基于数值模拟的注塑成形工艺参数优化方法研究

【作者】 单志；

【导师】 梅益；

【作者基本信息】 贵州大学 ， 机械制造及自动化， 2009， 硕士

【摘要】 在注塑成形过程中,熔体在型腔内的状态与变化直接影响产品最终的质量和性能。运用数值模拟软件模拟成形过程,可以预测成形后的产品可能出现的缺陷,从而辅助模具设计和成形工艺设置,成为提高产品质量的重要手段。虽然运用数值模拟软件能够代替试模来反复验证工艺参数是否合适,但却难以得到最优工艺参数。本文应用Moldflow软件按照正交表进行数值模拟分析,获取了该工艺参数下的制品质量,预测了制品翘曲、收缩率、熔接痕等缺陷;通过选取并分析企业实际生产中产生欠注的某塑料制品,从工艺上和结构上提出了三种解决方案,并成功解决了该问题。基于CAE软件模拟结果图,量化翘曲结果为数值形式。选用收缩率在制品内的差值(最大值和最小值的差值)和翘曲作为考察质量指标,选用工艺参数熔体温度、模具温度、注射时间、保压时间和保压压力为影响因素,应用Taguchi DOE技术研究了工艺参数对制品质量的影响,确定了工艺参数对产品质量指标的影响程度,获取近似最优工艺参数组合,并将该组合在CAE软件中进行验证,结果显示了正交实验设计在理论上可行性。以数值模拟获取的数据为样本,采用支持向量机建立注塑产品质量和工艺参数之间关系的模型,代替了用CAE软件进行模拟,使得制品质量预测更加快捷,并基于该关系模型,采用遗传算法获得了成形工艺的全局最优解。更多还原

【Abstract】 It has a direct impact on the quality and performances of products in the injection molding process include the state of the melt and the cavity. The use of numerical simulation software to simulate forming process can predict shaped product’s defect as well as aid mold design and molding process settings, which is an important tool to improve product quality. Although the use of numerical simulation software can replace the test mode to validate the suitability of process parameters without trying again and again, it is difficult to obtain optimal process parameters.In this paper, by using Moldflow software with the orthogonal, forming process has simulated, then the quality of products on some special process parameters is obtained and some defect such as warpage, shrinkage and weld line are well predicted; Considering the problems existing on the plastic products by analyzing insufficient injection products, three candidates solutions inspired from process and structure to solve those problem is proposed. A numerical result is quantified with warpage numerical simulation results getting from CAE simulation software. Choosing Shrinkage rate in the margin (the difference between maximum and minimum values) and warping as the quality inspection factors and the process parameters such as melt temperature, mold temperature, injection time, packing time and packing pressure as the influence factors, the impact on product quality of process parameters is investigated by applying the technique of Taguchi DOE, then the influence degree of the process parameters on product quality and the approximate optimal combination of process parameters are obtained. Using those parameters based on CAE software, the results strongly demonstrates the feasibility of the orthogonal experimental design in the theory. Taking numerical simulation data as samples, the relationship model between injection molding process parameters and product quality is established by suing Support Vector Machine, which can replace the CAE software to simulate and make the prediction of products quality more advantageous. Based on that relational model, the global optimal solution of forming process is obtained by applying genetic algorithms更多还原