二板式注塑机前模板结构优化及系列化设计研究
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摘要
注塑机模板作为保证模具可靠锁紧的关键部件,它在工作中的状态直接影响塑料制件的成型质量。论文结合国家科技支撑计划项目课题“精密塑料注射成型装备先进设计平台及关键结构技术研究”,以宁波海天塑机集团HTK2000型二板式注塑机前模板为研究对象,以基于有限元理论的静力学仿真计算为理论基础,系统地对注塑机前模板进行了结构优化分析,在此基础上,对前模板进行了系列化设计。
第1章,介绍了论文的研究背景和研究意义,总结了注塑机模板设计及优化研究现状,阐述了基于有限元理论的性能仿真技术和结构设计优化方法,提出了论文的主要研究内容和总体结构框架。
第2章,提出了二板式注塑机前模板受力状况的基本假设,运用有限元仿真分析软件ANSYS对HTK2000型二板式注塑机前模板进行了FEA仿真分析；建立了前模板结构拓扑优化数学模型,运用ANSYS对前模板进行了拓扑优化分析；根据前模板拓扑优化分析结果,设计了三种改进的拓扑结构；并通过仿真进行了分析验证。
第3章,建立了二板式注塑机前模板结构参数的双目标优化问题模型；在iSIGHT平台上集成了ANSYS软件系统,以FEA方法集成遗传算法NCGA对注塑机前模板结构参数的双目标优化问题进行求解；得到了前模板参数优化的Pareto最优解集,并选取两种典型优化方案进行了分析验证。
第4章,研究了产品系列化设计的常用方法,提出了二板式注塑机前模板的系列化设计准则；基于相似理论与量纲分析法对注塑机前模板的规格进行系列化设计；基于sPareto最优解集对注塑机前模板的性能进行系列化设计。
第5章,通过实验方法对注塑机前模板进行应力测试,以验证论文所采用的前模板静力学FEA方法的正确性。
第6章,总结了本课题的研究成果,分析概述了二板式注塑机前模板分析优化中仍然存在的问题,并展望了今后的研究方向。
As the key components of an injection molding machine, mold platens play an important role in the injection process of fixing the mold and insuring the clamping, which has much influence on the quality of plastic products. With the support of "National Key Technology R&D Program:Research on Advanced Design Platform and Key Structure Technology of Precision Injection Molding Equipment", and based on FEA Theory, the dissertation has done a systematic research on the structural optimization and serial design of the mold platens.
In Chapter 1, the development and the situation of injection molding machines and their clamping units are described. The research on simulation and optimization of mold platens are reviewed. The simulation method, the design and optimization technology based on FEA is briefly studied. The research content and architecture of the dissertation is introduced.
In Chapter 2, based on FEA Theory, the stress and displacement distribution of the mold platen under the load condition is attained by applying simulation analysis using ANSYS. The topology optimization model of the mold platen is built, and the topology optimization is performed in APDL. By modifying the output results of the topology optimization calculation, three different improved topology structures of the mold platen are designed and analyzed.
In Chapter 3, the bi-objective optimization model of the mold platen is established, with minimizing its volume and diminish the deformation being the two objectives. An algorithm of integrating NCGA with FEA is proposed to solve the bi-objective optimization problem of the mold platen. By integrating iSIGHT with ANSYS, the algorithm is realized and a Pareto Frontier of the mold platen optimization problem is generated. Two typical optimization cases on the Pareto Frontier are analyzed and discussed.
In Chapter 4, concepts and methods of Serial Design are described. The standard of the mold platen serial design is proposed. Based on the Similarity Theory and the Dimensional Analysis Method, the size serial design of mold platens is carried on. Based on the sPareto Frontier Method and the Fuzzy Set Theory, the property serial design of mold platens is given.
In Chapter 5, a stress-measurement test is arranged to contrast the results with that attained by the FEA Method and to verify the methods of the dissertation.
In Chapter 6, the achievements of this dissertation are summarized and the ways for further research are pointed out.
第1章,介绍了论文的研究背景和研究意义,总结了注塑机模板设计及优化研究现状,阐述了基于有限元理论的性能仿真技术和结构设计优化方法,提出了论文的主要研究内容和总体结构框架。
第2章,提出了二板式注塑机前模板受力状况的基本假设,运用有限元仿真分析软件ANSYS对HTK2000型二板式注塑机前模板进行了FEA仿真分析；建立了前模板结构拓扑优化数学模型,运用ANSYS对前模板进行了拓扑优化分析；根据前模板拓扑优化分析结果,设计了三种改进的拓扑结构；并通过仿真进行了分析验证。
第3章,建立了二板式注塑机前模板结构参数的双目标优化问题模型；在iSIGHT平台上集成了ANSYS软件系统,以FEA方法集成遗传算法NCGA对注塑机前模板结构参数的双目标优化问题进行求解；得到了前模板参数优化的Pareto最优解集,并选取两种典型优化方案进行了分析验证。
第4章,研究了产品系列化设计的常用方法,提出了二板式注塑机前模板的系列化设计准则；基于相似理论与量纲分析法对注塑机前模板的规格进行系列化设计；基于sPareto最优解集对注塑机前模板的性能进行系列化设计。
第5章,通过实验方法对注塑机前模板进行应力测试,以验证论文所采用的前模板静力学FEA方法的正确性。
第6章,总结了本课题的研究成果,分析概述了二板式注塑机前模板分析优化中仍然存在的问题,并展望了今后的研究方向。
As the key components of an injection molding machine, mold platens play an important role in the injection process of fixing the mold and insuring the clamping, which has much influence on the quality of plastic products. With the support of "National Key Technology R&D Program:Research on Advanced Design Platform and Key Structure Technology of Precision Injection Molding Equipment", and based on FEA Theory, the dissertation has done a systematic research on the structural optimization and serial design of the mold platens.
In Chapter 1, the development and the situation of injection molding machines and their clamping units are described. The research on simulation and optimization of mold platens are reviewed. The simulation method, the design and optimization technology based on FEA is briefly studied. The research content and architecture of the dissertation is introduced.
In Chapter 2, based on FEA Theory, the stress and displacement distribution of the mold platen under the load condition is attained by applying simulation analysis using ANSYS. The topology optimization model of the mold platen is built, and the topology optimization is performed in APDL. By modifying the output results of the topology optimization calculation, three different improved topology structures of the mold platen are designed and analyzed.
In Chapter 3, the bi-objective optimization model of the mold platen is established, with minimizing its volume and diminish the deformation being the two objectives. An algorithm of integrating NCGA with FEA is proposed to solve the bi-objective optimization problem of the mold platen. By integrating iSIGHT with ANSYS, the algorithm is realized and a Pareto Frontier of the mold platen optimization problem is generated. Two typical optimization cases on the Pareto Frontier are analyzed and discussed.
In Chapter 4, concepts and methods of Serial Design are described. The standard of the mold platen serial design is proposed. Based on the Similarity Theory and the Dimensional Analysis Method, the size serial design of mold platens is carried on. Based on the sPareto Frontier Method and the Fuzzy Set Theory, the property serial design of mold platens is given.
In Chapter 5, a stress-measurement test is arranged to contrast the results with that attained by the FEA Method and to verify the methods of the dissertation.
In Chapter 6, the achievements of this dissertation are summarized and the ways for further research are pointed out.
引文
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[Hiro 2003] Hiro Hiroyasu, Haiyan Miao, Tomo Hiroyasu, Mitunori Miki, Jiro Kamiura and Sinya Watanabe. Genetic Algorithms Optimization of Diesel Engine Emissions and Fuel Efficiency with Air Swirl, EGR, Injection Timing and Multiple Injections[J]. Society of Automotive Engineer,2003,112(4):1353-1364.
[Mattson 2004] Mattson CA, Mullur AA, Messac A. Smart Pareto Filter Obtaining a Minimal Representation of Multiobjective Design Space[J]. Engineering Optimization,2004,36(6):721-740
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[Sun 2004]Shu-Huang Sun. Optimum topology design for the stationary platen of a plastic injection machine[J]. Computers in Industry,2004,55:147-158.
[Tong 2006] Xiao-yan Tong, Guo-biao Cai, Yun-tao Zheng, Jie Fang. Optimization of system parameters for gas-generator engines[J]. Acta Astronautica,2006(59):246-252.
[Yin 2008]Yin Bo, Xu Dian, An Yi-ran, Chen Yao-song. Aerodynamic Optimization of 3D Wing Based on iSIGHT[J]. Applied Mathematics and Mechanics,2008,29(5):603-610.
[Zhou 1991] Zhou M.,Rozvany G.I.N.. The COC algorithm, part Ⅱ:Topological, geometry and generalized shape optimizatioin[J]. Computer Methods in Applied Mechanics and Engineering,1991,89(1-3):309-336.
[Zhou 1993] Zhou M.,Rozvany G.I.N.. DCOC:an optimality criteria method for large systems Part Ⅱ:algoritm[J]. Structural and Multidisciplinary Optimization,1993,6(4):250-262.
[包陈2009]包陈,王呼佳等ANSYS工程分析进阶实例(修订版).北京：中国水利水电出版社,2009.10
[薄瑞峰2006]薄瑞峰,李瑞琴.基于Pareto最优的概念结构方案多目标决策方法[J].西安交通大学学报,2006,40(9)：1114-1116
[陈兵2006]陈兵,徐旭,蔡国飙.基于遗传算法和空间推进方法的高超声速进气道优化设计研究[J].宇航学报,2006,27(5)：1010-1015,1101.
[陈敏2003]陈敏.机械产品系列化设计方法研究.四川轻化工学院学报[J],2003,16(2)：66-69.
[戴晓明2004]戴晓明,遗传算法的若干研究与应用[D].上海交通大学博士论文,2004.
[丁永红1994]丁永红,徐敬一.注塑机模板的实用计算模型[J].塑料科技,1994(2)：42-43.
[丁志浩2004]丁志浩.产品系列化设计——电动工具的系列化设计[D].南京理工大学硕士学位论文,2004.
[董威2005]董威.基于Pareto遗传算法的起重机主梁优化设计.大连理工大学硕士学位论文,2005.
[樊冰峰1997]樊冰峰.注射机合模机构主要构件的有限元分析及结构优化[D].北京化工学院学位论文,1997.
[高卫中2003]高卫中.面向RE的产品系列化设计方法研究及应用[D].山东理工大学硕士学位论文,2003.
[高瑜2006]高瑜.注塑机合模装置主要构件的有限元分析及优化设计[D].太原理工大学硕士学位论文,2006.
[耿建光2002]耿建光.工程系统过程集成和设计优化——iSIGHT中的过程集成与设计自动化.军民两用技术与产品,2002.11：45-48.
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