油窗端蓋注塑模具設(shè)計(jì)

以上為資料預(yù)覽概圖，下載文件后為壓縮包資料文件?！厩逦?，無水印，可編輯】dwg后綴為cad圖，doc后綴為word格式，需要請自助下載即可，有疑問可以咨詢QQ 197216396 或 11970985 Intelligence and Automation CAD Soft WaresWith advancement of technology and high一speed development of world，Upgrade and innovation of Products are speeded up. No matter what industrial Products and appliance，are mostly molded by mold. Therefore，Plastic Parts design advances higher demands for periods and Precision of mold design and Manufacture . Because mold design depends on designers experience and Knowledge completely by traditional CAD soft wares ，50 efficiency and quality cant completely satisfy the demands of mold development. So intelligence and automation are very important in mold design .This issue Has joined the expert system to mold design，and developed an intelligentzed Injection mold design system .Basing on the Plastic Parts information，the System can implement automatically reasoning and analysis by the interrelatedknowledge，and select an relevant model from the model base，then rebuild the model by Parameterized technology，finally finish the design Process of injection mold .The entire design Process is completed by computer automatically without the calculation of designers，which decreases flaws caused by lack of experience of mold designers，and helps to avoid mistakes and improve efficiency and quality of mold design .This Paper summarized the design knowledge of injection molds side action; Then builds knowledge base suing the hybrid representation of framerepresentation and ruler representation :and introduces the Principles ，Processed method of compute automatic design system for side action in detail :Taking the best quality of Plastic Parts and highest efficiency as main purpose ，this paper finally develops side action :and also builds the graph library of side action using Parameterized technology based on Solid works .In information management system，Plastic Parts are decaled with in aspect of shrinkage and draft，which will make model、more Precision for the next design .An actual Process of the mold design for atypical Plastic Part has been demonstrated，which shows that the idea of system is feasible and this system can be used expediently to satisfy the demands of mold design. This paper also investigates menu and interface of this software，and finally Designs a laconic ，intuitive and manipulated friendly interface for injection mold design in order to make this software more acceptable to users.Mold Cavities and CoresThe cavity and core give the molding its external and internal shapes respectively, the impression imparting the whole of the form to the molding.We then proceeded to indicate alternate ways by which the cavity and core could be incorporated into the mold and we found that these alternatives fell under two main headings,namelythe integer method and the insert method.Another method by which the cavity can be incorporated is by means of split inserts or splits.When the cavity or core is machined from a large plate or block of steel,or is cast in one piece,and used without bolstering as one of the mod plates ,it is termed an integer cavity plate or integer core plate. This design is preferred for single-impression molds because of characteristics of the strength,smaller size and lower cost. It is not used as mush for multi-impression molds as there are other factors such as alignment which must be taken into consideration.Of the many manufacting processes available for preparing molds only two are normally used in this case. There are a direct machining operation on a rough steel forging or blank using the conventional machine tools, or the precision invstment casting technique in which a master pattern is made of the cavity and core. The pattern is then used to prepare a casting of the cavity or core by a special process.A 4.25%nickel-chrome-molybdenum steel(BS 970-835 M30) is normally specified for integer mold plates which are to be made by the direct machining method.The precision investment casting method usually utilizes a high-chrome steel.For molds containting intricate impressions, and for multi-impression molds, it is not satisfactory to attempt to machine the cavity and core plates from single blocks of steel as with integer molds. The machining sequences and operation would be altogether too complicated and costly. The insert-bloster assembly method is therefore used instead.The method consists in machining the impression out of small blocks of steel.These small blocks of steel are known,after machininf, as inserts, and the one which forms the male part is termed the core insert and, conversely, the one which forms the female part the cavity insert. These are the inserted and securely fitted into holes in a substantial block or plate of steel called a bloster. These holes are either sunk part way or are machined right through the bolster plate. In the latter case there will be a plate fastened behind the bolster and this secures the inserts in position.Both the integer and the insert-bolster methods have their advantages depending upon the size, the shape of the molding, the complexity of the mold, whether a single impression or a multi-impression ;old is desired,the cost of making the mold, ect. It can therefore be said that in general, once the characteristics of the mold reqired to do a particular job which have been weighed up, the decision as to which design to adopt can be made. Some of these considerations have already been discussed under various broad headings, such as cost, but to enable the reader to weigh them up more easily, when faced with a particular problem, the comparison of the relative advantages of each system is discussed under a number of headings. Unquestionably for single impression molds the integer design is ti be preferred irrespective of whether the component form is a simple or a complex one. The resulting mold will be stronger, smaller, less costly, and generally incorporate a less elaborate colling system than the insert-bolster design. It should be borne in mind that local inserts can be judiciously used to simplify the general manufactureof the mold impression.For multi-impression molds the choices is not so clear-cut. In the majority of cases the insert-bolster method of construction is used, the case of manufacture, mold alignment, and resulting lower mold costs being the overriding factors affecting the choices. For compenents of very simple form it is often advantangeous to use one design for one of the mold plates and the alternative design for the other. For example, consider a multi-impression mold for a box-type compenent. The cavity plate could be of the integer design to gain the advantages of strength, thereby allowing a smaller mold plate, while the core plate couls be of the insert-bolster design which will simplify machining of the plate and allow for adjustments for mold alignment.The Injection MoldingInjection molding ( British Engish : Molding ) is a manufacturing process for producing parts form both thermoplastic and thermosetting plastic materials.Material is fed into a heated brarel, mixed, and forced into a mold cavity where it cools and hardens to configuration of the mold cavity. After a product is designed, usually by an industrial designer or an engineer, molds aer made by a moldmaker ( or a toolmaker ) from metal, usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection molding is widely used for manufacturing a varitey of parts, from the smallest compenent to entire body panels of cars.Injection molding machines consist of a material hopper, an injection ram of screw-type plunger, and a heating unit. They are also known as presses. They hold the molds in which the compenents are shaped. Presses are rated by tonnage, which expresses the amount of clamping force that the machine can exert. This force keeps the mold closed during the injection process. Tonnage can vary from less than 5 tons to 6000 tons, with the higher figures used in determined by the projected area of the part being molded.This projected area is multiplied by a champ force of 2 to 8 tons for each square inch of the projected area. As a rule of thumb, 4 or 5 t/in can be used for most products. If the plastic material is very stiff, it will require more injection pressure to fill the mold, thus more clamp tonnage to hold the mold closed. The required force can also be determined by the material used and the size of the part, larger parts require higher clamping force. Mold or die are the common terms used to describe the tooling used to produce plastic parts in molding.Traditionally, molds have been expensive to manufacture. They were usually only used in mass production where thousands of parts were being produced. Molds are typically constructed from hardened steel, pre-hardened steel, aluminium, and/or beryllium-copper alloy. The chioce of material to build a mold from is primarily one of economics. Steel molds generally cost more to construct, but their longer number of parts made before wearing out. Pre-hardened steel molds are less wear resistant and are used for lower volume requirements or large compenents. The steel hardness is tyoically 38-45 on the Rockwell-C scale ( HRC). Hardened steel molds are heat treated after machining. These are by far the superior in terms of wear resistance and lifespan. Typical hardness ranges between 50 to 60 Rockwell scale. Aluminium molds can cost substantially less , and when designed and machined with morden computerized equipment, can be economical for molding tens or even hundreds of thousands of parts. Beryllium copper is used in areas of the mold which require fast removal or area that see the most shear heat generated. The molds can be manufactured by either CNC or by using Electrical Discharge Machining processes.Standard two plates tooling: core and cavity are inserts in a mold base “Family mold ” of 5 different parts.The mold consists of two primary compenents, the injection mold ( A plate ) and the ejector mold ( B plate ). Plastic resin enters the mold through a sprue in the injection mold, the sprue bush is to seal tightly against the nozzle of the injection barrel of the molding machine and allow molten plastic to flow from the barrel into the mold , also known as cavity. The sprue bush directs the molten plastic to the cavity images through channels that are machined into the faces of the A or B plates. These channels allow plastic to run along them, so they are referred to as runners. The molten plastic flows through the runner and enters one or more specialized gates and into the cavity geometry to form the desired part.The amount of resin required to fill the sprue, runner and cavities of a mold is a shot. Trapped air in the mold can escape through air vents that are grinded into the parting line of the mold. If the trapped air is not allowed to escape , it is compressed by the pressure of the incoming material and is squeezed into the corners of the cavity , where it prevents filling and causes other defects as well . The air can become so compressed that it ignites and burns the surrounding plastic material. To allow for removal of the molded part from the mold , the mold features must not overhang one another in the direction that the mold opens , unless parts of the mold are designed to move from between such overhangs when the mold opens ( utilizing composnents called Lifters ).外文資料翻譯智能型模具CAD系統(tǒng)隨著科學(xué)技術(shù)的不斷進(jìn)步和社會(huì)的高速發(fā)展，產(chǎn)品更新?lián)Q代越來越快。無論是工業(yè)產(chǎn)品還是家電產(chǎn)品，大多數(shù)應(yīng)用模具成型。因此，對(duì)模具的設(shè)計(jì)和制造提出了更高的要求。傳統(tǒng)的模具CAD軟件完全依賴于設(shè)計(jì)人員的經(jīng)驗(yàn)和知識(shí)，設(shè)計(jì)效率和設(shè)計(jì)質(zhì)量很難滿足模具發(fā)展的要求。因此在模具設(shè)計(jì)的過程中，使用智能型模具CAD系統(tǒng)顯得尤為重要。本課題將專家系統(tǒng)技術(shù)引入到模具設(shè)計(jì)中，開發(fā)了智能注塑模具設(shè)計(jì)系統(tǒng)。該系統(tǒng)利用塑件產(chǎn)品信息，通過推理機(jī)對(duì)知識(shí)庫中的相關(guān)知識(shí)進(jìn)行自動(dòng)推理、分析、決策，得出模具結(jié)構(gòu)總體方案以及相關(guān)尺寸，從模型庫中選出相應(yīng)模型，通過參數(shù)化驅(qū)動(dòng)重新建模，最終自動(dòng)完成注塑模具設(shè)計(jì)過程。本文在前面幾屆研究生開發(fā)的基礎(chǔ)上，總結(jié)了注塑模具斜銷側(cè)向分型與抽芯機(jī)構(gòu)設(shè)計(jì)知識(shí)，結(jié)合模具設(shè)計(jì)知識(shí)的特點(diǎn)，利用框架/規(guī)則混合表示方法建立了注塑模具側(cè)向分型與抽芯機(jī)構(gòu)設(shè)計(jì)知識(shí)庫;詳細(xì)介紹了斜銷側(cè)向分型與抽芯機(jī)構(gòu)的設(shè)計(jì)理論、過程和方法:系統(tǒng)以成型制品質(zhì)量最優(yōu)、效率最高為目標(biāo)，最終形成了斜銷側(cè)向分型與抽芯機(jī)構(gòu)的計(jì)算機(jī)自動(dòng)設(shè)計(jì)系統(tǒng)。以Solid works為平臺(tái)，采用參數(shù)化技術(shù)建立了側(cè)向分型與抽芯機(jī)構(gòu)的實(shí)體模型庫。系統(tǒng)通過推理機(jī)對(duì)知識(shí)的推理，模型的調(diào)入，參數(shù)的驅(qū)動(dòng)，實(shí)現(xiàn)側(cè)向分型與抽芯機(jī)構(gòu)的自動(dòng)化設(shè)計(jì)。系統(tǒng)還對(duì)塑件模型進(jìn)行了收縮率和脫模斜度的處理，實(shí)現(xiàn)了從塑件模型到模具模型的轉(zhuǎn)化，使設(shè)計(jì)結(jié)果更加準(zhǔn)確、嚴(yán)謹(jǐn)。通過典型制品的模具設(shè)計(jì)實(shí)例，演示了系統(tǒng)的設(shè)計(jì)過程。結(jié)果表明，系統(tǒng)設(shè)計(jì)思路正確，操作方便簡單，運(yùn)行可靠，適合模具設(shè)計(jì)要求。同時(shí)，本文在系統(tǒng)軟件菜單、界面、設(shè)計(jì)思路等方面也做了大量的工作，使本系統(tǒng)軟件更加人性化，具備了良好的實(shí)用性。型腔和型芯模具的型腔和型芯分別形成塑件內(nèi)部和外部形狀，型腔形狀決定了塑件形狀，接下來我們簡要說明選擇那種型腔和型芯安裝在模具中。這些方式可以歸納為兩大類，即整體形式和鑲拼形式。另一種組成型腔的方式是加入拼塊或滑塊。當(dāng)型腔或型芯由一塊大的鋼板或鋼塊加工而成，或是鑄成一體，不需要使用支承件而形成一塊模板時(shí)，就構(gòu)成整體式模腔板或型芯板。這種設(shè)計(jì)因具有強(qiáng)度高，尺寸小和成本低的特性，而主要應(yīng)用在單型腔模具中。整體式型腔和型芯一般不用在多型腔模具中，因?yàn)槎嘈颓荒＞咴O(shè)計(jì)時(shí)必須考慮一些其他因素，例如安裝組合鑲件等。在模具制造的眾多方法中，用于加工整體式型腔板或型芯板的方法主要有兩種：使用傳統(tǒng)機(jī)床對(duì)粗鍛鋼材料直接加工，或是利用精確的熔模鑄造技術(shù)將坯料加工成型腔和型芯。用于制造型腔和型芯的坯料經(jīng)常需要特殊工藝的處理。通常，4.25%的鎳鎘鉬合金鋼是生產(chǎn)整體式模板的指定材料，選用這種材料時(shí)采用直接的機(jī)加工方式。精確的熔模鑄造常常用來加工高鉻鋼。對(duì)于成型部位復(fù)雜的模具和多腔模具，也像整體式模具那樣用一塊鋼材加工型腔和型芯并不容易。如果采用整體式結(jié)構(gòu)，則加工順序和操作過程將變得非常復(fù)雜，成本也高，因此鑲拼式裝配方式替代了整體式。鑲拼式型腔由小鋼塊加工而成。加工后的小鋼塊作為鑲件，形成型芯部分的稱為型芯嵌件，相反地，形成型腔部分的成為型腔嵌件。然后，把這些鑲件牢固地安裝在被稱為墊板的孔中，墊板由實(shí)心鋼板或鋼塊加工而成。這些安裝孔有的是由墊板的局部凹陷形成，有的是在墊板上直接加工而成。在后一種方式中，墊板后部還要增加一塊模板，起加固作用，確保鑲件安裝到位。整體式和鑲拼式結(jié)構(gòu)均有優(yōu)點(diǎn)，這取決于塑件尺寸和形狀，模具的復(fù)雜程度，所需的是單型腔模具還是多型腔模具以及模具制造成本等。通常，塑件的形狀，尺寸等特性確定后，采用哪種形式的型腔和型芯就已經(jīng)確定了。在不同的章節(jié)中，我們已經(jīng)討論過型腔和型芯的安裝方式所涉及的問題，例如成本等，但為使讀者在處理特殊問題時(shí)更容易知道重點(diǎn)所在，我們將用一定的章節(jié)再次討論每種結(jié)構(gòu)優(yōu)缺點(diǎn)的對(duì)比。毫無疑問，對(duì)于單型腔模具，無論是簡單還是復(fù)雜，整體式型腔是首選方式。若選擇整體式，則模具的強(qiáng)度高，體積小，成本低，而冷卻系統(tǒng)的設(shè)計(jì)卻比鑲拼式簡單，方便。設(shè)計(jì)時(shí)需要常記于心的是，適當(dāng)?shù)厥褂描偧梢院喕＞咝颓坏募庸ぶ圃祀y度。對(duì)于多型腔模具，選擇哪種方式不是很明顯。大多數(shù)型腔模具采用鑲拼式結(jié)構(gòu)，這種結(jié)構(gòu)加工簡單，裝配容易，模具成本低，這些是影響選擇哪種結(jié)構(gòu)形式的重要因素。一種非常簡單且具有很多優(yōu)點(diǎn)的設(shè)計(jì)是采用一種形式設(shè)計(jì)模板，而采用另一種形式設(shè)計(jì)模具的其他部分。例如，采用箱形組件設(shè)計(jì)多型腔模具。型腔板設(shè)計(jì)成小型整體式模板，以滿足模具高強(qiáng)度的要求；型芯板則設(shè)計(jì)成鑲拼式，可因簡化模板加工過程，并且能根據(jù)模具需要進(jìn)行調(diào)整。注塑成型注塑成型是將熱塑性和熱固性塑料加工成零件的制造過程。材料被入加熱筒中，混合后壓入模腔，冷卻硬化成它們的形狀。通常工業(yè)設(shè)計(jì)師或工程師設(shè)計(jì)完一個(gè)產(chǎn)品后，模具制造師（或工人）就會(huì)用金屬，通常為剛或鋁，制造模具，且精加工以達(dá)到理想效果。從最小的部件到整個(gè)汽車的面板，注塑成型廣泛應(yīng)用于各種零部件的制造。 模具注塑機(jī)由一個(gè)料斗、注射活塞或螺旋式活塞以及一個(gè)加熱裝置構(gòu)成。他們也被稱為壓力機(jī)，內(nèi)含零部件形成的模具。壓力機(jī)以噸位來衡量，表示機(jī)器可以施加的鎖模力。鎖模力保障模具在注塑的過程中是封閉的。噸位可以從少于5t到6000t，較高的噸位應(yīng)用于相對(duì)少量的生產(chǎn)中。需要多少鎖模力取決于零件的投影面積。每平方英寸的投影面積要乘以2-8t的鎖模力。根據(jù)經(jīng)驗(yàn)法則，每平方英寸的投影面積對(duì)應(yīng)4-5t的鎖模力，即可應(yīng)用于大部分產(chǎn)品。如果塑料很硬，它需要更多的壓力來填充模具，因此需要更多的鎖模力來保障模具的封閉性。所需的壓力也取決于使用的材料及零件的大小，越大的零件需要的鎖模力越大。實(shí)際的注塑模具如所示。注塑或沖模是描述注塑中用于制造塑料零件的工具的常用術(shù)語。傳統(tǒng)上，模具制造一直很昂貴。它們通常只使用于成千上萬的大批量零件的生產(chǎn)。模具通常由淬火鋼、預(yù)硬鋼、鋁或鈹銅合金制成。選擇制造模具的原料首先要考慮經(jīng)濟(jì)因素，鋼模具成本較高，但使用壽命較長。在用完之前，鋼模能制造更多的零件，這會(huì)抵消最初的高成本投入。預(yù)硬鋼模具不耐磨，適用于小批量生產(chǎn)或制造較大的零件。鋼的硬度通常是38-45HRC，淬硬鋼模具加工后要進(jìn)行熱處理。這類模具在耐磨性和使用壽命方面具有較強(qiáng)的優(yōu)勢，其典型的硬度范圍介于50-60HRC之間。鋁模具成本大幅度減少，利用現(xiàn)代計(jì)算機(jī)設(shè)備設(shè)計(jì)與加工，對(duì)于注塑成千上萬個(gè)零件來說是經(jīng)濟(jì)的。鈹-銅合金使用于制造需快速去熱或消除產(chǎn)生的熱能的模具。這類模具可利用數(shù)控加工或電火花加工來生產(chǎn)。標(biāo)準(zhǔn)的兩板模具包括：型芯和型腔所在的模具內(nèi)部，其余的則為五個(gè)不同的典型模具結(jié)構(gòu)。模具有兩個(gè)主要部分構(gòu)成：合模（A板）和出模（B板）。塑料樹脂通過注塑模具澆道進(jìn)入模具，澆口套密封緊接在注塑機(jī)注射料筒的噴嘴處，讓熔化的塑料從料筒流到模具，也就是型腔。澆口套通常加工成A、B板的管道引導(dǎo)熔化的塑料流向型腔。這些管道使塑料沿著他們流動(dòng)，進(jìn)入幾何形狀的型腔，形成所需的零件。填充模具澆口套、流道和型腔的大量樹脂是一瞬間。模具里積存的空氣可以通過模具分型線的通風(fēng)口排出。如果積存的空氣不能排出，進(jìn)料的壓力會(huì)把它們擠壓到型腔的角落，這會(huì)妨礙填充并導(dǎo)致其他問題。空氣壓縮到一定程度會(huì)被引燃，導(dǎo)致周圍的塑料燃燒。為了消除成型模具某個(gè)部分，模具不能彼此懸垂于模具打開的方向，除非該模具部分設(shè)計(jì)成模具打開時(shí)懸空一定（所用的組件稱為側(cè)抽芯）。油窗端蓋注塑模具設(shè)計(jì)摘 要塑料工業(yè)是當(dāng)今世界上增長最快的工業(yè)門類之一，而注塑模具是其中發(fā)展較快的種類，因此，研究注塑模具對(duì)了解塑料產(chǎn)品的生產(chǎn)過程和提高產(chǎn)品質(zhì)量有很大意義。注射模技術(shù)的不斷發(fā)展需要越來越多的工藝流程。注射成型過程中最重要的問題是模具的正確設(shè)計(jì)。從根本上說，注射模具包括澆口和澆注系統(tǒng)，另一部分是放置頂出系統(tǒng)。模具零件是在分型面被定位的。注射模具型腔選擇等設(shè)計(jì)計(jì)算要求掌握加工材料、注射機(jī)和模具等方面的準(zhǔn)確知識(shí)。模具的制造成本隨著型腔數(shù)目的增加而增加，而相關(guān)的加工費(fèi)用減少了。一個(gè)給定的模具零件的生產(chǎn)周期取決于壁厚、注射速度、收縮率、模內(nèi)材料的冷卻時(shí)間、冷卻的效能及必要的輔助時(shí)間，如壓力持續(xù)時(shí)間、排氣時(shí)間及延遲時(shí)間等。本設(shè)計(jì)介紹了注射成型的基本原理，特別是單分型面注射模具的結(jié)構(gòu)與工作原理，對(duì)注塑產(chǎn)品提出了基本的設(shè)計(jì)原則；詳細(xì)介紹了冷流道注射模具澆注系統(tǒng)、溫度調(diào)節(jié)系統(tǒng)和頂出系統(tǒng)的設(shè)計(jì)過程，通過本設(shè)計(jì)，可以對(duì)注塑模具有一個(gè)初步的認(rèn)識(shí)，注意到設(shè)計(jì)中的某些細(xì)節(jié)問題，了解模具結(jié)構(gòu)及工作原理。關(guān)鍵詞：塑料模具，參數(shù)化，分型面，澆注系統(tǒng)，模具型腔。THE PLASTIC INJECT MODLE DESIGNABSTRACTplastic industry is in the world grows now one of quickest industry classes, but casts the mould is development quick type, therefore, the research casts the mold to understand the plastic product the production process and improves the product quality to have the very big significance. The continuing development of injection mold technology demands more and more of the processes. The most important problem in the process of injection molding is undoubtedly the correct design of injection mold . Basically the injection mold consists of two halves.One mold half contains the sprue bushing and runner system, the other half houses the ejection system. The molded part is located at the parting line.To set up a calculation conceiving the choice of cavities in an injection mold requires accurate knowledge of the matrrial to be processed, of the injection-molding machine and of the molds. The mold costs increase with the rising number of cavities and the relative machine costs decrease. The production time required for a given molded part depends on the wall thicknes, the injection speed, the recovery rate, the time required to coll the molded material, the cooling capacity of the mold and the necessary incidental time such as duration of pressure holding time, ejection time, delay time, ect.This design introduced the injection takes shape the basic principle, specially single is divided the profile to inject the mold the structure and the principle of eork, to cast the product to propose the basic principle of design; Introducted in detail the cold flod channel injection evil spirit mold pours the system, the temperature contral system and goes against the system the design process, and has given the explanation to the mold intensity request; Through this design, may to cast the mold to have a preliminary understanding, notes in the design certain detail question, understands the mold structure and the principle of work; Through to the PROGRAM study, may establish the simple components the components storehouse, thus effective enhancement eorking efficiency.KEY WORDS: The plastic mold, the parameterization, inlays, divides the profile43目錄前言1第一章：制件的結(jié)構(gòu)與工藝性分析21.1制件相關(guān)信息21.2材料的相關(guān)性質(zhì)31.2.1 基本特性31.2.2 主要用途31.2.3 成型特點(diǎn)31.3塑件的脫模斜度41.4塑件的尺寸精度及表面質(zhì)量要求4第二章：初選注射機(jī)62.1 計(jì)算塑件體積和最大投影面積62.2選擇壓力機(jī)62.3確定型腔數(shù)目7第三章 模具設(shè)計(jì)93.1 型腔的分布設(shè)置93.2 分型面的確定93.3 澆口的確定原則103.4 澆注系統(tǒng)的確定113.4.1 主流道的設(shè)計(jì)113.4.2 分流道的設(shè)計(jì)123.4.3 冷料穴的設(shè)計(jì)133.4.4澆口的相關(guān)參數(shù)選擇143.5成型零部件的結(jié)構(gòu)設(shè)計(jì)143.5.1 型腔的結(jié)構(gòu)設(shè)計(jì)143.5.2 型芯的結(jié)構(gòu)設(shè)計(jì)153.6 模具成型零部件尺寸計(jì)算153.5.1 計(jì)算成型零部件尺寸要考慮的因素163.5.2 制件尺寸的公差轉(zhuǎn)換163.5.3成型零部件尺寸計(jì)算173.7 模架的選用203.7.1 模架型號(hào)的確定203.7.2 模架具體尺寸的確定213.8 結(jié)構(gòu)零部件的設(shè)計(jì)223.8.1 支承板的設(shè)計(jì)223.8.2 墊塊的設(shè)計(jì)223.8.3 定模座板和動(dòng)模座板的設(shè)計(jì)223.8.4 導(dǎo)柱的設(shè)計(jì)233.8.5 導(dǎo)套的設(shè)計(jì)243.8.6 設(shè)計(jì)導(dǎo)柱導(dǎo)套需要注意的事項(xiàng)243.9推出機(jī)構(gòu)的設(shè)計(jì)243.9.1 推桿的設(shè)計(jì)25第四章 冷卻系統(tǒng)的設(shè)計(jì)284.1 冷卻水孔直徑的確定284.2 冷卻水回路的布置原則28第五章 注射機(jī)的相關(guān)校核295.1 注射機(jī)額定注射量的校核295.2注射壓力的校核295.3鎖模力的校核295.4模具安裝尺寸的校核305.41噴嘴尺寸校核305.4.2模具厚度校核305.5 開模行程的校核31結(jié)論32謝 辭33參考文獻(xiàn)34外文資料翻譯41前言 塑料工業(yè)是新興的工業(yè)，是隨著石油工業(yè)的發(fā)展因應(yīng)運(yùn)而生的，目前塑料制件幾乎已經(jīng)進(jìn)入一切工業(yè)部門以及人民日常生活的各個(gè)領(lǐng)域。塑料工業(yè)又是一個(gè)飛速發(fā)展的工業(yè)領(lǐng)域。塑料作為一種新的工程材料，其不斷被開發(fā)與應(yīng)用，加之成型工藝的不斷成熟，完善和發(fā)展，極大的促進(jìn)了塑料成型方法的研究與運(yùn)用和塑料模具的開發(fā)與制造。隨著工業(yè)塑料制件和日用塑料之間的品種和需求量日益增加，這些產(chǎn)品的更新?lián)Q代的周期越來越短。因此對(duì)塑料的品種、產(chǎn)量和質(zhì)量都提出了越來越高的要求。對(duì)塑料制件提出高要求的同時(shí)意味著對(duì)塑料模具提出了很高的要求。因?yàn)槟＞呤撬芰瞎I(yè)生產(chǎn)中重要的工藝設(shè)備，因此模具設(shè)計(jì)顯得越來越重要。塑料模具的設(shè)計(jì)是模具制造中的關(guān)鍵工作。通過合理設(shè)計(jì)制造出來的模具不僅能順利的成型高質(zhì)量的塑件，還能簡化模具的加工過程和實(shí)施塑件的高效率生產(chǎn)，從而達(dá)到降低生產(chǎn)成本和提高附加價(jià)值的目的。近幾年來塑料成型工藝迅速發(fā)展，塑料模具種類不斷增加。結(jié)構(gòu)也更為復(fù)雜，在該套模具的設(shè)計(jì)中采用的是一模四腔的模具結(jié)構(gòu)。該套模具的澆口采用的是側(cè)澆口。側(cè)澆口又稱標(biāo)準(zhǔn)澆口，這種澆口一般開設(shè)在分型面上，塑料熔體內(nèi)側(cè)或外側(cè)注入型腔，其截面形狀多為矩形，改變澆口的寬度與厚度可以調(diào)節(jié)熔體的剪切速率及澆口的凍結(jié)時(shí)間。這類澆口可以根據(jù)塑件的形狀特征選擇其位置，加工和修正方便，普遍用于中小型塑件的多型腔模具，且對(duì)各種塑料的成型適應(yīng)性均較強(qiáng)。其澆口截面小，減少了澆注系統(tǒng)塑料的消耗量，同時(shí)去除澆口容易，且不留明顯痕跡。因此塑件的表面不受損傷，不致因澆口痕跡而影響塑件的表面質(zhì)量與美觀效果。該套模具的工作原理是當(dāng)注射結(jié)束時(shí)，模具在開模力的作用下從D-D分型面分型，當(dāng)動(dòng)模向后移動(dòng)一定距離后推出機(jī)構(gòu)開始工作，推桿推動(dòng)推件板把塑件從型芯上推下,完成整個(gè)開模過程 。 第一章：制件的結(jié)構(gòu)與工藝性分析1.1 制件相關(guān)信息名稱：端蓋 材料：PS；精度：一般，零件直觀圖如圖1-1所示：圖1-1 制件立體圖生產(chǎn)批量：中批生產(chǎn)； 粗超度要求：Ra=0.6um；用途：利用PS透明度高的特點(diǎn)，制造儀器端蓋，一方面防塵，阻擋異物進(jìn)入儀器；另一方面可從頂部區(qū)域，觀察儀器內(nèi)部油面，以便隨時(shí)掌握油量，及時(shí)添加。側(cè)壁上長條形孔洞，用于扣緊端蓋，保證端蓋與儀器牢固結(jié)合。表面質(zhì)量要求：要求頂面必須光滑平整，無澆口痕跡及頂出痕跡；四壁光滑，無明顯痕跡。1.2材料的相關(guān)性質(zhì) 1.2.1 基本特性PS（聚苯乙烯）是無色透明并有金屬光澤的非結(jié)晶型線性結(jié)構(gòu)的高聚物，落地式發(fā)出類似金屬的聲音，密度為1.054g/cm3。聚苯乙烯的透明度好，透光率高，在塑料中期光學(xué)性能僅次于有機(jī)玻璃。聚苯乙烯有優(yōu)良的電性能，尤其是高頻絕緣性能，并具有一定的化學(xué)穩(wěn)定性。聚苯乙烯能耐除硝酸以外的酸及堿、醇、油、水等，但對(duì)與氧化劑、苯、四氯化碳、酮類、酯類等的抵抗力較差。聚苯乙烯的著色性能優(yōu)良，能染成各種鮮艷的顏色。但其耐熱性低，熱變形溫度一般在70-90，所以只能用在不高的溫度下。聚苯乙烯質(zhì)地硬而脆，有較高的熱膨脹系數(shù)，塑件易產(chǎn)生內(nèi)應(yīng)力易開裂，因此限制了它在工程上的應(yīng)用。近幾十年來，由于有了改性聚苯乙烯和以聚苯乙烯為基體的共聚物，從而擴(kuò)大了它的用途。1.2.2 主要用途 聚苯乙烯是僅次于聚乙烯和聚氯乙烯的第三大塑料品種。在工業(yè)上可用作制作儀表外殼、燈罩、化學(xué)儀器零件、透明模型等。在電器方面用于制作良好的絕緣材料，如電視機(jī)的結(jié)構(gòu)零件、接線盒和電池盒等。在日用品方面則廣泛用于制作包裝材料、各種容器和玩具等。1.2.3 成型特點(diǎn)聚苯乙烯成型性能優(yōu)良，吸水性小，可不進(jìn)行干燥處理。由于熱膨脹系數(shù)較高，故而塑件中不宜含有嵌件，否則會(huì)因兩者的熱膨脹系數(shù)相差太大而導(dǎo)致開裂。宜采用高料溫，高模具溫度，低注射壓力成型并延長注射時(shí)間，以防止縮孔和變形，降低內(nèi)應(yīng)力。由于聚苯乙烯流動(dòng)性很好，故而在模具設(shè)計(jì)中大多采用點(diǎn)澆口進(jìn)料。聚苯乙烯可采用注射，擠出，真空等多種方法成型。 1.3塑件的脫模斜度由于塑件成型冷卻過程中產(chǎn)生收縮，使其緊箍在凸模或型芯上，為了便于脫模，防止因脫模力過大而拉壞塑件或使其表面受損，與脫模方向平行的塑件內(nèi)、外表面都應(yīng)具有合理的斜度。以下是 PS的脫模斜度推薦值：型腔：35-130型芯：30-40對(duì)于本制件而言，型腔取1脫模斜度，型芯取30脫模斜度。1.4塑件的尺寸精度及表面質(zhì)量要求該制件為簡單的殼類零件，側(cè)面有一成型孔。表面粗糙度為0.6.屬于一般的粗糙度要求。由于上表面要求不能出現(xiàn)任何形式的不光整現(xiàn)象，側(cè)面也要求盡量平整，故而最初大致確定，制件注塑成型時(shí)，從底部耳邊處進(jìn)料，即澆口開在耳邊，同時(shí)剛好開在最大分型面處。制件的詳細(xì)尺寸見零件圖，如下圖1-2所示：圖1-2 制品零件圖制件各個(gè)尺寸的相關(guān)要求如下：制件內(nèi)輪廓徑向尺寸44和側(cè)壁成型孔尺寸18、4為MT3，其余尺寸，為一般精度MT5。第二章：初選注射機(jī)2.1 計(jì)算塑件體積和最大投影面積考慮到制件形狀簡單，體積較小，批量不大，故而初定模具生產(chǎn)為一模兩腔。一次開模，耗費(fèi)塑料的總體積，可以分兩部分：制件部分的體積V1和料把的體積V2。V1KPCA=248.1kN （公式 5-2）故注塑機(jī)的額定鎖模力符合要求。5.4模具安裝尺寸的校核5.41噴嘴尺寸校核 注塑模澆口套始端凹坑的球面半R2應(yīng)大于注塑機(jī)噴嘴球頭半徑R1,以利用同心和緊密接觸，本設(shè)計(jì)按半徑R2= R1+（0.52）計(jì)算，故符合要求；主流道的始端直徑d1應(yīng)大于注塑機(jī)噴嘴孔直徑d2，本設(shè)計(jì)按d1=d2+（0.51）mm關(guān)系計(jì)算，亦符合要求。5.4.2模具厚度校核模具厚度（閉合高度）必須滿足下式： 式中所設(shè)計(jì)的模具高度（mm）； 注塑機(jī)所允許的最小模具厚度（mm）； 注塑機(jī)所允許的最大模具厚度（mm）。結(jié)合注塑機(jī)的參數(shù),模具總高度為235mm,XS-Z125型號(hào)注射機(jī)的裝模高度介于200mm與300mm之間,因此本設(shè)計(jì)符合要求。5.5 開模行程的校核注塑機(jī)模座間距是指注塑機(jī)動(dòng)模座和定模座之間的間距，對(duì)于所選用的注塑機(jī)，模具的閉模高度必須滿足 開模取出塑件所需的開模距離必須小于注塑機(jī)的最大開模行程。本設(shè)計(jì)選用注塑機(jī)為液壓-機(jī)械式鎖模機(jī)構(gòu)，液壓-機(jī)械式鎖模機(jī)構(gòu)的最大開模行程由屈肘機(jī)構(gòu)的最大行程決定，與模具厚度決定無關(guān)。