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存檔編碼：無(wú)無(wú)錫錫太太湖湖學(xué)學(xué)院院 2013 屆屆畢畢業(yè)業(yè)作作業(yè)業(yè)周周次次進(jìn)進(jìn)度度計(jì)計(jì)劃劃、檢檢查查落落實(shí)實(shí)表表 系別：信機(jī)系 班級(jí)：機(jī)械（96）學(xué)生姓名：謝兵兵 課題（設(shè)計(jì)）名稱(chēng)：LED導(dǎo)光柱注塑模具設(shè)計(jì) 開(kāi)始日期：2012年11月12日周次起止日期工作計(jì)劃、進(jìn)度每周主要完成內(nèi)容存在問(wèn)題、改進(jìn)方法指導(dǎo)教師意見(jiàn)并簽字備 注1-32012年11月12日-2012年12月2日教師下達(dá)畢業(yè)設(shè)計(jì)任務(wù)，學(xué)生初步閱讀資料，完成畢業(yè)設(shè)計(jì)開(kāi)題報(bào)告按照任務(wù)書(shū)要求查閱論文相關(guān)參考資料，填寫(xiě)畢業(yè)設(shè)計(jì)開(kāi)題報(bào)告書(shū)存在問(wèn)題：對(duì)課題所涉及的內(nèi)容不怎么了解，對(duì)設(shè)計(jì)目的及要求不明確。改進(jìn)方法：向指導(dǎo)老師請(qǐng)教，通過(guò)導(dǎo)師指導(dǎo)后，查閱相關(guān)資料，重新填寫(xiě)報(bào)告。4-102012年12月3日-2013年1月20日指導(dǎo)專(zhuān)業(yè)實(shí)訓(xùn)注塑模具綜合實(shí)訓(xùn)，塑件加工方法和加工工藝編制存在問(wèn)題：只能在校內(nèi)查閱注塑模具的相關(guān)資料，并沒(méi)有實(shí)際了解。改進(jìn)方法：到廠里實(shí)地考察，積累經(jīng)驗(yàn)。11-122013年1月21日-3月1日指導(dǎo)畢業(yè)實(shí)習(xí)到無(wú)錫新區(qū)某塑料模具廠實(shí)習(xí)，學(xué)習(xí)塑料模具的成型原理存在問(wèn)題：在實(shí)習(xí)過(guò)程中，雖然初步理解注塑成型原理，但是一些因素的影響容易被我忽視。改進(jìn)方法：向廠里經(jīng)驗(yàn)豐富的老師傅學(xué)習(xí)，分析各種因素對(duì)塑件的影響。132013年3月4日-3月8日收集資料對(duì)注塑模具的各個(gè)部件進(jìn)行分析存在問(wèn)題：由于實(shí)習(xí)的原因，我沒(méi)有過(guò)多的時(shí)間去查閱注塑模具各部件的設(shè)計(jì)原則及注意事項(xiàng)。改進(jìn)方法：利用晚上有限的時(shí)間上網(wǎng)查資料，看視頻。142013年3月11日-3月15日初步確定正文部分的目錄確定LED注塑模的設(shè)計(jì)分為幾大部分存在問(wèn)題：漏掉溫度調(diào)節(jié)系統(tǒng)的設(shè)計(jì)。改進(jìn)方法：上網(wǎng)查找溫度調(diào)節(jié)系統(tǒng)的相關(guān)資料，明確溫度調(diào)節(jié)系統(tǒng)的重要性。152013年3月18日-3月22日正文部分的具體設(shè)計(jì)確定正文部分的框架存在問(wèn)題：對(duì)一些重要章節(jié)沒(méi)有作重點(diǎn)介紹。改進(jìn)方法：向同學(xué)和導(dǎo)師請(qǐng)教，確定重點(diǎn)章節(jié)。162013年3月25日-3月29日填寫(xiě)中英文摘要根據(jù)正文部分的重點(diǎn)以及相關(guān)資料，完成中英文摘要。存在問(wèn)題：英文翻譯某些語(yǔ)句不通順，還有部分中文不會(huì)翻譯。改進(jìn)方法：向校英語(yǔ)老師和導(dǎo)師請(qǐng)教，使英文和中文一致。172013年4月1日-4月5日LED導(dǎo)光柱裝配圖的繪制完成LED裝配圖存在問(wèn)題：在繪制裝配圖過(guò)程中，發(fā)現(xiàn)某些數(shù)據(jù)明顯錯(cuò)誤。改進(jìn)方法：對(duì)于某些數(shù)據(jù)的錯(cuò)誤，重新修改正文部分，使各數(shù)據(jù)合理。182013年4月8日-5月12日LED導(dǎo)光柱零件圖的繪制從LED導(dǎo)光柱裝配圖中拆分，完成各零件圖存在問(wèn)題：零件圖粗實(shí)線(xiàn)不分，缺少相關(guān)數(shù)據(jù)的標(biāo)注。改進(jìn)方法：重新標(biāo)注，使零件圖達(dá)到標(biāo)準(zhǔn)要求。192013年4月15日-4月19日修改正文部分根據(jù)導(dǎo)師指導(dǎo)，修改正文存在問(wèn)題：正文部分有些章節(jié)未充分考慮各種因素的影響。改進(jìn)方法：在導(dǎo)師的細(xì)心指導(dǎo)下，修改正文。202013年4月22日-4月26日修改LED裝配圖和零件圖依據(jù)修改的正文內(nèi)容，重新修改裝配圖和零件圖存在問(wèn)題：圖紙尺寸和正文部分的計(jì)算尺寸有些不符。改進(jìn)方法：嚴(yán)格按照正文數(shù)據(jù)的要求，修改圖紙。212013年4月29日-5月3日完成致謝、參考目錄整理論文，填寫(xiě)致謝和參考文獻(xiàn)存在問(wèn)題：對(duì)于參考文獻(xiàn)沒(méi)有嚴(yán)格按照學(xué)校的標(biāo)準(zhǔn)。改進(jìn)方法：按照學(xué)校模板，重新修改參考文獻(xiàn)。222013年5月6日-5月10日總計(jì)畢業(yè)論文對(duì)LED注塑模具進(jìn)行系統(tǒng)的總結(jié)存在問(wèn)題：總結(jié)過(guò)程中依然會(huì)發(fā)現(xiàn)某些錯(cuò)誤。改進(jìn)方法：針對(duì)某些錯(cuò)誤，認(rèn)真修改。232013年5月13日-5月17日導(dǎo)師檢查根據(jù)導(dǎo)師的意見(jiàn)修改論文存在問(wèn)題：對(duì)于參考文獻(xiàn)沒(méi)有嚴(yán)格按照學(xué)校的標(biāo)準(zhǔn)。改進(jìn)方法：按照學(xué)校模板，重新修改參考文獻(xiàn)。242013年5月20日-5月25日完成論文最后的相關(guān)工作論文打印、裝訂、上交存在問(wèn)題：打印時(shí)發(fā)現(xiàn)有些內(nèi)容不符合學(xué)校要求。改進(jìn)方法：按照學(xué)校要求重新打印。說(shuō)明：1、“工作計(jì)劃、進(jìn)度”、“指導(dǎo)教師意見(jiàn)并簽字”由指導(dǎo)教師填寫(xiě)，“每周主要完成內(nèi)容”，“存在問(wèn)題、改進(jìn)方法”由學(xué)生填寫(xiě)。2、本表由各系妥善歸檔，保存?zhèn)洳?。周次起止日期工作?jì)劃、進(jìn)度每周主要完成內(nèi)容存在問(wèn)題、改進(jìn)方法指導(dǎo)教師意見(jiàn)并簽字備 注編 號(hào) 無(wú)錫太湖學(xué)院 畢 業(yè) 設(shè) 計(jì) （ 論 文 ） 題目： LED 導(dǎo)光柱注塑模具設(shè)計(jì) 信 機(jī) 系 模 具 設(shè) 計(jì) 與 制 造 專(zhuān) 業(yè) 學(xué) 號(hào)： 0923259 學(xué)生姓名： 謝兵兵 指導(dǎo)教師： 范圣耀（職稱(chēng)：副教授） （職稱(chēng)： ） 2013 年 5 月 25 日 無(wú)錫太湖學(xué)院本科畢業(yè)設(shè)計(jì)（論文） 誠(chéng) 信 承 諾 書(shū) 本人鄭重聲明：所呈交的畢業(yè)設(shè)計(jì)（論文） LED 導(dǎo)光柱注塑模 具設(shè)計(jì) 是本人在導(dǎo)師的指導(dǎo)下獨(dú)立進(jìn)行研究所取得的成果，其內(nèi)容 除了在畢業(yè)設(shè)計(jì)（論文）中特別加以標(biāo)注引用，表示致謝的內(nèi)容外，本 畢業(yè)設(shè)計(jì)（論文）不包含任何其他個(gè)人、集體已發(fā)表或撰寫(xiě)的成果作品。 班 級(jí)： 機(jī)械 96 學(xué) 號(hào)： 0923259 作者姓名： 2013 年 5 月 25 日 無(wú) 錫 太 湖 學(xué) 院 信 機(jī) 系 模 具 設(shè) 計(jì) 與 制 造 專(zhuān) 業(yè) 畢 業(yè) 設(shè) 計(jì) 論 文 任 務(wù) 書(shū) 一、題目及專(zhuān)題： 1、題目 LED 導(dǎo)光柱注塑模具設(shè)計(jì) 2、專(zhuān)題 二、課題來(lái)源及選題依據(jù) 本次畢業(yè)設(shè)計(jì)題目是 LED 導(dǎo)光柱注塑模具設(shè)計(jì)，課題來(lái)源于無(wú)錫新區(qū) 某模具有限公司。其研究的內(nèi)容是電子產(chǎn)品中 LED 導(dǎo)光柱的注塑模具設(shè)計(jì)。 LED 導(dǎo)光柱主要起導(dǎo)光作用，它能夠使一切 LED 燈發(fā)光，透光度達(dá)到 98%。注塑模具在現(xiàn)代生活中的地位越來(lái)越高，因此對(duì)塑料模具質(zhì)量的要求 也越來(lái)越高，這就要求塑料模具的開(kāi)發(fā)、設(shè)計(jì)與制造的水平也必須越來(lái)越高。 LED 導(dǎo)光柱在工廠生產(chǎn)中屬于大批量生產(chǎn)，故將要求我們精確設(shè)計(jì)出相應(yīng)的 塑料模具。 本課題的選擇主要有下面幾方面的依據(jù)： 1、塑料模具與自己的專(zhuān)業(yè)接近，完成該課題可對(duì)我們大學(xué)期間所學(xué)知 識(shí)進(jìn)行一次全面的專(zhuān)業(yè)訓(xùn)練，可以培養(yǎng)我們掌握如何運(yùn)用過(guò)去所學(xué)知識(shí)去解 決生產(chǎn)中實(shí)際問(wèn)題的方法。 2、我在無(wú)錫一家模具廠實(shí)習(xí)，該廠正好生產(chǎn)導(dǎo)光柱，我對(duì)制件的尺寸 都有深入的了解，可以減少許多不必要的麻煩。 I 三、本設(shè)計(jì)（論文或其他）應(yīng)達(dá)到的要求： 正確合理分析零件工藝用途及結(jié)構(gòu)； 理解并掌握注塑模具的原理； 了解注塑模具的各種結(jié)構(gòu)以及各自的特點(diǎn)； 能夠掌握注塑模具上各個(gè)部分的作用； 對(duì)于注塑模具設(shè)計(jì)，能夠掌握模具中各個(gè)部分的設(shè)計(jì)原則以及能夠合 理分析各因素對(duì)設(shè)計(jì)的影響； 熟練使用各種制圖軟件。 四、接受任務(wù)學(xué)生： 機(jī)械 96 班 姓名 謝兵兵 五、開(kāi)始及完成日期： 自 2012 年 11 月 12 日 至 2013 年 5 月 25 日 六、設(shè)計(jì)（論文）指導(dǎo)（或顧問(wèn)）： 指導(dǎo)教師簽名 簽名 簽名 教 研 室 主 任 學(xué)科組組長(zhǎng)研究所所長(zhǎng) 簽名 系主任 簽名 II 2012 年 11 月 12 日 摘 要 本次畢業(yè)設(shè)計(jì)的題目是 LED 導(dǎo)光柱注塑模具設(shè)計(jì)。目前，塑料制件幾乎已經(jīng)進(jìn)入了 一切工業(yè)部門(mén)以及人民生活的各個(gè)領(lǐng)域。隨著工業(yè)塑料制件和日用塑料制件的品種和需 求量日益增加，這些產(chǎn)品更新?lián)Q代的周期越來(lái)越短，因此對(duì)塑料的品種、產(chǎn)量和質(zhì)量都 提出了越來(lái)越高的要求，這就要求塑料模具的開(kāi)發(fā)、設(shè)計(jì)與制造的水平也必須越來(lái)越高。 在現(xiàn)代塑料成型生產(chǎn)中，塑料制件的質(zhì)量與塑料成型模具、塑料成型設(shè)備和塑料成 型工藝這三項(xiàng)因素密切相關(guān)。在這三項(xiàng)要素中，塑料成型模具質(zhì)量最為關(guān)鍵，它最能反 映出整個(gè)塑料成型生產(chǎn)過(guò)程的技術(shù)含量及經(jīng)濟(jì)效益，它的功能是雙重的：賦予塑料熔體 以期望的形狀、性能、質(zhì)量；冷卻并推出成型的制件。 本文主要內(nèi)容是對(duì) LED 導(dǎo)光柱注塑模具的成型部位、澆注系統(tǒng)、導(dǎo)向機(jī)構(gòu)、推出機(jī) 構(gòu)、排氣系統(tǒng)及冷卻系統(tǒng)等進(jìn)行詳細(xì)的分析、計(jì)算及設(shè)計(jì)。在設(shè)計(jì)過(guò)程中，我們需要充 分考慮塑料變形、收縮率、排氣等各種因素的影響，使其滿(mǎn)足總體的設(shè)計(jì)要求。 關(guān)鍵詞：LED 導(dǎo)光柱；注塑成型；注塑模具；結(jié)構(gòu)設(shè)計(jì)。 I Abstract My graduation thesis topic is LED guide beam injection mold design. Plastic parts almost go into all industrial sectors and the people of all areas of life today. With the variety and the demand of industrial plastic parts and plastic parts for daily use increasing, the product replacement cycles are getting shorter, which causes higher and higher demands for the plastic varieties, yield and quality, so the development of plastic mold design and manufacturing level should also grow. In modern injection molding production, the quality of the plastic parts is closely related to the three factors which include plastic mold, plastic molding equipment and plastic molding process. In these three elements, plastic mold quality is the most critical, it is best to reflect the technical content and economic benefits of the plastic molding production process, its function is twofold: making the plastic melt the desired shape, performance, quality ; cooling and launched the formed workpieces. This article main content is about a detailed analysis, calculation and design of the LED light guide forming parts of injection mould, pouring system, guide mechanism, institution, exhaust system and cooling system, etc. In the design process, we need to fully consider the plastic deformation, shrinkage rate, exhaust and other factors, making it satisfy the requirement of the overall design. Key words: LED guide beam; Injection molding; Injection mould; structural design. II 目 錄 摘 要 .III ABSTRACT .IV 目 錄 .V 1 緒論 .1 1.1 本課題的研究?jī)?nèi)容和意義 .1 1.1.1 本課題的研究?jī)?nèi)容.1 1.1.2 本課題的意義 .2 1.2 國(guó)內(nèi)外的發(fā)展概況 .3 1.2.1 注塑模具國(guó)外研究現(xiàn)狀 .3 1.2.2 注塑模具國(guó)內(nèi)研究現(xiàn)狀 .3 1.2.3 注塑模具發(fā)展趨勢(shì).4 1.3 本課題應(yīng)達(dá)到的要求 .4 2 塑料制件的工藝性 .5 2.1 塑料的基本組成及分類(lèi) .5 2.2 塑件材料的物理性質(zhì)及其用途和成型特點(diǎn) .8 2.2.1 塑件材料物理性質(zhì).8 2.2.2 主要用途以及成型特點(diǎn) .9 2.3 LED 導(dǎo)光柱的幾何結(jié)構(gòu) .9 2.4 LED 導(dǎo)光柱相關(guān)數(shù)據(jù)的確定 .12 2.4.1 塑件厚壁的確定 .12 2.4.2 脫模斜度的確定 .13 2.4.3 圓角的的確定 .13 2.4.4 LED 導(dǎo)光柱的體積及質(zhì)量 .13 3 注射成型原理以及注塑機(jī)的選擇 .14 3.1 注射成型原理 .14 3.1.1 柱塞式注塑機(jī)注射成型原理 .14 3.1.2 螺桿式注塑機(jī)注射成型原理 .14 3.2 注射成型工藝 .16 3.2.1 成型前的準(zhǔn)備 .16 3.2.2 注射過(guò)程 .16 3.2.3 塑件的后處理 .16 3.3 注塑機(jī)的選擇 .17 3.3.1 注塑機(jī)的分類(lèi) .17 3.3.2 注塑機(jī)的類(lèi)型選擇.18 I 3.3.3 注塑機(jī)參數(shù)的校核.19 4 分型面的選擇與澆注系統(tǒng)的設(shè)計(jì) .21 4.1 分型面及其選擇 .21 4.1.1 型腔數(shù)目的確定和布置 .21 4.1.2 分型面的形式 .22 4.1.3 分型面的設(shè)計(jì)原則.22 4.2 澆注系統(tǒng)的設(shè)計(jì) .22 4.2.1 普通澆注系統(tǒng)設(shè)計(jì)的基本原則 .23 4.2.2 主流道的設(shè)計(jì) .23 4.2.3 分流道的設(shè)計(jì) .24 4.2.4 澆口的設(shè)計(jì) .25 5 成型零部件設(shè)計(jì) .27 5.1 成型零件的結(jié)構(gòu)設(shè)計(jì) .27 5.1.1 凹模的結(jié)構(gòu)分析 .27 5.1.2 型芯和成型桿的結(jié)構(gòu)分析 .27 5.2 影響塑料尺寸精度的主要因素 .27 5.2.1 塑料制品的成型收縮 .27 5.2.2 模具成型零件的制造公差 z .28 5.2.3 模具成型零件的磨損 c.28 5.3 成型零件的工作尺寸的計(jì)算 .28 6 導(dǎo)向機(jī)構(gòu)和推出機(jī)構(gòu)的設(shè)計(jì) .31 6.1 導(dǎo)向機(jī)構(gòu)的設(shè)計(jì) .31 6.1.1 導(dǎo)向機(jī)構(gòu)的功用 .31 6.1.2 導(dǎo)向裝置類(lèi)型 .31 6.1.3 導(dǎo)柱導(dǎo)向機(jī)構(gòu) .31 6.1.4 導(dǎo)套的設(shè)計(jì) .32 6.2 推出機(jī)構(gòu)的設(shè)計(jì) .33 6.2.1 推出機(jī)構(gòu)的結(jié)構(gòu)組成 .33 6.2.2 推出機(jī)構(gòu)的設(shè)計(jì)原則 .33 6.2.3 頂出部件 .34 6.2.4 復(fù)位部件 .35 6.2.5 導(dǎo)向部件和限位零件 .35 7 其它部件的設(shè)計(jì) .36 7.1 溫度調(diào)節(jié)系統(tǒng)的設(shè)計(jì) .36 7.1.1 冷卻系統(tǒng)的設(shè)計(jì)原則 .36 7.1.2 冷卻系統(tǒng)的計(jì)算 .36 II 7.2 模架的設(shè)計(jì) .38 7.2.1 模板的布置 .38 7.2.2 模板的標(biāo)準(zhǔn)化 .38 7.3 排氣系統(tǒng)的設(shè)計(jì) .39 7.3.1 排氣槽的位置及作用 .40 7.3.2 排氣方式 .40 7.3.3 溢流槽 .40 8 結(jié)論 .41 致 謝 .42 參考文獻(xiàn) .43 0 1 緒論 注塑模具設(shè)計(jì)是對(duì)所學(xué)模具專(zhuān)業(yè)知識(shí)的一次鞏固，是在進(jìn)行社會(huì)實(shí)踐工作之前對(duì)所 學(xué)各課程的一次綜合性總復(fù)習(xí)，也是對(duì)在校學(xué)習(xí)的一次全面檢測(cè)。注塑模具是一種生產(chǎn) 塑膠制品的工具，也是賦予塑膠制品完整結(jié)構(gòu)和精確尺寸的工具。注塑成型是批量生產(chǎn) 某些形狀復(fù)雜部件時(shí)用到的一種加工方法，具體指將受熱融化的材料由高壓射入模腔， 經(jīng)冷卻固化后，得到成形品，其原理是將顆粒狀或粉末狀的塑料從注射機(jī)的料斗送進(jìn)加 熱的料筒中，經(jīng)過(guò)加熱融化成流動(dòng)狀態(tài)后，在柱塞或螺桿的推動(dòng)下，熔融塑料被壓縮并 向前移動(dòng)，通過(guò)料筒前端的噴嘴以很快的速度注入溫度較低的閉合模腔中，充滿(mǎn)形腔的 熔料在受壓的情況下，經(jīng)冷卻固化后即可保持模具形腔所賦予的形狀，然后開(kāi)模分型獲 得成型塑件。到目前為止，除氟塑料外，幾乎所有的熱塑性塑料都可以采用這種方法成 型。它具有成型周期短，能一次成型外形復(fù)雜、尺寸精確、帶有金屬或非金屬的嵌件的 塑料制品。根據(jù)產(chǎn)品的批量、結(jié)構(gòu)、尺寸與精度，可采用一模一腔，也可采用一模多腔。 注射成型加工方式通常只適用于熱塑料品的制品生產(chǎn)，用注射成型工藝生產(chǎn)的塑料 制品十分廣泛，從生活日用品到各類(lèi)復(fù)雜的機(jī)械，電器、交通工具零件等都是用注射模 具成型的，它是塑料制品生產(chǎn)中應(yīng)用最廣的一種加工方法。 1.1 本課題的研究?jī)?nèi)容和意義 1.1.1 本課題的研究?jī)?nèi)容 本課題來(lái)源于無(wú)錫新區(qū)某模具有限公司。其研究的內(nèi)容是電子產(chǎn)品中LED導(dǎo)光柱的注 塑模具設(shè)計(jì)。LED 導(dǎo)光柱是用在一切 LED燈上的導(dǎo)光作用，透光度可達(dá)到 98%以上。導(dǎo)光 柱就是將光以最小的損耗從一個(gè)光源傳輸?shù)骄嚯x該光源一定距離的另一個(gè)點(diǎn)的裝置。導(dǎo) 光柱可以用來(lái)將PCB上LED的光傳輸?shù)疆a(chǎn)品面板上來(lái)顯示相關(guān)的狀態(tài)，也可以聚集和指引 光線(xiàn)用做LCD顯示屏的背光，同時(shí)也可以用來(lái)照亮在透過(guò)式窗口上的圖案。導(dǎo)光柱最佳 最有效的設(shè)計(jì)就是將LED固定到導(dǎo)光柱的內(nèi)部。在這種結(jié)構(gòu)中LED 是植入導(dǎo)光柱內(nèi)部的， LED發(fā)出的所有光線(xiàn)全部會(huì)被導(dǎo)光柱所捕獲，考慮到 LED與導(dǎo)光柱之間存在空氣間隙而產(chǎn) 生的菲涅耳損耗，光線(xiàn)捕獲率可以達(dá)到92%。通常情況下，如果LED在導(dǎo)光柱的外部，并 且與導(dǎo)光柱之間有空氣間隙時(shí)光線(xiàn)的耦合和捕獲效率是較低的，相反，如果LED處于導(dǎo)光 柱表面空氣的交界面內(nèi)部時(shí)，效率是最高的。 注塑模，又稱(chēng)為注射模，是由動(dòng)模和定模兩大部分組成。動(dòng)模是安裝在注射機(jī)的移 動(dòng)工作臺(tái)上，定模則安裝在注射機(jī)的固定工作臺(tái)面上。動(dòng)模和定模閉合后已經(jīng)塑化的塑 料可以通過(guò)澆注系統(tǒng)注入到模具型腔中冷卻、固化與定型。一般通常要求注射模分開(kāi)以 后，制品盡量滯留在動(dòng)模一側(cè)，然后由設(shè)置在動(dòng)模內(nèi)的推出機(jī)構(gòu)將塑料制品從模內(nèi)推出。 1 一般來(lái)說(shuō)，注塑模的總體結(jié)構(gòu)主要分為七大部分：成型部件、澆注系統(tǒng)、導(dǎo)向和定 位部件、推出機(jī)構(gòu)、溫度調(diào)節(jié)系統(tǒng)、側(cè)向分型抽芯機(jī)構(gòu)以及標(biāo)準(zhǔn)模架，具體結(jié)構(gòu)如圖 1.1 所示。因此，本課題的研究主要圍繞這七大部分進(jìn)行。 （1）成型部件的設(shè)計(jì) 成型部件是指構(gòu)成模具型腔、直接與塑料熔體相接觸并成型 制品的模具零件或部件。通常有凸模、型芯、成形桿、凹模、鑲件等零件或部件。在動(dòng) 模與定模閉合后，成形零部件便確定了制品的內(nèi)、外輪廓和尺寸。 （2）澆注系統(tǒng)的設(shè)計(jì) 澆注系統(tǒng)是指由注射機(jī)噴嘴到型腔之間的進(jìn)料通道，主要是 由主流道、分流道、澆口和冷料穴組成。澆注系統(tǒng)的設(shè)計(jì)主要是確定主流道的結(jié)構(gòu)、分 流道的截面形狀以及澆口的類(lèi)型和數(shù)量。 編號(hào)
無(wú)錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
相關(guān)資料
題目： LED導(dǎo)光柱注塑模具設(shè)計(jì)
信機(jī) 系 模具設(shè)計(jì)與制造專(zhuān)業(yè)
學(xué) 號(hào)： 0923259
學(xué)生姓名： 謝兵兵
指導(dǎo)教師： 范圣耀 （職稱(chēng)：副教授 ）
（職稱(chēng)： ）
2013年5月25日
目 錄
一、畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告
二、畢業(yè)設(shè)計(jì)（論文）外文資料翻譯及原文
三、學(xué)生“畢業(yè)論文（論文）計(jì)劃、進(jìn)度、檢查及落實(shí)表”
四、實(shí)習(xí)鑒定表
無(wú)錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
開(kāi)題報(bào)告
題目： LED導(dǎo)光柱注塑模具設(shè)計(jì)
信機(jī) 系 模具設(shè)計(jì)與制造 專(zhuān)業(yè)
學(xué) 號(hào)： 0923259
學(xué)生姓名： 謝兵兵
指導(dǎo)教師： 范圣耀 （職稱(chēng)：副教授）
（職稱(chēng)： ）
2012年11月25日
課題來(lái)源
經(jīng)學(xué)校老師的介紹，我在無(wú)錫某模具廠實(shí)習(xí)，該廠大批量生產(chǎn)導(dǎo)光柱，經(jīng)過(guò)幾個(gè)月時(shí)間的親身實(shí)踐，我對(duì)導(dǎo)光柱的尺寸以及加工的流程都有了一定程度的了解，因此選擇自己熟悉的產(chǎn)品作為畢業(yè)論文的課題是一個(gè)明智的選擇。
科學(xué)依據(jù)（包括課題的科學(xué)意義；國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì)；應(yīng)用前景等）
（1）課題科學(xué)意義
塑料模具在現(xiàn)代生活中的地位越來(lái)越高，因此對(duì)塑料模具質(zhì)量的要求也越來(lái)越高，這就要求塑料模具的開(kāi)發(fā)、設(shè)計(jì)與制造的水平也必須越來(lái)越高。
各種塑料模具越來(lái)越趨于微型化、精密化，其零件結(jié)構(gòu)設(shè)計(jì)中的槽逢孔尺寸要求在0.3mm以下，尺寸精度要求越來(lái)越高。如BP機(jī)中零件尺寸極其微小，對(duì)模具的要求更高。這類(lèi)微型沖件和塑件用的模具，已成為高技術(shù)模具或?qū)＠湍＞?。隨著現(xiàn)代化工業(yè)和科學(xué)技術(shù)的發(fā)展，塑料模具的應(yīng)用越來(lái)越廣泛，其適應(yīng)性也越來(lái)越強(qiáng)。已成為工業(yè)國(guó)家制造工藝水平的標(biāo)志和獨(dú)立的基礎(chǔ)工業(yè)體系。
（2）國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì)
當(dāng)前來(lái)看，國(guó)內(nèi)塑料模具市場(chǎng)以注塑模具需求量最大，其中發(fā)展重點(diǎn)為工程塑料模具。近來(lái)我國(guó)模具工業(yè)發(fā)展迅速，前景光明。以上海為主的長(zhǎng)三角洲地區(qū)是中國(guó)塑料模具工業(yè)最為發(fā)達(dá)的地區(qū)。目前相當(dāng)多的發(fā)達(dá)國(guó)家塑料模具企業(yè)移師中國(guó)，是國(guó)內(nèi)塑料模具工業(yè)迅速發(fā)展的重要原因之一。中國(guó)技術(shù)人才水平普遍提高以及平均勞動(dòng)力成本低都是吸引外資的優(yōu)勢(shì)，這些都是塑料模具市場(chǎng)迅速成長(zhǎng)的重要因素所在，所以中國(guó)塑模市場(chǎng)的前景一片光明。
近幾年來(lái)，雖然我國(guó)塑料模具無(wú)論是在數(shù)量上，還是在質(zhì)量、技術(shù)和能力等方面都有了很大發(fā)展，但總體上還是與工業(yè)發(fā)達(dá)的國(guó)家相比仍有較大的差距。例如，許多先進(jìn)的技術(shù)如CAD／CAE／CAM技術(shù)的普及率還不高。另外，我國(guó)塑料模具行業(yè)與其發(fā)展需要和國(guó)外先進(jìn)水平相比，還存在很多方面的問(wèn)題?，F(xiàn)在應(yīng)用模具CAD／CAM技術(shù)設(shè)計(jì)模具已較為普遍，隨著通用機(jī)械CAD/CAM技術(shù)的發(fā)展，塑料注射模CAD/CAM已經(jīng)不斷的深化?，F(xiàn)代模具是多學(xué)科知識(shí)集聚的高新技術(shù)產(chǎn)業(yè)的一部分，是國(guó)民經(jīng)濟(jì)的裝備產(chǎn)業(yè)，其技術(shù)、資金與勞動(dòng)相對(duì)密集。
研究?jī)?nèi)容
① 分析零件工藝用途及結(jié)構(gòu)；
② 掌握注塑模具的原理；
③ 了解注塑模具的各種結(jié)構(gòu)以及各自的特點(diǎn)；
④ 掌握注塑模具上各個(gè)部分的作用；
⑤ 對(duì)于注塑模具設(shè)計(jì)，能夠掌握模具中各個(gè)部分的設(shè)計(jì)原則以及合理分析各因素對(duì)設(shè)計(jì)的影響。
擬采取的研究方法、技術(shù)路線(xiàn)、實(shí)驗(yàn)方案及可行性分析
在畢業(yè)實(shí)習(xí)調(diào)研以及查閱有關(guān)資料的基礎(chǔ)上，結(jié)合零件的外形及加工要求，可以先分析本課題的裝配圖以及各部分零件圖，然后通過(guò)工藝性分析，分別進(jìn)行成型部分的設(shè)計(jì)、澆注系統(tǒng)的設(shè)計(jì)、導(dǎo)向機(jī)構(gòu)的設(shè)計(jì)、推出機(jī)構(gòu)的設(shè)計(jì)、排氣系統(tǒng)的設(shè)計(jì)等等，最后設(shè)計(jì)出來(lái)的制件還要通過(guò)相應(yīng)的檢驗(yàn)。
研究計(jì)劃及預(yù)期成果
研究計(jì)劃：
2012年11月12日-2012年12月2日：按照任務(wù)書(shū)要求查閱論文相關(guān)參考資料，填寫(xiě)畢業(yè)設(shè)計(jì)開(kāi)題報(bào)告書(shū)。
2012年12月3日-2013年3月1日 ：填寫(xiě)畢業(yè)實(shí)習(xí)報(bào)告。
2013年3月4日-2013年3月14日 ：按照要求修改畢業(yè)設(shè)計(jì)開(kāi)題報(bào)告。
2013年3月15日-2013年3月21日：學(xué)習(xí)并翻譯一篇與畢業(yè)設(shè)計(jì)相關(guān)的英文材料。
2013年3月22日-2013年4月11日：注塑模具正文設(shè)計(jì)。
2013年4月12日-2013年4月25日：繪制裝配圖和零件圖。
2013年4月26日-2013年5月20日：畢業(yè)論文撰寫(xiě)和修改工作。
預(yù)期成果：
通過(guò)不同方案的比較，以及考慮不同因素的影響，最后確定合理的LED導(dǎo)光柱注塑模具設(shè)計(jì)方案，該方案能夠最大程度地滿(mǎn)足使用要求。
特色或創(chuàng)新之處
（1）適用于本廠的某生產(chǎn)線(xiàn)的優(yōu)化設(shè)計(jì)；
（2）在不影響加工精度的前提下最大限度的減少成本，并降低工人的勞動(dòng)強(qiáng)度和生產(chǎn)成本；
（3）本課題的在滿(mǎn)足使用要求的同時(shí)，充分考慮產(chǎn)品的外形美觀。
已具備的條件和尚需解決的問(wèn)題
（1）設(shè)計(jì)思路已經(jīng)非常明確，對(duì)注塑模具的設(shè)計(jì)流程有充分的認(rèn)識(shí)；
（2）通過(guò)四年的大學(xué)學(xué)習(xí)，我已經(jīng)積累了一定的相關(guān)方面的經(jīng)驗(yàn)；
（3）學(xué)院圖書(shū)館收藏了許多有關(guān)專(zhuān)業(yè)方面的知識(shí)書(shū)籍和期刊等；
（4）雖然在老師的指導(dǎo)下設(shè)計(jì)了相應(yīng)的方案，但是依然會(huì)有某些因素沒(méi)有充分考慮，另外產(chǎn)品能否符合人們的要求也依然未知。
指導(dǎo)教師意見(jiàn)
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見(jiàn)
教研室主任簽名：
年 月 日
系意見(jiàn)
主管領(lǐng)導(dǎo)簽名：
年 月 日
China's plastic mold industry and its development trend
First: china's plastic mold industry
China'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-inch big-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 days Electrical 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 a two-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.
The present condition of the plastic mould level at home and abroad:
The whole, China plastic mould whether in quantity, or in quality, technology and ability has made a great progress, but with the needs of the development of the national economy, the world advanced level, compared to a gap still. Some large, sophisticated, complex, the long life of high-grade plastic mould still need to import a lot of every year. In the total amount of demand exceeding supply at the same time, some cheap plastic mold but supply exceeds demand, market competition is intense, and some technical content is too high middle-grade plastic mould also has the trend of supply exceeds demand
Joining the WTO, plastic mold and die industry to bring huge challenge, at the same time bring more opportunities. Because of China's cheap plastic mold to products, product price obvious advantages, some even only 1/5 of the price the foreign product one third to, to join the WTO, foreign similar products to domestic little impact, and cheap Chinese exports of mould is increase; In the high precision mould, before joining the WTO was mainly rely on imports, join WTO, not only for the exquisite products import has brought more convenient, but also lead to more foreign investment to China factory, bring foreign advanced mould technology and management experience, to cultivate Chinese professional mould talents to the role.
In recent years, Chinese plastic mould manufacturing conditions have improved greatly. Large plastic mould has produced single set of weight can up to 50 tons of injection mold, precision plastic mould has reached the accuracy of 2 μ m, precision parts high small module gear mould and reach the requirements of the highlights learn lamp mould etc has also can produce, plastic mold cavity has been able to produce a mode of plastic mold cavity 7800, high-speed mold production speed can have up to 6 m/min above the high-speed plastic different profile extrusion die and the dual chamber co-extrusion profiles, double-color coextrusion, soft hard co-extrusion, were crowded, again of extrusion and low foaming raw steel-plastic co-extrusion, etc. Various kinds of mold. In the production means, mould enterprise equipment to numerical control rate has increased greatly, CAD/CAE/CAM technology has greatly expanded the applications, high speed processing and RP/RT adoption of advanced technologies such as has been more and more, standard mould using coverage and die commercialization rate is greatly improved, the share of mould of hot flow path are improved greatly. In addition, foreign invested enterprise vigorous development of further promoted the plastic mould design and manufacture level and improve the management level of enterprises, some enterprise already informatization management and digital no PIC manufacturing.
As mould design and processing enterprises to raise the level of, mould manufacturing is from the past relies mainly on the transformation of the skills of fitter mainly rely on technology. This is not only the means of production change, and change the way of production and the rise of the concept. This is a trend that the standardization of mould continuous improvement, the precision of more and more high, production cycle is more and more short, fitter proportion more and more low, and finally promote the overall level of the die and mould industry is rising. China mold and die industry at present more than 10 national high and new technology enterprise, about 200 ﹑ high technology and new technology enterprise. And adapt to the trend, the main production mold backbone strength from skill talented person gradually into technology talents is an inevitable requirement. Of course, now and for quite a long time, and highly talented person still very important, because after all, hard to get rid of mould to skill depend on.
Existing main problems
China plastic mould industry and foreign standards, mainly exist in the following questions.
(1) the unbalanced development, product overall level is low. Although the individual enterprise products has reached or come close to the advanced international level, but overall, the accuracy, the roughness of the cavity surface, production cycle, life index and international advanced level there is a big gap between compared. Including production mode and the overall level of enterprise management, with foreign industrial developed countries there are compared for more than 10 years the gap.
(2) process equipment backward, organization and coordination ability is poor. Though some of the technological transformation of the enterprise after in recent years, has been more advanced technology and equipment level, some of the foreign invested enterprise level of equipment is not behind abroad, but most of the enterprise process equipment is still lag behind. More importantly, the enterprise organization coordinated ability is poor, difficult to integrate or transfer of social resources use, thus it will be difficult to undertake larger projects.
(3) most enterprise development ability is weak, the innovation ability is not enough. On the one hand, low level of technical personnel proportion is not quite high, on the other hand is the scientific development less input; More important concepts backward, insufficient attention to innovation and development. Mould enterprise not only to pay attention to the development of the mould, also want to pay attention to the innovation of the product.
(4) short-term relief to the contradiction between supply and demand. In recent years, domestic plastics mould domestic market meet rate has been less than 74%, including a large, precision, long life mold meet more rate low, less than 60% estimate. Meanwhile, industrial developed countries are accelerating the mould transferring to China, international purchasing more and more, the international market has a good prospect. The market demand, production is difficult to keep up with development at that time, in short supply situation will continue for a period of time.
There are many reasons which creates the above disparity ,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: .
(1) Country to mold industry policy support dynamics also insufficiently
Although the country already was clear about has promulgated the mold profession industrial policy, but necessary policy few, carried out dynamics to be weak. At present enjoyed the mold product increment duty enterprise nation 185, the majority enterprise still the tax burden is only overweight. The mold enterprise carries on the technological transformations introduction equipment to have to pay the considerable amount the tax money, affects the technology advancement, moreover privately operated enterprise loan extremely difficult .
(2) Talented person serious insufficient, the scientific research development and the technical attack investment too urine
Mold profession is the technology, the fund, the work crowded industry, along with the time progress and the technical development, grasps the talented person which and skilled utilizes the new technology exceptionally short, the high-quality mold fitter and the enterprise management talent extremely is also anxious. Because the mold enterprise benefit unsatisfactory and takes insufficiently the scientific research development and the technical attack, the scientific research unit and the universities, colleges and institutes eye stares at is creating income, causes the mold profession invests too few in the scientific research development and the technical attack aspect, causes the mold technological development step not to be big, progresses not quick .
(3) The craft equipment level to be low, also necessary is not good, the use factor low
recent years our country engine bed profession progressed quickly, has been able to provide the quite complete precision work equipment, but compared with the overseas equipment, still had a bigger disparity. Although the domestic many enterprises have introduced many overseas advanced equipment, but the overall equipment level low are very more than the overseas many enterprises. As a result of aspect the and so on system and fund reason, introduces the equipment not necessary, the equipment and the appendix not necessary phenomenon are extremely common, the equipment utilization rate low question cannot obtain the comparatively properly solution for a long time .
(4) Specialization, standardization, commercialized degree low, the cooperation ability
Because receives "large and complete" "small and entire" the influence since long ago, mold specialization level low, the specialized labor division is not careful, the commercialized degree is low. At present domestic every year produces mold, commodity mold minister 40% About, other for from produce uses for oneself. Between the mold enterprise cooperates impeded, completes the comparatively large-scale mold complete task with difficulty. Mold standardization level low, mold standard letter use cave rare is low also to the mold quality, the cost has a more tremendous influence, specially has very tremendous influence .
(5) To the mold manufacture cycle) the mold material and the mold correlation technology falls
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 .
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 factory communications and broadcasting companies, such as mold manufacturers 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 new company 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 plastic mould 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 80 per 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 the construction 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-conditioners and 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:the direction