基于 Moldflow 的汽车中控台框架翘曲变形分析及优化

以某汽车中控台框架为研究对象,测量试模样品发现其翘曲变形量超过了装配要求。通过Moldflow软件模拟了该塑件实际的注塑过程,翘曲变形量的模拟值与实测平均值的最大误差为5.98%,发现该塑件翘曲变形的主要因素为冷却不均和收缩不均。本文在原物料中添加质量分数为25%的玻璃纤维以及优化工艺参数后,翘曲变形量的模拟值与初始方案相比降低了86.22%。试模验证表明,优化后的翘曲变形量模拟值与实测平均值的最大误差为4.35%,证明了Moldflow软件模拟分析的准确性。试模后各检测点的最大翘曲变形量降到了1.6 mm以下,较优化之前降低了80%以上,为类似大型复杂注塑件的翘曲变形分析及优化提供了思路。

基于Moldflow软件对薄壁件某塑料喷嘴的注塑方案优化研究

喷嘴注塑产品的质量和性能很大程度上由注塑方案和工艺参数所决定,不当的注塑方案和工艺参数会导致充填不足、熔接线过多、翘曲变形量大等问题。为了可以减少生产周期,节约生产成本,利用三维软件UG对喷嘴进行建模,基于模流分析软件Moldflow软件对喷嘴注塑产品进行分析和优化,通过比较点浇口和侧浇口两种方案的分析结果,最终确定该产品点浇口的方案更好。并通过设计正交实验,得到优化后的工艺参数。

基于MoldFlow太阳能储能系统下盖成型模拟及应用

以太阳能储能系统下盖模流分析为例,反复修改流道和浇口截面尺寸与长度以及主流道位置,确定流道尺寸。运用MoldFlow对设计好的流道进行充填分析,以使成型达到流动平衡,并进行冷却、翘曲分析,预测成型缺陷,提出解决措施,为模具设计提供浇注系统和冷却系统方案和注射成型工艺参数,并应用于模具设计和实际生产。

Mold Filling and Prevention of Gas Entrapment in High-pressure Die-casting

This paper presents some results of direct observation of mold filling in a specially designed die-casting by X-ray diffraction, including comparison with numerical simulation. Based on such work the authors discuss how to prevent gas entrapment and propose new methods.

基于Moldex 3D与正交试验的离心泵泵头注塑工艺优化

以商用离心泵泵头为研究对象,运用Moldex3D模流分析软件对其注塑成型过程进行了模拟。根据产品的结构特点设置了三种浇口方案,通过对注塑过程的模拟分析选出最佳方案来获得模具设计思路并预测制品成型后可能存在的质量问题。结果表明,平衡进浇方案的制品具有最好的综合性能,制品的翘曲变形量为1.588 mm,体积收缩率为2.444%。确认最佳浇口方案后,将充填时间(A)、保压时间(B)、冷却时间(C)和模具温度(D)作为实验因素,采用田口法构建五因素四水平的正交试验来获得最佳工艺参数,并使用极差和方差分析对结果进行置信度检测。以翘曲总位移结果为主要权重对象,通过极差分析确定了成型参数的最优组合为A_(1)B_(1)C_(1)D_(1),方差分析则验证了极差分析的结果置信度高于99%。相较于初始方案,制品的翘曲变形量从1.588 mm降低至1.214 mm,降低了23.6%;冷却时间降低至10 s,降低了40%。得知模流分析技术的使用让产品的质量和生产效率都得到了明显的优化,为预测塑件性能、降低生产成本、提高生产效率提供了一种可行的方式。

基于Moldflow的排水泵过滤网注塑工艺优化与模具设计

利用Moldflow对塑料排水泵过滤网的注塑成型过程进行仿真,通过对其结构分析制定了合理的浇口位置和冷却水路。利用三因素三水平正交试验,研究了熔体温度(A)、充填压力(B)和开模时间(C)对于塑件翘曲变形的影响,得出较优的工艺参数组合为A_(1)B_(3)C_(3),即熔体温度220℃,充填压力80%,开模时间6 s,此时塑件的最大翘曲变形量为0.632 8 mm,与优化前相比降低了10.37%。最后依据Moldflow的分析结果,利用UG软件对注塑模具的结构进行了设计,根据塑件卡扣的结构特点,型腔采用整体式结构,型芯设计为组合式(主型芯+滑块)结构,并采用三组“斜导柱+滑块”式侧向抽芯机构解决脱模问题。为实现顺序脱模,借助尼龙塞以增加定模板与动模板之间的开模阻力,设计了内置式“小拉杆+拉杆套”结构的定距分型机构;考虑到塑件形状和模具结构与成本,设计了沿塑件侧壁轮廓排布的圆推杆脱模机构;为避免气纹、气穴等缺陷的形成,在型腔处设计了排气槽结构。该模具结构设计较为合理,可为其他结构相似塑件的模具设计提供有益参考和指导。

Irregular initial solidification by mold thermal monitoring in the continuous casting of steels:A review

Occasional irregular initial solidification phenomena,including stickers,deep oscillation marks,depressions,and surface cracks of strand shells in continuous casting molds,are important limitations for developing the high-efficiency continuous casting of steels.The application of mold thermal monitoring(MTM) systems,which use thermocouples to detect and respond to temperature variations in molds,has become an effective method to address irregular initial solidification phenomena.Such systems are widely applied in numerous steel companies for sticker breakout prediction.However,monitoring the surface defects of strands remains immature.Hence,indepth research is necessary to utilize the potential advantages and comprehensive monitoring of MTM systems.This paper summarizes what is included in the irregular initial solidification phenomena and systematically reviews the current state of research on these phenomena by the MTM systems.Furthermore,the influences of mold slag behavior on monitoring these phenomena are analyzed.Finally,the remaining problems of the formation mechanisms and investigations of irregular initial solidification phenomena are discussed,and future research directions are proposed.

Management of Strawberry Grey Mold Disease Using Biocontrol Agents and Plant Extracts

Strawberry (Fragaria × ananassa Duch.) is a significant global soft fruit crop, prized for its nutrient content and pleasant flavor. However, diseases, particularly grey mold caused by Botrytis cinerea Pers. Fr. poses major constraints to strawberry production and productivity. Grey mold severely impacts fruit quality and quantity, diminishing market value. This study evaluated five B. cinerea isolates from various locations in the Ri-Bhoi district of Meghalaya. All isolates were pathogenic, with isolate SGM 2 identified as highly virulent. Host range studies showed the pathogen-producing symptoms in the fava bean pods, marigold, gerbera, and chrysanthemum flowers and in the fava bean, gerbera, and lettuce leaves. In vitro tests revealed that neem extract (15% w/v) achieved the highest mycelial growth inhibition at 76.66%, while black turmeric extract (5% w/v) had the lowest inhibition at 9.62%. Dual culture methods with bio-control agents indicated that Bacillus subtilis recorded the highest mean inhibition at 77.03%, while Pseudomonas fluorescens had the lowest at 20.36% against the two virulent isolates. Pot evaluations demonstrated that B. subtilis resulted in the lowest percent disease index at 20.59%, followed by neem extract at 23.31%, with the highest disease index in the control group at 42.51%. Additionally, B. subtilis significantly improved plant growth, yielding an average of 0.32 kg compared to 0.14 kg in the control. The promising results of B. subtilis and neem leaf extract from this study suggest their potential for eco-friendly managing grey mold in strawberries under field conditions.

Effects of the Water-Cement Ratio and the Molding Temperature on the Hydration Heat of Cement

The effects of the water-cement ratio and the molding temperature on the hydration heat of cement were investigated with semi-adiabatic calorimetry.The specimens were prepared with water-cement ratios of 0.31,0.38,and 0.45,and the molding temperature was specified at 10 and 20℃.The experimental results show that,as the water-binder ratio increases,the value of the second temperature peak on the temperature curve of the cement paste decreases,and the age at which the peak appears is delayed.The higher the water-cement ratio,the higher the hydration heat release in the early period of cement hydration,but this trend reverses in the late period.There are intersection points of the total hydration heat curve of the cement pastes under the influence of the water-cement ratio,and this law can be observed at both molding temperatures.With the increase in the molding temperature,the age of the second temperature peak on the temperature curve of the cement paste will advance,but the temperature peak will decrease.The higher the molding temperature,the earlier the acceleration period of the cement hydration began,and the larger the hydration heat of the cement in the early stage,but the smaller the total heat in the late period.A subsection function calculation model of the hydration heat,which was based on the existing models,was proposed in order to predict the heat of the hydration of the concrete.

Assessing efficacy of standard impregnation techniques on die-cast aluminum alloys using X-ray micro-CT

Utilizing lightweight Al alloys in various industrial applications requires achieving precise pressure tightness and leak requirements.Vacuum pressure impregnation(VPI)with thermosetting polymers is commonly used to address leakage defects in die-cast Al alloys.In this study,the efficacy of the VPI technique in sealing alloy parts was investigated using a combination of nondestructive micro X-ray computed tomography(micro XCT)and a standard leak test.The results demonstrate that the commonly used water leak test is insufficient for determining the sealing performance.Instead,micro XCT shows distinct advantages by enabling more comprehensive analysis.It reveals the presence of a low atomic number impregnates sealant within casting defects,which has low grey contrast and allows for visualizing primary leakage paths in 3D.The effective atomic number of impregnated resin is 6.75 and that of Al alloy is 13.69 by dual-energy X-ray CT.This research findings will contribute to enhancing the standard VPI process parameters and the properties of impregnating sealants to improve quality assurance for impregnation in industrial metals.

基于Moldflow的绗缝机夹子注塑模设计

以绗缝机夹子的短板为例,基于Moldflow有限元分析软件,合理确定了塑件的浇口位置和浇口形式,精确预测出塑件的充型时间、注射压力、锁模力等工艺参数,并分析出塑件的体积收缩率及熔接线、气穴等潜在缺陷的位置。有限元模拟结果为注塑成型设备的选型和成型工艺参数的合理制定提供了可靠依据,为模具的优化设计提供了方向。基于Moldflow分析结果,设计出一套一模两腔侧浇口、带斜导柱侧向分型与抽芯机构的注塑模具并一次性试模成功。Moldflow有限元分析软件在注塑模设计中的应用不仅有效降低了模具设计的成本和周期,也为同类零件的模具优化设计提供了参考。

Elimination of cracks in stainless steel casings via 3D printed sand molds with an internal topology structure

The important supporting component in a gas turbine is the casing,which has the characteristics of large size,complex structure,and thin wall.In the context of existing 3DP sand casting processes,casting crack defects are prone to occur.This leads to an increase in the scrap rate of casings,causing significant resource wastage.Additionally,the presence of cracks poses a significant safety hazard after the casings are put into service.The generation of different types of crack defects in stainless steel casings is closely related to casting stress and the high-temperature concession of the sand mold.Therefore,the types and causes of cracks in stainless steel casing products,based on their structural characteristics,were systematically analyzed.Various sand molds with different internal topology designs were printed using the 3DP technology to investigate the impact of sand mold structures on high-temperature concession.The optimal sand mold structure was used to cast casings,and the crack suppression effect was verified by analyzing its eddy current testing results.The experimental results indicate that the skeleton structure has an excellent effect on suppressing cracks in the casing.This research holds important theoretical and engineering significance in improving the quality of casing castings and reducing production costs.

基于Moldex3D的油漆桶桶盖注塑成型过程分析

利用模流分析软件Moldex3D模拟油漆桶桶盖注塑成型过程,研究桶盖模具使用阀式热流道与开式热流道两种不同浇注方案的成型差异,并结合仿真结果设计热流道。通过设计Taguchi DOE实验的因素与水平,优化桶盖产品的注塑工艺参数。结果表明:设定工艺参数为熔体温度250℃,保压时间2 s,冷却时间18 s时,产品没有短射、包封等外观质量问题;优化后的注塑工艺参数有效降低了产品的冷却时间。

基于Moldflow的汽车把手气辅注塑工艺多目标优化

汽车内饰把手是典型的棒状类零件,常采用气体辅助注射成型(GAIM)技术进行生产,以满足把手强度和轻量化要求。由于GAIM技术的成型参数多,塑件成型质量控制难度大,通过运用Moldflow模流仿真分析并结合Taguchi试验方法,以塑件的气体穿透长度和横截面最小壁厚为质量目标来优化成型工艺参数,选择熔体温度、模具温度、气体压力、气体保压时间和预注射量5个主要因素进行正交试验,采用极差分析研究上述5个工艺参数对气体穿透长度和横截面最小壁厚的影响规律,应用多目标综合平衡法得到优化的工艺参数组合,即熔体温度为250℃、模具温度为50℃、气体压力为10 MPa、气体保压时间为10 s、预注射量为75%。通过实际GAIM验证,塑件气体穿透效果良好,满足穿透长度和横截面最小壁厚的要求,塑件质量减轻25%以上,并具有良好的表面质量和尺寸精度,能够显著缩短成型周期,节约塑料材料,提高生产质量和效率,并满足汽车轻量化要求。

Non-Darcy Flow in Molding Sands

Darcy’s law is widely used to describe the flow in porous media in which there is a linear relationship between fluid velocity and pressure gradient. However, it has been found that for high numbers of Reynolds this law ceases to be valid. In this work, the Ergun equation is employed to consider the non-linearity of air velocity with the pressure gradient in casting sands. The contribution of non-linearity to the total flow in terms of a variable defined as a non-Darcy flow fraction is numerically quantified. In addition, the influence of the shape factor of the sand grains on the non-linear flow fraction is analyzed. It is found that for values of the Reynolds number less or equal than 1, the contribution of non-linearity for spherical particles is around 1.15%.

基于Moldflow的车身后护板微孔发泡注塑工艺多目标优化

使用Moldflow软件模拟车身后护板注塑工艺,采用正交试验及灰色关联分析结合熵权法优化注塑工艺参数,并进行了实际试模验证。结果表明:使用微孔发泡注塑成型可实现车身后护板减重及降低翘曲变形量;优化的工艺参数为熔体温度235℃,模具温度35℃,充填时间3.5 s,充填体积百分比92%,初始气体含量1.2%(w),所制零件总质量为1362.2 g,z方向翘曲变形量为1.006 mm,较采用微孔发泡默认工艺组合分别减少了18.4 g,0.478 mm;采用灰色关联分析结合熵权法对工艺优化能满足产品减重和降低翘曲变形量的要求。

基于Moldflow的数码相机前盖塑料成型工艺研究

文章以某数码相机前盖塑件为研究对象,采用Moldflow和Pro/E软件进行塑料成型工艺研究。利用Moldflow软件完成相机前盖模流仿真,对填充时间和气穴分布、回路冷却介质温度和管壁温度、翘曲变形等参数进行分析,然后使用Pro/E软件进行模具结构设计。基于Moldflow的数码相机前盖塑料成型工艺研究为缩短塑件开发周期,提高制品质量,降低生产成本,增强企业竞争力提供参考。

基于Moldflow优化的计算机CPU涡轮风扇模具设计

结合CPU涡轮风扇的注射成型要求,采用CAE辅助分析优化得到了塑件的成型方案为1模1腔、正面中心轴顶端进浇模腔布局,单点热嘴环形热浇口浇注。利用分层抽芯的方法将单个涡轮叶槽的脱模采用上、中、下3层滑块的顺序实施抽芯的方法进行侧抽芯脱模,从而得到整个涡轮风扇叶槽的所需脱模机构为27个滑块机构,分别为上层9个上滑块机构、中层9个中滑块机构、下层9个下滑块机构。根据滑块机构的抽芯驱动需要,将模具的整体结构采用一种假三板模结构,分3次开模,第一次开模用作下层9个滑块机构的侧抽芯驱动;第二次开模用作上层9个滑块机构的侧抽芯驱动;第三次开模用作塑件的完全脱模,第三次开模打开后,随着中层9个油缸驱动9个中滑块侧抽芯动作的完成,塑件自动脱落而实现完全脱模。结合涡轮风扇叶槽难以脱模的实践难题,设计了3层滑块机构按序抽芯,根据模具开模提供的驱动进行设计,有效地解决了涡轮风扇塑件的成型难题,机构动作可靠,生产效率较高。

基于Moldflow的按钮开关帽注塑模具设计

针对某种塑料按钮开关帽带有环形侧凹且帽体壁厚变化不均匀的结构特点,设计了一套带斜导柱侧抽芯机构的一模两腔模具。为改善塑件质量及解决塑件脱模问题,首先,结合Moldflow软件仿真确定了浇口位置和冷却系统,并对塑件的成型过程进行仿真分析,结果显示,塑料熔体充满型腔的时间短且两型腔的充型一致性好,同时,塑件的体积收缩率小且两型腔内的塑件体积变化均匀,型腔内气体的排出情况较好,气穴少,塑件产生的翘曲变形量在合理变形范围之内。其次,对模具结构进行设计,主要包括分型面、成型零件以及侧抽芯机构。由于塑件带有环形侧凹,型芯设计成组合式结构,并由大型芯、滑块和成型杆成型塑件的帽体部分,采用斜导柱侧抽芯机构实现塑件环形侧凹的成型并脱模。通过Moldflow软件分析和优化模具设计方案,可以加快模具的设计过程,提高塑件的成型质量。

基于Moldflow软件的短射法气辅成型数值分析及优化

使用数值成型对短射法气辅成型进行分析及优化。依据经验设计,对塑料扶手设计了3种进气方案,仿真结果表明:设置进气点位于浇口位置附近(方案3),气体虽未能充满所有部位熔体内部,但气道质量最佳。以方案3为基础,优化工艺参数,得到最佳方案为熔体注射量40%,气体延迟时间2.5 s,此时气体充满熔体内部,熔体壁厚减小且壁厚均匀,气道质量较好。以翘曲变形量为考察对象,运用正交试验法继续优化其他工艺参数,得到了最佳工艺方案为:熔体温度240℃,模具温度60℃,保压压力3 MPa,保压时间10 s。