Development Of New-Style Rubber Injection Molding Vulcanization Machine And Study Of Molding Mechanism

The present thesis pays a great attention on design and development of new-style rubber injection molding vulcanization machine, and study of injection molding process numerical simulation.In the first part, the development status of rubber injection molding process and equipment was introduced, characteristics of rubber injection molding machine were explained, and the structure and its characteristics of plastic injection molding machine and rubber injection molding machine were analyzed.In connection with the specific process requirements, we designed the "FIFO" type XZL-1000X1600 rubber injection molding vulcanization machine independently. This type of device synthesized the advantages of ram injection apparatus and reciprocating-screw injection apparatus with the following characteristics: compact structure, high-precision injection, abundant in material plasticization, more homogeneous residence time in the material barrel, to facilitate the replacement of materials, energy savings, with a short clamping time, die highly adaptive automatic, rapid, stable and reliable clamping. The paper describes how to define the main characteristic parameters of rubber injection molding machine. The injection apparatus, clamping apparatus and hydraulic control system were designed and a set of design drawings for the XZL-1000X1600 rubber injection molding vulcanization machine was completed. Development of the equipment will provide rubber injection machine for the further theoretical study and lay the foundation for the development series. The paper describes how to define the main characteristic parameters of rubber injection molding machine. The injection apparatus, clamping apparatus and hydraulic control system were designed, and design drawings of main parts for the XZL-1000X1600 rubber injection molding vulcanization machine were completed. Development of this type of equipment will provide new-style "FIFO" rubber injection machine for the theoretical study and provide scientific approach for the development series. In the second part, with the help of injection molding CAE (Computer Aided Engineering) simulation software Moldflow and Taguchi DOE (Design of Experiment) technology, the process of injection molding was simulated, and the analysis result of simulation was validated by test. At first, the process of filling, packing and cooling about telephone panel injection molding was simulated by CAE technology. The defects which are inclined to appear during process of injection molding including weld lines, air traps, sink mark, shrinkage and warpage were analyzed. And then the approach of defining the processing parameter appropriately was discussed. Secondary, based on numerical simulation analysis of filling / packing process of injection molding, the variation of sprue freezing time and quality of parts (such as weight variation, sink mark and volumetric shrinkage) with different pressures and forms (such as stationary pressure, linear pressure and step pressure) was analyzed. Thereby we can define the optimal pressure and pressure form and improve the quality of parts. At last, based on the combination of injection molding simulation CAE technology and Taguchi DOE technology, with the direction of overall balance and range analysis methods, the multi-index parameter optimization relating to shrinkage, sink mark and residual stress was designed and analyzed. And then, based on an industrial product, the influence of processing parameter on variation of shrinkage and warpage was studied. Processing parameters were optimized by range analysis method of DOE. Furthermore together with product testing to verify the accuracy of conclusions, and eventually achieve the optimal configuration parameters purposes.