电控气喇叭零部件模具设计毕业设计说明书(1)

电控气喇叭零部件模具设计毕业设计#说明书#(1) 毕业设计() 课名称: 电控气喇叭零部件模具设计 完成时间 2010 年 1 月 18 日 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 目 录 摘要...........................................................1 1.0模具行业及产品发展现状......................................1 2.0选题意义....................................................3 2.1产品的设计及要求............................................3 3.0塑件模型建立................................................4 3.1模型3D图...................................................4 3.2塑件2D图技术条件...........................................4 3.3塑件参数设计................................................5 3.3.1 材料选择.................................................5 3.4塑件收缩率..................................................8 3.5塑件的壁厚..................................................8 3.6塑件结构工艺性..............................................8 3.7分型面的设计................................................9 4.0塑件体积的计算.............................................10 4.1注塑机的初选...............................................10 4.2按注射机的最大注射量确定型腔数目...........................12 5.0注塑机的校核...............................................13 5.1最大注塑量的校核...........................................13 5.2模具闭合高度的确定.........................................14 5.3模架的选择.................................................14 6.0浇注系统设计...............................................15 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 6.1主流道设计.................................................15 6.2分流道设计.................................................16 6.3浇口的设计.................................................17 7.0成型零部件的设计...........................................17 7.1型芯.......................................................18 7.2型腔、型芯工作尺寸计算.....................................18 8.0侧向分型与抽芯机构.........................................19 8.1抽芯力的确定...............................................20 8.2抽芯距的计算...............................................21 8.3斜导柱侧向分型与抽芯机构...................................21 8.3.1斜导柱的工作原理.........................................21 8.3.2斜导柱的设计.............................................错误～未定义书签。 8.3.3斜导柱长度的计算.........................................错误～未定义书签。 8.3.4斜导柱直径的计算.........................................错误～未定义书签。 8.4斜滑块的设计...............................................错误～未定义书签。 8.5斜滑块限位装置的设计.......................................24 9.0导向机构的设计.............................................错误～未定义书签。 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 9.1导柱的设计.................................................错 误～未定义书签。 9.2导套的结构设计.............................................错 误～未定义书签。 10.0推出机构的设计............................................25 10.1推件力的计算..............................................26 10.2推杆的设计................................................26 11.0模具排气槽的设计及冷却方式................................27 12.0模具装配图................................................27 13.0模具设计的创新与特色总结..................................30 13.1设计存在的问题与解决设想..................................30 13.2 绘图软件之间的转换效果差.................................31 参考文献......................................................32 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 电控气喇叭零部件模设计 楼士童 浙江工贸职业技术学院汽车与机电工程系，班级:模具0801 摘要: 机电与控制通过对电控气喇叭零部件塑件的设计分析～设计出该塑件的模具。在整个模具设计过程中～涉及到了塑件的结构设计、对塑件进行模流分析、注塑机和模架的选择及注塑机的一些重要工艺参数的校核～并详细叙述了模具设计中的分型面设计、浇注系统设计、成型零件设计、顶出机构设计和冷却系统设计～最后还对成型零件制订加工工艺。 在模具设计过程中～采用了Moldflow、Pro/ENGINEER、AutoCAD等著名的设计分析软件～采用这些软件进行设计分析～优化了设计的参数和缩短了设计时间～提高了设计效率。 通过整个模具设计～本人已经能够熟练地使用当前常用的设计分析软件～学会了根据计算或者依据选择一些参数, 增加了对注塑模具的了解。 关键词:模具设计,模流分析,工艺,分型面 1.0模具行业及产品发展现状 模具作为重要的生产装备和工艺发展方向，在现代工业的规模生产中日益发挥着重要作用。通过模具进行产品生产具有优质、高校、节能、节材、成本底等显著特点。因而在汽车、机械、电子、轻工、家电、通讯、军事和航天等领域的产品中获得广泛应用。其中60%~80%的零件采用模具加工生产，作用不可代替。 塑料工业是一个新兴的工业领域，又是一个发展迅速的领域。塑料已经进入一工业部门以及人民的日常生活中，塑料因其材料本身易得、性能优越、加工方便，而广泛应用于包装、日用消费品、农业、交通运输、电子、电讯、机械化工、建筑材料等各个领域，并显示出巨大的优越性和发展潜力。当今世界把一个国家的塑料消耗量和塑料工业水平，作为衡量一个国家工业发展水平的重要标志之一。 随着机械、电子、家电、日用五金等工业产品塑料化趋势的不断增强以及塑料制件(塑件)的广泛应用与不断发展、更新换代迅速，对塑料成型成型工艺以及塑料模具设计方面的知识。 1 但是我国模具行业总体落后的面貌尚未得到更本改变，长期以来，设计制造水平在总体落后于先进国家。我门应该重视模具生产化，专业化和商品化的发展，逐步建立适应我国的模具科研开发、人才培训和产品生产的基本体技术的发展与塑料模具在数量、质量、精度和复杂程度等方面都提出了更高的要求，这就要求从事塑料成型和模具设计的人员更多的掌握塑料 在大型塑料模方面，已能生产三十四英寸大屏幕彩电塑壳模具，六千克大容量洗衣机全套塑料模具及汽车保险杠和整体仪表板等塑料模具。在精密塑料模具方面，已能生产多型腔小模数齿轮模具和600腔塑封模具，还能生产厚度仅为0.08mm的1模2腔的航空杯模具和难度较高的塑料门窗挤出模等。 在精度方面，塑料模型腔制造精度可达0.02,0.05mm(国外可达0.005,0.01mm)，分型面接触间隙为0.02mm，模板的弹性变形为0.05mm，型面的表面粗糙度值为Ra0.2,0.25mm，塑料模寿命已达100万次(国外可达300万次)，模具制造周期仍比国外长2,4倍。 成型工艺方面，多材质塑料成型模、高效多色注塑模、镶件互换结构和抽芯脱模机构的创新方面也取得较大进展。热流道模具开始推广，有的厂采用率达20%以上，一般采用内热式或外热式热流道装置，少数单位采用具有世界先进水平的高难度针阀式热流道模具[2]。 在制造技术方面，CAD/CAM/CAE技术的应用水平上了一个新台阶，以生产家用电器的企业为代表，陆续引进了相当数量的CAD/CAM系统。这些系统和软件的引进，实现了CAD/CAM的集成，并能支持CAE技术对成型过程，取得了一定的技术经济效益，促进和推动了我国模具CAD/CAM技术的发展[3]。 模具使用材料方面，国内已较广泛地采用一些新的塑料模具钢，如:P20，3Gr2Mo、PMS、SM?、SM?等，对模具的质量和使用寿命有着直接的重大影响，但总体使用量仍较少。塑料模具标准模架、标准推杆和弹簧等越来越广泛得到应用，并且出现了一些国产的商品化的热流道系统元件。 国外先进工业国家在链条与模具生产中均采用了可靠性设计以及CAD,CAM技术，开发新品速度快、精度高，质量较有保证。大多数新产品具有高耐磨、高疲劳、高精度的特点，结构形式上有微型链以及多种输送链、缆链、倍速链等，在材料上则使用了耐磨、耐热、塑料、含油粉末冶金等材料，进一步提高了链条的性能。 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 在加工方面，一般规格链条链板多采用高速多颗冲裁工艺，滚子制造采用五工位冷挤压机加工，套筒采用高速精密且具有自动检测功能的卷管机加工;喷丸、挤孔、表面硬化处理等新工艺应用很普遍;零件热处理一般采用热处理自动生产线，热处理质量由在线检测设备检测与控制;热处理工艺有趋于向温度、炉压、炉气组分以及淬火介质等多参数综合控制，零件质量稳定可靠，技术性能较高;在装配工艺上则普遍采用组装、铆头、检测、预拉，拆节多功能自动装配线。 在材料使用方面，国外则采用专用模具材料DINI、2316等，其综合机械性能，耐磨、耐腐蚀性能及抛光亮度都比较优异。 在塑料件方面，有数据显示，今后5年，中国塑料市场的年增长幅度将在8%到 [4]14%之间，需求总额将超过3500亿元。随着人们生活水平提高，塑料产品的加速普及与换代升级必将产生惊人的市场推动力，小家电的市场发展前景非常广阔。2006年，中国塑料消费市场份额将进一步扩大，针对部分塑料质量标准不一的状况，国家将会出台更严格的塑料产品质量标准，促进了塑料品牌的优胜劣汰，强势品牌的塑料厂家成为真正的赢家。 2.0选题意义 由于新技术、新材料、新工艺的不断发展，促使模具技术不断进步，对模具技术的要求越来越高，对人才的知识、能力、素质的要求也在不断提高。通过各种渠道培养更多的模具人才，搞好技术创新，则可以不断提高我国模具设计和制造以及维修水[6]平。 本毕业设计通过对一个电控气喇叭零部件的塑料产品及其模具的设计，锻炼了塑料制品的设计及成型工艺的选择能力;塑料制品成型模具的设计能力、塑料制品的质量分析及工艺改进能力、塑料模具结构改进设计能力，熟悉了模具设计的常用商业软件。 2.1产品的设计及要求 零件名称:电控气喇叭零部件 生产批量:大批量 未注公差取:MT5级精度 工作要求:化学性能稳定，能耐一般的化学腐蚀，对皮肤无刺激，无害，在一定的温度、酸性条件下，不易氧化腐蚀分解，并具有良好的绝缘性。 3 3.0塑件模型建立 毕业设计的塑料件原型来源于市场上电控气喇叭中的零部件,毕业设计参考市场 上电控气喇叭中的零部件设计出经过改进的产品，并且绘制出这个容器的3D图和2D图。 3.1 模型3D图 模型绘制采用PTC公司的产品Pro/ENGINEER Wildfire 4.0,最终绘制出来的3D结构如图1所示: 图1 塑件模型3D图 3.2 塑件2D图技术条件 本模型2D图由Pro/E 3D图转换而来,并在软件AutoCAD上进行整理绘制出来的2D 图如图2所示，如果需要更加详细的塑件尺寸，请参照附件中的塑件的2D图。 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 图2 塑件2D图 1)塑件精度等级及尺寸公差:塑件采用的精度等级为5级。 2)塑件的表面质量:该塑件要求外形要求不高，外表面没有斑点，粗糙度可取Ra3.2μm。 3.3 塑件参数设计 3.3.1 材料选择 这个电控气喇叭零部件为一般的零件, 没有特别的要求,根据以上的依据,选择材料PP为塑料件的材料。PP材料说明:中文名称:聚丙烯。基本特性如下: 无色、无味、无毒。不吸水，光泽好，易着色。外观似聚乙烯，但比聚乙烯更透明、更轻。密度为0。90~0。91g/cm?。卓越的介电性能、耐水性、化学稳定性、高频绝缘性能;定向拉伸后抗弯曲疲劳强度特别高;耐热性好，能在100?以上的温度下进行消毒灭菌;具有特别高的抗弯曲疲劳强度，聚丙烯在氧、热、光的作用下极易解聚、老化，所以必须加入防老化剂。 典型应用范围:汽车工业(主要使用含金属添加剂的PP:挡泥板、通风管、风扇等)，器械(洗碗机门衬垫、干燥机通风管、洗衣机框架及机盖、冰箱门衬垫等)，日用消费品(草坪和园艺设备如剪草机和喷水器等)。防腐管道、管件、输油管、离 5 心泵和鼓风机等;瓦楞板、门窗结构、墙壁装饰物等;插座、插头、开关和电缆。凉鞋、雨衣、玩具和人造革等 。 注塑模工艺条件: 干燥处理:不吸水，故不需要干燥处理。 熔化温度:164~170?。 模具温度:40~90?，建议使用80?左右。结晶程度主要由模具温度决定。 注射压力:可大到1800bar。 注射速度:通常，使用高速注塑可以使内部压力减小到最小。如果制品表面出现了缺陷，那么应使用较高温度下的低速注塑。 流道和浇口:对于冷流道，典型的流道直径范围是4~7mm。建议使用通体为圆形的注入口和流道。所有类型的浇口都可以使用。典型的浇口直径范围是 1~1.5mm，但也可以使用小到0.7mm的浇口。对于边缘浇口，最小的浇口深度应为壁厚的一半;最小的浇口宽度应至少为壁厚的两倍。PP材料完全可以使用热流道系统。 成型特点:流动性好，过热时极易分解，加稳定剂和润滑剂，控制成型温度及熔体的滞留时间。成型温度范围小，必须严格控制料温，模具应有冷却装置;模具浇注系统应粗短，浇口截面宜大。 化学和物理特性:PP是一种半结晶性材料。它比PE要更坚硬并且有更高的熔点。 由于均聚物型的PP温度低于-35?时会脆裂，因此许多商业的PP材料是加入 1~4%乙烯的无规则共聚物或更高比率乙烯含量的钳段式共聚物。共聚物型的PP材料有较低的热扭曲温度(100?)、低透明度、低光泽度、低刚性，但是有有更强的抗冲击强度。PP的强度随着乙烯含量的增加而增大。PP的维卡软化温度为150?。由于结晶度较高，这种材料的表面刚度和抗划痕特性很好。PP不存在环境应力开裂问题。通常，采用加入玻璃纤维、金属添加剂或热塑橡胶的方法对PP进行改性。PP的流动率MFR范围在1~40。低MFR的PP材料抗冲击特性较好但延展强度较低。对于相同MFR的材料，共聚物型的强度比均聚物型的要高。由于结晶，PP的收缩率相当高，一般为1.8~2.5%。并且收缩率的方向均匀性比PE-HD等材料要好得多。加入30%的玻璃添加剂可以使收缩率降到0.7%。均聚物型和共聚物型的PP材料都具有优良的抗吸湿性、抗酸碱腐蚀性、抗溶解性。然而，它对芳香烃(如苯)溶剂、氯化烃(四氯化their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 碳)溶剂等没有抵抗力。PP也不象PE那样在高温下仍具有抗氧化性。本制件采用pp(聚丙烯)材料制作，对其材料分析如下: 表1 注塑塑料对比 塑料 PP聚丙烯 PE聚乙烯 名称 结晶部分多时，塑料硬度高、韧性大、抗材料 较大的机械强度和良好的综合性能。 拉强度高，但整体尺寸变小，耐冲击强度特性 及断裂强度底。 聚乙烯制件最显著的特点是收缩率大，这成型 PP在氧、热、光的作用下极易解聚、老化，与材料的可结晶性和模具温度有关。定型工艺 所以必须加入防老化剂。 后塑件在强的收缩牵引作用下，可令制件特点 变形和翘曲。 PP塑料的温度与熔融粘度的关系比较独特，聚乙烯的注射温度一般在120,310?之注射 在达到塑化温度后在继续盲目升温，必将PP间，温度超过300?时，收缩率会明显增温度 的热降解。 大。 注射 PP采用中等注射速度效果较好，注射时需要聚乙烯的注射压力一般选择在68.6,速度 采用较高的注射压力，其溢边料为0.04mm左137.2Mpa之间。注射速度不易过快，以保及压 右。并需要调配好保压压力和保压时间。 证结晶程度高。 力 PP的模具温度相对较高，一般调节在75, 由于模具温度对收缩率影响很大，因此要模具85?，为缩短生产周期，应维持模具温度的 经常保持模具相对恒定的温度，一般在温度 相对稳定，制件在取出后可采用冷水浴等方 40,80?之间。 法来补偿冷固定型时间。 表2 PP的注射工艺参数 工艺参数 规格 工艺参数 规格 温度t/? 40~80 预热和干燥 注射压力/Mpa 70~120 时间 τ/h 0~5 7 注射时间 0~5 前段 180~200 料筒温度t/? 成型时间τ/s 保压时间 20~60 中段 200~220 冷却时间 15~50 后段 160~170 成型周期 40~220 ,1min螺杆转速n/(r?) 模具温度t/? 40~80 30~60 3.4塑件收缩率 根据以上选用的材料，查相关资料可知，PP的收缩率为1.0,2.5%，这里选择偏中值，为1.75%。 3.5塑件的壁厚 一般说来，塑件的厚度越厚就越能满足产品的强度和刚度的性能要求，但是从塑件的成型过程看来，塑件的壁厚越厚，冷却的时间就越长，整个塑件的成型周期就要延长，提高了生产的成本，降低了生产的效率，同时，塑件的壁厚越厚，收缩率就增大，这样使的得产品的尺寸不稳定性增加，降低了产品的质量。因此产品的厚度必须得适中，根据材料的的特性，查阅相关的资料，查得PP制品的壁厚通常为0.5、1、1.2、1.5、2、2.5、3、3.5mm。本次设计中，塑件的壁厚为1mm。 3.6塑件的结构工艺性 该塑件尺寸较小，除两个面属要侧抽芯外，其它结构相对比较简单，复杂程度中等。要想获得优质的塑料制件，除塑件的结构工艺性设计时，需遵循的几个原则。 1) 在设计塑件时，应考虑原材料的成型工艺性，如流动性、收缩率等。 2) 在设计塑件的同时应考虑其模具的总体结构，使模具型腔易于制造，模具抽芯和推出机构简单。 3) 在保证塑件使用性能、物理性能与力学性能、电性能、耐化学腐蚀性能和耐热性能等的前提下，力求结构简单，壁厚均匀，使用方便。 4) 当对结构设计的塑件外观要求较高时，应先通过造型，然后逐步绘制图样。 塑件的尺寸精度不仅与模具制造精度及其使用磨损有关，而且还与塑件收缩率的波动、成型工艺条件的变化、塑件成型后的时效变化和模具的结构形状有关。可见，their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 塑件的尺寸精度一般不高，因此，在保证使用要求的前提下尽可能选用低的精度等级。该按键开关选用IT5级。 模具在使用过程中，由于型腔磨损而使表面粗糙度值不断加大，所以应随时给予抛光复原。透明塑件要求型腔和型芯的表面粗糙度相同，而不透明塑件则根据使用情况来决定它们的表面粗糙度。该按键开关内表面的粗糙度可略高与开关外表面的粗糙度。 为保证塑件有足够的强度和刚度，而且也为了塑料在成型时保持良好的流动状态，承受脱模推出了。壁厚应尽可能一致，防止塑件变形、缩孔及凹陷等缺陷。该开关外壳壁厚为1mm。 为了满足制品表面光滑的要求与提高成型效率采用侧浇口进料，塑料熔体通过开关顶部的平面处注入型腔。查表和参考工厂实际应用的情况，聚丙稀的成型工艺参数可作如下选择。试模时，可根据实际情况作适当调整。 该塑件尺寸较小，除两个面需要侧抽芯外，其他结构比较简单，复杂程度不高。 尺寸精度分析 该塑件尺寸精度无特殊要求，所有尺寸均为自由尺寸，可按MT5查取公差，其主要尺寸公差标注如下(单位均为mm): ，0.40，0.44，0.20，0.76，0.5627,0.118,0.1塑件外形尺寸(型腔):、、、、、、、2521.53200000 ，0.32，0.38，0.44，0.20、、、。111623R10000 00内形尺寸(型芯):、。 1634,,0.380.76 该塑件整体结构复杂程度一般，而尺寸较多，多为曲面特征。除了配合部分尺寸精度要一般求较高外，其它面精度要求相对较低，但外观表面粗糙度要求较高，再结合其材料性能，故选精度等级:IT5级。 还有部分尺寸较小，对模具设计与制造没有太大影响，可忽略不计。 3.7分型面设计 分型面设计如图3所示: 图3 分型面 选择这样的分型面是因为便于塑件的脱模和简化模具结构。分型面确定之后就在软件中绘制出 9 来，为了能够实现下来的分型能够顺利进行，有对塑件的分型面进行检测的必要，如图为对分型面的自交检测，结果为没有发现自交截。如果发现有相交的分型面，应该对分型面作修整，否则在软件中无法分型。 4.0塑件体积的计算 1)计算塑件的体积 根据塑件的三维模型，由PROE软件中的自动计算体积，质量功能可以得出制件的体积和质 3量，塑件的密度=0.9如下图(过程略): kgcm\, 3cm由上图再经过单位换算得制件的体积V=4.5 4.1注射机的的初选 注射模一次成型的塑料重量应在注射机理论注射量的10%~80%之间为好，塑件形状简单，溶体流动性好，根据两个塑件的体积加上浇注系统上的凝料初步确定注射机位XS-ZY-60。 注射机的主要参数 3额定注射量(cm): 60 螺杆(柱塞)直径(mm): 38 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 注射压力(MPa): 122 注射行程(mm):1705 注射方式:柱塞式 锁模力(kN):500 2最大成型面积(cm): 130 最大开合模行程(mm): 180 模具最大厚度(mm): 200 模具最小厚度(mm):70 喷嘴圆弧半径(mm): 12 喷嘴孔直径(mm): 4 顶出形式: 中心设有顶出，机械顶出 动、定模固定板尺寸(mm): 330×440 拉杆空间(mm): 190×300 合模方式: 液压-机械 液压泵流量(L/min):70、12 液压泵压力(MPa): 6.5 加热功率(kW): 2.7 机器外形尺寸(mm): 3160×850×1550 注塑机如下图: 11 4.2 按注射机的最大注射量确定型腔数目 根据: kmm,p1n, k得: nmm，1m, pk 注射机最大注射量的利用系数，一般取0.8; k, m,注射机最大注射量，cmз或g; p m,浇注系统凝料量，cmз或g; 1 m,单个塑件体积或质量，cmз或g( 经计算结合模具的闭合高度和开模行程确定该模具为一模两腔。 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 5.0注射机的校核 5.1 最大注射量的校核 最大注射量是指注射机在对空注射的条件下，注射螺杆或柱塞做一次最大注射行程时，注射装置所能达到的最大注射量。设计模具时，应满足注射成型塑件所需的总注射量小于所选注射机的最大注射量，即: nm，m,km jn 经估算浇注系统凝料体积为2.5 cm?; 式中: n——型腔数目 m——单个塑件的体积或质量，cm?或g; m——浇注系统凝料，cm?或g; j m——注射机最大注射量，cm?或g; n k——注射机最大注射量利用参数，一般取0.8. 所以根据式子:nm+m=2×4.5cm?+2.5cm?=11.5cm? j Km=0.8×11.5=9.2cm? n 9.2,60 所以注射机的最大注射量符合要求。 S,H，H，a，(5~10)mm校核 max12 S式中:――注射机最大开模行程，mm; max H―― 塑件脱模所需顶距离，mm; 1 H―― 塑件高度，mm; 2 考虑到本模具的型腔均布于动、定模板，顶杆顶出工件后，仍留在动模部分的型腔中，故其不影响开模行程的大小，可忽略。查《塑料成型工艺与模具设计》(第二版)表 13 4.2得:注射机最大开模行程: ,300 mm ,而H1=39mm ,a=36mm, ,34mm ,可求得: SHmax2 ++a+(5,10)mm,114mm?,300mm。 HHS12max 所以，所选注射机的开模行程符合所选的模具。 5.2模具闭合高度的确定 组成模具闭合高度的模板及其零件的尺寸有: 定模座板=20mm; H1 型腔板=50mm; H2 型芯板H=30mm; 3 =70mm; 垫块H4 H 动模板=20mm; 5 则该模具的闭合高度为: HHHH=+H++=20+50+30+70+20=190mm 3512 H 由于XS-ZY-60型注塑机所允许的模具最小厚度=70mm;模具最大厚度min Hmin,H,HmaxH=200mm;，所以模具闭合高度满足的安装要求。 max 5.3模架选择 模架的选择:注塑模模架国家标准有两个，即GB/T12556——1990《塑料注射模中小型模架及其技术条件》和GB/T12555——1990《塑料注射模大型模架》。由于塑料模具的蓬勃发展，现在在全国的部分地区形成了自己的标准，该设计采用龙记标准模架，型号为:CI7070100B160。模架如下图4所示: their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 图4 模架模型 6.0浇注系统的设计 浇注系统是指模具中由注射机喷嘴到型腔之间的进料通道。其一般由主流道、分流道、浇口和冷料穴等四部分组成。 应遵循如下基本原则: 1)了解塑料的成型性能 2)尽量避免或减产生熔接痕 3)有利于型腔中气体的排出 4)防止型芯的变形和嵌件的位移 5)尽量采用较短的流程充满型腔 6)流动距离比和流动面积比的校核 6.1主流道的设计 主流道是指浇注系统中从注射机喷嘴与模具浇口套接触处开始到分流道为止的塑料熔体流动通道，是熔体最先流经模具的部分，他的形状与尺寸对塑料熔体的流动速度和充模时间有较大的影响，因此必须使熔体的温度和压力损失最小。 主流道通常设计在模具的浇口套中,为了让主流道凝料能顺利从浇口套中拔出,主 0 流道设计成圆锥形,其锥角a为3。如图: 15 图5浇口套 6.2分流道的设计 分流道是指主流道末端与浇口之间的一段流动通道。分流的作用是改变熔体的流向，使其以平稳的流态均衡的分配到各个型腔。设计时应尽量减少过程中的热量损失与压力损失。 o分流道截面选U形截面，宽度b选6mm，深度h=3.75mm,R=3mm，斜角取6。分流道的长度根据型腔大小取36。 分流道的分置如下图: 图6 分流道布置 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 6.3浇口的设计 浇口是连接分流道与型腔的熔体通道。浇口的设计与位置的选择恰当与否，直接关系到塑件能否被完好高质量的注射成型。 根据制件的外形，选用侧浇口，深度t=1mm，宽度b=1.5mm。 本次设计采用的浇口为矩形侧浇口,其优点有: 侧浇口多为扁平状,可以缩短浇口的冷却时间,从而缩短成型周期; 易于去除浇注系统的凝料而不影响塑件的外观; 可根据塑胶件的形状特点灵活地设置浇口的位置; 浇口位于分型面上,易于加工; 适用一模多腔的模具,提高注塑效率。 7.0成型零部件的设计 型腔可采用整体式或组合式结构。 根据制件的复杂程度，且型腔的形状复杂，所以型腔选择半合模形式。 推件方式的选择 注塑模中的脱模机构可以在注塑的每一个循环中将塑件从型腔内或型芯上自动的脱出模外。推杆脱模机构在生产实际中应用广泛，是脱模机构的典型型式，它一般包括推杆、拉料杆、复位杆、推杆固定板等组成，当开模到一定距离时，注塑机推出装置推动推板并带动所有推杆、拉料杆和复位杆一道前进，将塑件和浇注系统一起推出模外。合模时复位杆首先与定模边的分型面相接触，而将推板和所有的复位杆一道推回原位。根据塑件的形状特点， 模具型腔在定模部分，型心在动模部分。其推出机构可采用推杆推出机构、推件板推出机构。为了便于加工，降低模具成本，我们采用推件板推出机构，推件板推出机构推出力大而均匀，推出平稳可靠，塑件上没有推出痕迹。推杆与推件板用螺钉连接的形式，在推出过程中，可以防止推件板早推出过程中脱落。本模具为推件板镶入动模板内的形式，并且与动模板作导向配合，推出机构工作时，推件板除了和型芯做配合外，还依靠推杆进行支承与导向，这种推出机构 17 结构紧凑，推板在推出过程中也不会掉下 。 从以上分析得出:该塑件采用推件板推出机构。当注射成型后，动模部分向后退，推杆向前推，滑块向左右移动，推杆推动推件板将制件推出。 根据制件成型特点和经济效益，采用半合模结构。该结构广泛应用于中小型塑件的模具中。加工方法可采用普通机加工、数控机床、电火花、电铸成型等方法。将一个整体型腔嵌入到型腔固定板中，嵌入的型腔材料可用低碳钢或低碳合金钢，渗碳淬火后抛光 7.1型芯 型芯是用来成型塑料制品的内表面的成型零件。要求表面光滑，精度要求不高。本制件的型芯简单。 7.2型腔、型芯工作尺寸计算 PP塑料的收缩率是1.0%--2.5% 平均收缩率: S =(1.0%+2.5%)/2=1.75% +δz+δz型腔内径: (L)=,( 1+S)L-0.75?, m0s0 ，,，,zz型腔深度: ,,(Hm),(1，s)Hs,0.5,00 0,，z型芯外径: (lm),,,(1，s)ls，0.75,0,,z 0,，z型芯深度: (lm),,,(1，s)ls，0.5,0,,z D, 型腔径向尺寸(mm ); 模 - 塑件外形基本尺寸(mm); D Q-塑件平均收缩率; 平 -塑件公差(参考文献[4]) , -成形零件制造公差，一般取1/3—1/4; ,, -塑件内形基本尺寸( mm); d d-型芯径向尺寸(mm); 模 H-型腔深度(mm); 模 -塑件高度(mm) H h-型芯高度(mm); 模 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. -塑件孔深基本尺寸(mm); h 表3型芯、型腔尺寸计算 基本尺寸公差值平均收类型 计算公式 计算结果 /mm /mm 缩率 ，0.14 ,32,32.140.56 0 ，0.11 ,23,23.10.44 0 ，0.05 ,18,18.20.20 0型腔径向尺 ，0.05寸 1.9 2 0.20 0 +δz+δz，0.08 (L)=,( 1+S)L-0.75?, 10.95m0s011 0.32 0 ，0.095 15.9916 0.38 0 ，0.1 1.331.5 0.40 0 ，0.05 27.427 0.20 01.75% ，0.1，, ，,1.8zz2 0.40 0,,(Hm),(1，s)Hs,0.5,型腔轴向尺00 ，0.11寸 4.875 0.44 0 ，0.19 34.234 0.76 0 ，0.05 0.921 0.20 0 0,，z(lm),,,(1，s)ls，0.75, 型芯径向尺0,,z0 ,16,16.570.38 ,0.095寸 型芯轴向尺0,，0z 34.98(lm),,,(1，s)ls，0.5, 34 0.76 ,0.190,,z寸 8.0侧向分型与抽芯机构 19 当在注射成型的塑件上与开合模方向不同的内侧或外侧具有孔、凹穴或凸台时，塑件就不能直接推杆等推出脱模，此时，模具上成型该处的零件必须制成可侧向移动的活动型芯，以便在塑件推出之前，先将侧向成型零件抽出，然后再把塑件从模内推出，否则就无法脱模;该模具的侧抽芯机构如图7。 本制件需要二个侧型芯。侧向分型机构有以下几个元件组成: (1)侧向成型元件 侧向成型元件是成型塑件形状的零件。 (2)运动元件 运动元件是指安装并带动侧向成型块或侧向型芯并在模具导滑槽内运动的零件 (3)传动元件 传动元件是指开模时带动元件做侧向分型或抽芯，合模时又使之复位的元件。 (4)锁紧元件 为了防止注射时运动元件受到侧向压力而产生位移的零件称为锁紧元件。 (5)限位元件 为了使运动元件在侧向分型或侧向抽芯结束时停留在所要求的位置上，以保证合模时传动元件能顺利的使其复位，必须设置运动元件在侧向抽芯结束时的限位元件 图7 侧抽芯机构 8.1抽芯力的确定 由于塑件包紧在侧向型芯或粘附在侧向型腔上，因此在各种类型的侧向分型与抽芯机构中，侧向分型与抽芯时必然会遇到抽拔的阻力，侧向分型与抽芯的力(简称抽their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 芯力)一定要大于抽拔阻力。侧向抽芯力与脱模力的计算方式相同，即Fm=Ap(μcos α-sin α)。 8.2抽芯距地计算 在设计侧向分型与抽芯机构时，除了计算侧向抽拔力以外，还必须考虑侧向抽芯距(亦称抽拔距)的问题。侧向抽芯距一般比在塑件上的侧孔的深度大2~3mm，用公式表示为: s=s+(2~3) 1 式中 s:抽芯距，mm; s:塑件上侧孔深度，mm 1 所以s=7+3=10mm 8.3 斜导柱侧向分型与抽芯机构 8.3.1斜导柱的工作原理 开模时，动模部分向后移动，塑件包在凸模随着动模一起移动，在斜导柱的作用下，侧滑块带动侧型芯在动模板上的导滑槽内向上侧做侧向抽芯。侧向抽芯结束后，斜导柱脱离侧滑块，侧滑块在弹簧的作用下拉紧在限位挡块上，以便再次合模时斜导柱能准确的插入侧滑块的斜导孔中，迫使其复位。 8.3.2 斜导柱的设计 000斜导柱的的倾斜角α取2033比较理想，一般设计时取α?25，最常用的是12?α?22?，本设计中α取20?。 8.3.3斜导柱长度的计算 在侧型芯滑块抽芯方向与开模方向垂直时，可以推导出斜导柱的工作尺寸L的计算公式为: sL, sin, 21 斜导柱的总长度为: L,L，L，L，L，L12345z dhds2,,,tan，，tan，，(5~10)mm,,2cos2sin 式中 L——斜导柱的总长度; z d——斜导柱的固定部分大端直径; 2 h——斜导柱固定板厚度; d——斜导柱工作部分尺寸; s——侧向抽芯距; 由此计算出: L,L，L，L，L，Lz12345 17161210 ,tan20，，tan20，，52cos202sin20 ,57mm 所以斜导柱的长度选60mm 8.3.4 斜导柱直径的计算 由于计算比较复杂，有时为了便利，也可用查表的方法确定斜导柱的直径。先按已求的抽芯力F和选定的斜导柱倾斜角α，再教材中的表10.1查出最大弯曲力F，w然后根 图8斜导柱 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 据F和F以及斜导柱的倾斜角α的数值在表10.2中查出斜导柱的直径d。由此w 查出的直径为12mm。 8.4斜滑块的设计 侧滑块是斜导柱侧向分型中的一个重要零件，侧型芯是模具的成型零件，常用T8、T10、45刚、CrWMn、P20等材料制造，硬度要求大于40HRC。 图9 斜滑块的剖面图 图10斜滑块的左视图 23 图11 斜滑块的俯视图 8.5斜滑块限位装置的设计 侧滑块与斜导柱分别工作在模具动、定模两侧抽芯机构，开模抽芯后，侧滑块必须停留在刚脱离斜导柱的位置上，以便合模时斜导柱准确的插入侧滑块的斜导孔中，因此，必须设计侧滑块的定位装置，以保证侧滑块脱离斜销后可靠的停留在正确的位置。 图12 斜滑块的限位装置 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 9.0导向机构的设计 导向机构的作用: 1)定位作用; 2)导向作用; 3)承受一定的侧向压力。 9.1导柱的设计 长度 导柱导向部分的长度应比凸模端面的高度高出8—12 cm，以免出 现导柱末导正方向而型芯先进入型腔的情况。 形状 导柱前端应做成锥台形，以使导柱能顺利地进入导向孔。 材料 导柱应具有硬而耐磨的表面和坚韧而不易折断的内芯，因此多采 用20钢(经表面渗碳淬火处理)，硬度为50—55HRC。 9.2导套的结构设计 用与导柱相同的材料制造导套，其硬度应略低与导柱硬度，这样 材料 可以减轻磨损，一防止导柱或导套拉毛。 形状 为使导柱顺利进入导套，导套的前端应倒圆角。导向孔作成通孔， 以利于排出孔内的空气。 10.0推出机构的设计 注塑模中的脱模机构可以在注塑的每一个循环中将塑件从型腔内或型芯上自动的脱出模外。推杆脱模机构在生产实际中应用广泛，是脱模机构的典型型式，它一般包括推杆、拉料杆、复位杆、推杆固定板等组成，当开模到一定距离时，注塑机推出装置推动推板并带动所有推杆、拉料杆和复位杆一道前进，将塑件和浇注系统一起推出模外。合模时复位杆首先与定模边的分型面相接触，而将推板和所有的复位杆一道推回原位。 根据塑件的形状特点， 模具型腔在定模部分，型心在动模部分。其推出机构可采用推杆推出机构、推件板推出机构。由于分型面有台阶，为了便于加工，降低模具成本，我们采用推件板推出机构，推件板推出机构推出力大而均匀，推出平稳可靠，塑件上没有推出痕迹。推杆与推件板用螺钉连接的形式，在推出过程中，可以防止推件板早 25 推出过程中脱落。本模具为推件板镶入动模板内的形式，并且与动模板作导向配合，推出机构工作时，推件板除了和型芯做配合外，还依靠推杆进行支承与导向，这种推出机构结构紧凑，推板在推出过程中也不会掉下 ，推件板和型芯的配合为H7/f7-H8/f7。 10.1推件力的计算 对于一般塑件和通孔壳形塑件，按下式计算，并确定其脱模力(Q): QLhpf,,cossin,,，， 式中 --型芯或凸模被包紧部分的断面周长(cm); L h --被包紧部分的深度(cm); --由塑件收缩率产生的单位面积上的正压力，一般取 p 7.8——11.8MPa; --磨擦系数，一般取0.1~1.2; f , --脱模斜度; ,，， L=100.5mm H=34mm 00Q,100.5mm，34mm，10MPa0.1cos1,sin1，， ,2819(N) 10.2 推杆的设计 1)推杆的强度计算查《塑料模设计手册之二》由式5-97得 221,64，，l4，Qd=() 3,n，，E d——圆形推杆直径cm ,——推杆长度系数?0.7 l——推杆长度cm their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. n——推杆数量 72 E——推杆材料的弹性模量E=2.110N/ cm， Q——总脱模力 取 D=8mm。 2)推杆压力校核 查《塑料模设计手册》式5-98 Q4=,, ,s2nd，, 取320N/mm? ,s < 推杆应力合格，硬度HRC50,65 ,,s 推出机构如图所示: 图16 推出机构 11.0模具排气槽的设计及冷却方式 当塑料熔体充填型腔时，必须顺序地排出型腔及浇注系统内的空气及塑料受热而 产生的气体。如果气体不能被顺利排出，塑料会由于填充不足而出现气泡、接缝或表 27 面轮廓不清等缺陷，甚至气体受压而产生高温，使塑料焦化。特别是对大型塑件、容器类和精密塑件，排气槽将对它们的品质带来很大的影响，对于在高速成行中排气槽的作用更为重要。我们的塑件并不是很大，而且不属于深型腔类零件，因此本方案设计在分型面之间、推杆预模板之间及活动型芯与模板之间的配合间隙进行排气，间隙值取0.04?。 根据塑件材料特性和模具结构该模具采用风冷冷却方式。 12.0模具装配图 图18模具配套图 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 图19 模具配套图 图20 模具配套图 29 13.0模具设计的创新与特色总结 本次毕业设计时间不长，真正的设计时间为两个月，但并不意味着本次毕业设计任务是式的设计，最大的特点就是整个过程都离不开计算机，是名副其实的计算机辅助设计。创新与特色主要体现在如下几个方面: 在塑料件的设计阶段，采用了软件对塑料件的厚度以及拔模斜度进行检测。这样做可以在模具设计的初始阶段就能确保塑件设计的合理性，避免了在注塑成型的时候塑件由于厚度不均或者是拔模斜度不合理而导致的塑件质量的下降。 在模具设计初始阶段采用模流分析软件对整个模具设计进行优化。模流分析采用的是著名的分析软件Moldflow Plastics Advisers(中文称为模具顾问)进行分析，此软件为注塑模采购者、设计者和制造者提供了一个准确易用的方法来优化他们的模具设计。它可以设计浇注系统并进行浇注系统平衡、可以计算注塑周期、锁模力和注塑体积等等。这些参数对后面的设计计算如注塑机的选择及其校核、浇注系统的设计和冷却系统的设计提供了很大的帮助。 整个模具结构设计核心部分都在计算机上完成。采用计算机辅助设计可以大大减轻人的工作量，而在计算机绘图时基本由单个软件Pro/ENGINEER绘制，单个软件绘图的效率和质量很明显要优越于在各个绘图软件中转换。在使用软件绘图中，很多标准零件都是直接从软件中提取出来，并不是要单个零件慢慢的绘制，特别是模架方面，直接可以调用一些厂商的模架，大大缩短整个模具设计时间。 计算机辅助和课本理论相结合。绘图和分析基本上在计算机上完成，而一些计算仍然需要参考课本上的知识进行人工的核算，如设计中的注塑机校核和浇注系统的计算等等，这样使得以前学习到的知识能够得到了很好的应用。 13.1设计存在的问题与解决设想 本次模具设计中，存在了不少的问题，而这些问题由于时间或者是能力的不足，并不能在短时间内解决，但是却不能够忽略，主要问题体现在如下几个方面: 问题:理论上，模流分析可以优化模具设计的各个方面，如浇口位置、注塑压力、注塑温度、浇注系统平衡优化、冷却系统优化等等。而在本次设计当中，并非都使用了模流分析软件的各个功能，只是参考了其中的一些参数，如注塑压力，注塑体积和塑件的重。 their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development. 原因:以前没有深入的接触过模流分析软件，对此软件使用并不是很熟练;模具顾问软件始终是一种模拟分析软件，可能软件本身就存在一些问题，有些参数跟实际的还是有些出入，也就是并不能完全依赖从模流分析中分析出来的结果。 解决设想:一是加深对模具顾问的认识，使得设计人员能够很好的使用模具顾问这软件;二是需要有更加准确可靠的分析软件，或者是在不同的分析软件上进行分析，对比不同的分析结果，这样能够得到更加可靠的数据。 13.2绘图软件之间的转换效果差 问题:从Pro/ENGINEER转换成AutoCAD的二维平面图时，转化的效果相当差。如应该为圆的地方在AutoCAD中一开始显示的是八方形，显示效果差，虽然能通过一些设置重新生成质量稍好的，但是仍然不尽人意。 原因:软件之间的数据转换问题 解决设想:一是尽量的使用单一软件，这个可能不存在转换质量的问题;但是由于软件各有所长，Pro/ENGINEER擅长于三维，而AutoCAD二维功能强大，只能等待软件的升级，或者可以对他们进行二次开发，专门针对这个问题开发出解决此问题的平台。 31 参考文献: [1]屈华昌主编，《塑料成型工艺与模具设计》，高等教育出版社，2007. [2] 钱泉森主编。《塑料成型工艺及模具设计》，高等教育出版社，2004. [3] 杜志俊主编。《现代模具技术综述》，高等教育出版社，1999年第6期. [4] 黄标主编。业界人士谈2006家电产品发展趋势，中山日报，2006年2月. [5] 杨静雅主编。小家电产品的发展两个大趋势，厦门晚报，2006第176期. [6] 王文广，田宝善，田雁辰主编《塑料注塑模具设计技巧与设计》，化学工业出版社，2004. [7] 黄虹主编。《塑料成型加工与模具》，化学工业出版社，2003. [8] 李奇，朱江峰，江莹主编。模具构造与制造，清华大学出版社，2004. [9] 钱泉森主编。《塑料成型工艺及模具设计》，山东科学技术出版社，2004. [10] Miguel Sanchez-Soto.Optimizing the gas-injection molding of an automobile plastic overusing experimental design procedure,J,，Journal of Materials Processing Technology， 2006年178期，第26-29页. their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development.