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注塑模的参数控制型腔布局设计系统外文文献翻译中英文翻译外文翻译

一、外文原文

AParametric-ControlledCavityLayoutDesignSystemforaPlasticInjectionMould

M.L.H.LowandK.S.Lee

DepartmentofMechanicalEngineering,NationalUniversityofSingapore,Singapore

Today,thetime-to-marketforplasticproductsisbecomingshorter,thustheleadtimeavailableformakingtheinjectionmouldisdecreasing.Thereispotentialfortimesavinginthemoulddesignstagebecauseadesignprocessthatisrepeatableforeverymoulddesigncanbestandardised.Thispaperpresentsamethodologyfordesigningthecavitylayoutforplasticinjectionmouldsbycontrollingthegeometricalparametersusingastandardisationtemplate.Thestandardizationtemplateforthecavitylayoutdesignconsistsoftheconfigurationsforthepossiblelayouts.Eachconfigurationofthelayoutdesignhasitsownlayoutdesigntableofallthegeometricalparameters.Thisstandardisationtemplateispre-definedatthelayoutdesignlevelofthemouldassemblydesign.Thisensuresthattherequiredconfigurationcanbeloadedintothemouldassemblydesignveryquickly,withouttheneedtoredesignthelayout.Thismakesitusefulintechnicaldiscussionsbetweentheproductdesignersandmoulddesignerspriortothemanufactureofthemould.Changescanbemadetothe3Dcavitylayoutdesignimmediatelyduringthediscussions,thussavingtimeandavoidingmiscommunication.Thisstandardisationtemplateforthecavitylayoutdesigncanbecustomisedeasilyforeachmouldmakingcompanytotheirownstandards.

Keywords:

Cavitylayoutdesign;Geometricalparameters;

Mouldassembly;Plasticinjectionmoulddesign;Standardisation

template

1.Introduction

Plasticinjectionmouldingisacommonmethodforthemassproductionofplasticpartswithgoodtolerances.Therearetwomainitemsthatarerequiredforplasticinjectionmoulding.Theyaretheinjection-mouldingmachineandtheinjectionmould.Theinjection-mouldingmachinehasthemouldmountedonitandprovidesthemechanismformoltenplastictransferfromthemachinetothemould,clampingthemouldbytheapplicationofpressureandtheejectionoftheformedplasticpart.Theinjectionmouldisatoolfortransformingthemoltenplasticintothefinalshapeanddimensionaldetailsoftheplasticpart.Today,asthetime-to-marketforplasticpartsisbecomingshorter,itisessentialtoproducetheinjectionmouldinashortertime.

Muchworkhadbeendoneonapplyingcomputertechnologiestoinjectionmoulddesignandtherelatedfield.Knowledge-basedsystems（KBS）suchasIMOLD[1,2],IKMOULD[3],ESMOLD[4],theKBSoftheNationalChengKangUniversity,Taiwan[5],theKBSofDrexelUniversity[6],etc.weredevelopedforinjectionmoulddesign.SystemssuchasHyperQ/Plastic[7],CIMP[8],FIT[9],etc.aredevelopedfortheselectionofplasticmaterialsusingaknowledge-basedapproach.Techniqueshavealsobeendevelopedforpartingdesignininjectionmoulding[10–12].

Ithasbeenobservedthatalthoughmould-makingindustriesareusing3DCADsoftwareformoulddesign,muchtimeiswastedingoingthroughthesamedesignprocessesforeveryproject.Thereisgreatpotentialfortimesavingatthemoulddesignstageiftherepeatabledesignprocessescanbestandardizedtoavoidroutinetasks.Awell-organisedhierarchicaldesigntreeinthemouldassemblyisalsoanimportantfactor[13,14].However,littleworkhasbeendoneincontrollingtheparametersinthecavitylayoutdesign;thusthisareawillbeourmainfocus.Althoughtherearemanywaysofdesigningthecavitylayout[15,16],moulddesignerstendtouseonlyconventionaldesigns,thusthereisaneedtoapplystandardisationatthecavitylayoutdesignlevel.

Thispaperpresentsamethodologyfordesigningthecavitylayoutforplasticinjectionmouldsbycontrollingtheparametersbasedonastandardisationtemplate.First,awell-organisedmouldassemblyhierarchydesigntreehadtobeestablished.Then,theclassificationofthecavitylayoutconfigurationhadtobemadetodifferentiatebetweenthosewithstandardconfigurationsandthosewithnon-standardconfigurations.Thestandardconfigurationswillbelistedinaconfigurationdatabaseandeachconfigurationhasitsownlayoutdesigntablethatcontrolsitsowngeometricalparameters.Thisstandardizationtemplateispre-definedatthelayoutdesignlevelofthemouldassemblydesign.

2.CavityLayoutDesignforaPlasticInjectionMould

Aninjectionmouldisatoolfortransformingmoltenplasticintothefinalshapeanddimensionaldetailsofaplasticpart.Thus,amouldcontainsaninverseimpressionofthefinalpart.Mostofthemouldsarebuiltupoftwohalves:

thefrontinsertandthebackinsert.Incertainmould-makingindustries,thefrontinsertisalsoknownasthecavityandthebackinsertisknownasthecore.Figure1showsafrontinsert（cavity）andabackinsert（core）.Moltenplasticisinjectedintotheimpressiontofillit.Solidificationofthemoltenplasticthenformsthepart.Figure2showsasimpletwo-platemouldassembly.

2.1DifferenceBetweenaSingle-CavityandaMulti-CavityMould

Veryoften,theimpressioninwhichmoltenplasticisbeingfilledisalsocalledthecavity.Thearrangementofthecavitiesiscalledthecavitylayout.Whenamouldcontainsmorethanonecavity,itisreferredtoasamulti-cavitymould.Figures3（a）and3（b）showsasingle-cavitymouldandamulti-cavitymould.

Asingle-cavitymouldisnormallydesignedforfairlylargepartssuchasplottercoversandtelevisionhousings.Forsmallerpartssuchashandphonecoversandgears,itisalwaysmoreeconomicaltodesignamulti-cavitymouldsothatmorepartscanbeproducedpermouldingcycle.Customersusuallydeterminethenumberofcavities,astheyhavetobalancetheinvestmentinthetoolingagainstthepartcost.

2.2Multi-CavityLayout

Amulti-cavitymouldthatproducesdifferentproductsatthesametimeisknownasafamilymould.However,itisnotusualtodesignamouldwithdifferentcavities,asthecavitiesmaynotallbefilledatthesametimewithmoltenplasticofthesametemperature.

Ontheotherhand,amulti-cavitymouldthatproducesthesameproductthroughoutthemouldingcyclecanhaveabalancedlayoutoranunbalancedlayout.Abalancedlayoutisoneinwhichthecavitiesarealluniformlyfilledatthesametimeunderthesamemeltconditions[15,16].Shortmouldingcanoccurifanunbalancedlayoutisbeingused,butthiscanbeovercomebymodifyingthelengthandcross-sectionoftherunners（passagewaysforthemoltenplasticflowfromthespruetothecavity）.Sincethisisnotanefficientmethod,itisavoidedwherepossible.Figure4showsashortmouldingsituationduetoanunbalancedlayout.

Abalancedlayoutcanbefurtherclassifiedintotwocategories:

linearandcircular.Abalancedlinearlayoutcanaccommodate2,4,8,16,32etc.cavities,i.e.itfollowsa2nseries.Abalancedcircularlayoutcanhave3,4,5,6ormorecavities,butthereisalimittothenumberofcavitiesthatcanbeaccommodatedinabalancedcircularlayoutbecauseofspaceconstraints.Figure5showsthemulti-cavitylayoutsthathavebeendiscussed.

3.TheDesignApproach

Thissectionpresentsanoverviewofthedesignapproachforthedevelopmentofaparametric-controlledcavitylayoutdesignsystemforplasticinjectionmoulds.Aneffectiveworkingmethodofmoulddesigninvolvesorganisingthevarioussubassembliesandcomponentsintothemostappropriatehierarchydesigntree.Figure6showsthemouldassemblyhierarchydesigntreeforthefirstlevelsubassemblyandcomponents.Othersubassembliesandcomponentsareassembledfromthesecondlevelonwardstothenthlevelofthemouldassemblyhierarchydesigntree.Forthissystem,thefocuswillbemadeonlyonthe“cavitylayoutdesign”.

3.1StandardisationProcedure

Inordertosavetimeinthemoulddesignprocess,itisnecessarytoidentifythefeaturesofthedesignthatarecommonlyused.Thedesignprocessesthatarerepeatableforeverymoulddesigncanthenbestandardised.ItcanbeseenfromFig.7thattherearetwosectionsthatinterplayinthestandardizationprocedureforthe“cavitylayoutdesign”:

componentassemblystandardisationandcavitylayoutconfigurationstandardisation.

3.1.1ComponentAssemblyStandardisation

Beforethecavitylayoutconfigurationcanbestandardised,thereisaneedtorecognisethecomponentsandsubassembliesthatarerepeatedthroughoutthevariouscavitiesinthecavitylayout.Figure8showsadetailed“cavitylayoutdesign”hierarchydesigntree.Themaininsertsubassembly（cavity）inthesecondlevelofthehierarchydesigntreehasanumberofsubassembliesandcomponentsthatareassembleddirectlytoitfromthethirdlevelonwardsofthehierarchydesigntree.Theycanbeviewedasprimarycomponentsandsecondarycomponents.Primarycomponentsarepresentineverymoulddesign.Thesecondarycomponentsaredependentontheplasticpartthatistobeproduced,sotheymayormaynotbepresent

inthemoulddesigns.

Asaresult,puttingthesecomponentsandsubassembliesdirectlyunderthemaininsertsubassembly,ensuresthateveryrepeatablemaininsert（cavity）willinheritthesamesubassembliesandcomponentsfromthethirdlevelonwardsofthehierarchydesigntree.Thus,thereisnoneedtoredesignsimilarsubassembliesandcomponentsforeverycavityinthecavitylayout.

3.1.2CavityLayoutConfigurationStandardisation

Itisnecessarytostudyandclassifythecavitylayoutconfigurationsintothosethatarestandardandthosethatarenonstandard.Figure9showsthestandardisationprocedureofthecavitylayoutconfiguration.

Acavitylayoutdesign,canbeundertakeneither