快速热循环注塑模具及工艺关键技术研究
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摘要
注塑成型是塑料加工中重要的成型方法之一,在家用电器、汽车、电子、航空航天、日用品等国民经济的各个领域都有广泛的应用。但由于注塑成型过程的复杂性,成型产品表面易产生熔接痕、流痕、浮纤等各种缺陷,既影响产品的外观质量,又减弱了产品的力学性能,给产品的正常使用带来隐患。为提高成型产品表面质量,目前生产中主要通过塑料喷涂技术使其表面质量得到提高,但喷涂是对塑料产品的二次加工,既浪费生产原料和能源,增加塑料制品的生产成本,又造成了严重的环境污染,并危害操作人员的身体健康。如何减少注塑产品的成型缺陷,全面提高产品质量,取消或减少产品表面喷涂量,是注塑成型加工及模具设计与制造领域的重要研究课题。近年来,为满足人们对塑料产品的外观、性能、成本以及环保等方面的要求,快速热循环注塑成型(Rapid Heat Cycle Molding, RHCM)技术应运而生。利用该技术能获得表面无熔接痕、无纤维暴露等表面缺陷的高光泽度塑料产品,显著提升产品的质量。使用该技术既可以取消污染严重且成本昂贵的喷涂工艺,直接降低塑料产品的生产成本,又满足了社会的环保要求,使注塑成型实现真正的绿色化生产。因此,该技术市场竞争力强大,应用前景十分广阔。
本文根据快速热循环注塑成型工艺原理,研究了该新型注塑工艺的系统组成,探讨了在实际生产中建立稳定生产线的原则和要求。通过与常规注塑工艺进行对比,研究了RHCM产品及其模具结构与常规注塑产品及其模具结构的异同,建立了RHCM产品和模具设计及模具加工的原则与方法。结合生产实际,讨论了模具温度对RHCM成型产品质量的影响,研究了注塑周期内RHCM模具的温度变化过程。为提高RHCM模具的使用寿命,研究了模具工作过程中的应力应变状态,提出了能有效提高模具使用寿命的方法。针对RHCM模具加热管道优化设计理论缺乏,产品质量不稳定的现状,建立了模具加热管道的优化设计模型,实现了模具结构的优化,提高了产品质量并保证了生产效率。从RHCM注塑成型工艺特点出发,开发了电热式模具温度控制系统,建立了快速热循环注塑工艺实验线,利用该实验线研究了纤维增强聚合物在RHCM注塑工艺下的性能特点,为该工艺的推广应用提供了技术指导。
RHCM注塑工艺过程与常规注塑工艺过程不同,生产中增加了模具的快速加热与快速冷却两个阶段。在模具加热阶段,需将模具型腔成型面温度升高到塑料的热变形温度以上,以保证塑料熔体具有良好的充模状态；而在冷却阶段,需要使熔体温度迅速降低到塑料的顶出温度以下,减少注塑成型周期。根据该技术特点,通过与常规注塑技术进行比较,分析了RHCM注塑工艺对其产品和模具结构设计的独特要求,提出了RHCM产品和模具关键部位的设计准则,为生产中产品和模具设计提供了重要的依据。从模具材料、磨具磨料和抛光方法等方面对模具的抛光技术进行研究,实现了RHCM模具型腔表面的精密抛光。针对RHCM产品产生翘曲变形和表面缩痕的现象,分析了其产生变形和表面缩痕的机理,研究获得了注塑工艺参数对上述两种缺陷的影响程度,保证了注塑生产的顺利进行。根据以上研究,分析了利用蒸汽加热和电加热两种不同模具加热方式下的快速热循环注塑工艺的系统组成,详细研究了两种方式对蒸汽源或加热棒、冷却水源、模温控制系统、工艺监控系统和模具结构的要求,并探讨了两种方式在实际生产实施中的关键技术。
模具温度对成型塑料产品的质量具有至关重要的作用。结合实际RHCM注塑工艺的生产流程,详细研究了模具温度对RHCM成型产品质量的影响。根据传热学的基本理论,研究了RHCM注塑周期内模具与加热系统、塑件、冷却系统和周围环境的热量传递过程,建立了RHCM模具加热和冷却阶段的温度场分析模型,研究获得了模具型腔板在注塑过程中温度瞬时变化规律,并讨论了加热管道间距、管道直径和数目、管道到型腔壁面距离等因素对蒸汽加热RHCM模具型腔板的加热效率和其温度分布的影响规律和程度。利用生死单元技术,模拟了电加热RHCM注塑周期内模具型腔板温度变化的全过程,对有效控制模具温度,提高模具设计精度和工艺调整的准确性提供重要依据。
生产过程中,由于模具温度的升高及模板之间的相互约束,模具内部不可避免地会产生热变形和热应力,同时,工作过程中,模具还要承受合模压力、注射压力等各种机械应力的影响,当模具内部产生的应力较大时,模具将会产生过量变形,从而影响产品的精度、生产成本及其表面质量。随着生产的连续进行,模具的变形将会发生周期性的变化,易造成模具表面产生疲劳裂纹,使模具失效。针对RHCM模具使用寿命较低的问题,根据型腔板在实际模具中的约束状态,建立了模具型腔板的应力分析模型,研究了工作过程中模具型腔板的应力分布及其变形趋势,并讨论了RHCM模具的热变形和热疲劳机理及其影响因素,提出了一种带有“部分冷间隙”的快速热循环注塑模具新结构,有效控制了热应力。通过对不同“冷间隙”下模具型腔板的使用寿命进行评估,给出了实际模具设计及其装配的合理化建议。
RHCM技术实施的关键是在注塑周期中,能够使模具型腔快速加热和冷却到预定的温度,若加热后,模具型腔表面温度较低或温度分布不均,既会影响制品的表面质量和生产效率,又会导致生产的制品产生翘曲变形现象。为获得高品质的RHCM产品并保证生产效率,特别要求加热时RHCM模具型腔成型面能在尽量短的时间内达到工艺要求的温度,并具有良好的温度分布均匀性。通常情况下,RHCM模具型腔板内部存在较多的加热管道,加热管道的布局对模具型腔板的加热效率和其成型面温度的均匀性具有十分重要的作用,合理的加热管道设计既能保证产品的生产效率又能保证成型产品的质量。针对目前RHCM模具加热管道设计较为盲目的现状,本文提出了将有限元模拟技术和现代智能算法有效集成,以此实现RHCM模具加热管道优化设计的策略。以大型液晶平板电视机面板的蒸汽加热RHCM注塑模具为例,研究了影响其模具型腔成型面温度分布的主要因素。对平面型电视机面板结构,以模具型腔成型面的温度分布均匀性为目标函数,以加热管道之间的间距为设计变量,建立了模具内部加热管道布局的优化设计模型,利用响应面近似模型和遗传算法,优化了平面型电视机面板RHCM模具加热管道的布局。对弧面型电视机结构,以加热管道的中心坐标位置作为设计变量,以模具的加热效率和型腔成型面的温度分布均匀性作为目标函数,建立了其内部加热管道布局的多目标优化设计模型。通过集成CAD模型建立、有限元计算和基于Pareto的遗传算法,实现了弧面型液晶电视机面板的RHCM模具加热管道布局的优化设计。
纤维增强注塑产品由于比普通注塑产品具有更优良的机械性能和热性能,其使用价值越来越受到人们的重视。快速热循环注塑工艺能够消除纤维增强产品表面的浮纤现象,提高产品的表面质量,因此能扩大纤维增强注塑产品的使用范围。为研究纤维增强注塑产品在RHCM注塑工艺下的性能特点,本文首先利用所建立的多目标优化设计体系对所设计的电加热RHCM模具的加热棒布局进行了优化。然后,根据电加热方式RHCM注塑工艺原理,开发了与之匹配的模温控制系统,建立了快速热循环注塑工艺实验线。以纤维增强ABS为例,通过对注塑得到的标准试样进行力学性能测试,研究了纤维增强聚合物在RHCM注塑工艺下的冲击和拉伸强度随模具温度的变化关系。同时,揭示了纤维增强聚合物熔接痕形成机理及其特点,研究了其表面熔接痕形貌随成型时模具温度变化的规律。通过对纤维增强聚合物表面浮纤现象的分析,研究了注塑制品表面质量及其粗糙度与模具温度的对应关系。
快速热循环注塑技术是近年来发展起来的一种新型技术,已成为聚合物加工领域的重要成型方法,研究快速热循环注塑工艺的成型机理,推广快速热循环注塑工艺的使用范围是当前该工艺面临的重要的问题。本文针对该工艺及其模具技术所做的系列研究,对提高快速热循环注塑产品质量和生产效率具有较大的工程应用价值,针对该工艺所建立的实验线以及研究获得的纤维增强聚合物在RHCM注塑工艺下的性能特点对于扩大该工艺的使用范围具有重要的指导作用。
Injection molding technology is an important molding method of plastics, now it has been widely used in almost all fields of the national economy, such as household appliances, automobiles, electronics, aerospace, commodities and so on. However, as the complexity of the injection molding process, there are always many problems on the parts produced by conventional injection method, such as weld mark, flow mark, fiber exposure and so on. As a result, the appearance of the parts is seriously affected. The mechanical properties are decreased as well, leading to a hidden danger for the application of the parts. Therefore, spraying and coating have to be employed after injection molding process so as to improve the part's performance or appearance. These subsequent re-processing operations increase the part manufacturing processes, waste raw material and energy. Especially, they also increase the production cost and cause environment pollution inevitably. How to reduce the defects of the injected polymer parts, improving the product quality and canceling the spraying or coating process is one of important research subjects of the injection molding technology. In order to meet the requirements of the customers on the appearance, performance cost and environment of the plastic parts, rapid heat cycle molding (RHCM) technology is developed in recent years. Using this technology, high-quality plastic parts with excellent appearance and no weld marks can be produced and fiber exposure on the part surface can be avoided as well. Especially, the subsequent processing processes, such as spraying and coating which seriously pollute the environment can be eliminated. Thus, the whole production process flowchart is shortened. The energy, material and production cost are decreased. RHCM is a kind of potential green manufacturing technology and has a broad application prospect in plastic injection molding industry.
Based on the principles of the rapid heat cycle molding technology, firstly, the compositions of this new injection method are researched and the requirements of the production line established in the enterprise are discussed. Compared with the conventional injection molding process, the differences between the RHCM injection process and the conventional one are studied. The design rules of the products and molds for RHCM technology are established and the processing method of the mold is also discussed. Secondly, considering the working conditions of the mold in practical production process, the temperature and stress field during the injection process are studied. The service lifetime of the mold is estimated. Thirdly, in order to improving the production efficiency and the part quality, optimization models for different layouts of heating channels in the mold are proposed, the structures of the mold are then optimized according to the models. According to the characteristics of the RHCM technology, a mold temperature control equipment and a cooling system for the electrical experiment mold are developed. By using them, the mechanical properties and appearance of the glass-fiber reinforced parts which are injected by RHCM injection method are researched.
Different from the conventional injection molding process, the mold must be rapidly heated and cooled down to designated temperatures in RHCM injection molding cycle. In heating stage, the cavity surface of the mold should be heated up to the heat distortion temperature of polymer for ensuring good filling state of the plastic melt. In cooling stage, the mold and the polymer melt must be cooled down to ejected temperature of the polymer part rapidly in order to reduce the molding cycle. According to this characteristic, the structures of the products and mold for the technology are analyzed, and the principles that are needed to follow in structure design of RHCM products and the mold are presented. By researching on the mold material, machine method and polishing techniques, the precision machining of the mold cavity plate is achieved. Aiming at reducing the warpage and sink marks that are usually appeared on the RHCM injected parts, the mechanisms of the two defects are analyzed. The influence of the injection parameters on the warpage and the sink marks are also studied. Based on the researches above, the Steam-assisted Rapid Heat Cycle Molding (SRHCM) and electrical Rapid Heat Cycle Molding (ERHCM) are discussed respectively. The compositions of the two systems in which the molds are heated in different ways are analyzed. The requirements of both the two systems for the vapor source or heating rods, cooling water, mold temperature control equipments, process monitoring supervisory system and mold structures are proposed, and the key technologies for the application of the two different systems are studied.
As the temperature distribution of the mold has significant effect on the part quality, the heat transfer process among the mold, heating system, plastic part, cooling system and ambience are all analyzed according to the heat transfer theory. The temperature field models for both the SRHCM mold and the ERHCM mold are established based on the above analysis and the finite element simulation theory. The instantaneous temperature of the cavity plate are obtained through the finite element simulation and the factors that influence the heating efficiency and temperature distribution on the mold cavity, including the spaces between channels, the diameters and numbers of channels and the distances from the cavity surface to the channels are all discussed. By using death-to-birth element technique, the temperature of the ERHCM mold during the whole injection molding cycle are obtained which is of great help to grasp the mold temperature and set the parameters values of the injection process.
During the practical injection process, as the rising of the mold temperature and the restriction between the mold plates, the thermal distortion and stress are brought inevitably. Meantime, the mold also suffers great clamping pressure, injection pressure and other mechanical stress during the injection cycle. As a result, a much larger deformation of the mold is induced. The precision, cost and the surface quality of the part are affected. With the continuous production, fatigue cracks are much easier to generate on the RHCM mold due to the great stresses, and the mold lifetime becomes shorter. Therefore, the stress and strain analysis model for the mold is established according to the restriction state of the mold plates. The stress and strain distributions of the mold and the factors that affect the mold deformation and the lifetime are discussed. A new fixing mode called "partial cold gap" fixing mode for the RHCM mold is proposed. With this method, the thermal expansion of the mold is compensated effectively which is of much help to decrease the stress and improve lifetime of the mold. At last, the lifetimes of the mold with different "cold gap" are estimated in this section, and the recommendations for the mold assembly are proposed.
During RHCM process, the production efficiency and the part's quality are seriously affected by the temperature and its distribution uniformity on the mold cavity surface. Warpage and weld mark are easy to be formed if the temperature is low or distributed unevenly on the mold cavity surface after heating and cooling processes. Therefore, there is a strict requirement on the temperature of mold cavity surface after heating process in order to obtain high-quality plastic parts and ensure the production efficiency. Commonly, there are much more heating channels in RHCM mold, the layout of them has a great effect on the heating efficiency and the temperature distribution of the mold. Optimization modes integrated the finite element technique with the artificial intelligence algorithm together are proposed to optimize the channels layout. For the purposes of achieving a uniform temperature distribution on the cavity surface of the mold, the distances between the neighbor heating channels were considered as the main design variables for plane surface LCD TV model. An objective function to optimize the temperature distribution uniformity is proposed. By using a quadric response surface equation genetic algorithm, the layout of the channels is optimized. For arc surface LCD TV model, the center coordinates of the heating channels are considered as the main design variables. Multi-objective functions for optimizing the temperature distribution uniformity and heating efficiency are established. The layout of the heating channels is optimized by integrating the establishment of CAD model, the finite element method and Pareto-based genetic algorithm.
As the fiber reinforced plastic products have much more excellent mechanical and thermal properties, they have occupied an important position in the injection field. By using the RHCM technology, the fiber exposure on the fiber reinforced products surface can be avoided and the surface appearance can be greatly improved, so the fiber-reinforced products can be used more widely. For studying the performances of the fiber reinforced products injected by RHCM technology, the layout of heating rods for the designed experiment mold is optimized and a mold temperature controlling system for ERHCM mold is developed. A production line for experiment is established in our laboratory. The fiber reinforced ABS is used as an example to study the relationship between the mechanical properties and the mold temperature. At the same time, the formation of the weldline on the fiber reinforced product is described. The relationship between the surface quality and roughness of the part and the mold temperature are also researched.
Although RHCM technology is a new injection method, it has become a very important molding way of the polymer. Studying the molding mechanism of the RHCM technology, promoting the application of the new injection method is one of important issues for the technology. Researches on the key technologies of the related products and the mold are of great industrial interest for its practical application. The established production line for experiment based on the RHCM theory is of much help to research the mechanism of the technology and also has a very important effect to promote the application of the technology.
本文根据快速热循环注塑成型工艺原理,研究了该新型注塑工艺的系统组成,探讨了在实际生产中建立稳定生产线的原则和要求。通过与常规注塑工艺进行对比,研究了RHCM产品及其模具结构与常规注塑产品及其模具结构的异同,建立了RHCM产品和模具设计及模具加工的原则与方法。结合生产实际,讨论了模具温度对RHCM成型产品质量的影响,研究了注塑周期内RHCM模具的温度变化过程。为提高RHCM模具的使用寿命,研究了模具工作过程中的应力应变状态,提出了能有效提高模具使用寿命的方法。针对RHCM模具加热管道优化设计理论缺乏,产品质量不稳定的现状,建立了模具加热管道的优化设计模型,实现了模具结构的优化,提高了产品质量并保证了生产效率。从RHCM注塑成型工艺特点出发,开发了电热式模具温度控制系统,建立了快速热循环注塑工艺实验线,利用该实验线研究了纤维增强聚合物在RHCM注塑工艺下的性能特点,为该工艺的推广应用提供了技术指导。
RHCM注塑工艺过程与常规注塑工艺过程不同,生产中增加了模具的快速加热与快速冷却两个阶段。在模具加热阶段,需将模具型腔成型面温度升高到塑料的热变形温度以上,以保证塑料熔体具有良好的充模状态；而在冷却阶段,需要使熔体温度迅速降低到塑料的顶出温度以下,减少注塑成型周期。根据该技术特点,通过与常规注塑技术进行比较,分析了RHCM注塑工艺对其产品和模具结构设计的独特要求,提出了RHCM产品和模具关键部位的设计准则,为生产中产品和模具设计提供了重要的依据。从模具材料、磨具磨料和抛光方法等方面对模具的抛光技术进行研究,实现了RHCM模具型腔表面的精密抛光。针对RHCM产品产生翘曲变形和表面缩痕的现象,分析了其产生变形和表面缩痕的机理,研究获得了注塑工艺参数对上述两种缺陷的影响程度,保证了注塑生产的顺利进行。根据以上研究,分析了利用蒸汽加热和电加热两种不同模具加热方式下的快速热循环注塑工艺的系统组成,详细研究了两种方式对蒸汽源或加热棒、冷却水源、模温控制系统、工艺监控系统和模具结构的要求,并探讨了两种方式在实际生产实施中的关键技术。
模具温度对成型塑料产品的质量具有至关重要的作用。结合实际RHCM注塑工艺的生产流程,详细研究了模具温度对RHCM成型产品质量的影响。根据传热学的基本理论,研究了RHCM注塑周期内模具与加热系统、塑件、冷却系统和周围环境的热量传递过程,建立了RHCM模具加热和冷却阶段的温度场分析模型,研究获得了模具型腔板在注塑过程中温度瞬时变化规律,并讨论了加热管道间距、管道直径和数目、管道到型腔壁面距离等因素对蒸汽加热RHCM模具型腔板的加热效率和其温度分布的影响规律和程度。利用生死单元技术,模拟了电加热RHCM注塑周期内模具型腔板温度变化的全过程,对有效控制模具温度,提高模具设计精度和工艺调整的准确性提供重要依据。
生产过程中,由于模具温度的升高及模板之间的相互约束,模具内部不可避免地会产生热变形和热应力,同时,工作过程中,模具还要承受合模压力、注射压力等各种机械应力的影响,当模具内部产生的应力较大时,模具将会产生过量变形,从而影响产品的精度、生产成本及其表面质量。随着生产的连续进行,模具的变形将会发生周期性的变化,易造成模具表面产生疲劳裂纹,使模具失效。针对RHCM模具使用寿命较低的问题,根据型腔板在实际模具中的约束状态,建立了模具型腔板的应力分析模型,研究了工作过程中模具型腔板的应力分布及其变形趋势,并讨论了RHCM模具的热变形和热疲劳机理及其影响因素,提出了一种带有“部分冷间隙”的快速热循环注塑模具新结构,有效控制了热应力。通过对不同“冷间隙”下模具型腔板的使用寿命进行评估,给出了实际模具设计及其装配的合理化建议。
RHCM技术实施的关键是在注塑周期中,能够使模具型腔快速加热和冷却到预定的温度,若加热后,模具型腔表面温度较低或温度分布不均,既会影响制品的表面质量和生产效率,又会导致生产的制品产生翘曲变形现象。为获得高品质的RHCM产品并保证生产效率,特别要求加热时RHCM模具型腔成型面能在尽量短的时间内达到工艺要求的温度,并具有良好的温度分布均匀性。通常情况下,RHCM模具型腔板内部存在较多的加热管道,加热管道的布局对模具型腔板的加热效率和其成型面温度的均匀性具有十分重要的作用,合理的加热管道设计既能保证产品的生产效率又能保证成型产品的质量。针对目前RHCM模具加热管道设计较为盲目的现状,本文提出了将有限元模拟技术和现代智能算法有效集成,以此实现RHCM模具加热管道优化设计的策略。以大型液晶平板电视机面板的蒸汽加热RHCM注塑模具为例,研究了影响其模具型腔成型面温度分布的主要因素。对平面型电视机面板结构,以模具型腔成型面的温度分布均匀性为目标函数,以加热管道之间的间距为设计变量,建立了模具内部加热管道布局的优化设计模型,利用响应面近似模型和遗传算法,优化了平面型电视机面板RHCM模具加热管道的布局。对弧面型电视机结构,以加热管道的中心坐标位置作为设计变量,以模具的加热效率和型腔成型面的温度分布均匀性作为目标函数,建立了其内部加热管道布局的多目标优化设计模型。通过集成CAD模型建立、有限元计算和基于Pareto的遗传算法,实现了弧面型液晶电视机面板的RHCM模具加热管道布局的优化设计。
纤维增强注塑产品由于比普通注塑产品具有更优良的机械性能和热性能,其使用价值越来越受到人们的重视。快速热循环注塑工艺能够消除纤维增强产品表面的浮纤现象,提高产品的表面质量,因此能扩大纤维增强注塑产品的使用范围。为研究纤维增强注塑产品在RHCM注塑工艺下的性能特点,本文首先利用所建立的多目标优化设计体系对所设计的电加热RHCM模具的加热棒布局进行了优化。然后,根据电加热方式RHCM注塑工艺原理,开发了与之匹配的模温控制系统,建立了快速热循环注塑工艺实验线。以纤维增强ABS为例,通过对注塑得到的标准试样进行力学性能测试,研究了纤维增强聚合物在RHCM注塑工艺下的冲击和拉伸强度随模具温度的变化关系。同时,揭示了纤维增强聚合物熔接痕形成机理及其特点,研究了其表面熔接痕形貌随成型时模具温度变化的规律。通过对纤维增强聚合物表面浮纤现象的分析,研究了注塑制品表面质量及其粗糙度与模具温度的对应关系。
快速热循环注塑技术是近年来发展起来的一种新型技术,已成为聚合物加工领域的重要成型方法,研究快速热循环注塑工艺的成型机理,推广快速热循环注塑工艺的使用范围是当前该工艺面临的重要的问题。本文针对该工艺及其模具技术所做的系列研究,对提高快速热循环注塑产品质量和生产效率具有较大的工程应用价值,针对该工艺所建立的实验线以及研究获得的纤维增强聚合物在RHCM注塑工艺下的性能特点对于扩大该工艺的使用范围具有重要的指导作用。
Injection molding technology is an important molding method of plastics, now it has been widely used in almost all fields of the national economy, such as household appliances, automobiles, electronics, aerospace, commodities and so on. However, as the complexity of the injection molding process, there are always many problems on the parts produced by conventional injection method, such as weld mark, flow mark, fiber exposure and so on. As a result, the appearance of the parts is seriously affected. The mechanical properties are decreased as well, leading to a hidden danger for the application of the parts. Therefore, spraying and coating have to be employed after injection molding process so as to improve the part's performance or appearance. These subsequent re-processing operations increase the part manufacturing processes, waste raw material and energy. Especially, they also increase the production cost and cause environment pollution inevitably. How to reduce the defects of the injected polymer parts, improving the product quality and canceling the spraying or coating process is one of important research subjects of the injection molding technology. In order to meet the requirements of the customers on the appearance, performance cost and environment of the plastic parts, rapid heat cycle molding (RHCM) technology is developed in recent years. Using this technology, high-quality plastic parts with excellent appearance and no weld marks can be produced and fiber exposure on the part surface can be avoided as well. Especially, the subsequent processing processes, such as spraying and coating which seriously pollute the environment can be eliminated. Thus, the whole production process flowchart is shortened. The energy, material and production cost are decreased. RHCM is a kind of potential green manufacturing technology and has a broad application prospect in plastic injection molding industry.
Based on the principles of the rapid heat cycle molding technology, firstly, the compositions of this new injection method are researched and the requirements of the production line established in the enterprise are discussed. Compared with the conventional injection molding process, the differences between the RHCM injection process and the conventional one are studied. The design rules of the products and molds for RHCM technology are established and the processing method of the mold is also discussed. Secondly, considering the working conditions of the mold in practical production process, the temperature and stress field during the injection process are studied. The service lifetime of the mold is estimated. Thirdly, in order to improving the production efficiency and the part quality, optimization models for different layouts of heating channels in the mold are proposed, the structures of the mold are then optimized according to the models. According to the characteristics of the RHCM technology, a mold temperature control equipment and a cooling system for the electrical experiment mold are developed. By using them, the mechanical properties and appearance of the glass-fiber reinforced parts which are injected by RHCM injection method are researched.
Different from the conventional injection molding process, the mold must be rapidly heated and cooled down to designated temperatures in RHCM injection molding cycle. In heating stage, the cavity surface of the mold should be heated up to the heat distortion temperature of polymer for ensuring good filling state of the plastic melt. In cooling stage, the mold and the polymer melt must be cooled down to ejected temperature of the polymer part rapidly in order to reduce the molding cycle. According to this characteristic, the structures of the products and mold for the technology are analyzed, and the principles that are needed to follow in structure design of RHCM products and the mold are presented. By researching on the mold material, machine method and polishing techniques, the precision machining of the mold cavity plate is achieved. Aiming at reducing the warpage and sink marks that are usually appeared on the RHCM injected parts, the mechanisms of the two defects are analyzed. The influence of the injection parameters on the warpage and the sink marks are also studied. Based on the researches above, the Steam-assisted Rapid Heat Cycle Molding (SRHCM) and electrical Rapid Heat Cycle Molding (ERHCM) are discussed respectively. The compositions of the two systems in which the molds are heated in different ways are analyzed. The requirements of both the two systems for the vapor source or heating rods, cooling water, mold temperature control equipments, process monitoring supervisory system and mold structures are proposed, and the key technologies for the application of the two different systems are studied.
As the temperature distribution of the mold has significant effect on the part quality, the heat transfer process among the mold, heating system, plastic part, cooling system and ambience are all analyzed according to the heat transfer theory. The temperature field models for both the SRHCM mold and the ERHCM mold are established based on the above analysis and the finite element simulation theory. The instantaneous temperature of the cavity plate are obtained through the finite element simulation and the factors that influence the heating efficiency and temperature distribution on the mold cavity, including the spaces between channels, the diameters and numbers of channels and the distances from the cavity surface to the channels are all discussed. By using death-to-birth element technique, the temperature of the ERHCM mold during the whole injection molding cycle are obtained which is of great help to grasp the mold temperature and set the parameters values of the injection process.
During the practical injection process, as the rising of the mold temperature and the restriction between the mold plates, the thermal distortion and stress are brought inevitably. Meantime, the mold also suffers great clamping pressure, injection pressure and other mechanical stress during the injection cycle. As a result, a much larger deformation of the mold is induced. The precision, cost and the surface quality of the part are affected. With the continuous production, fatigue cracks are much easier to generate on the RHCM mold due to the great stresses, and the mold lifetime becomes shorter. Therefore, the stress and strain analysis model for the mold is established according to the restriction state of the mold plates. The stress and strain distributions of the mold and the factors that affect the mold deformation and the lifetime are discussed. A new fixing mode called "partial cold gap" fixing mode for the RHCM mold is proposed. With this method, the thermal expansion of the mold is compensated effectively which is of much help to decrease the stress and improve lifetime of the mold. At last, the lifetimes of the mold with different "cold gap" are estimated in this section, and the recommendations for the mold assembly are proposed.
During RHCM process, the production efficiency and the part's quality are seriously affected by the temperature and its distribution uniformity on the mold cavity surface. Warpage and weld mark are easy to be formed if the temperature is low or distributed unevenly on the mold cavity surface after heating and cooling processes. Therefore, there is a strict requirement on the temperature of mold cavity surface after heating process in order to obtain high-quality plastic parts and ensure the production efficiency. Commonly, there are much more heating channels in RHCM mold, the layout of them has a great effect on the heating efficiency and the temperature distribution of the mold. Optimization modes integrated the finite element technique with the artificial intelligence algorithm together are proposed to optimize the channels layout. For the purposes of achieving a uniform temperature distribution on the cavity surface of the mold, the distances between the neighbor heating channels were considered as the main design variables for plane surface LCD TV model. An objective function to optimize the temperature distribution uniformity is proposed. By using a quadric response surface equation genetic algorithm, the layout of the channels is optimized. For arc surface LCD TV model, the center coordinates of the heating channels are considered as the main design variables. Multi-objective functions for optimizing the temperature distribution uniformity and heating efficiency are established. The layout of the heating channels is optimized by integrating the establishment of CAD model, the finite element method and Pareto-based genetic algorithm.
As the fiber reinforced plastic products have much more excellent mechanical and thermal properties, they have occupied an important position in the injection field. By using the RHCM technology, the fiber exposure on the fiber reinforced products surface can be avoided and the surface appearance can be greatly improved, so the fiber-reinforced products can be used more widely. For studying the performances of the fiber reinforced products injected by RHCM technology, the layout of heating rods for the designed experiment mold is optimized and a mold temperature controlling system for ERHCM mold is developed. A production line for experiment is established in our laboratory. The fiber reinforced ABS is used as an example to study the relationship between the mechanical properties and the mold temperature. At the same time, the formation of the weldline on the fiber reinforced product is described. The relationship between the surface quality and roughness of the part and the mold temperature are also researched.
Although RHCM technology is a new injection method, it has become a very important molding way of the polymer. Studying the molding mechanism of the RHCM technology, promoting the application of the new injection method is one of important issues for the technology. Researches on the key technologies of the related products and the mold are of great industrial interest for its practical application. The established production line for experiment based on the RHCM theory is of much help to research the mechanism of the technology and also has a very important effect to promote the application of the technology.
引文
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