Cycle Time Reduction in Injection Molding by Using Milled Groove Conformal Cooling

This paper presents simulation study on Milled Grooved conformal cooling channels(MGCCC)in injection molding.MGCCC has a more effective cooling surface area which helps to provide efficient cooling as compared to conventional cooling.A case study of Encloser part is investigated for cycle time reduction and quality improvement.The performance designs of straight drilled are compared with MGCCC by using Autodesk Moldflow Insight(AMI)2016.The results show total 32.1% reduction of cooling time and 9.86% reduction of warpage in case of MGCCC as compared to conventional cooling.

Effect of Different Shapes of Conformal Cooling Channel on the Parameters of Injection Molding

Cooling system improvement is important in injection molding to get betterquality and productivity. The aim of this paper was to compare the different shapes of theconformal cooling channels (CCC) with constant surface area and CCC with constantvolume in injection molding using Mold-flow Insight 2016 software. Also the CCC resultswere compared with conventional cooling channels. Four different shapes of the CCC suchas circular, elliptical, rectangular and semi-circular were proposed. The locations of thecooling channels were also kept constant. The results in terms of cooling time, cycle timereduction and improvement in quality of the product shows that no significant effect ofCCC’s shapes when surface area of CCC kept constant. On the other hand, the rectangularCCC shows better result as compared to other shapes of CCC when volume of CCC werekept constant.

A Tool Path Re-generation Algorithm for Die & Mold Machining

Facing the challenges of a shorter product design a nd manufacturing lead-time, many mold companies are using 3-D CAD/CAM software s ystems in design and manufacturing. A new product file is often issued to the mo ld design department before it is completely finalized and the design may have t o be iterated many times during the mold design and making processes. In practic e, if a mold has been modified, all the tool paths that cover the modified regio n must be re-generated, no matter how small the modified region may be. With th e available tool path generation systems, if a tool path needs to be re-generat ed, all the cutter location (CL) points must be re-calculated, and none of the original CL points can be re-used. It would require as much time to re-gen erate the modified tool path as in the original case. On the other hand, the mod ified region is usually quite small compared with the entire mold. The complete re-generation process is therefore highly unproductive and time-consuming. This paper proposes an efficient tool path re-generation approach for 3-axis d ie and mold machining. It is assumed in this research that a gouge-free too l path has been generated for the original mold and the same ball end-mill is to be used to generate the tool path for the modified mold. It is shown in th is work that if the boundary of the modified region is interference-free, the a ffected CL points are enclosed by a set of CL points which correspond to the poi nts on the boundary of the modified region. An efficient tool path re-generatio n algorithm was developed in this research. With this algorithm, a closed CL cur ve is first generated from the boundary of the affected region. The CL points fo r the original mold are then analyzed by comparing the x and y values with the b oundary of the affected CL points. If the CL points are not affected by the modi fication, they are output to the new CL file directly. Otherwise, they are remov ed and replaced by the new CL points. The algorithm has been tested using severa l industrial parts, and results show that it is efficient, robust, and the re-g enerated tool path is gouge-free and smooth.

CAx Process Chain for Automated Laser Drilling of Tool Molds

Rotation sintering, also known as slush molding, is used to manufacture molded skins, such as dashboards or door interior panels for cars. At present, approximately 80% of such molded skins are manufactured using electroforms to achieve the complex free-form surfaces, and surface structures, such as leather graining that the industry demands. The manufacture of these electroforms is, however, time-consuming and expensive. This project aims to replace conventional electroforms with laser-drilled molds. Holes in tool molds should be drilled by using laser radiation as part of an automated process. The system consists of a robot with a fiber-laser beam source. A CAx （computer-aided x） process chain has been developed for this purpose in which the CAD （computer-aided design） data of the tool molds are processed, drill hole fields generated, and a machine-specific RC （robot control） program created. Process-specific fundamentals, such as suitable process windows and process control, have been devised to manufacture holes using fiber laser radiation The advantages of the new laser-drilled tool molds may result in substituting them for conventional electroforms, allowing old markets to be re-entered or additional markets to be created and targeted through new molds or lower costs.

水稻营养秧盘成型机制浆装置的优化设计

为解决水稻营养秧盘成型机制浆装置现存在的漏液锈蚀、管道堵塞和结构布置不合理等问题,在分析研究成型机整体配置的基础上,优化设计一种满足作业条件、避免锈蚀堵塞的制浆装置,并进行研制试验。试验结果表明,该制浆装置结构布置合理性更好,材料选型优秀,制浆效率较原系统提高17.74%,同比增长22.42%,与现有的水稻营养秧盘成型机可充分适配,满足设计要求。该制浆装置可有效解决实际生产中的问题,面向实际需求,可为研究浆料混拌提供一定参考。

低熔点合金在异形复材零件成型工装的应用

针对低熔点合金的基本特性分析了其作为低温固化的异形复材零件成型工装材料的优势。结合具体案例,介绍了低熔点合金工装的设计与制造过程。经过实际应用生产出的零件尺寸与表面精度符合使用要求,表明该技术在工程上具备可行性与推广价值。

汽车注塑模具加工中数控机床误差控制

针对汽车注塑模具加工过程中,空间误差未得到有效控制,导致实际应用中汽车注塑模具质量不高的问题,提出了数控机床加工汽车注塑模具时的误差控制方法。首先,建立空间误差模型分析数控机床加工汽车注塑模具时产生的误差;其次,将模具生产质量作为优化目标,将模具工艺参数作为决策变量,基于神经网络算法建立误差控制目标函数;最后,通过白鲨优化算法求解目标函数,实现误差控制。仿真结果表明,所提方法具有较高的控制精度,可降低模具加工过程中的缩痕程度,翘曲变形量始终保持在0.230 mm以下,误差控制效果好。

Rapid Tooling Technique Based on Stereolithograph Prototype

Rapid tooling technique based on the sterelithograph prototype is investigated. The epoxy tooling technological process was elucidated. It is analyzed in detail that the epoxy resin formula is easy to cast, curing process, and release agents. The transitional plaster model is also proposed. The mold to encrust mutual.inductors with epoxy and mold to inject plastic soapboxes was made with the technique The tooling needs very little time and cost, for the process is only to achieve the nice replica of the prototype. It is benefit for the trial and small batch of production.

HSM strategy study for hardened die and mold steels manufacturing based on the mechanical and thermal load reduction strategy

The paper discussed cutter-work engagement situation hidden behind the mechanical and thermal load effect on cutting edges during high speed hard machining process. The engagement situation was investigated in great detail using experimental and geometrical analytic measures. Experiments were conducted using A1TiN-coated micro-grain carbide end mill cutters to cut hardened die steel. On the basis, a general high speed hard machining strategy, which aimed at eliminating excessive engagement situation during high-speed machining （HSM） hard machining, was proposed. The strategy includes the procedures to identify prone-to-overload areas where excessive engagement situation occurs and then to create a reliable tool path, which has the effect of cutting load reduction to remove the prone-to-overload areas.

Comparative Moisture Performance of Wood/Wood-Based Claddings Predicted by Four Hygrothermal Simulation Tools

A number of hygrothermal(HAM)numerical simulation packages are available,either wholly or partially dedicated to heat,air and moisture transfer simulations of building materials and wall assemblies.The objective of this work was to compare the HAM responses and moisture performance of western red cedar and composite wood claddings of a wood frame wall as predicted by four HAM simulation tools:DELPHIN,WUFI,hygIRC,and COMSOL.Three Canadian cities having different climates were selected for simulation:Ottawa(ON),Vancouver(BC)and Calgary(AB).In each city,simulations were run for two years as selected from a historical climate data set based on the moisture index(MI).The wall orientation receiving the most wind-driven rain for the two years was selected for simulations.Material properties were taken from the National Research Council(NRC)material property database.Cladding temperature and relative humidity(RH)values as well as the moisture accumulated in the entire structure were compared amongst the results obtained from the four tools.The mold growth index on the cladding surface was used as a basis for comparing the moisture performance.

一种涡轮盘榫槽的组合加工刀具设计研究

汽轮机涡轮盘连接叶片的位置通常采用榫槽结构。针对小型燕尾型榫槽,目前常采用一种成型刀具一次加工成型,导致被加工零件精度低、表面粗糙度差且刀具成本高。为解决目前制造工艺的局限性,提出了一种组合刀具设计思路。首先,根据燕尾槽型榫槽的结构特点,设计出4把刀的刀具型线和尺寸参数,通过UG等建模软件建立模型,利用ANSYS软件进行有限元分析;然后,制定组合刀具的制造工艺方案,通过NUMROTO刀具编程软件进行路径规划和程序编制;最后在SAACKE五轴工具磨床上磨削加工出合格的组合刀具。通过仿真及实际切削试验验证了该方案切实可行,相较于传统加工方法,有着加工精度高、表面粗糙度低、切削热低且成本低等优点。

精密模具的发展与专业人才培养

当今社会中模具制造与生活息息相关,在新时代的今天,制造业的蓬勃发展以超出想象。机械工业的高端发展,数控机床的广泛利用以及高精尖的精密设备都促进了模具行业精度的提高。精密模具已经越来越被厂家认可,高端设备也越来越受到人们的青睐。那么如何才能随着科技水平的发展培养出适应现代化先进技术的高端人才呢?这就需要提高职业技能水平的稳健和扎实,也需要高等职业院校为培养人才做出贡献。

晶体管外壳封装元器件高可靠性成型工艺优化与工装设计

针对晶体管外壳(TO)封装元器件在单板设计中的高可靠性要求,以及成型难度大、成型钳不易操作等问题,对TO封装元器件成型过程的机理与操作进行分析并设计简易成型工装,经实际操作验证进一步优化工装设计。结果表明,工装成型方法可靠、成型质量高、成型操作简单、成型效率高且工艺稳定性好,能够很好地应用于印制电路板生产过程中TO封装器件的成型。

聚氨酯组合物提取工具痕迹效果研究

本文对聚氨酯组合从物理、化学性质等角度展开分析研究,根据反应特性提取以木质、金属、塑料、漆面四种常见的承痕客体上的工具痕迹,以硅橡胶制模法为对照实验,在操作时间、材料性质、提取效果三方面进行对比,来确定聚氨酯组合物是否能代替硅橡胶制模法的可行性。

常见工模具钢分类及热处理工艺

工模具钢是模具制造业的基础,它的选择对模具加工行业中的模具设计和制造有着至关重要的作用。工模具钢广泛应用于汽车、航空航天、无线电仪表等行业,且随着模具加工行业的进步和模具钢的大范围应用,研究工模具钢的性能就显得十分重要。热处理工艺是将模具钢应用于实际中的重要一环,合理的热处理工艺可以改善模具钢的强度性能和工艺性能。目前,在试验研究和实际生产领域已有多种热处理工艺,并且研究人员仍在致力于更加高效、更加绿色的新工艺开发。主要概述了一些常见的工模具钢热处理工艺,并对其发展趋势做出展望。

3D打印砂型在机床工作台铸件上的应用

根据铸件结构、尺寸及现有3D打印设备等条件,规划了机床工作台铸件砂型的整体3D打印方案,确定了工作台铸件的浇注系统、工装配箱、熔炼工艺与关键参数,针对工作台铸件生产过程中常见的铸造缺陷进行了分析和预防,目前已大批量生产出质量稳定,成品率高的机床工作台铸件。

一种“鸭嘴”式浇管在机床铸件生产中的应用

探讨了“鸭嘴”式浇管在机床铸件实型铸造中的应用,重点分析了其优点与局限性。研究表明,“鸭嘴”式浇管能够有效控制铸件凝固过程中的浇口封闭时间,利用石墨化膨胀补偿铸件收缩,显著降低缩孔和缩松缺陷的倾向。此外,该浇管形状设计使其在清理过程中的效率提高,适应性良好,特别是在无法使用圆形浇口的狭窄位置。然而,其独特结构可能导致流场紊流,增加气泡和夹渣的风险,需在具体铸件结构设计时谨慎评估。未来的研究应集中于优化“鸭嘴”式浇管的设计参数,以进一步提升铸件质量。

模具制造中的高速加工技术

分析了传统电加工工艺在模具制造中存在的主要问题 ,介绍了超高速加工技术的主要特点 ,论述了超高速加工用于模具制造的关键技术 ,列举了一些应用实例和使用效果 。

基于UG的斜齿轮三维参数化设计方法——扫描成型法

提出一种斜齿轮三维参数化通用设计方法———扫描成型法。该方法利用UG软件的相关功能 ,生成斜齿轮的端面和法面轮廓线 ,并沿螺旋线扫描获得斜齿轮廓面 ;通过对造型实体进行裁剪操作生成单个轮齿 ,然后通过布尔运算获得完整轮齿 。

复合材料构件成型模具的参数化设计

文摘实现复合材料构件成型工装的快速设计对缩短生产准备时间、提高构件质量具有重要意义。本文分析了复合材料构件成型模具的结构和建模特点及要求,提取了结构各部分的设计参数;基于CATIA和CAA平台开发了复合材料构件成型模具设计系统,并应用于飞机复合材料构件的成型模具设计中,验证了本文方法的可行性。