摘要
塑料工业是国民经济中的一个非常重要的行业,引起了人们的关注,获得了迅速的发展。塑料由于本身的优点,在工程中得到越来越多的应用,在汽车、家电、仪器仪表、建筑装饰等领域得到了广泛的应用。注塑成型在整个塑料制品生产行业占有非常重要的地位。在汽车行业中,正朝着塑料化的趋势发展,更多的汽车部件正用塑料代替传统的金属材料。塑料成型CAE技术是当前塑料加工行业的研究热点,但是当前的注射成型CAE技术仍存在一系列的问题。
本论文是针对汽车零部件塑料化发展,对注塑制件的要求越来越高的趋势提出的。文中分析了汽车复杂注塑件成型工艺的研究背景及意义,塑料零部件设计技术的国内外研究状况,汽车零部件塑料化发展趋势,国内外汽车外饰件材料的研究开发状况,注塑制品易出现的缺陷、原因和解决方法,优化理论的发展及在注塑成型设计中的应用。总结得出用数值优化方法分析注塑件的成型工艺具有一定的现实意义。
本文中以汽车外饰件中的观后镜为例子,讨论在塑料原料、注塑机、模具结构等确定的情况下,工艺参数对成型制品质量的影响。以注塑件成型质量中的翘曲量为优化目标,以注射温度、模具温度、注射时间、保压时间、冷却时间为影响翘曲量的工艺参数,实际经验取值范围为参数水平。注塑模拟软件Moldflow为数值翘曲预测手段,以数值模拟得到的数据为实验数据,用正交试验法安排实验数据,通过回归分析、BP神经网络和RBF神经网络,建立预测注塑产品翘曲量的数学模型,并比较其预测精度,得到有效的预测模型。最后在遗传算法中调用得到的数学模型进行寻优,达到对注塑工艺条件的优化,缩短生产时间,提高制件质量。
Plastics industry has been a very important industry in national economy , and caused concerns among people , also gained prompt development. Because of the merit of itself, plastic has got more and more application in many fields,such as automobile, home appliance , instrument appearance , architectural decoration. Injection mould molding is very important in the whole plastics industry. In automobile industry,it has a trend that more and more automobile components are using plastic to replace the tradition metal material. CAE technology for plastic molding is very hot in current plastic processes industry, but there still exists series's problem.
The thesis is according to the trend that more and more automobile components are using plastic and requires high quality. In this thesis, introduced the background and significance of researching injection molding process parameter of complicated vehicle exterior,the technology level of plastic componts home and abroad,the plastic trend of automobile components,the research and development of automobile exterior material home and abroad,analized the default of plastic injection parts and the reason ,the way to solve it,the development and application in injection molding of optimization method. Based to all,we know using numerical optimization method to analyze process parameters in injection molding has practical significance.
In this thesis,using rear view mirror as the model,discussing how the process parameters affects the quality of the model when the material, injection machine , mould structure etc.,are certain. Warpage of the plastic will be set as the goal of the optimization. The injection temperatrure,mold surface temperature,injecting time, filling pressure,cooling time will be set as experiment genes. The value in the range of real project will be set as experiment levels. Injection process and warpage will be canied out in Moldflow. The data from numerical simulation will be arranged by Orthogonal Experiment. Then it will build mathematic model of injection moulding by regression analysis , BP neural networks and RBF neural networks,compare the effects of the three modles,and chose the best one. At last, the best modle is used as a Fit Function in the Genetic Algorithm (GA), with which can give the most appropriate parameter. Based to this thesis ,we can shorten the production time,improve the quality of the plastic part.
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