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参数控制型腔布局系统注射注塑模具类外文文献翻译中英文翻译外文翻译.docx

参数控制型腔布局系统注射注塑模具类外文文献翻译中英文翻译外文翻译

IntJAdvManufTechnol（2003）21:

807–819

OwnershipandCopyright

AParametric-ControlledCavityLayoutDesignSystemfora

PlasticInjectionMould

M.L.H.LowandK.S.Lee

DepartmentofMechanicalEngineering,NationalUniversityofSingapore,Singapore

Today,thetime-to-marketforplasticproductsisbecomingshorter,thustheleadtimeavailableformakingtheinjectionmouldisdecreasing.Thereispotentialfortimesavinginthemoulddesignstagebecauseadesignprocessthatisrepeatableforeverymoulddesigncanbestandardised.Thispaperpresentsamethodologyfordesigningthecavitylayoutforplasticinjectionmouldsbycontrollingthegeometricalpara-metersusingastandardisationtemplate.Thestandardisationtemplateforthecavitylayoutdesignconsistsoftheconfigur-ationsforthepossiblelayouts.Eachconfigurationofthelayoutdesignhasitsownlayoutdesigntableofallthegeometricalparameters.Thisstandardisationtemplateispre-definedatthelayoutdesignlevelofthemouldassemblydesign.Thisensuresthattherequiredconfigurationcanbeloadedintothemouldassemblydesignveryquickly,withouttheneedtoredesignthelayout.Thismakesitusefulintechnicaldiscussionsbetweentheproductdesignersandmoulddesignerspriortothemanu-factureofthemould.Changescanbemadetothe3Dcavitylayoutdesignimmediatelyduringthediscussions,thussavingtimeandavoidingmiscommunication.Thisstandardisationtem-plateforthecavitylayoutdesigncanbecustomisedeasilyforeachmouldmakingcompanytotheirownstandards.

Keywords:

Cavitylayoutdesign;Geometricalparameters;Mouldassembly;Plasticinjectionmoulddesign;Standardis-

ationtemplate

onitandprovidesthemechanismformoltenplastictransferfromthemachinetothemould,clampingthemouldbytheapplicationofpressureandtheejectionoftheformedplasticpart.Theinjectionmouldisatoolfortransformingthemoltenplasticintothefinalshapeanddimensionaldetailsoftheplasticpart.Today,asthetime-to-marketforplasticpartsisbecomingshorter,itisessentialtoproducetheinjectionmouldinashortertime.

Muchworkhadbeendoneonapplyingcomputertechno-logiestoinjectionmoulddesignandtherelatedfield.Knowl-edge-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.Thereisgreatpotentialfortimesavingatthemoulddesignstageiftherepeatabledesignprocessescanbestandard-isedtoavoidroutinetasks.Awell-organisedhierarchicaldesigntreeinthemouldassemblyisalsoanimportantfactor[13,14].

However,littleworkhasbeendoneincontrollingthepara-

metersinthecavitylayoutdesign;thusthisareawillbeourmainfocus.Althoughtherearemanywaysofdesigningthe

1.Introduction

Plasticinjectionmouldingisacommonmethodforthemassproductionofplasticpartswithgoodtolerances.Therearetwomainitemsthatarerequiredforplasticinjectionmoulding.Theyaretheinjection-mouldingmachineandtheinjectionmould.Theinjection-mouldingmachinehasthemouldmounted

Correspondenceandoffprintrequeststo:

K.S.Lee,DepartmentofMechanicalEngineering,NationalUniversityofSingapore,10KentRidgeCrescent,Singapore119260.E-mailaddress:

mpeleeks@nus.edu.sg

Received8January2002

Accepted16April2002

cavitylayout[15,16],moulddesignerstendtouseonlyconven-tionaldesigns,thusthereisaneedtoapplystandardisationatthecavitylayoutdesignlevel.

Thispaperpresentsamethodologyfordesigningthecavitylayoutforplasticinjectionmouldsbycontrollingtheparametersbasedonastandardisationtemplate.First,awell-organisedmouldassemblyhierarchydesigntreehadtobeestablished.Then,theclassificationofthecavitylayoutconfigurationhadtobemadetodifferentiatebetweenthosewithstandardcon-figurationsandthosewithnon-standardconfigurations.Thestandardconfigurationswillbelistedinaconfigurationdatabaseandeachconfigurationhasitsownlayoutdesigntablethatcontrolsitsowngeometricalparameters.Thisstandardisation

808M.L.H.LowandK.S.Lee

Fig.1.Frontinsert（cavity）andbackinsert（core）.

templateispre-definedatthelayoutdesignlevelofthemouldassemblydesign.

2.CavityLayoutDesignforaPlastic

InjectionMould

Aninjectionmouldisatoolfortransformingmoltenplasticintothefinalshapeanddimensionaldetailsofaplasticpart.Thus,amouldcontainsaninverseimpressionofthefinalpart.Mostofthemouldsarebuiltupoftwohalves:

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

Fig.2.Asimplemouldassembly.

2.1DifferenceBetweenaSingle-Cavityanda

Multi-CavityMould

Veryoften,theimpressioninwhichmoltenplasticisbeingfilledisalsocalledthecavity.Thearrangementofthecavitiesiscalledthecavitylayout.Whenamouldcontainsmorethanonecavity,itisreferredtoasamulti-cavitymould.Figures3（a）and3（b）showsasingle-cavitymouldandamulti-cavitymould.Asingle-cavitymouldisnormallydesignedforfairlylargepartssuchasplottercoversandtelevisionhousings.Forsmallerpartssuchashandphonecoversandgears,itisalwaysmoreeconomicaltodesignamulti-cavitymouldsothatmorepartscanbeproducedpermouldingcycle.Customersusuallydeter-minethenumberofcavities,astheyhavetobalancethe

investmentinthetoolingagainstthepartcost.

2.2Multi-CavityLayout

Amulti-cavitymouldthatproducesdifferentproductsatthesametimeisknownasafamilymould.However,itisnotusualtodesignamouldwithdifferentcavities,asthecavitiesmaynotallbefilledatthesametimewithmoltenplasticofthesametemperature.

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

Abalancedlayoutcanbefurtherclassifiedintotwocategor-

ies:

linearandcircular.Abalancedlinearlayoutcanaccommo-date2,4,8,16,32etc.cavities,i.e.itfollowsa2nseries.Abalancedcircularlayoutcanhave3,4,5,6ormorecavities,butthereisalimittothenumberofcavitiesthatcanbeaccommodatedinabalancedcircularlayoutbecauseofspaceconstraints.Figure5showsthemulti-cavitylayoutsthathavebeendiscussed.

3.TheDesignApproach

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

Fig.3.（a）Asinglecavitymould.（b）Amulti-cavitymould.

ACavityLayoutDesignSystem809

3.1StandardisationProcedure

Fig.4.Shortmouldinginanunbalancedlayout.

Inordertosavetimeinthemoulddesignprocess,itisnecessarytoidentifythefeaturesofthedesignthatarecom-monlyused.Thedesignprocessesthatarerepeatableforeverymoulddesigncanthenbestandardised.ItcanbeseenfromFig.7thattherearetwosectionsthatinterplayinthestan-dardisationprocedureforthe“cavitylayoutdesign”:

componentassemblysta

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