超薄塑件注塑成形特性的试验研究与数值模拟

薄壁注塑成形技术具有节约材料、降低成本、减少制品重量和外形尺寸等优点，可促进移动电话等电子产品的迅速发展，特别是超薄塑件的注塑成形技术在微机电领域具有巨大的应用潜力。但随着制品厚度的减小也使注射成形难度加大，填充过程更为复杂，成形特性有待探索。设计制造出可成形超薄塑件的模具，利用正交试验方法(田口方法)进行充模试验和数值模拟技术研究各工艺参数(注射速度、注射压力、熔体温度、注射量和制品厚度等)对超薄塑件注塑成形充模过程的影响。研究结果表明，制品厚度对超薄塑件的填充起决定性作用；注射量及注射速度对超薄塑件注塑成形的填充起主导作用，提高注射速度能大幅度地提高填充率；熔体温度和注射压力相对于注射量和注射速度只起次要作用，但在填充过程中，高的熔体温度和注射压力也是必要的。

Experiment Research and Numerical Simulation of Injection Molding Characteristics for Ultra-thin Wall Plastic Parts

Thin-wall injection molding has some apparent advantages such as saving materials, reducing production costs, weights and shape sizes, etc., and accelerates the rapid development of electronic productions (mobile phones, for instance). Especially the ultra-thin wall injection molding has great application potentialities on MEMS. However, due to the product thickness becomes thinner, the molding process becomes more difficult and complicated, systematic investigation is lacking in molding characteristics for ultra-thin wall plastic parts. A mold for the forming of ultra-thin wall plastic parts is designed and manufactured. By using the orthogonal experiment method (Taguchi method) and numerical simulation, the influence of different process parameters (injection rate, injection pressure, melt temperature, metering size and product thickness) on the molding process for ultra-thin wall plastic parts is discussed. The results show that product thickness is the decisive parameter to the molding, metering size and injection rate are the principal factors in molding process, higher injection rate can make a big increase in the filling ratio, melt temperature and injection pressure are the secondary factors, but higher melt temperature and injection pressure are also necessary in molding process.