后视镜外壳注塑CAE与模具设计

CAE and Mold Design of Injection Molding Process for Rearview Mirror Shell

以某型轿车左右外后视镜镜壳为例,在详细分析镜壳塑件结构、成型材料性能和塑件壁厚的基础上,运用MFI 2015对其浇口位置进行了仿真分析。在综合"最佳浇口位置"、塑件结构和成对注塑的基础上,确定了本模具采用热流道的牛角形潜伏浇口浇注系统方案。在对塑料成型工艺分析中,对影响产品质量的填充时间、流动前沿温度、速度压力切换时的压力、冻结层因子、熔接线、气穴、锁模力、缩痕、体积收缩率、总变形量等进行了分析。运用UG软件对型腔、型芯结构,导向与塑件精度保证机构、顶出机构和四套侧向滑块分型、九套斜顶抽芯机构,及其复位机构、冷却系统及模具的整体进行了分析设计,完成了一次注射成型配对后视镜镜壳塑件的模具设计。创造性地使用了由大、小导柱导套+锥台定位+楔紧镶块调节+厚薄调节垫组成的"五位一体"精度保证与保持系统,使得塑件精度更高。经使用证明:模具结构合理,产品成型完整、质量达到设计要求。

Based on the detailed analysis of mirror shell plastic structure,molding material properties and plastic thickness for the left and right exterior rearview mirror shells of a car,the MFI 2015 software was used to simulate the injection gate location.Based on the comprehensive"best gate location",plastic structure and paired injection molding,horn-shaped latent gate pouring system with hot runner was determined.In the plastic molding process analysis,the filling time,the flow front temperature,the pressure during speed pressure switching,the frozen layer factor,the weld line,the cavitation,the clamping force,the sink marks,the volume shrinkage ratio,the total deformation etc that affecting the product quality were further examined.The UG software was utilized to overall analysis and design of the cavity,core structure,guidance and plastic parts precision assurance mechanism,ejection mechanism and four sets of lateral slider type,nine sets of inclined core-pulling mechanism and its reset mechanism,cooling system and the mold as a whole,and consequently the design for one-off injection molding of the paired rearview mirror shell mold was completed.At the same time,the"five-in-one"precision assurance and maintenance system consisting of both large and small guide pillar and guide sleeve,frustum positioning,wedge insert adjustments,and adjustment pads for thickness improve the precision of plastic.It was proved in actual practice that the mold structure is reasonable,the product mouding is integral,and the quality meets the design requirements.