Optimization of mold temperature profile and process parameters for weld line reduction and short cycle time in rapid heat cycle molding
Optimization of mold temperature profile and process parameters for weld line reduction and short cycle time in rapid heat cycle molding
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DOI：
10.1007/s00170-019-03685-3
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发表时间：
2019-04
期刊：
影响因子：
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通讯作者：
S. Kitayama;Ryoto Ishizuki;M. Takano;Yoshikazu Kubo;Shuji Aiba
中科院分区：
文献类型：
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作者：
S. Kitayama;Ryoto Ishizuki;M. Takano;Yoshikazu Kubo;Shuji Aiba
熔接痕减少是塑料注射成型（PIM）中的主要关注点之一，其导致塑料产品的高表面外观和高强度。为了解决这个问题，快速热循环成型（RHCM）作为一种创新的PIM技术引起了人们的关注。在RHCM中，模具温度分布在减少熔接痕方面起着至关重要的作用。另一方面，粉末注射成形还需要高生产率和高表面外观，并且将观察到它们之间的权衡。为了同时达到减少熔接痕和提高生产率的目的，在RHCM中调整模具温度分布和其他工艺参数是很重要的。试错法被广泛用于调整它们，但这是一项非常耗时的任务。在本文中，模具温度分布和几个工艺参数进行了优化，以减少熔接痕和短的周期时间。因此，进行多目标设计优化。PIM中的数值模拟是如此密集，采用基于径向基函数的序列近似优化，以确定帕累托前沿与少量的模拟。通过数值计算结果，阐明了熔接痕减少量和循环时间之间的权衡关系。在数值计算结果的基础上，利用Sodick公司的GL100型PIM机床进行了实验。通过数值计算和实验结果证实了该方法在快速热锻成形中的有效性。
Weld line reduction is one of the major concerns in plastic injection molding (PIM) that results in high surface appearance and high strength of a plastic product. To resolve this issue, rapid heat cycle molding (RHCM) has attracted attention as an innovative PIM technology. In the RHCM, the mold temperature profile plays a crucial role in weld line reduction. On the other hand, high productivity as well as high surface appearance is also required in the PIM, and the trade-off between them will be observed. To achieve weld line reduction and high productivity simultaneously, it is important to adjust both the mold temperature profile and other process parameters in RHCM. A trial and error method is so widely used to adjust them, but it is much time-consuming task. In this paper, the mold temperature profile and several process parameters are optimized for the weld line reduction and the short cycle time. Therefore, multi-objective design optimization is performed. Numerical simulation in PIM is so intensive that a sequential approximate optimization using radial basis function is adopted to identify the Pareto frontier with a small number of simulations. The trade-off between the weld line reduction and the cycle time is clarified through the numerical result. Based on the numerical result, the experiment using a PIM machine (GL100, Sodick) is carried out. It has been confirmed through the numerical and experimental result that the proposed approach in RHCM is valid for the weld line reduction and the short cycle time.