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塑料注塑成型模塑的自動(dòng)化裝配組件
摘要 一個(gè)注射成型機(jī)是一個(gè)包含了產(chǎn)品生產(chǎn)部分和與之相關(guān)的非生產(chǎn)部分自動(dòng)化裝配組件，本篇論文論述了注射成型模塑的兩個(gè)關(guān)鍵的裝配組件。顧名思義，它們是由計(jì)算機(jī)設(shè)計(jì)出來(lái)，并且決定非生產(chǎn)部件在裝配組件中的位置和取向，這種從表官現(xiàn)象和客觀(guān)取向所設(shè)計(jì)的組件，是意欲表現(xiàn)出注射成型裝配組件的。據(jù)此，這種設(shè)計(jì)允許設(shè)計(jì)者忽略一個(gè)模塑制件的細(xì)節(jié)，直接描述只見(jiàn)的那一部分的重要及其原因，因此它給設(shè)計(jì)者提供了一次設(shè)計(jì)裝配的機(jī)會(huì)，一個(gè)系統(tǒng)的簡(jiǎn)單幾何方法通常意欲在相同的條件下推斷出一個(gè)客觀(guān)配件在裝配組件中的位置，而在這種粗略設(shè)計(jì)和系統(tǒng)簡(jiǎn)單的幾何方法的基礎(chǔ)上，模塑自動(dòng)化裝配組件被進(jìn)一步研究。
關(guān)鍵詞：模塑裝配組件，表觀(guān)現(xiàn)象，注射成型，客觀(guān)取向，
1 簡(jiǎn)介
注射成型是生產(chǎn)塑料注塑模塑的重要過(guò)程。它所必需的設(shè)備包含了兩個(gè)關(guān)鍵的部分：注射成型機(jī)和注射模具。今天所用的注射模具機(jī)就是所謂的萬(wàn)能機(jī)。不同尺寸的塑件通過(guò)它而被生產(chǎn)出來(lái)，但是這些尺寸被限制在一定的范圍內(nèi)。這些模具是根據(jù)塑件設(shè)計(jì)出來(lái)的。對(duì)于不同的模具形狀就需要有不同的模具布局與之對(duì)應(yīng)，一個(gè)注射成型模具的最基本的任務(wù)就是將熔化了的材料生產(chǎn)成不同形狀的制品，這個(gè)任務(wù)是由包含了陽(yáng)模、型腔、嵌件、一級(jí)頂出機(jī)構(gòu)的型腔系統(tǒng)完成的。一個(gè)型腔系統(tǒng)的幾何形狀和尺寸是由塑件直接決定的，因此一個(gè)型腔所有的構(gòu)件都叫做產(chǎn)品生產(chǎn)部分（產(chǎn)品就是指塑件，部件就是指注射模具的構(gòu)件，另外產(chǎn)品成型是最基本任務(wù)，一個(gè)注射成型機(jī)需要完成很多任務(wù)，例如，分配，熔料，冷卻融化物注射塑件，功能部件所完成的這些任務(wù)與注射成型不同結(jié)構(gòu)和尺寸的塑件非常相似，他們的結(jié)構(gòu)和幾何形狀與塑件成型模具不相關(guān)，但是他們的尺寸可以根據(jù)塑件的尺寸而不斷改變，因此我們可以從中得到結(jié)論，一個(gè)注射成型機(jī)包含了塑件生產(chǎn)部分和與之相關(guān)的非生產(chǎn)部分的自動(dòng)化裝配組件。）
生產(chǎn)部分的設(shè)計(jì)師在總結(jié)了所生產(chǎn)塑件的幾何性能而得到的，在最幾年CAD/CAM技術(shù)已經(jīng)被成功的應(yīng)用在幫助模具設(shè)計(jì)者設(shè)計(jì)的塑件生產(chǎn)部分，一個(gè)塑件的自動(dòng)化的生產(chǎn)受到了越來(lái)越大的重視，然而幾乎沒(méi)有相關(guān)的作品被刊登出來(lái)，盡管他同生產(chǎn)部分的設(shè)計(jì)營(yíng)養(yǎng)重要，當(dāng)應(yīng)用CAD系統(tǒng)設(shè)計(jì)產(chǎn)品生產(chǎn)部分和所有的注射成型裝配組件時(shí)模具工業(yè)免領(lǐng)著以下兩種困難，第一，在一個(gè)模具系統(tǒng)中往往有一百多個(gè)廠(chǎng)品生產(chǎn)部分，并且這些部分之間互相聯(lián)系互相制約，對(duì)于模具設(shè)計(jì)者在一個(gè)裝配組件取向和安排這些組件時(shí)非常浪費(fèi)時(shí)間的，另外當(dāng)模具設(shè)計(jì)者大部分的時(shí)間用來(lái)思考實(shí)際存在的客觀(guān)部件的選用原則，例如，螺絲、底座，系統(tǒng)應(yīng)用了一個(gè)完全不同的客觀(guān)無(wú)體幾何水平，結(jié)果高水平的客觀(guān)取向想法不得不翻譯成低水平的CAD系統(tǒng)，例如，線(xiàn)、平面、塊，因此，發(fā)展一個(gè)模塑自動(dòng)化裝配組件顯得非常重要，在這篇論文中我們論述了模塑自動(dòng)化組建的兩個(gè)關(guān)鍵因素。在計(jì)算機(jī)中涉及一個(gè)模具生產(chǎn)部分和一個(gè)模具生產(chǎn)裝配組件，并且決定組成部分在一個(gè)裝配組件中的位置和客觀(guān)取向。
這篇論文簡(jiǎn)要地描述了模塑裝配組件的相關(guān)研究并且論述了注射成型模塑一個(gè)裝配組件的一個(gè)不可缺少的設(shè)計(jì)，一個(gè)簡(jiǎn)單的幾何方法被用來(lái)決定一個(gè)部件在模具裝配組件中的位置和客觀(guān)取向，介紹了注塑成型模塑的自動(dòng)化裝配組件的一個(gè)例子。
2 相關(guān)的研究
關(guān)于模塑注塑這個(gè)課題，已經(jīng)在很多領(lǐng)域被廣泛研究，例如，動(dòng)力機(jī)體學(xué)，人工智能，和模塑幾何性能學(xué)。湯木編輯了一本模塑組件的書(shū)，他在其中報(bào)道了許多關(guān)于模塑裝配組件的專(zhuān)業(yè)術(shù)語(yǔ)，再這些專(zhuān)業(yè)術(shù)語(yǔ)中，一些組件被比喻成鼻子。一些感觀(guān)機(jī)體被弧線(xiàn)連接起來(lái)。然而，這些感官機(jī)體并沒(méi)有重合在一起。這就嚴(yán)重的影響了改性過(guò)程。例如，一個(gè)幾何裝配移動(dòng)所有與之相關(guān)的部件沒(méi)有相應(yīng)的移動(dòng)。邁克發(fā)明了一種支持包含了最基本信息的數(shù)據(jù)庫(kù)的有等級(jí)差別的裝配組建系統(tǒng),這些最基本的信息包含了兩個(gè)部件之間的墊片,這些改型基體之際取決于與之相關(guān)的實(shí)體,但是這些有等級(jí)模具差別的模具組建僅僅代表了這些模具中的一部分。
自動(dòng)化取向指代的是一些組件在裝配組件中的布局,這就意味著模具設(shè)計(jì)者可以避免直接定義這些改性機(jī)體,另外,一個(gè)部件位置的改變,將會(huì)隨著與之相連的任意一個(gè)部件的改動(dòng)而變動(dòng),存在著三種技術(shù)推斷計(jì)算一個(gè)部件在一個(gè)裝配組件中的位置和取向,這三種技術(shù)分別是數(shù)字迭代技術(shù),系統(tǒng)代數(shù)技術(shù),和系統(tǒng)幾何技術(shù),邁克指出數(shù)字迭代技術(shù)使用計(jì)算存在與空間關(guān)系中任何一個(gè)部件的位置和取向,他們的方法包含了三個(gè)步驟,產(chǎn)生約束等式,減少約束等式的數(shù)量 和解決這些等式,存在著16個(gè)等式與條件不符,18個(gè)等式符合條件,6個(gè)對(duì)任何機(jī)體合適的等式,另外2個(gè)附加等式符合旋轉(zhuǎn)部分,通常這些等式的數(shù)量超過(guò)了可以利用的等式,因此這就需要一種技術(shù)篩選到不需要的公式,牛頓力學(xué)公式被用來(lái)解決這個(gè)問(wèn)題。這種技術(shù)有兩個(gè)缺點(diǎn)：第一、這種方法嚴(yán)重的依賴(lài)這前面的方法；第二、數(shù)字迭代技術(shù)不能區(qū)別不同的數(shù)字基礎(chǔ),因此,他很可能緊急用在空間關(guān)系的問(wèn)題上,這個(gè)領(lǐng)域不是數(shù)學(xué)方面的空白,但是在理論上還很模糊。
愛(ài)波和波斯提出了一種方法用來(lái)計(jì)算裝配組建中的每一個(gè)部件在兩個(gè)部件之間旋轉(zhuǎn)和改觀(guān)方面所需要的空間關(guān)系,每一個(gè)部件存在著關(guān)于空間關(guān)系的6個(gè)轉(zhuǎn)變(3個(gè)移動(dòng)和三個(gè)旋轉(zhuǎn))。這種技術(shù)需要大量的計(jì)算機(jī)程序應(yīng)用和數(shù)據(jù)計(jì)算,同樣他不能用來(lái)解決在任何時(shí)間出現(xiàn)的所用問(wèn)題,尤其是當(dāng)一個(gè)等式不能在程序中被重寫(xiě)的時(shí)候。
開(kāi)若發(fā)明了一種能夠決定一個(gè)剛性物體的位置和趨向的集合方法,這種方法用來(lái)解決一系列的幾何約束.這種幾何方法是通過(guò)產(chǎn)生一系列畝任何約束的系統(tǒng)方法來(lái)解決問(wèn)題的.這就導(dǎo)致了DOF數(shù)量的下降,開(kāi)若利用了一種解決問(wèn)題的技術(shù)稱(chēng)作"上帝"這是一個(gè)包含了一個(gè)點(diǎn),兩條標(biāo)準(zhǔn)角形軸線(xiàn)的技術(shù).7條約束現(xiàn)在圖表中被定義出來(lái),關(guān)于這個(gè)圖表顯示了約束之間的關(guān)系.經(jīng)試驗(yàn)分析后確定一個(gè)幾何物體的最終布局,一步一步的在每一部解決客觀(guān)物體的布局,分析的結(jié)果決定哪一種方法將會(huì)滿(mǎn)足一個(gè)物體同時(shí)解除約束,這考慮到不見(jiàn)自由運(yùn)行的程度,然后得出哪一種行為約束了部件的自由運(yùn)行,在每異步結(jié)束的時(shí)候一種正確的方法被應(yīng)用到確定裝配組建技術(shù)的計(jì)劃中.根據(jù)賽若和褥子開(kāi)若的方法在發(fā)展莫塑裝配組建技術(shù)中起到了重大的作用,這種系統(tǒng)的幾何方法可以解決所有的約束條件,并且與數(shù)字迭代技術(shù)相比他擁有跟吸引人的數(shù)字計(jì)算技術(shù),但是要應(yīng)用這種方法就需要大量的應(yīng)用程序。
盡管和多的設(shè)計(jì)者積極的投入到莫塑裝配組建技術(shù)上,但是關(guān)于塑料注射成型莫塑裝配組建技術(shù)的成果很少被系統(tǒng)的報(bào)道.螺絲發(fā)明一種支持支持注射成型的設(shè)計(jì)系統(tǒng),這個(gè)系統(tǒng) 通過(guò)高水平的功能莫塑組建支持了注射成型莫塑技術(shù),因?yàn)槠渌说募夹g(shù)僅僅是建立在A(yíng)UTOCAD的基礎(chǔ)上,所以只能用寫(xiě)簡(jiǎn)單的塊和線(xiàn)框表示出來(lái)。
3 注射成型裝配組件的代表
注射成型模塑的自動(dòng)化裝配組件的兩個(gè)關(guān)鍵技術(shù)是在計(jì)算機(jī)重將模塑裝配組件表示出來(lái)和決定部件的生產(chǎn)部分在裝配組件中的位置和取向,在這個(gè)階段我們可以利用客觀(guān)取祥和表管線(xiàn)向來(lái)代表注射成型的裝配組件。
在計(jì)算機(jī)中設(shè)計(jì)一個(gè)設(shè)計(jì)裝配組件，這個(gè)技術(shù)要求考慮到每一個(gè)部件的結(jié)構(gòu)和關(guān)系,這種設(shè)計(jì)必須支持所有的部件在裝配組件中的配合,所有部件間的改變關(guān)系和裝配組件作為一個(gè)整體的操作要求.另外,裝配組件的這種設(shè)計(jì)要求設(shè)計(jì)者在設(shè)計(jì)師必須滿(mǎn)足以下的要求：
1、到模具設(shè)計(jì)者考慮到實(shí)際存在的物體水平時(shí)就必須可以利用高水平的客觀(guān)技術(shù)；
2、裝配組件的這種設(shè)計(jì)必須能夠正確的表現(xiàn)出自動(dòng)生產(chǎn)過(guò)程的功能。
為了滿(mǎn)足這些要求一種具有表觀(guān)現(xiàn)象和客觀(guān)趨向的有等級(jí)差別的模具被應(yīng)用在注射成型技術(shù)中,一個(gè)裝配組件可以被分成很多集合裝配,這個(gè)集合裝配有包含了很多的構(gòu)件,因此有等級(jí)差別的模具能夠分成合適的代表兩個(gè)構(gòu)件之間的結(jié)構(gòu).一個(gè)等級(jí)差別的模具暗示了一個(gè)明確的裝配組件組,另外,一個(gè)等級(jí)差別的膜具能夠直接表現(xiàn)出一個(gè)構(gòu)件對(duì)另一個(gè)構(gòu)件的依賴(lài)。帶有表觀(guān)現(xiàn)象，要求設(shè)計(jì)者站在一個(gè)比實(shí)際應(yīng)用模具更高的水平線(xiàn)。幾何形狀是直接的有尺寸的,和有設(shè)計(jì)者能夠通過(guò)一系列參數(shù)直接定位的.然而,客觀(guān)趨向的模具設(shè)計(jì)者超出了這些細(xì)節(jié).另外,他同樣也可以使設(shè)計(jì)者由于幾何形狀之間的關(guān)系筆可觀(guān)趨向的模具設(shè)計(jì)者容易做出變動(dòng).沒(méi)有客觀(guān)取向設(shè)計(jì)者就要根據(jù)模具要求這的要求考慮到所有的幾何結(jié)構(gòu),因此,這就是設(shè)計(jì)的每一次改變直接根據(jù)模具要求這的改變而改變.另外,客觀(guān)取向的設(shè)計(jì)能夠給設(shè)計(jì)者提供更高水平的組件物體,例如,當(dāng)模具設(shè)計(jì)者考慮到物體的真實(shí)水平時(shí),如一個(gè)冷卻水孔相關(guān)的客觀(guān)表象在計(jì)算機(jī)中表現(xiàn)出來(lái)。
客觀(guān)取向模具設(shè)計(jì)是一個(gè)在考慮到現(xiàn)實(shí)事件中的模具技術(shù)的基礎(chǔ)上所應(yīng)用的一種新的方法,它的基礎(chǔ)是客觀(guān)物體,這個(gè)物體結(jié)合了數(shù)據(jù)結(jié)構(gòu)和性能客觀(guān)取向方法被用來(lái)理解問(wèn)題和設(shè)計(jì)程序和數(shù)據(jù)庫(kù),另外,客觀(guān)取向代表了裝配組件制造時(shí)單位客觀(guān)物體和總的組件的包含與被包含關(guān)系。
4 注射成型模塑的自動(dòng)化裝配組件
許多注塑成型的裝配組件包含了生產(chǎn)部分合非生產(chǎn)部分, 生產(chǎn)部分單個(gè)組件的設(shè)計(jì)師在塑件幾何性能的基礎(chǔ)上得到的,通常產(chǎn)品生產(chǎn)部分應(yīng)由于高水平裝配組件相同的取向,通常這些構(gòu)件的位置和大小直接由設(shè)計(jì)者制定,對(duì)于產(chǎn)品省唱本的設(shè)計(jì),傳統(tǒng)的方法是設(shè)計(jì)者從目錄冊(cè)中直接選擇所需要的模型,對(duì)這些選擇的產(chǎn)品生產(chǎn)部分建立幾何模型塊,然后再將這些塊加入到注射成型裝配組件中,這樣的設(shè)計(jì)及浪費(fèi)時(shí)間與錯(cuò)誤百出.在我們所應(yīng)用的新的設(shè)計(jì)方法中所有生產(chǎn)部分的設(shè)計(jì)數(shù)據(jù)實(shí)在裝配組件和客觀(guān)需要的基礎(chǔ)上得到的,這些數(shù)據(jù)不僅包含了幾何形狀和生產(chǎn)部分的尺寸,而且還包含了部件之間的空間約束.另外,許多有固定路線(xiàn)的部件例如:頂出和復(fù)位同樣也在這個(gè)數(shù)據(jù)庫(kù)中,因此,模具設(shè)計(jì)必須選則應(yīng)用這要求的模具生產(chǎn)部分而確定它的結(jié)構(gòu),然后計(jì)算機(jī)軟件會(huì)自動(dòng)的確定出這些部分所要求的部件的取向和位置,然后再將這些部件加入到裝配組件中。
5 模具非標(biāo)準(zhǔn)的集合裝配
產(chǎn)品的生產(chǎn)部分可以進(jìn)一步分為標(biāo)準(zhǔn)件合非標(biāo)準(zhǔn)件。這些非標(biāo)準(zhǔn)件使用與一系列,底座,導(dǎo)向機(jī)構(gòu)等裝配組件構(gòu)成的.除了確定產(chǎn)品的性狀外,一個(gè)模具還必須同時(shí)完成許多其他的功能,例如冷卻,注射產(chǎn)品,頂出,合模導(dǎo)向等,許多的模具應(yīng)有相似的性能因此這就導(dǎo)致了他們?cè)诮Y(jié)構(gòu)上的相似.抹具結(jié)構(gòu)設(shè)計(jì)中有許多標(biāo)準(zhǔn)要求,抹具非標(biāo)準(zhǔn)部件就是在這些標(biāo)準(zhǔn)組件的基礎(chǔ)上設(shè)計(jì)而成的。
根據(jù)裝配組件設(shè)計(jì)師的客觀(guān)取祥和表關(guān)現(xiàn)象,模具組件的表觀(guān)現(xiàn)象是非標(biāo)準(zhǔn)件首先應(yīng)該考慮到的,另外,客觀(guān)組件的設(shè)計(jì)受到組件構(gòu)件之間的相互關(guān)系和構(gòu)件的功能的限制,然后利用這些客觀(guān)組件一個(gè)有等級(jí)差比的集合裝配(模具的非標(biāo)準(zhǔn)部件)就形成了,這些模具的生產(chǎn)部分可以直接由目錄數(shù)據(jù)庫(kù)中的數(shù)據(jù)確定。
5.1 標(biāo)準(zhǔn)件的自動(dòng)設(shè)計(jì)
一個(gè)標(biāo)準(zhǔn)件就是一個(gè)自動(dòng)組件,在數(shù)據(jù)庫(kù)中他的空間約束是由墊片,平面直線(xiàn)和弧線(xiàn)確定的但是他與非標(biāo)準(zhǔn)件不同,標(biāo)準(zhǔn)件的位置和客觀(guān)取向并不確定.在設(shè)計(jì)時(shí)軟件通過(guò)簡(jiǎn)單的公事之直接推斷出標(biāo)準(zhǔn)件地幾何形狀。
5.2裝配組件的復(fù)位設(shè)計(jì)
自動(dòng)化設(shè)計(jì)的一個(gè)關(guān)鍵考慮因素是復(fù)位過(guò)程,復(fù)位是指嵌件在設(shè)計(jì)過(guò)程中流出的相應(yīng)的一定空間使之歸位的操作。當(dāng)一個(gè)噴出設(shè)備加入到裝配組件中就要求在設(shè)計(jì)過(guò)程中留出相應(yīng)的孔，以便復(fù)位。
既然利用了客觀(guān)取向技術(shù),每一個(gè)裝配組件都可以有兩種表示方式:實(shí)際存在的和客觀(guān)設(shè)計(jì)。實(shí)際存在的物體空間時(shí)根據(jù)一個(gè)真實(shí)物體索要占據(jù)的空間決定的.無(wú)論何時(shí)一個(gè)客觀(guān)構(gòu)件被加入到裝配組件中,它的這是空間尺寸也同時(shí)被設(shè)計(jì)出來(lái).復(fù)位操作技術(shù)是根據(jù)相關(guān)構(gòu)件的相互關(guān)系而設(shè)計(jì)的.另外由于實(shí)際空間和真實(shí)空間的關(guān)系,復(fù)位技術(shù)的設(shè)計(jì)也要根據(jù)實(shí)際物體做出相應(yīng)的改變.這種自動(dòng)復(fù)位功能進(jìn)一步說(shuō)明了客觀(guān)取向的優(yōu)點(diǎn)。
5.3 系統(tǒng)應(yīng)用技術(shù)
在客觀(guān)取祥和表管線(xiàn)向基礎(chǔ)上設(shè)計(jì)而出的末塑自動(dòng)化裝配組件技術(shù),已經(jīng)在美國(guó)國(guó)立大學(xué)被應(yīng)用在IMOLD領(lǐng)域內(nèi).這種繪圖技術(shù)提高了應(yīng)用程序的一個(gè)有效方式 ,通過(guò)這種技術(shù)使用這可以將其他部分加入到裝配組件中修改參數(shù)等.盡管繪圖技術(shù)提供了很好的功能但是上文提到的方法仍然被用來(lái)推斷構(gòu)件的布局,因?yàn)樵谠O(shè)計(jì)過(guò)程中必須考慮到構(gòu)件自由運(yùn)行的程度和檢查構(gòu)件在加入到裝配組件以前所需要的空間.這種系統(tǒng)的約簌條件和圖表約束是相輔相成的。
這種裝配組件使用IMOLD技術(shù)設(shè)計(jì)的,模具中的每一個(gè)非標(biāo)準(zhǔn)件被自動(dòng)的安置在裝配組件。同樣,標(biāo)準(zhǔn)件例如螺釘也是被自動(dòng)的加入到裝配組件中,復(fù)位技術(shù)也不例外。
6 結(jié)論
在表觀(guān)現(xiàn)象和客觀(guān)取向技術(shù)上所設(shè)計(jì)的具有等級(jí)差別的具有注射模塑裝配組件不僅僅提高了裝配組件設(shè)計(jì)技術(shù),而且同時(shí)提高了操作功能和幾何約束性,例如自由的程度,配合條件,鑲嵌和取向約束.因?yàn)?裝配組件設(shè)計(jì)的這一技術(shù)的提高,它的變動(dòng)例如,裝配組件中某一構(gòu)件的尺寸變化可以在整體設(shè)計(jì)完以后在做出變動(dòng)。裝配組件構(gòu)件的封鑄有以下兩個(gè)特點(diǎn)：1因?yàn)榕浜霞夹g(shù)在裝配構(gòu)件中封鑄自動(dòng)化裝配組件設(shè)計(jì)就可以被容易的利用；2裝配組件的封鑄使得裝配組件的設(shè)計(jì)在應(yīng)用過(guò)程中自動(dòng)完成，例如復(fù)位和構(gòu)件檢查。提出了簡(jiǎn)單的統(tǒng)計(jì)方法可以直接降低自動(dòng)化設(shè)計(jì)過(guò)程中程序的難度。
編號(hào)
無(wú)錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
相關(guān)資料
題目：基于Pro/E的便攜式手機(jī)充電器
上蓋注塑模設(shè)計(jì)
信機(jī) 系 機(jī)械工程及其自動(dòng)化 專(zhuān)業(yè)
學(xué) 號(hào)： 0923225
學(xué)生姓名： 顧 亞 勵(lì)
指導(dǎo)教師： 曹亞玲 （職稱(chēng)：講 師）
（職稱(chēng)： ）
2013年5月25日
目 錄
一、畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告
二、畢業(yè)設(shè)計(jì)（論文）外文資料翻譯及原文
三、學(xué)生“畢業(yè)論文（論文）計(jì)劃、進(jìn)度、檢查及落實(shí)表”
四、實(shí)習(xí)鑒定表
無(wú)錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
開(kāi)題報(bào)告
題目：基于Pro/E的便攜式手機(jī)充電器
上蓋注塑模設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化 專(zhuān)業(yè)
學(xué) 號(hào)： 0923225
學(xué)生姓名： 顧 亞 勵(lì)
指導(dǎo)教師： 曹亞玲 （職稱(chēng)：講師 ）
（職稱(chēng)： ）
2012年11月25日
課題來(lái)源
本課題來(lái)源于生活生產(chǎn)實(shí)際。
科學(xué)依據(jù)（包括課題的科學(xué)意義；國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì)；應(yīng)用前景等）
（1）課題科學(xué)意義
隨著現(xiàn)代制造技術(shù)的迅速發(fā)展、計(jì)算機(jī)技術(shù)的應(yīng)用，在玩具產(chǎn)業(yè)中模具已經(jīng)成為生產(chǎn)各種玩具不可缺少的重要工藝裝備。特別是在塑料產(chǎn)品的生產(chǎn)過(guò)程中，塑料模具的應(yīng)用及其廣泛，在各類(lèi)模具中的地位也越來(lái)越突出，成為各類(lèi)模具設(shè)計(jì)、制造與研究中最具有代表意義的模具之一。而注塑模具已經(jīng)成為制造塑料制造品的主要手段之一，且發(fā)展成為最有前景的模具之一。注射成型是當(dāng)今市場(chǎng)上最常用、最具前景的塑料成型方法之一，因此注塑模具作為塑料模的一種，就具有很大的市場(chǎng)需求量。所以我選充電器注塑模具設(shè)計(jì)作為我畢業(yè)設(shè)計(jì)的課題。
本課題應(yīng)用性強(qiáng)，涉及的知識(shí)面與知識(shí)點(diǎn)較多，如注塑成型、模具設(shè)計(jì)、三維造型、運(yùn)動(dòng)仿真以及二維三維軟件的應(yīng)用。
（2） 研究狀況及其發(fā)展前景
近年來(lái)我國(guó)的模具技術(shù)有了很大的發(fā)展，在大型模具方面，已能生產(chǎn)大屏彩電注塑模具、大容量洗衣機(jī)全套塑料模具以及汽車(chē)保險(xiǎn)杠和整體儀表板等塑料模具。機(jī)密塑料模具方面，已能生產(chǎn)照相機(jī)塑料件模具、多型腔小模數(shù)齒輪模具及塑封模具。
在成型工藝方面，多材質(zhì)塑料成行模、高效多色注塑模、鑲件互換結(jié)構(gòu)和抽芯脫模機(jī)構(gòu)的創(chuàng)新業(yè)取得了較大進(jìn)展。氣體輔助注射成形技術(shù)的使用更趨成熟。熱流道模具開(kāi)始推廣，有些單位還采用具有世界先進(jìn)水平的高難度針閥式熱流道模具。
在制造方面，CAD/CAM/CAE技術(shù)的應(yīng)用上了一個(gè)新臺(tái)階，一些企業(yè)引進(jìn)CAD/CAM系統(tǒng)，并能支持CAE技術(shù)對(duì)成形過(guò)程進(jìn)行分析。近年來(lái)我國(guó)自主開(kāi)發(fā)的塑料膜CAD/CAM系統(tǒng)有了很大發(fā)展，如北航華正軟件工程研究所開(kāi)發(fā)的CAXA系統(tǒng)、華中理工大學(xué)開(kāi)發(fā)的注塑模HSC5.0系統(tǒng)及CAE軟件等。
優(yōu)化模具系統(tǒng)結(jié)構(gòu)設(shè)計(jì)和型件的CAD/CAE/CAM，并使之趨于智能化，提高型件成形加工工藝和模具標(biāo)準(zhǔn)化水平，提高模具制造精度與質(zhì)量，降低型件表面研磨、拋光作業(yè)量和縮短制造周期；研究、應(yīng)用針對(duì)各類(lèi)模具型件所采用的高性能、易切削的專(zhuān)用材料，以提高模具使用性能；為適應(yīng)市場(chǎng)多樣化和個(gè)性化，應(yīng)用快速原型制造技術(shù)和快速制模技術(shù)，以快速制造成塑料注塑模，縮短新產(chǎn)品試制周期。這些是未來(lái)5～20年注塑模具生產(chǎn)技術(shù)的總體發(fā)展趨勢(shì)，具體表現(xiàn)在以下幾個(gè)方面：
1.提高大型、精密、復(fù)雜、長(zhǎng)壽命模具的設(shè)計(jì)水平及比例。這是由于塑料模成型的制品日漸大型化、復(fù)雜化和高精度要求以及因高生產(chǎn)率要求而發(fā)展的一模多腔所致。
2.在塑料模設(shè)計(jì)制造中全面推廣應(yīng)用CAD/CAM/CAE技術(shù)。CAD/CAM軟件的智能化程度將逐步提高；塑料制件及模具的3D設(shè)計(jì)與成型過(guò)程的3D分析將在我國(guó)塑料模具工業(yè)中發(fā)揮越來(lái)越重要的作用。
3.推廣應(yīng)用熱流道技術(shù)、氣輔注射成型技術(shù)和高壓注射成型技術(shù)。采用熱流道技術(shù)的模具可提高制件的生產(chǎn)率和質(zhì)量，并能大幅度節(jié)省塑料制件的原材料和節(jié)約能源，所以廣泛應(yīng)用這項(xiàng)技術(shù)是塑料模具的一大變革。制訂熱流道元器件的國(guó)家標(biāo)準(zhǔn)，積極生產(chǎn)價(jià)廉高質(zhì)量的元器件，是發(fā)展熱流道模具的關(guān)鍵。氣體輔助注射成型可在保證產(chǎn)品質(zhì)量的前提下，大幅度降低成本。氣體輔助注射成型比傳統(tǒng)的普通注射工藝有更多的工藝參數(shù)需要確定和控制，而且常用于較復(fù)雜的大型制品，模具設(shè)計(jì)和控制的難度較大，因此，開(kāi)發(fā)氣體輔助成型流動(dòng)分析軟件，顯得十分重要。另一方面為了確保塑料件精度，繼續(xù)研究開(kāi)發(fā)高壓注射成型工藝與模具也非常重要。
4.開(kāi)發(fā)新的成型工藝和快速經(jīng)濟(jì)模具。以適應(yīng)多品種、少批量的生產(chǎn)方式。
5.提高塑料模標(biāo)準(zhǔn)化水平和標(biāo)準(zhǔn)件的使用率。我國(guó)模具標(biāo)準(zhǔn)件水平和模具標(biāo)準(zhǔn)化程度仍較低，與國(guó)外差距甚大，在一定程度上制約著我國(guó)模具工業(yè)的發(fā)展，為提高模具質(zhì)量和降低模具制造成本，模具標(biāo)準(zhǔn)件的應(yīng)用要大力推廣。為此，首先要制訂統(tǒng)一的國(guó)家標(biāo)準(zhǔn)，并嚴(yán)格按標(biāo)準(zhǔn)生產(chǎn)；其次要逐步形成規(guī)模生產(chǎn)，提高商品化程度、提高標(biāo)準(zhǔn)件質(zhì)量、降低成本；再次是要進(jìn)一步增加標(biāo)準(zhǔn)件的規(guī)格品種。
6.應(yīng)用優(yōu)質(zhì)材料和先進(jìn)的表面處理技術(shù)對(duì)于提高模具壽命和質(zhì)量顯得十分必要。
研究?jī)?nèi)容
本課題主要是針對(duì)顯示器后蓋的模具設(shè)計(jì),通過(guò)對(duì)塑件進(jìn)行工藝的分析和比較,最終設(shè)計(jì)出一副注塑模。
該課題從產(chǎn)品結(jié)構(gòu)工藝性，具體模具結(jié)構(gòu)出發(fā)，通過(guò)查閱相關(guān)資料，對(duì)塑件的材料進(jìn)行分析和選用，并且對(duì)塑件的結(jié)構(gòu)，成型工藝進(jìn)行分析和確定。
模具的設(shè)計(jì)需要對(duì)的澆注系統(tǒng)、模具成型部分的結(jié)構(gòu)、頂出系統(tǒng)、冷卻系統(tǒng)、注塑機(jī)的選擇及有關(guān)參數(shù)的校核、都有詳細(xì)的設(shè)計(jì)，同時(shí)并簡(jiǎn)單的編制了模具的加工工藝。其中模具的成型部分的設(shè)計(jì)包括分型面的設(shè)計(jì)，澆注系統(tǒng)的設(shè)計(jì)，成型零件的工作尺寸和外形尺寸的設(shè)計(jì)
模架的設(shè)計(jì)包括模架的組成，相關(guān)零部件的尺寸設(shè)計(jì)，各零部件的用途，以及模擬模架的開(kāi)模，合模。
最后還要有對(duì)成型零件，模架的安裝尺寸，合模力，頂出力，開(kāi)模行程的校核，確保所設(shè)計(jì)的模具符合要求。
擬采取的研究方法、技術(shù)路線(xiàn)、實(shí)驗(yàn)方案及可行性分析
研究方法：通過(guò)閱讀有關(guān)資料，文獻(xiàn)，收集篩選，整理課題研究所需的有關(guān)數(shù)據(jù)，理論依據(jù)，綜合運(yùn)用所學(xué)理論知識(shí)研究論文課題。
方案設(shè)計(jì)：在工藝分析的基礎(chǔ)上，綜合考慮產(chǎn)品的產(chǎn)量和精度要求。所用材料的性能，設(shè)備情況及模具制造情況，確定該工件的工藝規(guī)程和每道工序的注塑模結(jié)構(gòu)形式。
結(jié)構(gòu)設(shè)計(jì)：在方案設(shè)計(jì)的基礎(chǔ)上，進(jìn)一步設(shè)計(jì)模具各部分零件的具體結(jié)構(gòu)尺寸。
1．注塑的工藝分析：分析塑件的結(jié)構(gòu)形狀，尺寸精度，材料是否符合，注塑工藝要求，從而確定注塑的可能性。
2．確定注塑模工藝方案及模具結(jié)構(gòu)形式：工序數(shù)目，工序性質(zhì)，工序順序，工序組合及模具結(jié)構(gòu)形式。
3．注塑模具的設(shè)計(jì)計(jì)算。注塑壓力、注射的塑件的體積，所需原來(lái)的體積，成型時(shí)間確定，確定各主要零件的外形尺寸，計(jì)算模具的閉合高度，確定所用注塑機(jī)。
4． 繪制注塑?？傃b圖
5．通過(guò)對(duì)論文課題的學(xué)習(xí)研究，達(dá)到鞏固，擴(kuò)大，深化已學(xué)理論知識(shí)，提高思考分析解決實(shí)際問(wèn)題等綜合素質(zhì)的目的。
研究計(jì)劃及預(yù)期成果
研究計(jì)劃：實(shí)習(xí)調(diào)研、開(kāi)題準(zhǔn)備、工藝設(shè)計(jì)和擬定、模具結(jié)構(gòu)設(shè)計(jì)、編寫(xiě)設(shè)計(jì)說(shuō)明書(shū)。
2012年11月12日-2012年12月12日：查閱論文相關(guān)參考資料，填寫(xiě)開(kāi)題報(bào)告書(shū)。
2012年12月30日-2013年1月20日：填寫(xiě)畢業(yè)實(shí)習(xí)報(bào)告。
2013年3月11日-2013年3月15日：學(xué)習(xí)模具設(shè)計(jì)以及相關(guān)知識(shí)，考慮設(shè)計(jì)。
2013年3月16日-2013年3月17日：翻譯一篇相關(guān)的英文材料，規(guī)劃整體方案。
2013年3月18日-2013年4月26日：明確塑件設(shè)計(jì)要求及批量，計(jì)算塑件的體積和質(zhì)量，注塑機(jī)的確定；模具成型零件的工作尺寸有關(guān)計(jì)算；圖表配圖設(shè)計(jì)及相關(guān)計(jì)算。
2013年4月22日-2013年4月26日：Pro/E、CAD繪圖。
2013年5月6日-2013年5月24日：畢業(yè)論文撰寫(xiě)和修改工作。
預(yù)期成果：
本課題旨在通過(guò)對(duì)顯示器外殼產(chǎn)品的模具設(shè)計(jì)，系統(tǒng)的了解塑料及塑料的成型基本理論，能夠正確分析成型工藝對(duì)模具的要求。掌握塑件的成型工藝分析方法，能根據(jù)塑件的正確使用和工藝要求進(jìn)行一般的塑件產(chǎn)品設(shè)計(jì)。掌握各類(lèi)塑料模具結(jié)構(gòu)特點(diǎn)，零部件設(shè)計(jì)與計(jì)算，具備獨(dú)立中等復(fù)雜的注射模具的能力。了解塑料模具材料的選用和新技術(shù)發(fā)展等其他知識(shí)。培養(yǎng)分析問(wèn)題以及運(yùn)用所學(xué)知識(shí)解決實(shí)際工程問(wèn)題的綜合能力。
特色或創(chuàng)新之處
手機(jī)充電器是我們?nèi)粘Ｉ钪胁豢扇鄙俚碾娖?，各個(gè)廠(chǎng)商生產(chǎn)的便攜式手機(jī)充電器都不一樣，但是現(xiàn)在越來(lái)越多的消費(fèi)者注重了便攜式手機(jī)充電器的外觀(guān)、實(shí)用性等等。有著新穎外觀(guān)切使用的顯示器是非常受廣大消費(fèi)者的喜愛(ài)，所以各個(gè)生產(chǎn)廠(chǎng)商努力設(shè)計(jì)生產(chǎn)出各種新穎時(shí)尚切安全使用的便攜式手機(jī)充電器吸引消費(fèi)者的眼球。
已具備的條件和尚需解決的問(wèn)題
已具備的條件：
已具備的條件：已學(xué)過(guò)的塑料成型加工工藝、注塑模具的設(shè)計(jì)，并結(jié)合日常生活中所積累的相關(guān)知識(shí)，詢(xún)問(wèn)老師和有工作經(jīng)驗(yàn)者，同時(shí)有部分可參考的同類(lèi)設(shè)計(jì)資料及圖紙。
尚需解決的問(wèn)題：缺乏實(shí)踐經(jīng)驗(yàn)，并需要老師在設(shè)計(jì)過(guò)程中加以指導(dǎo)
尚需解決的問(wèn)題：
理論與實(shí)踐有著不可避免的差距，由于沒(méi)有設(shè)計(jì)經(jīng)驗(yàn)，在實(shí)際設(shè)計(jì)時(shí)，會(huì)遇到許多問(wèn)題。而且平時(shí)沒(méi)把三維軟件學(xué)好，設(shè)計(jì)繪圖時(shí)耗費(fèi)很大精力和時(shí)間。自身設(shè)計(jì)能力需要實(shí)踐經(jīng)驗(yàn)進(jìn)一步加強(qiáng)鞏固。
指導(dǎo)教師意見(jiàn)
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見(jiàn)
教研室主任簽名：
年 月 日
系意見(jiàn)
主管領(lǐng)導(dǎo)簽名：
年 月 日
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 stage.
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. Introduction
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.
4. 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