and analytical solid modeling.
In the CSG approach, various geometric patterns such as cylinders, spheres, and cones are combined by Boolean algebra to create designs.
In the B-Rep method, a profile of the part is defined and then swept, either linearly or radially, and the enclosed area represents the solid form.
4. Analytical Method
This method is similar to the B-Rep but enhances the creation of finite element model during generation of the design. Commercial packages do not use strictly one method or another. As an example, CSG packages may use B-Rep techniques to generate initial patterns, while B-Rep or analytical packages may use Boolean algebra to subtract patterns, such as cylinders or cones, from a design to create a hole in the design.
7.2.2 CAM
Computer-aided manufacture (CAM) centers around four main areas: NC, process planning, robotics, and factory management.
5. Numerical Control
The importance of NC in the CAM area is that the computer can generate a NC program directly from a geometric model or part. At present, automatic capabilities are generally limited to highly symmetric geometries and other specialized parts. However, in the near future some companies will not use drawings at all, but will be passing part information directly from design to manufacturing via a data base. As the drawings disappear, so will many of the problems, since computer models developed from a common integrated database will be used by both design and manufacturing. This can be done even though the departments may be widely separated geographically, because in essence they will be no farther apart than the terminals on their respective desks.
6. Process Planning
Process planning involves the detailed planning of the production sequence from start to finish. What is relevant to CAM is a process planning system that is able to produce process plans directly from the geometric model database with almost no human assistance.
Robots
Many advances are being made to integrate robots into the manufacturing system, as in on-line assembly, welding, and painting.
7. Factory Management
Factory management uses interactive factory data collection to get timely information from the factory floor. At the same time, it uses this data to calculate production priorities and dynamically determine what work needs to be done next to ensure that the master production schedule is being properly executed. The system can also be directly modified to satisfy a specific need without calling in computer programming experts.
sually purchased with the system or from
7.3 CAE
Computer-aided engineering simplifies the creation of the database, by allowing everal applications to share the information in the database. These applications include, for example, (a) finite-element analysis of stresses, strains, deflections, and temperature distribution in structures and load-bearing members, (b) the generation, storage, and trieval of NC data, and (c) the design of integrated circuits and other electronic devices.
With the increasing sophistication of computer hardware and software, one area which has grown rapidly is computer simulation of manufacturing processes and systems. Process simulation takes two basic forms: (a) it is a model of a specific operation intended to determine the viability of a process or to optimize or improve its performance; (b) it models multiple processes and their interactions, and it helps process planners and plant designers in the layout of machinery and facilities.
Individual processes have been modeled using various mathematical schemes. Finite-element analysis has been increasingly applied in software packages (process simulation) that are commercially available and inexpensive. Typical problems addressed are process viability (such as the formability of sheet metal in a certain die), and process optimization (for example, the material flow in forging in a given die, to identify potential defects, or mold design in casting, to eliminate hot spots, to promote uniform cooling, and to minimize defects).
Simulation of an entire manufacturing system involving multiple processes and equipment helps plant engineers to organize machinery and to identify critical machinery elements. In addition, such models can assist manufacturing engineers with scheduling and routing (by discrete event simulation). Commercially available software packages are often used for these simulations.
Polymer processing, in its most general context, involves the transformation of a solid (sometimes liquid) polymeric resin, which is in a random form (e.g. powder, pellets, beads), to a solid plastics product of specified shape, dimensions, and properties. The ultimate properties of the article are closely related to the microstructure. Therefore, the control of the process and product quality must be based on an understanding of the interactions between resin properties, equipment design, operating conditions, thermo-mechanics history, microstructure, and ultimate product properties. Mathematical modeling and computer simulation have been employed to obtain an understanding of these interactions. Such an approach has gained more importance in view of the expanding utilization of computer aided engineering (CAE) systems in conjunction with plastics processing.
7.3.1 MPI Introduction
MPI, as one of simulation software of MOLDFLOW corporation, is a set of integrated CAE simulations for plastics molding process, including MPI/Flow analysis, MPI/Co-Injection analysis, MPI/Gas analysis, MPI/Optim analysis, MPI/Microcellular analysis, MPI/Shrink analysis, MPI/Cool analysis, MPI/Warp analysis, MPI/Stress analysis. MPI provides solution in all stages of design and manufacturing, to improve productivity and enhance part quality. Key features of MPI include:
(1) Unique, patented fusion technology. MPI/Fusion allows you to analyze CAD solid models of thin-walled parts directly, resulting in a significant decrease in model preparation time. The timesaving allow you to analyze more design iterations as well as perform more in-depth analyses.
(2) Powerful workflow and productivity tools. The user-friendly environments in MPI employ visualization and project management tools that allow you to undertake extensive design analysis and optimization. After your analyses are complete, you can produce detailed, web-ready design reports quickly and easily.
(3) Proven solutions for all types of applications. Moldflow’s analysis products can simulate plastics flow and packing, mold cooling, and part shrinkage and warpage for thermoplastic injection molding, gas-assisted injection molding, co-injection molding and injection- compression molding processes. Additional modules simulate reactive molding processes including thermoset and rubber injection molding, reaction injection molding (RIM), structural reaction injection molding (SRIM), resin transfer molding, microchip encapsulation and underfill (flip-chip) encapsulation.
(4) The world’s best 3D solution. Using a proven solution technique based on a solid tetrahedral finite element volume mesh, MPI/3D allows you to perform true 3-dimensional flow simulations on parts that tend to be very thick and solid in nature as well as those that have extreme changes from thin to thick.
(5) The widest range of supported geometry types. Moldflow’s MPI technology can be used on all CAD model geometry types, including traditional midplane models, wire frame and surface models, thin-walled solids and thick or difficult-to-midplane solids. Regardless of your design geometry, you can accomplish simulation tasks in an easy-to-use, consistent, integrated environment that works with your model.
(6) Unsurpassed network computing options. Moldflow Plastics Insight (MPI) has been developed with network computing environments in mind. For example, users can run MPI/Synergy, the pre- and post-processor, on user-friendly Windows PC while running the analysis solvers on powerful UNIX workstations. Users can also take advantage of a distributed computing environment from within MPI and assign analyses to run on whatever network computers are available at any given time.
7.3.2 MPI Modules
1. MPI/Flow
MPI/Flow simulates the filling and packing phases of the injection molding process to predict the flow behavior of thermoplastic melts so you can ensure parts of acceptable quality can be manufactured efficiently.
Using MPI/Flow, you can
n predict and visualize the flowfront progression to see how the mold fills;
n determine injection pressure and clamp force requirements;
n optimize part wall thickness to achieve uniform filling;
n minimize cycle time, and reduce part cost;
n predict weld line locations and either move, minimize, or eliminate them, identify potential air traps and determine locations for proper mold venting;
n optimize process conditions such as injection time, injection velocity profile, melt temperature, packing pressure, packing time, and cycle time;
n determine areas of high volumetric shrinkage that could cause part warpage problems;
n determine gate freeze time.
2. MPI/Cool
MPI/Cool provides tools for modeling mold cooling circuits, inserts, and bases around a part and analyzing the efficiency of the mold's cooling system.
MPI/Cool simulations allow users to:
n optimize part and mold designs to achieve uniform cooling with the minimum cycle time;
n view the temperature difference between the core and cavity mold surfaces;
n minimize unbalanced cooling and residual stress to reduce or eliminate part warpage;
n predict temperature for all surfaces within the mold: part, runners, cooling channels, inserts;
n predict the required cooling time for the part and cold runner to determine overall cycle time.
3. MPI/Warp
MPI/Warp provides users with an understanding of the causes of shrinkage and warpage in injection molded plastic parts and predicts where deformations will occur.
MPI/Warp allows you to:
n evaluate final part shape before machining the mold;
n evaluate both single cavity and multi-cavity molds, scale shrinkage and warpage results for better visualization of deformation;
n query any two points to determine any dimensional change between the two;
n constrain the part on a plane for better measurement of deflection;
n separate total displacement into X-, Y-, and Z-axis displacements to show only the deflection in each direction;
n show shrinkage and warpage as a visible displacement plot or as a color contour or shaded plot;
n export warp geometry in the STL format to use as a reference when sizing the mold;
n export warp mesh model for an iterative warpage analysis.
4. MPI/Fiber
MPI/Fiber predicts the fiber orientation due to flow in fiber-filled plastics and the resultant mechanical strength of the plastic/fiber composite.
It is important to understand and control the orientation of fibers within fiber filled plastics to reduce shrinkage variations across the molded part to minimize or eliminate part warpage.
MPI/Fiber allows you to:
n predict fiber orientation and thermo-mechanical property distributions in the molded part;
n predict elastic modulus and average modulus in the flow and transverse-flow directions;
n predict linear thermal expansion coefficient (LTEC) and average LTEC;
n calculate Poisson’s Ratio, a measure of the transverse contraction of a part compared to its length when exposed to tensile stress;
n optimize filling pattern and fiber orientation to reduce shrinkage variations and part warpage;
n increase part strength by inducing fiber orientation along load bearing part surfaces.
5. MPI/Optim
MPI/Optim allows you to perform an injection molding machine-specific analysis which
takes into account the actual machine response time, maximuminjection velocity, and the number of steps that can be programmed for velocity and pressure profiles on the machine controller. The analysis aim is to achieve uniform flow front velocity and temperature profiles through the injection molding machine nozzle, the mold feed system, and the part cavities.
MPI/Optim allows you to:
n automatically determine the optimum processing conditions, including stroke length, injection velocity profile, velocity-to-pressure switch-over, and pressure profile, required to produce a
收藏