很好的模具设计专业英语课程PPT.ppt

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1、Unit Three Mold Constructions Passage One Plastics Forming and Molds Passage Two Three-plate Injection MoldsPassage Three Pressure Casting Dies Passage Four Piercing Die and Blanking Die DesignUnit Three Mold Constructions Passage One Plastics Forming and Molds 1 1 1.General The continuing developme

2、nt of injection mold technolo-gy demands more and more of the processes.The most important problem in the process of injection molding is undoubtedly the correct design of injection mold，because the molding shop has little influence，if any，on the construction of the machine.Efficient production of t

3、he most diverse injection-molded parts depends primarily on the injection mold.The durability of the molds depends on their care and treatment.Since the moving components and cavity of the mold are always hardened and ground，they should produce between 500 000 and 1 000 000 000 shots.Unit Three Mold

4、 Constructions For ease of construction and to lower manufacturing cost，injection molds are becoming standardized.Some firms offer ready-made bases of square or round design as standard or stripper plate molds for immediate use.Only the inserts then have to be fitted into the bases.2.Basic Mold Cons

5、truction （1）Operating Principle Basically the injection mold consists of two halves.One mold half contains the sprue bushing and runner system，the other half houses the ejection system.The molded part is located at the parting line（ref.To DIN 16700）.（2）Single or Multicavity Molds To set up a calcula

6、tion conceiving the choice of cavities in an injection mold requires accurate knowledge of the material to beUnit Three Mold Constructions processed，of the injection-molding machine and of the molds.The mold costs increase with the rising number of cavities and the relative machine costs decrease.Th

7、e production time required for a given molded part depends on the wall thickness，the injection speed，the recovery rate，the time required to cool the molded material，the cooling capacity of the mold and the necessary incidental time such as duration of pressure holding time，ejection time，delay time，e

8、tc.Therefore the decision concerning the number of cavities to be determined depends on:size of the order（number of molded parts in connec-tion with delivery time）;shape of the molded parts（size，quality require-ments）;Unit Three Mold Constructions injection-molding machine（clamping force，plasti-cizi

9、ng and injection capacity）;mold costs.There are several known procedures for calculating the economical number of cavities.Unfortunately they are so varied that it is impossible to condense them.As an example:The theoretical max.number of cavities is:F1=Max.injection volume of machine（cm3）/Volume of

10、 molded parts，sprue and runner（cm3）F2=Plasticizing capacity（cm3/min）/Number of shots/min（part，sprue and runner（cm3）F2 must be equal to or smaller than F1.F1 is the maximum number of cavities attainable.Unit Three Mold Constructions The most important problem in the process of injection molding is un

11、doubtedly the correct design of injection mold，because the molding shop has little influence，if any，on the construction of the machine.注射成型过程中最重要的问题毫无疑问是注射模具的正确设计，因为成型车间对注射件的影响很小，即便有，也是对机器的结构有影响的。句中“if any”引出转折状语从句，译为“即便要”。Notes:New Words and Expressions New Words and Expressions：Unit Three Mold Con

12、structions injection mold注射模具molding shop成型车间，造型车间 injection-molded注射成型的 grind r ind（ground，ground）v.磨削，磨光 single-cavity mold单型腔注射模具 multicavity mold多型腔注射模具 clamping force夹紧力，合模力 plasticize pl stisaiz v.（使）成为可塑;（使）可塑 injection capacity注射容量 ExercisesExercises：Whats the advantage of standardization of

13、 injection molds?Unit Three Mold Constructions From the above，what does the decision concerning the number of cavities to be determined depend on?参考译文：参考译文：塑料成型与模具塑料成型与模具 1.1.概要概要 注射模技术的不断发展需要越来越多的工艺流程。注射成型过程中最重要的问题毫 无疑问是注射模具的正确设计，因为成型车间对注射模具的影响很小，即便有，也是对机器的结构有影响的。高效率地生产各类注射成型零件首先取决于注射模具。模具的使用寿命取决于对

14、它们的维护保养和加工处理，例如对一些活动件及型腔的 表面硬化和磨削加工，使得它们的生产批量可以达到500 0001 000 000 000件。为了简化模具结构和降低制造成本，使注射模具标准化，许多制造商提供了已经生产 好的标准方形或圆形底译Unit Three Mold Constructions Unit Three Mold Constructions 及脱模板供直接使用，仅需要将它们很好地与机座配合起来就可以了。2.2.模具的基本结构模具的基本结构 （1）工作原理 从根本上说，注射模具包括两个部分:一部分包括浇口和浇注系统，另一部分是放置顶出系统。模具零件是在分型面被定位的（参考DIN

15、16700）。（2）单型腔注射模具及多型腔注射模具 注射模具型腔选择等设计计算要求掌握加工材料、注射机和模具等方面的准确知识。模具的制造成本随着型腔数目的增加而增加，而相关的加工费用减少了。一个给定的模具 零件的生产周期取决于壁厚、注射速度、收缩率、模内材料的冷却时间、冷却的效能及必要 的辅助时间，如压力持续时间、排气Unit Three Mold Constructions 时间及延迟时间等。因此确定型腔数量的主要因素涉及以下几点:订单大小（制品数量及相关交货时间）;制品形状（尺寸、质量要求）;注射机（合模力、可塑性、注射容量）;模具费用。尽管已有多种计算经济型腔数目的方法，但这些计算方法多

16、种多样，根本没法将它们 提炼成为简便公式。例如:型腔的理论最大数目为 F1=注射机注射容量的最大值（cm3）/制件、注料口和流道体积（cm3）F2=注塑容量（cm3/min）/制造数量/min（制件、注料口和流道（cm3）F2必须小于等于F1，F1是可得到的型腔数目的最大值。Unit Three Mold Constructions Passage Two Three-plate Injection Molds2 2 Three-plate injection molds are injection molds possessing two parting lines，having been

17、designed as degating molds.This means that the sprue is separated from the parts in the mold.At the conclusion of injection the mold opens at the first parting line，which contains the sprue and runner and separated the pinpoint gate from the part.Only when the second parting line opened，the part wou

18、ld be released.There are several possibilities for achieving this.In Fig.3-1，with short stroke distances of plate 2，compression spring 4 or spring washers can be inserted between plate 1 and plate 2，which push plate 2 forward.The stop 3 limits the stroke.Unit Three Mold Constructions The retention s

19、ystem of plate 1 shown in Fig.3-2 is often employed.Dowel 2 is provided with an annular groove 3 into which the ball catch 4 is pushed.A not too heavy plate can be carried along by the resultant adhesive effect.The plate 2 to be moved in Fig.3-3 is connected to the ejector plates by ejector rods，whi

20、ch in turn are fixed in their basic position by strong spring 3.Plate 2 is carried along until the ejector plates are stopped by running against the ejector bar of the machine.Then only the complete mold body keeps moving on in the usual manner.Care must be taken with this design that the ejector ba

21、r 5 is slightly delayed.Unit Three Mold Constructions Fig.3-1 Spring type 1plate;2push plate;3stop;4compression spring Fig.3-2 Retention system 1plate;2dowel;3annular groove;4ball catchUnit Three Mold Constructions They must not be rigidly connected to the ejector plate;otherwise there would be a te

22、ndency for the parts to be pushed back into the cavities in plate 2.With this design the stroke of plate 2 can be arbitrary.Moreover，when the ejector rods 4 are hardened and guided in bushes，these ejector rods can take over the function of the guide pins fitted on the fixed mold half，so that the spa

23、ce between plates 1 and 2 is not cluttered up with protruding rods or springs.This can be of advantage if a rather complicated runner system has to be designed.Fig.3-4 shows a mechanical type of plate movement.Although more elaborate，it is nevertheless the safest way，particularly if large，heavy plat

24、es have to be moved.The latch 3，which hooks over plate 1，moves the latter along.Unit Three Mold Constructions The movement is continued until the pin 2 in the hook is lifted by the rise in the guide strip 4 on which it runs.The pin has to escape upward，thereby releasing the hook from the plate 2.The

25、 plate now pushes up against a stop，which in this case has been fitted to the underside of the guide strip at 6，and the mold can continue opening.The hook is pushed down again by the leaf spring 5.Fig.3-5 illustrates a typical degating tool.Contrary to the usual mold design，this tool has an addition

26、al mold parting line for the star-shaped runner.Mold constructed on this principle is preferably employed because of the simplicity of the gating technique.But there is some concern that bulky runner often do not drop easily between the mold parting lines.It is important that a sufficiently large ga

27、p always be set.Unit Three Mold Constructions Fig.3-3 Three-plate injection mold 1plate1;2plate2;3spring;4ejector rod;5ejector bar Fig.3-4 Plate movement 1plate;2pin;3latch;4guide strip;5leaf spring;6waterway Unit Three Mold Constructions Fig.3-5 Typical degating tool 1sprue separating area;2latch;3

28、sprue;4retainer pin;5head of bolt;6sprue-stripping plate;7pin;8guide strip;9waterway;10bolt;11main parting line;12ejector rod;13stripper sleeve;14plate assembly;15mold cores Unit Three Mold Constructions At the conclusion of injection the mold first parted at 1 in the sprue separating area when the

29、machine opens.The complete mold block，with the exception of the fixed mold half，is interlocked within itself by the latch 2.As the sprue 3 is held captive by the undercut in the retainer pin 4，the part is severed from the sprue，which stays on the fixed half.When the head of the bolt 5 catches the sp

30、rue-stripping plate 6，this is moved forward，thereby stripping the sprue from the retaining pin 4.When the sequence has been completed，the pin 7 of latch 2 has arrived at the inclined plane of the guide strip Unit Three Mold Constructions 8 in position 9，forcibly lifting the latch and thereby ending

31、the interlock.The head of bolt 10 reached the plates along the fixed position.The continuing sequence of the opening movement consists of tile mold opening at the main parting line 11，thereby creating the drop-out opening for the ejected part.As the opening sequence continues，the head of ejector rod

32、 12 pushes against the ejector of the molding machine and stops the plate assembly 14 as well as the stripper sleeve 13.The mold core 15 fitted into the plate assembly 14 withdraws from the part，and the ejection process is concluded.Unit Three Mold Constructions Contrary to the usual mold design，thi

33、s tool has an additional mold parting line for the star-shaped runner.与通常的模具设计不同，在此模具中为星形流道设计了一个附加的模具分型线。句中“Contrary to”译为“与相反”。At the conclusion of injection the mold first parted at 1 in the sprue separating area when the machine opens.当注射成型结束时，随着机器的打开，模具将首先在浇道分离面1处分型。句中短语“At the conclusion of”译为“

34、当完结时”。Notes:New Words and Expressions New Words and Expressions：Unit Three Mold Constructions three-plate injection mold三板式注射模具 spruespru n.注料口，流道，直浇道 pinpoint gate针孔型浇口 compression spring压缩弹簧 spring washer弹簧垫圈 stopst p n.止动销，制动销，限位器 retention system滞留系统 dowel dau l n.定位销，轴销 annular groove环形凹槽 ball

35、catch门碰球，球掣 ejector plate顶料板 ejector rod顶料杆，出料杆 protruding rod凸出杆，伸出杆 protruding spring凸出弹簧 latchl t n.插销，撞锁，弹簧锁 Unit Three Mold Constructions pinpin n.钉，销leaf spring片弹簧star-shaped runner星形流道 gating technique脉冲选通技术 bulky runner大流道，大浇道 sprue separating area浇道分离面 undercut nd k t v.下（部凹）陷 retainer pin开

36、口销，固定销 sprue-stripping plate注料口分模板 stripping stripi n.抽钉，脱模，拆模 inclined plane倾斜面，斜面 plate assembly板装置，板组合 stripper sleeve分型（模）套 mold core型芯 ExercisesExercises：How many parting lines for a three-plate injection mold?And try to point out where they are in Fig.3-3.Unit Three Mold Constructions Try to e

37、xplain the mechanism of mold release for a three-plate mold.参考译文：参考译文：三板式注射模具三板式注射模具 三板式注射模具是具有两个分型面的注射模具，这种模具带有浇口，也就是直浇道在 模型中和塑件相分离。在注射结束之后，模具沿第一层分型面开模，其中包含了注料口、浇 道和塑件中分流的针孔型浇口。仅当沿第二层分型面开模时，塑件才脱离型芯。有多种可能性来实现这种情况。在图3-1中，模板2具有一个短小的行程距离，压缩弹簧4或弹簧垫圈可以插入模板1 和模板2之间，推动模板2向前，而止动销3则可以限制模板2的行程。在图3-2中，模板1在滞留系统

38、中也经常被使用。定位销2中有一个环形凹槽3可以使球掣4进入，一块不太厚的模板可以沿着黏合面而移动。译Unit Three Mold Constructions Unit Three Mold Constructions 图3-1 弹簧式 1模板;2动模板;3止动销;4压缩弹簧 图3-2 滞留系统 1模板;2定位销;3环形凹槽;4球掣Unit Three Mold Constructions 图3-3中的模板2通过顶料杆和顶料板相连。顶料杆由强度很大的弹簧3依次固定在 它们的基本位置。模板2被移动直到顶料板由于撞上机器的推出杆而停止。当一个完整的模型保持正常方式运行时，需注意推出杆5应设计得稍长

39、 点。图3-3 三板式注射模具1模板1;2模板2;3弹簧;4顶料杆;5推出杆Unit Three Mold Constructions 顶料杆不能和顶料板刚性相连，否则塑件将会有被 推回模板2型腔的可能。对于这种设计，模板2的行程可以是任意的。而且当顶料杆4被加固并且用轴套引导时，这些顶料杆可替代导向销的作用来与定模部分配合，所 以在模板1和模板2之间不能乱放伸出杆或弹簧。如果要设计一个非常复杂的浇道系统，这种方法具有优势。图3-4所示为平板运动的机械形式。虽然这种形式更为精细，但这无疑是最安全的方法，特别是当大而重的平板需要被移动时。挂在模板1上的插销3沿着模板移动，直到销被滑块抬起，销不得

40、不向上移动，所以释放了模板1上的挂钩。这时模板反向止动销向上推，在这种情况下，止动销已在6处与导轨的下侧相配合，所以模具能一直打开。然后，挂钩再一次被片弹簧5向下拉。Unit Three Mold Constructions 图3-4 模板运动 1模板;2销;3插销;4导轨;5片弹簧;6冷却水道 Unit Three Mold Constructions 图图3-5 3-5 典型注塑模具典型注塑模具 1浇道分离面;2、10插销;3直浇道;4固定销;5、10插销头;6注料口分模板;7销;8导轨;9冷却水道;11主要分型线;12预料杆;13分型（模）套;14模板装置;15模具型芯Unit Thre

41、e Mold Constructions 图3-5所示为一典型注塑模具。与通常的模具设计不同，在此模具中为星形流道设计 了一个附加的模具分型线。因为有简单的脉冲选通技术，所以用这种方法设计的模具更适 于使用。但是需要注意的是，通常大浇道不易滴在分型线之间，所以大的间隙设计是非常重要的。当注射成型结束时，随着机器的打开，模具将首先在浇道分离面1处分型。一个完整的具有非固定板的模型装置是通过插销2使它们连接在一起，直浇道3被固定销4中的下陷所约束。塑件从直浇道被切断，直浇道继续停留在固定部分。当插销头5的销头到达注料口分模板6时，这次运动停止，从而直浇道从止动销4中脱模。Unit Three Mo

42、ld Constructions 当运作完成时，插销2中的销7在位置9处沿着导轨8到达倾斜面，强制抬起插销从而结束互锁。插销10的销头沿着固定方向到达模板。开模运动的持续进行由塑料模型在主要分型 线11处的开模组成，从而为喷出部分创造了脱落开模。当开模动作继续进行时，顶料杆12 的杆头推动模具机构的推出器，使板装置14和分型套13停止。装在板装置14中的型芯15 从塑件中退出，从而注射过程结束。Unit Three Mold Constructions Passage Three Pressure Casting Dies 3 3 A pressure casting die is an as

43、sembly of materials，mostly ferrous metals，each of which plays a part in a mechanism which will operate under conditions of rapidly changing temperatures，as the molten metal is injected under pressure and then immediately cooled.Some parts of the die merely act as holding elements;others，such as the

44、die inserts and the cores，have to withstand the impact and high temperature of the molten metal.The mechanisms for moving the ejectors and cores must work smoothly in the constantly changing temperature of a die.Parts which act as bearings are made either of non-ferrous metals such as phosphor bronz

45、e，or the steel surfaces are given a nitride or other treatment to resist wear.Unit Three Mold Constructions The die insert for producing the shape of the casting has to be machined accurately and heat treated to provide the best possible mechanical properties at high temperature.Most die casting die

46、s operate automatically and，while this leads to high productivity when there are no delays，the cost of breakdowns are correspondingly high.During the past decade the manufacture of dies has been revolutionized by sophisticated methods ranging from improved spark erosion to computer-controlled die ma

47、king.Among other efforts the Science Research Council is supporting a large scale research programme to include die heat treatment and surface coat-ings，computer-aided die design，special machining processes and the economics of die manufacture.A single die may contain 10 or more different steels plu

48、sUnit Three Mold Constructions several non-ferrous metals and special heat resisting alloys.Fig.3-6 and Fig.3-7 illustrate schematically a die which typifies the various components，each of which involves design，engineering and metallurgical problems.Fig.3-6 Typical die assembly 1ejector pins;2ejecto

49、r plates;3ejector return pin;4base support;5guide pillar;6die insert waterway;7die insert;8fixed core;9moving core;10moving core holder;11angle pin;12core locking wedge;13cascade waterway;14plunger bush;15guide bush Unit Three Mold Constructions Fig.3-7 Views illustrating structural features of die

50、shown in Fig.3-6 （The commentary is the same with Fig.3-6）Unit Three Mold Constructions Low alloy steel and cast iron components.The ejector box is constructed of several rectangular blocks built up to contain the ejector plates which are guided by round section runner bars or guide pillars.The box