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1、徐州工程学院毕业设计(论文)附录2Integrated simulation of the injection molding process with stereolithography moldsAbstract Functional parts are needed for design verication testing, eld trials, customer evaluation, and production planning. By eliminating multiple steps, the creation of the injection mold directly
2、 by a rapid prototyping (RP) process holds the best promise of reducing the time and cost needed to mold low-volume quantities of parts. The potential of this integration of injection molding with RP has been demonstrated many times. What is missing is the fundamental understanding of how the modica
3、tions to the mold material and RP manufacturing process impact both the mold design and the injection molding process. In addition, numerical simulation techniques have now become helpful tools of mold designers and process engineers for traditional injection molding. But all current simulation pack
4、ages for conventional injection molding are no longer applicable to this new type of injection molds, mainly because the property of the mold material changes greatly. In this paper, an integrated approach to accomplish a numerical simulation of injection molding into rapid-prototyped molds is estab
5、lished and a corresponding simulation system is developed. Comparisons with experimental results are employed for verication, which show that the present scheme is well suited to handle RP fabricated stereolithography (SL) molds. Keywords Injection molding Numerical simulation Rapid prototyping 1 In
6、troductionIn injection molding, the polymer melt at high temperature is injected into the mold under high pressure 1. Thus, the mold material needs to have thermal and mechanical properties capable of withstanding the temperatures and pressures of the molding cycle. The focus of many studies has bee
7、n to create the injection mold directly by a rapid prototyping (RP) process. By eliminating multiple steps, this method of tooling holds the best promise of reducing the time and cost needed to create low-volume quantities of parts in a production material. The potential of integrating injection mol
8、ding with RP technologies has been demonstrated many times. The properties of RP molds are very different from those of traditional metal molds. The key differences are the properties of thermal conductivity and elastic modulus (rigidity). For example, the polymers used in RP-fabricated stereolithog
9、raphy (SL) molds have a thermal conductivity that is less than one thousandth that of an aluminum tool. In using RP technologies to create molds, the entire mold design and injection-molding process parameters need to be modied and optimized from traditional methodologies due to the completely diffe
10、rent tool material. However, there is still not a fundamental understanding of how the modications to the mold tooling method and material impact both the mold design and the injection molding process parameters. One cannot obtain reasonable results by simply changing a few material properties in cu
11、rrent models. Also, using traditional approaches when making actual parts may be generating sub-optimal results. So there is a dire need to study the interaction between the rapid tooling (RT) process and material and injection molding, so as to establish the mold design criteria and techniques for
12、an RT-oriented injection molding process. In addition, computer simulation is an effective approach for predicting the quality of molded parts. Commercially available simulation packages of the traditional injection molding process have now become routine tools of the mold designer and process engin
13、eer 2. Unfortunately, current simulation programs for conventional injection molding are no longer applicable to RP molds, because of the dramatically dissimilar tool material. For instance, in using the existing simulation software with aluminum and SL molds and comparing with experimental results,
14、 though the simulation values of part distortion are reasonable for the aluminum mold, results are unacceptable, with the error exceeding 50%. The distortion during injection molding is due to shrinkage and warpage of the plastic part, as well as the mold. For ordinarily molds, the main factor is th
15、e shrinkage and warpage of the plastic part, which is modeled accurately in current simulations. But for RP molds, the distortion of the mold has potentially more inuence, which have been neglected in current models. For instance, 3 used a simple three-step simulation process to consider the mold di
16、stortion, which had too much deviation. In this paper, based on the above analysis, a new simulation system for RP molds is developed. The proposed system focuses on predicting part distortion, which is dominating defect in RP-molded parts. The developed simulation can be applied as an evaluation tool for RP mold design and process optimization. Our simulation system is veried by an experimental example.Although many materials are availabl
