Optimization Design System Of Plastic Injection Mold Based On CAD/CAE Integrated Model

With the further application of computer technology in the field of injection molddesign, there are more and more researches focusing on integration of integrativemodeling, numerical simulation, comprehensive evaluation and optimal design techniqueswith professional CAD platform, which contributes to avoid model conversion betweendesign and analysis software, reduces dependence on experience in analysis resultevaluation, and promotes automation and intelligence of design process. With the financialsupport from the Technology Project of Guangdong Province (2007B010400082) and theNational Key Technology R&D Program of China (2011BAF16B00), the methodologiesof CAD/CAE integration and design optimization have been studied in this paper, and anoptimization design system of injection mold based on CAD/CAE integrated model hasalso been developed.It is the key for the integration of CAD and CAE to construct a unified data model.Therefore, this paper, which proposes a CAD/CAE integrated model combining thedefinition of finite element model with boundary representative geometric model, achievesseamless integration between geometric and finite element modeling on professional CADplatform by using parametric composite modeling, mesh generation and engineeringproperties mapping techniques. Based on this integrated model, an injection moldoptimization design system, including design, analysis, evaluation and optimizationfunction, is designed. And the framework and component modules of the system arediscussed.In order to solve the problem of relative isolation of the design and analysis process,this paper proposes an integrated design method for CAD/CAE integration of the injectionmold, and conducts in-depth study for the aspects of product, filling system, coolingsystem and mold structure. Meanwhile, the feature recognition technology is studied tohelp realizing CAD/CAE integration. By recognition of detailed features of product andcooling system, the product geometric model is idealized and the cooling system CAEmodel is automatically extracted, which provides a strong support for the creation of theCAD/CAE integrated model. Visual display and comprehensive evaluation of injected molding CAE analysisresults are very important to the automatic optimization of design schemes. For this reason,an approach to achieve visualization of data field calculated by CAE software on CADplatform is proposed. Through the analysis of injection mold design objectives, this paperestablishes an open set of evaluation criteria for design optimization, which focuses on theresearch of calculation of optimization criterions and mathematical judgment method ofconstraint criterions. On this basis, a design optimization process and design optimizationmethod based on injection molding simulation is proposed.The mold deformation simulation in the process of injection molding is greatsignificance to the mold structure optimization, weight reduction and cost saving.According to this reason, by the detailed analysis of optimization objective, constraintconditions and design variable, this paper proposes an injection mold design optimizationprocess based on structure analysis and focuses on the construction of structural analysismodel of injection mold. Several kinds of structural analysis models of injection mold areestablished through simplifying mechanical model, and the pressure analysis result of theproduct is imported as the mold cavity load by matching mesh. Based on these studies, themold structural analysis is carried out in the CAD/CAE integrated system. By comparingthe deformation simulation results of the box injection mold with the experiments, the bestsimplified scheme of injection mold structure is presented.On the basis of the above theoretic achievement, a prototype system based onCAD/CAE integrated model has been developed. And some practical cases are studied toillustrate the system function and demonstrate the usefulness and feasibility of the system.