注塑成型模具设计工具中英文对照外文翻译文献

中英文对照外文翻译文献(文档含英文原文和中文翻译)外文：The development of plastic mouldChina's industrial plastic moulds from the start to now, after more than half a century, there has been great development, mold levels have been greatly enhanced. Mould has been at large can produce 48-inchbig-screen color TV Molded Case injection mold, 6.5 kg capacity washing machine full of plastic molds, as well as the overall car bumpers and dashboards, and other plastic mould precision plastic molds, the camera is capable of producing plastic mould , multi-cavity mold small modulus gear and molding mold. --Such as Tianjin and Yantai daysElectrical Co., Ltd Polaris IK Co. manufactured multi-cavity mold VCD and DVD gear, the gear production of such size precision plastic parts, coaxial, beating requirements have reached a similar foreign the level of product, but also the application of the latest gear design software to correct contraction as a result of the molding profile error to the standard involute requirements. Production can only 0.08 mm thickness of atwo-cavity mold and the air Cup difficulty of plastic doors and windows out of high modulus, and so on. Model cavity injection molding manufacturing accuracy of 0.02 to 0.05 mm, surface roughness Ra0.2 μ m, mold quality, and significantly increase life expectancy,non-hardening steel mould life up to 10~ 30 million, hardening steel form up to 50 ~ 10 million times, shorten the delivery time than before, but still higher than abroad,and the gap between a specific data table.Process, the multi-material plastic molding die, efficient multicolor injection mould, inserts exchange structure and core pulling Stripping the innovative design has also made great progress. Gas-assisted injection molding, the use of more mature technologies, such as Qingdao Hisense Co., Ltd., Tianjin factorycommunications and broadcasting companies, such as moldmanufacturers succeeded in 29 ~ 34-inch TV thick-walled shell, as well as some parts on the use of gas-assisted mould technology Some manufacturers also use the C-MOLD gas-assisted software and achieved better results. Prescott, such as Shanghai, such as the newcompany will provide users with gas-assisted molding equipment and technology. Began promoting hot runner mold, and some plants use rate of more than 20 percent, the general heat-thermal hot runner, or device, a small number of units with the world's advanced level of rigorous hot runner-needle device, a small number of units with World advanced level of rigorous needle-hot runner mould. However, the use of hot runner overall rate of less than 10%, with overseas compared to 50 ~ 80%, the gap larger. In the manufacturing technology, CAD / CAM / CAE technology on the level of application of a new level to the enterprise for the production of household appliances representatives have introduced a considerable number of CAD / CAM systems, such as the United States EDS UG Ⅱ, the United States Parametric Technology Pro / Engineer, the United States CV CADS5 company, the British company DOCT5 Deltacam, HZS's CRADE Japan, the company's Cimatron Israel, the United States AC-C-Tech Mold Company and Australia's MPA Mold flow Mold analysis software, and so on. These systems and the introduction of the software, although a lot of money spent, but in our country die industry, and achieving a CAD / CAM integration, and to support CAE technology to forming processes such as molding and cooling, such as computer simulation, and achieved certain The technical and economic benefits, promote and facilitate China's CAD / CAM technology. In recent years, China's own development of the plasticmould CAD / CAM system has achieved significant development, the main guarantor Software Engineering Institute, is the development of CAXA, Huazhong University of Science HSC5.0 development of the system and injection mold CAE software, and so on, these Die of domestic software with the specific circumstances in the application of computer and lower prices, and other characteristics, in order to further universal CAD / CAM technology has created good conditions.In recent years, China has been more extensive use of some new plastic mold steel, such as: P20, 3Cr2Mo, PMS, SM Ⅰ, SM Ⅱ, and the quality of life of mold has a direct significant impact on the overall use of the still less . Plastic Moulds standard model planes, such as standard putter and spring has given more applications, and there have been some of the commercialization of domestic hot runner system components. However, at present China Die level of standardization and commercialization in the general level of below 30 percent and foreign advanced industrial countries has reached 70 percent compared to 80 percent, still a large gap. Table 1, at home and abroad plastic mould technology comparison table? Domestic projects abroad cavity injection model mm0.02 accuracy of 0.005 ~ 0.01 ~ 0.05mm cavity surface roughness Ra0.01 ~ 0.05 μ mRa0.20 μ m non-hardened steel die life 10 to 60 million 10 ~ 30 million hardened steel die life 160 ~ 300 million of 50 ~ 100 million hot runner mould overall utilization rate of more than 80per cent less than 10 per cent level of standardization of 70 ~ 80% less than 30% of medium-sized plastic mould production cycle about a month 2 ~ 4 months in the mold industry in the amount of 30 to 40% 25 to 30% According to the parties concerned forecast, the market's overall vigorous mold is a smooth upward, in the next Die market, the development of plastic mould faster than the other Die, die in the proportion of industry will gradually improve. With the continuous development of the plastics industry, put on the plastic mold growing demands is a normal, and so sophisticated, large-scale, complex, long-life plastic mould development will be higher than the overall pace of development. At the same time, imports in recent years because of the mold, precision, large, complex, long-life die in the majority, therefore, reduce imports, increase Guochanhualu: perspective, in the mold of such high-end market share will gradually increase. The rapid development of theconstruction industry so that the various Profile Extrusion Die, PVC plastic pipe fittings Die Die market become a new economic growth point, the rapid development of highways, car tires also put a higher demand, radial tire Die, Die particularly active pace of development will also be higher than the overall average level of the plastic and wood, plastic and metal to make plastic molds in the automotive, motorcycle industry in the demand for huge household appliances industry in the "10th Five-Year Plan" period have greater development, especially refrigerators,air-conditionersand microwave ovens, and other parts of the great demand for plastic moulds, and electronics and communications products, in addition to audio-video products, such as color televisions, laptop computers and set-top boxes will be given a wider network development, which are Plastic Mold market is the growth point. Second, China's industrial and technological plastic mould the future direction of the major developments will include:1, raising large, sophisticated, complex, long-life mold design and manufacturing standards and proportion. This is due to the molding plastic mould products increasingly large, complex and high-precision requirements, as well as requirements for high productivity and the development of a multi-mode due.2, in the design and manufacture of plastic mould fully promote the use of CAD / CAM / CAE technology. CAD / CAM technology has developed into a relatively mature technology common in recent years CAD / CAM technology hardware and software prices has been reduced to SMEs generally acceptable level of popularity for further create good conditions; based on network CAD / CAM / CAE system integration structure the initial signs of emerging, and it will solve the traditional mixed CAD / CAM system can not meet the actual production process requirements of the division of collaboration; CAD / CAM software will gradually improve intelligence plastic parts and the 3-D mold design andprototyping process 3-D analysis will be in our plastic mould industries play an increasingly important role.3, promote the use of hot runner technology, gas-assisted injection molding technology and high-pressure injection molding technology. Using hot runner mould technology can improve the productivity and quality of parts and plastic parts can be substantial savings of raw materials and energy conservation, extensive application of this technology is a big plastic mould changes. Hot Runner components formulate national standards, and actively produce cheap high-quality components, the development of hot runner mold is the key. Gas-assisted injection molding product quality can be guaranteed under the premise of substantially lower cost. Currently in the automotive and appliance industries gradually promote the use of the Chiang Kai-shek. Gas-assisted injection molding of the ordinary than the traditional injection of more parameters need to identify and control, and its more commonly used in large, complex products, mold design and control more difficult, therefore, the development of gas-assisted molding flow analysis software It seems very important. On the other hand in order to ensure precision plastic parts to continue to study the development of technology and high-pressure injection molding and injection-compression molding mould and die technology is also very important.4, the development of new plastics molding technology and rapid economic mold. To adapt to more variety, less volume of production.5, and improve standardization of plastic mould standard parts usage. China's mold and die level of standard parts standardization still low, the gap between the large and foreign, to a certain extent constraining the development of industries in our country die, die to improve quality and reduce manufacturing costs Die, Die standard parts to vigorously promote the application. To this end, first of all, to formulate a unified national standards, and in strict accordance with the standards of production, secondly it is necessary to gradually scale production, to improve the commercialization of the standard of quality, and reduce costs; again it is necessary to further increase the standard specifications of varieties.6, Die application quality materials and advanced surface treatment technology for improving the quality of life and mold it is necessary.7, research and application of high-speed die measurement technology and reverse engineering. CMM-use 3D scanner or reverse engineering is the realization of plastic moulds CAD / CAM one of the key technologies.Research and Application of diversity, adjustment, cheap detection equipment is to achieve the necessary precondition for reverse engineering.译文：塑料模具的发展我国塑料模工业从起步到现在，历经半个多世纪，有了很大发展，模具水平有了较大提高。

外文翻译及原文(文档含英文原文和中文翻译)【原文一】CONCURRENT DESIGN OF PLASTICS INJECTION MOULDS AbstractThe plastic product manufacturing industry has been growing rapidly in recent years. One of the most popular processes for making plastic parts is injection moulding. The design of injection mould is critically important to product quality and efficient product processing.Mould-making companies, who wish to maintain the competitive edge, desire to shorten both design and manufacturing leading times of the by applying a systematic mould design process. The mould industry is an important support industry during the product development process, serving as an important link between the product designer and manufacturer. Product development has changed from the traditional serial process of design, followed by manufacture, to a more organized concurrent process where design and manufacture are considered at a very early stage of design. The concept of concurrent engineering (CE) is no longer new and yet it is still applicable and relevant in today’s manuf acturing environment. Team working spirit, management involvement, total design process and integration of IT tools are still the essence of CE. The application of The CE process to the design of an injection process involves the simultaneous consideration of plastic part design, mould design and injection moulding machine selection, production scheduling and cost as early as possible in the design stage.This paper presents the basic structure of an injection mould design. The basis of this system arises from an analysis of the injection mould design process for mould design companies. This injection mould design system covers both the mould design process and mould knowledge management. Finally the principle of concurrent engineering process is outlined and then its principle is applied to the design of a plastic injection mould.Keywords :Plastic injection mould design, Concurrent engineering, Computer aided engineering, Moulding conditions, Plastic injection moulding, Flow simulation1.IntroductionInjection moulds are always expensive to make, unfortunately without a mould it can not be possible ho have a moulded product. Every mould maker has his/her own approach to design a mould and there are many different ways of designing and building a mould. Surely one of the most critical parameters to be considered in the design stage of the mould is the number of cavities, methods of injection, types of runners, methods of gating, methods of ejection, capacity and features of the injection moulding machines. Mould cost, mould quality and cost of mould product are inseparableIn today’s completive environment, computer aided mould filling simulation packages can accurately predict the fill patterns of any part. This allows for quick simulations of gate placements and helps finding the optimal location. Engineers can perform moulding trials on the computer before the part design is completed. Process engineers can systematically predict a design and process window, and can obtain information about the cumulative effect of the process variables that influence part performance, cost, and appearance.2.Injection MouldingInjection moulding is one of the most effective ways to bring out the best in plastics. It is universally used to make complex, finished parts, often in a single step, economically, precisely and with little waste. Mass production of plastic parts mostly utilizes moulds. The manufacturing process and involving moulds must be designed after passing through the appearance evaluation and the structure optimization of the product design. Designers face a hugenumber of options when they create injection-moulded components. Concurrent engineering requires an engineer to consider the manufacturing process of the designed product in the development phase. A good design of the product is unable to go to the market if its manufacturing process is impossible or too expensive. Integration of process simulation, rapid prototyping and manufacturing can reduce the risk associated with moving from CAD to CAM and further enhance the validity of the product development.3. Importance of Computer Aided Injection Mould DesignThe injection moulding design task can be highly complex. Computer Aided Engineering (CAE) analysis tools provide enormous advantages of enabling design engineers to consider virtually and part, mould and injection parameters without the real use of any manufacturing and time. The possibility of trying alternative designs or concepts on the computer screen gives the engineers the opportunity to eliminate potential problems before beginning the real production. Moreover, in virtual environment, designers can quickly and easily asses the sensitivity of specific moulding parameters on the quality and manufacturability of the final product. All theseCAE tools enable all these analysis to be completed in a meter of days or even hours, rather than weeks or months needed for the real experimental trial and error cycles. As CAE is used in the early design of part, mould and moulding parameters, the cost savings are substantial not only because of best functioning part and time savings but also the shortens the time needed to launch the product to the market.The need to meet set tolerances of plastic part ties in to all aspects of the moulding process, including part size and shape, resin chemical structure, the fillers used, mould cavity layout, gating, mould cooling and the release mechanisms used. Given this complexity, designers often use computer design tools, such as finite element analysis (FEA) and mould filling analysis (MFA), to reduce development time and cost. FEA determines strain, stress and deflection in a part by dividing the structure into small elements where these parameters can be well defined. MFA evaluates gate position and size to optimize resin flow. It also defines placement of weld lines, areas of excessive stress, and how wall and rib thickness affect flow. Other finite element design tools include mould cooling analysis for temperature distribution, and cycle time and shrinkage analysis for dimensional control and prediction of frozen stress and warpage.The CAE analysis of compression moulded parts is shown in Figure 1. The analysis cycle starts with the creation of a CAD model and a finite element mesh of the mould cavity. After the injection conditions are specified, mould filling, fiber orientation, curing and thermal history, shrinkage and warpage can be simulated. The material properties calculated by the simulation can be used to model the structural behaviour of the part. If required, part design, gate location and processing conditions can be modified in the computer until an acceptable part is obtained. After the analysis is finished an optimized part can be produced with reduced weldline (known also knitline), optimized strength, controlled temperatures and curing, minimized shrinkage and warpage.Machining of the moulds was formerly done manually, with a toolmaker checking each cut. This process became more automated with the growth and widespread use of computer numerically controlled or CNC machining centres. Setup time has also been significantly reduced through the use of special software capable of generating cutter paths directly from a CAD data file. Spindle speeds as high as 100,000 rpm provide further advances in high speed machining. Cutting materials have demonstrated phenomenal performance without the use of any cutting/coolant fluid whatsoever. As a result, the process of machining complex cores and cavities has been accelerated. It is good news that the time it takes to generate a mould is constantly being reduced. The bad news, on the other hand, is that even with all these advances, designing and manufacturing of the mould can still take a long time and can be extremely expensive.Figure 1 CAE analysis of injection moulded partsMany company executives now realize how vital it is to deploy new products to market rapidly. New products are the key to corporate prosperity. They drive corporate revenues, market shares, bottom lines and share prices. A company able to launch good quality products with reasonable prices ahead of their competition not only realizes 100% of the market before rival products arrive but also tends to maintain a dominant position for a few years even after competitive products have finally been announced (Smith, 1991). For most products, these two advantages are dramatic. Rapid product development is now a key aspect of competitive success. Figure 2 shows that only 3–7% of the product mix from the average industrial or electronics company is less than 5 years old. For companies in the top quartile, the number increases to 15–25%. For world-class firms, it is 60–80% (Thompson, 1996). The best companies continuously develop new products. AtHewlett-Packard, over 80% of the profits result from products less than 2 years old! (Neel, 1997)Figure 2. Importance of new product (Jacobs, 2000)With the advances in computer technology and artificial intelligence, efforts have been directed to reduce the cost and lead time in the design and manufacture of an injection mould. Injection mould design has been the main area of interest since it is a complex process involving several sub-designs related to various components of the mould, each requiring expert knowledge and experience. Lee et. al. (1997) proposed a systematic methodology and knowledge base for injection mould design in a concurrent engineering environment.4.Concurrent Engineering in Mould DesignConcurrent Engineering (CE) is a systematic approach to integrated product development process. It represents team values of co-operation, trust and sharing in such a manner that decision making is by consensus, involving all per spectives in parallel, from the very beginning of the productlife-cycle (Evans, 1998). Essentially, CE provides a collaborative, co-operative, collective and simultaneous engineering working environment. A concurrent engineering approach is based on five key elements:1. process2. multidisciplinary team3. integrated design model4. facility5. software infrastructureFigure 3 Methodologies in plastic injection mould design, a) Serial engineering b) Concurrent engineeringIn the plastics and mould industry, CE is very important due to the high cost tooling and long lead times. Typically, CE is utilized by manufacturing prototype tooling early in the design phase to analyze and adjust the design. Production tooling is manufactured as the final step. The manufacturing process and involving moulds must be designed after passing through the appearance evaluation and the structure optimization of the product design. CE requires an engineer to consider the manufacturing process of the designed product in the development phase.A good design of the product is unable to go to the market if its manufacturing process is impossible. Integration of process simulation and rapid prototyping and manufacturing can reduce the risk associated with moving from CAD to CAM and further enhance the validity of the product development.For years, designers have been restricted in what they can produce as they generally have todesign for manufacture (DFM) – that is, adjust their design intent to enable the component (or assembly) to be manufactured using a particular process or processes. In addition, if a mould is used to produce an item, there are therefore automatically inherent restrictions to the design imposed at the very beginning. Taking injection moulding as an example, in order to process a component successfully, at a minimum, the following design elements need to be taken into account:1. . geometry;. draft angles,. Non re-entrants shapes,. near constant wall thickness,. complexity,. split line location, and. surface finish,2. material choice;3. rationalisation of components (reducing assemblies);4. cost.In injection moulding, the manufacture of the mould to produce the injection-moulded components is usually the longest part of the product development process. When utilising rapid modelling, the CAD takes the longer time and therefore becomes the bottleneck.The process design and injection moulding of plastics involves rather complicated and time consuming activities including part design, mould design, injection moulding machine selection, production scheduling, tooling and cost estimation. Traditionally all these activities are done by part designers and mould making personnel in a sequential manner after completing injection moulded plastic part design. Obviously these sequential stages could lead to long product development time. However with the implementation of concurrent engineering process in the all parameters effecting product design, mould design, machine selection, production scheduling,tooling and processing cost are considered as early as possible in the design of the plastic part. When used effectively, CAE methods provide enormous cost and time savings for the part design and manufacturing. These tools allow engineers to virtually test how the part will be processed and how it performs during its normal operating life. The material supplier, designer, moulder and manufacturer should apply these tools concurrently early in the design stage of the plastic parts in order to exploit the cost benefit of CAE. CAE makes it possible to replace traditional, sequential decision-making procedures with a concurrent design process, in which all parties can interact and share information, Figure 3. For plastic injection moulding, CAE and related design data provide an integrated environment that facilitates concurrent engineering for the design and manufacture of the part and mould, as well as material selection and simulation of optimal process control parameters.Qualitative expense comparison associated with the part design changes is shown in Figure 4 , showing the fact that when design changes are done at an early stages on the computer screen, the cost associated with is an order of 10.000 times lower than that if the part is in production. These modifications in plastic parts could arise fr om mould modifications, such as gate location, thickness changes, production delays, quality costs, machine setup times, or design change in plastic parts.Figure 4 Cost of design changes during part product development cycle (Rios et.al, 2001)At the early design stage, part designers and moulders have to finalise part design based on their experiences with similar parts. However as the parts become more complex, it gets rather difficult to predict processing and part performance without the use of CAE tools. Thus for even relatively complex parts, the use of CAE tools to prevent the late and expensive design changesand problems that can arise during and after injection. For the successful implementation of concurrent engineering, there must be buy-in from everyone involved.5.Case StudyFigure 5 shows the initial CAD design of plastics part used for the sprinkler irrigation hydrant leg. One of the essential features of the part is that the part has to remain flat after injection; any warping during the injection causes operating problems.Another important feature the plastic part has to have is a high bending stiffness. A number of feeders in different orientation were added to the part as shown in Figure 5b. These feeders should be designed in a way that it has to contribute the weight of the part as minimum aspossible.Before the design of the mould, the flow analysis of the plastic part was carried out with Moldflow software to enable the selection of the best gate location Figure 6a. The figure indicates that the best point for the gate location is the middle feeder at the centre of the part. As the distortion and warpage of the part after injection was vital from the functionality point of view and it has to be kept at a minimum level, the same software was also utilised to yiled the warpage analysis. Figure 5 b shows the results implying the fact that the warpage well after injection remains within the predefined dimensional tolerances.6. ConclusionsIn the plastic injection moulding, the CAD model of the plastic part obtained from commercial 3D programs could be used for the part performance and injection process analyses. With the aid ofCEA technology and the use of concurrent engineering methodology, not only the injection mould can be designed and manufactured in a very short of period of time with a minimised cost but also all potential problems which may arise from part design, mould design and processing parameters could be eliminated at the very beginning of the mould design. These two tools help part designers and mould makers to develop a good product with a better delivery and faster tooling with less time and money.References1. Smith P, Reinertsen D, The time-to-market race, In: Developing Products in Half the Time. New York, Van Nostrand Reinhold, pp. 3–13, 19912.Thompson J, The total product development organization. Proceedings of the SecondAsia–Pacific Rapid Product Development Conference, Brisbane, 19963.Neel R, Don’t stop after the prototype, Seventh International Conference on Rapid Prototyping, San Francisco, 19974.Jacobs PF, “Chapter 3: Rapid Product Development” in Rapid Tooling: Technologies and Industrial Applications , Ed. Peter D. Hilton; Paul F. Jacobs, Marcel Decker, 20005.Lee R-S, Chen, Y-M, and Lee, C-Z, “Development of a concurrent mould design system: a knowledge based approach”, Computer Integrated Manufacturing Systems, 10(4), 287-307, 19976.Evans B., “Simultaneous Engineering”, Mechanical Engi neering , V ol.110, No.2, pp.38-39, 19987.Rios A, Gramann, PJ and Davis B, “Computer Aided Engineering in Compression Molding”, Composites Fabricators Association Annual Conference , Tampa Bay, 2001【译文一】塑料注塑模具并行设计塑料制品制造业近年迅速成长。

塑料注射成型外文文献翻译、中英文翻译、外文翻译外文翻译原文：Injection MoldingMany different processes are used to transform plastic granules, powders, and liquids into product. The plastic material is in moldable form, and is adaptable to various forming methods. In most cases thermosetting materials require other methods of forming. This is recognized by the fact that thermoplastics are usually heated to a soft state and then reshaped before cooling. Theromosets, on the other hand have not yet been polymerized before processing, and the chemical reaction takes place during the process, usually through heat, a catalyst, or pressure. It is important to remember this concept while studying the plastics manufacturing processes and polymers used.Injection molding is by far the most widely used process of forming thermoplastic materials. It is also one of the oldest. Currently injection molding accounts for 30% of all plastics resin consumption. Since raw material can be converted by a single procedure, injection molding is suitable for mass production of plastics articles and automated one-step production of complex geometries. In most cases, finishing is not necessary. Typical products include toys, automotive parts, household articles, and consumer electronics goods.Since injection molding has a number of interdependent variables, it is a process of considerable complexity. The success of the injection molding operation is dependent not only in the proper setup of the machine hydraulics, barrel temperaturevariations, and changes in material viscosity. Increasing shot-to-shot repeatability of machine variables helps produce parts with tighter tolerance, lowers the level of rejects, and increases product quality (i.e., appearance and serviceability).The principal objective of any molding operation is the manufacture of products: to a specific quality level, in the shortest time, and using repeatable and fully automaticcycle. Molders strive to reduce or eliminate rejected parts in molding production. For injection molding of high precision optical parts, or parts with a high added value such as appliance cases, the payoff of reduced rejects is high.A typical injection molding cycle or sequence consists of five phases;1. Injection or mold filling2. Packing or compression3. Holding4. Cooling5. Part ejectionPlastic granules are fed into the hopper and through an in the injection cylinder where they are carried forward by the rotating screw. The rotation of the screw forces the granules under high pressure against the heated walls of the cylinder causing them to melt. As the pressure building up, the rotating screw is forced backward until enough plastic has accumulated to make the shot. The injection ram (or screw) forces molten plastic from the barrel, through the nozzle, sprue and runner system, and finally into the mold cavities. During injection, the mold cavity is filled volumetrically. When the plastic contacts the cold mold surfaces, it solidifies (freezes) rapidly to produce theskin layer. Since the core remains in the molten state, plastic follows through the core to complete mold filling. Typically, the cavity is filled to 95%~98% during injection. Then the molding process is switched over to the packing phase.Even as the cavity is filled, the molten plastic begins to cool. Since the cooling plastic contracts or shrinks, it gives rise to defects such as sink marks, voids, and dimensional instabilities. To compensate for shrinkage, addition plastic is forced into the cavity. Once the cavity is packed, pressure applied to the melt prevents molten plastic inside the cavity from back flowing out through the gate. The pressure must be applied until the gate solidifies. The process can be divided into two steps (packing and holding) or may be encompassed in one step(holding or second stage). During packing, melt forced into the cavity by the packing pressure compensates for shrinkage. With holding, the pressure merely prevents back flow of the polymer malt.After the holding stage is completed, the cooling phase starts. During, the part is held in the mold for specified period. The duration of the cooling phase depends primarily on the material properties and the part thickness. Typically, the part temperature must cool below the material’s ejection temperature. While cooling the part, the machine plasticates melt for the next cycle.The polymer is subjected to shearing action as well as the condition of the energy from the heater bands. Once the short is made, plastication ceases. This should occur immediately before the end of the cooling phase. Then the mold opens and the part is ejected.When polymers are fabricated into useful articles they are referred to as plastics, rubbers, and fibers. Some polymers, forexample, cotton and wool, occur naturally, but the great majority of commercial products are synthetic in origin. A list of the names of the better known materials would include Bakelite, Dacron, Nylon, Celanese, Orlon, and Styron.Previous to 1930 the use of synthetic polymers was not widespread. However, they should not be classified as new materials for many of them were known in the latter half of the nineteenth century. The failure to develop them during this period was due, in part, to a lack of understanding of their properties, in particular, the problem of the structure of polymers was the subject of much fruitless controversy.Two events of the twentieth century catapulted polymers into a position of worldwide importance. The first of these was the successful commercial production of the plastic now known as Bakelite. Its industrial usefulness was demonstrated in1912 and in the next succeeding years. T oday Bakelite is high on the list of important synthetic products. Before 1912 materials made from cellulose were available, but their manufacture never provided the incentive for new work in the polymer field such as occurred after the advent of Bakelite. The second event was concerned with fundamental studies of the nature polymers by Staudinger in Europe and by Carohers, who worked with the Du Pont company in Delaware. A greater part of the studies were made during the 1920’s. Staudinger’s work was primarily fundamental. Carother’s achievements led t o the development of our present huge plastics industry by causing an awakening of interest in polymer chemistry, an interest which is still strongly apparent today.The Nature of ThermodynamicsThermodynamics is one of the most important areas ofengineering science used to explain how most things work, why some things do not the way that they were intended, and why others things just cannot possibly work at all. It is a key part of the science engineers use to design automotive engines, heat pumps, rocket motors, power stations, gas turbines, air conditioners, super-conducting transmission lines, solar heating systems, etc.Thermodynamics centers about the notions of energy, the idea that energy is conserved is the first low of thermodynamics. It is starting point for the science of thermodynamics is entropy; entropy provides a means for determining if a process is possible.This idea is the basis for the second low of thermodynamics. It also provides the basis for an engineering analysis in which one calculates the maximum amount of useful that can be obtained from a given energy source, or the minimum amount of power input required to do a certain task.A clear understanding of the ideas of entropy is essential for one who needs to use thermodynamics in engineering analysis. Scientists are interested in using thermodynamics to predict and relate the properties of matter; engineers are interested in using this data, together with the basic ideas of energy conservation and entropy production, to analyze the behavior of complex technological systems.There is an example of the sort of system of interest to engineers, a large central power stations. In this particular plant the energy source is petroleum in one of several forms, or sometimes natural gas, and the plant is to convert as much of this energy as possible to electric energy and to send this energy down the transmission line.Simply expressed, the plant does this by boiling water andusing the steam to turn a turbine which turns an electric generator.The simplest such power plants are able to convert only about 25 percent of the fuel energy to electric energy. But this particular plant converts approximately 40 percent;it has been ingeniously designed through careful application of the basic principles of thermodynamics to the hundreds of components in the system.The design engineers who made these calculations used data on the properties of steam developed by physical chemists who in turn used experimental measurements in concert with thermodynamics theory to develop the property data.Plants presently being studied could convert as much as 55 percent of the fuel energy to electric energy, if they indeed perform as predicted by thermodynamics analysis.The rule that the spontaneous flow of heat is always from hotter to cooler objects is a new physical idea. There is noting in the energy conservation principle or in any other law of nature that specifies for us the direction of heat flow. If energy were to flow spontaneously from a block of ice to a surrounding volume of water, this could occur in complete accord with energy conservation. But such a process never happens. This idea is the substance of the second law of thermodynamics.Clear, a refrigerator, which is a physical system used in kitchen refrigerators, freezers, and air-conditioning units must obey not only the first law (energy conservation) but the second law as well.To see why the second law is not violated by a refrigerator, we must be careful in our statement of law. The second law of thermodynamics says, in effect, that heat never flowsspontaneously from a cooler to a hotter object.Or, alternatively, heat can flow from a cooler to a hotter object only as a result of work done by an external agency. We now see the distinction between an everyday spontaneous process, such as the flow of heat from the inside to the outside of a refrigerator.In the water-ice system, the exchange of energy takes place spontaneously and the flow of heat always proceeds from the water to the ice. The water gives up energy and becomes cooler while the ice receives energy and melts.In a refrigerator, on the other hand, the exchange of energy is not spontaneous. Work provided by an external agency is necessary to reverse the natural flow of heat and cool the interior at the expense of further heating the warmer surroundings.译文：塑料注射成型许多不同的加工过程习惯于把塑料颗粒、粉末和液体转化成最终产品。

Figure 1. Organization of the IKEM Project2 Intelligent Mold Design ToolThe mold design tool in its basic form is a Visual Basic application taking input from a text file that contains information about the part and a User Input form. The text file contains information about the part geometry parsed from a Pro/E information file. The input is used to estimate the dimensions of mold and various other features.2.1 Literature ReviewDesign of molds is another stage of the injection molding process where the experience of an engineer largely helps automate the process and increase its efficiency. The issue that needs attention is the time that goes into designing the molds. Often, design engineers refer to tables and standard handbooks while designing a mold, which consumes lot of time. Also, a great deal of time goes into modeling components of the mold in standard CAD software. Differentresearchers have dealt with the issue of reducing the time it takes to design the mold in different ways. Koelsch and James have employed group technology techniques to reduce the mold design time. A unique coding system that groups a class of injection molded parts, and the tooling required ininjection molding is developed which is general and can be applied to other product lines.A software system to implement the coding system has also been developed. Attempts were also directed towards the automation of the mold design process by capturing experience and knowledge of engineers in the field. The development of a concurrent mold design system is one such approach that attempts to develop a systematic methodology for injection mold design processes in a concurrent engineering environment. The objective of their research was to develop a mold development process that facilitates concurrent engineering-based practice, andFigure 2. Organization of the Mold Design Module.While most of the input, like the number of cavities, cavity image dimensions, cycle time are based on the client specifications, other input like the plasticizing capacity, shots per minute etc., can be obtained from the machine specifications. The output of the application contains mold dimensions and other information, which clearly helps in selecting the standard mold base from catalogs. Apart from the input and output, the Figure 2 also shows the various modules that produce the final output.2.5 Framing rulesAt this stage, the expert’s knowledge is represented in the form of multiple If-Then statements. The rules may be representations of both qualitative and quantitative knowledge. By qualitative knowledge, we mean deterministic information about a problem that can be solved computationally. By qualitative we mean information that is not deterministic, but merely followed as a rule based on previous cases where the rule has worked. A typical rule is illustrated below:If Material = “Acetal” AndRunner Length <= 3 AndRunner Length > 0 ThenRunner Diameter =0.062End IfWhen framing the rules it is important that we represent the information in a compact way while avoiding redundancy, incompleteness and inconsistency. Decision tables help take care of all the above concerns by checking for redundancy and comprehensive expression of the problem statement. As an example, in the process of selecting an appropriate mold base, the size of mold base depends on the number of cavities and inserts. To ensure that all possible combinations of。

外文翻译：Injection moulding for Mold Design and ManufactureThe mold is the manufacturing industry important craft foundation, in our country, the mold manufacture belongs to the special purpose equipment manufacturing industry. China although very already starts to make the mold and the use mold, but long-term has not formed the industry. Straight stabs 0 centuries 80's later periods, the Chinese mold industry only then drives into the development speedway. Recent years, not only the state-owned mold enterprise had the very big development, the three investments enterprise, the villages and towns (individual) the mold enterprise's development also quite rapidly.Although the Chinese mold industrial development rapid, but compares with the demand, obviously falls short of demand, its main gap concentrates precisely to, large-scale, is complex, the long life mold domain. As a result of in aspect and so on mold precision, life, manufacture cycle and productivity, China and the international average horizontal and the developed country still had a bigger disparity, therefore, needed massively to import the mold every year .The Chinese mold industry except must continue to sharpen the productivity; from now on will have emphatically to the profession internal structure adjustment and the state-of-art enhancement. The structure adjustment aspect, mainly is the enterprise structure to the specialized adjustment, the product structure to center the upscale mold development, to the import and export structure improvement, center the upscale automobile cover mold forming analysis and the structure improvement, the multi-purpose compound mold and the compound processing and the laser technology in the mold design manufacture application, the high-speed cutting, the super finishing and polished the technology, the information direction develops .The recent years, the mold profession structure adjustment and the organizational reform step enlarges, mainly displayed in, large-scale, precise, was complex, the long life, center the upscale mold and the mold standard letter development speed is higher than the common mold product; The plastic mold and the compression casting moldproportion increases; Specialized mold factory quantity and its productivity increase; "The three investments" and the private enterprise develops rapidly; The joint stock system transformation step speeds up and so on. Distributes from the area looked, take Zhujiang Delta and Yangtze River delta as central southeast coastal area development quickly to mid-west area, south development quickly to north. At present develops quickest, the mold produces the most centralized province is Guangdong and Zhejiang, places such as Jiangsu, Shanghai, Anhui and Shandong also has a bigger development in recent years.Although our country mold total quantity had at present achieved the suitable scale, the mold level also has the very big enhancement, after but design manufacture horizontal overall rise and fall industry developed country and so on Yu De, America, date, France, Italy many. The current existence question and the disparity mainly display in following several aspects:(1) The total quantity falls short of demandDomestic mold assembling one rate only, about 70%. Low-grade mold, center upscale mold assembling oneself rate only has 50% about.(2) The enterprise organizational structure, the product structure, the technical structure and the import and export structure does not gatherIn our country mold production factory to be most is from the labor mold workshop which produces assembles oneself (branch factory), from produces assembles oneself the proportion to reach as high as about 60%, but the overseas mold ultra 70% is the commodity mold. The specialized mold factory mostly is "large and complete", "small and entire" organization form, but overseas mostly is "small but", "is specially small and fine". Domestic large-scale, precise, complex, the long life mold accounts for the total quantity proportion to be insufficient 30%, but overseas in 50% above 2004 years, ratio of the mold import and export is 3.7:1, the import and export balances the after net import volume to amount to 1.32 billion US dollars, is world mold net import quantity biggest country .(3) The mold product level greatly is lower than the international standardThe production cycle actually is higher than the international water broadproduct level low mainly to display in the mold precision, cavity aspect and so on surface roughness, life and structure.(4) Develops the ability badly, economic efficiency unsatisfactory our country mold enterprise technical personnel proportion lowThe level is lower, also does not take the product development, and frequently is in the passive position in the market. Our country each mold staff average year creation output value approximately, ten thousand US dollars, overseas mold industry developed country mostly 15 to10, 000 US dollars, some reach as high as 25 to10, 000 US dollars, relative is our country quite part of molds enterprises also continues to use the workshop type management with it, truly realizes the enterprise which the modernized enterprise manages fewTo create the above disparity the reason to be very many, the mold long-term has not obtained the value besides the history in as the product which should have, as well as the most state-owned enterprises mechanism cannot adapt the market economy, but also has the following several reasons: .The mold material performance, the quality and the variety question often can affect the mold quality, the life and the cost, the domestically produced molding tool steel and overseas imports the steel products to compare has a bigger disparity. Plastic,plate, equipment energy balance, also direct influence mold level enhancement.RSP ToolingRapid Solidification Process (RSP) Tooling, is a spray forming technology tailored for producing molds and dies [2-4]. The approach combines rapid solidification processing and netshape materials processing in a single step. The general concept involves converting a mold design described by a CAD file to a tooling master using a suitable rapid prototyping (RP) technology such as stereolithography. A pattern transfer is made to a castable ceramic, typically alumina or fused silica. This is followed by spray forming a thick deposit of tool steel (or other alloy) on the pattern to capture the desired shape, surface texture and detail. The resultant metal block is cooled to room temperature and separated from the pattern. Typically, the deposit’s exterior walls are machined square, allowing it to be used as an insert in a holding block such as a MUD frame [5]. The overall turnaround time for tooling is about three days, stating with a master. Molds and dies produced in this way have been used for prototype and production runs in plastic injection molding and die casting.An important benefit of RSP Tooling is that it allows molds and dies to be made early in the design cycle for a component. True prototype parts can be manufactured to assess form, fit, and function using the same process planned for production. If the part is qualified, the tooling can be run in production as conventional tooling would. Use of a digital database and RP technology allows design modifications to be easily made.Experimental ProcedureAn alumina-base ceramic (Cotronics 780 [6]) was slurry cast using a silicone rubber master die, or freeze cast using a stereolithography master. After setting up, ceramic patterns were demolded, fired in a kiln, and cooled to room temperature. H13 tool steel was induction melted under a nitrogen atmosphere, superheated about100︒C, and pressure-fed into a bench-scale converging/diverging spray nozzle, designed and constructed in-house. An inert gas atmosphere within the spray apparatus minimized in-flight oxidation of the atomized droplets as they deposited onto the tool pattern at a rate of about 200 kg/h. Gas-to-metal mass flow ratio was approximately 0.5.For tensile property and hardness evaluation, the spray-formed material was sectioned using a wire EDM and surface ground to remove a 0.05 mm thickheat-affected zone. Samples were heat treated in a furnace that was purged with nitrogen. Each sample was coated with BN and placed in a sealed metal foil packet as a precautionary measure to prevent decarburization.Artificially aged samples were soaked for 1 hour at temperatures ranging from 400 to 700︒C, and air cooled. Conventionally heat treated H13 was austenitized at 1010︒C for 30 min., air quenched, and double tempered (2 hr plus 2 hr) at 538︒C.Microhardness was measured at room temperature using a Shimadzu Type M Vickers Hardness Tester by averaging ten microindentation readings. Microstructure of the etched (3% nital) tool steel was evaluated optically using an Olympus Model PME-3 metallograph and an Amray Model 1830 scanning electron microscope. Phase composition was analyzed via energy-dispersive spectroscopy (EDS). The size distribution of overspray powder was analyzed using a Microtrac Full Range Particle Analyzer after powder samples were sieved at 200 μm to remove coarse flakes. Sample density was evaluated by water displacement using Archimedes’ principle and a Mettler balance (Model AE100).A quasi 1-D computer code developed at INEEL was used to evaluate multiphase flow behavior inside the nozzle and free jet regions. The code's basic numerical technique solves the steadystate gas flow field through an adaptive grid, conservative variables approach and treats the droplet phase in a Lagrangian manner with full aerodynamic and energetic coupling between the droplets and transport gas. The liquid metal injection system is coupled to the throat gas dynamics, and effects of heat transfer and wall friction are included. The code also includes a nonequilibriumsolidification model that permits droplet undercooling and recalescence. The code was used to map out the temperature and velocity profile of the gas and atomized droplets within the nozzle and free jet regions.Results and DiscussionSpray forming is a robust rapid tooling technology that allows tool steel molds and dies to be produced in a straightforward manner. Each was spray formed using a ceramic pattern generated from a RP master.Particle and Gas BehaviorParticle mass frequency and cumulative mass distribution plots for H13 tool steel sprays are given in Figure 1. The mass median diameter was determined to be 56 μm by interpolation of size corresponding to 50% cumulative mass. The area mean diameter and volume mean diameter were calculated to be 53 μm and 139 μm, respectively. Geometric standard deviation, d=(d84/d16)½ , is 1.8, where d84 and d16 are particle diameters corresponding to 84% and 16% cumulative mass in Figure 1.Figure1. Cumulative mass and mass frequency plots of particles in H13 tool stepsprays.Figure2 gives computational results for the multiphase velocity flow field (Figure 2a), and H13 tool steel solid fraction (Figure2b), inside the nozzle and free jetregions. Gas velocity increases until reaching the location of the shock front, at which point it precipitously decreases, eventually decaying exponentially outside the nozzle. Small droplets are easily perturbed by the velocity field, accelerating inside the nozzle and decelerating outside. After reaching their terminal velocity, larger droplets (〜150 μm) are less perturbed by the flow field due to their greater momentum.It is well known that high particle cooling rates in the spray jet (103-106 K/s) and bulk deposit (1-100 K/min) are present during spray forming [7]. Most of the particles in the spray have undergone recalescence, resulting in a solid fraction of about 0.75. Calculated solid fraction profiles of small (〜30 μm) and large (〜150 μm) droplets with distance from the nozzle inlet, are shown in Figure 2b.Spray-Formed DepositsThis high heat extraction rate reduces erosion effects at the surface of the tool pattern. This allows relatively soft, castable ceramic pattern materials to be used that would not be satisfactory candidates for conventional metal casting processes. With suitable processing conditions, fine surface detail can be successfully transferred from the pattern to spray-formed mold. Surface roughness at the molding surface is pattern dependent. Slurry-cast commercial ceramics yield a surface roughness of about 1 μm Ra, suitable for many molding applications. Deposition of tool steel onto glass plates has yielded a specular surface finish of about 0.076 μm Ra. At the current state of development, dimensional repeatability of spray-formed molds, starting with a common master, is about ±0.2%.Figure 2. Calculated particle and gas behavior in nozzle and free jet regions.(a) Velocity profile.(b) Solid fraction.ChemistryThe chemistry of H13 tool steel is designed to allow the material to withstand the temperature, pressure, abrasion, and thermal cycling associated with demanding applications such as die casting. It is the most popular die casting alloy worldwide and second most popular tool steel for plastic injection molding. The steel has low carbon content (0.4 wt.%) to promote toughness, medium chromium content (5 wt.%) to provide good resistance to high temperature softening, 1 wt% Si to improve high temperature oxidation resistance, and small molybdenum and vanadium additions (about 1%) that form stable carbides to increase resistance to erosive wear[8]. Composition analysis was performed on H13 tool steel before and after spray forming.Results, summarized in Table 1, indicate no significant variation in alloy additions.MicrostructureThe size, shape, type, and distribution of carbides found in H13 tool steel is dictated by the processing method and heat treatment. Normally the commercial steel is machined in the mill annealed condition and heat treated(austenitized/quenched/tempered) prior to use. It is typically austenitized at about 1010︒C, quenched in air or oil, and carefully tempered two or three times at 540 to 650︒C to obtain the required combination of hardness, thermal fatigue resistance, and toughness.Commercial, forged, ferritic tool steels cannot be precipitation hardened becauseafter electroslag remelting at the steel mill, ingots are cast that cool slowly and formcoarse carbides. In contrast, rapid solidification of H13 tool steel causes alloying additions to remain largely in solution and to be more uniformly distributed in the matrix [9-11]. Properties can be tailored by artificial aging or conventional heat treatment.A benefit of artificial aging is that it bypasses the specific volume changes that occur during conventional heat treatment that can lead to tool distortion. These specific volume changes occur as the matrix phase transforms from ferrite to austenite to tempered martensite and must be accounted for in the original mold design. However, they cannot always be reliably predicted. Thin sections in the insert, which may be desirable from a design and production standpoint, are oftentimes not included as the material has a tendency to slump during austenitization or distort during quenching. Tool distortion is not observed during artificial aging ofspray-formed tool steels because there is no phase transformation.注塑模具之模具设计与制造模具是制造业的重要工艺基础，在我国，模具制造属于专用设备制造业。

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模具外文翻译外文文献英文文献注塑模The Injection Molding1、The injection moldingInjection molding is principally used for the production of the thermoplastic parts,although some progress has been made in developing a method for injection molding some thermosetting materials.The problem of injection a method plastic into a mold cavity from a reservoir of melted material has been extremely difficult to solve for thermosetting plastic which cure and harden under such conditions within a few minutes.The principle of injection molding is quite similar to that of die-casting.The process consists of feeding a plastic compound in powered or granular form from a hopper through metering and melting stages and then injecting it into a mold.After a brief cooling period,the mold is opened and the solidified part ejected.Injection-molding machine operation.The advantage of injection molding are：（ⅰ）a high molding speed adapter for mass production is possible；（ⅱ）there is a wide choice of thermoplastic materials providing a variety of useful properties；（ⅲ）it is possible to mold threads,undercuts,side holes,and large thin section.2、The injection-molding machineSeveral methods are used to force or inject the melted plastic into the mold.The most commonly used system in the larger machines is the in-line reciprocating screw,as shown in Figure 2-1.The screw acts as a combination injection and plasticizing unit.As the plastic is fed to the rotating screw,it passes through three zones as shown：feed,compression,and metering.After the feed zone,the screw-flight depth is gradually reduced,force theplastic to compress.The work is converted to heat by conduction from the barrel surface.As the chamber in front of the screw becomes filled,it forces the screw back,tripping a limit switch that activates a hydraulic cylinder that forces the screw forward and injects the fluid plastic into the closed mold.An antiflowback valve presents plastic under pressure from escaping back into the screw flight.The clamping force that a machine is capable of exerting is part of the size designation and is measured in tons.A rule-of-thumb can be used to determine the tonnage required for a particular job.It is based on two tons of clamp force per square inch of projected area.If the flow pattern is difficult and the parts are thin,this may have to go to three or four tons.Many reciprocating-screw machines are capable of handing thermosetting plastic materials.Previously these materials were handled by compression or transfer molding.Thermosetting materials cure or polymerize in the mold and are ejected hot in the range of 375°C～410°C.T hermosetting parts must be allowed to cool in the mold in order or remove them without distortion. Thus thermosetting cycles can be faster.Of course the mold must be heated rather than chilled,as with thermoplastics.3、Basic Underfeed MouldA simple mould of this type is shown in Figure3-1,and the description of the design and the opening sequence follows.The mould consists of three basic parts,namely：the moving half,the floating cavity plate and the feed plate respectively.The moving half consists of The moving mould plate assembly,support block,backing plate,ejector assembly and the pin ejection system.Thus the moving half in this design is identical with the moving half of basic moulds.The floating cavity plate,which may be of the integer or insert-bolster design,is located on substantial guide pillars（not shown）fitted in the feed plate.These guide pillars must be of sufficient length to support the floating cavity plate over its full movement and still project to perform the function of alignment between the cavity and core when the mould is being closed.Guide bushes are fitted into the moving mould plate and the floating cavity plate respectively.The maximum movement of the floating cavity plate is controlled by stop or similar device.The moving mould plate is suitably bored to provide a clearance for the stop bolt assembly.The stop bolts must be long enough to provide sufficient space between the feed plate and the floating cavity plate for easy removal of the feed system.The minimum space provide for should be 65mm just sufficient for an operator to remove the feed system by hand if necessary.The desire operating sequence is for the first daylight to occur between the floating cavity plate.This ensures the sprue is pulled from the sprue bush immediately the mouldis opened.T o achieve this sequence,springs may be incorporated between the feed plate and the floating cavity plate.The springs should be strong enough to give an initial impetus to the floating cavity plate to ensure it moves away with the moving half.It is normal practice to mount the springs on the guide pillars（Figure3-2）and accommodate them in suitable pocket in the cavity plate.The major part of the feed system（runner and sprue）is accommodated in the feed plate to facilitate automatic operation,the runner should be of a trapezoidal form so that once it is pulled from the feed plate is can easily beextracted.Note that if a round runner is used,half the runner is formed in the floating cavity plate,where it would remain,and be prevented from falling or being wiped clear when the mould is opened.Now that we have considered the mould assembly in the some detail,we look at the cycle of operation for this type of mould.The impressions are filled via the feed system（Figure3-1（a））and after a suitable dwell period,the machine platens commence to open.A force is immediately exerted by the compression springs,which cause the floating cavity plate to move away with the moving half as previously discussed.The sprue is pulled from the sprue bush by the sprue puller.After the floating cavity plate has moved a predetermined distance,it is arrested by the stop bolts.The moving half continues to move back and the moldings,having shrunk on to the cores,are withdrawn from the cavities.The pin gate breaks at its junction with the runner（Figure3-1（b））.The sprue puller,being attached to the moving half,is pulled through the floating cavity plate and thereby release the feed system which is then free to fall between the floating cavity plate and the feed plate.The moving half continues to move back until the ejector system is operated and the moldings are ejected （Figure3-1（c））.When the mould is closed,the respective plates are returned to their molding position and the cycle is repeated.4、Feed SystemIt is necessary to provide a flow-way in the injection mould to connect the nozzle（of the injection machine）to each impression.This flow-way is termed the feed system.Normally thefeed system comprises a sprue,runner and gate.These terms applyequally to the flow-way itself,and to the molded material which is remove from the flow-way itself in the process of extracted the molding.A typical feed system for a four-impression,two plate-type mould is shown in Figure4-1.It is seen that the material passes through the sprue,main runner,branch runner and gate before entering the impression.As the temperature of molten plastic is lowered which going through the sprue and runner,the viscosity will rise;however,the viscosity is lowered by shear heat generated when going through the gate to fill the cavity.It is desirable to keep the distance that the material has to travel down to a minimum to reduce pressure and heat losses.It is for this reason that careful consideration must be given to the impression layout gate’s design.4.1.SprueA sprue is a channel through which to transfer molten plastic injected from the nozzle of the injector into the mold.It is a part of sprue bush,which is a separate part from the mold.4.2.RunnerA runner is a channel that guides molten plastic into the cavity of a mold.4.3.GateA gate is an entrance through which molten plastic enters the cavity.The gate has the following function：restricts the flow and the direction of molten plastic；simplifies cutting of a runner and moldings to simplify finishing of parts；quickly cools and solidifies to avoid backflow after molten plastic has filled up in the cavity.4.4.Cold slug wellThe purpose of the cold slug well,shown opposite the sprue,is theoretically to receive the material that has chilled at the front of nozzle during the cooling and ejection phase.Perhaps of greater importance is the fact that it provides position means whereby the sprue bush for ejection purposes.The sprue,the runner and the gate will be discarded after a part is complete.However,the runner and the gate are important items that affect the quality or the cost of parts.5、EjectionA molding is formed in mould by injecting a plastic melt,under pressure,into animpression via a feed system.It must therefore be removed manually.Furthermore,all thermoplastic materials contract as they solidify,which means that the molding will shrink on to the core which forms it.This shrinkage makes the molding difficult to remove. Facilities are provided on the injection machine for automatic actuation of an ejector system,and this is situated behind the moving platen.Because of this,the mould’s ejector system will be most effectively operated if placed in the moving half of the mould,i.e. the half attached to the moving platen.We have stated previously that we need to eject the molding from the core and it therefore follows that the core,too,will most satisfactorily be located in the moving half.The ejector system in a mould will be discussed under three headings,namely：（ⅰ）the ejector grid;（ⅱ）the ejector plate assembly; and（ⅲ）the method of ejection.5.1、Ejector gridThe ejector grid（Figure5-1）is that part of the mould which supports the mould plate and provides a space into which theejector plate assembly can be fitted and operated.The grid normally consists of a back plate on to which is mounted a number of conveniently shaped “support blocks”.The ejector plate assembly is that part of the mould to which the ejector element is attached.The assembly is contained in a pocket,formed by the ejector grid,directly behind the mould plate.The assembly（Figure5-2）consists of an ejector plate,a retaining plate and an ejector rod.One end of this latter member is threaded and it is screwed into the ejector plate.In this particular design the ejector rod function not only as an actuating member but also as a method of guiding the assembly.Note that the parallel portion of the ejector rod passes through an ejector rod bush fitted in the back plate of the mould.5.2、Ejection techniquesWhen a molding cools,it contracts by an amount depending on the material being processed.For a molding which has no internal form,for example,a solid rectangular block,the molding will shrink away from the cavity walls,thereby permitting a simple ejection technique to be adopted.However,when the molding has internal form,the molding,as it cools,will shrink onto the core and some positive type of ejection is necessary.The designer has several ejection techniques from which to choose，but in general,the choice will be restricted depending upon the shape of the molding.The basic ejection techniques are as follows：（ⅰ）pin ejection（ⅱ）sleeve ejection（ⅲ）stripper plate ejection and（Ⅳ）air ejection.Figure 2-1aFigure 2-1bFigure 3-1Figure 3-2Figure 4-1aFigure 4-1bFigure 5-1Figure 5-2注塑模1、注塑模尽管成型某些热固性材料的方法取得了一定的进步，但注塑模主要（还是）用来生产热塑性塑件。

Injection molding die design is a crucial aspect of the manufacturing process to produce high-quality plastic products. Various technical references have been published over the years, providing valuable insights into the design principles, strategies, and best practices related to injection molding die design. Here are some key references that can be used as a starting point for further exploration:1.Injection Mold Design Engineering (David O. Kazmer, 2011) This bookprovides a comprehensive overview of injection mold design, covering topics such as mold geometry, gating systems, cooling and heating, ejector systems, and mold materials. It also discusses the analysis and optimization of molddesigns using computer-aided engineering tools.2.Injection Molds and Molding: A Practical Manual (Jiri Karasek, 2006)This practical manual offers a step-by-step guide to injection mold design and production. It covers various aspects of mold design, including cavity and core geometry, runner systems, venting, cooling, ejection, and mold materials. The book also addresses common design challenges and troubleshootingtechniques.3.Plastic Injection Molding: Manufacturing Process Fundamentals(Douglas M. Bryce and Charles A. Daniels, 2014) This reference provides an in-depth understanding of the injection molding process and its fundamentals. It discusses the principles of mold design, material selection, process parameters, molding defects, and mold maintenance. The book emphasizes the importance of considering the design-for-manufacturability aspect in mold design.4.Mold Design Using SolidWorks (Edward J. Bordin, 2010) Focused onmold design using SolidWorks software, this book provides practical insights into mold design methodology, including parting line creation, runner system design, cooling strategies, and mold analysis. It also covers advanced topicssuch as hot runner systems and side actions.5.Designing Injection Molds for Thermoplastics (H.T. Rowe, 2010) Thiscomprehensive reference addresses the design considerations specific tothermoplastic injection molds. It covers mold configuration, gating design,cooling strategies, shrinkage and warpage control, and mold materials. Thebook also includes case studies and practical tips for mold design optimization.6.Mold-Making Handbook (Kurtz Ersa Corporation, 2009) Thishandbook offers practical advice on mold design, construction, andmaintenance. It covers topics like mold steel selection, surface finishing, cavity design, cooling channels, ejection systems, and high-precision molding. Thereference provides insights into the latest developments in mold-makingtechnology.These references provide a solid foundation for understanding injection mold design principles, methodologies, and considerations. Additionally, industrypublications, research papers, and case studies can offer further insights into specific design aspects, material selection, and advanced techniques. It is important to consult multiple sources and stay updated with the latest trends and advancements in injection mold design to ensure efficient and robust manufacturing processes.。

0800123UGNX模具设计_注塑模中英文对照_1002附录A1（中英文对照表-零件类1）中文名称英文名称中文别称1. 零件类（模板）模架mold base 模胚隔热板thermal insulation board定模座板top clamping plate 定模底板、面板热流道板hot runner manifold 分流板推流道板runner stripper plate 脱料板、水口推板、水口板型腔固定板cavity plate 定模板、定模框、A板、母模推件板stripper plate 脱模板型芯固定板core plate 动模板、动模框、B板、公模支承板support plate 垫板、托板垫块spacer block 模脚、方铁、登仔推杆固定板ejector retainer plate 顶针固定板、面针板推板ejector plate 推顶杆板、顶针垫板、底针板动模座板bottom clamping plate 动模底板、底板2. 零件类（浇注系统）定位圈locating ring 定位环、法蓝浇口套sprue bushing 浇口衬套、唧咀、唧嘴浇口镶块gating insert 入水镶件拉料杆sprue puller 拉料销、水口勾针热流道系统hot runner system流道板runner plate温流道板warm runner plate分流锥sprue spreader二级喷嘴secondary nozzle鱼雷形组合体torpedo body assembly管式加热器cartridge heater 筒式加热器热管heat pipe 导热管加热圈heating ring热电偶thermocouple 探针、探温针阀式热嘴valve gating nozzle 阀针式热嘴、阀节喷嘴阀针valve pin热嘴hot nozzle 热喷嘴热嘴垫圈nozzle seat3. 零件类（顶出系统）推杆ejector pin 顶杆、顶针带肩推杆shouldered ejector pin 阶梯推杆、台阶顶针扁推杆flat ejector pin 扁顶杆、扁顶针推管ejector sleeve 司筒、顶管、套筒推管芯子ejector sleeve pin 中心销、司筒针中文名称英文名称中文别称3. 零件类（顶出系统）推块ejector pad 顶块推件环stripper ring 脱模圈斜顶杆angle ejector rod 斜导杆斜顶lifter自润滑活型芯组件slide core guide unit 斜顶滑座导滑座slide base斜导杆固定座angle ejector rod fixed seat自润滑板guide plate挡块baffle block挡块固定螺钉baffle block set screw复位杆return pin 回程销、回针限位块stop block 止动件限位钉stop pin 垃圾钉4. 零件类（成型零部件）型腔cavity 母模仁型芯core 公模仁、模芯侧型芯side core 侧模芯镶件mould insert 镶块型腔镶件cavity insert 上内模、母模入子型芯镶件core insert 下内模、公模入子活动镶件movable insert 拼块split螺纹型芯threaded core螺纹型环threaded cavity嵌件insert镶针insert pin5. 零件类（温度调节系统）快速接头jiffy quick connector管接头hose nippler三通接头three way cock四通接头four-way connection弯管接头pipe bend水嘴water nozzle 水接头油嘴oil nozzle 油接头软管hose 喉管水管water tube油管oil tube气管air tube中文名称英文名称中文别称5. 零件类（温度调节系统）管夹hose clip 软管卡子丝堵pipe plug 螺塞、喉塞冷却管cooling pipe隔水片baffle 挡水板O形圈o-ring 密封圈、O形环止水栓stopcock 导流塞流量计flow meter集水器siamese 集水块集油器oil collector 集油块节流阀throttle valve 截流阀流量分配器flow divider 分流器6. 零件类（侧向分型与抽芯机构）滑块slide 行位斜导柱angle pin 斜销、斜导边弯销clog-leg cam锁紧块locking block 楔紧块、铲鸡滑块导板slide glide strip 滑块导轨、压条耐磨板wear plate 硬片、油板球头顶丝ball plunger 波子螺丝、波子弹弓限位块stop block 止动件滑块定位器slide retainer 行位管位7. 零件类（导向、定位系统）导柱guide pin 边钉、导边直身导柱straight leader pins 直导柱带肩导柱shoulder leader pin 台阶导柱推板导柱ejector guide pin 中托边方型导柱guide square 方导柱三板模导柱support pins 细水口导边、水口边三板模导套runner stripper plate bushing 水口板导套、水口套导向条gib block 导向块导套guide bushing 边司直导套straight bushing带肩导套shoulder bushing 有托导套推板导套ejector guide bush 中托司套定位销dowel pin 销钉、管钉定位块locating block直身锁side lock 边锁、侧锁扣、直身定位块斜度锁taper lock 斜度定位块中文名称英文名称中文别称8. 零件类（开关模控制）定距拉杆puller bolt 拉杆螺丝、拉杆定距拉板puller plate 拉板止动螺钉stop bolt 限动螺栓锁模板safety bar 安全杆、锁模扣、安全扣阻尼销parting locks 尼龙拉钩、树脂开闭器、拉模扣分型面锁模装置parting lock set 分型拉钩、扣鸡、扣机顶出预复位机构early ejector return 早回机构、先复位机构9. 零件类（其他功能件）螺钉screw 螺丝螺帽screw cap 螺丝帽内六角螺钉shcs 杯头螺丝内六角沉头螺钉fhcs 平头螺丝无头螺丝grub screw弹簧spring 弹弓圆线弹簧wire spring扁弹簧flat spring氮气弹簧gas spring齿轮gear wheel轴承bearing马达motor止动键locking key卡簧clamp spring油缸hydraulic cylinder 液压缸气缸air cylinder排气阀air evacuation valve支撑柱support pillar 支承柱、撑头承压块pressure block吊模块lifting bars for mold 模具起吊块吊环lifting eye bolts 吊环螺钉挤紧块clamping block 锁定块垫圈washer 垫片弹簧垫圈spring washer 弹垫标牌nameplate铭牌保护盖protective cover 防护罩顶模块ejector rod 顶出杆、顶棍行程开关position limit switch 限位开关计数器counters中文名称英文名称中文别称9. 零件类（其他功能件）压力传感器pressure transducer日期章date markers 日期标记电源插座power socket公插male connector母插female connector电线electric wire接线盒connection box 接线箱保护盒protection box保护柱stand off调整板adjustment plate压板stopper plate中文名称英文名称中文别称10. 相关术语类(设计系统)模具工程mold engineering工程力学engineering mechanics工程热力学engineering thermodynamics流变学rheology塑料成形模具mould for plastics 塑料模、塑胶模注射模injection mould 注塑模注射模设计design of injection mould 热塑性塑料注射模injection mould forthermoplastics热固性塑料注射模injection mould for thermoses双色模double-color mould叠层模stack injection mould热流道模hot runner mould绝热流道模insulated runner mould 温流道模二板模two plate mold 大水口模三板模three plates mold 细水口模浇注系统feed system冷流道系统cold runner system主流道sprue 注入口、注道分流道runner浇口gate 入水浇口形式gate type 入水形式浇口大小gate size 入水大小浇口位置gate location 入水位置直接浇口direct gate 大水口环形浇口ring gate 环型浇口盘形浇口dish gate轮辐浇口spoke gate点浇口pin-point gate 细水口、针点式浇口侧浇口edge gate 边缘浇口潜伏浇口submarine gate 潜水口隧道式浇口tunnel gate 月牙形浇口、牛角形浇口、香蕉形浇口冷料穴cold-slug well 冷料井溢料槽flash groove 跑胶道、流胶沟排气槽air vent 排气道、排气孔、疏气位分型面parting surface 分模面分型线parting line 分模线中文名称英文名称中文别称10. 相关术语类(设计系统)水平分型面（线）horizontal parting line垂直分型面（线）vertical parting line定模fixed half 固定侧动模moving half 可动侧排气系统vent system顶出系统ejection system 脱模系统顶出机构ejection mechanisms 脱模机构成型零部件molding parts冷却系统cooling system冷却通道cooling channel加热系统heating system 供热系统收缩率shrinkage 缩水抽芯力core-pulling force抽芯距core-pulling distance投影面积projected area脱模斜度draft 拔模斜度模具寿命die life模腔数cavity number11. 相关术语类(注塑成型)注射机injection molding machine 注塑机、射出成型机、啤机注射能力shot capacity 注塑容量、注塑能力注射压力injection pressure 注塑压力、射胶压力锁模力clamping force 合模力成型压力moulding pressure 成形压力模内压力internal mould pressure 型腔压力开模力mould opening force脱模力ejection force 顶出力闭合高度mould-shut height最大开距maximum daylight 模板开距脱模距stripper distance最大容模厚度max mold height 最大模厚最小容模厚度min. mould thickness 最小模厚拉杆内距space between tie bars 拉杆间距、导柱内距注射装置injection unit 射胶系统预塑化装置preplasticator合模装置clamping unit 锁模系统控制装置control unit 控制系统机械手mechanical arm 机械臂中文名称英文名称中文别称11. 相关术语类(注塑成型)快速换模系统quick die change system 快速换模装置顺序阀sequence valve喷嘴直径nozzle diameter喷嘴球半径nozzle radius成型周期molding cycle 模塑周期注射时间injection time 射出时间保压时间packing time冷却时间cooling time顶出时间ejection time 脱模时间开、合模时间time of mold open & close塑料Plastics 塑胶塑件plastic parts 塑胶件项目名称project name产品名称product name 品名外观件appearance part总产量total product电镀plating 喷镀油漆paint蚀纹texture 咬花光面shiny side热板焊hot plate welding超声波焊ultrasonic welding 超声焊摩擦焊friction welding振动焊vibration welding壁厚wall thickness加强筋rib圆角fillet尖角sharp corner 锐角、利角凸台convex plate文字text孔位hole location工艺分析process analysis 过程分析流动分析flow analysis 充填分析顶白ejected mark 顶痕毛刺burr 毛边缩痕sink mark 凹痕水波痕water wave effect表面光泽度不良gloss ng中文名称英文名称中文别称11. 相关术语类(注塑成型)银丝纹silver streak 银条纹、银丝气泡bubble黑条纹dark streak烧焦burn 烧伤、烧黑黑点black spots 黑色斑翘曲warpage熔接线weld lines 熔合线熔接痕welding mark 溶合痕尺寸不稳定dimensional instability裂痕flaw 裂缝变色discoloration 褪色困气air trapping缺胶short shot 充填不足、欠注、短射试模mold trial注射速度injection rate 注射速率干燥温度drying temperature 烘干温度干燥时间drying time 烘干时间成型温度injection temperature 注塑温度、喷射温度模具温度mould temperature12. 相关术语类(材料)模板mould plate标准件standard parts电极electrode铜电极copper electrode 铜公石墨电极graphite electrode钨电极tungsten electrode钢steel 钢铁、钢材热作钢hot work tool steel 热锻模具钢冷作钢cold work steel预硬钢prehardened steel碳素钢carbon steel 碳钢碳素工具钢carbon tool steel不锈钢stainless steel铬钼钢chrome molybdenum steel合金工具钢alloy tool steel高速工具钢high speed tool steel硬质合金钢hard alloy steel弹簧钢spring steel中文名称英文名称中文别称12. 相关术语类(材料)灰口铸铁grey cast iron 灰铸铁、灰口铁紫铜copper黄铜brass青铜bronze铍铜BeCu铍青铜beryllium bronze铝aluminum13. 相关术语类(技术参数)结晶性crystallinity 结晶度透明性transparency 透明度耐热性heat resistance 抗热性熔融指数melt index 熔体流动指数剪切速率shear rate 剪切率剪切应力shear stress摩擦系数frictional coefficient布氏硬度brinell hardness HB洛氏硬度rockwell hardness HRC肖氏硬度shore hardness Hs维氏硬度vickers hardness HV金属疲劳metal fatigue疲劳寿命fatigue life密度density重量weight重心centre of gravity面积area体积volume承压面积bearing area 支承面积雷诺数reynolds number导热性thermal conductivity 导热率、导热系数比热容specific heat 比热热量heat quantity温差temperature difference弹性模量modulus of elasticity 弹性模数、杨氏模量截面惯性矩second moment of area 截面二次轴矩截面模量section modulus 截面系数泊松比poisson ratio 横向变形系数拉伸强度tensile strength 抗拉强度压缩强度compressive strength 抗压强度中文名称英文名称中文别称13. 相关术语类(技术参数)屈服强度yield strength剪切强度shear strength 抗剪强度冲击强度impact strength 抗冲强度扭曲强度torsional strength 抗扭强度、扭转强度弯曲强度bending strength 抗弯强度、抗挠强度屈服应力yield stress 延展率elongation 延伸率载荷load弹性变形elastic deformation 弹性形变热膨胀系数thermal expansion coefficient14. 相关术语类(表面处理)热处理heat treatment调质thermal refining TR渗碳carburizing退火annealing回火tempering氮化nitriding NT、渗氮真空氮化vacuum nitriding 真空渗氮真空渗碳氮化vacuum carbonitriding 真空碳氮化离子氮化plasma nitriding离子渗碳氮化ion carbonitriding淬火quenching hardening QH高频淬火high frequency hardening真空淬火vacuum hardening化学电镀chemical plating 化学镀阳极氧化处理anodizing 阳极氧化发黑blackening 染黑法喷砂处理sand blast时效处理seasoning15. 相关术语类(加工)加工中心机床machine centers 加工中心CNC铣床cnc milling machine 数控铣床高速铣床high speed milling machine仿形铣床profiling milling machine 靠模铣床仿形车床copy lathe 靠模车床锯床saw machine刨床planing machines磨床grinding machines中文名称英文名称中文别称15. 相关术语类(加工)车床lathe摇臂钻床radial drilling machine 旋臂钻床钻床drilling machine 钻孔机雕刻机engraving machines电火花机electric discharge machines 火花机线切割放电机wire E.D.M. 线割放电加工机测量机measuring machines三座标测量仪three-coordinates measuringmachine合模机die spotting machine机加工machining 切削加工锻造forging铸造casting精密压铸accurate die casting电铸electroforming热轧hot rolling HR冷轧cold rolling 冷压延拉拔draw out挤压extrusion 挤制加工锯削sawing雕削carving-and-scraping铣削milling镗削boring锉削加工filing车削turning钻孔drilling铰孔reaming 铰孔修润拉削broaching刮削scraping磨削grinding研磨加工lapping切削cutting砂纸加工coated abrasive machining抛光加工polishing 抛亮光电火花加工electrical discharge machining 放电加工、EDM 线切割加工spark-erosion wire cutting WEDM电解研磨electrochemical lapping化学研磨chemical polishing中文名称英文名称中文别称15. 相关术语类(制图)技术制图technical drawing 工程制图技术参数technical parameter表面粗糙度surface finish 表面光洁度公差与配合common difference &cooperation形位公差geometric tolerance 几何公差尺寸公差dimension tolerance公差范围tolerance limits 容差极限基孔制basic hole system基轴制basic shaft system三角函数trigonometric function装配图assembly drawing 组装图、总装图、组合图模具排位图die layout 结构草图零件图part drawing 散件图工艺图process drawing 工艺过程图件号no.名称designation实际尺寸actual size标准尺寸stock size材质material 材料、物料数量quantity订货号order no. 订单号备注remarks 附注供应商supplier 供货商模号mold no设计design审核checked by 核对批准approve 审批比例scale单位unit张次sheet版本revision 版次图纸大小drawing sheet size模具公差mold tolerance日期date客户customer技术要求technical requirement 技术条件、技术规定使用说明书operation specifications 操作规范中文名称英文名称中文别称16. 相关术语类(流程、商务)流程优化process optimization 过程优化时间计划表time schedule 工作进度表、时间安排表设计优化design optimization产品分析报告product analysis report流动分析报告flow analysis report结构分析报告structural analysis report模具性能与寿命分析analysis of performance andlife of mold行政部administrative department 行政司营销部marketing department 市场部、市场销售部项目部project department工程部engineering department技术部technical department 技术研发部制造部manufacture department 生产部质检部quality inspection department 品保部采购部purchasing department财务科finance section客服部customer service department 客户服务部董事长board chairman 董事局主席总经理general manager技术总监technical director工程部经理engineering manager制造部经理manufacturing manager 生产部经理模具项目经理mold project manager模具设计师mould designer模具分析师mould analyst项目工程师project engineer钳工fitter模具成本mold cost 模具费用利润profit报价单quotation设计成本design cost 设计费制造成本manufacturing cost 生产成本材料成本material cost 物料成本调试成本debugging cost 调试费用管理成本administration cost 管理费税收revenue 交期delivery time 发货期、交货期。

2 Injection molding machineFrom Plastics Wiki, free encyclopediaInjection molding machines consist of two basic parts, an injection unit and a clamping unit. Injection molding machines differ in both injection unit and clamping unit. The name of the injection molding machine is generally based on the type of injection unit used.2.1Types of injection molding machinesMachines are classified primarily by the type of driving systems they use: hydraulic, electric, or hybrid.2.1.1HydraulicHydraulic presses have historically been the only option available to molders until Nissei Plastic Industrial Co., LTD introduced the first all-electric injection molding machine in 1983. The electric press, also known as Electric Machine Technology (EMT), reduces operation costs by cutting energy consumption and also addresses some of the environmental concerns surrounding the hydraulic press.2.1.2ElectricElectric presses have been shown to be quieter, faster, and have a higher accuracy, however the machines are more expensive.2.1.3HybridHybrid injection molding machines take advantage of the best features of both hydraulic and electric systems. Hydraulic machines are the predominant type in most of the world, with the exception of Japan.2.2Injection unitThe injection unit melts the polymer resin and injects the polymer melt into the mold. The unit may be: ram fed or screw fed.The ram fed injection molding machine uses a hydraulically operated plunger to push the plastic through a heated region. The high viscosity melt is then spread into a thin layer by a "torpedo" to allow for better contact with the heated surfaces. The melt converges at a nozzle and is injected into the mold.Reciprocating screw A combination melting, softening, and injection unit in an injection molding machine. Another term for the injection screw. Reciprocating screws are capable of turning as they move back and forth.The reciprocating screw is used to compress, melt, and convey the material. The reciprocating screw consists of three zones (illustrated below):•feeding zone•compressing zone•metering zoneWhile the outside diameter of the screw remains constant, the depth of the flights on the reciprocating screw decreases from the feed zone to the beginning of the metering zone. These flights compress the material against the inside diameter of the barrel, which creates viscous (shear) heat. This shear heat is mainly responsible for melting the material. The heater bands outside the barrel help maintain the material in the molten state. Typically, a molding machine can have three or more heater bands or zones with different temperature settings.Injection molding reciprocating screw An extruder-type screw rotates within a cylinder, which is typically driven by a hydraulic drive mechanism. Plastic material is moved through the heated cylinder via the screw flights and the material becomes fluid. The injection nozzle is blocked by the previous shot, and this action causes the screw to pump itself backward through the cylinder. (During this step, material is plasticated and accumulated for the next shot.) When the mold clamp has locked, the injection phase takes place. At this time, the screw advances, acting as a ram. Simultaneously, the non-return valve closes off the escape passages in the screw and the screw serves as a solid plunger, moving the plastic ahead into the mold. When the injection stroke and holding cycle is completed, the screw is energized to return and the non-return valve opens, allowing plastic to flow forward from the cylinder again, thus repeating the cycle.2.2.1Feed hopperThe container holding a supply molding material to be fed to the screw. The hopper located over the barrel and the feed throat connects them.2.2.2Injection ramThe ram or screw that applies pressure on the molten plastic material to force it into the mold cavities.2.2.3Injection screwThe reciprocating-screw machine is the most common. This design uses the same barrel for melting and injection of plastic.The alternative unit involves the use of separate barrels for plasticizing and injecting the polymer. This type is called a screw-preplasticizer machine or two-stage machine. Plastic pellets are fed from a hopper into the first stage, which uses a screw to drive the polymer forward and melt it. This barrel feeds a second barrel, which uses a plunger to inject the melt into the mold. Older machines used one plunger-driven barrel to melt and inject the plastic. These machines are referred to as plunger-type injection molding machines.2.2.4BarrelBarrel is a major part that melts resins transmitted from hopper through screws and structured in a way that can heat up resins to the proper temperature. A band heater, which can control temper atures in five sections, is attached outside the barrel. Melted resins are supplied to the mold passing through barrel head, shot-off nozzle, and one-touch nozzle.2.2.5Injection cylinderHydraulic motor located inside bearing box, which is connected to injection cylinder load, rotates screw, and the melted resins are measures at the nose of screw. There are many types of injection cylinders that supply necessary power to inject resins according to the characteristics of resins and product types at appropriate speed and pressure. This model employs the double cylinder type. Injection cylinder is composed of cylinder body, piston, and piston load.2.3Clamping unitThe clamping unit holds the mold together, opens and closes it automatically, and ejects the finished part. The mechanism may be of several designs, either mechanical, hydraulic or hydromechanical.Toggle clamps - a type clamping unit include various designs. An actuator moves the crosshead forward, extending the toggle links to push the moving platen toward a closed position. At the beginning of the movement, mechanical advantage is low and speed is high; but near the end of the stroke, the reverse is true. Thus, toggle clamps provide both high speed and high force at different points in the cycle when they are desirable. They are actuated either by hydraulic cylinders or ball screws driven by electric motors. Toggle-clamp units seem most suited to relatively low-tonnage machines.Two clamping designs: (a) one possible toggle clamp design (1) open and (2) closed; and (b) hydraulic clamping (1) open and (2) closed. Tie rods used to guide movuing platens not shown.Hydraulic clamps are used on higher-tonnage injection molding machines, typically in the range 1300 to 8900 kN (150 to 1000 tons). These units are also more flexible than toggle clamps in terms of setting the tonnage at given positions during the stroke.Hydraulic Clamping System is using the direct hydraulic clamp of which the tolerance is still and below 1 %, of course, better than the toggle system. In addition, the Low Pressure Protection Device is higher than the toggle system for 10 times so that the protection for the precision and expensive mold is very good. The clamping force is focus on the central for evenly distribution that can make the adjustment of the mold flatness in automatically. Hydromechanical clamps -clamping units are designed for large tonnages, usually above 8900 kN (1000 tons); they operate by (1) using hydraulic cylinders to rapidly move the mold toward closing position, (2) locking the position by mechanical means, and (3) using high pressure hydraulic cylinders to finally close the mold and build tonnage.2.3.1Injection moldThere are two main types of injection molds: cold runner (two plate and three plate designs) and hot runner– the more common of the runnerless molds.2.3.2Injection platensSteel plates on a molding machine to which the mold is attached. Generally, two platens are used; one being stationary and the other moveable, actuated hydraulically to open and close the mold. It actually provide place to mount the mould. It contains threaded holes on which mould can be mounted using clamps.2.3.3Clamping cylinderA device that actuates the chuck through the aid of pneumatic or hydraulic energy.2.3.4Tie BarTie bars support clamping power, and 4 tie bars are located between the fixing platen and the support platen.3 Injection mouldFrom Wikipedia, the free encyclopediaMold A hollow form or cavity into which molten plastic is forced to give the shape of the required component. The term generally refers to the whole assembly of parts that make up the section of the molding equipment in which the parts are formed. Also called a tool or die. Moulds separate into at least two halves (called the core and the cavity) to permit the part to be extracted; in general the shape of a part must be such that it will not be locked into the mould. For example, sides of objects typically cannot be parallel with the direction of draw (the direction in which the core and cavity separate from each other). They are angled slightly; examination of most household objects made from plastic will show this aspect of design, known as draft. Parts that are "bucket-like" tend to shrink onto the core while cooling and, after the cavity is pulled away, are typically ejected using pins. Parts can be easily welded together after moulding to allow for a hollow part (like a water jug or doll's head) that couldn't physically be designed as one mould.More complex parts are formed using more complex moulds, which may require moveable sections, called slides, which are inserted into the mould to form particular features that cannot be formed using only a core and a cavity, but are then withdrawn to allow the part to be released. Some moulds even allow previously moulded parts to be re-inserted to allow a new plastic layer to form around the first part. This system can allow for production of fully tyred wheels.Traditionally, moulds have been very expensive to manufacture; therefore, they were usually only used in mass production where thousands of parts are being produced.Molds require: Engineering and design, special materials, machinery and highly skilled personnel to manufacture, assemble and test them.Cold-runner moldCold-runner mold Developed to provide for injection of thermoset material either directly into the cavity or through a small sub-runner and gate into the cavity. It may be compared to the hot-runner molds with the exception that the manifold section is cooled rather than heated to maintain softened but uncured material. The cavity and core plates are electrically heated to normal molding temperature and insulated from the cooler manifold section.3.1.1Types of Cold Runner MoldsThere are two major types of cold runner molds: two plate and three plate.3.1.2Two plate moldA two plate cold runner mold is the simplest type of mold. It is called a two plate mold because there is one parting plane, and the mold splits into two halves. The runner system must be located on this parting plane; thus the part can only be gated on its perimeter.3.1.3Three plate moldA three plate mold differs from a two plate in that it has two parting planes, and the mold splits into three sections every time the part is ejected. Since the mold has two parting planes, the runner system can be located on one, and the part on the other. Three plate molds are used because of their flexibility in gating location. A part can be gated virtually anywhere along its surface.3.1.4AdvantagesThe mold design is very simple, and much cheaper than a hot runner system. The mold requires less maintenance and less skill to set up and operate. Color changes are also very easy, since all of the plastic in the mold is ejected with each cycle.3.1.5DisadvantagesThe obvious disadvantage of this system is the waste plastic generated. The runners are either disposed of, or reground and reprocessed with the original material. This adds a step in the manufacturing process. Also, regrind will increase variation in the injection molding process, and could decrease the plastic's mechanical properties.3.1.6Hot runner moldHot-runner mold -injection mold in which the runners are kept hot and insulated from the chilled cavities. Plastic freezeoff occurs at gate of cavity; runners are in a separate plate so they are not, as is the case usually, ejected with the piece.Hot runner molds are two plate molds with a heated runner system inside one half of the mold.A hot runner system is divided into two parts: the manifold and the drops. The manifold has channels that convey the plastic on a single plane, parallel to the parting line, to a point abovethe cavity. The drops, situated perpendicular to the manifold, convey the plastic from the manifold to the part.3.1.7Types of Hot Runner MoldsThere are many variations of hot runner systems. Generally, hot runner systems are designated by how the plastic is heated. There are internally and externally heated drops and manifolds.3.1.8Externally heated hot runnersExternally heated hot runner channels have the lowest pressure drop of any runner system (because there is no heater obstructing flow and all the plastic is molten), and they are better for color changes none of the plastic in the runner system freezes. There are no places for material to hang up and degrade, so externally heated systems are good for thermally sensitive materials.3.1.9Internally heated hot runnersInternally heated runner systems require higher molding pressures, and color changes are very difficult. There are many places for material to hang up and degrade, so thermally sensitive materials should not be used. Internally heated drops offer better gate tip control. Internally heated systems also better separate runner heat from the mold because an insulating frozen layer is formed against the steel wall on the inside of the flow channels.3.1.10 insulated hot runnersA special type of hot runner system is an insulated runner. An insulated runner is not heated; the runner channels are extremely thick and stay molten during constant cycling. This system is very inexpensive, and offers the flexible gating advantages of other hot runners and the elimination of gates without the added cost of the manifold and drops of a heated hot runner system. Color changes are very easy. Unfortunately, these runner systems offer no control, and only commodity plastics like PP and PE can be used. If the mold stops cycling for some reason, the runner system will freeze and the mold has to be split to remove it. Insulated runners are usually used to make low tolerance parts like cups and frisbees.3.1.11 DisadvantagesHot-runner mold is much more expensive than a cold runner, it requires costly maintenance, and requires more skill to operate. Color changes with hot runner molds can be difficult, since it is virtually impossible to remove all of the plastic from an internal runner system.3.1.12 AdvantagesThey can completely eliminate runner scrap, so there are no runners to sort from the parts, and no runners to throw away or regrind and remix into the original material. Hot runners are popular in high production parts, especially with a lot of cavities.Advantages Hot Runner System Over a Cold Runner System include:•no runners to disconnect from the molded parts•no runners to remove or regrind, thus no need for process/ robotics to remove them•having no runners reduces the possibility of contamination•lower injection pressures•lower clamping pressure•consistent heat at processing temperature within the cavity•cooling time is actually shorter (as there is no need for thicker, longer-cycle runners)•shot size is reduced by runner weight•cleaner molding process (no regrinding necessary)•nozzle freeze and sprue sticking issues eliminated中文翻译注塑模具设计与制造2 注射机选自《维基百科》注射机由两个基本部分组成，注射装置和夹紧装置。

第一篇译文（中文）2.3注射模2.3.1注射模塑注塑主要用于热塑性制件的生产，它也是最古老的塑料成型方式之一。

目前，注塑占所有塑料树脂消费的30%。

典型的注塑产品主要有杯子器具、容器、机架、工具手柄、旋钮（球形捏手）、电器和通讯部件（如电话接收器），玩具和铅管制造装置。

聚合物熔体因其较高的分子质量而具有很高的粘性；它们不能像金属一样在重力流的作用下直接被倒入模具中，而是需要在高压的作用下强行注入模具中。

因此当一个金属铸件的机械性能主要由模壁热传递的速率决定，这决定了最终铸件的晶粒度和纤维取向，也决定了注塑时熔体注入时的高压产生强大的剪切力是物料中分子取向的主要决定力量。

由此所知，成品的机械性能主要受注射条件和在模具中的冷却条件影响。

注塑已经被应用于热塑性塑料和热固性塑料、泡沫部分，而且也已经被改良用于生产反应注塑过程，在此过程中，一个热固树脂系统的两个组成部分在模具中同时被注射填充，然后迅速聚合。

然而大多数注塑被用热塑性塑料上，接下来的讨论就集中在这样的模具上。

典型的注塑周期或流程包括五个阶段（见图2-1）：（1）注射或模具填充；（2）填充或压紧；（3）定型；（4）冷却；（5）零件顶出。

图2-1 注塑流程塑料芯块（或粉末）被装入进料斗，穿过一条在注射料筒中通过旋转螺杆的作用下塑料芯块（或粉末）被向前推进的通道。

螺杆的旋转迫使这些芯块在高压下对抗使它们受热融化的料筒加热壁。

加热温度在265至500华氏度之间。

随着压力增强，旋转螺杆被推向后压直到积累了足够的塑料能够发射。

注射活塞迫使熔融塑料从料筒，通过喷嘴、浇口和流道系统，最后进入模具型腔。

在注塑过程中，模具型腔被完全充满。

当塑料接触冰冷的模具表面，便迅速固化形成表层。

由于型芯还处于熔融状态，塑料流经型芯来完成模具的填充。

典型地，在注塑过程中模具型腔被填充至95%~98%。

然后模具成型过程将进行至压紧阶段。

当模具型腔充满的时候，熔融的塑料便开始冷却。

编号：毕业设计外文翻译（原文）题目：Injection Molding Guide 学院：机电工程学院专业：机械设计制造及其自动化学生姓名：学号：指导教师单位姓名：职称：2014年5月26日Injection Molding GuideINTRODUCTIONObjectiveThis document provides guidelines for part design, mold design and processing of styrenic block copolymer (SBC) TPEs. The GLS product families that include styrenic TPEs are Kraton compounds, Dynaflex TPE compounds and Versaflex TPE alloys.SBC RheologyOne major characteristic of SBCs is that they are shearing dependent. A material is shear dependent when its viscosity is higher at low shear rates (such as extrusion) and lower at high shear rates (as in injection molding). Therefore, SBC compounds will flow more easily into thin areas of the mold at high shear rates. The shear thinning behavior of SBCs should be considered when designing injection molds and also when setting mold conditions during processing.Figure 1.The effect of shear rate on the viscosity of GLSstyrenic TPE compounds (measured at 390°F (200°C)).To obtain information regarding the viscosity of an individual grade, refer to the Product Technical Data Sheet, available at or contact your GLS representative.PART DESIGNGeneral Part Design ConceptsWhen designing a TPE part, there are a few general rules to follow:•The part wall thickness should be as uniform as possible. Transitions from thick to thin areas should be gradual to prevent flow problems, back fills, and gas traps.•Thick sections should be cored out to minimize shrinkage and reduce part weight (and cycle time).•Radius / fillet all sharp corners to promote flow and minimize no-fill areas.•Deep unventable blind pockets or ribs should be avoided.•Avoid thin walls that cannot be blown off the cores by air-assist ejection.•Long draws with minimum draft may affect ease of ejection.Flow Length and Wall ThicknessThe maximum achievable flow length is dependent on the specific material selected, the thickness of the part, and processing conditions. Generally, GLS compounds will flow much further in thinner walls than other types of TPEs. The flow to thickness ratio should be 200 maximum; however this is dependent on the material and the part design. High flow GLS TPE compounds (such as Versalloy) have been used successfully to fill flow ratios up to 400.The measurement of spiral flow offers a comparative analysis of a material’s ability to fill a part. The spiral flow test is performed by injecting a material into a spiral mold (similar to a ribbon formed into a spiral). The distance the material flows is measured in inches. In this case, the spiral flow test was conducted using two different injection speeds (3 in/sec and 5 in/sec). The typical spiral flow lengths for the various GLS product families are summarized in Table 1. With specific compounds, flow lengths of up to 40 inches (at 5 in/sec injection speed) are possible.Table 1. Typical Spiral Flow Lengths for GLS Compounds*SeriesFlow length, in3 in/sec 5 in/secDynaflex ® D 13-15 18-20Dynaflex ® G 12-22 18-30Versaflex ® 9-16 13-26*Spiral flow tests performed using 0.0625 in thickness and 0.375 in width channel at 400°F.For spiral flow information about a specific grade or additional details about the spiral flow test procedure, please refer to the GLS Corporation TPE Tips Sheet #7, available at or by contacting your GLS representative.UndercutsThe flexibility and elastic nature of TPEs allows for the incorporation of undercuts into the part design. Because of their excellent recovery characteristics, GLS compounds are capable of being stretched and deformed, allowing them to be pulled from deep undercuts (Figure 2). If both internal and external undercuts are present on the same part, slides or core splits may be necessary. Parts with internal undercuts (e.g. bulb shaped parts) may be air ejected from the core by use of a poppet valve in the core. Minor permanent elongation (3% - 8%) due to deformation may occur during ejection.Figure 2. An example of TPE parts with large undercuts.Gate and Knit Line LocationsThe product engineer should indicate the areas of the part that are cosmetic and those that are functional and include this information on the drawing. This will help the mold designer to determine the allowable gate and knit line locations.AnisotropyThermoplastic materials that have different properties in the flow direction versus the cross-flow direction (90ºperpendicular to the flow direction) are characterized as “anisotropic” materials. Properties that may be affected are shrinkage and tensile properties. Anisotropy is caused when the polymer chains orient in the direction of flow, which leads to higher physical properties in the flow direction. Wall thickness, injection speed, melt temperature and mold temperature are a few variables that affect anisotropy. Depending on the processing conditions and mold design, most GLS styrenic TPE compounds exhibit a degree of anisotropy.ShrinkageDue to their anisotropic nature, GLS styrenic TPE compounds shrink more in the flow direction than in the cross-flow direction. Generally, SEBS compounds have higher shrinkage and are more anisotropic than SBS compounds. Typical shrinkage values for SEBS-based compounds are 1.3% - 2.5%, whereas those for SBS based compounds are 0.3% - 0.5 %. Softer SEBS compounds (below 30 Shore A) will shrink more than harder 6 materials. Some grades, such as Dynaflex G7700, G7800, and G7900 Series contain filler, which reduces their shrinkage.The shrinkage values reported by GLS are determined using a 0.125” thick plaque. It should be noted that shrinkage is not an exact number, but a range value. This range can beaffected by the part wall thickness, melt temperature, mold temperature, injection speed, hold/pack pressures and also the time between molding and measuring. As a result, prototyping is strongly recommended for parts with close tolerances to better quantify the realistic shrinkage of a specific grade of material in a specific application.For shrinkage values for specific grades, please refer to the product Technical Data Sheet, available at or by contacting your GLS representative.MOLD DESIGNTypes of MoldsGLS SBC compounds can be molded in two- and three-plate molds. Both conventional and hot runner tool designs have been used with GLS compounds. Self-insulating hot runner tool designs are not recommended due to the potential for material degradation in the stagnation zones. Two-shot molds and insert molds can also be used. If a family mold is required, the cavity volumes should be similar, otherwise over packing and flashing of the smaller cavity may occur.Steel SelectionGLS styrenic TPEs are generally non-abrasive and non-corrosive. The selection of tool steel will depend on the quantity and quality of parts to be produced. For high volume production, the initial expense of quality tooling is a sound investment.A wide variety of tool steels are available for injection mold construction. Table 2 lists the properties of common tool steels and the typical mold components for which they are used. Soft metals, such as aluminum and beryllium copper, can be used for prototype parts or short production runs up to 10,000 parts.Table 2. Typical Tool Steel for Injection Mold ConstructionSteelTypeSteel Properties Mold ComponentP-20 Pre-hardened, machines well, highcarbon, general-purpose steel.Disadvantage: May rust ifimproperly stored.Mold bases, ejector plates, and somecavities (if nickel or chrome plated toprevent rust).H-13 Good general purpose tool steel. Canbe polished or heat-treated. Bettercorrosion resistance.Cavity plates and core plates.S-7 Good high hardness, improvedtoughness, general-purpose toolsteel.Machines well, shock resistant,polishes well. Disadvantage: Highercost.Cavity plates, core plates and laminates,as well as thin wall sections.A-2 Good high toughness tool steel.Heat-treats and polishes well.Ejector pins, ejector sleeves, and ejectorblades.D-2 Very hard, high wear characteristics,high vanadium content, somewhatbrittle. Disadvantage: Difficult tomachine.Gate blocks, gibe plates to preventgalling, gate blocks to prevent wear.420 SS Tough corrosion resistant material.Heat-treats and polishes well.Disadvantage: High cost.Cavity blocks, ejector pins, sleeves, etc.Some part designs may benefit from the use of higher thermal conductivity materials such as beryllium copper. This material is less durable than steel and may hob or wear faster than steel if used at the parting-line. Beryllium copper can be used for inserts, slides or cores to increase heat transfer rates and reduce cycle times. In cases where there is a long draw core, a fountain-type bubbler may be beneficial.Mold Surface Treatment, Finishing and TexturingMost GLS materials replicate the mold surface fairly well. To produce a glossy surface, a polished mold is required and an unfilled grade should be used. A highly polished tool and a transparent material are required to produce a part with good clarity. If a matte finish similar to that of a thermoset rubber is required, a rougher mold texture should be used (or a GLS product such as GLS Versalloy TPV alloys, which naturally produce a matte surface). In general, an EDM surface will produce a good texture and may improve release from the tool during part ejection. Matte surfaces can also help to hide any flow marks or other surface defects. Vapor honing, sand or bead blasting and chemical etching are also used to produce textured surfaces with varying degrees of gloss and appearance. To aid in release, the cavity or core may be coated with a release coating such as PTFE impregnated nickel after it has been given a sandblast or EDM finish.Sprue and Sprue Puller DesignThe sprue should have sufficient draft, from 1º to 3º to minimize drag and sprue sticking. Longer sprues may require more taper (3°- 5°), as shown in Figure 3. Typically, the sprue diameter should be slightly larger than the nozzle diameter. An EDM finish is acceptable for most styrenic TPE materials. Permanent surface lubricant treatments have also been used successfully.Sprue puller designs vary with the hardness of the material. The different sprue designs possible and their relative dimensions are shown in Figures 4 through 7. In addition, Table 3 shows the typical hardness range for which a particular sprue design is applicable.Table 3. Typical Sprue Designs for Various Hardness ValuesTypical TPE HardnessRangeMost Common Sprue Puller Types Figure >50 Shore A Tapered, Pin, Z-Type 3, 4 and 640-70 Shore A Undercut 55-40 Shore A Pine Tree 7Hot sprue bushings and extended nozzles may also be used with GLS compounds. In many molds, the sprue is the thickest wall section in the mold and will control the minimum cooling time. The use of a hot sprue, which may be viewed as an extension of the machinenozzle, can sometimes reduce cycle time. Extended machine nozzles may also be used to reduce sprue length and size. When hot sprues are used, the machine nozzle tip should be a free-flow nozzle rather than a reverse tip.Figure 3. Tapered Sprue Puller Figure 4. Z-Pin Sprue PullerFigure 5. Undercut Sprue PullerFigure 6. Sucker Pin Sprue PullerFigure 7. Pine Tree Sprue PullerConventional Runner Configuration and DesignA balanced runner configuration is critical to achieve uniform part quality from cavity to cavity. In a balanced runner system, the melt flows into each cavity at equal times and pressure. The runner balance can be designed by using computer mold-flow analysis programs and verified by performing short-shot studies.An unbalanced runner may result in inconsistent part weights and dimensional variability. The cavity closest to the sprue may be over packed and flashing may occur. As a result of over packing, parts may also develop high molded-in stresses, which lead to warpage. Examples of balanced runner systems are shown in Figures 8 and 9.Figure 8. Example of Balanced Spider Runner Figure9. Example of Balanced Cross-RunnerFigure 10 shows different runner cross-sections and their associated efficiency. Full round runners have the least resistance to flow and surface area, allowing the material to stay molten longer. The second most efficient runner cross-section is the modified trapezoid. This runner geometry most closely simulates a full round runner but only requires machining in only one plate. Figure 11 shows typical ball cutter dimensions and the corresponding modified trapezoid runner sizes. Figure 12 illustrates typical runner dimensions.Figure 10. Typical Runner Cross-SectionsFigure 11. Modified Trapezoid Runner SizesFigure 12. Runner Design and DimensionsCold slug wells should be used at each runner transition (turn). Cold slug wells serve to remove the leading edge of the melt. The slug well associated with the sprue should be large enough to trap the cold material formed in the machine nozzle during the mold-open cycle. Typical slug well dimensions are approximately 1.5 to 2.0 times the diameter or width of the feed runner.Runner KeepersRunner keepers or sucker pins provide undercuts to keep the runner on the desired plate but should not restrict material flow through the runner. Figures 8 and 9 show typical locations for runner keepers and sucker pins. Figure 13 illustrates an example design of a runner keeper.Figure 13. Runner Keeper designGate Design and LocationMost conventional gating types are suitable for processing GLS styrenic TPE compounds.The type of gate and the location, relative to the part, may affect the following: •Part packing•Gate removal or vestige•Part cosmetic appearance•Part dimensions (including warpage)The type of gate selected is dependent on both part and tool design. The gate location is equally important. To prevent the chances of jetting, locate the gate entrance in an area where the flow will impinge on a cavity wall. For automatically degating tools, the highly elastic nature of softer TPEs makes submarine gate designs or three plate tools with selfdegating drops more difficult. Higher hardness and filled grades usually have lower ultimate elongation and therefore are more easily degated. To assure the gates will break at a specific location, they should have a short land length to create a high stress concentration.Tab/Edge GatesTab or edge gates (Figure 14) most commonly utilize a conventional sprue and cold runner system. They are located along the tool parting line. A small undercut can be placed where the gate meets the part to minimize gate vestige caused by degating. Advantages of edge gates are ease of fabrication, modification and maintenance. The 14 gate depth (D) should be 15% - 30% of the wall thickness at the gate entrance. Common practice is to start “steel safe”. A good starting point for the gate width should be 1.0 - 1.5 times the gate depth. The gate land should be equal to or slightly longer than gate depth. The gate size may also depend on the part volume. The gate area may be inserted to facilitate gate maintenance or modification.Figure 14. Tab or edge gate Figure 15. Submarine Gate Submarine or tunnel gates are self-degating. During part ejection, the tool steel separates the part and the runner. Figure 15 shows a typical design of a submarine gate. Cashew type submarine gates should not be used for medium to soft hardness compounds due to their high coefficient of friction and high elongation.Fan GatesA fan gate is a streamlined variation of a tab gate (Figure 16). The fan gate distributes material into the cavity more evenly; thus it is normally used in parts that require a high degree of flatness and absence of flow lines. It also minimizes the possibility of gate pucker or part warpage.Figure 16. Fan gateSprue or Direct GateThe sprue or direct gate is often used on prototype parts because it is inexpensive. This type of gating is not recommended for GLS styrenic compounds because of their high elongation. In addition, the sprue will need to be trimmed thus appearance quality of the part is usually poor. If sprue gating is selected, care should be taken to keep both the sprue length and diameter as short and small as possible.Diaphragm GateThe diaphragm gate is used to maintain the concentricity of round parts. It allows even flow into the cavity and minimizes the potential for knit lines. Due to anisotropic shrinkage, flat round parts using center or diaphragm gating may not lay flat. A ring gate may also be used on the outside of a circular part.Table 4 compares the advantages and disadvantages of the various gate types discussed in this section. Table 4. Advantages and Disadvantages of Various Gate TypesGate Type Advantage DisadvantageEdge/Tab/Fan Gate • Appropriate for flat parts • Easy to modify • Post-mold gate/runnerremoval is difficult• Poor gate vestigeSubmarine Gate • Automatic gate removal• Minimal gate vestige• More difficult to machine Diaphragm Gate • Concentricity• Appropriate for round parts• No knit lines• Scrap • Post-molding gate removalPin gate (3-plate) •Automatic gate removal•Minimal gate vestige•Localized cooling •Requires floater plate •More scrap •Higher tool costValve gate (Hot runner systems) •Minimal gate vestige•Positive shut-off•Minimizes post pack•Higher tool cost•Higher maintenance•Only for hot runner systemsGate LocationStyrenic TPE compounds are anisotropic, thus they have different physical properties in the flow direction versus the cross-flow direction. Depending on the product's intended usage, these property differences could be critical to the performance of the final part. As a result, the anisotropic nature of the styrenic TPE needs to be taken into consideration when determining the gate location on the part.The material flow may be estimated by eye or by using flow analysis programs. For higher shrinkage grades, the part m ay shrink near the gate, which causes “gate pucker” if there is a high molded-in stress at the gate. Parts shaped like a handle grip may warp toward the gate side of the part. Locating the gate at the top of the part minimizes this problem. Using two gates on opposite sides of the part can also address the issue, but it will result in two knit lines. If filling problems exist in thin walled parts, adding flow channels or minor changes in wall thickness can alter the flow. In some cases, it may be necessary to add a second gate to properly fill the parts.The gate should be placed so that the flow path is as short as possible. Locating the gate at the heaviest cross section of the part can improve packing and minimize voids or sinks. If possible, the gate should be positioned so as to avoid obstructions (flowing around cores or pins) in the flow path.The flow path of the material should minimize the possibility of formation of knit lines and flow marks. Upon injection, the material should impinge off the cavity wall to reduce the possibility of jetting. To minimize the effect of molded-in stress (at the gate) on part performance, the gate should be located in noncritical areas of the part. Also, the gate location should allow for easy manual or automatic degating.Mold VentingMold venting is critical to the quality and consistency of the finished part. Venting is required to allow the air in the sprue, runner and cavity to leave the tool as the melt flows into the cavity. Inadequate venting may cause short-shots, poor surface appearance, or weak weld-lines. Potential air traps in the part design can be predicted by flow simulation software. Once the tool has been built, short-shot studies can be used to find the critical venting areas.Vents should be placed at the last place to fill and in areas where weld lines occur. The typical vent size for GLS compounds is 0.0005” - 0.0010” (0.012 mm - 0.025 mm) with a 0.040” - 0.060” (10 mm – 15 mm) land. Past the land, the vent depth should be increased to 0.005” - 0.010” (0.12 mm - 0.25 mm) to provide a clear passage for the air to exit the tool (Figure 17). Venting in areas below the parting line can be accomplished by allowing the ejector pin to be 0,001 loose on each side (Figure 18). Venting of ribs or pockets can be achieved by venting down an ejector pin, or with the use of porous mold steels. Ejector pinvents are self-cleaning, but they should be wiped once a day to remove buildup. Porous plug vents need to be replaced, or dismantled and cleaned when they become clogged.Figure 17. Mold vent design Figure 18. Venting through an ejector pinPart EjectionPart ejection is more difficult in long draw areas. A 3° - 5° draft per side on all long draw areas is recommended. Ejector pins should be located at runner transitions and in areas of the part where appearance is not critical. The diameter of ejector pins should be as large as possible to minimize push-through marks. Larger pins also allow for easier ejection of warmer parts, which can reduce cycle time. Ejector blades, ejector sleeves and stripper rings can be used for part ejection. Air ejection and the use of poppet can help strip large undercuts, providing the material has room to deform when the air is applied. Mold surface texturing and special mold surface treatments can also help to pull the parts from the “A” half. Advancing cores are used usually when ejecting large internal undercuts.Mold CoolingThe mold should have adequate cooling to optimize cycle time. The use of mold materials with high heat transfer, such as beryllium copper, can be used to cool slides or inserts. Commercially available fountain-type bubblers may also help to cool long cores. Separate chillers for the movable and stationary sides are suggested. This allows the processor to use differential cooling to help retain the parts on the movable (“B”) plate. Connecting cooling lines from the A to the B plate should be avoided. Special cooling for cores and slides is also an option to improve cooling efficiency.HOT RUNNER SYSTEMSThe differences between hot runner systems; cold runners and hot sprues are summarized in Table 5. GLS SEBS compounds are quite heat stable and are used successfully in hot runner tools today.Selecting a particular type of hot runner system is influenced by the product design and production requirements. There are many hot runner component and tool manufacturers available. If possible, utilize a system or component supplier with experience in styrenic TPEs. SBS compounds can crosslink (forming gels) if they are held at high temperatures for too long a period of time, therefore hot runner tools are not recommended for these materials.Manifold DesignTable 5. Comparative Assessment of Hot Runner SystemsSystem Type Advantage DisadvantageCold runner ·Lower tool cost·Easily modified·Enables use of robotics ·Typically governs cycle time ·Potential for cold slugs ·Potential for sprue sticking ·Scrap (though regrindable)Hot Sprue or Extended Nozzle ·Faster cycle·Minimizes scrap·Easily maintained·Better temperature control·Higher tool cost·Potential heat degradation for SBScompoundsHot Runner ·No runner scrap·Faster cycle time·Precise temperature control ·Highest tool cost ·Purging·Material degradation ·MaintenanceExternally heated systems are best. Internally heated manifolds are not suitable for TPEs. These systems typically have hot spots and stagnation zones that cause partially solidified material to cling to the cooler manifold walls. For maximum flexibility, the design should be naturally or geometrically balanced. Rheological balancing is possible, but only for a specific grade or rheometric curve. Internally heated manifolds are not suitable for TPEs –these systems typically have hot spots and stagnation zones that cause partially solidified material to cling to the cooler manifold walls. All passages should be highly polished circular cross sections with gentle bends to minimize the possibility of stagnation zones. In order to maintain high shear, minimize residence times and promote flow, the passages should have a diameter of 0.250” to 0.375”. Individualized zone controls for the hot runners are recommended and allow the operator to adjust the balance slightly to make the parts more uniform.Hot Runner System GatesValve GatesValve gates offer the best solution for high production parts where surface quality is critical, such as medical and cosmetic products. Since valve gates leave only a slight ring on the part, gate vestige is minimized. Further improvement can be obtained by positioning the valve recessed below the part surface or concealing the gate in the part detail for aesthetic products. An example of a hot runner system with a valve gate is shown in Figure 19.Image provided by Mold-Masters Limited, Dura is a registered trade-mark of Mold-Masters Limited.Figure 19. Hot Runner System using valve gateThe gate diameter of a valve gate should be approximately 0.030” to 0.125”, depending on the size and thickness of the part. Valve gates do not require the material in the part to freeze before the valve is closed and hold pressure is released. Therefore, the screw recovery for the next cycle can start earlier and the total cycle time may be decreased. For very thick wall parts with the potential for sinks or shrink voids, valve gates can be held open for an extended time to supply make-up material and eliminate voids and sinks.Valve gate elements need to be insulated from the mold plates to maintain proper temperature control. Only valve gates can be used for multi-cavity foam molding or cascade molding to fill long thin flows without knit lines. Due to the low viscosity of some GLS grades, properly maintained tight valve gates are required to prevent leakage or hair flash. Valve gates may be pneumatically or hydraulically activated. Individual heater controls at each gate will allow fine control of the melt viscosity and filling.Hot Tip GatesHot tip gates are suitable for SBC compounds but will leave some gate vestige (which can be as high as 50% to 75% of the gate diameter). Vestige can be minimized by slightly recessing the gate below the part surface. The land length of the hot tip should be less than the diameter of the gate.The elements of the hot tip should be properly insulated from the mold plates and cavity.In order to achieve this, the land length of the gate may need to be lengthened and a portion of the land should be part of the cavity. All passages within the tip should be 20 highly polished and streamlined to minimize stagnation and degradation zones. The efficiency of the design may be verified by recording the time it takes to make a complete color change while producing parts. This demonstrates whether there is any residual dead zone material that continues to enter the melt stream.For hot tip gate systems, there should be a delay long enough for the part to set up completely before mastication is initiated for the next cycle. Without a delay, the parts may become over packed. This is particularly important for low hardness, high flow materials. To reduce over packing for thick-walled parts with large gates, use minimal back pressure during mastication.Since TPE compounds are slightly compressible in the molten state, larger runner volumes can cause hot tip gates to drool after the mold is opened. To prevent drool, the runner system should be minimized and the melt decompressed before the mold opens.Hot tips may be used to fill a secondary cold runner to supply material to multiple parts. Each hot tip gate should use an individual temperature controller. If the hot tip manufacturer selected does not have prior SBC compound experience, it may be necessary to experimentally determine the best gate type and geometry through prototyping. OVERMOLDINGOne of the largest areas of growth for TPEs is overmolding. Many product designers are utilizing TPEs to add a “soft touch” to a rigid material. GLS compounds can be overmolded onto many different substrates to alter the surface feel, improve aesthetics, and cushion against vibration – the possibilities are limitless.Most Dynaflex®and Kraton®compounds (and Versalloy®TPV Alloys) are suitable for two-shot or insert molding onto a PP (and in some cases, PE) substrate. The Versaflex® OM grades have been specially formulated to bond PC, ABS, nylon 6/6, PC/ABS, and PPO. The new Versollan® OM series, based on BASF high performance polyurethane (TPU), are TPU alloys specifically designed for thin-wall overmolding (both insert and two-shot molding) o nto PC, ABS, and PC/ABS substrates.With new innovative technologies, GLS continues to develop TPEs that bond to a variety of substrates. For additional information about the standard Versaflex OM series and the development of new TPEs that bond to unusual substrates, please contact your GLS Representative.For more information about overmolding part design, mold design and processing, please refer to the GLS publication “Overmolding Guide”, available at or by contacting your GLS representative.MACHINE SELECTIONMachine Types。

外文翻译-模具类注塑机模具设计外文翻译毕业设计题目:操纵机构及其面板凸轮机构模具设计原文1:Plastic Material Molding译文1:塑料成型原文2:The Injection-molding Maching 译文2:注塑机Plastic Material MoldingPlastic objects are formed by comperssion,transfer,and injection molding.Other processes arecasting, extrusion and laminating, filament winding, sheet forming, jointing, foaming, andmaching. Some of these and still otherrs are used for rubber. A reason for a variety of processes isthat different materials must be worked in differentways. Also, each methods is advantageous for certain kind of product(Table 1)Table 1 Characteristics of Forming and Shaping Processesfor Plastics and Composite Materialsprocess CharacteristicsExtrusion Long, uniform, solid or hollow complex cross-sections;high production rates; low tooling costs; widetolerrances.Injection molding Complex shapes of various sizes, eliminating assembly;high production rates; costly tooling; good dimensionalaccurancy.Structural foam molding Large parts with high stiffness-to-weight ratio; lessexpensive tooling than in injection molding; lowproduction rates.Blow molding Hollow thin-walled parts of various sizes; highproduction rates and low cost for making containers.Rotational molding Large hollow shapes of relatively simple shape;lowtooling cost; low production rates.Thermoforming Shallow or relatively deep cavities; low tooling costs;medium production rates.Compression molding Parts similar to impression-die forging;relativelyinpensive tooling; medium production rates.Transfer molding More complex parts than compression molding andhigher production rates; some scrap loss; mediumtooling cost.1Casting Simple or intricate shapes made with flexible molds;low production rates.Processing of composite materials Long cycle time; tolerances and tooling cost depend onprocess.There are two main steps in the manufacture of plastic products. The first is a chemical process to create the resin. The second is to mixand shape all the material into the finished article or product.1.1 Compression MoldingIn compression molding, a preshaped charge of material, a premeasured volume of powder, or a viscous mixture of liquid redin and filler material is placed directly into a heated mold cavity. Forming is done under pressure from a plug or from the upper half of the die (Figer 1). Compression molding results in the formation of flash (if additional plastic is forced between the mold halves, because of a poor mold fit or wear, it is called flash.), which is subsequently removed by trimming or other means.Typical parts made are dishes, handles, container caps, fittings, electrical and electronic components, washing-machine agitators, and housings. Fiber-reinforced parts with long chopped fibers are formed by this process exclusively.Compression molding is used mainly with thermosetting plastics, with the original material being in a partially ploymerized state. Cross-linking (in these ploymers, additional element link one chain to another. The best example is the use of sulfur to cross-link elastomers to create automobile tires) is completed in the heated die; curing times rang from0.5 to 5 minutes, depending on the material and on part thickness and geometry. The thicker the material is, the longer it will take to cure. Elastomers are also shaped by compression molding.Three types of compression molds are available as follows:2Figuer 1 Typres of compression moldinga. flash-type, for shallow or flat parts,b. positive, for high density parts,c. semipositive, for quality production.1.2 Transfer MoldingTransfer molding represents a further development of compression molding. The uncured thermosetting material is placed in a heatedtransfer pot or chamber (Figer 2). After the materialis heated, it is injected into heated closed molds. A ram, a plunger, or a rotating-screw feeder (depending on the type of machine used)forces the material to flow through the narrow channels into the mold cavity.Typical parts made by transfer molding are electrical and electronic components and rubber and silicone parts. This process is particularly suitable for intricate parts with varying wall thickness.1.3 Injection MoldingInjection molding (injection of plastic into a catity of desired shape. The plastic is then cooled and ejected in its final form. Most consumer productions such as telephones, computer casings, and CD players are injection molded. ) is principally used for the production of thermoplastic parts, although some process has been made in developing a method for injection molding some3thermosetting materials.Figure 2 Sequence of operations in transfer molding forthermosetting plastics The problem of injection a melted plastic into a mold cavity from a reservoir melted material has been extremelydifficult to solve for thermosetting plastics which cure and harden such conditions within a few minutes. The principle of injection molding is quite similar to that of die-casting. Plastic powder is loaded into thefeed hopper and a certain amount feeds into the heating chamber when the plunger draws back. The plastic powder under heat and pressures in the heating chamber becomes a fluid. After the mold is closed, the plunger moves forward, forcing some of the fluid plastic into the mold cavity under pressures. Since the mold in cooled by circulating cold water, the plastic hardens and the part may be ejected when the plunger draws back and the mold opens. Injection-molding machines can be arranged for manual operation, automatic single-cycle operation, and ful automatic operation. Typical machines produce molded parts weighing up to 22 ounces at the rate of four shots per minute, and it is possible on molded parts machines to obtain a rate of six shots per minute. The molds used are similar to the dies of a die-casting machine. The advantages of injection molding are as follows:1. A high molding speed adapted for mass production is possible,2. There is a wide choice of thermoplastic materials providing a variety of usefulproperties,3. It is possible to mold threads,(“sideways” racesses or projections of the molded part thatprevent its removal from the mold along the parting direction. They can accommodated4by specialized mold design such as sliders.), side holes, and large thin sections. 1.4 Thermoplastic Mold DesignBasically, there are two types of transfer mold: the conventional sprue type and the positive plunger type. In the sprue type the plastic performs are placed in a separate loading chamber above the mold cavity. One or more sprues (the runway between the injection machine's nozzle and the runners or the gate) lead down to the parting surface of the mold where they connect with gates to the mold cavity or cavities (Figer 3). Special press with a floating intermediate platen are especially useful for accommodating the two parting surface molds. The plunger acts directly on the plastic material, forcing it through the sprues and gates into the mold cavities. Heat and pressure must be maintained for a definite time for curing. When the part is cured the press is opened, breaking the sprues from the gates. The cull and sprues and raised upward, being held by a tapered, dovetailed projection machine on the end ofFigure 3 Schematic illustration of transfer moldingthe plunger. They can easily be removed from the dovetail by pushing horizontally. In a positive plunger-type transfer mold the sprue is eliminated so that the loading chamber extends through to the mold parting surface and connects directly with the gates (the entrance to the mold cavity). The positive plunger type is preferred, because themold is less complicated, and less material is wasted. Parts made by transfer molding have greater strength, more uniform densities, closer dimensional tolerances, and the parting plane (the separation plane of the two mold halves) requires less cleaning as compression molding.The following figure shows a typical two-plate mold and indicates the structure of mold and the arrangement of all parts in mold (Figure4).5Figure 4 The typical structure of two-plate mold作者:Yijun Huang国籍:china出处:Qinghua university press6塑料成型塑料制品一般是由压缩，传递和注塑成型等方法形成的。

A CAD/CAE-integrated injection mold design system for plastic productsAbstract Mold design is a knowledge-intensive process. This paper describes a knowledge-based oriented, parametric, modular and feature-based integrated computer-aided design/computer-aided engineering (CAD/CAE) system for mold design. Development of CAx systems for numerical simulation of plastic injection molding and mold design has opened new possibilities of product analysis during the mold design. The proposed system integrates Pro/ENGINEER system with the specially developed module for the calculation of injection molding parameters, mold design, and selection of mold elements. The system interface uses parametric and CAD/CAE feature-based database to streamline the process of design, editing, and reviewing. Also presented are general structure and part of output results from the proposed CAD/ CAE-integrated injection mold design system.Keywords Mold design . Numerical simulation . CAD . CAE1 IntroductionInjection molding process is the most common molding process for making plastic parts. Generally, plastic injection molding design includes plastic product design, mold design, and injection molding process design, all of which contribute to the quality of the molded product as well as production efficiency [1]. This is process involving many design parameters that need to be considered in a concurrent manner. Mold design for plastic injection molding aided by computers has been focused by a number of authors worldwide for a long period. Various authors have developed program systems which help engineers to design part, mold, and selection parameters of injection molding. During the last decade, many authors have developed computer-aided design/computer-aided engineering (CAD/CAE) mold design systems for plastic injection molding. Jong et al. [2] developed a collaborative integrated design system for concurrent mold design within the CAD mold base on the web, using Pro/E. Low et al. [3] developed an application for standardization of initial design of plastic injection molds. The system enables choice and management of mold base of standard mold plates, but does not provide mold and injection molding calculations. The authors proposed a methodology of standardizing the cavity layout design system for plastic injection mold such that only standard cavity layouts are used. When standard layouts are used, their layout configurations can be easilystored in a database. Lin at al. [4, 5] describe a structural design system for 3D drawing mold based on functional features using a minimum set of initial information. In addition, it is also applicable to assign the functional features flexibly before accomplishing the design of a solid model for the main parts of a drawing mold. This design system includes modules for selection and calculation of mold components. It uses Pro/E modules Pro/Program and Pro/Toolkit, and consists of modules for mold selection, modification and design. Deng et al. [6, 7] analyzed development of the CAD/CAE integration. The authors also analyzed systems and problems of integration between CAD and CAE systems for numerical simulation of injection molding and mold design. Authors propose a feature ontology consisting of a number of CAD/CAE features. This feature represents not only the geometric information of plastic part, but also the design intent is oriented towards analysis. Part features contain the overall product information of a plastic part, wall features, development features (such as chamfer, ribs, boss, hole, etc.), treatment features which contain analysis-related design information and sub wall developed features. Wall and development features are so called “component features〞. God ec et al. [8, 9] developed a CAE system for mold design and injection molding parameters calculations. The system is based on morphology matrix and decision diagrams. The system is used for thermal, rheological and mechanical calculation, and material base management,Fig. 1 General structure of integrated injection mold design system for plastic productsbut no integration with commercial CAx software is provided. Huang et al. [10] developed a mold-base design system for injection molding. The database they used was parametric and feature-based oriented. The system used Pro/E for modeling database components. Kong et al. [11]developed a parametric 3D plastic injection mold design system integrated with solid works. Other knowledge-based systems, such as IMOLD, ESMOLD, IKMOULD, and IKBMOULD, have been developed for injection mold design. IMOLD divides mold design into four major steps; parting surface design, impression design, runner system design, and mold-base design. The software uses a knowledge-based CAD system to provide an interactive environment, assist designers in the rapid completion of mold design, and promote the standardization of the mold design process. IKB-MOULD application consists of databases and knowledge bases for mold manufacturing. Lou et al. [12] developed an integrated knowledge-based system for mold base design. The system has module for impression calculation, dimension calculation, calculation of the number of mold plates and selection of injection machine. The system uses Pro/ Mold Base library. This paper describes KBS and key technologies, such as product modeling, the frame-rule method, CBS, and the neural networks. A multilayer neural network has been trained by back propagation BP. This neural network adopts length, width, height and the number of parts in the mold as input and nine parameters (length, width, and height of up and down set-in, mold bases side thickness, bottom thickness of the core, and cavity plates) as output. Mok et al. [13, 14] developed an intelligent collaborative KBS for injection molds. Mok at el. [15] has developed an effective reuse and retrieval system that can register modeled standard parts using a simple graphical user interface even though designers may not know the rules of registration for a database. The mold design system was developed using an Open API and commercial CAD/computer aided manufacturing (CAM)/CAE solution. The system was applied to standardize mold bases and mold parts in Hyundai Heavy Industry. This system adopted the method of design editing, which implements the master model using features. The developed system provides methods whereby designers can register the master model, which is defined as a function of 3D CAD, as standard parts and effectively reuse standard parts even though they do not recognize the rules of the database.Todic et al. [16] developed a software solution for automated process planning for manufacturing of plastic injection molds. This CAD/CAPP/CAM system does not provide CAE calculation of parameters of injection molding and mold design. Maican et al. [17] used CAE for mechanical, thermal, and rheological calculations. They analyzed physical, mechanical, and thermal properties of plastic materials. They defined the critical parameters of loaded part. Nardinet al. [18] tried to develop the system which would suit all the needs of the injection molding for selection of the part–mold–technology system. The simulation results consist of geometrical and manufacturing data. On the basis of the simulation results, part designers can optimize part geometry, while mold designers can optimize the running and the cooling system of the mold. The authors developed a program which helps the programmers of the injection molding machine to transfer simulation data directly to the machine. Zhou et al. [1] developed a virtual injection molding system based on numerical simulation. Ma et al. [19] developed standard component library for plastic injection mold design using an object-oriented approach. This is an objector iented, library model for defining mechanical components parametrically. They developed an object-oriented mold component library model for incorporating different geometric topologies and non-geometric information. Over the years, many researchers have attempted to automate a wholeFig. 2 Structure of module for numerical simulation of injection molding processFig. 3 Forms to define the mold geometrymold design process using various knowledge-based engineering (KBE) approaches, such as rule-based reasoning (RBR), and case base (CBR) and parametric design template (PDT). Chan at al. [20] developed a 3D CAD knowledge-based assisted injection mold design system (IKB mold). In their research, design rules and expert knowledge of mold design were obtained from experienced mold designers and handbooks through various traditional knowledge acquisition processes. The traditional KBE approaches, such as RBR, CBR, and simple PDT have been successfully applied to mold cavity and runner layout design automation of the one product mold. Ye et al. [21] proposed a feature-based and object-oriented hierarchical representation and simplified symbolic geometry approach for automation mold assembly modeling. The previously mentioned analysis of various systems shows that authors used different ways to solve the problems of mold design by reducing it to mold configureator (selector). They used CAD/CAE integration for creating precision rules for mold-base selection. Many authors used CAE system for numerical simulation of injection molding to define parameters of injection molding. Several also developed original CAE modules for mold and injection molding process calculation. However, common to all previously mentioned systems is the lack of module for calculation of mold and injection molding parameters which would allow integration with the results of numerical simulation. This leads to conclusion that there is a need to create a software system which integrates parameters of injection molding with the result obtained by numericalFig. 4 Forms to determine the distance between the cooling channels and mold cavityFig. 5 Mold-base selector formssimulation of injection molding, mold calculation, and selection. All this would be integrated into CAD/CAE-integrated injection mold design system for plastic products.2 Structure of integrated CAD/CAE systemAs is well known, various computational approaches for supporting mold design systems of various authors use design automation techniques such as KBE (RBR, CBR, PDT) or design optimisation techniques such as traditional (NLP,LP, BB, GBA, IR, HR) or meta heuristic search such as (TS, SA, GA) and other special techniques such as (SPA, AR, ED).The developed interactive software system makes possible to perform: 3D modeling of the parts, analysis of part design and simulation model design, numerical simulation of injection molding, and mold design with required calculations.The system consists of four basic modules:& Module for CAD modeling of the part& Module for numerical simulation of injection molding processFig. 6 Form for mechanical mold calculation& Module for calculation of parameters of injection molding and mold design calculation and selection& Module for mold modeling (core and cavity design and design all residual mold components) The general structure of integrated injection mold design system for plastic products is shown in Fig. 1.2.1 Module for CAD modeling of the part (module I)The module for CAD modeling of the part is the first module within the integrated CAD/CAE system. This module is used for generating CAD model of the plastic product and appropriate simulation model. The result of this module is solid model of plastic part with all necessary geometrical and precision specifications. Precision specifications are: project name, number, feature ID, feature name, position of base point, code number of simulation annealing, trade material name, material grade, part tolerance, machine specification (name, clamping force, maximal pressure, dimensions of work piece), and number of cavity. If geometrical and precision specification is specified (given) with product model, the same are used as input to the nextmodule, while this module is used only to generate the simulation model.2.2 Module for numerical simulation of injection molding process (module II)Module II is used for numerical simulation of injection molding process. User implements an iterative simulation process for determining the mold ability parameters of injection molding and simulation model specification. The structure of this module is shown in Fig. 2.After a product model is imported and a polymer is selected from the plastic material database, user selects the best location for gating subsystem. The database contains rheological, thermal, and mechanical properties of plastic materials. User defines parameters of injection molding and picks the location for the gating subsystem. Further analyses are carried out: the plastic flow, fill time, injection pressure, pressure drop, flow front temperature, presence of weld line, presence of air traps, cooling quality, etc.The module offers four different types of mold flow analysis. Each analysis is aimed at solving specific problems:& Part analysis—This analysis is used to test a known gate location, material, and part geometry to verify that a part will have acceptable processing conditions.& Gate analysis—This analysis tests multiple gate locations and compares the analysis outputs to determine the optimal gate location.& Sink mark analysis—This analysis detects sink mark locations and depths to resolve cosmetic problems before the mold is built eliminating quality disputes that could arise between the molder and the customer.The most important parameters are the following: [22]& Part thickness& Flow length& Radius and drafts,& Thickness transitions& Part material& Location of gates& Number of gates& Mold temperature& Melt temperature& Injection pressure& Maximal injection molding machine pressureIn addition to the previously mentioned parameters of injection molding, the module shows following simulation results: welding line position, distribution of air traps, the distribution of injection molding pressure, shear stressFig. 7 Segment of the mechanical calculation algorithmdistribution, temperature distribution on the surface of the simulation model, the quality of filling of a simulation model, the quality of a simulation model from the standpoint of cooling, and time of injection molding [22, 23]. A part of output results from this module are the input data for thenext module. These output results are: material grade and material supplier, modulus of elasticity in the flow direction, modulus of elasticity transverse direction, injection pressure, ejection temperature, mold temperature, melting temperature, highest melting temperature thermoplastic, thermoplastic density in liquid and solid state, and maximum pressure of injection molding machine. During implementation of iterative SA procedure, user defines the moldability simulation model and the parameters of injection molding. All results are represented by different colors in the regions of the simulation model.2.3 Module for calculation of parameters of injection molding and mold design calculation and selection (module III)This module is used for analytical calculations, mold sizing, and its selection. Two of the more forms for determining the dimensions of core and cavity mold plates are shown in Fig. 3.Based on the dimensions of the simulation model and clamping force (Fig. 3) user selects the mold material and system calculates the width and length of core and cavity plates. Wall thickness between the mold cavity to the cooling channel can be calculated with the following three criteria: criterion allowable shear stress, allowable bending stress criterion, and the criterion of allowable angle isotherms are shown in Fig. 4 [22, 24]. The system adopts the maximum value of comparing the values of wall thickness calculated by previously mentioned criteria.Fig. 8 Forms for standard mold plates selectionFig. 9 Forms for mold plate model generationBased on the geometry of the simulation model, user select shape and mold type. Forms for the selection mold shape, type, and subsystems are shown in Fig. 5. Once these steps are completed, user implements the thermal, rheological, and mechanical calculation of mold specifications. An example of one of the several forms for mechanical mold calculation is shown in Fig. 6.Segment of the algorithm of mechanical calculations is shown in Fig. 7.f max maximal flexure of cavity platef dop allowed displacement of cavity plateε elastic deformationαmin minimal value of shrinkage factorE k modulus of elasticity of cavity plateG shear modulusS k wall thickness distance measuring between cavity and waterlined KT cooling channel diameterAfter the thermal, rheological, and mechanical calculations, user selects mold plates from the mold base. Form for the selection of standard mold plates is shown in Fig. 8. The system calculates the value of thickness of risers, fixed, and movable mold plates (Fig. 8). Based on the calculated dimensions, the system automatically adopts the first major standard value for the thickness of risers, movable, and fixed mold plate. Calculation of the thickness and the adoption of standard values are presented in the form as shown in Fig. 8.The interactive system recommends the required mold plates. The module loads dimensions from the database and generates a solid model of the plate. After the plate selection, the plate is automatically dimensioned, material plate isFig. 10 Structure of module IVassigned, and 3D model and 2D technical drawing are generated on demand. Dimensions of mold component (e.g., fixed plate) are shown in the form for mold plate mode generation, as shown inThe system loads the plate size required from the mold base. In this way, load up any other necessary standard mold plates that make up the mold subassembly. Subassembly mold model made up of instance plates are shown in Fig. 10Then get loaded other components of subsystems as shown in Fig. 5. Subsystem for selection other components include bolts and washers. The way of components selection are based on a production rules by authors and by company “D-M-E〞[25, 26].2.4 Module for mold modeling (core and cavity design and design all residual mold components; module IV)This module is used for CAD modeling of the mold (core and cavity design). This module uses additional software tools for automation creating core and cavity from simulation (reference) model including shrinkage factor of plastics material and automation splitting mold volumes of the fixed and movable plates. The structure of this module is shown in Fig. 11.Additional capability of this module consists of software tools for:& Applying a shrinkage that corresponds to design plastic part, geometry, and molding conditions, which are computed in module for numerical simulation& Make conceptual CAD model for nonstandard plates and mold components& Design impression, inserts, sand cores, sliders and other components that define a shape of molded part& Populate a mold assembly with standard components such as new developed mold base which consists of DME mold base and mold base of enterprises which use this system, and CAD modeling ejector pins, screws, and other components creating corresponding clearance holes& Create runners and waterlines, which dimensions was calculated in module for calculating of parameters of injection molding and mold design calculation and selection& Check interference of components during mold opening, and check the draft surfacesAfter applied dimensions and selection mold components, user loads 3D model of the fixed (core) and movable (cavity) plate. Geometry mold specifications, calculated in the previous module, are automatically integrated into this module, allowing it to generate the final mold assembly. Output from this module receives the complete mold model of the assembly as shown in Fig. 15. Thismodule allowsFig. 11 Subassembly model of moldFig. 12 CAD model of the test Productmodeling of nonstandard and standard mold components that are not contained in the mold base.3 Case studyThe complete theoretical framework of the CAD/CAE-integrated injection mold design system for plastic products was presented in the previous sections. In order to complete this review, the system was entirely tested on a real case study. The system was tested on few examples of similar plastic parts. Based on the general structure of the model of integrated CAD/CAE design system shown in Fig. 1, the authors tested the system on some concrete examples. One of the examples used for verification of the test model of the plastic part is shown in Fig. 12.The module for the numerical simulation of injection molding process defines the optimal location for setting gating subsystem. Dark blue regions indicate the optimal position for setting gating subsystem as shown in Fig. 13.Based on dimensions, shape, material of the case study product (Fig. 11), optimal gating subsystem location (Fig. 13), and injection molding parameters (Table 1), the simulation model shown in Fig. 14 was generated.One of the rules for defining simulation model gate for numerical simulation:IF (tunnel, plastic material, mass) THEN prediction dimension (upper tunnel, length, diameter1, diameter2, radius, angle, etc.)Part of the output results from module II, which are used in module III are shown in Table 1.Fig. 13 Optimal gating subsystem location in the partTable 1 Part of the output results from the module for the numerical simulation of injection molding processMaterial grade and material supplier Acrylonitrile butadiene styrene 780(ABS 780),Kumho Chemicals Inc.Max injection pressure 100 MPaMold temperature 60°C ili 40Melt Temperature 230°CInjection Time 0,39 s 0,2 sInjection Pressure 27,93 MPaRecommended ejection temperature 79°CModulus of elasticity, flow direction for ABS 780 2,600 MPaModulus of elasticity, transverse direction for ABS 780 2,600 MPaPoision ratio in all directions for ABS 780 0.38Shear modulus for ABS 780 942 MPaDensity in liquid state 0.94032 g/cm3Density in solid state 1.047 g/cm3In module III, the system calculates clamping force F=27.9 kN (Fig. 3), cooling channel diameter d KT=6 mm, cooling channel length lKT090 mm (Fig. 4). Given the shape and dimensions of the simulation model, square shape of mold with normal performance was selected as shown in Fig. 5. Selected mold assembly standard series: 1,616, length and width of mold housing 156×156 mm as shown in Fig. 8. In the segment of calculation shown in Fig. 8, mold design system panel recommends the following mold plates:& Top clamping plate N03-1616-20& Bottom clamping plate N04-1616-20& Fixed mold plate (core plate) N10A-1616-36& Movable plate (cavity plate) N10B-1616-36& Support plate N20-1616-26& Risers N30-1616-46& Ejector retainer plate N40-1616-10& Ejector plate N50-1616-12After finishing the fixed and movable mold plates from the standpoint of CAD modeling core and cavity plates, cooling channel, followed by manual selection of other mold standard components such as sprue bush, locating ring, guide pins, guide bush, leading bushing guide, spacer plates, screws (M4×10, M10×100, M10×30, M6×16, M10×30, etc.) and modeling nonstandard mold components (if any) ejector pins, ejector holes, inserts etc. A complete model of the mold assembly with tested simulation model is shown in Fig. 15.Fig. 14 Simulation model of plastic partFig. 15 Model of the mold assembly with tested simulation model4 ConclusionThe objective of this research was to develop a CAD/CAE integrated system for mold design which is based on Pro/ ENGINEER system and uses specially designed and developed modules for mold design. This paper presents a software solution for multiple cavity mold of identical molding parts, the so-called one product mold. The system is dedicated to design of normal types of molds for products whose length and width are substantially greater than product height, i.e., the system is customized for special requirements of mold manufacturers. The proposed system allows full control over CAD/CAE feature parameters which enables convenient and rapid mold modification. The described CAD/CAE modules are feature-based, parametric, based on solid models, and object oriented. The module for numerical simulation of injection molding allows the determination selection of injection molding parameters. The module for calculation of parameters of injection molding process and mold design calculation and selection improves design Fig. 15 Model of the mold assembly with tested simulation model faster, reduces mold design errors, and provides geometric and precision information necessary for complete mold design. The knowledge base of the system can be accessed by mold designers through interactive modules so that their own intelligence and experience can also be incorporated into the total mold design. Manufacture of the part confirms that the developed CAD/CAE system provides correct results and proves to be a confident software tool.Future research will be directed towards three main goals. The first is to develop a system for automation of family mold design. Another line of research is the integration with CAPP system for plastic injection molds manufacturing developed at the Faculty of Technical Sciences. Finally, following current trends in this area, a collaborative system using web technologies and blackboard architecture shall be designed and implemented.塑料制品的CAD / CAE集成的注塑模具设计系统摘要：模具设计是一个知识密集的过程。

外文资料翻译系部：专业：姓名：学号：外文出处：dvanced English literacy course（用外文写）附件：指导老师评语签名：年月日第一篇译文（中文）2.3注射模2.3.1注射模塑注塑主要用于热塑性制件的生产，它也是最古老的塑料成型方式之一。

目前，注塑占所有塑料树脂消费的30%。

典型的注塑产品主要有杯子器具、容器、机架、工具手柄、旋钮（球形捏手）、电器和通讯部件（如电话接收器），玩具和铅管制造装置。

聚合物熔体因其较高的分子质量而具有很高的粘性；它们不能像金属一样在重力流的作用下直接被倒入模具中，而是需要在高压的作用下强行注入模具中。

因此当一个金属铸件的机械性能主要由模壁热传递的速率决定，这决定了最终铸件的晶粒度和纤维取向，也决定了注塑时熔体注入时的高压产生强大的剪切力是物料中分子取向的主要决定力量。

由此所知，成品的机械性能主要受注射条件和在模具中的冷却条件影响。

注塑已经被应用于热塑性塑料和热固性塑料、泡沫部分，而且也已经被改良用于生产反应注塑过程，在此过程中，一个热固树脂系统的两个组成部分在模具中同时被注射填充，然后迅速聚合。

然而大多数注塑被用热塑性塑料上，接下来的讨论就集中在这样的模具上。

典型的注塑周期或流程包括五个阶段（见图2-1）：（1）注射或模具填充；（2）填充或压紧；（3）定型；（4）冷却；（5）零件顶出。

图2-1 注塑流程塑料芯块（或粉末）被装入进料斗，穿过一条在注射料筒中通过旋转螺杆的作用下塑料芯块（或粉末）被向前推进的通道。

螺杆的旋转迫使这些芯块在高压下对抗使它们受热融化的料筒加热壁。

加热温度在265至500华氏度之间。

随着压力增强，旋转螺杆被推向后压直到积累了足够的塑料能够发射。

注射活塞迫使熔融塑料从料筒，通过喷嘴、浇口和流道系统，最后进入模具型腔。

在注塑过程中，模具型腔被完全充满。

当塑料接触冰冷的模具表面，便迅速固化形成表层。

由于型芯还处于熔融状态，塑料流经型芯来完成模具的填充。

附录1：外文翻译微通道注塑成型模具设计大规模生产微流体装置对于其中的生物医学应用是重要的一次性设备被广泛使用。

注射成型是一种众所周知的生产方法的设备以大规模低成本。

在这项研究中，注塑过程适用于制造具有单个微通道的微流体装置。

至提高产品质量，采用高精度机械加工制造的微流体装置的模具。

常规注塑机是在这个过程中实现的。

在不同的模具温度下进行注模。

通过测量部件变形来表征注射件的翘曲。

评估了模具温度对最终装置质量的影响在零件变形和粘接质量方面。

从实验结果来看，翘曲和模制件的粘合质量之间的一致性被观察。

发现随着片的翘曲减小，粘接质量下降增加。

接合断裂压力的最大值和最小值在相同的模具温度下发现翘曲点。

这个模具温度被命名为设计的微流体装置的最佳温度。

它是观察到在45℃的模具温度下产生的微流体装置能够承受高达74巴的压力1介绍微流体装置的微尺度和纳米级制造是一种学术研究和行业的热门话题。

重复，高效，大规模生产的微流体装置是对于一次性设备的生物医学应用而言至关重要广泛使用。

当微流体装置的制造是关心，基本上有两种常见的方法：直接基板制造和基于模具的技术。

直接底物制造包括蚀刻，激光烧蚀和机械加工。

另一方面，基于模具的技术包括软光刻，热压花和注射成型。

虽然模具的制造可能是复杂的;一旦模具该模具可以很好地被使用好几次。

之后完成模具，其余的制造程序是简单且高度可重现（即，低成本复制）使基于模具的技术非常适合批量生产。

在基于模具的技术中，注塑成型是一个很好的成型宏观尺度的制造工艺（尺寸大于毫米），其中熔化的材料被注入进入模具以获得所需的形状。

使用的材料一般通过陶瓷和金属的塑料也可以用塑料模塑粘合剂。

在此过程中，材料被供应到加热桶，混合，并强制进入其中冷却的模具腔并根据腔体的形状固化[1]。

一旦已经制造了一个模具，可以有几千个零件模仿了很少或没有额外的努力。

产品好尺寸公差和过程几乎不需要完成对最终产品的操作。

考虑到这些方面，注射成型是制造零件的流行制造工艺在大规模上广泛应用于航空航天，汽车，医疗，玩具和光学[2]。

注塑模具产品开发中英⽂对照外⽂翻译⽂献中英⽂对照外⽂翻译⽂献(⽂档含英⽂原⽂和中⽂翻译)参数化建模滚珠丝杠主轴摘要产品开发过程的数值优化可以成功地应⽤于产品设计的早期阶段。

在滚珠丝杠驱动器很常见的情况下，动态现象⼤多数根据滚珠丝杠本⾝的⼏何形状⽽定。

轴向和扭转刚度相同的丝杠，最⼤速度和加速度不仅取决于伺服电机，也取决于丝杆直径，凹槽斜率和球半径。

此外联轴器的设计参数影响使优化变得更加困难。

为了捕捉这些影响，有效的数据（通常是有限元或MBS）模型是必要的。

在这项⼯作中，⼀个新的更准确和有效的计算滚珠丝杠主轴轴向和扭转刚度被提出。

我们分析得到描绘的丝杠⼏何参数对⼤多数刚度的依赖关系的参数⽅程。

此外，我们增加⼀个确定函数的分析模型，从⽽提⾼了准确性。

在许多例⼦帮助下，所提出的分析模型针对有限元模型和⽬录数据进⾏了验证。

1 绪论滚珠丝杠主轴的轴向和扭转刚度中对滚珠丝杠驱动器动态特性起着重要作⽤，因为它基本上决定了滚珠丝杠驱动器的第⼀个和第⼆个特征值。

当⽤有限元建模时，滚珠丝杠驱动器的螺纹通常被忽略并且⼀些平均直径被⽤来建⽴简化的滚珠丝杆模型。

因此，关键是得到最接近的平均直径。

在⼤多数关于前⼈建模与仿真下，滚珠丝杆传动建模集中在滚珠丝刚螺母和滚珠丝杠主轴部件。

Jarosch ⽐较了不同类型的滚珠丝杠，但考虑到主轴简化为圆柱体，直径等于主轴外径，从⽽忽视了削减主轴螺纹。

随着了解的实际轴向uz k 和单位长度的螺杆扭转刚度z k ?，平均直径可以被计算为E k d uzuz m π4,= （1） 4,32G k d zz m π??= （2）杨⽒模量和剪切模量分别为E 和G 。

平均直径总是⽐主轴外径⼩。

对于每个刚度我们得到两个不同的平均直径。

这取决于每个应⽤的平均直径的最好选择。

这两个直径也可以做到线性组合。

⼀般滚珠丝杠制造商提供轴向刚度数据，但没有扭转刚度。

基于这个原因我们使⽤有限元法（FEM ）来计算两者滚珠丝杠主轴轴向和扭转刚度。

Injection mold design and the new-type injekt by shaping technologeThe plastic injection mold is in the present all plastics mold，uses the broadest mold, can take shape the complex high accuracy，plastic product. Under only is sketchily introduces.The design plastic injection mold first must have the certain，understanding to the plastic, the plastic principal constituent is a polymer. Like we often said the ABS plastic then is the propylene nitrile, the pyprolylene, the styrene three kind of monomers uses the emulsion, the main body or aerosol gathers the legitimate production,enable it to have three kind of monomers the high performance and may the compression molding, injects under the certain temperature and the pressure to the mold cavity, has the flow distortion, the obtaining cavity shape, after guarantees presses cooling to go against becomes the plastic product. The polymer member assumes the chain shape structure generally, the linear molecule chain and a chain molecule thought is the thermoplastic, may heat up the cooling processing repeatedly, but passes through heats up many members to occur hands over the association response, including forms netted the build molecular structure plastic usually is this, cannot duplicate injects the processing, also is the thermosetting plastics which said.Since is the chain shape structure, that plastic when processing contracts the direction also is with the polymer molecular chain under the stress function the orientation and the cooling contraction related, must be more than in the flow direction contraction its vertical direction in contraction. The product contraction also with the product shape, therunner, the temperature,guarantees presses factor and so on time and internal stress concerns.In the usual book provides the shrinkage scope is broad, considers is product wall thickness, the structure and the determination casts the temperature pressure size when the practical application and the orientation. The common product if does not have the core strut, the contraction correspondingly wants big. The plastic casts the mold basically to divide into the static mold and to move the mold. Injection Molding . Injection molding is principally used for the production of thermolplastic part ,although some progress has been made in developing a method for injection molding some thermosetting materials .The problem of injecting a melted plastic into a mold cavity from a reservoir of melted material has been extremely difficult to solve for thermosetting plastics which cure and harden under such conditions within a few minutes 。

The introdution of the Injection Mold1. Mold basic knowledge1.1 IntroductionThere is a close relationship with all kinds of mold,which are refered to our daily production, and life in the use of the various tools and products, the large base of the machine tool, the body shell, the first embryo to a small screws, buttons, as well as various home appliances shell. Mold’s shape determine the shape of these products, mold’s precision and machining quality determine the quality of these products,too. Because of a variety of products, appearance, specifications and the different uses,mold devide into Die Casting into the mould, die forging, die-casting mould, Die, and so on other non - plastic molds, as well as plastic mold. In recent years, with the rapid development of the plastics industry, and GM and engineering plastics in areas such as strength and accuracy of the continuous enhancement , the scope of the application of plastic products have also constantly expanded, such as: household appliances, instrumentation, construction equipment, automotive, daily hardware, and many other fields, the proportion of plastic products is rapidly increasing. A rational design of plastic parts often can replace much more traditional metal pieces. The trend of industrial products and daily products plasticed is rising day after day.1.2 Mold general definitionIn the industrial production，with the various press and the special instruments which installed in the press,it produces the required shape parts or products through pressure on the metal or non-metallic materials, this special instruments collectively call as the mold.1.3 Mold general classificationMold can be divided into plastic and non - plastic mould: (1) Non-plastic mould: Die Casting, forging Die, Die, die-casting mould and so on. A. Die Casting - taps, pig iron platformB. Forging Die - car body C. Die - computer panel D. Die Casting Die - superalloy, cylinder body (2) For the production technology and production, the plastic mold are divided into different products: A. Injection molding die - TV casing, keyboard button (the most common application) B. Inflatable module - drink bottles C. Compression molding die - bakeliteswitches, scientific Ciwan dish D. Transfer molding die - IC products E. Extrusion die - of glue, plastic bags F. Hot forming die - transparent shell molding packaging G. Rotomoulding mode - Flexible toy doll. Injection Molding is the most popurlar method in plastics producing process. The method can be applied to all parts of thermoplastic and some of thermosetting plastics, the quantity of plastic production is much more than any other forming method.Injection mold as one of the main toolsof injection molding processing,whosh production efficiency is low or high in the quality of precision、manufacturing cycle and the process of injection molding and so on,directly affect the quality of products, production, cost and product updates, at the same time it also determines the competitiveness of enterprises in the market's response capacity and speed. Injection Mold consists of a number of plate which mass with the various component parts. It divided into: A molding device (Die, punch)B positioning system (I. column I. sets) C fixtures (the word board, code-pit) D cooling system (carrying water hole) E thermostat system (heating tubes, the hotline) F-Road System (jack Tsui hole, flow slot, streaming Road Hole) G ejection system (Dingzhen, top stick).1.4 Type of moldIt can be divided into three categories according to gating system with the different type of mold :(1) intake die: Runner and gate at the partig line,it will strip together with products when in the open mode,it is the most simple of design, easy processing and lower costing.So more people operations by using large intake system. (2) small inlet die:It general stay in the products directly,but runner and gate are not at the partig line.Therefore,it should be design a multi-outlet parting line.And then it is more complex in the designing, more difficult in processing, generally chosing the small inlet die is depending on the product’s requirements. (3) hot runner die:It consists of heat gate, heat runner plate, temperature control box. Hot runner molds are two plate molds with a heated runner system inside one half of the mold. A hot runner system is divided into two parts: the manifold and the drops. The manifold has channels that convey the plastic on a single plane, parallel to the parting line, to a point above the cavity. The drops, situated perpendicular to the manifold, convey the plastic from the manifold to the part. The advantages of hot runner system ：(1)No outlet expected, no need processing, the whole process fully automated, save time and enhance the efficiency of the work. (2) small pressure loss.2、Injection MoldThere are many rules for designing molds.These rules and standard practices are based on logic,past experience,convenience,and economy.For designing,mold making,and molding,it is usually of advantage to follow the rules.But occasionally,it may work out better if a rule is ignored and an alternative way is selected.In some texts,the most common rules are noted,but the designer will learn only from experience which way to go.The designer must ever be open to new ideas and methods,to new molding and mold material that may affect these rules.The process consists of feeding a plastic compound in powdered or granular form from a hopper through metering and melting stages and then injecting it into a mold.Injection molding process: Mold is a production of plastic tool. It consists of several parts and this group contains forming cavities. When it injects molding, mold clamping in the injection molding machine, melting plastic is Injected forming cavities and cooling stereotypes in it, then it separate upper and lower die,it will push the production from the cavity in order to leave the mold through ejection system, finally mold close again and prepared the next injection. The entire process of injection is carried out of the cycle.An injection mold consists of at least two halves that are fastened to the two platens of the injection molding machine so that can be opened and closed.In the closed position,the product-forming surfaces of the two mold halves define the mold cavity into which the plastic melt is injected via the runner system and the gate.Cooling provisions in the mold provide for cooling and solidification of the molded product so that it can be subsequently ejected.For product ejection to occur,the mold must open.The shape of the molded product determines whether it can be ejected simply by opening the two mold halves or whether undercuts must be present.The design of a mold is dictated primarily by the shape of the product to be molded and the provisions necessary for product ejection.Injection-molded products can be classified as:1).Products without undercuts.2).products with external undercuts of lateral openings.3).products with internal undercuts.4).products with external and internal undercuts.3.The composition of injection mold3.1 Mold Cavity SpaceThe mold cavity space is a shape inside the mold,when the molding material is forced into this space it will take on the shape of the cavity space.In injection molding the plastic is injected into the cavity space with high pressure,so the mold must be strong enough to resist the injection pressure without deforming.3.2 Number of CavitiesMany molds,particularly molds for larger products,ate built for only 1 cavity space,but many molds,especially large production molds,are built with 2 or more cavities.The reason for this is purely economical.It takes only little more time to inject several cavities than to inject one.Today,most multicavity molds are built with a preferred number ofcavities:2,4,6,8,12,16,24,32,48,64,96,128.These numbers are selected because the cavities can be easily arranged in a rectangular pattern,which is easier for designing and dimensioning,for manufacturing,and for symmetry around the center of the machine ,which is highly desirable to ensure equal clamping force for each cavity.3.3 Cavity and CoreBy convention,the hollow portion of the cavity space is called the cavity.The matching,often raised portion of the cavity space is called the core.Most plastic products are cup-shaped.This does not mean that they look like a cup,but they do have an inside and an outside.The outside of the product is formed by the cavity, the inside by the ually,the cavities are placed in the mold half that is mounted on the injection side,while the cores are placed in the moving half of the mold.The reason for this is that all injection molding machines provide an ejection mechanism on the moving platen and the products tend to shrink onto and cling to the core,from where they are then ejected.Most injection molding machines do not provide ejection mechanisms on the injection side.For moulds containing intricate impressions,and for multi-impression moulds, it is not satisfactory to attempt to machine the cavity and core plates from single blocks of steel as with integer moulds. The cavity and core give the molding its external and internal shapes respectively, the impression imparting the whole of the form to the molding.3.4 The Parting LineTo be able to produce a mold,we must have ta least two separate mold halves,with the cavity in one side and the core in the other.The separation between these plates is called the parting line,and designated P/L.Actually,this is a parting area or plane,but,by cinvention,in this intext it is referred to as a line. The parting surfaces of a mould are those portion of both mould plates, adjacent to the impressions, which butt together to form a seal and prevent the loss of plastic material from the impression.The parting line can have any shape, many moldings are required which have a parting line which lies on a non-planar or curved surface,but for ease of mold manufacturing,it is preferable to have it in one plane.The parting line is always at the widest circumference of the product,to make ejection of the product from the mold possible.With some shapes it may be necessary to offset the P/L,or to have it at an angle,but in any event it is best to have is so that itan be easily machined,and often ground, to ensure that it shuts off tightly when the mold is clamped during injection.If the parting line is poorly finished the plastic will escape,which shows up on the product as an unsightly sharp projection,which must then be removed;otherwise,the product could be unusable.There is even a danger that the plastic could squirt out of the mold and do personal danger.3.5 Runners and GatesNow,we must add provisions for bringing the plastic into these cavity spaces.This must be done with enough pressure so that the cavity spaces are filled completely before the plastic "freezes"(that is,cools so much that the plastic cannot flow anymore).The flow passages are the sprue,from wherethe machine nozzle contactss the mold,the runners,which distribute the plastic to the individual cavities, the wall of the runner channel must be smooth to prevent any restriction to flow. Also, as the runner has to be removed with the molding, there must be no machine marks left which would tend to retain the runner in the mould plate.And the gates which are small openings leading from the runner into the cavity space. The gate is a channel or orifice connecting the runner with the impression. It has a small cross-sectional area when compared with the rest of the feed system. The gate freezes soon after the impression is filled so that the injection plunger can be withdrawn without the probability of void being created in the molding by suck-back.4. The injection molding machine processInjection Mold is installed in the injection molding machine, and its injection molding process is completed by the injection molding machine. Following is the injection molding machine process.The molding machine uses a vacuum to move the plastic from the dryer to it's initial holding chamber. This chamber is actually a small hopper on the back of the "barrel" of the machine。