空调面盖模内装饰成型注塑CAE优化分析

Injection Moulding CAE Optimization Analysis for In-mold Decoration Air Conditioner Covers

针对空调面盖塑件采用模内装饰(IMD)工艺成型中内壁内衬本体的注塑成型进行了计算机辅助工程(CAE)仿真优化分析,获得了该IMD塑件成型模具设计所需的浇注系统、冷却系统及注塑工艺参数。IMD塑件由带油墨印刷图案的聚甲基丙烯酸甲酯(PMMA)-环氧树脂(EP)共聚物(PMI)+PMMA(PMI+PMMA)外壁预成型膜片,与聚碳酸酯(PC)和丙烯腈-丁二烯-苯乙烯共聚物(ABS)的混合物内壁内衬本体通过注塑结合而成。采用Moldflow CAE分析中“重叠注塑分析”序列对IMD的注塑成型进行优化分析,分析模型中,将IMD塑件的预成型膜片设置为使用PMI+PMMA材质镶件的第一射,内壁内衬本体成型设置为使用PC+ABS材质的第二射。结果表明,在控制内壁内衬本体熔料温度低于预成型膜片熔化温度20℃及最优浇口采用单点Φ4 mm热浇口浇注的条件下,第二射内壁内衬本体注塑成型优化获得最优浇口位置对应的前沿温度差为9.5℃,注塑时间为1.533 s,注塑压力为104.52 MPa,能有效防止预成型膜片重熔;进一步的流动分析中保压优化为80 MPa/8 s、60 MPa/4 s、40 MPa/4 s、20 MPa/2 s。进一步的冷却翘曲分析中,冷却系统优化为采用24条Φ10 mm管道进行冷却,在料温247.5℃的条件下,模温可控制为77.44℃,成型周期可控为43.5 s,塑件翘曲变形可控制在2.609 mm以下,塑件整体成型精度能控制在MT4~MT6等级范围内,能有效满足塑件的成型要求。

For the air conditioner cover plastic parts,the computer aided engineering(CAE)simulation optimization analysis was conducted on the injection moulding of the inner lining body in the in-mold decoration(IMD)process.The required gating system,cooling system,and injection moulding process parameters for the IMD plastic part molding mould design were obtained.The IMD plastic part was composed of a preformed outer wall film of polymethyl methacrylate(PMMA)-epoxy resin(EP)copolymer(PMI)+PMMA(PMI+PMMA)with ink printed patterns,and an inner lining body of a mixture of polycarbonate(PC)and acrylonitrile-butadiene-styrene copolymer(ABS)by the injection molding.The injection molding of IMD was optimized using the“overlapping injection molding analysis”sequence in the Moldflow CAE analysis.In the analysis model,the preformed membrane of IMD plastic part was set as the first shot using PMI+PMMA material inserts,and the inner lining body was formed as the second shot using PC+ABS material.The results show that,under the conditions of controlling the temperature of the molten material in the inner lining body to be 20℃lower than the melting temperature of the preformed membrane and using a single pointΦ4 mm hot gate for the optimal gating,the second injection molding optimization of the inner lining body obtains a front temperature difference of 9.5℃corresponding to the optimal gate position,an injection time of 1.533 s,and an injection pressure of 104.52 MPa,which could effectively prevent the remelting of the preformed membranes.In the further flow analysis,the pressure is respectively optimized to 80 MPa/8 s,60 MPa/4 s,40 MPa/4 s,and 20 MPa/2 s.In the further cooling and warping analysis,the cooling system is optimized to use 24Φ10 mm pipes for cooling.Under the condition of material temperature of 247.5℃,the mould temperature could be controlled at 77.44℃,the forming cycle could be controlled at 43.5 s,and the warping deformation could be controlled below 2.609 mm.The overall forming accuracy of the plastic part could be controlled in the range of MT4 to MT6,effectively meeting the forming requirements of the plastic parts.