Optimization of PP/EPDM Composite Injection Molding Process Based on Multi-factor Interaction
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摘 要
通过Moldflow仿真软件建立了汽车侧踏板聚丙烯/三元乙丙烯(PP/EPDM)复合材料端盖注射成型仿真模型,采用析因设计筛选出对工件翘曲、体积收缩、表面缩痕等缺陷影响最显著的主因子与交互因子,应用正交试验设计方法模拟得到最佳注射成型工艺,并进行了验证。结果表明:对目标值影响显著的主因子为熔体温度、模具温度、注射时间、保压时间和保压压力,交互因子为熔体温度与模具温度、注射时间与保压时间;最优注射成型工艺为熔体温度220℃、模具温度40℃、注射时间2 s、保压时间25 s、保压压力60 MPa,模拟得到的最大翘曲量比原工艺方案的减小了33.21%,体积收缩率降低了39.61%,表面质量显著提高。
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Abstract
The simulation model of injection molding of automotive rocker panel end cap polypropylene/ethylene propylene diene monomer (PP/EPDM) composite was established by Moldflow software. Main factors and interaction factors affecting warping, volume shrinkage, surface sink marks of the workpiece were filtered by factorial design. The optimal injection molding process was simulated by orthogonal test design method and verified. The results show that the main factors affecting the target values were melt temperature, mold temperature, injection time, packing time and packing pressure. The interaction factors were melt temperature and mold temperature, injection time and packing time. The optimal injection molding process was as follows:melt temperature of 220℃, mold temperature of 40℃, injection time of 2 s, packing time of 25 s and packing pressure of 60 MPa. Comparing with the original process, the maximum warpage decreased by 33.21%, volume shrinkage was reduced by 39.61%, and the surface quality was improved significantly.
中图分类号 TQ320.66 DOI 10.11973/jxgccl201803016
所属栏目 物理模拟与数值模拟
基金项目 国家自然科学基金资助项目(51605234);宁夏自然科学基金资助项目(NZ16046);宁夏高校科学研究项目(NGY2016067);湖南大学汽车车身先进设计制造国家重点实验室开放基金资助项目(31515007)
收稿日期 2017/1/17
修改稿日期 2018/1/30
网络出版日期
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备注王冠(1985-),男,河南郑州人,讲师,博士
引用该论文: WANG Guan,WANG Xulin,KOU Linyuan,YI Jie,LIU Zhiwen,XU Congchang,LI Luoxing. Optimization of PP/EPDM Composite Injection Molding Process Based on Multi-factor Interaction[J]. Materials for mechancial engineering, 2018, 42(3): 87~94
王冠,王旭林,寇琳媛,易杰,刘志文,徐从昌,李落星. 基于多因子交互作用的PP/EPDM复合材料注射成型工艺优化[J]. 机械工程材料, 2018, 42(3): 87~94
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【2】HARRY D H, PARROTT R G, HARRY D H, et al. Numerical simulation of injection mold filling[J]. Polymer Engineering & Science, 1970, 10(10):209-214.
【3】TADMOR Z, BROYER E C, GUTFINGER C. Flow analysis network—A method for solving flow problem in polymer processing[J]. Polymer Engineering & Science, 1974, 14(9):660-665.
【4】HIEBER C A, SHEN S F. A finite-element/finite-difference simulation of the injection-molding filling process[J]. Journal of Non-Newtonian Fluid Mechanics, 1980, 7(1):1-32.
【5】SEOW L W, LAM Y C. Optimizing flow in plastic injection molding[J]. Journal of Materials Processing Technology, 1997, 72(3):333-341.
【6】YAMAKAWA S, SHAW C, SHIMADA K. Layered tetrahedral meshing of thin-walled solids for plastic injection molding FEM[J]. Computer-Aided Design, 2005, 38(4):245-255.
【7】GUPTA A, KELLY P. Optimal galerkin finite element methods for non-isothermal liquid composite moulding process simulations[J]. International Journal of Heat & Mass Transfer, 2013, 64:609-622.
【8】戴亚春, 王匀, 周建忠, 等. 微齿轮注塑成型正交优化及数值模拟[J]. 材料工程, 2010(7):46-48.
【9】王善凯, 李晶, 胡激涛, 等. 基于Moldflow汽车配件注塑工艺参数优化[J]. 西安工程大学学报, 2015, 29(6):692-697.
【10】刘色容, 林有希, 卢月美, 等. 工艺参数对模内覆模注塑件翘曲变形的影响[J]. 工程塑料应用, 2015, 43(7):46-51.
【11】刘朝福, 刘建伟, 何玉林. 基于正交试验的PP车门内饰板注塑工艺参数优化[J]. 合成树脂及塑料, 2015, 32(1):50-53.
【12】党玉春, 丁清国, 刘泓滨. 基于DOE因子交互作用的注射成型工艺参数优化研究[J]. 新技术新工艺, 2013 (10):75-78.
【13】林权. 基于综合平衡法的注塑工艺参数多目标优化设计[J]. 塑料科技, 2011, 39(1):84-88.
【14】叶久新, 王群. 塑料成型工艺及模具设计[M]. 北京: 机械工业出版社, 2008:62-63.
【15】王首绪, 龙琰, 郭四泽. 基于t分布理论的公路定额数据小样本容量的收敛条件[J].长沙理工大学学报(自然科学版), 2007, 4(2):13-15.
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