1、英文原文 Injection Molding CAE Technology0 IntroductionPlastic products from product design to production including molding plasticproducts design mold design mold manufacturing and injection molding processparameters and several other main areas. The traditional injection mold design mainlyrely on the
2、designers experience while the injection molding process is very complexplastic melt flow properties of different and ever-changing products and die structureprocess conditions vary forming various defects mold design often require repeatedtrial-mode maintenance mode can be put into production with
3、little of a successfulidentify problems not only to re-adjust the process parameters or even to modify theplastic products and molds not only time-consuming and laborious but also reducesproduct development time . The use of injection molding CAE technology in moldmanufacturing prior to simulate inj
4、ection molding process including filling packingand cooling and the early detection of problems optimize mold design and processconditions set to reduce the number of test mode in order to improve productionefficiency has become a injection molding technology is an important direction ofdevelopment.
5、1 The history of Injection Molding CAE technologyInjection Molding CAE technology is based on plastics processing rheology and heattransfer of the basic theory the melt in the mold cavity in the flow heat transferphysics mathematical model using numerical solution method of constructing thetheory th
6、e use of computer visualization technology image visually simulate thedynamics of the actual shape of the melt filling and cooling process an analysistechniques.The 20th century 60 years the United Kingdom the United States and Canada andother countries of the scholars such as JRPearson United Kingd
7、om JFStevensonAmerica MRKamal Canada and KKWang America etc. to carry out a series ofplastic melt in the mold-type cavity flow and cooling of basic research. At areasonable simplification based on 60 years completed a one-dimensional flow andcooling analysis programs 70 years to complete the two-dim
8、ensional cooling analysisprograms and 80 years from the injection molding CAE technology has begun totheoretical research into the practical phase launched a three-dimensional flow andcooling analysis and the study extended to packing fiber orientation and warpageprediction of molecular and other fi
9、elds. After 90 years carried out into the flowpacking cooling and stress analysis the whole process of injection molding processesare integrated research.CAE technologies for the injection mold design provides a reliable guarantee that itsapplication is mold design in the history of a major change.2
10、 The role of Injection Molding CAE technologyUsing traditional methods of design of injection mold design success will rely heavilyon the experience of designers but also for complex parts gate position is reasonableor not the location of the exhaust slot settings to determine the location of weld l
11、inesand so very difficult. Die in delivery will normally take before the test mode afterrepeated changes until the products have been qualified which inevitably led to theextension of the production cycle and generally difficult to obtain an optimal designand process parameters. The use of injection
12、 molding CAE technical design mold isnot true because of mold design concept stage can make use of CAE technology ininjection molding process simulation flow making usually only in the mold tryoutphases in order to find problems such as short shots weld lines or holes appear in thesurface appearance
13、 of parts and other issues have been avoided. While helping thedesigner to complete the balance of the system such as flow channel design exhaustducts setting rationally determine the injection molding process parameters etc. sothat usually makes the modification must be repeated tryout to determine
14、 structuralparameters of the mold die design and process parameters in the conceptual stage ableto determine reduce the mold design and manufacturing cycle and improve the molddesign quality.Therefore the role of injection molding CAE software mainly as follows:1 Optimize design of plastic productsP
15、lastic wall thickness gate number and location of the design of flow channel systemfor the quality of plastic products have a significant impact. Depends on theexperience of the past designers using manual methods to achieve time-consumingeffort but the use of CAE technology to quickly design the be
16、st products.2 optimize the plastic mold designCan be cavity size gate location and number of flow channel dimensions and coolingsystems to optimize the design. On the computer simulation test mold mold repairmold and improve quality and reduce the number of actual tryout.3 to optimize injection proc
17、ess parametersSimulation of the injection process and found possible shape defects to determine thebest injection pressure clamping force mold temperature melt temperature injectiontime and cooling time.This shows that the injection molding CAE technology in terms of improvingproductivity reduce mol
18、d design and manufacture cycle and to ensure product qualityor reduce costs reduce labor intensity and so on have very significant technicaladvantages and economic significance.3 Injection Molding CAE software types and their detailsTo date a mature business are more injection molding CAE software M
19、oldflowCorporation Moldflow software and AC-Tech Inc. February 2000 was MoldflowMerger and C-Mold software is an excellent representative There are also foreignThe TMCONCEPT CADMold Fidap Stirm100 Polyflow and Chinas Taiwan regionMoldex-peer software applications are relatively wide and domestic in
20、the quotEighthFive-Yearquot period began research in this area and now Huazhong University ofTechnology HSCAE software and Zhengzhou University Z -Mold software in Chinain the leading position.Moldflow software is specialized in injection molding CAE software and consultingfor Moldflows range of pro
21、ducts the company issued since 1976 the worlds first setof injection molding CAE software has been a leading injection molding CAEsoftware market. To 2004 Moldflow Injection Molding CAE software in the globalmarket share of over 75.MoldFlow software includes three parts: MoldFlow Plastics Advisers p
22、roductoptimization consultant MPA MoldFlow Plastics Insisht injection moldingsimulation analysis MPI and MoldFlow Plastics Xpert injection molding processcontrol specialists MPX.Under normal circumstances the most commonly used MPI is mainly used forinjection molding process simulation to get the be
23、st number and location of the gatereasonable flow channel system and cooling system and cavity size gate size runnersize and cooling systems to optimize the size and the injection molding processparameters may also be optimized.Moldflow Software Moldflow analysis techniques can be divided into three
24、 kindsnamely Midplane Fusion and 3D .4 Moldflow analysis of MidplaneMidplane in the surface flow applications began in the 20th century the 80s. Thegrid is a three-node triangular element its principle is the 3D geometric model ofsimplified geometric model of the neutral surface to be created in the
25、 model grid themiddle of the wall thickness using established simulation analysis of the neutralsurface ie to flow in plane to simulate three-dimensional solid flow. The analysis oftechnological development has been very mature and stable and the advantages forthe analysis of speed and high efficien
26、cy.Based on the flow of surface flow simulation of injection molding technologysoftware applications the longest widest range. But the practice shows that based onthe surface flow simulation software in the application of technology that hassignificant limitations specifically as follows:1 The user
27、must construct a mid-surface model. Using manual directly from thephysical model structure in the surface model is very difficult and often takes a lot oftime and can not be converted from other CAD models.2 can not be described in a number of three-dimensional features. If they can notdescribe the
28、inertia effect gravitational effects on melt flow which fail to predict jetphenomenon melt the forefront of Quan phenomena.3 The use of CAD phase of the product model and stages of the use of CAE analysismodel is not unified so that the inevitable second modeling CAD and CAE systemsintegration can n
29、ot be achieved.5 Moldflows Fusion analysisFusion double flow analysis technique is based on Moldflows patented DualDomain of analysis techniques. Fusion launched in 2000 analysis techniquesenabling users do not need to extract the neutral surface can be analyzed to overcomethe reconstruction of the
30、geometric model thus greatly reducing the burden on theuser modeling. Grid is also a triangular element and its principle is to mold cavity orthe products in the thickness direction is divided into two parts finite element meshon the surface of the cavity or the products. In the flow process the upp
31、er and lowersurface of the plastic melt at the same time two and to coordinate movement of thesimulation shown .Clearly Fusion technology the surface of the grid is based on the neutral surface isstill not solve the fundamental problem the neutral surface so double-sidedapplication of the principle
32、of streaming technologies and methods applied in thesurface flow with no difference in the nature the The difference is two-sided flowusing a series of related algorithms will flow along the surface of the single-strandedmelts evolved along the upper and lower surface of the coordination of the flow
33、 ofdual-stream.Double-sided flow of technologys biggest advantage is that the model greatly shortenthe preparation time thus greatly reducing the burden on the user modeling will takeseveral hours or even days of the original modeling work reduced to a few minutes.Therefore based on double-sided flo
34、w simulation software technology although theadvent of time only a few years but in the world but has a huge user base get themajority of customers for their support and praise.But the double-sided flow of technology has the following deficiencies:1 The two-sided flow of technology does not fundamen
35、tally resolve the issue of aneutral face they still can not describe some three-dimensional features such as theinertial effect can not describe gravity effect on the melt flow which fail to predict jetphenomenon melt cutting-edge Quanyong phenomena.2 the upper and lower surfaces corresponding to th
36、e melt flow front there aredifferences. As the upper and lower surface of the grid can not be one correspondencebut the grid shape orientation and size can not be completely symmetrical so how theupper and lower surfaces corresponding to the difference between the melt flow frontcontrol is within th
37、e scope permitted by Difficulties in the implementation ofdouble-sided streaming technology.3 melt is only along the upper and lower surface flows in the thickness direction isnot to make any treatment lack of realism.6 Moldflows 3D analysis techniquesThese two techniques have overlooked the thickne
38、ss direction of the physical quantityonly two-dimensional simulation and therefore results are not very precise. MoldflowCorporations 3D 3D analysis technology uses a true three-dimensional solid modelflow analysis techniques through rigorous theoretical derivation and repeatedverification the inert
39、ial effect non-isothermal flow taking into account factors suchas finite element analysis the melt thickness direction of the physical quantitychanges will no longer be ignored can be a more comprehensive description of theprocess of filling flow phenomena so that results of the analysis more realis
40、ticconditions applicable to all plastic products. Its three-dimensional grid is from thefour-node tetrahedron unit. And using the new 3D stereoscopic display technologycan quickly model clearly shows that internal and external flow field temperaturefield stress field and velocity field such as analy
41、sis results. For the above-mentionedresults of the analysis can also be used such as bit lines or equipotential surfacedisplay so that physical models and external changes in the variables show moreclearly the case Moldfiow also offers animation capabilities through 3D animationdisplay plastic melt
42、in the changes in the flow cavity allowing users to moreintuitively see the design and manufacturing process may encounter problems.But the 3D technology meshing demanding more complex equations to calculate theamount of large long duration and the computational efficiency is low not suitablefor sho
43、rt development cycle and need to be repeatedly revised by CAE verificationinjection mold design. Therefore the current penetration rate of the technology is notvery high but it will eventually replace the surface flow of technology anddouble-sided streaming technology.7 Development Trend of Injectio
44、n MoldingInjection Molding CAE technology whether in theory or in the application have madegreat strides but in the following still needs further improvement and development :1 mathematical models numerical algorithms to gradually improve theInjection Molding CAE technology practicality depending on
45、 the accuracy of themathematical model and numerical algorithm accuracy. The current commercialsimulation software models do not fully consider the physical quantities in thethickness direction of the impact of the software in order to further improve theanalysis accuracy and scope to further improv
46、e the existing mathematical models andalgorithms.2 the whole process of injection molding simulationAt present the injection molding simulation software are mainly filling flow packingcooling stress and strain and warpage analysis modules each module was developedbased on independent mathematical mo
47、dels these models has been simplified to alarge extent ignored of the mutual effects. However in view of injection moldingprocess plastic melt filling flow packing and cooling are intertwined and affect eachother and therefore filling flow packing and cooling analysis module must beorganically combi
48、ned to carry out coupling analysis in order to comprehensivelyreflect the real situation of injection molding.3 optimization theory and algorithms so that CAE technology quotactivequotto optimize the designArtificial intelligence technologies such as expert systems and neural networks on thedesign c
49、alculations so that simulation can quotwisdomquot to choose the injection moldingprocess parameters product size and cooling to fix the piping layout programs toreduce manual intervention in the program.4 a new method of injection molding simulation analysis of the currentIn the conventional injecti
50、on molding technology based on and the development of anumber of new injection molding methods such as gas-assisted injection thin wallinjection molding reaction injection and co-injection . However no specific methodsfor these molding simulation software so untapped.5 injection mold CAD / CAE / CAM
