塑料注塑模具中英文对照外文翻译文献.docx

塑料注塑模具中英文对照外文翻译文献.docx

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塑料注塑模具中英文对照外文翻译文献

外文翻译及原文

（文档含英文原文和中文翻译）

【原文一】

CONCURRENTDESIGNOFPLASTICSINJECTIONMOULDS

Abstract

Theplasticproductmanufacturingindustryhasbeengrowingrapidlyinrecentyears.Oneofthemostpopularprocessesformakingplasticpartsisinjectionmoulding.Thedesignofinjectionmouldiscriticallyimportanttoproductqualityandefficientproductprocessing.Mould-makingcompanies,whowishtomaintainthecompetitiveedge,desiretoshortenbothdesignandmanufacturingleadingtimesofthebyapplyingasystematicmoulddesignprocess.

Themouldindustryisanimportantsupportindustryduringtheproductdevelopmentprocess,servingasanimportantlinkbetweentheproductdesignerandmanufacturer.Productdevelopmenthaschangedfromthetraditionalserialprocessofdesign,followedbymanufacture,toamoreorganizedconcurrentprocesswheredesignandmanufactureareconsideredataveryearlystageofdesign.Theconceptofconcurrentengineering（CE）isnolongernewandyetitisstillapplicableandrelevantintoday’smanufacturingenvironment.Teamworkingspirit,managementinvolvement,totaldesignprocessandintegrationofITtoolsarestilltheessenceofCE.TheapplicationofTheCEprocesstothedesignofaninjectionprocessinvolvesthesimultaneousconsiderationofplasticpartdesign,moulddesignandinjectionmouldingmachineselection,productionschedulingandcostasearlyaspossibleinthedesignstage.

Thispaperpresentsthebasicstructureofaninjectionmoulddesign.Thebasisofthissystemarisesfromananalysisoftheinjectionmoulddesignprocessformoulddesigncompanies.Thisinjectionmoulddesignsystemcoversboththemoulddesignprocessandmouldknowledgemanagement.Finallytheprincipleofconcurrentengineeringprocessisoutlinedandthenitsprincipleisappliedtothedesignofaplasticinjectionmould.

Keywords:

Plasticinjectionmoulddesign,Concurrentengineering,Computeraidedengineering,Mouldingconditions,Plasticinjectionmoulding,Flowsimulation

1.Introduction

Injectionmouldsarealwaysexpensivetomake,unfortunatelywithoutamoulditcannotbepossiblehohaveamouldedproduct.Everymouldmakerhashis/herownapproachtodesignamouldandtherearemanydifferentwaysofdesigningandbuildingamould.Surelyoneofthemostcriticalparameterstobeconsideredinthedesignstageofthemouldisthenumberofcavities,methodsofinjection,typesofrunners,methodsofgating,methodsofejection,capacityandfeaturesoftheinjectionmouldingmachines.Mouldcost,mouldqualityandcostofmouldproductareinseparable

Intoday’scompletiveenvironment,computeraidedmouldfillingsimulationpackagescanaccuratelypredictthefillpatternsofanypart.Thisallowsforquicksimulationsofgateplacementsandhelpsfindingtheoptimallocation.Engineerscanperformmouldingtrialsonthecomputerbeforethepartdesigniscompleted.Processengineerscansystematicallypredictadesignandprocesswindow,andcanobtaininformationaboutthecumulativeeffectoftheprocessvariablesthatinfluencepartperformance,cost,andappearance.

2.InjectionMoulding

Injectionmouldingisoneofthemosteffectivewaystobringoutthebestinplastics.Itisuniversallyusedtomakecomplex,finishedparts,ofteninasinglestep,economically,preciselyandwithlittlewaste.Massproductionofplasticpartsmostlyutilizesmoulds.Themanufacturingprocessandinvolvingmouldsmustbedesignedafterpassingthroughtheappearanceevaluationandthestructureoptimizationoftheproductdesign.Designersfaceahugenumberofoptionswhentheycreateinjection-mouldedcomponents.Concurrentengineeringrequiresanengineertoconsiderthemanufacturingprocessofthedesignedproductinthedevelopmentphase.Agooddesignoftheproductisunabletogotothemarketifitsmanufacturingprocessisimpossibleortooexpensive.Integrationofprocesssimulation,rapidprototypingandmanufacturingcanreducetheriskassociatedwithmovingfromCADtoCAMandfurtherenhancethevalidityoftheproductdevelopment.

3.ImportanceofComputerAidedInjectionMouldDesign

Theinjectionmouldingdesigntaskcanbehighlycomplex.ComputerAidedEngineering（CAE）analysistoolsprovideenormousadvantagesofenablingdesignengineerstoconsidervirtuallyandpart,mouldandinjectionparameterswithouttherealuseofanymanufacturingandtime.Thepossibilityoftryingalternativedesignsorconceptsonthecomputerscreengivestheengineerstheopportunitytoeliminatepotentialproblemsbeforebeginningtherealproduction.Moreover,invirtualenvironment,designerscanquicklyandeasilyassesthesensitivityofspecificmouldingparametersonthequalityandmanufacturabilityofthefinalproduct.AlltheseCAEtoolsenablealltheseanalysistobecompletedinameterofdaysorevenhours,ratherthanweeksormonthsneededfortherealexperimentaltrialanderrorcycles.AsCAEisusedintheearlydesignofpart,mouldandmouldingparameters,thecostsavingsaresubstantialnotonlybecauseofbestfunctioningpartandtimesavingsbutalsotheshortensthetimeneededtolaunchtheproducttothemarket.

Theneedtomeetsettolerancesofplasticparttiesintoallaspectsofthemouldingprocess,includingpartsizeandshape,resinchemicalstructure,thefillersused,mouldcavitylayout,gating,mouldcoolingandthereleasemechanismsused.Giventhiscomplexity,designersoftenusecomputerdesigntools,suchasfiniteelementanalysis（FEA）andmouldfillinganalysis（MFA）,toreducedevelopmenttimeandcost.FEAdeterminesstrain,stressanddeflectioninapartbydividingthestructureintosmallelementswheretheseparameterscanbewelldefined.MFAevaluatesgatepositionandsizetooptimizeresinflow.Italsodefinesplacementofweldlines,areasofexcessivestress,andhowwallandribthicknessaffectflow.Otherfiniteelementdesigntoolsincludemouldcoolinganalysisfortemperaturedistribution,andcycletimeandshrinkageanalysisfordimensionalcontrolandpredictionoffrozenstressandwarpage.

TheCAEanalysisofcompressionmouldedpartsisshowninFigure1.TheanalysiscyclestartswiththecreationofaCADmodelandafiniteelementmeshofthemouldcavity.Aftertheinjectionconditionsarespecified,mouldfilling,fiberorientation,curingandthermalhistory,shrinkageandwarpagecanbesimulated.Thematerialpropertiescalculatedbythesimulationcanbeusedtomodelthestructuralbehaviourofthepart.Ifrequired,partdesign,gatelocationandprocessingconditionscanbemodifiedinthecomputeruntilanacceptablepartisobtained.Aftertheanalysisisfinishedanoptimizedpartcanbeproducedwithreducedweldline（knownalsoknitline）,optimizedstrength,controlledtemperaturesandcuring,minimizedshrinkageandwarpage.

Machiningofthemouldswasformerlydonemanually,withatoolmakercheckingeachcut.ThisprocessbecamemoreautomatedwiththegrowthandwidespreaduseofcomputernumericallycontrolledorCNCmachiningcentres.SetuptimehasalsobeensignificantlyreducedthroughtheuseofspecialsoftwarecapableofgeneratingcutterpathsdirectlyfromaCADdatafile.Spindlespeedsashighas100,000rpmprovidefurtheradvancesinhighspeedmachining.Cuttingmaterialshavedemonstratedphenomenalperformancewithouttheuseofanycutting/coolantfluidwhatsoever.Asaresult,theprocessofmachiningcomplexcoresandcavitieshasbeenaccelerated.

Itisgoodnewsthatthetimeittakestogenerateamouldisconstantlybeingreduced.Thebadnews,ontheotherhand,isthatevenwithalltheseadvances,designingandmanufacturingofthemouldcanstilltakealongtimeandcanbeextremelyexpensive.

Figure1CAEanalysisofinjectionmouldedparts

Manycompanyexecutivesnowrealizehowvitalitistodeploynewproductstomarketrapidly.Newproductsarethekeytocorporateprosperity.Theydrivecorporaterevenues,marketshares,bottomlinesandshareprices.Acompanyabletolaunchgoodqualityproductswithreasonablepricesaheadoftheircompetitionnotonlyrealizes100%ofthemarketbeforerivalproductsarrivebutalsotendstomaintainadominantpositionforafewyearsevenaftercompetitiveproductshavefinallybeenannounced（Smith,1991）.Formostproducts,thesetwoadvantagesaredramatic.Rapidproductdevelopmentisnowakeyaspectofcompetitivesuccess.Figure2showsthatonly3–7%oftheproductmixfromtheaverageindustrialorelectronicscompanyislessthan5yearsold.Forcompaniesinthetopquartile,thenumberincreasesto15–25%.Forworld-classfirms,itis60–80%（Thompson,1996）.Thebestcompaniescontinuouslydevelopnewproducts.AtHewlett-Packard,over80%oftheprofitsresultfromproductslessthan2yearsold!

（Neel,1997）

Figure2.Importanceofnewproduct（Jacobs,2000）

Withtheadvancesincomputertechnologyandartificialintelligence,effortshavebeendirectedtoreducethecostandleadtimeinthedesignandmanufactureofaninjectionmould.Injectionmoulddesignhasbeenthemainareaofinterestsinceitisacomplexprocessinvolvingseveralsub-designsrelatedtovariouscomponentsofthemould,eachrequiringexpertknowledgeandexperience.Leeet.al.（1997）proposedasystematicmethodologyandknowledgebaseforinjectionmoulddesigninaconcurrentengineeringenvironment.

4.ConcurrentEngineeringinMouldDesign

ConcurrentEngineering（CE）isasystematicapproachtointegratedproductdevelopmentprocess.Itrepresentsteamvaluesofco-operation,trustandsharinginsuchamannerthatdecisionmakingisbyconsensus,involvingallperspectivesinparallel,fromtheverybeginningof