注塑模具随形冷却水道冷却效能分析

设计了汽车仪表盘注塑模具,采用无冷却水道、传统冷却水道和随形冷却水道3种冷却系统。利用ANSYS软件对模具进行热分析,模拟了无冷却水道、传统冷却水道和随形冷却水道模具的温度场,分析在不同冷却水道的塑件达到脱模温度的时间、冷却性能、冷却均匀性。结果表明,随形冷却水道模具达到顶出时间仅需要29 s,与无冷却水道达到顶出时间相比,缩短了371 s,与传统冷却水道相比,缩短了10 s;当随形冷却水道模具达到开模时刻(29 s),无冷却水道模具型腔表面的平均温度约为132.36℃,传统冷却水道模具型腔表面的平均温度约为62.56℃,随形冷却水道模具型腔表面的平均温度约为47.20℃,随形冷却水道模具型腔表面的平均温度与同时刻无冷却水道模具相比降低了85.16℃,与传统冷却水道相比,降低了15.36℃,冷却性能分别提升了64.34%和24.54%;随形冷却模具型腔表面的冷却均匀性最佳,方差仅为3.32,与无冷却系统模具相比,减小了5.32,与传统冷却系统相比,减小了10.93。因此,注塑模具采用随形冷却水道,在缩短生产周期的同时,还能提高产品的生产质量。     

CAE技术整合随形水路设计的电机盒模具研究

以电机盒塑料件为例,在相同的模具设计条件下,将传统冷却水路设计更改为随形冷却水路设计,利用实体三维网格的Moldex3D模流分析软件分析了两种冷却水路对模具的冷却效果.结果表明,随形冷却水路改善了模具的热平衡问题,电机盒的最大翘曲变形量从1.2 mm下降到0.5 mm,模具冷却时间从9 s下降到6 s,生产效率提高了12.5％.经实际验证,该模具已投入批量生产.     

多孔隔板注射成型随形水路优化及模具结构设计

传统冷却水路设计受制于模具结构及加工条件，常导致冷却效率低，成型质量不佳等问题，为此以多孔隔板塑件为例，应用模流分析技术进行冷却水路优化设计，通过比较分析传统常规水路与随形水路对产品成型冷却影响，获知随形冷却水路对比常规水路，达到顶出温度时间减少了24%，成型周期时间节约了30.5%，热移除效率提高了23.8%，产品温度分布均匀性提高了27.25%，有效最高温度下降了10.15%，有效最低温度也下降了10.60%，产品总体翘曲变形量下降了13.56%，随形水路对改善冷却效果作用显著。最后，对一模一腔的随形水路多孔隔板注塑模进行结构设计，为了避免结构干涉，采用了潜伏浇口搭配“一内三外”的侧向抽芯结构方式，有效地简化了模具结构，使加工的多孔隔板质量优良，为类似产品注塑模具设计提供参考。     

汽车后视镜壳的随形冷却水道注塑模具设计

以汽车后视镜壳为实例,采用传统CNC和金属3D打印的复合技术,制作出含传统冷却水道和随形冷却水道镶嵌的注塑模具。将传统冷却方案与随形冷却方案的模流分析结果进行对比,并完成了汽车后视镜产品的生产。实践证明,含随形冷却水道方案的产品注塑冷却时间显著缩短,冷却效果显著改善。传统冷却水道方案的型腔表面平均温度为130℃,而随形冷却水道方案的型腔表面平均温度约为100℃,与传统冷却水道方案相比,随形冷却水道方案的型腔表面平均温度降低了近30℃;传统冷却水道方案的冷却时间为36 s,而随形冷却水道方案的冷却时间为13. 3 s,与传统冷却水道方案相比,随形冷却水道方案的冷却时间减少了近2/3;传统冷却水道方案的平均翘曲变形量达到0. 486 9 mm,而随形冷却水道方案的平均翘曲变形量达到0. 256 6 mm,与传统冷却水道方案相比,随形冷却水道方案的平均翘曲变形量明显减少,减少了约1/2。     

基于Moldflow的肥皂盒盖随形冷却水道的设计与分析

以曲面体肥皂盒盖为研究对象,通过实例设计出随形冷却水道,采用Moldlfow软件对传统线性冷却水道与随形冷却水道进行了系统模拟分析。通过塑件表面温度、冷却时间和翘曲变形量等模拟结果的对比,结果显示:随形冷却水道能使塑件冷却更加均匀、冷却时间缩短,并提高了生产效率;与此同时,产品的尺寸精度也有明显改善,产品质量得到进一步的优化与提升。最后通过质量(成型窗口)分析,得到了最佳参数组合,进而得到了优化方案。     

曲面塑件随形冷却水道设计

随形冷却水道可改善传统冷却直水道冷却不均匀问题,但设计和制造过程中需通过大量实验确定参数,浪费材料,效率低和制造成本高。文章以曲面塑件为研究对象,设计了5种冷却水道,通过Moldflow软件模拟分析比较,得出冷却性能最佳的方案,结果表明,与传统冷却直水道相比,最佳冷却时间缩短了61. 67%,型腔最高温度减少了32. 99℃,温度均匀性提高了5. 5%,最大翘曲变形量减少了0. 97 mm,利用三维扫描仪分别扫描随形冷却塑件与直水道塑件,并与三维设计塑件进行CAD曲面比较,分析翘曲变形偏差值。实践发现,随形冷却水道塑件与直水道塑件相比,注塑周期相差1. 07 s,翘曲变形偏差值相差1. 9 mm,与Moldflow模拟分析数据较为接近。     

随形冷却和SLM技术在注塑模具中的应用

内置随形冷却水路的模具制造技术不仅可以为模具设计师带来更大的设计空间,简化冷却水路的设计方法,而且使模具冷却效率大大提高。     

基于3D打印的注塑模随形冷却水路优化设计

以某产品后盖为研究对象,针对存在的冷却时间过长、产品翘曲变形和尺寸不稳定的问题,设计了基于金属3D打印技术的随形冷却水路,并借助Moldex3D软件进行模拟分析。通过对传统水路与随形水路的模拟分析结果进行比较,发现随形水路方案可以显著提高冷却效率和减小产品翘曲变形,其中冷却效率提高了35.64%,产品翘曲变形减小了35.09%。     

基于3D打印技术的注塑模随形冷却水路设计

针对净水器滤瓶盖传统水路冷却方案存在的问题,结合产品结构特点,设计了随形水路冷却系统,并借助Moldflow模拟仿真软件,利用有限元(FEM)冷却求解器,采用周期内瞬态冷却分析模式,分析比较了传统水路冷却方案和随形水路冷却方案的冷却效果。结果表明,与传统水路冷却方案相比,采用随形水路冷却方案可以显著提高模具的冷却效率和温度分布均匀性,其中冷却效率提高了28.2%,周期内模具温度分布均匀性提高了40.6%,冷却结束时模具温度分布均匀性提高了87.7%,产品表面温度均匀性提高了87.1%。     

随形冷却对车灯壳注塑成型翘曲变形影响分析

冷却系统的设计在注塑模具中非常重要,它关系到制品的冷却效率和成型质量。传统冷却水道通常为简单直行管道,冷却效果不理想。激光3D打印技术的出现使注塑模具随形冷却结构的制造成为现实。以某车灯外壳为例,设计了随形结构的冷却系统。利用有限元分析软件ANSYS瞬态热分析对比了直行与随形冷却设计的冷却效率和模腔温度场分布结果,同时使用模流分析软件Moldflow对比分析了两种冷却方案中制品的翘曲变形。结果表明,随形冷却设计使模腔表面温度场分布更均匀,且能更快速调控模具温度,缩短了注塑成型周期;更重要的是可大大降低制品的翘曲变形。     

注塑模具随形冷却水道的设计方法与分析

随着3D打印技术的发展,注塑模具的冷却水道设计由传统的直线型设计优化为随形水道设计.对国内外随形冷却水道的设计方法和发展现状进行了综述,并对随形冷却水道的设计原则、截面形状变化、布局以及优化技术进行了详细的阐述,并做了归纳总结.注塑模具采用随形水道设计,可使冷却介质与型腔表面距离一致,能提高冷却效率、成型效率和模具型腔表面温度分布的均匀性,从而使成型制品的质量和性能得到较大改善和提高.     

狭长型薄壁零件的注塑模3D打印随形水路设计及开发

针对狭长型薄壁零件的注塑模具冷却优化问题,以典型零件引水管为研究对象,采用随形水路的冷却设计方案,通过Moldflow软件,进行随形水路与传统水路的仿真模拟及对比.结果 表明,随形冷却在产品表面温度分布均匀性上提升了52.6％,冷却时间上缩短了19.7％,整个注射过程填充情况良好,体积收缩符合要求;并采用选择性激光熔化...     

The design of conformal cooling channels in injection molding tooling

Solid Freeform Fabrication technologies have demonstrated the potential to produce tooling with cooling channels, which are conformal to the molding cavity. 3D Printed tools with conformal cooling channels have demonstrated simultaneous improvements in production rate and part quality as compared with conventional production tools. Conformal cooling lines of high performance and high complexity can be created, thus presenting a challenge to the tooling designer. A systematic, modular approach to the design of conformal cooling channels is presented. Cooling is local to the surface of the tool, so the tool is divided into geometric regions and a channel system is designed for each region. Each channel system is itself modeled as composed of cooling elements, typically the region spanned by two channels. Six criteria are applied, including: a transient heat transfer condition, which dictates a maximum distance from mold surface to cooling channel; considerations of pressure and temperature drop along the flow channel; and considerations of the strength of the mold. These criteria are treated as constraints, and successful designs are sought that define windows bounded by these constraints. The methodology is demonstrated through application to a complex core and cavity for injection molding.     

注塑模具随形冷却结构对制品成型的热响应分析

研究了模具随形冷却结构对制品成型的热响应变化,利用有限元软件Ansys对线性与随形2种冷却结构进行瞬态热响应分析与对比,得到了2种结构模式的冷却效率和型腔温度场分布规律,并借助Moldflow和计算流体动力学（CFD）软件对注塑制品在随形冷却结构模式下成型所得到的温度场分布及其可能产生的缺陷进行了分析研究。结果表明,随形冷却结构较传统水道具有更均匀的冷却效果,冷却时间缩短了50 %,体积收缩率降低了15 %,且能更迅速地调控模具温度,更快地进入稳定的工作状态。     

智能热水壶主体复杂抽芯及随形水路注塑模设计

根据智能热水壶主体结构特点和技术要求设计了一副复杂侧向抽芯及随形水路注塑模具。模具采用顺序侧向抽芯及延时侧向抽芯机构,有效改善了包紧力大、脱模困难塑件的注塑模具结构。定模型芯和动模型芯采用3D打印随形水路,有效改善了熔体热量多、成型零件温差大、温度高注塑模具的温度控制系统。模具采用了多项先进的创新技术,成型零件温差降低了50 %,注射成型周期缩短了约18 %,塑件变形量减小了75 %,尺寸精度提高了2级,达到了MT3（GB/T 14486—2008）。试模一次成功,成型塑件的外观质量和尺寸精度均达到了设计要求。     

基于随形水路技术的带把双色水杯注塑模具设计

针对带把双色水杯的结构特点,设计了带哈呋滑块结构的转盘式双色注塑模。该模具采用热流道技术以消除流道凝料,实现生产自动化;其型腔采用常规水路,型芯采用随形水路,模拟结果表明该冷却方式能有效改善冷却效果、显著提高冷却效率和生产率。含随形水路的镶块与型芯基座采用机加工、成型部分采用金属粉末选择性激光烧结的3D打印技术成型。哈呋滑块的分型由压缩弹簧和T形扣来实现。模具结构合理,动作可靠。     

Production of injection molding tooling with conformal cooling channels using the three dimensional printing process

A Solid Freeform Fabrication Process called Three Dimensional Printing is applied to the fabrication of injection molding tooling with cooling channels which are conformal to the molding cavity. The tool is created by spreading layers of stainless steel powder and selectviely joining the powder in the layers by ink‐jet printing of a binder material. Unbound powder is removed from without and within the green part thus defined. The green part is sintered and infiltrated with a copper alloy to produce a fully dense tool. The infiltrant is kept out of the cooling channels by elevating the tool above the free surface of the pool of infiltrant in the crucible, thus creating a controlled negative pressure within the infiltrant. An upper limit to the separation of tooling cavity and cooling channel was derived based on transient heat transfer considerations. A tooling set was created to mold a split ring shape and conformal cooling channels were placed in both the cavity and core sides of the tool. The performance of this tool was compared against the performance of a tooling set with straight cooling channels. Thermocouples buried in the core and cavity showed that the conformal tool had no period of transient behavior at the start of molding, while the tool with straight channels took 10–15 cycles to come to an equilibrium temperature some 40°C above the temperature of the coolant. The conformal tool was also found to maintain a more uniform temperature within the tool during an individual molding cycle. The gap in the molded split rings did not change from cycle to cycle with the conformal tool, while it did with the conventional tool. A 2‐D finite difference model accurately captured the observed temperature histories of the mold with conformal cooling channels.     

机械通风横流式冷却塔组的节能试验研究

以多主机空调系统中的机械通风横流式冷却塔组为研究对象,对独立运行的塔组和连通运行的塔组以及在塔组中是否实行风路控制进行了冷却效果的比较。结果表明,在试验所测试的条件下,实行风路控制的连通运行的塔组与独立运行的塔组相比,单位负荷冷吨数提高了36.55%;与未采用风路控制的连通运行塔组相比,风机停用塔的平均风量提高37.65%,总风量提高6.9%,节能效果明显。     

汽车右后门板顺序阀热流道大型薄壁注塑模具设计

根据汽车右后门板的结构特点,设计了一副大型薄壁顺序阀控制的热流道注塑模具.通过前期的模流分析,确定了先进合理的模具浇注系统.通过采用"斜顶+斜顶杆"与"油缸+T形块+滑块"的侧向抽芯结构,成功解决了塑件内外倒扣多、脱模困难的难题.通过采用"直通式水管+隔片式冷却水井"近乎"随形水路"的温度控制系统,模具成型周期下降了约...     

Efficient cooling of hot spots in injection molding. A biomimetic cooling channel versus a heat‐conductive mold material and a heat conductive plastics

This study aimed at optimizing the injection molding process of an automotive oil filter housing made from PA6.6. Mass accumulations in its design intensely increased the cooling time. In a first successful approach, a copper alloy mold insert (λ = 106 Wm^?1 K^?1) that contains two externally cooled heat‐conducting copper pins (λ = 310 Wm^?1 K^?1) was installed. We hypothesized that a biomimetic cooling channel structure in a steel mold insert would even perform superior. Using simulation software Sigmasoft® v5.0, the mold insert materials (steel Bohler X20Cr13, Ampcoloy® 83), the plastics grade PA66‐GF35 (λ = 0.27 Wm^?1 K^?1 or λ = 0.40 Wm^?1 K^?1), and three cooling designs were evaluated for their impact on cooling the hot spots in the part: the copper pin‐system, a conformal cooling channel, and blood‐vessel like channels. In the latter, the major artery branches into two sub‐arteries, which further divide into two capillary tubes each. The capillaries merge into two sub‐veins and those fuse in the major vein again. As expected, the plastics heat conductivity dominates the cooling. The biomimetic (blood‐vessel) channels, as hypothesized, cooled the major hot spot more efficient than the conformal channel and the copper pin system do. In detail, compared to the heat‐conductive insert, the cycle time may be reduced by 10 s, in spite of the lower heat conductivity λ (23.5 Wm^?1 K^?1) of the steel insert. Using the biomimetic (blood‐vessel) structure in a heat‐conductive mold insert would reduce the cycle time by a further second. However, raising the heat conductivity of the plastics would save another 15s. Experimental tests proved the cooling efficiency. Nevertheless, cooling channels only perform well, if they are close enough to the mass accumulation. In conclusion, transferring biologic cooling structures to injection molding seems to be promising. Ongoing advances in Additive Manufacturing will help to efficiently implement these structures into mold inserts for injection molding. POLYM. ENG. SCI., 59:E180–E188, 2019. © 2018 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers.