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英文原文 CONCURRENT DESIGN OF PLASTICS INJECTION MOULDS Assist Prof Dr A YAYLA Prof Dr Pa a YAYLA Abstract The plastic product manufacturing industry has been growing rapidly in recent years One of the most popular processes for making plastic parts is injection moulding The design of injection mould is critically important to product quality and efficient product processing Mould making companies who wish to maintain the competitive edge desire to shorten both design and manufacturing leading times of the by applying a systematic mould design process The mould industry is an important support industry during the product development process serving as an important link between the product designer and manufacturer Product development has changed from the traditional serial process of design followed by manufacture to a more organized concurrent process where design and manufacture are considered at a very early stage of design The concept of concurrent engineering CE is no longer new and yet it is still applicable and relevant in today s manuf acturing environment Team working spirit management involvement total design process and integration of IT tools are still the essence of CE The application of The CE process to the design of an injection process involves the simultaneous consideration of plastic part design mould design and injection moulding machine selection production scheduling and cost as early as possible in the design stag This paper presents the basic structure of an injection mould design The basis of this system arises from an analysis of the injection mould design process for mould design companies This injection mould design system covers both the mould design process and mould knowledge management Finally the principle of concurrent engineering process is outlined and then its principle is applied to the design of a plastic injection mould Keywords Plastic injection mould design Concurrent engineering Computer aided engineering Moulding conditions Plastic injection moulding Flow simulation 1 Introductio Injection moulds are always expensive to make unfortunately without a mould it can not be possible ho have a moulded product Every mould maker has his her own approach to design a mould and there are many different ways of designing and building a mould Surely one of the most critical parameters to be considered in the design stage of the mould is the number of cavities methods of injection types of runners methods of gating methods of ejection capacity and features of the injection moulding machines Mould cost mould quality and cost of mould product are inseparable In today s completive environment computer aided mould filling simulation packages can accurately predict the fill patterns of any part This allows for quick simulations of gate placements and helps finding the optimal location Engineers can perform moulding trials on the computer before the part design is completed Process engineers can systematically predict a design and process window and can obtain information about the cumulative effect of the process variables that influence part performance cost and appearance 2 Injection Moulding Injection moulding is one of the most effective ways to bring out the best in plastics It is universally used to make complex finished parts often in a single step economically precisely and with little waste Mass production of plastic parts mostly utilizes moulds The manufacturing process and involving moulds must be designed after passing through the appearance evaluation and the structure optimization of the product design Designers face a huge number of options when they create injection moulded components Concurrent engineering requires an engineer to consider the manufacturing process of the designed product in the development phase A good design of the product is unable to go to the market if its manufacturing process is impossible or too expensive Integration of process simulation rapid prototyping and manufacturing can reduce the risk associated with moving from CAD to CAM and further enhance the validity of the product development 3 Importance of Computer Aided Injection Mould Design The injection moulding design task can be highly complex Computer Aided Engineering CAE analysis tools provide enormous advantages of enabling design engineers to consider virtually and part mould and injection parameters without the real use of any manufacturing and time The possibility of trying alternative designs or concepts on the computer screen gives the engineers the opportunity to eliminate potential problems before beginning the real production Moreover in virtual environment designers can quickly and easily asses the sensitivity of specific moulding parameters on the quality and manufacturability of the final product All theseCAE tools enable all these analysis to be completed in a meter of days or even hours rather than weeks or months needed for the real experimental trial and error cycles As CAE is used in the early design of part mould and moulding parameters the cost savings are substantial not only because of best functioning part and time savings but also the shortens the time needed to launch the product to the market The need to meet set tolerances of plastic part ties in to all aspects of the moulding process including part size and shape resin chemical structure the fillers used mould cavity layout gating mould cooling and the release mechanisms used Given this complexity designers often use computer design tools such as finite element analysis FEA and mould filling analysis MFA to reduce development time and cost FEA determines strain stress and deflection in a part by dividing the structure into small elements where these parameters can be well defined MFA evaluates gate position and size to optimize resin flow It also defines placement of weld lines areas of excessive stress and how wall and rib thickness affect flow Other finite element design tools include mould cooling analysis for temperature distribution and cycle time and shrinkage analysis for dimensional control and prediction of frozen stress and warpage The CAE analysis of compression moulded parts is shown in Figure 1 The analysis cycle starts with the creation of a CAD model and a finite element mesh of the mould cavity After the injection conditions are specified mould filling fiber orientation curing and thermal history shrinkage and warpage can be simulated The material properties calculated by the simulation can be used to model the structural behaviour of the part If required part design gate location and processing conditions can be modified in the computer until an acceptable part is obtained After the analysis is finished an optimized part can be produced with reduced weldline known also knitline optimized strength controlled temperatures and curing minimized shrinkage and warpage Machining of the moulds was formerly done manually with a toolmaker checking each cut This process became more automated with the growth and widespread use of computer numerically controlled or CNC machining centres Setup time has also been significantly reduced through the use of special software capable of generating cutter paths directly from a CAD data file Spindle speeds as high as 100 000 rpm provide further advances in high speed machining Cutting materials have demonstrated phenomenal performance without the use of any cutting coolant fluid whatsoever As a result the process of machining complex cores and cavities has been accelerated It is good news that the time it takes to generate a mould is constantly being reduced The bad news on the other hand is that even with all these advances designing and manufacturing of the mould can still take a long time and can be extremely expensive Figure 1 CAE analysis of injection moulded parts Many company executives now realize how vital it is to deploy new products to market rapidly New products are the key to corporate prosperity They drive corporate revenues market shares bottom lines and share prices A company able to launch good quality products with reasonable prices ahead of their competition not only realizes 100 of the market before rival products arrive but also tends to maintain a dominant position for a few years even after competitive products have finally been announced Smith 1991 For most products these two advantages are dramatic Rapid product development is now a key aspect of competitive success Figure 2 shows that only 3 7 of the product mix from the average industrial or electronics company is less than 5 years old For companies in the top quartile the number increases to 15 25 For world class firms it is 60 80 Thompson 1996 The best companies continuously develop new products At Hewlett Packard over 80 of the profits result from products less than 2 years old Neel 1997 Figure 2 Importance of new product Jacobs 2000 With the advances in computer technology and artificial intelligence efforts have been directed to reduce the cost and lead time in the design and manufacture of an injection mould Injection mould design has been the main area of interest since it is a complex process involving several sub designs related to various components of the mould each requiring expert knowledge and experience Lee et al 1997 proposed a systematic methodology and knowledge base for injection mould design in a concurrent engineering environment 4 Concurrent Engineering in Mould Design Concurrent Engineering CE is a systematic approach to integrated product development process It represents team values of co operation trust and sharing in such a manner that decision making is by consensus involving all per spectives in parallel from the very beginning of the product life cycle Evans 1998 Essentially CE provides a collaborative co operative collective and simultaneous engineering working environment A concurrent engineering approach is based on five key elements 1 process 2 multidisciplinary team 3 integrated design model 4 facility 5 software infrastructure Figure 3 Methodologies in plastic injection mould design a Serial engineering b Concurrent engineering In the plastics and mould industry CE is very important due to the high cost tooling and long lead times Typically CE is utilized by manufacturing prototype tooling early in the design phase to analyze and adjust the design Production tooling is manufactured as the final step The manufacturing process and involving moulds must be designed after passing through the appearance evaluation and the structure optimization of the product design CE requires an engineer to consider the manufacturing process of the designed product in the development phase A good design of the product is unable to go to the market if its manufacturing process is impossible Integration of process simulation and rapid prototyping and manufacturing can reduce the risk associated with moving from CAD to CAM and further enhance the validity of the product development For years designers have been restricted in what they can produce as they generally have to design for manufacture DFM that is adjust their design intent to enable the component or assembly to be manufactured using a particular process or processes In addition if a mould is used to produce an item there are therefore automatically inherent restrictions to the design imposed at the very beginning Taking injection moulding as an example in order to process a component successfully at a minimum the following design elements need to be taken into account 1 geometry draft angles Non re entrants shapes near constant wall thickness complexity split line location and surface finish 2 material choice 3 rationalisation of components reducing assemblies 4 cost In injection moulding the manufacture of the mould to produce the injection moulded components is usually the longest part of the product development process When utilising rapid modelling the CAD takes the longer time and therefore becomes the bottleneck The process design and injection moulding of plastics involves rather complicated and time consuming activities including part design mould design injection moulding machine selection production scheduling tooling and cost estimation Traditionally all these activities are done by part designers and mould making personnel in a sequential manner after completing injection moulded plastic part design Obviously these sequential stages could lead to long product development time However with the implementation of concurrent engineering process in the all parameters effecting product design mould design machine selection production scheduling tooling and processing cost are considered as early as possible in the design of the plastic part When used effectively CAE methods provide enormous cost and time savings for the part design and manufacturing These tools allow engineers to virtually test how the part will be processed and how it performs during its normal operating life The material supplier designer moulder and manufacturer should apply these tools concurrently early in the design stage of the plastic parts in order to exploit the cost benefit of CAE CAE makes it possible to replace traditional sequential decision making procedures with a concurrent design process in which all parties can interact and share information Figure 3 For plastic injection moulding CAE and related design data provide an integrated environment that facilitates concurrent engineering for the design and manufacture of the part and mould as well as material selection and simulation of optimal process control parameters Qualitative expense comparison associated with the part design changes is shown in Figure 4 showing the fact that when design changes are done at an early stages on the computer screen the cost associated with is an order of 10 000 times lower than that if the part is in production These modifications in plastic parts could arise fr om mould modifications such as gate location thickness changes production delays quality costs machine setup times or design change in plastic parts Figure 4 Cost of design changes during part product development cycle Rios et al 2001 At the early design stage part designers and moulders have to finalise part design based on their experiences with similar parts However as the parts become more complex it gets rather difficult to predict processing and part performance without the use of CAE tools Thus for even relatively complex parts the use of CAE tools to prevent the late and expensive design changesand problems that can arise during and after injection For the successful implementation of concurrent engineering there must be buy in from everyone involved 5 Case Study Figure 5 shows the initial CAD design of plastics part used for the sprinkler irrigation hydrant leg One of the essential features of the part is that the part has to remain flat after injection any warping during the injection causes operating problems Another important feature the plastic part has to have is a high bending stiffness A number of feeders in different orientation were added to the part as shown in Figure 5b These feeders should be designed in a way that it has to contribute the weight of the part as minimum as possible Before the design of the mould the flow analysis of the plastic part was carried out with Moldflow software to enable the selection of the best gate location Figure 6a The figure indicates that the best point for the gate location is the middle feeder at the centre of the part As the distortion and warpage of the part after injection was vital from the functionality point of view and it has to be kept at a minimum level the same software was also utilised to yiled the warpage analysis Figure 5 b shows the results implying the fact that the warpage well after injection remains within the predefined dimensional tolerances 6 Conclusions In the plastic injection moulding the CAD model of the plastic part obtained from commercial 3D programs could be used for the part performance and injection process analyses With the aid of CEA technology and the use of concurrent engineering methodology not only the injection mould can be designed and manufactured in a very short of period of time with a minimised cost but also all potential problems which may arise from part design mould design and processing parameters could be eliminated at the very beginning of the mould design These two tools help part designers and mould makers to develop a good product with a better delivery and faster tooling with less time and money Referenc 1 Smith P Reinertsen D The time to market race In Developing Products in Half the Time New York Van Nostrand Reinhold pp 3 13 1991 2 Thompson J The total product development organization Proceedings of the Second Asia Pacific Rapid Product Development Conference Brisbane 1996 3 Neel R Don t stop after the prototype Seventh International Conference on Rapid Prototyping San Francisco 1997 4 Jacobs PF Chapter 3 Rapid Product Development in Rapid Tooling Technologies and Industrial Applications Ed Peter D Hilton Paul F Jacobs Marcel Decker 2000 5 Lee R S Chen Y M and Lee C Z Development of a concurrent mould design system a knowledge based approach Computer Integrated Manufacturing Systems 10 4 287 307 1997 6 Evans B Simultaneous Engineering Mechanical Engineering Vol 110 No 2 pp 38 39 1998 7 Rios A Gramann PJ and Davis B Computer Aided Engineering in Compression Molding Composites Fabricators Association Annual Conference Tampa Bay 2001 中文譯文 塑料注射模具的并行設(shè)計(jì) 摘要 塑料產(chǎn)品制造業(yè)已在近幾年迅速增長(zhǎng) 用于制造塑料部件的最流行的過程之一是注塑 注塑模具的設(shè)計(jì)是非常重要的產(chǎn)品質(zhì)量和高效的產(chǎn)品加工 模具制造公司 誰(shuí)愿意以保持競(jìng)爭(zhēng)優(yōu)勢(shì) 縮短應(yīng)用系統(tǒng)的模具設(shè)計(jì)過程中 設(shè)計(jì)和制造 領(lǐng)先時(shí)代的欲望 模具行業(yè)在產(chǎn)品開發(fā)過程中的重要支撐產(chǎn)業(yè) 作為產(chǎn)品的設(shè)計(jì)者和制造 商之間的一個(gè)重要環(huán)節(jié) 從產(chǎn)品的發(fā)展 改變了傳統(tǒng)的串行設(shè)計(jì)過程中 其次是制造 一 個(gè)更有組織的并發(fā)設(shè)計(jì)和制造過程中被認(rèn)為是在一個(gè)非常早期的設(shè)計(jì)階段 并行工程 CE 的概念已不再是新鮮事 但它仍然是適用的 在今天的化學(xué)品制造 acturing 環(huán)境相 關(guān) 團(tuán)隊(duì)合作精神 管理人員的參與 整個(gè)設(shè)計(jì)過程和集成的 IT 工具仍然是 CE 的本質(zhì) 同時(shí)考慮應(yīng)用的 CE 程序設(shè)計(jì)的一個(gè)注入進(jìn)程涉及的塑料零件設(shè)計(jì) 模具設(shè)計(jì)和注塑機(jī)選擇 生產(chǎn)調(diào)度和成本盡早在設(shè)計(jì)雄鹿 本文介紹了注塑模具設(shè)計(jì)的基本結(jié)構(gòu) 這個(gè)系統(tǒng)的基礎(chǔ)上產(chǎn)生的注塑模具設(shè)計(jì)過程的分 析 模具設(shè)計(jì)公司 注塑模具設(shè)計(jì)系統(tǒng)涵蓋了模具設(shè)計(jì)工藝和模具知識(shí)管理 最后的原則 的并發(fā)工程過程的概述 然后被施加到其原理的塑料注射模具的設(shè)計(jì) 關(guān)鍵詞 注塑模具的設(shè)計(jì) 并行工程 計(jì)算機(jī)輔助工程 成型條件 注塑成型 流程模擬 1 導(dǎo)論 注塑模具往往成本很大 不幸的是沒有的模具 它不能是可能浩有一個(gè)模制產(chǎn)品 每一 個(gè)模具制造商都有他 她自己的方式來(lái)設(shè)計(jì)模具 模具的設(shè)計(jì)和建設(shè)一個(gè)有許多不同的方式 當(dāng)然 模具的設(shè)計(jì)階段 要考慮的最重要的參數(shù)之一是空腔 注射方法 跑步者的類型的 選通的方法 噴射 容量和特性的注塑機(jī)的方法的數(shù)量 模具成本 模具的模具產(chǎn)品的質(zhì) 量和成本是分不開的 在今天的環(huán)境 計(jì)算機(jī)輔助模具填充仿真工具包 可以準(zhǔn)確地預(yù)測(cè)任何部分的填充圖案 這可以快速模擬的門安置 并幫助找到最佳的位置 以前的部分設(shè)計(jì)完成后 工程師可以 在電腦上進(jìn)行成型試驗(yàn) 工藝工程師可以系統(tǒng)地預(yù)測(cè)設(shè)計(jì)和工藝窗口 可以獲取信息的過 程變量影響性能 成本和外觀的累積效應(yīng) 2 注塑成型 注塑成型是最好的塑料帶出最有效的方法之一 這是普遍使用的 往往是在一個(gè)單一的步 驟 使復(fù)雜 成品零件經(jīng)濟(jì) 精確和廢物少 大規(guī)模生產(chǎn)的塑料部件大多采用的模具 后 通過的外觀評(píng)價(jià)及結(jié)構(gòu)優(yōu)化的產(chǎn)品設(shè)計(jì) 制造過程中 涉及模具的設(shè)計(jì)必須 設(shè)計(jì)人員面 臨的注塑成型部件的選擇 當(dāng)他們創(chuàng)建一個(gè)龐大的數(shù)字 并行工程要求工程師在開發(fā)階段 考慮制造過程的設(shè)計(jì)的產(chǎn)品 一個(gè)好的設(shè)計(jì)的產(chǎn)品是不能去的市場(chǎng) 如果其生產(chǎn)過程中是 不可能的 或過于昂貴 與從 CAD 到 CAM 過程的仿真 快速原型制造的集成可以降低風(fēng)險(xiǎn) 進(jìn)一步提升產(chǎn)品開發(fā)的有效性 3 計(jì)算機(jī)輔助注塑模具設(shè)計(jì)的重要性 注塑模具設(shè)計(jì)任務(wù)可以是非常復(fù)雜的 計(jì)算機(jī)輔助工程 CAE 分析工具使設(shè)計(jì)工程師提 供了巨大的優(yōu)勢(shì) 幾乎和零件 模具及注塑參數(shù)沒有真正的使用任何制造和時(shí)間的考慮 嘗試另一種設(shè)計(jì)或概念在計(jì)算機(jī)屏幕上的可能性給出了工程師的機(jī)會(huì) 以消除潛在的問題 然后再開始真正的生產(chǎn) 此外 在虛擬環(huán)境中 設(shè)計(jì)人員可以快速 方便地評(píng)估特定的成 型參數(shù)對(duì)最終產(chǎn)品的質(zhì)量和可制造性的靈敏度 所有 theseCAE 工具 使所有這些分析 在 一米的幾天甚至幾個(gè)小時(shí)內(nèi)完成 而不是幾周或幾個(gè)月需要對(duì)實(shí)際的試驗(yàn)和錯(cuò)誤周期 由 于采用的是早期設(shè)計(jì)的零件 模具和成型工藝參數(shù) CAE 不僅是因?yàn)樽罴训墓δ艿囊徊糠?節(jié)省時(shí)間 也縮短了所需的時(shí)間向市場(chǎng)推出的產(chǎn)品 節(jié)約成本是巨大的 需要設(shè)定的公差 以滿足的塑料部分關(guān)系到成型過程中的各個(gè)方面 包括零件的尺寸和 形狀 樹脂的化學(xué)結(jié)構(gòu) 使用的填料 模腔布局 澆注 模具冷卻和釋放機(jī)制 鑒于這種 復(fù)雜性 設(shè)計(jì)人員經(jīng)常使用電腦的設(shè)計(jì)工具 如有限元分析 FEA 和模流分析 MFA 以 減少開發(fā)時(shí)間和成本 有限元分析確定應(yīng)變 應(yīng)力和偏轉(zhuǎn)通過劃分成小的元素 這些參數(shù) 可以很好地定義的結(jié)構(gòu)的一部分中 MFA 評(píng)估澆口位置和大小以優(yōu)化樹脂流動(dòng) 它還定義 的焊接線 過度緊張的地區(qū) 壁和肋骨厚度如何影響流量的位置 其他有限元設(shè)計(jì)工具 包括模具的冷卻溫度分布 分析和三維控制和預(yù)測(cè)分析的凍結(jié)應(yīng)力和翹曲的周期時(shí)間和收 縮 圖 1 中所示的壓縮模制零件的 CAE 分析 分析周期開始與創(chuàng)建的 CAD 模型和有限元網(wǎng)格的 模腔 注射后的條件規(guī)定 可以模擬模具填充 纖維取向 固化和熱歷史 收縮和翹曲 通過模擬計(jì)算出的材料性能 可以使用的部分的結(jié)構(gòu)的行為進(jìn)行建模 如果需要的話 部 件設(shè)計(jì) 澆口位置和加工條件可以在計(jì)算機(jī)中進(jìn)行修改 直到獲得一個(gè)可以接受的部分 分析完成后 就可以生產(chǎn)出一個(gè)優(yōu)化的部分減少熔合線 又稱 knitline 優(yōu)化的強(qiáng)度 控制溫度和固化 最小化收縮和翹曲 模具加工的前身是手工完成 檢查每個(gè)切與工具制 造商 這個(gè)過程變得更加自動(dòng)化的發(fā)展和廣泛使用的計(jì)算機(jī)數(shù)控 CNC 加工中心 安裝時(shí)間 也顯著減少了通過使用特殊的軟件 能夠直接從 CAD 數(shù)據(jù)文件生成的刀具路徑 高達(dá) 10 萬(wàn) 轉(zhuǎn)的主軸轉(zhuǎn)速提供高速加工的進(jìn)一步發(fā)展 切削材料表現(xiàn)出驚人的性能 而無(wú)需使用任何 任何切割 冷卻流體 其結(jié)果是 已加速加工復(fù)雜的過程中 芯和模腔 不斷地被降低 所花費(fèi)的時(shí)間 以生成的模具 這是好消息 另一方面 壞消息是 即使所有這些進(jìn)步 設(shè)計(jì)和制造的模具還需要很長(zhǎng)的時(shí)間 可能會(huì)非常昂貴 CAE 分析圖 1 的注射成型部件 現(xiàn)在很多公司高管意識(shí)到它是多么的重要部署新產(chǎn)品迅速推向市場(chǎng) 新產(chǎn)品是企業(yè)繁榮 的關(guān)鍵 他們帶動(dòng)公司收入 市場(chǎng)份額 底線和股價(jià) 一個(gè)公司能夠推出優(yōu)質(zhì)的產(chǎn)品 合 理的價(jià)格 領(lǐng)先的競(jìng)爭(zhēng)不僅實(shí)現(xiàn)了 100 的市場(chǎng)份額 競(jìng)爭(zhēng)對(duì)手的產(chǎn)品之前到達(dá) 但也往 往保持優(yōu)勢(shì)地位 競(jìng)爭(zhēng)力的產(chǎn)品后 終于被宣布為幾年 史密斯 1991 對(duì)于大多