| In this paper,based on Moldex 3D and Abaqus/FE-safe,the coupling analysis of injection-structure-fatigue is carried out for a flat support mold and a barrel cavity mold.The purpose is to provide a more reliable and simple prediction and evaluation method of mold deformation and fatigue life for engineering designers,the specific work contents are as follows:(1)The model simplification rules for the structural analysis of injection mold are put forward,and the flat support mold is simplified by UG software.The analysis model is established and divided into mold base and core cavity.The core cavity is used as the mold base for mold flow analysis in Moldex 3D,the simulation results of the flat support are obtained.(2)Based on the data interface between FEA interface module of Moldex 3D software and Abaqus,taking a flat support mold as the simulation object,the maximum time of cavity pressure is determined,and the pressure at this time is taken as the load to carry out the injection structure coupling analysis.CT2010 static strain gauge is used to test the resistance strain of the injection mold.The test results are compared with the injection structure coupling analysis results.The experimental results show that the simulation results have high accuracy.(3)Based on material mechanics,the mechanical model of the cavity walls and the bottom of the cavity of the rectangular cavity injection mold is established,and the formula of the stiffness and strength analysis of the rectangular formwork is derived.Referring to the stress analysis results of the injection-structure coupling contact surface,the stiffness and strength of the flat support mold are verified by mechanical analysis.The thickness of the cavity walls and the cavity bottom plate is optimized by the calculation results,and the stiffness is verified by the injection-structure coupling analysis again.Based on the above research content,the detailed flow of predicting mold deformation is summarized,which provides the theoretical basis and analysis method for engineering designers to predict the deformation of the mold and reduce the production cost of injection mold.(4)The coupling field analysis of multi software is applied to the fatigue life research of injection mold.Based on the results of injection-structure coupling analysis,taking a cavity mold as the research object,the OBD result file derived from structural analysis in Abaqus is imported into FE-safe to complete the injection-structure-fatigue coupling analysis.(5)Orthogonal and response surface are designed to study the influence of packing pressure,cavity wall thickness and cavity bottom thickness on the fatigue life of injection mold.Taking injection-structure-fatigue coupling analysis as the simulation means,the experiments are completed,and the data are statistically analyzed by using Excel,SPSS and Minitab software.The influence degree and regression equation of packing pressure,cavity wall thickness and cavity bottom thickness on the fatigue life of injection mold are obtained,and the regression equation is verified by three examples,which has reference value in practical application.In this paper,the coupling analysis of injection-structure-fatigue is carried out in view of the problems existing in the prediction of structural stress and strain and fatigue life of injection molding.The scientific method for calculating mold deformation and regression equation for predicting mold life are explored.It is of great engineering value for guiding the design and development of the mold. |
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