Design And Simulation Research Of Injection System Of 2500KN All Electric Injection Molding Machine

The injection molding machine has a pivotal position in the plastics industry, however, with the enhancement of public's attention to energy issues, high energy consumption of the injection molding machine has become an increasingly prominent. Thus energy saving has become one of the main directions for the development of injection molding machine. Electric injection machine is a kind of injection machine which uses servo-drived motor to drive executive parts to complete actions such as closing mold, plasticizing and injection. Except for the characteristics of low energy consumption, low noise, environmental protection, easy to install and maintain, electric injection machine can improve production efficient and production quality. Thus energy saving has become one of the main directions for the development of injection molding machine.The main contents of this paper are as follows:(1)After analysis of the main technical parameters of the same or similar tonnage of all electric injection molding machine designed at home and abroad, the main technical parameters of injection system were designed, then technical parameters of plasticizing, injection and injection plant were calculated. Besides, standard parts such as servo-drive moters, gear boxes and ball screw were chosen.(2)The screw was designed and checked based on theotitical study, with the consideration of force analysis, barrel was designed and checked by finite element software ANSYSWorkbench. Injection system program was determined, and then parts and assembly were built by Solidworks.(3)The virtual prototyping model of the injection systemis was built by ADAMS, then kinetics and dynamics simulations of injection plant move, plasticizing and injection process were arranged. Finally, simulation and theoretical results were compared to verify the reasonability of design.(4)For the processing of polycarbonate, firstly, with orthogonal test and finite element methods, screw lead, depth of screw channel, stud width, bolt gap were chosen as variables, plastic properties of metering section of screw was simulated by preprocessing software GAMBIT, POLYFLOW and postprocessing software CFD-Post. Secondly, through range analysis, shear rate, speed, pressure, shear stress and viscosity were also evaluated. Finally, the optimal parameters of screw lead, depth of screw channel, bolt gap and stud width were 44mm,3.08mm,0.22mm and 4.00mm, respectively.(5)Based on energy consumption, polycarbonate of LEXAN OQ2720 was chosen as raw material, with orthogonal test method and POLYFLOW, numerical simulations were used to obtain the optimal plastic process parameters. The optimal parameters of screw speed, barrel temperature and back pressure were 40r/min,300? and 1MPa, respectively.The influence order of process parameters on energy consumption is:back pressure, barrel temperature and screw speed. Besides, by using factorial design theory and standard orthogonal table, the interaction effect of the three processing parameters and their influence on energy consumption were studied. Research results indicate that interaction effect do exists between back pressure and barrel temperature, barrel and screw speed, barrel temperature and screw speed. Influence of interaction effect between the three parameters on energy consumption is smaller than back pressure and barrel temperature, but bigger than screw speed.