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南京理工大學泰州科技學院
畢業(yè)設計（論文）任務書
系 部：
機械工程系
專 業(yè)：
機械工程及自動化
學 生 姓 名：
學 號：
設計(論文)題目：
骨輪零件的注射模設計
起 迄 日 期:
2009年3月09日 ~ 6月14日
設計(論文)地點:
指 導 教 師:
專業(yè)負責人:
發(fā)任務書日期: 2009年 2 月 26 日
任務書填寫要求
1．畢業(yè)設計（論文）任務書由指導教師根據(jù)各課題的具體情況填寫，經(jīng)學生所在專業(yè)的負責人審查、系部領導簽字后生效。此任務書應在第七學期結束前填好并發(fā)給學生；
2．任務書內(nèi)容必須用黑墨水筆工整書寫或按教務處統(tǒng)一設計的電子文檔標準格式（可從教務處網(wǎng)頁上下載）打印，不得隨便涂改或潦草書寫，禁止打印在其它紙上后剪貼；
3．任務書內(nèi)填寫的內(nèi)容，必須和學生畢業(yè)設計（論文）完成的情況相一致，若有變更，應當經(jīng)過所在專業(yè)及系部主管領導審批后方可重新填寫；
4．任務書內(nèi)有關“系部”、“專業(yè)”等名稱的填寫，應寫中文全稱，不能寫數(shù)字代碼。學生的“學號”要寫全號；
5．任務書內(nèi)“主要參考文獻”的填寫，應按照國標GB 7714—2005《文后參考文獻著錄規(guī)則》的要求書寫，不能有隨意性；
6．有關年月日等日期的填寫，應當按照國標GB/T 7408—2005《數(shù)據(jù)元和交換格式、信息交換、日期和時間表示法》規(guī)定的要求，一律用阿拉伯數(shù)字書寫。如“2008年3月15日”或“2008-03-15”。
畢 業(yè) 設 計（論 文）任 務 書
1．本畢業(yè)設計（論文）課題應達到的目的：
塑料件在各行業(yè)及日常生活廣泛使用，塑料模具的設計制造的社會需求也日益增長，而且要求越來越高。通過對骨輪零件注射模設計，培養(yǎng)學生檢索資料，綜合應用所學知識，并根據(jù)工程實際的要求解決工程實際問題的方法與能力，訓練學生模具設計制造的基本技能和模具CAD設計能力，提高獨立工作的能力，適應社會需求。
2．本畢業(yè)設計（論文）課題任務的內(nèi)容和要求（包括原始數(shù)據(jù)、技術要求、工作要求等）：
本設計要求學生根據(jù)所給骨輪零件實物，測繪零件圖紙，設計成型注射模具，并學習Pro/Engineer、UG或Solid edge等大型CAD軟件在模具設計中的應用，具體要求如下：
1） 查閱資料（不少于15篇），翻譯一定量的外文資料（不少于3000漢字），撰寫開題報告及文獻綜述（不少于2000字）；
2） 測繪塑件圖紙，完成其CAD三維造型設計；
3） 完成塑件注射模具方案設計和相關設計計算，要求一模兩腔；
4） 完成該注射模具裝配圖設計和全部零件圖紙設計；
5） 模具成型零件CAD三維造型設計；
6） 完成該注射模具模板、成型零件等主要件的制造工藝設計；
7） 撰寫設計說明書。
畢 業(yè) 設 計（論 文）任 務 書
3．對本畢業(yè)設計（論文）課題成果的要求〔包括畢業(yè)設計論文、圖表、實物樣品等〕：
課題成果內(nèi)容包括：
1) 塑件圖紙及CAD三維數(shù)據(jù)模型；
2) 全套注射模具圖紙，成型零件三維造型；
3) 全套模具制造工藝規(guī)程；
4) 畢業(yè)設計論文。
4．主要參考文獻：
[1] 成都科技大學，北京化工學院，天津輕工業(yè)學院合編.塑料成型模具[M].北京：中國輕工業(yè)出版社，1982.
[2] 胡石玉.模具制造技術[M].南京：東南大學出版社，1997.
[3] 駱志斌.模具工手冊[M].南京：江蘇科學技術出版社，2000.
[4] 林清安.Pro/ENGINEER零件設計（基礎篇上、下）[M].北京：北京大學出版社，2000.
[5] 《機械設計手冊》聯(lián)合編寫組.機械設計手冊（第3版上、中、下）[M].北京：化學工業(yè)出版社，1987.
[6] 齊月靜, 秦志峰, 齊鎖來等編著.SolidWorks 2006中文版完全自學專家指導教程[M].北京：機械工業(yè)出版社，2006.
[7] 岳榮剛編著.SolidWorks 2006零件與裝配設計教程[M].北京：冶金工業(yè)出版社，2006.
[8] 王慶五, 仇亞琴, 張昱等編著.SolidWorks 2006中文版模具設計專家指導教程[M].北京：機械工業(yè)出版社，2006.
畢 業(yè) 設 計（論 文）任 務 書
5．本畢業(yè)設計（論文）課題工作進度計劃：
起 迄 日 期
工 作 內(nèi) 容
2009年
3月09日 ～ 3 月30 日
熟悉課題，查閱有關資料，完成資料翻譯，完成開題報告
3月31日 ～ 4 月07 日
測繪塑件零件圖紙，熟悉Solidworks或PRO/E三維CAD軟件，完成塑件三維數(shù)據(jù)模型設計
4月08日 ～ 4 月15 日
進行注射模結構方案設計,完成零件設計
4月16日 ～ 4 月23 日
基本掌握CAD軟件操作，完成塑件注射模方案設計和基本計算
4月24日 ～ 5 月15日
完成塑件注射模零件造型、裝配體設計和修改完善
5月16日 ～ 5月23日
完成塑件注射模工程圖和裝配圖設計
5月24日 ～ 6 月07日
完成塑件注射模制造工藝設計，撰寫設計說明書
6月07日 ～ 6 月10日
修改并打印設計說明書和圖紙，整理相關資料，提交畢業(yè)設計成果
6月11日 ～ 6月14日
準備論文答辯
所在專業(yè)審查意見：
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畢業(yè)設計(論文)外文翻譯
（原文）
院 （系）： 國防生學院
專 業(yè)：機械設計制造及其自動化
學生姓名： 蔡秀濱
學 號： 1001020105
指導教師單位： 機電工程學院
姓 名： 郭中玲
職 稱： 高級工程師
2014年 3 月 9 日
Contents
1.The Injection Molding 1
2.Automated surface ?nishing of plastic injection mold steel with spherical grinding and ball burnishing processes 14
第 22 頁 共 23 頁
桂林電子科技大學畢業(yè)（論文）報告專用紙
The Injection Molding
Alp Tekin Ergenc , Deniz Ozde Koca
Yildiz Tecnical University, Mechanical Engineering Department, IC Engines Laboratory, Turkey
The Introduction of Molds
The mold is at the core of a plastic manufacturing process because its cavity gives a part its shape. This makes the mold at least as critical-and many cases more so-for the quality of the end product as, for example, the plasticiting unit or other components of the processing equipment.
Mold Material
Depending on the processing parameters for the various processing methods as well as the length of the production run, the number of finished products to be produced, molds for plastics processing must satisfy a great variety of requirements. It is therefore not surprising that molds can be made from a very broad spectrum of materials, including-from a technical standpoint-such exotic materials as paper matched and plaster. However, because most processes require high pressures, often combined with high temperatures, metals still represent by far the most important material group, with steel being the predominant metal. It is interesting in this regard that, in many cases, the selection of the mold material is not only a question of material properties and an optimum price-to-performance ratio but also that the methods used to produce the mold, and thus the entire design, can be influenced.
A typical example can be seen in the choice between cast metal molds, with their very different cooling systems, compared to machined molds. In addition, the production technique can also have an effect; for instance, it is often reported that, for the sake of simplicity, a prototype mold is frequently machined from solid stock with the aid of the latest technology such as computer-aided (CAD) and computer-integrated manufacturing (CIMS). In contrast to the previously used methods based on the use of patterns, the use of CAD and CAM often represents the more economical solution today, not only because this production capability is available pin-house but also because with any other technique an order would have to be placed with an outside supplier.
Overall, although high-grade materials are often used, as a rule standard materials are used in mold making. New, state-of-the art (high-performance) materials, such as ceramics, for instance, are almost completely absent. This may be related to the fact that their desirable characteristics, such as constant properties up to very high temperatures, are not required on molds, whereas their negative characteristics, e. g. low tensile strength and poor thermal conductivity, have a clearly related to ceramics, such as sintered material, is found in mild making only to a limited degree. This refers less to the modern materials and components produced by powder metallurgy, and possibly by hot isocratic pressing, than to sintered metals in the sense of porous, air-permeable materials.
Removal of air from the cavity of a mold is necessary with many different processing methods, and it has been proposed many times that this can be accomplished using porous metallic materials. The advantages over specially fabricated venting devices, particularly in areas where melt flow fronts meet, I, e, at weld lines, are as obvious as the potential problem areas: on one hand, preventing the texture of such surfaces from becoming visible on the finished product, and on the other hand, preventing the microspores from quickly becoming clogged with residues (broken off flash, deposits from the molding material, so-called plate out, etc.). It is also interesting in this case that completely new possibilities with regard to mold design and processing technique result from the use of such materials.
A. Design rules
There are many rules for designing molds. These rules and standard practices are based on logic, past experience, convenience, and economy. For designing, mold making, and molding, it is usually of advantage to follow the rules. But occasionally, it may work out better if a rule is ignored and an alternative way is selected. In this text, the most common rules are noted, but the designer will learn only from experience which way to go. The designer must ever be open to new ideas and methods, to new molding and mold materials that may affect these rules.
B. The basic mold
1. Mold cavity space
The mold cavity space is a shape inside the mold, “excavated” in such a manner that when the molding material is forced into this space it will take on the shape of the cavity space and, therefore, the desired product. The principle of a mold is almost as old as human civilization. Molds have metals into sand forms. Such molds, which are still used today in foundries, can be used only once because the mold is destroyed to release the product after it has solidified. Today, we are looking for permanent molds that can be used over and over. Now molds are made from strong, durable materials, such as steel, or from softer aluminum or metal alloys and even from certain plastics where a long mold life is not required because the planned production is small. In injection molding the plastic is injected into the cavity space with high pressure, so the mold must be strong enough to resist the injection pressure without deforming.
2. Number of cavities
Many molds, particularly molds for larger products, are built for only cavity space, but many molds, especially large production molds, are built with 2 or more cavities. The reason for this is purely economical. It takes only little more time to inject several cavities than to inject one. For example, a 4-cavity mold requires only one-fourth of the machine time of a single-cavity mold. Conversely, the production increases in proportion to the number of cavities. A mold with more cavities is more expensive to build than a single-cavity mold, but not necessarily 4 times as much as a single-cavity mold. But it may also require a larger machine with larger platen area and more clamping capacity, and because it will use 4 times the amount of plastic, it may need a large injection unit, so the machine hour cost will be higher than for a machine large enough for the smaller mold.
3. Cavity shape and shrinkage
The shape of the cavity is essentially the “negative” of the shape of the desired product, with dimensional allowance added to allow for shrinking of the plastic. The shape of the cavity is usually created with chip-removing machine tools, or with electric discharge machining, with chemical etching, or by any new method that may be available to remove metal or build it up, such as galvanic processes. It may also be created by casting certain metals in plaster molds created from models of the product to be made, or by casting some suitable hard plastics. The cavity shape can be either cut directly into the mold plates or formed by putting inserts into the plates.
C. Cavity and core
By convention, the hollow portion of the cavity space is called the cavity. The matching, often raised portion of the cavity space is called the core. Most plastic products are cup-shaped. This does not mean that they look like a cup, but they do have an inside and an outside. The outside of the product is formed by the cavity, the inside by the core. The alternative to the cup shape is the flat shape. In this case, there is no specific convex portion, and sometimes, the core looks like a mirror image of the cavity. Typical examples for this are plastic knives, game chips, or round disks such as records. While these items are simple in appearance, they often present serious molding problems for ejection of the product. The reason for this is that all injection molding machines provide an ejection mechanism on the moving platen and the products tend to shrink onto and cling to the core, from where they are then ejected. Most injection molding machines do not provide ejection mechanisms on the injection side.
Polymer Processing
Polymer processing, in its most general context, involves the transformation of a solid (sometimes liquid) polymeric resin, which is in a random form (e.g., powder, pellets, beads), to a solid plastics product of specified shape, dimensions, and properties. This is achieved by means of a transformation process: extrusion, molding, calendaring, coating, thermoforming, etc. The process, in order to achieve the above objective, usually involves the following operations: solid transport, compression, heating, melting, mixing, shaping, cooling, solidification, and finishing. Obviously, these operations do not necessarily occur in sequence, and many of them take place simultaneously.
Shaping is required in order to impart to the material the desired geometry and dimensions. It involves combinations of viscoelastic deformations and heat transfer, which are generally associated with solidification of the product from the melt.
Shaping includes: two-dimensional operations, e.g. die forming, calendaring and coating; three-dimensional molding and forming operations. Two-dimensional processes are either of the continuous, steady state type (e.g. film and sheet extrusion, wire coating, paper and sheet coating, calendaring, fiber spinning, pipe and profile extrusion, etc.) or intermittent as in the case of extrusions associated with intermittent extrusion blow molding. Generally, molding operations are intermittent, and, thus, they tend to involve unsteady state conditions. Thermoforming, vacuum forming, and similar processes may be considered as secondary shaping operations, since they usually involve the reshaping of an already shaped form. In some cases, like blow molding, the process involves primary shaping (pair-son formation) and secondary shaping (pair son inflation).
Shaping operations involve simultaneous or staggered fluid flow and heat transfer. In two-dimensional processes, solidification usually follows the shaping process, whereas solidification and shaping tend to take place simultaneously inside the mold in three dimensional processes. Flow regimes, depending on the nature of the material, the equipment, and the processing conditions, usually involve combinations of shear, extensional, and squeezing flows in conjunction with enclosed (contained) or free surface flows.
The thermo-mechanical history experienced by the polymer during flow and solidification results in the development of microstructure (morphology, crystallinity, and orientation distributions) in the manufactured article. The ultimate properties of the article are closely related to the microstructure. Therefore, the control of the process and product quality must be based on an understanding of the interactions between resin properties, equipment design, operating conditions, thermo-mechanical history, microstructure, and ultimate product properties. Mathematical modeling and computer simulation have been employed to obtain an understanding of these interactions. Such an approach has gained more importance in view of the expanding utilization of computer design/computer assisted manufacturing/computer aided engineering (CAD/CAM/CAE) systems in conjunction with plastics processing.
It will emphasize recent developments relating to the analysis and simulation of some important commercial process, with due consideration to elucidation of both thermo-mechanical history and microstructure development.
As mentioned above, shaping operations involve combinations of fluid flow and heat transfer, with phase change, of a visco-elastic polymer melt. Both steady and unsteady state processes are encountered. A scientific analysis of operations of this type requires solving the relevant equations of continuity, motion, and energy (I. e. conservation equations).
Injection Molding
Many different processes are used to transform plastic granules, powders, and liquids into final product. The plastic material is in moldable form, and is adaptable to various forming methods. In most cases thermoplastic materials are suitable for certain processes while thermosetting materials require other methods of forming. This is recognized by the fact that thermoplastics are usually heated to a soft state and then reshaped before cooling. Theromosets, on the other hand have not yet been polymerized before processing, and the chemical reaction takes place during the process, usually through heat, a catalyst, or pressure. It is important to remember this concept while studying the plastics manufacturing processes and the polymers used.
Injection molding is by far the most widely used process of forming thermoplastic materials. It is also one of the oldest. Currently injection molding accounts for 30% of all plastics resin consumption. Since raw material can be converted by a single procedure, injection molding is suitable for mass production of plastics articles and automated one-step production of complex geometries. In most cases, finishing is not necessary. Typical products include toys, automotive parts, household articles, and consumer electronics goods,
Since injection molding has a number of interdependent variables, it is a process of considerable complexity. The success of the injection molding operation is dependent not only in the proper setup of the machine variables, but also on eliminating shot-to-shot variations that are caused by the machine hydraulics, barrel temperature variations, and changes in material viscosity. Increasing shot-to-shot repeatability of machine variables helps produce parts with tighter tolerance, lowers the level of rejects, and increases product quality ( i.e., appearance and serviceability).
The principal objective of any molding operation is the manufacture of products: to a specific quality level, in the shortest time, and using a repeatable and fully automatic cycle. Molders strive to reduce or eliminate rejected parts, or parts with a high added value such as appliance cases, the payoff of reduced rejects is high.
A typical injection molding cycle or sequence consists of five phases:
1 Injection or mold filling
2 Packing or compression
3 Holding
4 Cooling
5 Part ejection
Injection Molding Overview
Process
Injection molding is a cyclic process of forming plastic into a desired shape by forcing
the material under pressure into a cavity. The shaping is achieved by cooling
(thermoplastics) or by a chemical reaction (thermosets). It is one of the most common
and versatile operations for mass production of complex plastics parts with excellent
dimensional tolerance. It requires minimal or no finishing or assembly operations. In
addition to thermoplastics and thermosets, the process is being extended to such
materials as fibers, ceramics, and powdered metals, with polymers as binders.
Applications
Approximately 32 percent by weight of all plastics processed go through injection molding
machines. Historically, the major milestones of injection molding include the invention of the
reciprocating screw machine and various new alternative processes, and the application of computersimulation to the design and manufacture of plastics parts.
Development of the injection molding machine
Since its introduction in the early 1870s, the injection molding machine has undergone significant
modifications and improvements. In particular, the invention of the reciprocating screw machine hasrevolutionized the versatility and productivity of the thermoplastic injection molding process.
Benefits of the reciprocating screw
Apart from obvious improvements in machine control and machine functions, the major
development for the injection molding machine is the change from a plunger mechanism to a
reciprocating screw. Although the plunger-type machine is inherently simple, its popularity was
limited due to the slow heating rate through pure conduction only. The reciprocating screw can
plasticize the material more quickly and uniformly with its rotating motion, as shown in Figure 1. Inaddition, it is able to inject the molten polymer in a forward direction, as a plunger.
Development of the injection molding process
The injection molding process was first used only with thermoplastic polymers. Advances in the
understanding of materials, improvements in molding equipment, and the needs of specific industrysegments have expanded the use of the process to areas beyond its original scope.
Alternative injection molding processes
During the past two decades, numerous attempts have been made to develop injection molding
processes to produce parts with special design features and properties. Alternative processes derivedfrom conventional injection molding have created a new era for additional applications, more designfreedom, and special structural features. These efforts have resulted in a number of processes,including:
Co-injection (sandwich) molding
Fusible core injection molding)
Gas-assisted injection molding
Injection-compression molding
Lamellar (microlayer) injection moldin
Live-feed injection molding
Low-pressure injection molding
Push-pull injection molding
Reactive molding
Structural foam injection molding
Thin-wall molding
Computer simulation of injection molding processes
Because of these extensions and their promising future, computer simulation of the process has alsoexpanded beyond the early "lay-flat," empirical cavity-filling estimates. Now, complex programs simulate post-filling behavior, reaction kinetics, and the use of two materials with different properties, or two distinct phases, during the process.
The Simulation section provides information on using C-MOLD products.Among the Design topicsare several examples that illustrate how you can use CAE tools to improve your part and molddesign and optimize processing conditions.
Co-injection (sandwich) molding
Overview
Co-injection molding involves sequential or concurrent injection of two different but
compatible polymer melts into a cavity. The materials laminate and solidify. This process
produces parts that have a laminated structure, with the core material embedded between
the layers of the skin material. This innovative process offers the inherent flexibility of
using the optimal properties of each material or modifying the properties of the molded
part.
FIGURE 1. Four stages of co-injection molding. (a) Short shot of skin polymer melt (shown in dark green)is injected into the mold. (b) Injection of core polymer melt until cavity is nearly filled, as shown in (c). (d)Skin polymer is injected again, to purge the core polymer away from the sprue.
Fusible core injection molding
Overview
The fusible (lost, soluble) core injection molding process illustrated below produces
single-piece, hollow parts with complex internal geometry. This process molds a core
inside the plastic part. After the molding, the core will be physically melted or chemically
dissolved, leaving its outer geometry as the internal shape of the plastic part.
FIGURE 1. Fusible (lost, soluble) core injection molding
Gas-assisted injection molding
Gas-assisted process
The gas-assisted injection molding process begins with a partial or full injection of
polymer melt into the mold cavity. Compre