Shanghai Daoqin Plastics Co., Ltd.

　1 injection molding CAE technology overview

　　鉴于数 value technology in USA aviation aerospace field/area formed application, 1978 year, large 利亚人 Austin Moldflow company, forecast injection molding processing in type 腔充填 process, most injection molding CAE （ Computer-Aided-Engineering ） technology, 即计算 machine engineering （ use machine upper 显示结果取代 true production mold trial process ）. 1992 year, USA Cornell large K.K.Wang research small formed injection molding CAE technology 里程碑式 工 as, 建立 二维平面 issues flow 充填, holding pressure, cooling process formed 数学模 type and can 行 数 value method; 1999 year, 三维实体模 type flow 计算开始 achieve product 化[1, 2]. currently 专业化 molding processing soft parts has: Moldflow company MPI MPA, MPX series, in large HSCAE6.10, large Zmold soft parts, and Taiwan company Moldex3D soft parts [[3, 4], this soft parts basic can formed injection molding processing in 充填, holding pressure, cooling and its deformation analysis forecast.

　　 in plastics products production in, polymer/macromolecule material, mold, molding process 三者关系密切; in processing in, due to products complex, material features and complex conditions and 不确定 factors make material molding process versus complex deformation history and versus 态变化. for complex deformation history and versus 态变化, analysis method / semi analysis method application to very large made, has method is table/sheet value methods 开辟 崭 new application outlook/prospects. usually, injection molding process value achieve below/following 四 方面[5]:

　　（ 1 ） engineering issues and 凝练. in for molding process and mold design positive 确认识 and understanding upper, use tool has engineering 背景, force 学涵义 “理论模 type ”描述该 issues;

　　（ 2 ） polymer/macromolecule material features 描述. in “理论模 type ” frame lower, use series parameters and 本构模 type polymer/macromolecule molding process in to temperature degree, pressure function lower time 变化 形式, 以明确 plastics raw materials in products molding process in is;

　　（ 3 ） 明确“数学模 type ”. according to 确定 描述 molding process parameters, molding process 数学 - material 理 - force 学方程;

　　（ 4 ） use combined 适 数 value methods achieve for molding process value analysis.

　　 injection molding CAE technology commonly used 数学模 type and methods, 详见文献[5-7] and related 文献, this again fine 述.

　　 in raw materials price day rise, can 源, force cost increase lower, product quality and cost already formed is enterprise development 生命线. 实践证明, injection molding CAE technology for add fast new product development, improve/increase product quality, reduce cost key/critical function, is enterprise competition advantages strong/high has force 手段. 但CAE technology usually requirements relatively strong/high Knowledge 背景, make CAE technology and has difficult degree, difficult 于发挥 CAE technology function.

　　本文 main/primary introduction CAE technology in injection molding, and new molding in application, combined 实例, CAE technology positive use methods, understanding its for production 实践 指导 function and application 局限.

　　2.CAE technology in injection molding in application

　　 in injection molding processing production in, mold trial and amount issues formed in product and mold design, therefore good design as, 调模时试错（ trials and errors ） debugging as amount can decrease/reduce, meanwhile amount products qualification rate can has improve/increase, material is 必然. CAE analysis tool can forecast can can issues, issues causes and solutions, has CAE, design as can high high quality 进行[8].

　　CAE as is design 辅助工 tool, use basic process/workflow and steps 如图 1 示. 图 1 in 5-7 步 is large 家熟悉 CAE soft parts application process.

图 1 CAE analysis basic process/workflow 图[9]

　　 use CAE technology can forecast in injection molding processing in issues [9, 10], is type 腔否充填满, is generate flash, 凹痕, weld lines and other; mold structure is combined 理, more system balanced, products thick degree design, cooling tube/pipe design is combined and other; molding process parameters setting, holding pressure 切换点, injection shot speed degree, holding pressure time and other, detailed inner 容请参考 related 文献.

　　 currently CAE soft parts can for Common issues very good forecast. this from products molding quality degree introduction CAE application.

　　2.1 weld lines forecast

　　 large cationic 摩托车 rear injection molding products, 如图 2 示, material is ABS, products in design in, due to decoration and function need, products thick degree from 3.5mm to 0.8mm, CAE analysis application soft parts is large 学橡塑 mold engineering in made Partmolding soft parts [11] and product CAE analysis soft parts. is design is combined 理, 并确定 weld lines 位置.

　　 from 图 2 can 知, 两 模拟结果 for forecast weld lines A, forecast relatively good; for/regarding in thin separation B, 模拟结果 1 and injection sample comparison combined, 模拟结果 2 for products thin B 处 模拟 has 偏差. causes in 于模拟 use is di type, in value method tips/techniques upper, 模拟 2 use soft parts 忽略 两 平面 issues 匹配, has true.

　　 another, products for products surface gas 穴（ air trap ） forecast, can through flow analysis formed.

图 2 摩托车 rear 视镜 模拟结果[5]

图 3 plastics products molding Common defect

　　2.2 molding in other appearance defect forecast

　　 injection molding production in Common defect, flash / flash/burrs （ Flash ）, flow marks （ Flow Line ）, short 射（ Short Shot ）, 凹痕 / shrink 痕（ Sink Mark ）（图 3a ）, shrink 孔（ Void ）, strip/profile 纹（ Streak ）, 射流（ Jetting ）（图 3b ）, 亮斑（图 3c ） and warpage （ Warpage ） and other, make products qualification rate method improve/increase, cost method reduce. CAE technology currently can solution issues, is full 部, this 里做一 simple nano.

　　● flash / flash/burrs 判断, need according to flow, holding pressure analysis 结果人工判断, pressure high easy generate flash, weld lines, gas 穴 位置, soft parts can 自动识别.

　　● flow marks, for plastics products, especially is transparent plastics products effect/influence very large, currently also can 模拟.

　　● short 射, through analysis 结果, can 判断出 design solution/scheme is 否出现 short 射.

　　● 凹痕, can use holding pressure analysis in Sink Mark Index parameters 进行判断, Sink Mark Index value large, 说明凹痕出现 概 rate large.

　　● 出现 in products in shrink 孔（图 4a ）, currently product 化 模拟 soft parts is easy obtain, need 实体模 type and analysis tips/techniques formed.

　　● 射流, due to gate 位置不当 and fast formed, currently need 实体模 type and analysis tips/techniques, CAE soft parts difficult formed.

　　● strip/profile and currently method amount 化模拟, can according to experience 提出修改 solution/scheme.

　　● warpage deformation analysis currently product soft parts more can use formed, is is hot elastic property （不 is hot viscous elastic property ）方程, 模拟 数 value 结果容 easy large.

　　3 injection molding CAE technology application

　　 energy saving material injection molding technology, 经 十 more year development, already 取 良 good formed 效, 如传统 injection molding 方面涉 and hot system, full electrical injection molding machine, thin housing/shell （ Thin-Wall ） high speed injection molding machine, micro fine injection molding machine and other; more material composite/compounding new molding technology （ Multimaterial Multiprocess ）, gas 体 / liquid 体辅助 injection molding, 三明治 injection molding, injection molding pressure shrink molding, more formed separation injection molding, inner coating molding （ In Mold Decoration ）, inner molding （ Molded Interconnected Device ） and other. this molding technology energy saving, material 效果良 good, this technology application need core mold technology 搭配才 can formed 功.

　　 technology new 先于模拟理论, is has principle positive understanding need time. currently product soft parts can gas 体辅助 injection molding, injection molding pressure shrink molding, more formed separation injection molding, inner coating molding and other analysis, degree, use property, property has 待于进一步改进完善.

　　因 is transparent plastics products, especially is optical products, optical sheet/slice, 镜头, is has relatively good market outlook/prospects and profit products, 取代玻璃 development trend day obvious, molding difficult degree relatively large, therefore use year solution transparent plastics products issues, CAE technology application and for production function. transparent plastics products commonly used plastics has PC, PMMA, mCOC, PS and other, different plastics use molding processing methods, molding process conditions has relatively large difference, molding quality （ main/primary is optical property can and other inner in quality ）也 has versus 应 差别.

　　3.1 molding mold temperature degree stability time forecast

　　 issues 提出: use PC material, injection molding processing 一模四穴 optical sheet/slice, products in thin 1.7mm, thick 7mm[12, 13], production process unstable, products qualification rate relatively low. can stability production, improve/increase products qualification rate.

图 4 optical sheet/slice 模拟

　　 analysis solution/scheme: use 三维实体模 type and viscous elastic property 本构方程进行 CAE analysis, 发现（ 1 ） products in to right 端出现熔接痕, long degree and products semi 径一样; （ 2 ） mold temperature degree low, thick degree large, flow 充填不 good, easy generate gas 孔.

　　改进 methods: use mold fast speed cooling technology mold temperature degree control. in products 圆心（ products most thin 处） upper use add hot rod increase hot, improve/increase thin temperature degree, let melt more easy 充填; use mold temperature machine improve/increase overall mold temperature degree.

　　 can property use ANSYS combined has CAE product analysis soft parts [12]. rear solution/scheme use CAE technology 模拟发现: （１） improve/increase mold temperature degree, can has decrease/reduce understanding 线, long degree decrease/reduce 50-70%, in sheet/slice outer 围（ use 时切割掉 方）, improve/increase product quality; （２） production use mold temperature degree, 按原始 solution/scheme provide process conditions, need 13-16 production cycle rear can stability, can stability production.

　　 issues generate is is plastics raw materials cost high, production solution/scheme in 进行 8-10 cycle preheating mold, has machine stability as temperature degree scope/range; rear, use hot water add hot mold, decrease/reduce raw materials meanwhile stability production, improve/increase products qualification rate.

　　3.2 improve/increase products quality methods

　　 this residual stress and degree is indicators research optical products quality. generally 讲, residual stress large injection molding products optical property can 会变差[14]. in CAE analysis upper, combined 一 实验结果, can through plastics Raw Materials, molding process conditions, molding process methods and other improve/increase optical products quality.

　　一 optical 镜头, use PC processing, its transparent degree and 流明达不 to technology requirements, through CAE analysis combined light elastic testing equipment, optical amount equipment 发现, PC products internal stress large PMMA, in conditions 允许 情况 lower （ main/primary is products function requirements ）, use PMMA rear, issues solution.

　　 process conditions for PC residual stress and optical property can effect/influence, detailed table/sheet １, 2[14], can use 参考设置 process parameters.

table/sheet 1 different process conditions lower PC sheet/plate residual stress 变化[14]

process parameters
  increase large trend
 应 force strip/profile 纹数
  for residual stress effect/influence
 
mold temperature degree ℃
 60, 70, 80
 9, 7, 5
 ↓ decrease/reduce trend
 
melt temperature degree ℃
 270, 290, 320
 3, 6, 14
 ↑ increase large trend
 
injection pressure MPa
 90, 95, 100
 5, 5, 4
 ↓ decrease/reduce trend
 
injection time s
 3, 4, 5
 5, 5, 5
 －没 effect/influence
 
holding pressure pressure MPa
 50, 70, 90
 5, 5, 5
 －没 effect/influence
 
holding pressure time s
 3, 4, 5
 8, 8, 8
 －没 effect/influence
 
cooling time s
 10, 20, 30
 6, 7, 7
 ↑ increase large trend
 

table/sheet 2 different process conditions lower PC sheet/plate degree 变化

process parameters
  increase large trend
  for optical property can degree effect/influence
 
mold temperature degree ℃
 60, 70, 80
 ↑ increase large trend
 
melt temperature degree ℃
 270, 290, 320
 ↑ increase large trend
 
injection pressure MPa
 90, 95, 100
 ↑ increase large trend
 
injection time s
 3, 4, 5
 －没 effect/influence
 
holding pressure pressure MPa
 50, 70, 90
 －没 effect/influence
 
holding pressure time s
 3, 4, 5
 －没 effect/influence
 
cooling time s
 10, 20, 30
 ↓ decrease/reduce trend
 

　　4 结论

　　CAE technology, 随 计算 machine technology, mold processing, molding process 进步而进步[15,16], CAE technology and application and improve/increase is industry competition need, is 科技进步 体现. CAE technology for production has 积极 指导意义, it is 辅助工 tool, solution issues can force and water and use has relatively large 关系, especially in new application and new product development 方面, inquiry has experience CAE engineering or research 人员会 to has 益 帮助.

　　5 致谢

　　感谢 in large mold research in 心（ Taiwan CYCU ）, 感谢郑州 large 学橡塑 mold engineering research in 心（ NERC ）, provide research conditions, separation its research 结果.