【摘要】：模內(nèi)注塑件(IML)因其外觀優(yōu)勢(shì),已成為家電行業(yè)重要外觀顯示部件,但是,模內(nèi)注塑制品也因其極易變形扭曲的工藝缺陷影響制品外觀精細(xì)化水平,甚至?xí)霈F(xiàn)運(yùn)輸、使用過程脫落零部件的問題。本研究主要針對(duì)家電的模內(nèi)注塑制品,通過軟件虛擬仿真結(jié)合實(shí)際試模,統(tǒng)計(jì)并分析典型家電模內(nèi)注塑制品的成形工藝,以及在不同數(shù)據(jù)下制品的平整度變形。通過CAE軟件分析模內(nèi)注塑制品壁厚、填充過程、保壓過程、模具溫度、冷卻過程,得出模內(nèi)注塑制品變形理論數(shù)據(jù)。同時(shí),結(jié)合CAE分析的數(shù)據(jù)進(jìn)行模具設(shè)計(jì),在模具結(jié)構(gòu)設(shè)計(jì)方案中設(shè)計(jì)出合理的制品澆口尺寸和位置、冷卻系統(tǒng)、頂出系統(tǒng)。模具制造完成后,根據(jù)CAE分析的理論數(shù)據(jù)并結(jié)合現(xiàn)場實(shí)際情況進(jìn)行模具調(diào)整試制,將制品放置一定時(shí)間后測量長度方向和寬度方向變形量,并與CAE軟件分析變形數(shù)據(jù)進(jìn)行對(duì)比,從而得到了預(yù)變形驗(yàn)證的數(shù)據(jù)并進(jìn)行開模驗(yàn)證。另一方面,本研究還試驗(yàn)并分析了冰箱顯示板和異形制品的多個(gè)預(yù)變形數(shù)據(jù),并開模驗(yàn)證了經(jīng)預(yù)變形處理的試驗(yàn)結(jié)果,驗(yàn)證了預(yù)變形對(duì)于改善模內(nèi)注塑制品翹曲變形重要作用。本研究還提出采用背面加筋位支撐、裝配矯正等方式可以控制調(diào)整變形。另一方面,預(yù)變形的驗(yàn)證雖然已經(jīng)在冰箱這兩款制品上驗(yàn)證成功,但由于這兩款制品都屬于平板件,對(duì)于非平板件制品來講,弧形方向是否增加預(yù)變形數(shù)據(jù)還需要進(jìn)一步的研究驗(yàn)證;避免出現(xiàn)帶弧度(非平板件)的制品在完全借鑒預(yù)變形數(shù)據(jù)后,因制品回彈尺寸不準(zhǔn)確造成裝配干涉甚至模具鑲塊報(bào)廢的問題。通過本課題研究,初步掌握了制品預(yù)變形規(guī)律,模內(nèi)注塑預(yù)變形的研究,對(duì)于今后家電類模內(nèi)注塑制品預(yù)變形設(shè)計(jì)數(shù)據(jù)提供了很好的借鑒和指導(dǎo)。同時(shí),通過預(yù)變形的應(yīng)用明顯提升家電類制品外觀精細(xì)化質(zhì)量水平,減小模內(nèi)注塑制品與裝配部件之間的裝配間隙,提升制品生產(chǎn)達(dá)成率,降低部件采購成本。增加制品外觀質(zhì)量市場競爭力。
[Abstract]:Because of its advantages in appearance, (IML) has become an important appearance display part in the household appliance industry. However, because of its easily distorted and distorted process defects, the internal injection molded products will affect the fine appearance level of the products, and even be transported. Problems with shedding parts during use. This research mainly aims at the household appliances injection molding products in the mold, through the software virtual simulation combined with the actual test mold, statistics and analysis of typical household electrical appliances mold injection molding process, as well as under the different data of the product smoothness deformation. The wall thickness, filling process, holding pressure process, mold temperature and cooling process of injection molding products were analyzed by CAE software, and the theoretical data of deformation of injection products were obtained. At the same time, according to the data of CAE analysis, the mold design is carried out, and the reasonable product gate size and position, cooling system and ejection system are designed in the design scheme of die structure. After the mold manufacture is finished, according to the theoretical data of CAE analysis and combined with the actual situation of the field, the mold is adjusted and manufactured. After the products are placed for a certain time, the deformation in the direction of length and width is measured and compared with the deformation data analyzed by CAE software. The data of pre-deformation verification are obtained and the open-die verification is carried out. On the other hand, several pre-deformation data of refrigerator display panel and special-shaped products are tested and analyzed, and the experimental results of pre-deformation are verified by opening mold, which proves that pre-deformation plays an important role in improving the warpage of injection molding products. This study also proposed that the adjustment of deformation can be controlled by means of backside stiffened position support and assembly correction. On the other hand, although the pre-deformation verification has been successfully verified on these two types of refrigerators, since both of these products belong to flat parts, for non-flat products, Whether the arc direction increases the pre-deformation data needs further research and verification; to avoid the occurrence of products with radians (non-plate) after the full use of pre-deformation data, Due to the inaccuracy of springback size, the assembly interference and even the scrap of die insert are caused. Through the research of this subject, we have preliminarily grasped the law of pre-deformation of products and the study of pre-deformation of injection molding in mold, which provides a good reference and guidance for the design data of pre-deformation of in-mold injection molded products of household appliances in the future. At the same time, the application of pre-deformation can obviously improve the fine quality level of household appliances, reduce the assembly gap between injection molding products and assembly parts, improve the production rate of products, and reduce the cost of purchasing parts. Increase product appearance quality market competitiveness.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TM925.21

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