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* Corresponding author. E-mail: renbin1981@zju.edu.cn Supported by National Natural Science Foundation of China (Grant No. 51205350), Hong Kong Scholars Program of China (Grant No. XJ2013015), and Zhejiang Provincial Research Program of Public Welfare Technology Application of China (Grant No. 2013C31027)
·714·
CHINESE JOURNAL OF MECHANICAL ENGINEERING
Vol. 27,aNo. 4,a2014
DOI: 10.3901/CJME.2014.0508.089, available online at www.springerlink.com; www.cjmenet.com; www.cjmenet.com.cn
1 State Key Laboratory of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, China 2 Department of Civil and Architectural Engineering, City University of Hong Kong, Hong Kong 999077, China
© Chinese Mechanical Engineering Society and Springer-Verlag Berlin Heidelberg 2014
to solve the optimization problem of overall performance of the HT160X1N high-speed injection molding machine. KWAK, et al[7], optimized injection molding conditions using a neural network program based on simulation results. CHEN, et al[8], applied the design of experiments approach to determine an optimal parameter setting of injection molding. LEE, et al[9], established a systematic methodology and knowledge base for an injection-molding mould design in a concurrent engineering environment. FOLGADO, et al[10], compared two mould manufacturing alternatives based on a life cycle cost model. Injection molding machines can inject the melted plastics into the mould to produce plastic product. Many researchers have focused on the design of injection molding machine. A synchronized system has been developed to support conceptual design of injection molding machine on the Internet[11]. Injection molding machines are composed of injection unit, clamping mechanism, injection moulds, hydraulic system, and control system. TSAI, et al[12], presented pragmatic techniques for mechatronic design and injection speed control of an ultra high-speed plastic injection molding machine. BULL, et al[13], have developed a novel wear tester to simulate the conditions of wear for the selection of coatings and surface treatments. JACHOWICZ[14] discussed the factors characterizing the
Structural Scheme Optimization Design for the Stationary Platen of a Precision Plastic Injection Molding Machine
REN Bin1, 2, *, ZHANG Shuyou1, and TAN Jianrong1
Received September 28, 2013; revised February 20, 2014; accepted May 8, 2014
Abstract: The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine. Keywords: finite element analysis, injection molding machine, stationary platen, topology optimization
wenku.baidu.com
1
Introduction ∗
The manufacturing of injection molding machines is one of the world’s fastest growing industries in accompany with the application of plastic production[1–2]. The development of precision injection molding techniques has attracted more and more attention. Precision injection molding techniques include injection molding process and injection molding machines. Injection molding process and mould design have critical effects on the quality of plastic parts. WANG, et al[3], studied on the residual stresses of the thin-walled injection molding. The effects of process conditions were investigated for the analysis and measurement of the deformation of injection molding plastic products[4]. Selection the proper setting for an injection molding process is important to influence the behavior of the polymeric material shaping[5]. DING, et al[6], proposed a new multi-objective optimization algorithm KSVC-SPEA
·714·
CHINESE JOURNAL OF MECHANICAL ENGINEERING
Vol. 27,aNo. 4,a2014
DOI: 10.3901/CJME.2014.0508.089, available online at www.springerlink.com; www.cjmenet.com; www.cjmenet.com.cn
1 State Key Laboratory of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, China 2 Department of Civil and Architectural Engineering, City University of Hong Kong, Hong Kong 999077, China
© Chinese Mechanical Engineering Society and Springer-Verlag Berlin Heidelberg 2014
to solve the optimization problem of overall performance of the HT160X1N high-speed injection molding machine. KWAK, et al[7], optimized injection molding conditions using a neural network program based on simulation results. CHEN, et al[8], applied the design of experiments approach to determine an optimal parameter setting of injection molding. LEE, et al[9], established a systematic methodology and knowledge base for an injection-molding mould design in a concurrent engineering environment. FOLGADO, et al[10], compared two mould manufacturing alternatives based on a life cycle cost model. Injection molding machines can inject the melted plastics into the mould to produce plastic product. Many researchers have focused on the design of injection molding machine. A synchronized system has been developed to support conceptual design of injection molding machine on the Internet[11]. Injection molding machines are composed of injection unit, clamping mechanism, injection moulds, hydraulic system, and control system. TSAI, et al[12], presented pragmatic techniques for mechatronic design and injection speed control of an ultra high-speed plastic injection molding machine. BULL, et al[13], have developed a novel wear tester to simulate the conditions of wear for the selection of coatings and surface treatments. JACHOWICZ[14] discussed the factors characterizing the
Structural Scheme Optimization Design for the Stationary Platen of a Precision Plastic Injection Molding Machine
REN Bin1, 2, *, ZHANG Shuyou1, and TAN Jianrong1
Received September 28, 2013; revised February 20, 2014; accepted May 8, 2014
Abstract: The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine. Keywords: finite element analysis, injection molding machine, stationary platen, topology optimization
wenku.baidu.com
1
Introduction ∗
The manufacturing of injection molding machines is one of the world’s fastest growing industries in accompany with the application of plastic production[1–2]. The development of precision injection molding techniques has attracted more and more attention. Precision injection molding techniques include injection molding process and injection molding machines. Injection molding process and mould design have critical effects on the quality of plastic parts. WANG, et al[3], studied on the residual stresses of the thin-walled injection molding. The effects of process conditions were investigated for the analysis and measurement of the deformation of injection molding plastic products[4]. Selection the proper setting for an injection molding process is important to influence the behavior of the polymeric material shaping[5]. DING, et al[6], proposed a new multi-objective optimization algorithm KSVC-SPEA