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材料加工技術雜志 187 188 2007 690 693 自適應電動溫度調節(jié)系統(tǒng) 注射成型的模具 Nardin B a B Zagar a came came A Glojek a D Kri AJ BZ TECOS 工具和模具開發(fā)中心的斯洛文尼亞 Kidri eva Cesta 3000 Sloveniac Celje b教員的電氣工程 斯洛文尼亞盧布爾雅娜 摘要 在模具的開發(fā)和生產過程中有一基本問題就是是否能夠對注塑模具的溫度 條件進行控制 精確的研究在模具熱力學過程表明 換熱是可以操縱熱量的手段 這樣的系統(tǒng)升級傳統(tǒng)冷卻系統(tǒng)在模具或可以是一個獨立的應用程序內部熱操作 在本文中 作者將目前的研究項目的結果 這是在三個階段 其結果是在 A686 2006 專利實施專利 測試階段 原型階段和產業(yè)化階段將出現 該項 目的主要結果是總的和快速在周期時間和整體影響重點變形的塑料產品質量在 線的模具溫度調節(jié)控制 提出了應用程序可以提供一個里程碑 模具溫度和產品質量控制的注射成 型過程中的領域 2006 Elsevier B V 保留所有權利 關鍵詞 注射成型 模具冷卻熱電模塊 數值模擬 1 介紹 定義的問題 開發(fā)技術的冷卻模具通過熱電的 TEM 意味著推導的工業(yè)實踐和存在的問題 即 在設計 工具制造和開發(fā)工具 目前的冷卻技術有技術的局限性 其局限性的 位置及提前預測與有限元分析 FEA 仿真包但不是完全可以避免的 結果一個多 元化國家的最先進的分析顯示 所有現有的冷卻系統(tǒng)不提供可控的傳熱能力足以 符合要求的工藝窗口當前聚合物加工技術 聚合物加工是當今有限 在任期縮短生產周期時間內 降低成本 只與熱容操 作功能 其他生產優(yōu)化功能已經驅動機械和聚合物加工的局限性 3 1 1 熱過程中注塑塑料加工 塑料的處理是基于傳熱塑膠材料和模腔之間 在計算傳熱應該考慮兩個主 要事實 首先是所有能源使用基于熱力學定律的第一定律節(jié)能 1 第二是速度的 傳熱 在傳熱分析的基本任務是隨時間和溫度計算其分布在研究系統(tǒng) 最后取 決于速度之間的熱傳導的系統(tǒng)和環(huán)境和速度的傳熱系統(tǒng)內部 基于傳熱可以作 為熱傳導 對流和輻射 1 1 2 冷卻時間 完成注射模塑過程周期由模具閉合階段 注入融化成腔 包裝壓力相位補償 收縮效應 冷卻階段 開模階段和部分排出期 在大多數情況下 最長時間的上 述所有階段是冷卻時間 冷卻時間在注射模塑過程被定義為時間需要冷卻塑料零件到彈射溫度 1 圖 1 模具溫度變化在一個周期的 2 一個冷卻過程的主要目的是降低額外冷卻時間 在理論上是不必要的 在 實踐中 它延伸從 45 到 67 的整個周期時間的 1 4 從文學與實驗 1 4 它可以看到 模具溫度影響極大 因此脫模時間冷卻時 間 成本 注射成型過程是一個循環(huán)過程 模具溫度變化見圖 1 溫度變化從平均價值 通過整體周期時間 2 塑料注射模具冷卻技術 因為它已經描述 已經有幾種不同的技術 讓用戶來冷卻模具 5 最傳統(tǒng)的 方法是用鉆井技術 即生產模具的洞 通過這些孔 coolinglines 冷卻介質流 動 消除生成和積累的熱量從模具 1 2 它也是非常方便的在不同的材料建造 不同的熱導率 目的是提高控制模具溫度條件 這樣的方法是所謂的被動方法對 模具溫度控制 這個具有挑戰(zhàn)性的任務是使一個活躍的系統(tǒng) 它可以改變熱條件 對于所需 的方面 比如產品質量或周期時間 一個這樣的方法是集成熱電氣模塊 TEM 它 可以改變熱條件期望的性質 對于模具 用這樣的方法 一個可以控制傳熱與時 間和空間變量 什么手段 溫度可以調節(jié)整個注塑周期 獨立于位置的模具 熱控 制是通過控制單元 輸入變量是收到的人工輸入或輸入從注塑仿真 與輸出值 控制單元模塊行為監(jiān)控TEM 2 1 熱電模塊 TEM 為需要的熱操作 TEM模塊集成到模具 熱量與電之間的交互變量對于換熱 是基于珀爾帖效應 珀爾帖效應的現象是眾所周知的 但它是直到現在從未用于 注塑應用程序 TEM模塊 見圖2 是一個設備由妥善安排雙P和N型半導體 放置兩 個陶瓷板之間形成熱與冷熱電冷卻器網站 權力的傳熱可以容易控制通過的大 小和極性的電流提供 圖 2 TEM 框圖 2 2 申請模具冷卻 應用程序的主要想法是插入到墻壁的 TEM 模塊模腔作為主要傳熱單元 這些基本的裝配中可以看到圖 3 二次傳熱是通過常規(guī)流體冷卻系統(tǒng)實現 允許熱流入與流出從模腔熱力學系統(tǒng) 圖 3 TEM 冷卻組件結構 設備呈現在圖 3包括熱電模塊 一個 使主要傳熱從或溫度可控表面模具 腔 B 二次傳熱是通過冷卻通道啟用 C 提供恒溫條件在模具 熱電模塊 一 操作作為熱泵和這樣操縱與熱派生或者從模具由流體冷卻系統(tǒng) C 系統(tǒng)二次加 熱與冷卻通道操作作為熱交換器 減少熱容的可控區(qū)域保溫 D 是安裝在模腔 F 和 模具結構板 E 圖4 溫度的檢測與調節(jié)結構 整個應用程序包括TEM模塊 一個溫度傳感器和電子裝置控制系統(tǒng)的完整 該系統(tǒng)被描述在圖4和包括一個輸入單元 輸入界面 和一個供應單位 單位為電 子和電力電子供應h橋單元 輸入和供應單位與溫度傳感器回路信息附在一個控制單元 作為執(zhí)行單元試 圖強加預定義的溫帶 時間 位置關系 使用珀爾帖效應 單位可以用于加熱或冷 卻的目的 二級除熱是通過流體冷卻媒體實現視為換熱器 如圖4 這單位是根據目前 的冷卻技術和作為一個水槽或源的熱 這允許完全控制過程從溫度 時間和位 置通過整個周期 此外 它允許不同的溫度 時間 位置概要文件在周期也為起點 和終點的過程 描述技術可用于各種工業(yè)和研究目的 精確的溫度 時間 位置控 制是必需的 本文所提出的系統(tǒng)在無花果 3和4的比較分析 從理論以及實踐的觀點 分 析了理論方面通過有限元模擬 而實用的開發(fā)和實現的原型到實際應用測試 3 有限元分析模具冷卻 當前的發(fā)展對注塑模具設計包括幾個階段 3 其中還設計和優(yōu)化一個冷卻 系統(tǒng) 這是現在由模擬使用定制的有限元軟件包 模塑仿真分析 4 可以預測 冷卻系統(tǒng)功能 特別是其影響塑料 與這種模擬 模具設計師收集信息在產品流 變學和變形由于收縮作為魔法作為生產時間周期信息 這個熱信息通常是準確的 但仍然可以不可靠的情況下的流變材料信息不足 高質量的輸入為熱調節(jié)TEM 需要得到一個圖片關于溫度分布在周期時間和整個 模具表面和整個模具厚度 因此 不同的過程模擬是必要的 圖5 在有限元環(huán)境原型截面 3 1物理模型 有限元分析 實現有限元分析為開發(fā)項目做是由于作者長期經歷這樣的包 4 和可能性來 執(zhí)行不同的測試在虛擬環(huán)境 整個冷卻系統(tǒng)設計了原型在有限元環(huán)境 見圖5 通 過溫度分布在每個部分的原型和聯系人之間的冷卻系統(tǒng)進行了探討 為模擬物 理特性在一個樣機 仿真模型構建了利用COMSOL軟件多重物理量 結果是一個有 限元模型與真實的原型 見圖7 通過它可以比較和評估結果 探討了有限元模型在術語的傳熱物理考慮兩個熱源 水換熱器與流體物理和 熱電模塊與傳熱物理 只有傳導和對流輻射進行分析 忽略了由于低相對溫度 因 此低影響溫度 有限元分析的邊界條件設定目標達到相同的工作條件 在實際測試 周圍的 空氣和水換熱器被設定在穩(wěn)定的溫度 20 C 圖 6 根據有限元分析的溫度分布 有限元分析的結果中可以看到圖6 即通過模擬溫度分布區(qū)域圖5所示 圖6 表示穩(wěn)態(tài)分析 非常準確的原型測試相比 為了模擬時域響應進行了瞬態(tài)仿真也 顯 示非常積極的結果對于未來的工作 才能夠實現一個溫差200 C在很短的時間 5 s 可能會導致一些問題在TEM結構 這些問題就都解決了幾個解決方案 比如足 夠的安裝 選擇合適的材料和應用智能化電子透射監(jiān)管 3 2實驗室測試 因為它已經描述 原型制作和測試 見圖7 結果顯示 設置的假設被證實 用TEM模塊 可以控制溫度分布的不同部分的模具在整個周期的時間 與實驗室 測試 這是證明了的 可以是實際的熱操縱監(jiān)管與TEM模塊 測試是在實驗室 模 擬真實的工業(yè)環(huán)境 注塑成型機克勞斯Maffei公里60 C 溫度傳感器 紅外攝像 機和原型TEM模塊 反應溫度在1 8 s多樣形式 5 80 C 代表一個廣闊的區(qū)域內 的熱量控制在注塑周期 圖7 在實際環(huán)境中的原型 4 結論 利用熱電模塊與它直接連接輸入和輸出之間的關系是一個里程碑冷卻應用 程序 它的引入對注塑模具與它的問題和問題處理的冷卻結構精密 高質量的塑 料部分代表了很高的期望 作者是假設使用珀爾帖效應可用于溫度控制在模具注塑 的方法有基于仿 真的工作和真正的生產實驗室設備證明 假設被證實 仿真結果顯示 一個廣泛 的領域可能的應用 TEM 模塊在注塑過程 與功能的溫度曲線提到跨周期時間 注射模塑過程可以完全控制 工業(yè)的問 題 如均勻冷卻問題類表面及其后果的塑料件外觀可以解決 填充墻的問題可以 解決薄長與過熱的一些表面在注射時間 此外 這樣的應用程序控制流變特性的 塑料材料可以獲得 用適當的熱調節(jié) TEM 是可能甚至控制熔體流動的模具 在充 填階段的模腔 這是做了適當的溫度分布的模具 更高的溫度對薄壁零件的產品 應用TEM模塊 可以顯著減少周期時間在注塑過程 時間的限制可能減少在 于框架的10 25 的額外的冷卻時間 在1 2節(jié)描述 應用 TEM 模塊可以積極控制產品的翹曲和調節(jié)量的產品翹曲的方式來達到 所需的產品公差 提出了 TEM 模塊冷卻應用注射模塑過程是一個優(yōu)先的選擇注意的專利 屬于 TECOS 舉行 參考文獻 1 I Cati Izmjena topline u kalupima za injekcijsko pre anje plastomera sDru tvo plasti ara i gumaraca Zagreb 1985 sc 2 I Cati F Johannaber Injekcijsko pre anje polimera i ostalih materiala s Dru tvo za plastiku i gumu Biblioteka polimerstvo Zagreb 2004 s 3 B Nardin K Kuzman Z Kampu Injection moulding simulation results as an input to the injection moulding process in AFDM 2002 The Second International Conference on Advanced Forming and Die Manufacturing Technology Pusan Korea 2002 4 TECOS Slovenian Tool and Die Development Centre Mold ow Simulation Projects 1996 2006 5 S C Chen et al Rapid mold surface heating cooling using electromagnetic induction technology ANTEC 2004 Conference CD ROM Chicago Illinois 16 20 May 2004 Journal of Materials Processing Technology 187 188 2007 690 693 Adaptive system for electrically driven thermoregulation of moulds for injection moulding B Nardin a B Zagar a A Glojek a D Kri aj bza TECOS Tool and Die Development Centre of Slovenia Kidri eva Cesta 25 3000 Celje Sloveniac b Faculty of Electrical Engineering Ljubljana Slovenia Abstract One of the basic problems in the development and production process of moulds for injection moulding is the control of temperature con ditions in the mould Precise study of thermodynamic processes in moulds showed that heat exchange can be manipulated by thermoelectrical means Such system upgrades conventional cooling systems within the mould or can be a stand alone application for heat manipulation within it In the paper the authors will present results of the research project which was carried out in three phases and its results are patented in A686 2006 patent The testing stage the prototype stage and the industrialization phase will be presented The main results of the project were total and rapid on line thermoregulation of the mould over the cycle time and overall in uence on quality of plastic product with emphasis on deformation control Presented application can present a milestone in the eld of mould temperature and product quality control during the injection moulding process 2006 Elsevier B V All rights reserved Keywords Injection moulding Mould cooling Thermoelectric modules FEM simulations 1 Introduction de nition of problem Development of technology of cooling moulds via thermo electrical TEM means derives out of the industrial praxis and problems i e at design tool making and exploitation of tools Current cooling technologies have technological limitations Their limitations can be located and predicted in advance with nite element analyses FEA simulation packages but not com pletely avoided Results of a diverse state of the art analyses revealed that all existing cooling systems do not provide con trollable heat transfer capabilities adequate to t into demand ing technological windows of current polymer processing technologies Polymer processing is nowadays limited in term of short ening the production cycle time and within that reducing costs only with heat capacity manipulation capabilities Other produc tion optimization capabilities are already driven to mechanical and polymer processing limitations 3 1 1 Thermal processes in injection moulding plastic processing Plastic processing is based on heat transfer between plastic material and mould cavity Within calculation of heat transfer one should consider two major facts rst is all used energy which is based on rst law of thermodynamics law of energy conservation 1 second is velocity of heat transfer Basic task at heat transfer analyses is temperature calculation over time and its distribution inside studied system That last depends on velocity of heat transfer between the system and surroundings and velocity of heat transfer inside the system Heat transfer can be based as heat conduction convection and radiation 1 1 2 Cooling time Complete injection moulding process cycle comprises of mould closing phase injection of melt into cavity packing pres sure phase for compensating shrinkage effect cooling phase mould opening phase and part ejection phase In most cases the longest time of all phases described above is cooling time Cooling time in injection moulding process is de ned as time needed to cool down the plastic part down to ejection temperature 1 Corresponding authors Tel 386 3 490920 fax 386 3 4264612 E mail address Blaz Nardin tecos si B Nardin 0924 0136 see front matter 2006 Elsevier B V All rights reserved doi 10 1016 j jmatprotec 2006 11 052 B Nardin et al Journal of Materials Processing Technology 187 188 2007 690 693 691 Fig 1 Mould temperature variation across one cycle 2 Fig 2 TEM block diagram The main aim of a cooling process is to lower additional cooling time which is theoretically needless in praxis it extends from 45 up to 67 of the whole cycle time 1 4 From literature and experiments 1 4 it can be seen that the mould temperature has enormous in uence on the ejection time and therefore the cooling time costs Injection moulding process is a cyclic process where mould temperature varies as shown in Fig 1 where temperature varies from average value through whole cycle time 2 Cooling technology for plastic injection moulds As it was already described there are already several differ ent technologies enabling the users to cool the moulds 5 The most conventional is the method with the drilling technology i e producing holes in the mould Through these holes cooling lines the cooling media is owing removing the generated and accumulated heat from the mould 1 2 It is also very convenient to build in different materials with different thermal conductiv ity with the aim to enhance control over temperature conditions in the mould Such approaches are so called passive approaches towards the mould temperature control The challenging task is to make an active system which can alter the thermal conditions regarding to the desired aspects like product quality or cycles time One of such approaches is integrating thermal electrical modules TEM which can alter the thermal conditions in the mould regarding the desired prop erties With such approach the one can control the heat transfer with the time and space variable what means that the temper ature can be regulated throughout the injection moulding cycle independent of the position in the mould The heat control is done by the control unit where the input variables are received from the manual input or the input from the injection moulding simulation With the output values the control unit monitors the TEM module behaviour 2 1 Thermoelectric modules TEM For the needs of the thermal manipulation the TEM module was integrated into mould Interaction between the heat and elec trical variables for heat exchange is based on the Peltier effect The phenomenon of Peltier effect is well known but it was until now never used in the injection moulding applications TEM module see Fig 2 is a device composed of properly arranged pairs of P and N type semiconductors that are positioned between two ceramic plates forming the hot and the cold thermoelectric cooler sites Power of a heat transfer can be easily controlled through the magnitude and the polarity of the supplied electric current 2 2 Application for mould cooling The main idea of the application is inserting TEM module into walls of the mould cavity serving as a primary heat transfer unit Such basic assembly can be seen in Fig 3 Secondary heat transfer is realized via conventional uid cooling system that allows heat ows in and out from mould cavity thermodynamic system Device presented in Fig 3 comprises of thermoelectric modules A that enable primarily heat transfer from or to tem perature controllable surface of mould cavity B Secondary heat transfer is enabled via cooling channels C that deliver constant temperature conditions inside the mould Thermoelec tric modules A operate as heat pump and as such manipulate with heat derived to or from the mould by uid cooling sys tem C System for secondary heat manipulation with cooling channels work as heat exchanger To reduce heat capacity of controllable area thermal insulation D is installed between the mould cavity F and the mould structure plates E Fig 3 Structure of TEM cooling assembly 692 B Nardin et al Journal of Materials Processing Technology 187 188 2007 690 693 Fig 4 Structure for temperature detection and regulation The whole application consists of TEM modules a temper ature sensor and an electronic unit that controls the complete system The system is described in Fig 4 and comprises of an input unit input interface and a supply unit unit for electronic and power electronic supply H bridge unit The input and supply units with the temperature sensor loop information are attached to a control unit that acts as an exe cution unit trying to impose prede ned temperate time position relations Using the Peltier effect the unit can be used for heating or cooling purposes The secondary heat removal is realized via uid cooling media seen as heat exchanger in Fig 4 That unit is based on current cooling technologies and serves as a sink or a source of a heat This enables complete control of processes in terms of temperature time and position through the whole cycle Furthermore it allows various temperature time position pro les within the cycle also for starting and ending procedures Described technology can be used for various industrial and research purposes where precise temperature time position con trol is required The presented systems in Figs 3 and 4 were analysed from the theoretical as well as the practical point of view The theoretical aspect was analysed by the FEM simulations while the practical one by the development and the implementation of the prototype into real application testing 3 FEM analysis of mould cooling Current development of designing moulds for injection moulding comprises of several phases 3 Among them is also design and optimization of a cooling system This is nowa days performed by simulations using customized FEM packages Mold ow 4 that can predict cooling system capabilities and especially its in uence on plastic With such simulations mould designers gather information on product rheology and deforma tion due to shrinkage as ell as production time cycle information This thermal information is usually accurate but can still be unreliable in cases of insuf cient rheological material informa tion For the high quality input for the thermal regulation of TEM it is needed to get a picture about the temperature distri bution during the cycle time and throughout the mould surface and throughout the mould thickness Therefore different process simulations are needed Fig 5 Cross section of a prototype in FEM environment 3 1 Physical model FEM analysis Implementation of FEM analyses into development project was done due to authors long experiences with such packages 4 and possibility to perform different test in the virtual envi ronment Whole prototype cooling system was designed in FEM environment see Fig 5 through which temperature distribution in each part of prototype cooling system and contacts between them were explored For simulating physical properties inside a developed prototype a simulation model was constructed using COMSOL Multiphysics software Result was a FEM model identical to real prototype see Fig 7 through which it was possible to compare and evaluate results FEM model was explored in term of heat transfer physics taking into account two heat sources a water exchanger with uid physics and a thermoelectric module with heat transfer physics only conduction and convection was analysed radiation was ignored due to low relative temperature and therefore low impact on temperature Boundary conditions for FEM analyses were set with the goal to achieve identical working conditions as in real test ing Surrounding air and the water exchanger were set at stable temperature of 20 C Fig 6 Temperature distribution according to FEM analysis B Nardin et al Journal of Materials Processing Technology 187 188 2007 690 693 693 Fig 7 Prototype in real environment Results of the FEM analysis can be seen in Fig 6 i e temper ature distribution through the simulation area shown in Fig 5 Fig 6 represents steady state analysis which was very accurate in comparison to prototype tests In order to simulate the time response also the transient simulation was performed showing very positive results for future work It was possible to achieve a temperature difference of 200 C in a short period of time 5 s what could cause several problems in the TEM structure Those problems were solved by several solutions such as adequate mounting choosing appropriate TEM material and applying intelligent electronic regulation 3 2 Laboratory testing As it was already described the prototype was produced and tested see Fig 7 The results are showing that the set assump tions were con rmed With the TEM module it is possible to control the temperature distribution on different parts of the mould throughout the cycle time With the laboratory tests it was proven that the heat manipulation can be practically regu lated with TEM modules The test were made in the laboratory simulating the real industrial environment with the injection moulding machine Krauss Maffei KM 60 C temperature sen sors infrared cameras and the prototype TEM modules The temperature response in 1 8 s varied form 5 up to 80 C what represents a wide area for the heat control within the injection moulding cycle 4 Conclusions Use of thermoelectric module with its straightforward con nection between the input and output relations represents a milestone in cooling applications Its introduction into moulds for injection moulding with its problematic cooling construction and problematic processing of precise and high quality plastic parts represents high expectations The authors were assuming that the use of the Peltier effect can be used for the temperature control in moulds for injection moulding With the approach based on the simulation work and the real production of laboratory equipment proved the assump tions were con rmed Simulation results showed a wide area of possible application of TEM module in the injection moulding process With mentioned functionality of a temperature pro le across cycle time injection moulding process can be fully controlled Industrial problems such as uniform cooling of problematic A class surfaces and its consequence of plastic part appear ance can be solved Problems of lling thin long walls can be solved with overheating some surfaces at injection time Further more with such application control over rheological properties of plastic materials can be gained With the proper thermal regulation of TEM it was possible even to control the melt ow in the mould during the lling stage of the mould cav ity This is done with the appropriate temperature distribution of the mould higher temperature on the thin walled parts of the product With the application of TEM module it is possible to signif icantly reduce the cycle time in the injection moulding process The limits of possible time reduction lies in the frame of 10 25 of additional cooling time describe in Section 1 2 With the application of TEM module it is possible to actively control the warping of the product and to regulate the amount of product warpage in the way to achieve required product tol erances The presented TEM module cooling application for injection moulding process is a matter of priority note for the patent held and owned by TECOS References c 1 I Cati Izmjena topline u kalupima za injekcijsko pre anje plastomera s Dru tvo plasti ara i gumaraca Zagreb 1985 sc c 2 I Cati F Johannaber Injekcijsko pre anje polimera i ostalih materiala s Dru tvo za plastiku i gumu Biblioteka polimerstvo Zagreb 2004 s 3 B Nardin K Kuzman Z Kampu Injection moulding simulation resultss as an input to the injection moulding process in AFDM 2002 The Sec ond International Conference on Advanced Forming and Die Manufacturing Technology Pusan Korea 2002 4 TECOS Slovenian Tool and Die Development Centre Mold ow Simulation Projects 1996 2006 5 S C Chen et al Rapid mold surface heating cooling using electromag netic induction technology ANTEC 2004 Conference CD ROM Chicago Illinois 16 20 May 2004