Q/SZJ191001-2017塑料件注射成型仿真分析規(guī)范SpecificationofInjectionMoldingProcessSimulationProcedureforPlasticPart20XX20XX-12-31實(shí)施20XX-11-27發(fā)布XXXX汽車工程技術(shù)有限公司發(fā)布Q/SZXX-X-2017塑料件注射成型仿真分析規(guī)范范圍本標(biāo)準(zhǔn)規(guī)定了塑料件結(jié)構(gòu)設(shè)計(jì)階段的注射成型塑料件工藝分析建模、邊界條件處理及后處理方法及分析結(jié)果檢查要點(diǎn)。本標(biāo)準(zhǔn)適用于CAE部門塑料件結(jié)構(gòu)設(shè)計(jì)階段的注射成型塑料件工藝分析。規(guī)范性引用文件無。術(shù)語和定義無流程圖ProcessFlowDiagram在產(chǎn)品開發(fā)階段，分析的目的是驗(yàn)證產(chǎn)品設(shè)計(jì)合理性，不考慮冷卻水路等模具及工藝優(yōu)化對(duì)產(chǎn)品的影響。以下流程主要針對(duì)‘充填+保壓+翹曲’分析序列。Intheproductdesignstage,thesimulationaimedtovalidationrationalityofthepartdesign.So,themold(coolingchannel)andprocessoptimizationwillbeignored.Theflowdiagramismainlyaimedto‘Fill+pack+Warp’analysissequence.圖1流程圖Fig1ProcessFlowDiagram工具描述ToolDescription仿真分析過程中需要用到的如下軟件:Thefollowingsoftwarefacilitatestheanalyticalsimulationprocess:前處理(Preprocessors):MoldflowSynergy,CADDoctor,Hypermesh,ANSA求解器(AnalysisCode):MoldflowInsight后處理(Postprocessors):MoldflowSynergy建模Modeling單位Units分析中所用單位制如下所示:Theunitsusedintheanalysisareasfollows:壓力(Pressure) Mpa溫度(Temperature) oC時(shí)間(Time) s力(Force) N質(zhì)量(Mass) g長度(Length) mm模型檢查CheckModel導(dǎo)入塑料件幾何模型前，檢查模型，確保CAD模型是CAD實(shí)體，不是面片：ThechecktheCADmodeltypeisCADbodybutnotsurfacebeforeimportthemodel.模型準(zhǔn)備PrepareFEModel為提高計(jì)算效率，需要對(duì)模型進(jìn)行簡化處理，去除小特征：圓角、倒角、臺(tái)階、過小的孔等。去除特征的基本原則：不影響塑料的流長對(duì)產(chǎn)品體積的改變不超過5%對(duì)產(chǎn)品局部壁厚的改變不超過20%與CAD軟件壁厚計(jì)算對(duì)比，整體壁厚的改變不超0.10mm過密的網(wǎng)孔需要用等效壁厚和形狀因子進(jìn)行簡化Forimprovingthecomputationalefficiency,thesmallfeatureshouldberemoved:fillet,chamfer,stepandverysmallholes,etal.Thefeatureremovingprincipals:Itshouldnotaffectthepolymer’sflowlengthThevolumeshouldnotbechangedmorethan5%Thelocalthicknessdistributionshouldnotbechangedmorethan20%ComparingwiththeCADthicknesscomputation,thenominalthicknessdistributionshouldnotbechangedmorethan0.10mmThedenseholeshouldbesimplifiedbyequivalentthicknessandshapefactor.網(wǎng)格劃分Meshing需要?jiǎng)澐志W(wǎng)格的部件有：產(chǎn)品、流道、水路、模仁等，不同部件采用的網(wǎng)格尺寸和類型都有區(qū)別，此處只定義產(chǎn)品和流道部分的網(wǎng)格劃分。網(wǎng)格類型選擇:Moldflow支持柱體單元、中性面、雙層面和四面體網(wǎng)格。大部分汽車用塑料件均采用雙層面或中性面網(wǎng)格壁厚超過5mm或者壁厚差異大的產(chǎn)品用四面體網(wǎng)格，如多孔格珊或門把手。普通流道和冷卻水路使用柱體單元有特殊要求的產(chǎn)品(如雙色成型、氣輔、IMD、微發(fā)泡等),根據(jù)具體情況選擇網(wǎng)格類型網(wǎng)格劃分尺寸與質(zhì)量：2.1 雙層面或中性面網(wǎng)格，網(wǎng)格邊長設(shè)置為產(chǎn)品壁厚的2倍～5倍2.2 四面體網(wǎng)格，網(wǎng)格邊長設(shè)置為產(chǎn)品壁厚的0.5倍～2倍2.3 壁厚變化區(qū)域至少三排網(wǎng)格才能捕捉到流動(dòng)問題，如圖2，圖3和圖4所示2.4 流道柱體單元的長度值為其直徑的1倍～3倍，對(duì)于澆口和流道要保證劃分為至少三個(gè)單元才能捕捉到流動(dòng)問題，如圖5所示2.5 雙層面或中性面網(wǎng)格最大縱橫比不超過20:1，平均縱橫比不超過3:1；具體參照表12.6 四面體網(wǎng)格必須由縱橫比合格的雙層面網(wǎng)格生成.2.7 雙層面網(wǎng)格匹配率至少90%(特大零件如保險(xiǎn)杠、儀表板至少85%),具體參照表1.Itwillmeshfollowingcomponents:part,runner,coolingchannelandmoldblock.Thedifferentcomponentmatcheddifferentmeshsizeandtype.Wearejustdefiningtherulesforpartandrunner.Meshselection:Moldflowsupportbeam,Midplane,DualDomainandTetraelements.1.1 MidplaneorDualDomainaresuitableformostoftheplasticpartinautomobileindustry.1.2 Tetraissuitableforthethickerpart(morethan5mm)or‘Chunky’part,suchasgrailwithmanyholes,doorknob.1.3 Beamissuitablefornormalrunnerandcoolingchannels.1.4 Forthespecialpart,itwilldependontherealsituation.Meshsizeandquality2.1 ForMidplaneorDualDomain,themeshsizeshouldbe2~5timesofpartthickness2.2 ForTetraelement,themeshsizeshouldbe0.5~2timesofpartthickness.2.3 Inthethicknessvibrationregion,thereareatleast3rowsofelementstopickuptheflowproblems.Pleasereviewfig.2,fig.3andfig.42.4 Forbeamrunner,themeshsizeshouldbe1~3timesofthediameter.Forthegateandrunner,thereareatleast3elementsonthelinetopickuptheflowproblems.Pleasereviewfig.5.2.5 ThemaxaspectratioofMidplaneandDualDomainshouldbenomorethan20:1.Theaverageaspectratioshouldbenomorethan3:1.Pleasereferencesheet1.2.6 TheTetraelementsshouldbeconvertedfromDualDomain.2.7 TheMatchratioshouldbeatleast90%(Forthehugepart,itshouldbemorethan85%).Pleasereferencesheet1.圖2粗糙與細(xì)化的網(wǎng)格預(yù)測遲滯Fig2Hesitationpredictionwithacoarseandfinemesh圖3粗糙與細(xì)化的網(wǎng)格預(yù)測困氣Fig3Airtrappredictionwithacoarseandfinemesh圖4粗糙與細(xì)化的網(wǎng)格預(yù)測熔接線Fig.4Weldlinepredictionwithacoarseandfinemesh圖5澆口的流道需要至少3個(gè)柱體單元Fig5Gateandrunnershouldbemeshedatleast3beamelements.表1網(wǎng)格質(zhì)量要求表Sheet1MeshqualityrequirementsMeshIssueDualDomainMidplane3D(Tetra)FreeedgesMustNOThaveanyOnlytypeofedgeallowedSameasDualDomainNon-manifoldedgeMustNOThaveanyValidatTcross-sectionsSameasDualDomainManifoldedgeOnlytypeofedgeallowedMostcommontypeofedgeSameasDualDomainMatchratio>85%forflow,>90%forwarpageNotApplicableNotApplicableReciprocalMatch>90%forwarpageNotApplicableNotApplicableAspectratioAverage<3:1,Maximum<20:1SameasDualDomain<20:1onDualDomainmeshbeforeconversionConnectivityregionsOnegroupforthepartSameasDualDomainSameasDualDomainElementorientationThetop(blue)sideoftheelementpointingoutwardSameasDualDomainConsistentmeshorientationOverlappingelementsMustNOThaveanySameasDualDomainSameasDualDomainIntersectionsMustNOThaveanySameasDualDomainSameasDualDomainZeroareaelementsMustNOThaveanySameasDualDomainSameasDualDomain材料/澆口位置/注塑機(jī)Material/Gatelocation/InjectionMachine選擇材料SelectMaterial選擇材料應(yīng)滿足產(chǎn)品的選材要求，在Moldflow材料庫中顯示‘質(zhì)量指示器’(圖6)品質(zhì)至少銀牌(Silver)，最好是金牌(Gold)。如材料庫沒有所用材料牌號(hào)，需材料供應(yīng)商推薦相近材料牌號(hào)。Thematerialshouldmatchtheproductproperties.ThematerialqualityindicatorsshouldbeSilverorGoldinMoldflow.Thematerialrepliershouldprovide圖6材料質(zhì)量指示器Fig6Materialqualityindicators澆口位置GateLocation需根據(jù)產(chǎn)品的功能和外觀特性布置澆口，放置在產(chǎn)品允許放置的合適位置。澆口放置應(yīng)遵循以下基本原則：a. 在壁厚區(qū)域b. 遠(yuǎn)離薄壁區(qū)域c. 避免噴射d. 避免熔接線出現(xiàn)在薄弱或者可見區(qū)域e. 避免困氣Placegates:a. Inthickerareas.b. Farfromthinareasc. Topreventjetting.d. Topreventweldlinefromforminginweakregions,orwheretheywillbevisible.e. Topreventairtraps.注塑機(jī)選擇SelectInjectionMachine所選擇的注塑機(jī)應(yīng)與實(shí)際生產(chǎn)時(shí)所采用的注塑機(jī)參數(shù)一致.Theselectedinjectionmachineparametricshouldmatchwithactualproductionmachine.圖7注塑機(jī)參數(shù)Fig6Materialqualityindicators確定成型條件Determinemoldingconditions合適的成型條件通過成型窗口(圖7)分析確定，然后在后續(xù)的填充分析中使用，可能需要進(jìn)行微小的修改。除了優(yōu)化成型條件，成型窗口分析還可用作快速初始分析，以比較材料或澆口位置。SuitablemoldingconditionsaredeterminedfromaMoldingWindow(Fig.7)analysis,andused,perhapswithslightmodification,insubsequentfillinganalyses.Inadditiontooptimizingthemoldingconditions,aMoldingWindowanalysisisusedasaquickinitialanalysistocomparematerialsorgatelocations.圖7成型窗口結(jié)果Fig.7MoldingWindowresult.設(shè)置工藝參數(shù)SettingmoldingParametric進(jìn)行模流分析時(shí)所采用的注塑工藝參數(shù)，可以借鑒成型窗口。以下是汽車各類產(chǎn)品常用的工藝參數(shù)，推薦參考；特殊產(chǎn)品注塑工藝參數(shù)另行商定。WecanusetheMoldingWindowresultsforreferencetorunMoldflow.Herearesomecommonmoldingparametricforplasticpartinautomobileindustry.Forsomespecialmoldingprocess,weshoulddecidethroughconsultation.表2常用工藝參數(shù)Sheet2Injectionmoldingparametric產(chǎn)品類型注射時(shí)間（s）保壓壓力冷卻時(shí)間(s)一段二段時(shí)間(s)壓力(Mpa)時(shí)間(s)壓力(s)特大型產(chǎn)品(保險(xiǎn)杠、儀表板類)8~125~8V/P切換壓力的60%~80%5~8V/P切換壓力的40%~60%20~30大型產(chǎn)品(門飾板、尾翼、大格柵類)5~105~83~615~20中型產(chǎn)品(C柱、副儀表，小格柵類）4~83~53~510~15小型產(chǎn)品2~53~51~35~10分析并查看結(jié)果ANALYSISANDREVIEWRESULTS根據(jù)分析目標(biāo)選擇對(duì)應(yīng)分析序列，并查看結(jié)果。主要檢查結(jié)果包含：充填時(shí)間、溫度、壓力、凍結(jié)時(shí)間、熔接線、困氣、鎖模力和翹曲。具體內(nèi)容，請(qǐng)參照模流分析結(jié)果檢查清單。Dependingthesimulationtarget,weselecttheanalysissequenceandreviewresults.Themainresultscontain:filltime,temperature,pressure,frozentime,weldline,airtraps,clampforceandwarpageetal.Fordetails,pleasecheckthesheet3:Moldflowresultschecklist.分析要求AnalysisRequirements表3模流分析結(jié)果檢查清單Sheet3Moldflowresultschecklist.檢查項(xiàng)目標(biāo)準(zhǔn)目標(biāo)值充填時(shí)間Filltime流動(dòng)平衡、無短射、等值線均勻無滯留Fillbalance,noshortshot,contourlineuniformandnohesitation無短射、無滯流Noshortshot,nohesitation.流動(dòng)前沿溫度Temperatureatflowfront均勻無突變,無異常，制品前沿溫度在成型溫度范圍內(nèi)Temperatureatflowfrontintherecommendedrangeanduniform.外觀件主面溫差5oC以內(nèi)，非外觀件主面溫差20oC以內(nèi).Forexteriorpart,thetemperaturechangeshouldbein5oConcardinalarea;forinteriorpart,temperaturechangeshouldbein20oConcardinalareaV/P切換壓力V/Pswitchoverpressure應(yīng)該在95％-99％之間;最大壓力不超過注塑機(jī)許用值的80%；分型面壓力不超過80MPa.Shouldbein95%~99%;themaxinjectionpressureshouldbein80%oftheinjectionmachinecapability.Thepressureonthepartingsurfaceshouldbenomorethan80MPa.95％-99％;分型面壓力<80MpaShouldbein95%~99%;Thepressureonthepartingsurfaceshouldbenomorethan80MPa.表3模流分析結(jié)果檢查清單（續(xù)）檢查項(xiàng)目標(biāo)準(zhǔn)目標(biāo)值保壓壓力Packpressure最大不超過注塑機(jī)許用值的80%Themaxpressureshouldbein80%ofmachinecapability.80%剪切速率Shearrate參考指標(biāo)：外觀區(qū)域不超過材料剪切速率最大值。Referencetarget:nomorethanthemax.shearratevalueincosmeticarea.材料許可值Theallowedshearratevalue.剪切應(yīng)力Shearstress參考指標(biāo)：外觀區(qū)域不超過材料剪切速率最大值Referencetarget:nomorethanthemax.shearstressvalueincosmeticarea.材料許可值Theallowedshearstressvalue.鎖模力Clampforce參考指標(biāo)：最大不超過注塑機(jī)許用值的80%Referencetarget:nomorethanthemax.clampforceofmachinecapability.80%困氣Airtraps制品表面重要位置沒有困氣，制品分型面能夠?qū)崿F(xiàn)排氣。Noairtrapsonthecosmetica