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西南交通大學(xué)本科畢業(yè)設(shè)計 論文 第 頁 畢業(yè)設(shè)計 論文 任務(wù)書 班 級 機電 2 班 學(xué)生姓名 莊 勇 學(xué) 號 20030346 發(fā)題日期 2007 年 3 月 25 日 完成日期 6 月 23 日 題 目 通用手機電池充電器外殼注塑模設(shè)計及編程 1 本論文的目的 意義意義模具設(shè)計工件是需要非常專業(yè)的知識和多年的經(jīng)驗才能 勝任的 隨著我國機械行業(yè)的飛速發(fā)展 模具設(shè)計工程師越來越短缺 已經(jīng)嚴(yán)重制 約了模具行業(yè)的健康發(fā)展 在廣東 浙江 上海 江蘇等地找到五年以上設(shè)計經(jīng)驗 的模具工程非常困難 而剛剛畢業(yè)的模具專業(yè)的學(xué)生又遠(yuǎn)遠(yuǎn)不能滿足企業(yè)的需要 通過本次畢業(yè)設(shè)計實踐 采用 CAD CAM MasterCAM UG Per E 技術(shù)可以使設(shè)計者 從繁沉計算和繪圖工件中得到解脫 采用人機結(jié)合 各盡所長 充分發(fā)揮其人的創(chuàng) 造思維能力 控制設(shè)計過程 使模具設(shè)計趨于合理化 而計算機則發(fā)揮其計算分折 和儲存信息的能力 兩者結(jié)合 發(fā)揮各自的優(yōu)勢 有利于獲得最優(yōu)的設(shè)計成果 縮 短開發(fā)周期 采用 CAE 技術(shù) 可以實現(xiàn)在計算機上 試模 即對整個注射過程進行 仿真分折 抱括 填充 保壓 冷卻 纖維取向 結(jié)構(gòu)應(yīng)力和收縮 以及整個塑料 封裝成型和熱固性塑料流動分折 預(yù)測未來產(chǎn)品可能纖維出現(xiàn)的缺陷 對存在的問 題在設(shè)計階段予以解決 直至提出最優(yōu)的設(shè)計參數(shù) 使一次試模成為可能 實現(xiàn)并行 工程 從而可以加快產(chǎn)品的開發(fā)進程 降低試模成本 提高生產(chǎn)效率 西南交通大學(xué)本科畢業(yè)設(shè)計 論文 第 頁 2 學(xué)生應(yīng)完成的任務(wù) 1 塑件制品分折 2 注塑機的確定 3 模具設(shè) 計的有關(guān)計算 4 模具結(jié)構(gòu)設(shè)計 5 注塑機的參數(shù)校核 6 模具凹凸模零件加工藝 7 后置處理及計算機編程 8 后附翻譯和實習(xí)報告 3 論文各部分內(nèi)容及時間分配 共 12 周 第一部分 注塑模具設(shè)計資料收集 1 周 第二部分 塑件制品分折 注塑機的確定 1 周 第三部分 模具設(shè)計的有關(guān)計算 3 周 第四部分 模具結(jié)構(gòu)設(shè)計 4 周 第五部分模具凹凸模零件加工藝 后置處理及計算機編程 2 周 評閱及答辯 1 周 備 注 參考文獻 洪慎章 塑料成型及模具設(shè)計 機械工業(yè)出版社 2006 年 唐海翔 UG NX2 注塑模具設(shè)計 清華大學(xué)出版社 2005 年 模具結(jié)構(gòu)設(shè)計 模具設(shè)計與制造技術(shù)教育叢書編委會編 機械工業(yè)出 版社 西南交通大學(xué)本科畢業(yè)設(shè)計 論文 第 頁 20005 年 注塑模設(shè)計與制造實戰(zhàn) 宋滿倉 黃銀國 機械工業(yè)出版社 2005 年 指導(dǎo)教師 張敬 2007 年 4 月 10 日 審 批 人 年 月 日 西南交通大學(xué)本科畢業(yè)設(shè)計 論文 第 1 頁 摘 要 摘 要 分析了手機充電器外殼的工藝特點 介紹了手機充電器外殼上蓋注射模結(jié)構(gòu)及模具 的工作過程 重點介紹了手機充電器外殼注射模結(jié)構(gòu)的設(shè)計 方法 分析和闡述了模具型芯零件及各標(biāo)準(zhǔn)件的選材 熱處理工藝 手機充電器外 殼的塑件的結(jié)構(gòu)要素 塑件的尺寸公差和精度的選擇 塑件 的體積和質(zhì)量的計算方法以及注射機的選擇和校核 此手機充電器外殼注射模設(shè)計 的結(jié)構(gòu)特點是點澆口形式的單分型面的注射模 該模具結(jié)構(gòu) 設(shè)計巧妙 操作方便 使用壽命長 塑件達到技術(shù)要求 關(guān)鍵詞 手機充電器外殼 注射模 型芯 型腔 Abstract Has analyzed the handset battery charger outer covering craft characteristic introduced the handset battery charger outer covering top head injection mold structure and the mold work process Introduced the handset battery charger outer covering injection mold structure design method with emphasis Analyzed and elaborated the mold core components selection the heat treatment craft the handset battery charger outer covering model the member model the size common difference and the precision choice model a volume and the quality computational method This handset battery charger outer covering injection mold designs the unique feature is the runner form three minute profiles injection molds is lateral pulls out the core injection mold After production confirmation this mold structural design ingenious the ease of operation the service life is long models to achieve the specification Key words handset battery charger outer covering injection mold slide core 西南交通大學(xué)本科畢業(yè)設(shè)計 論文 第 1 頁 目 錄 第 1 章 緒 論 1 1 1 模具工業(yè)在國民經(jīng)濟中的地位 1 2 2 國模具技術(shù)的現(xiàn)狀及發(fā)展趨勢 1 第 2 章 塑件工藝分析 3 2 1 塑件的結(jié)構(gòu)要素 3 2 1 1 ABS 的使用性能 3 2 1 2 ABS 材料的成形特點 3 2 1 3 ABS 的成型工藝 4 2 2 注射成型工藝 4 第 3 章 塑件幾何形狀的設(shè)計 6 3 1 塑件幾何形狀的設(shè)計 6 3 1 1 脫模斜度 6 3 1 2 加強筋 6 3 1 3 塑件的圓角 7 3 1 4 塑件的壁厚 7 3 1 5 孔 7 3 1 6 支承面 7 3 2 塑件尺寸公差與精度 7 第 4 章 分型面及型腔數(shù)目的確定 9 4 1 型腔分型面及型腔數(shù)目 9 4 2 型腔 型芯的結(jié)構(gòu) 9 4 2 1 型腔的結(jié)構(gòu)設(shè)計 10 4 2 2 型芯的結(jié)構(gòu)設(shè)計 10 第 5 章 注射機的選取和校核 11 5 1 根據(jù)型腔數(shù)選擇注射機 11 5 1 1 根據(jù)塑件形狀估算其體積和重量 11 5 1 2 選擇注射機 11 5 2 校核注射機有關(guān)工藝參數(shù) 12 5 2 1 注射量的校核 12 5 2 2 鎖模力的校核 12 5 2 3 開模行程的校核 13 第 6 章 成型零件的設(shè)計 13 6 1 成型零件的結(jié)構(gòu)設(shè)計 13 6 1 1 凹模的結(jié)構(gòu)設(shè)計 14 6 1 2 凸模和型芯的結(jié)構(gòu)設(shè)計 14 6 2 成型零件工作尺寸的計算 14 6 2 1 凹模與凸模工作尺寸 15 6 2 2 凹模與凸模尺寸計算 15 6 2 3 型腔的強度設(shè)計 16 第 7 章 澆注系統(tǒng)的設(shè)計 17 7 1 主澆道的設(shè)計 17 7 2 分澆道的設(shè)計 17 西南交通大學(xué)本科畢業(yè)設(shè)計 論文 第 1 頁 7 3 澆口的設(shè)計 18 7 4 冷料穴的設(shè)計 18 第 8 章 結(jié)構(gòu)零件的設(shè)計 19 8 1 脫模機構(gòu)的設(shè)計 19 8 1 1 機構(gòu)的設(shè)計原則 19 8 1 2 脫模機構(gòu)分類 19 8 2 脫模機構(gòu)的導(dǎo)向與復(fù)位 20 8 2 1 導(dǎo)向零件 20 8 2 2 復(fù)位零件 20 第 9 章 塑料模具鋼的選用 21 9 1 塑料模具材料應(yīng)具有的性能 21 9 2 模具選材原則 21 第 10 章 模具結(jié)構(gòu)及其工作過程 24 9 1 模架的選擇 24 9 2 模具工作過程 24 結(jié) 論 26 致 謝 27 參 考 文 獻 28 FABRICATION OF PIEZOELECTRIC CERAMlClPOLYMER COMPOSITES BY INJECTION MOLDING Leslie J Bowen and Kenneth W French Materials Systems Inc 53 Hillcrest Road Concord MA 01742 Abstract Research at the Materials Research Laboratory Pennsylvania State University has demonstrated the potential for improving hydrophone performance using piezoelectric ceramic polymer composites As part of an ONR funded initiative to develop cost effective manufacturing technology for these composites Materials Systems is pursuing an injection molding ceramic fabrication approach This paper briefly overviews key features of the ceramic injection molding process then describes the approach and methodology being used to fabricate PZT ceramic polymer composites Properties and applications of injection molded PZT ceramics are compared with conventionally processed material Introduction Piezoelectric ceramic polymer composites offer design versatility and performance advantages over both single phase ceramic and polymer piezoelectric materials in both sensing and actuating applications These composites have found use in high resolution medical ultrasound as well as developmental Navy applications Many composite configurations have been constructed and evaluated on a laboratory scale over the past thirteen years One of the most successful combinations designated 1 3 composite in Newnham s notation l 1 has a one dimensionally connected ceramic phase PZT fibers contained within a three dimensionally connected organic polymer phase Hydrophone figures of merit for this composite can be made over 10 000 times greater than those of solid PZT ceramic by appropriately selecting the phase characteristics and composite structure The Penn State composites were fabricated l by hand aligning extruded PZT ceramic rods in a jig and encapsulating in epoxy resin followed by slicing to the appropriate thickness and poling the ceramic Aside from demonstrating the performance advantages of this material the Penn State work highlighted the difficulties involved in fabricating 1 3 composites on a large scale or even for prototype purposes These are 11 The requirement to align and support large numbers of PZT fibers during encapsulation by the polymer 2 The high incidence of dielectric breakdown during poling arising from the significant probability of encountering one or more defective fibers in a typical large array Over the past five years several attempts have been made to simplify the assembly process for 1 3 transducers with the intention of improving manufacturing viability and lowering the material cost Early attempts involved dicing solid blocks of PZT ceramic into the desired configuration and back filling the spaces with a polymer phase This technique has found wide acceptance in the medical ultrasound industry for manufacturing high frequency transducers 2 More recently Fiber Materials Corp has demonstrated the applicability of its weaving technology for fiber reinforced composites to the assembly of piezoelectric composites 31 Another exploratory technique involves replicating porous fabrics having the appropriate connectivity 41 For extremely fine scale composites fibers having diameters in the order of 25 to 100 pn and aspect ratios in excess of five are required to meet device performance objectives As a result these difficulties are compounded by the additional challenge of forming and handling extremely fine fibers in large quantities without defects Recently researchers at Siemens Corp have shown that very fine scale composites can be produced by a fugitive mold technique However this method requires fabricating a new mold for every part 51 This paper describes a new approach to piezoelectric composite fabrication viz Ceramic injection molding Ceramic injection molding is a cost effective fabrication approach for both Navy piezoelectric ceramic polymer composites and for the fabrication of ultrafine scale piezoelectric composites such as those required for high frequency medical ultrasound and nondestructive evaluation The injection molding process overcomes the difficulty of assembling oriented ceramic fibers into composite transducers by net shape preforming ceramic fiber arrays Aside from this advantage the process makes possible the construction of composite transducers having more complex ceramic element geometries than those previously envisioned leading to greater design flexibility for improved acoustic impedance matching and lateral mode cancellation Process Descriotion Injection molding is widely used in the plastics industry as a means for rapid mass production of complex shapes at low cost Its application to ceramics has been most successful for small cross section shapes e g thread guides and large complex shapes which do not require sintering to high density such as turbine blade casting inserts More recently the process has been investigated as a production technology for heat engine turbine components 6 71 The injection molding process used for PZT molding is shown schematically in Figure 1 By injecting a hot thermoplastic mixture of ceramic powder and organic binder into a cooled mold complex shapes can be formed with the ease and rapidity normally associated with plastics molding Precautions such as hard facing the metal contact surfaces are important to minimize metallic contamination from the compounding and molding machinery For ceramics the binder must be removed nondestructively necessitating high solids loading careful control of the binder removal Powder Process i ng r 4 CERAMIC PREFORM Organic Binder I Granulate I PREFORM LAY UP TO FORM LARGER ARRAYS Lu i 1 1 and apply electrodes Figure 1 Injection Molding Process Route process and proper fixturing Once the binder is removed the subsequent firing poling and epoxy encapsulation processes are similar to those used for conventional PZTipolymer composites 11 I Thus the process offers the following advantages over alternative fabrication routes Complex near net shape capability for handling many fibers simultaneously rapid throughput typically seconds per part compatibility with statistical process control low material waste flexibility with respect to transducer design allows variation in PZT element spacing and shape and low cost in moderate to high volumes In general because of the high initial tooling cost the ceramics injection molding process is best applied to complex shaped components which require low cost in high volumes Comoosite Fabrication and Evaluation The approach taken to fabricate 1 3 piezoelectric composites is shown in Figure 2a which illustrates a PZT ceramic preform concept in which fiber positioning is achieved using a co molded integral ceramic base After polymer encapsulation the ceramic base is removed by grinding Aside from easlng the handling of many fibers this preform approach allows broad latitude in the selection of piezoelectric ceramic element geometry for composite performance optimization Tool design is important for successful injection molding of piezoelectric composites The approach shown in Figure 2b uses shaped tool inserts to allow changes in part design without incurring excessive retooling costs Figure 2c shows how individual preforms are configured to form larger arrays Figure 2a Preform Configuration Approx 400 ceramic elements REMOVABLE INSERT CAVITY TOOL BODY U SPRUE Figure 2b Injection Molding Tool Configuration Figure 2c Large Area Composite Arrays made from Preforms Figure 2 Preform Approach to Composite Fabrication In practice material and molding parameters must be optimized and integrated with injection molding tool design to realize intact preform ejection after molding Key parameters include PZT binder ratio PZT element diameter and taper PZT base thickness tool surface finish and the molded part ejection mechanism design In order to evaluate these process parameters without incurring excessive tool cost a tool design having only two rows of 19 PZT elements each has been adopted for experimental purposes Each row contains elements having three taper angles 0 1 and 2 degrees and two diameters 0 5 and lmm To accommodate molding shrinkage the size of the preform is maintained at 5Ox50mm to minimize the possibility of shearing off the outermost fibers during the cooling portion of the molding cycle Figure 3 Injection Molded 1 3 Composite Preforms 161 Figure 3 shows green ceramic preforms fabricated using this tool configuration Note that all of the PZT elements ejected intact after molding including those having no longitudinal tapering to facilitate ejection Slow heating in air has been found to be a suitable method for organic binder removal Finally the burned out preforms are sintered in a PbO rich atmosphere to 97 98 of the theoretical density No problems have been encountered with controlling the weight loss during sintering of these composite preforms even for those fine scale high surface area preforms which are intended for high frequency ultrasound L Figure 4 Scanning Electron Micrographs of As molded Upper and As sintered Lower Surfaces of PZT Fibers Figure 4 illustrates the surfaces of as molded and as sintered fibers showing the presence of shallow fold lines approximately 10pm wide which are characteristic of the injection molding process The fibers exhibit minor grooving along their length due to ejection from the tool Figure 5 shows the capability of near net shape molding for fabricating very fine scale preforms PZT element dimensions only 30pm wide have been demonstrated The as sintered surface of these elements indicates that the PZT ceramic microstructure is dense and uniform consisting of equiaxed grains 2 3pm in diameter Figure 5 Fine scale 2 2 Composite formed by Near Net shape Molding Upper Micrograph As sintered Surface Lower Micrograph In order to demonstrate the lay up approach for composite fabrication composites of approximately 10 volume percent PZT 5H fibers and Spurrs epoxy resin were fabricated by epoxy encapsulating laid up pairs of injection molded and sintered fiber rows followed by grinding away the PZT ceramic stock used to mold the composite preform Figure 6 shows composite samples made from freshly compounded PZT binder mixture and from reused material Recycling of the compounded and molded material appears to be entirely feasible and results in greatly enhanced material utilization Table 1 compares the piezoelectric and dielectric properties of injection molded PZT ceramic specimens with those reported for pressed PZT 5H samples prepared by the powder manufacturer When the sintering conditions are optimized for the PZT 5H formulation the piezoelectric and dielectric properties are comparable for both materials Since the donor doped PZT 5H formulation is expected to be particularly sensitive to iron contamination from the injection molding equipment the implication of these measurements is that such contamination is negligible in this injection molded PZT material Powder supplied by Morgan Matroc Inc Bedford Ohio Lot 105A 162 Table 1 Properties of Injection Molded Piezoelectric Ceramics Specimen Relative Dielectric d33 TY Pe Permittivity Loss 1 kHz1 pC N Die Pressed 3584 0 01 8 745 Inj Molded 3588 0 01 8 755 Aged 24 hours before measuremegt Poling conditions 2 4kV mm 60 C 2 minutes Figure 6 Injection Molded PZT Fiber Epoxy Resin Composites prepared by the Preform Lay up Method Summarv Ceramic injection molding has been shown to be a viable process for fabricating both PZT ceramics and piezoelectric ceramic polymer transducers The electrical properties of injection molded PZT ceramics are comparable with those prepared by conventional powder pressing with no evidence of deleterious effects from metallic contamination arising from contact with the compounding and molding equipment By using ceramic injection molding to fabricate composite preforms and then laying up the preforms to form larger composite arrays an approach has been demonstrated for net shape manufacturing of piezoelectric composite transducers in large quantities Ac knowledaements This work was funded by the Office of Naval Research under the direction of Mr Stephen E Newfield The authors wish to thank Ms Hong Pham for technical assistance and Dr Thomas Shrout of the Materials Research Laboratory Penn State University for electrical measurements References l R E Newnham et al Composite Piezoelectric Transducers Materials in Engineering Vol 2 pp 93 106 Dec 1980 21 C Nakaya et al IEEE Ultrasonics Symposium Proc Oct 16 18 1985 p 634 131 S D Darrah et al Large Area Piezoelectric Composites Proc of the ADPA Conference on Active Materials and Structures Alexandria Virginia Nov 4 8 1991 Ed G Knowles Institute of Physics Publishing pp 139 142 A Safari and D J Waller Fine Scale PZT Fiber Polymer Composites presented at the ADPA Conference on Active Materials and Structures Alexandria Virginia Nov 41 4 8 1991 5 U Bast D Cramer and A Wolff A New Technique for the Production of Piezoelectric Composites with 1 3 Connectivity Proc of the 7th CIMTEC Montecatini Italy June 24 30 1990 Ed P Vincenzini Elsevier pp 2005 201 5 G Bandyopadhyay and K W French Fabrication of Near net Shape Silicon Nitride Parts for Engine Application J Eng for Gas Turbines And Power 108 J Greim et al Injection Molded Sintered Turbocharger Rotors Proc 3rd Int Symp on Ceramic Materials and Components for Heat Engines Las Vegas Nev pp 1365 1375 Amer Cer Soc 1989 61 pp 536 539 1986 171 163