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1、Integrated CAD/CAE/CAM system for injection mouldingby Yuan Zhongshuang, Li Dequn, Chen Xing, Ye Xiangao,Gao Xianke and Xiao JingrongHuazhong University of Science & Technology, ChinaAn integrated CAD/CAE/CAM system, HSC-1.1, is described in this article. At the CAD/CAE stage the drawings of injecti
2、on moulded parts can be transformed into the drawings of the mould parts interactively and, according to the users needs, the mechanical check, runner balance analysis, flow simulation and cooling simulation can be carried out. NC tapes for wire cutting or milling machine tools can be generated at t
3、he CAM stage. The practice shows that the system is a useful tool for mould designers and manufacturers.IntroductionInjection moulding is one of the most important polymer processing operations in industry today. It is superior for mass production of complex parts to high precision at low cost. For
4、a long time, experience, intuition and trial and error have been key factors in mould designing, mould manufacturing and moulding operation. These approaches have become increasingly inefficient and costly, especially when applied to the moulding of large parts and parts of high precision or to the
5、processing of new kinds of polymers. Now some of these problems are being solved successfully by combining recent advances in CAD, CAE and CAM technology.In recent years more and more CAD/CAE/CAM systems for injection moulding have been developed and delivered in Western industrialized countries, su
6、ch as C-MOULD 3.1 of AC Technology Inc. in the USA, CAD-MOULD of IKV in Germany, McKAM-ll of McCill University in Canada, and MoldFlow in Australia. With the help of these software packages the productivity and quality of injection moulded parts can be improved and the start-up time can be shortened
7、.CAD/CAE/CAM technology for injection moulding has been developed quickly in China since1980. As a pioneer in this field in our country, we have studied and developed CAD/CAE/CAM technology of injection moulding for many years. Through five years development and practical verification, an integrated
8、 CAD/CAE/CAM system for injection moulding, HSC-1.1, has been developed and put into use successfully in many factories.System descriptionHSC-1.1 is developed on personal computers such as the PC386 and PC486. The desirable internal storage is 4 MB or more, and the external storage is more than 100
9、MB.Fig. 1 shows the software requirements of HSC-1.1. The system is developed and run under theenvironment of Operating System II (OS/2) or MS-DOS. In the system AutoCAD-10.0 is used only as a graphic editor and drawing software. Standard Fortran 77 and AutoLisp are used for programming. Except for
10、a few of programs for graphic driver, all the software in the system is independent of computers, which ensures good portability of the system.As shown in Fig. 2, HSC-1.1 integrates nine modules with their function design based on the requirements of users. All modules in the system are supervised b
11、y a main control program named control panel or control menu. Users can invoke any module by ordering the menu displayed on the screen by the control panel. The data exchange from one module to another is implemented automatically in the form of data files. Fig. 3 shows the data flowchart of HSC-1.1
12、.Function of CAD modulesThe task of CAD modules is to transform the drawings of injection moulded parts into the drawings of mould parts efficiently and provide necessary data for simulation and NC modules. Due to complex cavities, a surface modelling program has been eveloped for graphic input. Pla
13、nes, regular surfaces and bi-cubic surfaces can be created easily. The co-ordinates of points on surfacescan be calculated by the programusing dimensions of the part drawing and the co-ordinates of the points input before. While the part drawing is being input one surface after another, the dimensio
14、ns of the part will be transformed into the dimensions of the cavity and core through interaction. The data for the cavity and core are recorded for both mould design and simulation. A database for standard mould sets has been set up which contains ten kinds of standard mould sets issued by the Elec
15、trical Ministry of the Peoples Republic of China. Each kind of mould set contains 13 series. Hence there are 31150 combinations of mould sets altogether in the database. Once the cavity layout is determined, all the standard mould parts can be selected automatically and dimensioned through interacti
16、on. The system provides a group of functions for users to design the runner system, edit construction of cavity and core and arrange ejection pins and cooling lines. Finally all the mould part drawings including moving mould assembly, stationary mould assembly and general mould assembly drawing can be produced. Fig. 4 shows a mould assembly drawing of a switch socket made in the Shanghai No. 9 Radio Factory for colour TV sets. Function of C
