基于响应曲面的卡盖双浇口工艺参数优化与模具设计  

Optimization of Injection Process Parameters and Mold Design for Card-cover Based on the Response Surface Methodology

作　　者：王星星 施允洋[1] 张杰[1] WANG Xingxing;SHI Yunyang;ZHANG Jie(School of Mechanical and Electrical Engineering,Suqian College,Suqian 223800,China)

机构地区：[1]宿迁学院机电工程学院,江苏宿迁223800

出　　处：《塑料工业》2024年第1期67-75,共9页China Plastics Industry

基　　金：2021年宿迁市科技项目资助(编号:K202114);2022年江苏省高校自然基金项目资助(编号:22KJB460008);2022年宿迁市科技项目资助(编号:K202210)。

摘　　要：车用电源卡盖结构复杂与多加强筋的结构特征,在其注塑成型过程可能会阻碍了材料的流动诱发熔接线、翘曲变形等问题,影响产品的表面质量和结构强度。因此,本文将理论算法与有限元仿真相结合开展卡盖制品注塑成型工艺优化与模具设计研究。研究结果如下:首先,根据产品特征确定了点浇口及位置,进而结合Moldflow开展单浇口和双浇口的对比分析并确定了双浇口;其次,以熔接线长度为优化目标,建立响应曲面法实验方案并开展仿真分析;然后,利用最小二乘法、方差分析、回归分析等,确定了以熔接线为优化目标的最优工艺组合,即塑料制品的熔体温度(A)为260℃、模具温度(B)为65℃、注射时间(C)为1.5 s、保压压力(D)70 MPa及保压时间(E)10 s,此时的熔接线最大长度约为5.8 mm,相比于初始分析方案的31.5 mm降低了81.6%;最后,采用UG进行了卡盖的注塑模具设计并进行生产验证,产品填充完整且表面质量良好,为生产提供指导意义。The complex structure and multiple reinforcing ribs of the automotive power card-cover could prevent the flow of materials during injection molding process,which led to problems,such as,melting lines,warping deformation and so on.And it affected the surface quality and structural strength of the product.Therefore,the theoretical algorithm and finite element simulation were combined to research the injection molding process optimization and mold design of card-cover.The results show that firstly the point gate and its location are determined according to the product characteristics,and then the double gates structure is determined by Moldflow analyzed results.Secondly,taking the weld line as optimization objective,the experimental schemes of response surface method are established and the Moldflow analysis is carried out.Then,the least square method,variance analysis,regression analysis,etc.are adopted to ensure the best process parameters,the optimal process combination with the welding line as the optimization objective is determined as the melt temperature of plastic products(A)260℃,mold temperature(B)65℃,injection time(C)1.5 s,holding pressure(D)70 MPa and holding time(E)10 s.The maximum length of the fuse line is about 5.8 mm,which is reduced by 81.6%compared with the initial analysis scheme(31.5 mm).Finally,UG software is used to design the injection mold of the card-cover,the product is filled completely and the surface quality is good by production verification,which provides guidance for the production.

关 键 词：模流分析 响应曲面法 熔接线 模具设计 

分 类 号：TQ320.662[化学工程—合成树脂塑料工业]