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畢業(yè)設(shè)計(論文)開題報告
題目：加熱器底座塑料模具設(shè)計
系 別 機(jī)電信息系
專 業(yè) 機(jī)械設(shè)計制造及其自動化
班 級
姓 名
學(xué) 號
導(dǎo) 師
2012年12月24日
1.畢業(yè)設(shè)計（論文）綜述（題目背景、研究意義及國內(nèi)外相關(guān)研究情況）
1.1題目背景與研究意義：
我國塑料模工業(yè)從起步到現(xiàn)在，歷經(jīng)半個多世紀(jì)，有了很大發(fā)展，模具水平有了較大提高，尤其是塑料模具發(fā)展速度將高于其它模具，在模具行業(yè)中的比例將逐步提高。本設(shè)計題目涉及目標(biāo)均為工程實(shí)際零件，通過對塑件的實(shí)體測繪，完成基本參數(shù)的采集，然后運(yùn)用《塑料模具設(shè)計》《塑料成型工藝》等知識，指導(dǎo)學(xué)生利用CAD等軟件完成模具結(jié)構(gòu)的設(shè)計，并進(jìn)行相關(guān)的計算。本設(shè)計旨在鍛煉學(xué)生在技術(shù)應(yīng)用能力上達(dá)到培養(yǎng)目標(biāo)的基本要求，在塑料成型工藝與塑料模具設(shè)計技術(shù)方面得到全面提高。
1.2 國內(nèi)外相關(guān)研究情況：
塑料模具增長迅速，比重不斷提高。目前，塑料模具在整個模具行業(yè)中所占比重約為30%，在未來模具市場中，塑料模具的發(fā)展速度將高于其他模具。模具的精度將越來越高。10年前精密模具的精度一般為5微米，現(xiàn)已達(dá)到2-3微米，1微米精度的模具也將上市。多功能復(fù)合模具將進(jìn)一步發(fā)展。新型多功能復(fù)合模具除了沖壓成型零件外，還擔(dān)負(fù)疊壓、攻絲、鉚接和鎖緊等組裝任務(wù)，對鋼材的性能要求越來越高。熱流道模具在塑料模具中的比重也將逐漸提高。隨著塑料成型工藝的不斷改進(jìn)與發(fā)展，氣輔模具及適應(yīng)高壓注塑成型等工藝的模具也將隨之發(fā)展。標(biāo)準(zhǔn)件的應(yīng)用將日益廣泛。模具標(biāo)準(zhǔn)化及模具標(biāo)準(zhǔn)件的應(yīng)用將極大地影響模具制造周期，還能提高模具的質(zhì)量和降低模具制造成本?？焖俳?jīng)濟(jì)模具的前景十分廣闊。以塑代鋼、以塑代木的進(jìn)程進(jìn)一步加快，塑料模具的比例將不斷增大。由于機(jī)械零件的復(fù)雜程度和精度的不斷提高，對塑料模具的要求也越來越高。模具技術(shù)含量將不斷提高。
2．本課題研究的主要內(nèi)容和擬采用的研究方案、研究方法或措施
2.1主要內(nèi)容：
2.1.1 本設(shè)計是以工程實(shí)際零件——加熱器底座塑料模具設(shè)計為對象，用于電熱器元件的固定支撐放置，該零件一邊有橫向側(cè)孔，必須考慮測抽芯機(jī)構(gòu)才能完成，因此需要學(xué)生充分運(yùn)用所學(xué)知識進(jìn)行模具結(jié)構(gòu)設(shè)計；
2.1.2 確定模具的設(shè)計方案，進(jìn)行整體設(shè)計；
2.1.3 主要部件設(shè)計計算及校核；
2.1.4 繪制塑料件零件圖與模具裝配圖；
2.1.5編寫設(shè)計說明書。
2.2研究方法和步驟：
本設(shè)計題目涉及目標(biāo)均為工程實(shí)際零件，通過對塑件的實(shí)體測繪，完成基本參數(shù)的采集，然后運(yùn)用《注塑模具設(shè)計》、《塑料模具設(shè)計》、《塑料成型工藝》等知識，利用AutoCAD和Pro/E或soildworks等軟件完成模具結(jié)構(gòu)的設(shè)計，并進(jìn)行相關(guān)的校核計算，完成包括選材熱處理、制造工藝規(guī)程、可行性分析等工作。本設(shè)計旨在鍛煉我們在專業(yè)技術(shù)應(yīng)用能力上達(dá)到培養(yǎng)目標(biāo)的基本要求，在塑料成型工藝與塑料模具設(shè)計技術(shù)方面得到全面提高。
圖1.加熱器底座零件圖
2.3擬采用的研究方案：
方案一：選用臥式注射機(jī)，壓塊加螺釘固定，澆注系統(tǒng)選用側(cè)澆口；
方案二：選用立式注射機(jī)，螺釘固定，澆注系統(tǒng)選用點(diǎn)澆口。
方案比較：臥式注射機(jī)適合于高速化生產(chǎn)，模具裝拆及調(diào)整容易，采用螺釘加壓塊固定更加安全，側(cè)澆口形狀簡單，尺寸容易掌握。綜上所述，初步選用方案一。
3.本課題研究的重點(diǎn)及難點(diǎn)，前期已開展工作
3.1本課題研究的重點(diǎn)及難點(diǎn)：
此制品用于電熱器元件的固定支撐放置。制品材料為：ABS（丙烯腈—丁二烯—苯乙烯共聚物），此材料有良好的耐化學(xué)腐蝕、表面硬度、加工性和染色性。制品的壁厚、熔料溫度對收縮率影響極小。ABS有較強(qiáng)的抗沖擊強(qiáng)度，且在低溫下也不迅速下降。ABS有一定的硬度和尺寸穩(wěn)定性，易于成型加工，經(jīng)過調(diào)色可配成任何顏色。
此制品是批量生產(chǎn)，所以我將設(shè)計一套塑料成型模具。在設(shè)計模具時需要考慮制品的一些特點(diǎn)。制品的主要特點(diǎn)是該零件一邊有橫向側(cè)孔，兩側(cè)有兩個上下通孔，且上下孔形狀不規(guī)則，注塑時很復(fù)雜。塑件的尺寸精度有一定的要求，外型需光潔不得有劃傷，總體尺寸大小適中。取塑件的最大截面為分型面，底座上面的左右小孔和主體上左右相同的不規(guī)則通孔需要抽芯。開模后，塑件包緊動模型芯的力比較大，采用推管推出，推出力比較平穩(wěn)，塑件不易發(fā)生變形。
3.2前期已開展工作：
3.2.1已簡單查閱了資料，對注塑模具設(shè)計的流程有了一定的了解；
3.2.2已對塑件結(jié)構(gòu)有了了解，并繪制了CAD圖。
4.完成本課題的工作方案及進(jìn)度計劃（按周次填寫）
第1周：查閱和收集資料，初步了解課題；
第2-4周：塑件結(jié)構(gòu)分析與繪制，初步計劃了設(shè)計方案，完成開題報告；
第5-8周：澆注系統(tǒng)等結(jié)構(gòu)的選擇和尺寸計算，完成中期報告；
第9-12周：繪制裝配圖及零件圖；
第13-14周：編寫論文；
第15周：提交論文并進(jìn)行終期答辯。
參考文獻(xiàn)
[1] 曹宏深，趙仲治主編.《塑料成型工藝與模具設(shè)計》.北京：機(jī)械工業(yè)出版社，1993
[2] 李秦蕊主編.《塑料模具設(shè)計》.西安：西北工業(yè)大學(xué)出版社，1995
[3] 洪慎章主編.《實(shí)用注塑模具結(jié)構(gòu)圖集》.化學(xué)工業(yè)出版社，2009
[4] 孫玲主編.《塑料成型工藝與模具設(shè)計》.清華大學(xué)出版社，2008
[5] 孫錫紅.《我國塑料模具發(fā)展現(xiàn)狀及發(fā)展建議》.期刊電加工與模具.2010
[6] 《我國模具發(fā)展趨勢》.期刊模具制造.2003
[7] 蔣繼宏，王效岳主編《注射模具典型結(jié)構(gòu)100例》.中國輕工業(yè)出版社.2000
[8] 顏智偉主編《塑料模具設(shè)計與結(jié)構(gòu)設(shè)計》.北京：國防工業(yè)出版社.2006
[9] 廖念釗，莫雨松《互換性與技術(shù)測量》[M].中國計量出版社.2000
[10] 宋滿倉主編.《注塑模具設(shè)計》.北京：電子工業(yè)出版社.2010
[11] 王永平主編.《注塑模具設(shè)計經(jīng)驗(yàn)點(diǎn)評》.機(jī)械工業(yè)出版社.3003
[12] 張中元編. 《塑料成型工藝與模具設(shè)計》. 北京：航空工業(yè)出版社.2005
[13] 徐進(jìn)編. 《模具材料應(yīng)用手冊》. 北京：機(jī)械工業(yè)出版社.2008
[14] Mita.T.Yamaguchi.T.Kashiwase.T and Kawase,T. Realization og speed biped using modern control theory.Int. J.Control.1984,40.107-119.
[15] Eldukhri. E, E.Design and control of a biped walking robot.phD thesis.Department of Electronic and Electrical Engineering Univerity of Salford UK.
[16] Medrano-Xenda.G A and Eldukhri E.E.Biped robot locomotiong in the sagittal plane,Trans.Trans.Inst.Mcasmt and Control,1997.19.38-49.
5.指導(dǎo)教師意見（對課題的深度、廣度及工作量的意見）
指導(dǎo)教師：
年 月 日
6.所在系審查意見：
系主管領(lǐng)導(dǎo)：
年 月 日
畢業(yè)設(shè)計（論文）中期報告
題目： 加熱器底座塑料模具設(shè)計
系 別 機(jī)電信息系
專 業(yè) 機(jī)械設(shè)計制造及其自動化
班 級
姓 名
學(xué) 號
導(dǎo) 師
2013年3月20日
1. 設(shè)計（論文）進(jìn)展?fàn)顩r
1.1本次設(shè)計的塑料件為一長方形半封閉樣式的加熱器底座，產(chǎn)品特點(diǎn)為：底座必須棱廓分明且外表面光滑，底部有兩個空心圓柱，頂部有兩個不規(guī)則柱孔且對稱分布，兩側(cè)壁有圓孔，分模時要考慮側(cè)向抽芯，最后要求外表無明顯澆口痕跡；座體內(nèi)部不規(guī)則柱體要求與側(cè)壁之間光滑過度，在結(jié)構(gòu)設(shè)計時需整體考慮模具的合理性。
圖1 加熱器底座零件二維圖
圖2 加熱器底座零件三維圖
1.2在開題的基礎(chǔ)上進(jìn)行了部分零件的計算和設(shè)計，已調(diào)整了結(jié)構(gòu)方案，修改了零件圖的不合理結(jié)構(gòu)，并進(jìn)一步的完成了模具裝配草圖的繪制。
1.3通過計算塑料件的體積及查閱相關(guān)模具設(shè)計手冊完成了注塑機(jī)的選擇。選型為：G54-S-200/400型。相關(guān)參數(shù)如下：
理論注射量： 200/400cm3 最大注射面積：645cm2
最大模具厚度：406mm 鎖模力： 2540KN
最小模具厚度：165mm 定位孔直徑： 125mm
模板行程: 260mm 拉桿空間： 290×368mm
噴嘴球半徑： 18mm 噴嘴孔徑： 4mm
1.4確定主流道、分流道的形式和尺寸。其澆口套的尺寸如圖3所示。
分流道截面形狀及尺寸如圖4所示。
圖3澆口套形式與尺寸 圖4 分流道截面形狀
1.5確定模腔數(shù)量及其排列方式、澆口形式。
加熱器底座的尺寸不太大，為了降低注射成本，根據(jù)所選注塑機(jī)的注射量，采用一模兩型腔的模具。為了滿足較高的外觀要求，確定采用側(cè)澆口。其選用的側(cè)澆口結(jié)構(gòu)形式如圖5所示。
圖5 側(cè)澆口結(jié)構(gòu)形式
1.6計算并校核型腔部分的強(qiáng)度和剛度，根據(jù)圓形端蓋的高度確定型腔板的側(cè)壁厚度，型芯固定板的厚度。并確動模板、頂出板，支塊厚度及其模具安裝方法。
1.7完成了對模具工作部分尺寸進(jìn)行設(shè)計計算。
1.8完成了模具零件結(jié)構(gòu)設(shè)計。比如：導(dǎo)柱、導(dǎo)套、拉料桿、復(fù)位桿、頂
桿、滑塊、推板導(dǎo)柱導(dǎo)套等等。
1.9初步繪制模具裝配圖如圖6所示。
圖6 模具裝配圖
2. 存在問題及解決措施
2.1未考慮到模具冷卻問題。
解決措施：在模具內(nèi)添加了冷卻系統(tǒng)。
2.2中間型芯的固定存在問題，未限制周向轉(zhuǎn)動。
解決措施：在老師的指導(dǎo)下，查閱了相關(guān)手冊，在動模固定板和型芯的交界處安裝騎縫螺釘，防止其周向轉(zhuǎn)動。
3. 后期工作安排
12周－13周：完善模具結(jié)構(gòu)裝配圖，并完成所有零件圖的繪制工作。
14周－15周：完成模具零件的選材、工藝規(guī)程的編制。
16周－17周：對所有圖紙進(jìn)行校核，編寫設(shè)計說明書，所有資料提請指導(dǎo)教師檢查。
18周：準(zhǔn)備答辯；
指導(dǎo)老師簽字：
年 月 日
注：1. 正文：宋體小四號字，行距22磅；標(biāo)題：加粗 宋體四號字
2. 中期報告由各系集中歸檔保存，不裝訂入冊。
外文翻譯
Treating and the modern mould make high speed
One, summarizes
1 the present situation that the mould makes at present and trend
The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. Industrial product part rough process 75%, the finish machining 50% and plastic part 90% will be completed from the mould. The Chinese mould market demand already reaches scale of 500 hundred million yuan at present. The automobile mould , the annual growth rate covering piece of mould especially will exceed 20 %; Also prompt building material mould development , various heterotype material the mould , wall surface and floor mould become new mould growth point , plastic doors and windows and plastic drain-pipe increase to exceeding 30 by in the upcoming several years %; The home appliance mould annual growth rate will exceed 10 %; The IT industry year increases % speed equally exceeding 20 , the need to the mould accounts for 20 of mould marketplace %.2004 annual Chinese machine tools implements industry output value
will continue to increase. Our country mould fabrication market potential is enormous. The basis data counts , in recent years, our country mould year gross output value reaches 3 billion U. S. dollar , entrance exceeds 1 billion U. S. dollar, exceed 100 million U. S. dollar outlet. Increase by from 25% to increase to 2005 50% of 1995. The expert foretells that abroad: Asia portion being occupied by in mould fabrication in the whole world, will from 25% to increase to 2005 50% of 1995.
Chinese mould industry has been expanding by leaps and bounds , has formed east China and two big South China bases, and has expanded gradually arriving at other province. In 2002 (Shandong , Anhui , Sichuan) in 1996 ~, mould manufacturing industry output value annual average growth 14% , grows by 25% in 2003. In 2003 our country mould output value is 45 billion RMB. The gross product place occupies the world the 3rd, exports a mould increases 33.5% compared to last year 336,800,000 U. S. dollar. But, contents low our country technology moulds already pile up in excess of requirement , very most support of accurate , complicated top grade mould imports. Every year the entrance mould exceeds 1 billion U. S. dollar. Exceed 100 million U. S. dollar outlet.
Precise mould accuracy requires that 3 mu ms , large-scale moulds require that 8000 satisfied kN agree well with model force injection machine request in 2 ~; The minitype mould needs the request satisfying the diameter 1 mm silent stock tube. At present, adopt quick-cutting to produce a mould already becoming the general trend that the mould makes, a few moulds have produced a manufacturer in abroad , high-speed machine tool large area has substituted the electric spark machine tool , quick-cutting has improved the mould efficacy greatly. Machine tool enterprise aims at mould manufacturing enterprises , some treating centres 60% all above of the machine tool producing a factory sells treating enterprise to a mould. The mould fabrication enterprise substituting the electric spark finish machining mould gradually in abroad has adopt quick-cutting already commonly , quick-cutting has produced a mould already becoming the general trend that the mould makes gradually , has improved the mould efficacy and mass greatly. Adopt quick-cutting to replace electric spark producing a mould , can get on the stick obviously , improves mould accuracy , life time growing.
2 high speed processes application in making in the mould
2.1 quick-cutting merit:
1) cutter high rotation rate and the machine tool height enter be given to and high acceleration , improve metal excision rate greatly;
2) quick-cutting diminutions cut a force;
3) quick-cutting heat major part generate heat from the cuttings entrainment , workpiece being short;
4) quick-cutting cut down vibration , improve treating mass;
2.2 high speed treating apply to the beneficial result that the mould processes
1) fleetness rough process and half finish machining, improve treating efficiency;
2) high speed high-accuracy finish machining replace only entire the height processing , indicating mass , form accuracy rise , 50%, cuts down repair a mill by hand than EDM processes a potentiation;
3) cuts the surface processing final molding stiffly , improve surface mass , form accuracy, the treating (not only being that surface harshness is low, and the surface radiance is high) , being used for complicated surface has more advantage;
4) the surface loss that EDM treating produces , improve mould life-span 20%;
5) processes an electrode rapidly combining with the CAD/CAM technology , especially, the form is complicated , thin-wall is similar to an electrode.
3 adopt quick-cutting to process a mould needing the problem solving
In in the homeland, since the aspect cause such as fund , technology , the quick-cutting applying produce a mould be in the initial stage stage. Return the machine tool , cutter , handicraft back to existence as well as some problem of aspect needs to proceed orderly other solve.
The shortcoming is that finished cost is high, correct cutter sigmatism have comparatively high demand, can not have used big cutters , need to have the complicated computer programming technology to be used for support , equipment running cost height.
Two, the high speed processing a mould's processes a machine tool
Mould finish machining and hard cutting treating require that the numerical control high-speed machine tool , form board , model put up the precision processing need , high-effect numerical control machine tool etc.The mould aiming at produces a lot of machine tool enterprise , some treating centres 60% all above of the machine tool producing a factory sells enterprise to a mould.
The fixed assets having 5 billion yuan without exception in the upcoming several years throws into mould industry , 80% is the machine tool buying a mould process equipment , just saying every year having 4 billion yuan of RMB to buy Jinqie among them.
At present average our country numerical control machine tool utilization ratio approximately 20%, the high-speed machine tool utilization ratio 3 ~ 5%. Also, mould enterprise has the unit suitable to buy a high-speed machine tool , complies with 6000 ~ 40000 rmp's to have.
1 high-speed machine tool technology parameter demands
Process centre chief axis high-power , high rotation rate , satisfied rude finish machining; The finish machining mould wants to need to reach 15000 ~ 20000 rmp like the cutter , the machine tool with minor diameter. Generally, the chief axis rotation rate machine tool under 10000 rpm can carry out rough process and half finish machining , cannot reach the finish machining accuracy;
Have no way to reach 400 the above m/min cutting speed.
2 five scrolls of machine tools application increases a trend
1) treating route is nimble , the surface form is complicated;
2) treating range is big , the various type mould suitable processes;
3) cuts life-span of condition easy to cut down cutter wear , to raise a cutter,;
3 the softwares buying CAD/CAM and high-speed machine tools assort
On the grounds of the machine tool , major part counting , having several billions U. S. dollar to be used to enter port every year, the electromachining machine tool and the high-speed machine tool need to import.
Three, quick-cutting mould cutter technology
Quick-cutting processes the cutter needing allocating proper quick-cutting. Progressing processing cutter material's in high speed has urged development of high speed treating. The cutter , knife edge headquarter and high tenacity base gathering crystal strengthening the ceramics cutter being able to be used giving consideration to high hardness experience and observe carbide alloy coating becoming possibility. Gather the crystal cube nitriding boron (PCBN) bit, whose hardness may amount to 3500 ~ 4500 HV. Gather crystal miamond (PCD) it's hardness but amount to 6000 ~ 10000 HV. Germany SCS , Japan Mitsubishi (magical steel) and Sumitomo ,
Switzerland Shanteweike , USA Kenna are in recent years swiftly large wait for the famous abroad cutter company to successively have debuted the respective quick-cutting cutter, not only cutter having average structural steel of quick-cutting, the ceramics cutter still having direct quick-cutting of energy quenching hard steel is waiting for an effect to surpass the hard cutter, especially the coating cutter appears all of a sudden , bringing into play in quenching half finish machining and finish machining of hard steel. New cutter material and cutter technology appearing already make the bottleneck problem that high speed has processed no longer be able to appear on the cutter.
But, expensive entrance cutter price also blocks quick-cutting mould key factor.
Above to come to saying the cutter and the cutter holder acceleration reach 3 gs the sort, the cutter circular runout needs to be smaller than 0.015 mm, but the knife length is unable greater than 4 times cutters diameter. The reality according to SANDVIK company has counted , the carbide alloy has stood on in the entirety using carbon nitriding titanium (TICN) coating when milling cutters (58 HRC) carry out high speed bright metal chopping , rough process cutter linear speed has been 100 m/min about , whose linear speed has exceeded but 280 m/min when finish machining and microstoning. Such demands to cutter material (include the hardness , tenacity , red hardness keep the form (include row of crumbs function , surface accuracy , dynamic balance sex etc. (cutting the function) , the cutter under high temperature state)) as well as cutter life-span all has very highly.
Experience according to in the homeland mould high speed finish machining, linear speed has exceeded 400 ~ 800 m/min when adopt the young diameter ball head milling cutter to carry out mould finish machining. The machine tool choosing sufficient high-speed's cuts mould finish machining stiffly.
Delcam adopt 0.8 mm diameter cutter to process the narrow slot , rotation rate 40000 rpm , 0.1 mm depth, feed speed 30 m/min.
1 chooses the cutter parameter , the cutter waits if shouldering an anterior angle. The cutter requires that the ability processing request shock resistance tenacity more highly , requiring that heat resistance pounds than average is strong;
2 adopts various method improving cutter life-span , reduces cutter cost.
3 adopt the high speed hilt , HSK hilt , heat pressing applying the most being at present to pretend to grip a cutter. Pay attention to a cutter pretend to grip overall in the day afer tomorrow dynamic balance;
4current cutter enterprise has already done many jobs in the field of the technology resolving the quick-cutting cutter , serving facing the cutter processing may help to solve much problem , the cutter has produced a manufacturer becoming the main body , the reference cutter has produced the technology parameter that the manufacturer provides.
Four, improve quick-cutting mould efficiency technology
1 cutter diameter and the length choice
2 HSM and the EDM choice
3 does cutting and the lubricating cooling
4 feeds choice: Move forward generally giving amounts
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