摩托车导流板装饰盖注塑工艺参数优化

Optimization of injection process parameters for motorcycle deflector decorative cover

以某摩托车导流板装饰盖为研究对象,为获得零件最佳注塑工艺参数、最佳浇口位置及结构参数,结合成型零件特点和实际加工要求,以翘曲变形量作为衡量指标,进行浇注工艺分析。经过浇口匹配性分析确定浇注系统方案,基于田口试验法分别设计两组试验:一是选择熔体温度、模具温度、保压压力、注射时间为影响因素的L16(44)试验方案,通过成型工艺窗口分析确定各因素水平范围,极差分析得出各工艺参数对翘曲变形的影响显著性次序及最优工艺参数组合;二是在此工艺方案基础上,对零件上两处点浇口直径和第二点浇口位置进行优化,设计L16(43)试验,分析得出翘曲变形量最小的浇口结构组合。由第一次田口试验优化得到翘曲变形量为0.4891 mm,相较于田口试验的最小值减小了2.26%。第二次田口试验结果所得的翘曲变形量仅为0.4358 mm,相较于初始方案降低了10.9%,结果表明改善浇口位置及结构可以有效改善制件的翘曲变形。经过实际生产验证,零件具有良好的表面质量和尺寸精度,满足生产和使用要求。

The motorcycle deflector decorative cover was taken as the research object.In order to obtain the best injection molding process parameters,the optimal gate location and structural parameters,combined with the characteristics of the molded parts and the actual processing requirements,the warping deformation was taken as measurement indicators to analyze the injecting process.The injection system scheme was determined through gate matching analysis,and two sets of tests were designed based on taguchi experiment:the first group was to select L16(44)scheme with melt temperature,mold temperature,packing pressure and injection time as the influence factors,determine the level range of each factor through the molding process window analysis,and obtain the significant order of influence of each process parameter on warping deformation and the optimal combination of process parameters by range analysis.On the basis of the first scheme,the second group optimized the diameter of the two point gates on the part and the position of the second point gate,designed an L16(43)experiment to obtain the gate structure combination with the minimum warping deformation.The warping deformation optimized by the first taguchi experiment was 0.4891 mm,which was reduced by 2.26%compared with the minimum value of the test.The warping deformation obtained by the second group was only 0.4358 mm,which was reduced by 10.9%compared with the initial scheme,indicating that improving the location and structure of the point gate could effectively improve the warping deformation.After the actual production verification,the parts had good surface quality and dimensional accuracy,and met the production and use requirements.