The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improv...The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine.展开更多
The kinetic characteristics of the clamping unit of plastic injection molding machine that is controlled by close loop with newly developed double speed variable pump unit are investigated. Considering the wide variat...The kinetic characteristics of the clamping unit of plastic injection molding machine that is controlled by close loop with newly developed double speed variable pump unit are investigated. Considering the wide variation of the cylinder equivalent mass caused by the transmission ratio of clamping unit and the severe instantaneous impact force acted on the cylinder during the mold closing and opening process, an adaptive control principle of parameter and structure is proposed to improve its kinetic performance. The adaptive correlation between the acceleration feedback gain and the variable mass is derived. The pressure differential feedback is introduced to improve the dynamic performance in the case of small inertia and heavy impact load. The adaptation of sum pressure to load is used to reduce the energy loss of the system. The research results are verified by the simulation and experiment, The investigation method and the conclusions are also suitable for the differential cylinder system controlled by the traditional servo pump unit.展开更多
This study investigated the relationship between a subject’s evaluation of injection molding machines (IMMs) and formal design features using Kansei engineering. This investigation used 12 word pairs to evaluate the ...This study investigated the relationship between a subject’s evaluation of injection molding machines (IMMs) and formal design features using Kansei engineering. This investigation used 12 word pairs to evaluate the IMM configurations and employed the semantic differential method to explore the perception of 60 interviewees of 12 examples. The relationship between product feature design and corresponding words was derived by multiple regression analysis. Factor analysis reveals that the 12 examples can be categorized as two styles—advanced style and succinct style. For the advanced style, an IMM should use a rectangular form for the clamping-unit cover and a full-cover for the injection-unit. For the succinct style, the IMM configuration should use a beveled form for the safety cover and a vertical rectangular form for the clamping-unit cover. Quantitative data and suggested guidelines for the relationship between design features and interviewee evaluations are useful to product designers when formulating design strategies.展开更多
This paper introduces a new type machine for polyblends with excellent mixing capabilities of internal mixer and continuous molding character of extruder.The machine includes two functions - mixing and extrusion moldi...This paper introduces a new type machine for polyblends with excellent mixing capabilities of internal mixer and continuous molding character of extruder.The machine includes two functions - mixing and extrusion molding that have been composed together by rational design,so a tandem production mode - "batch + continuous" are opened up.The mathematical model of continuous mixing molding was established and verified availably by experimental research.The main physical mechanical property of vulcanizate,which had met national waterproof material standard,verified the machine practicability.The essential difference from other similar type machines is that this machine is not only suitable in producing granular and powder rubbers but also lumpish rubbers.展开更多
This study is based on the modification and development of a two-liter plastic container blow molding machine into a five-liter one provided with a translucent view stripe. This study considers some objectives includi...This study is based on the modification and development of a two-liter plastic container blow molding machine into a five-liter one provided with a translucent view stripe. This study considers some objectives including reducing the total cost, increasing the amount of plastic recovery, and raising the desired plastic materials. Proper designs were prepared and directly applied on spot. Tangible results were obtained. Among others, the modification of some components of the machine, e.g. the extruder, has led to the possible reuse of the milled (recovery) and extra material from the manufacturing processes. That was also conducive to an effective reduction in the cost of production to 50% in some cases. Prior to its modification, this old machine was used to produce polyvinyl chloride (PVC) containers that have become prohibited these days for their damaging effect on man’s life. For now, and after modification, it has become possible to use High Density Polyethylene (HDPE) material, a fact that has improved labor conditions, too.展开更多
To illuminate the necessity of model evolvement and rouse,dynamics of injection molding machine' sproduct models are analyzed.The performance knowledge is used to support the model evolvement andreuse.The driven f...To illuminate the necessity of model evolvement and rouse,dynamics of injection molding machine' sproduct models are analyzed.The performance knowledge is used to support the model evolvement andreuse.The driven factors of mechanical product model are concluded.The dynamic characteristics ofproduct model are described.The.performance knowledge is used to improve specific evolvement process.The upper-layer passing rules are adopted in the mechanical product comfiguration design.The rules ofproduct model evolvement are investigated.And the model evolvement of injection molding machine hasthree levels.Practical and effective realization arithmetic is given to roalize the performance knowledgereuse.Finally,HT1800X1N series injection molding machines are taken as examples to illuminate thatthe arithmetic is correct and practical.展开更多
A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating u...A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating under cutting and cooling under non-cutting. It shows that cutting speed and the tool-workpiece engagement condition are determinative for tool temperature in the operation. The suggested model was investigated by tests of AlTiN coated endmill machining hardened die steel JIS SKD61, where cutting temperature on the flank face of tool was measured with an optical fiber type radiation thermometer. Experimental results show that the tendency of cutting temperature to increase with cutting speed and engagement angle is intensified with the progressing tool wear.展开更多
Micro prism film used in LCD industry can be manufactured by roll to roll method with copper-plated roll mold. As copper-plated roll mold is getting larger, pitch error is getting severer. The pitch error drops the qu...Micro prism film used in LCD industry can be manufactured by roll to roll method with copper-plated roll mold. As copper-plated roll mold is getting larger, pitch error is getting severer. The pitch error drops the quality of micro prism film. The main cause of the pitch error was investigated during machining large roll mold whose machined length was 1 200 mm. The temperature of machining system was elevated during machining roll mold, and this elevation induced thermal expansion of the system. The temperature variation around the roll mold also made thermal expansion of the roll mold. The amount of thermal expansion had strong relationship to the amount of pitch error. Therefore, the roll mold was machined after warming-up of machining system and precise temperature controller around copper-plated roll mold was installed, which minimized the temperature variation. Finally, precise micro prism patterns without pitch error were machined on the large roll mold.展开更多
Computer aided design of heat treatment for AISI P20 mold steel with good machinability is attempted to proceed by the commercial software package Thermo-Calc (TCP+DICTRA). Through experimental and theoretical analysi...Computer aided design of heat treatment for AISI P20 mold steel with good machinability is attempted to proceed by the commercial software package Thermo-Calc (TCP+DICTRA). Through experimental and theoretical analysis of phase transformation during heat treatment, further knowledge of designing proper heat treatment is obtained. Then the machinability of AISI P20+Ni steel under given heat treatment condition is studied and the influencing factors to their machinability are analyzed. It is shown that heat treatment designed by computer simulation of carbide transformation is applicable to AISI P20+Ni steel with good machinability; AISI P20+Ni steel with tempered sorbite treated by quenching & tempering has optimal machinability; normalizing at the temperature of 910°C & tempering can avoid cracking and result in acceptable machinability in small thickness module.展开更多
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 ...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.展开更多
In order to improve the machinability but not to impair other properties of the prehardened mold steel for plastic, the composition was designed by application of Thermo-Calc software package to regulate the type of n...In order to improve the machinability but not to impair other properties of the prehardened mold steel for plastic, the composition was designed by application of Thermo-Calc software package to regulate the type of non-metallic inclusion formed in the steel. The regulated non-metallic inclusion type was also observed by SEM and EDX. Then the machinability assessment of the steel with designed composition under different conditions was studied by the measurement of tool wear amount and cutting force. The results show that the composition of free cutting elements adding to mold steel for plastic can be optimized to obtain proper type of non-metallic inclusion in the aid of Thermo-Calc, compared with the large volume fraction of soft inclusion which is needed for promoting ductile fracture at low cutting speeds, the proper type of inclusion at high cutting speeds is glassy oxide inclusion. All those can be obtained in the present work.展开更多
基金Supported by National Natural Science Foundation of China(Grant No.51205350)Hong Kong Scholars Program of China(Grant No.XJ2013015)Zhejiang Provincial Research Program of Public Welfare Technology Application of China(Grant No.2013C31027)
文摘The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine.
基金This project is supported by National Natural Science Foundation of China (No.50275102)Opening Foundation of State Key Lab of Fluid Power Transmission and Control of Zhejiang University, China (No.GZKF2002004).
文摘The kinetic characteristics of the clamping unit of plastic injection molding machine that is controlled by close loop with newly developed double speed variable pump unit are investigated. Considering the wide variation of the cylinder equivalent mass caused by the transmission ratio of clamping unit and the severe instantaneous impact force acted on the cylinder during the mold closing and opening process, an adaptive control principle of parameter and structure is proposed to improve its kinetic performance. The adaptive correlation between the acceleration feedback gain and the variable mass is derived. The pressure differential feedback is introduced to improve the dynamic performance in the case of small inertia and heavy impact load. The adaptation of sum pressure to load is used to reduce the energy loss of the system. The research results are verified by the simulation and experiment, The investigation method and the conclusions are also suitable for the differential cylinder system controlled by the traditional servo pump unit.
文摘This study investigated the relationship between a subject’s evaluation of injection molding machines (IMMs) and formal design features using Kansei engineering. This investigation used 12 word pairs to evaluate the IMM configurations and employed the semantic differential method to explore the perception of 60 interviewees of 12 examples. The relationship between product feature design and corresponding words was derived by multiple regression analysis. Factor analysis reveals that the 12 examples can be categorized as two styles—advanced style and succinct style. For the advanced style, an IMM should use a rectangular form for the clamping-unit cover and a full-cover for the injection-unit. For the succinct style, the IMM configuration should use a beveled form for the safety cover and a vertical rectangular form for the clamping-unit cover. Quantitative data and suggested guidelines for the relationship between design features and interviewee evaluations are useful to product designers when formulating design strategies.
基金National Natural Science Foundation of China(No.50375075)
文摘This paper introduces a new type machine for polyblends with excellent mixing capabilities of internal mixer and continuous molding character of extruder.The machine includes two functions - mixing and extrusion molding that have been composed together by rational design,so a tandem production mode - "batch + continuous" are opened up.The mathematical model of continuous mixing molding was established and verified availably by experimental research.The main physical mechanical property of vulcanizate,which had met national waterproof material standard,verified the machine practicability.The essential difference from other similar type machines is that this machine is not only suitable in producing granular and powder rubbers but also lumpish rubbers.
文摘This study is based on the modification and development of a two-liter plastic container blow molding machine into a five-liter one provided with a translucent view stripe. This study considers some objectives including reducing the total cost, increasing the amount of plastic recovery, and raising the desired plastic materials. Proper designs were prepared and directly applied on spot. Tangible results were obtained. Among others, the modification of some components of the machine, e.g. the extruder, has led to the possible reuse of the milled (recovery) and extra material from the manufacturing processes. That was also conducive to an effective reduction in the cost of production to 50% in some cases. Prior to its modification, this old machine was used to produce polyvinyl chloride (PVC) containers that have become prohibited these days for their damaging effect on man’s life. For now, and after modification, it has become possible to use High Density Polyethylene (HDPE) material, a fact that has improved labor conditions, too.
基金the National Natural Science Foundation(No50505044,60573175)the Key Technology Research and Development of China(No2006BAF01A37)+1 种基金the National High Technology Research and Development Programe of China(No2007AA04Z190)the Key Scientific and Techological Research Program of Zhejiang Province(No2008C11013)
文摘To illuminate the necessity of model evolvement and rouse,dynamics of injection molding machine' sproduct models are analyzed.The performance knowledge is used to support the model evolvement andreuse.The driven factors of mechanical product model are concluded.The dynamic characteristics ofproduct model are described.The.performance knowledge is used to improve specific evolvement process.The upper-layer passing rules are adopted in the mechanical product comfiguration design.The rules ofproduct model evolvement are investigated.And the model evolvement of injection molding machine hasthree levels.Practical and effective realization arithmetic is given to roalize the performance knowledgereuse.Finally,HT1800X1N series injection molding machines are taken as examples to illuminate thatthe arithmetic is correct and practical.
文摘A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating under cutting and cooling under non-cutting. It shows that cutting speed and the tool-workpiece engagement condition are determinative for tool temperature in the operation. The suggested model was investigated by tests of AlTiN coated endmill machining hardened die steel JIS SKD61, where cutting temperature on the flank face of tool was measured with an optical fiber type radiation thermometer. Experimental results show that the tendency of cutting temperature to increase with cutting speed and engagement angle is intensified with the progressing tool wear.
基金Project (2010-0008-277) supported by NCRC (National Core Research Center) Program through the National Research Foundation of Korea funded by the Ministry of Education, Science and Technology, Korea
文摘Micro prism film used in LCD industry can be manufactured by roll to roll method with copper-plated roll mold. As copper-plated roll mold is getting larger, pitch error is getting severer. The pitch error drops the quality of micro prism film. The main cause of the pitch error was investigated during machining large roll mold whose machined length was 1 200 mm. The temperature of machining system was elevated during machining roll mold, and this elevation induced thermal expansion of the system. The temperature variation around the roll mold also made thermal expansion of the roll mold. The amount of thermal expansion had strong relationship to the amount of pitch error. Therefore, the roll mold was machined after warming-up of machining system and precise temperature controller around copper-plated roll mold was installed, which minimized the temperature variation. Finally, precise micro prism patterns without pitch error were machined on the large roll mold.
基金supported by the key project of Science and Technology Commission of Shanghai Local Government(015211010)
文摘Computer aided design of heat treatment for AISI P20 mold steel with good machinability is attempted to proceed by the commercial software package Thermo-Calc (TCP+DICTRA). Through experimental and theoretical analysis of phase transformation during heat treatment, further knowledge of designing proper heat treatment is obtained. Then the machinability of AISI P20+Ni steel under given heat treatment condition is studied and the influencing factors to their machinability are analyzed. It is shown that heat treatment designed by computer simulation of carbide transformation is applicable to AISI P20+Ni steel with good machinability; AISI P20+Ni steel with tempered sorbite treated by quenching & tempering has optimal machinability; normalizing at the temperature of 910°C & tempering can avoid cracking and result in acceptable machinability in small thickness module.
文摘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.
基金Project(015211010) supported by the Key Project of Science and Technology Commission of Shanghai Local Govern ment China
文摘In order to improve the machinability but not to impair other properties of the prehardened mold steel for plastic, the composition was designed by application of Thermo-Calc software package to regulate the type of non-metallic inclusion formed in the steel. The regulated non-metallic inclusion type was also observed by SEM and EDX. Then the machinability assessment of the steel with designed composition under different conditions was studied by the measurement of tool wear amount and cutting force. The results show that the composition of free cutting elements adding to mold steel for plastic can be optimized to obtain proper type of non-metallic inclusion in the aid of Thermo-Calc, compared with the large volume fraction of soft inclusion which is needed for promoting ductile fracture at low cutting speeds, the proper type of inclusion at high cutting speeds is glassy oxide inclusion. All those can be obtained in the present work.