毕业论文-剃须刀盖塑料模具的设计.doc

摘 要时代的变化，社会的进步，人们对物质的需求越来越高，模具的地位在当今社会越来越重要。所以我这次的毕业设计就选择了设计一副模具，希望通过这次的设计能够使我的理论知识得到检验和实践。本论文是剃须刀盖塑料模具的设计，采用abs材料进行对模具的零件结构工艺分析的过程。在选择注塑机的时候要考虑模具的型腔数量和最大注射量以及注射压力等。利用ug、autocad绘图软件绘制出模具的装配图和零件图。并利用ug对模具的仿真加工，制定相应加工工艺的过程。关键词：剃须刀后盖； ug；点浇口； abs；注塑模具；目 录 引言1一、塑件成型工艺性分析2（一）塑件（剃须刀后盖）分析21.塑件结构分析22.成型工艺分析如下2（二）abs 的成型过程、工艺的参数31.注射成型过程32.abs 的注射工艺参数33.abs 化学和物理特性3（三）注塑模工艺条件3二、拟定模具结构形式4（一）分型面的选择41.分型面的选择原则42.分型面的确定4（二） 型腔数目的确定5三、注塑机型号的确定5（一）所需注射量的计算5（二）选择注射机5四、浇注系统设计6（一）主流道的设计61.主流道设计要点62.主流道浇口套的形式6（二） 分流道的布置形式61.分流道的长度62.分流道的形状、尺寸63.分流道的表面粗糙度6（三）浇口的设计71.浇口类型及位置的确定72.浇口结构尺寸的经验计算7五、成型零件的结构设计、计算7（一）成型零件的结构设计7（二）工作尺寸的校核81.型腔尺寸8型腔径向尺寸8型腔深度尺寸82.型芯尺寸8六、模架确定、标准件选用9七、脱模推出机构的设计10(一) 推出机构的设计原则：10（二）脱模机构的结构设计10八、设计侧向的抽芯机构10（一）斜顶的设计10（二）抽芯距的确定10九、排气系统的设定11十、冷却系统设计12 总 结13 参考文献14 致 谢15 引 言目前，我国的经济在经济全球化下得到了高速发展。这样一来为中国的模具产业提供了具有良好的条件和机遇。不但国内的模具市场在市场经济中所占的份额越来越多，而且有许多的国外公司向国内的模具制造企业采购。因此，展望未来，在良好的市场环境下我国的模具产业会逐步迈进模具制造强国的行列。然而在国民经济的快速发展下，国内的模具产量达到了一定的规模，但发展重点没有放在模具产品水平上。致使我国的模具在模具的精度要求和结构以及寿命上远远地低于国际水平。不但如此模具标准件的种类以及水平对整个模具行业的发展有重大影响。所以要不断地提高标准件水平，才能不断地提高我国模具的总体水平。综合看来提高模具工业水平是在国民经济发展中占有至关重要的地位。 一、塑件成型工艺性分析 （一）塑件（剃须刀后盖）成型分析塑件的视图如图所示:图1-1 xxxxx1 塑件结构分析该塑件结构较简单，复杂程度不高。保证塑件的壁厚尽可能均匀，以此减少气泡、缩孔等不良现象。又因为生产批量不是很多，还要保证生产成本低，所以考虑材料为abs。塑件的表面不允许有明显的熔接痕、飞边等工艺痕迹，要求表面光滑，对模具表面进行抛光处理。2成型工艺分析如下（1）精度等级有许多影响塑件精度因素，塑料的收缩率、注塑条件、模具结构、斜度、模具的磨损等都直接影响精度。根据sj13721978标准，abs塑料零件的精度分八个等级。查询可知，abs塑料零件尽可能选用一般精度m5级。（2）脱模斜度为了避免在塑件冷却收缩的时候紧紧卡在型腔部分，强行取出损坏塑件的表面质量。设计塑料零件时须考虑脱模方向于内外表面，使之平行，并尽量加大脱模斜度，为了容易脱模。 （二）abs 的成型过程、工艺的参数1注射成型过程（1）成型前的准备 对abs 的色泽、细度和均匀度等进行检验。（2）塑料颗粒在注射机料筒内先进行加热，达到熔融状态后，填充模具再经过压实和保持压力不变以及回流和冷却这五个阶段完成成型过程。2. abs 的注射工艺参数（1）注射机： 螺杆式（2）螺杆转速(r/min)： 30（3）料筒温度() ： 150170(后段)、165180(中段)、180200(前段)（4）喷嘴温度()： 170180（5）模具温度()： 4060（6）注射压力(mpa)： 100130（7）成型时间(s)：2s注射 ； 25s保压 ； 20s冷却 ；成型总周期 473. abs 化学和物理特性 abs为黄色无毒无味的不透明状的可塑性树脂。abs 特性很大程度上取决于三种单体和两相分子结构的比例，所以abs 材料具有良好的光泽度、流动性、耐化学药品性和电绝缘性。（三）注塑模工艺条件abs 容易吸水，建议加工前在80的条件下进行两个小时的干燥。熔化温度：210280；建议温度：245。注射速度：中高速度。abs 塑料的主要技术指标:密度（kg/dm3） 1.021.16 抗拉屈服强度(mpa) 50,比体积（dm3/ kg） 0.860.96 拉伸弹性模量(mpa) 1.8103,吸水率（pc100） 0.20.4 抗弯强度(mpa) 80收缩率(%) 0.40.8 冲击韧度( kj/m2) 261(无缺口)/11(缺口)熔点() 130160 硬度(hb) 9.7热变形温度() 90108(0.46 mpa) 83103(0.185mpa)体积电阻系数(cm) 6.910167 二、拟定模具结构形式 （一）分型面的选择在模具设计阶段，首先要确定模具分离的位置，然后才选择模具结构。分型面的合理设计，影响着塑件质量和工艺操作的难易程度。1分型面的选择原则：（1）要便于塑件脱模；（2）要保证塑件的质量；（3）要防止熔料从分型面处渗出；（4）要便于气体的排出；（5）要尽量便于加工成型零件；2分型面的确定在进行该塑件模具设计时，对上述原则已经充分的考虑，同时从塑件样图可看出该塑件具有明显的一个平面，再结合塑件形状，考虑其具有抽芯机构，所以选择采用该平面作为分型面，如图21所示：21 分型面示意图 （二）型腔数目的确定根据塑件的表面精度高，和模具加工以及产品的生产成本考虑，所以设定一模两腔。 三、注塑机型号的确定 所需注射量的计算1塑件质量、体积计算通过ug 建模查询可知一个塑件的体积v13.166cm3，两个约为6.322 cm3，按公式计算得注射量为：1.6 x 6.3cm3 = 10.08 cm3查得abs的密度为1.06g/ cm3 。故所需塑料为的质量1.06g/ cm310.08 cm3=10.68g2. 模具中冷凝料体积的估算本模具采用一模两腔，并按照体积的0.6倍估算凝料体积为：v2=v10.6=3.1660.6x23.799cm33. 该模具一次注射所需塑料abs体积 v0= v1+ v2=6.965 cm3 质量 m0=v0=1.06x6.9657.4g （二）锁模力的计算根据ug 建模分析，分型面上的单一投影面积a1约为1133.54 mm2，那么两个就约为2267 mm2。根据经验公式计算得施压面积为：1.35 x2267 mm2 =3060.6 mm2。查资料得：在abs成型时型腔内所产生的平均压力为34.3mpa,故所需锁模力为：3060.6 mm2 x 34.3mpa =104.98kn 取105kn （三）选择注射机通过分析，根据每一生产周期的注塑量和所需压力，查阅参考书，可选用xs-zy-125a 卧式注塑机比较合理，其主要技术参数:额定注射 125 注射压力 150螺杆直径 42锁模力 900kn注射时间 1.6s最大开合模行程 325mm模具最大厚度 350mm 模具最小厚度 220mm喷嘴圆弧半径 12mm喷嘴孔直径 4mm动、定模板尺寸 428mm458mm拉杆内间距 360 mm360mm顶出形式 模具两侧装有顶杆，离中心的距离分别为240mm 四、浇注系统设计 （一）主流道的设计1主流道设计要点 （1）设计圆锥形主流道，便于凝料脱离。(2）锥角度数=26。内壁表面粗糙度一般为ra=0.4。(3）设定主流道进口直径d=8mm的半球形凹坑。(4) 主流道末端与分流道连接处采用圆角衔接。其圆角半径r=13mm。(5) 为了减少流道内的凝料，尽量缩短主流道长度l，取值l=95mm。2主流道浇口套的形式为了避免损伤主流道的小端入口处，通常采用碳素工具钢，如t8a、t10a 等。本模具材料采用t8a,热处理硬度为50hrc55hrc，如图4-1示:4-1浇口套示意图 （二）分流道的布置形式本模具采用一模两腔平衡式分流道的结构形式，使塑料熔体由中心向四周分散而出。1分流道的长度两级分流道对称布局。一级管道长度取值44.5mm,二级管道长度取值57mm。2分流道的形状、尺寸一级管采用半圆形，二级管采用圆锥形。根据经验，要保证比主流道的大端小1-2mm，本模具的一级管直径6mm。圆锥形二极管的大端直径取4mm,小端和浇口的大小同取1.2mm。3分流道的表面粗糙度分流道表面粗糙度为：ra=1.6m。 （三）浇口的设计为了避免引起塑件的缺陷，要考虑浇口的形状、位置和大小等。应尽可能设在浇口壁比较厚的地方。1浇口类型及位置的确定由于该模具是中小型塑件的多腔模具，塑件外形为圆形，结构简单，故采用点浇口。2浇口结构尺寸的经验计算根据塑件的结构尺寸，本模具点浇口的进料口直径取1.2mm，浇口长度取1.6mm。 五、成型零件的结构设计、计算 （一）成型零件的结构设计1根据塑件轮廓，采用整体式凹模结构。该结构是由一块金属材料直接加工出来的。因为有良好的强度，不容易发生变形，表面光滑平整，不会又衔接的痕迹。但是加工精度要求很高，所以只适用于简单形状比较小的塑件。而本塑件分型面设置于没有突出的光滑顶面，凹模深度比较浅且形状简单的小型模具。故可采用整体凹模结构，如5-1 图示。5-1凹模结构图2因为该塑件的内部形状也简单，所以采用整体式凸模,如图5-2所示。5-2凸模示意图 （二）工作尺寸的校核经查询知：abs塑料的收缩率为0.3%0.8%。平均收缩率 s=(0.4%+0.8%)/2=0.6%模具的制造公差取 查塑料模塑成型技术书 国家标准模塑件公差数值表310，由样件知该塑件取公差等级为mt5级。1型腔尺寸型腔径向尺寸d1(max) =（d1+ d1scp% 3/4）+0=（38+38*0.0063*0.32/4）+00.18mm=37.98+0018mm型腔深度尺寸h1 (max)= (h+h scp% 2/3) +0 = (10+100.00620.2/3) +0006mm=9.93 +00.06 mm 2型芯尺寸型芯径向尺寸 d1(min)= (d1+d1scp%+3/4)0 = (36+360.006+30.32/4) 0-0.18mm=36.430-0.18 mm 型芯深度尺寸h2（min） = (h2+ h2scp%+2/3) 0 = (8+80.006+20.2/3) 00.06mm=8.1700.06mm 六、模架确定、标准件选择由前型腔的布局以及相互的位置大小，然后根据成型部件的尺寸与标准模架相结合，选用结构形式为a1-2730-z2.的标准模架，即可满足要求。 （一）定模座板（350mmx300mm、厚30mm）材料选用45钢。 （二）定模板（型腔固定板）（3000mmx300mm 厚60mm）用于固定型腔部分。一般选择45 钢，调质230hb270hb。 （三）动模型芯固定板（300mmx300mm 厚70mm）一般材料选用45 钢，进行回火和淬火。 （四）垫块（300mmx58mm 厚度90mm）1主要作用:适应注射机的模具安装厚度。2结构形式:该模具采用的垫块是平行的。3垫块材料: 该模具垫块采用q235a 制造。也可用ht200、球墨铸铁等。4支承板（300mmx300mm 厚45mm）作用是防止凸模、凹模、导柱、导套等零件脱出。5垫块的高度h 校核h =h1 +h2 +h3 +s=0+25+20+45=90mm, 符合要求。式中 h1顶出板限位钉的高度，因为本设计未采用，故其值为0；h2推板的厚度，为25 mm；h3推杆固定板厚度，为20mm；s推出行程，为45mm；6推板（300mmx120mm、厚25mm），材料为45 钢。7推板固定板（300mmx120mm、厚20mm），材料为45 钢。 七、脱模推出机构的设计 （一）推出机构的设计原则：（1） 应尽量设置在动模一侧。（2） 机构简单，推出动作可靠。 （3） 使脱模后的制品有良好的外观。（4） 合模时能准确复位。 （二）脱模机构的结构设计由该塑件的外形特征及内部型芯的情况，设置脱模机构为标准推杆及利用斜顶顶出。如图7-1所示：7-1结构示意图 八、设计侧向的抽芯机构根据设计要求采用斜顶顶出。 （一）斜顶的设计斜顶结构简单，制造方便，稳定性好，普遍用于内抽心距较小的模具。 （二）抽芯距的确定抽芯距应大于制品凸台高度2mm。设凸台高度为h，因此s=h(13)mm=22=4mm分析产品，根据查询得斜顶斜角5度。 九、排气系统的设定在成型过程中，除了有空气外还有在成型时产生的低挥发气体存在于模具型腔中。如果不能将这些气体排出模具外会在内部产生很大的压力，阻碍塑料熔体的快速填充。同时在高压下，气体压缩产生高温，可能会烧焦损伤塑件。甚至气体在一定的压缩下会渗入塑件内部，导致产品有气孔、疏松等缺陷。通常一般的模具是靠分型面的间隙排出气体，很少开设排气槽。而一般在凹模的分型面上开设排气槽，尺寸一为宽1.56mm，深0.020.05mm，要小于塑料的溢料间隙规格，避免熔料从排气槽溢出。根据本设计结构，利用分型面之间的间隙自然排气就可以了，不需要开设排气槽。 十、 冷却系统设计模具的温度过高会直接影响塑件的成型收缩，容易导致塑件脱模时变形，甚至还容易造成熔料溢出和粘在模具上。而温度过低时，将导致熔体流动性变差，从而使塑料零件的轮廓不清晰，表面有明显的缺陷，例如银丝和流纹状。本设计塑件材料为abs，流动性好，要求模具温度（一般低于80）较低，只需要调节水的流量就可以对模具进行冷却。 （一）冷却系统的设计原则：（1） 尽可能地增大冷却管直径和增加冷却管数量；（2） 冷却通道的布置应合理；（3） 结构应便于清理、加工； （二）冷却管道直径d查模具设计基础及模具cad表9-4知,为了使冷却水在冷却管内处于急流状态，取d=8mm,布局如图10-1所示：10-1冷却系统布局图we are floating on top of a frozen margarita. thats how our shipboard naturalist john fonseca describes the slushy ice that the silver explorer is plowing through as we enter greenlands prince christian sound, named after a long-ago danish royal who became king christian viii. in the distance, the water surface is a smooth sheet of dark-green jade under the overcast sky. the cruise ship suddenly feels larger as we slip into the narrow passage of the sound. bigger and bigger chunks of sea ice float by, like huge gobs of whipped cream dropped on the surface by some quirky norse god. the sculpted forms pass so close, its tempting to stretch out a finger for a poke and a taste. at its base, the rocky shore on each side is often green with moss and lichen. but it quickly becomes less hospitable and even forbidding, its glacier-scarred face climbing steeply until disappearing into low, filmy clouds. some patches of ice have lingered since last winter, though the august sun is converting the most exposed into waterfalls that trickle merrily into the brilliant sea. leaning on the observation deck at the ships level 6, fonseca tells us were looking at rocks that are 2 billion years old. some of the harsh striations have been dated to the tectonic plate shifts of 65 million years ago that broke up the earths landmass into the continents we know today. there are about 50 passengers on board, most huddled among the rails at 8 am in the bright red parkas provided by the silversea cruise line. the air temperature is 9 cthe water temperature is-12 c, expedition leader stefan kredel announces on a loudspeaker, just in case anybody is planning to strip off for a morning swim. our luxury vessel is small as cruise ships go. american tvs love boat may have had athousand cabins, sports courts and a pooland there are massive ships like that in the nextharbor with a big herd of passengers but things are more intimate here.silver explorers relative pettiness is key to our itinerary. at the moment, we are cruising overa channel 240 meters deep, but yesterday, winding through skoldungen fjord, we hadscooted over depths as shallow as 69 meters. you cant do that on the qeii. that flexibility is essential to the expedition ships and cruises offered by silversea. whilethe line offers the more traditional cruises focused on shipboard entertainment and portcalls for shopping and nightlife, the expedition variety is targeted at more adventuroussouls.we started these as outings to more out-of-the way places, specifically the arctic and theantarctic, for active travelers who wanted to learn about and explore wilder places upclose,says kernel.if parking your butt in a deck chair is your idea of a deluxe cruise, youre on the wrong ship.each day, silver explorer works its way as close to shore as possible before droppinganchor. then we pull on our waterproof pants, jackets and boots, and climb single-file intozodiacsthe big, motorized rubber rafts that will take us to the days adventure. yesterday, that was a 90-minute foray around thrym glacier. today, we zip ashore to visit the indigenous village of nanortalik, where small oil-heated houses painted in bright colors dot a mountain valley that clings to summers last yellow wildflowers. we explore an outdoor museum, watch a kayak demonstration at a traditional hunting camp, enjoy an inuit choir performance in the church, and enjoy coffee and a folk dancing at the local culture center. nanortalik means place of polar bears in the local inuit language, but a fanged ivory skull in the museum is the closest well come to seeing this fearsome creature on this voyage around southern greenland. tomorrow were promised a landing near two thermal pools with a view of passing icebergs. those swimming suits we packed will be used after all. each day, there is at least one lecture by an experta geologist, birder, viking scholar, botanist, anthropologist or marine biologist. these informal talks are comfortably spaced between gourmet meals and free-flowing wine and spirits, all of which can be enjoyed in the collegiality of the restaurant or in the cozy privacy of your cabin. the cabins are surprisingly spacious, and the butler assigned to my suite keeps the complimentary minibar stocked with my preferred beverages and snacks. he and the cabin valet will discreetly tidy up the room each day while im dining or sightseeing onshore. my water bottle is always full. my shoes are always shined. meals are five-star hotel quality, which chef piaa statuesque strawberry-blonde from germanysomehow pulls off even when the ship is days away from a market that meets her exacting standards. the sit-down dinner service (theres no assigned seating, except at the welcome and farewell dinners hosted by croatian captain denis radja) features gourmet european fare. lunches are expansive buffets in the restaurantthough in good weather, many of us sit in the sun on the observation deck, where there is a small buffet as well as sandwiches and pastas made to order. im slightly surprised to find that quite a few passengers have not only cruised with silversea before, but rather often. at one reception, a japanese lady gets applauded as the passenger aboard having the most cruise days with the line: 860! thats getting close to three years at sea. on this cruise, we are particularly pampered: there are only 56 passengersand 119 crewmembers. there are usually 120 to 150 passengers on board, and most cruises are fully bookedpopular destinations such as antarctica and the mediterranean as much as a year ahead. late summer timing and the challenge of booking return flights after disembarking at kangerlussuaq have kept our group on the small side. well all know each other pretty well at the end of our 12-day cruise. expedition leader kredel observes that well be extra-pampered with two crewmembers on board to every one passenger. but lets not have any talk of mutiny on this ship, he jokes. always remember: you are outnumbered.they are safe, easy and family friendly, no wonder growing numbers of people are spending their vacations on a cruise ship. zhou wenting goes aboard. imagine spending a holiday in a place where your every whim is catered for, where the sun and the ocean are on your doorstep and delicious food is served around the clock. you can go shopping in stores that have rock bottom prices, and if you grow tired of all the pampering, your bed is available anytime. you can travel with the whole family too, because there are activities tailored to suit all age groups. a vacation on an elegant cruise liner will meet the desire for an exotic experience, but will also be an enjoyable travel experience when accompanied by young children or elderly parents. family-friendly, safe and secure, cruise vacations have become very popular in china. during the upcoming national day golden week holiday, from oct 1 to oct 7, many families will board a ship to enjoy an exciting holiday at sea. the development of the cruise industry in recent years has been impressive. statistics from the china cruise and yacht industry association show chinese residents made 1.4 million trips on cruise liners last year, compared with nearly 10,000 in 2006. the association predicts the market will continue to boom in the next two years. residents of shanghai, the city that boasts the largest cruise ports of the four on the chinese mainland, are more likely to book cruises than people in other parts of the country, according to a report published by baidu incs travel website q last year. tourists from shanghai are also willing to spend more, many paying 4,000 yuan ($652) to 6,000 yuan, to take a cruise. xue yifan, who returned last week from a six-day cruise trip to japan and south korea with her 6-year-old son