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工程设计学报  2017, Vol. 24 Issue (6): 661-667    DOI: 10.3785/j.issn.1006-754X.2017.06.008
建模、分析、优化和决策     
汽车饰盖CAE分析及成型工艺优化
林权1, 刘瑞来2
1. 武夷学院 机电工程学院, 福建 武夷山 354300;
2. 武夷学院 生态与资源工程学院, 福建 武夷山 354300
CAE analysis and molding process optimization for automobile trim cover
LIN Quan1, LIU Rui-lai2
1. College of Mechanical and Electrical Engineering, Wuyi University, Wuyishan 354300, China;
2. College of Ecological and Resources Engineering, Wuyi University, Wuyishan 354300, China
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摘要:

针对汽车饰盖塑件不仅外观要求高,而且内置众多细小筋板等复杂结构导致缩痕、翘曲变形等注塑缺陷难以控制,造成产品模具结构与成型工艺设计困难,提出了一套含复杂筋板注塑件的成型工艺参数优化方法。基于CAD/CAE技术,通过模拟分析筋板壁厚对成型质量的影响,获知筋板厚度对产品翘曲变形量影响显著,但并不呈正相关,较大的筋板厚度导致产品缩痕明显,当筋板厚度为1 mm时产品缩痕达到最小值(0.02 mm)。运用综合平衡法对成型参数进行优化,使产品最大翘曲变形量下降约25%,再利用斐波那契法进行分段保压优化,通过8次迭代演算后符合收敛条件,获取了理想的保压参数,最大变形量继续下降约37%,最终产品翘曲变形量满足技术要求。生产实践证明该方法简单实用,不仅解决了筋板成型缩痕及翘曲变形难以控制的问题,而且缩短了产品研发周期和节约了成本,为类似产品成型设计提供参考。

关键词: 汽车饰盖筋板结构缩痕翘曲注塑模具优化设计    
Abstract:

Automobile trim cover's plastic parts are not only required highly in appearance, but also erected with many tiny gussets and other complicated structures, and it is difficult to control the injection and moulding defects such as sink marks, buckling and deformation, makes the design of product die structure and moulding process rather tough. Based on CAD/CAE technology and through simulation and analysis in the influences of gusset thickness on moulding quality, the range of buckling and deformation of the product had been obvious influenced by the of gusset thickness, but without positive correlation. Sink marks would be obviously caused by the larger gusset thickness. When the thickness was 1 mm, the minimum value of sink marks would be 0.02 mm. The molding parameters were optimized by using the comprehensive balance method, which made the maximum warpage of product decreased by about 25%. Then by Fibonacci method, sub-sectional pressure maintaining and optimization were conducted. Through iterative calculus and standard convergence for 8 times, the ideal pressure maintaining parameters were obtained and the maximum range of deformation continued to reduce about 37%, making the rage of buckling and deformation of the final product satisfied with technical requirements. A set of optimization methods for the molding process parameters of the injection molding parts with complex reinforcing plate was presented. The production practice proves that the method is simple and practical, which not only solves the problem of the shrinkage marks and unmanageable warping deformation, but also reduces development cycle and costs. In addition, it provides a reference for similar product.

Key words: automobile trim cover    stiffened plate structure    shrinkage mark    warpage    injection mold    optimization design
收稿日期: 2017-08-24 出版日期: 2017-12-28
CLC:  TQ320  
基金资助:

国家自然科学基金资助项目(51406141);福建省中青年教师教育科研项目(JAT170582)

作者简介: 林权(1980-),男,福建福州人,副教授,硕士,从事模具CAD/CAE技术研究,E-mail:12959392@qq.com,http://orcid.org/0000-0002-3791-2789
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引用本文:

林权, 刘瑞来. 汽车饰盖CAE分析及成型工艺优化[J]. 工程设计学报, 2017, 24(6): 661-667.

LIN Quan, LIU Rui-lai. CAE analysis and molding process optimization for automobile trim cover[J]. Chinese Journal of Engineering Design, 2017, 24(6): 661-667.

链接本文:

https://www.zjujournals.com/gcsjxb/CN/10.3785/j.issn.1006-754X.2017.06.008        https://www.zjujournals.com/gcsjxb/CN/Y2017/V24/I6/661

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