Knowledge-based product planning and engineering of injection-molded parts

这个项目的动机是由于在注塑零件的建造中缺乏一个支持设计师的综合方法。从产品规划到零件设计到零件几何形状的最终优化，设计师将得到本研究项目中结合多学科知识的开发程序和方法的支持。在产品规划的背景下，设计人员通过应用知识系统获得了客观的制造工艺和材料选择的机会。为了实现这一目标，将开发一种将现有专家知识以数据库（知识库）的形式存储的方法。通过随后的输入和基于过程的产品要求与专家知识的比较，可以评估可用的制造方法并做出客观的选择。所创建的知识库将通过选择特定制造过程产生的边界条件得到增强。基于这些信息，将向设计师提出必须由特定材料满足的材料特性，以便实现所需的产品特性，并允许使用选定的生产工艺进行加工。利用这些信息，可以创建一个可能材料的排名。具体材料的选择由用户自行决定。该项目的另一个目标包括开发集成产品仿真，以减少在成型零件设计和尺寸确定过程中必要的优化步骤。首先，集成产品仿真包括基于知识的成型件设计。这意味着在CAD环境中创建成型部件期间，对材料，生产和应力特定边界条件的依从性进行监控，如果必要，可以在设计过程中进行纠正干预。为此，在CAD环境中开发了知识形式化和实现的解决方案。它将以设计和分析功能的形式实现，以保证质量。评估是通过整合设计准则、设计规则和链接到已创建的数据库来完成的。其次，开发了基于知识的注射成型仿真分析方法，实现了零件流变学和周期时间的自动化优化设计。在流变性设计的基础上将确定程序。通过基于知识的分析，可以检测是否有必要通过在零件几何形状中实施助流和屏障来改善充型行为的质量。设计的周期时间优化方法允许对成型零件的几何形状进行优化，从而在随后的注射成型过程中实现均匀且快速的冷却。

The motivation for this project is due to the absence of an integrated approach of supporting the designer in the construction of injection-molded parts. Starting at the product planning via part design to the final optimization of the part geometry, the designer will be supported by the developed procedures and methods of this research project which combine multidisciplinary knowledge. In the context of the product planning, the designer gets the opportunity of an objective manufacturing process and material selection by the application of Knowledge-Based systems. To achieve this aim, a method in which the existing expert knowledge is stored in form of a database, the knowledge base, will be developed. By a subsequent input and by the process-based comparison of product requirements with the expert knowledge, the available manufacturing methods can be assessed and an objective choice can be taken. The created knowledge base will be enhanced by boundary conditions, which arise from the choice of a particular manufacturing process. Based on this information, material properties, that have to be fulfilled by a specific material will be proposed to the designer in order to achieve the required product properties and to allow a processing using the selected production process. Using this information, a ranking of the possible materials can be created. The selection of a specific material is carried out by the user.An additional objective of this project includes the development of an integrated product simulation in order to reduce the necessary optimization steps during the molded part design and dimensioning. Firstly, the integrated product simulation includes the Knowledge-Based molded part design. This means that the compliance with material, production, and stress-specific boundary conditions is monitored during the creation of the molded part in the CAD environment and, if necessary, a corrective intervention in the design process is possible. For this purpose, solutions for the formalization of knowledge and implementation are developed in the CAD environment. It will be implemented in the form of design and analysis features for quality assurance. The evaluation is done through the integration of design guidelines, design rules and a link to the databases which have been created. Secondly, methods for Knowledge-Based analysis of injection molding simulations are developed which enable automated rheological and cycle time optimizing part design. In the rheological design will be determined procedure based. By a knowledge-based analysis it can be detected whether it is necessary to improve the quality of the mold-filling behavior by an implementation of flow aids and barriers in the part geometry. The method for cycle time optimization of the design allows the optimization of the geometry of the molded-part to the effect that a uniform and thus rapid cooling is achieved in the subsequent injection molding process.