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Using Computer Simulation as a Process Design Tool for Resin Injection Pultrusion (RIP) 基于计算机仿真的树脂注射拉挤工艺设计
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1236
Zhongman Ding, Shoujie Li, L. J. Lee, Herbert Engelen
Resin Injection Pultrusion (RIP) is a new composite manufacturing process, which combines the advantages of the conventional pultrusion process and the Resin Transfer Molding (RTM) process. It is sometimes referred to the Continuous Resin Transfer Molding (C-RTM) process. The RIP process differs from the conventional pultrusion process in that the resin is injected into an injection-die (instead of being placed in an open bath) in order to eliminate the emission of volatile organic compounds (styrene) (VOC) during processing. Based on the modeling and simulation of resin/fiber “pultrudability”, resin flow, and heat transfer and curing, a computer aided engineering tool has been developed for the purpose of process design. In this study, the fiber stack permeability and compressibility are measured and modeled, and the resin impregnation pattern and pressure distribution inside the fiber stack are obtained using numerical simulation. Conversion profiles in die heating section of the pultrusion die can also be obtained using the simulation tool. The correlation between the degree-of-cure profiles and the occurrence of blisters in the pultruded composite parts is discussed. Pulling force modeling and analysis are carried out to identify the effect on composite quality due to interface friction between the die surface and the moving resin/fiber mixture. Experimental data are used to verify the modeling and simulation results.
树脂注射拉挤(RIP)是一种新型复合材料制造工艺,它结合了传统拉挤工艺和树脂传递成型(RTM)工艺的优点。它有时被称为连续树脂传递成型(C-RTM)工艺。RIP工艺与传统的拉挤工艺的不同之处在于,树脂被注射到注射模具中(而不是放在露天槽中),以消除加工过程中挥发性有机化合物(苯乙烯)(VOC)的排放。基于树脂/纤维“可拉伸性”、树脂流动、传热和固化的建模和仿真,开发了一种用于工艺设计的计算机辅助工程工具。本文对纤维堆的渗透性和压缩性进行了测量和建模,并通过数值模拟得到了纤维堆内部的树脂浸渍规律和压力分布。利用该仿真工具还可以得到拉挤模加热段的转换轮廓。讨论了固化度曲线与复合材料挤压件起泡发生的关系。为了确定模具表面与移动的树脂/纤维混合物之间的界面摩擦对复合材料质量的影响,进行了拉力建模和分析。用实验数据验证了建模和仿真结果。
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引用次数: 0
Identification of Preform Permeability Distribution in Resin Transfer Molding 树脂传递模塑中预成型体渗透性分布的识别
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1237
B. Minaie, Y. Chen, A. Mescher
This paper presents a numerical scheme that directly calculates the permeability field of the preform during the Resin Transfer Molding (RTM) process. The measured filling front locations as well as the corresponding inlet conditions are used in the proposed scheme to calculate the permeability field. The proposed scheme employs a numerical optimization algorithm to minimize a cost function that leads to the permeability filed of the preform. A time step independent RTM filling algorithm is utilized as a computational kernel to generate the cost function for the subsequent iterative minimization. The proposed permeability identification scheme is applied to test problems that involve isotropic and anisotropic permeability distribution within the perform. The results from these test problems verify the applicability of the proposed scheme.
本文提出了一种直接计算树脂传递模塑(RTM)过程中预制体渗透场的数值方案。该方案采用实测的充填前沿位置和相应的进口条件来计算渗透场。该方案采用数值优化算法最小化导致预制体磁导率场的代价函数。采用时间步长无关的RTM填充算法作为计算核,生成后续迭代最小化的代价函数。将所提出的渗透率识别方案应用于涉及各向同性和各向异性渗透率分布的测试问题。这些测试问题的结果验证了所提出方案的适用性。
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引用次数: 0
Validation of a New Closure Model for Flow-Induced Alignment of Fibers 一种新的纤维流致排列闭合模型的验证
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1246
A. Imhoff, S. Parks, C. Petty, A. Benard
A closure model for flow-induced orientation of short fibers is presented and discussed. The model retains all the six-fold symmetry and contraction properties of the fourth order tensor. A derivation of the model is presented and the conditions required for the model to be realizable are discussed. The model is validated against analytical and numerical solutions of the exact distribution function for the fiber orientation state for different flow fields. Variations of this model and its limitations are also discussed.
提出并讨论了短纤维流致取向的闭合模型。该模型保留了四阶张量的所有六重对称和收缩特性。给出了该模型的推导,并讨论了实现该模型所需的条件。根据不同流场下纤维取向状态精确分布函数的解析解和数值解对模型进行了验证。本文还讨论了该模型的各种变体及其局限性。
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引用次数: 0
Performance Predictor for Thin-Wall Plastic Parts Produced by Injection Molding 注射成型薄壁塑料件的性能预测
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1235
H. Wang, S. Ramaswamy, I. Dris, E. M. Perry, Dominic Gao
The objective of this work was to develop a numerical simulation tool that is able to predict the processing window for thin-wall plastic parts made by the injection molding process. This performance predictor links the processing conditions (filling time, resin inlet melt temperature, and so on) to the mechanical properties and failure mechanisms of the part, using empirical data developed for the thermal and shear degradation behavior of the resin. Usage of such a performance predictor will help to expedite the long process development cycle time and to reduce the potentially expensive tooling costs associated with the thin-wall segment of the plastics business.
这项工作的目的是开发一种数值模拟工具,能够预测通过注射成型工艺制造的薄壁塑料零件的加工窗口。该性能预测器将加工条件(填充时间、树脂入口熔体温度等)与零件的机械性能和失效机制联系起来,使用针对树脂的热降解和剪切降解行为开发的经验数据。使用这种性能预测器将有助于加快漫长的工艺开发周期,并降低与塑料业务薄壁部分相关的潜在昂贵的模具成本。
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引用次数: 0
Design to Evaluation: Desktop CAE for Injection Molding 从设计到评估:注塑成型的桌面CAE
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1230
Jun Hu
CAE tools for injection molding have been dramatically improved in the past several years. Prior to this period, advanced simulations provided a wealth of information about a part and mold design. A common complaint was that too much time was required to perform an advanced simulation. This is the part of reason for the rise in popularity of desktop CAE tools, which provide fast, useful results for those who wish to improve quality, increase profitability and eliminate inefficiencies in critical product and mold design. This paper discusses recently developed desktop CAE technology which greatly reduces the time required to run advanced simulations and quickly evaluates material selection, mold filling, part design, and runner balancing issues, and also optimizes cycle time and generates engineering reports.
在过去的几年中,注塑模具的CAE工具有了显著的改进。在此之前,先进的模拟提供了有关零件和模具设计的丰富信息。一个常见的抱怨是执行高级模拟需要太多时间。这是桌面CAE工具越来越受欢迎的部分原因,这些工具为那些希望提高质量、增加盈利能力和消除关键产品和模具设计效率低下的人提供了快速、有用的结果。本文讨论了最近开发的桌面CAE技术,该技术大大减少了运行高级模拟所需的时间,并快速评估材料选择,模具填充,零件设计和流道平衡问题,还优化了周期时间并生成工程报告。
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引用次数: 0
The Use of Advanced Aluminum Alloys for Enhanced Productivity in Plastic Injection Molding 先进铝合金在提高塑料注射成型生产效率中的应用
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1231
Jim Nerone, K. Ramani
New aluminum alloys, QC-7® and QE-7®, have thermal conductivities four times greater than traditional tool steels, and have significantly increased strength and hardness compared to traditional aluminum materials. Molds were constructed of P-20 tool steel and QE-7® aluminum and were used to provide experimental data regarding thermal mold characteristic and confirm injection molding simulation predictions using C-Mold®. The relationships between cooling time reduction (using aluminum alloys) and polymer type, cooling channel depth, part wall thickness, and coolant temperature were explored both experimentally and using simulation software. It was shown that the potential reduction in cooling time varied from 5% to 25%. The most significant percentage improvements were observed in parts with part wall thickness of 0.05″ to 0.10″ and in molds with cooling channels at a depth ratio (D/d) of 2.0. The thermal pulses in the steel mold 0.10″ from the surface were approximately 63% larger than in aluminum mold.
新型铝合金QC-7®和QE-7®的导热系数是传统工具钢的四倍,与传统铝材料相比,强度和硬度显著提高。模具由P-20工具钢和q -7®铝构成,并用于提供有关热模具特性的实验数据,并确认使用C-Mold®注塑模拟预测。通过实验和仿真软件探讨了冷却时间缩短(采用铝合金)与聚合物类型、冷却通道深度、零件壁厚和冷却剂温度之间的关系。结果表明,冷却时间的潜在减少幅度在5%到25%之间。在零件壁厚为0.05″至0.10″的零件和冷却通道深度比(D/ D)为2.0的模具中,观察到的百分比改善最为显著。钢模0.10″表面的热脉冲比铝模大63%左右。
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引用次数: 0
A Numerical Solution of the Inverse Problem for Thermoforming Processes Using Finite Element Analysis 热成形过程反问题的有限元数值解
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1240
Chao-Hsin Wang, H. F. Nied
Finite element analysis of thermoforming simulation based on isothermal as well as non-isothermal initial conditions has been applied successfully for predicating final thickness distributions. For these simulations, it is assumed that the initial sheet temperature is known and does not change significantly during forming at a rapid stretch rate. For a non-isothermal analysis, the temperature dependent material properties are necessary. In this paper sample results are presented for the so-called inverse thermoforming problem, where an initial temperature distribution is sought numerically that will result in a specific final thickness distribution. Thus, a finite element simulation is combined with an iterative algorithm to obtain inverse solutions for a thermoformed part. In this example, the required initial temperature distributions that result in a uniform final thickness are determined for a thermoformed part. It is shown that the calculated results are quite sensitive to perturbations in the specified initial temperature profile and thus the practical application of optimal temperature distributions may require high precision thermal sensors and controls. This initial temperature distribution can then be used for the determination of desired heating patterns on zone-controlled heaters of a thermoforming machine using transient heat transfer analysis.
基于等温和非等温初始条件的热成形模拟有限元分析已成功地应用于预测最终厚度分布。对于这些模拟,假设初始板料温度是已知的,并且在快速拉伸速率下成形过程中没有显着变化。对于非等温分析,与温度相关的材料性质是必要的。在本文中,给出了所谓的逆热成形问题的示例结果,其中通过数值方法寻求初始温度分布,从而得到特定的最终厚度分布。因此,有限元模拟与迭代算法相结合,以获得热成型零件的反解。在本例中,为热成型零件确定了产生均匀最终厚度所需的初始温度分布。计算结果对给定初始温度分布的扰动非常敏感,因此在实际应用中需要高精度的热传感器和控制。这个初始温度分布可以用来确定热成型机的区域控制加热器使用瞬态传热分析所需的加热模式。
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引用次数: 0
CAE Simulation and Verification of Wire Sweep for BGA 436 bga436导线扫描CAE仿真与验证
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1243
W. Jong, You-Ren Chen
The microelectronics industry continues to grow rapidly in size and importance. As thinner and denser IC packages become, packaging process becomes more challenging and troublesome. The ball grid array (BGA) technology uses substrate and solder balls to replace the traditional leadframe, which offers many advantages over fine pitch technology. These include better assembly yield, superior electrical performance, and higher I/O density. However, the high density of bonding wires form a separating layer which will hold back the molding compound flowing through these regions. The paper presents the simulation of melt-front advancement and wire sweep for BGA 436. The results has been verified by the experimental studies. It is found that the high-density of wires has played a very important role in performing the CAE analysis. It shows that the melt-front advancement can be precisely predicted by CAE simulation software with proper consideration of wire density. With the accurate simulation of melt-front advancement, the CAE results can be further used to perform further engineering analysis. The wire sweep of the package demonstrates the use of CAE analysis, which also shows very good agreement with the experimental study.
微电子工业的规模和重要性继续迅速增长。随着IC封装变得越来越薄、越来越密,封装过程变得越来越具有挑战性和麻烦。球栅阵列(BGA)技术使用基板和焊球来取代传统的引线框架,与细间距技术相比具有许多优点。这些优点包括更好的装配成品率、优越的电气性能和更高的I/O密度。然而,高密度的粘合线形成一个分离层,这将阻止成型化合物流过这些区域。本文介绍了bga436熔锋推进和钢丝扫描的仿真。实验结果证实了这一结论。研究发现,线材的高密度在CAE分析中起着非常重要的作用。结果表明,在适当考虑线材密度的情况下,CAE仿真软件可以准确地预测熔锋进程。通过对熔锋推进过程的精确模拟,可以进一步利用CAE结果进行进一步的工程分析。对该封装的导线扫描进行了CAE分析,结果与实验结果吻合较好。
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引用次数: 1
An Integrated Approach to Evaluate the Cycle Time in Injection Molding 注射成型周期时间的综合评价方法
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1222
D. Gao, W. Bushko
The cycle time prediction is considered as a critical issue in injection molding. It relates directly to the production rate and the part quality. It is commonly defined as the time duration between the start of the injection and the ejection of the part. When the cycle time exceeds the desired range, the production rate will be compromised. In some cases, due to excessively increased friction force, the part may be subject to severe failure such as breakage during ejection. Another possible situation is that the ejector pins can be damaged because the friction force exceeds the maximum ejection force that the machine can provide through the ejectors. If the part is ejected too early, only a thin layer of polymer is solidified and the ejection may cause the part to be deformed permanently which generally leads to surface defects. For most injection molders, the cycle time is estimated through molding trials, which is very costly and time consuming. In the case of testing a new material, it is even more difficult to determine a proper cycle time ranger due to the lack of knowledge on the material behavior.
循环时间预测是注射成型中的一个关键问题。它直接关系到生产率和零件质量。它通常被定义为从开始注射到出模之间的时间间隔。当循环时间超过预期范围时,生产速率将受到影响。在某些情况下,由于摩擦力过度增加,零件可能会出现严重的故障,例如在弹出过程中断裂。另一种可能的情况是,由于摩擦力超过了机器通过弹射器所能提供的最大弹射力,顶针可能会损坏。如果零件过早射出,只有一层薄薄的聚合物凝固,射出可能导致零件永久变形,通常导致表面缺陷。对于大多数注塑机来说,周期时间是通过成型试验来估计的,这是非常昂贵和耗时的。在测试新材料的情况下,由于缺乏对材料行为的了解,确定适当的循环时间范围更加困难。
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引用次数: 0
Effects of Process Conditions on Shrinkage and Warpage: Experiments and Simulations 工艺条件对收缩和翘曲的影响:实验和模拟
Pub Date : 2000-11-05 DOI: 10.1115/imece2000-1232
James T. Wang, C. Yoon
In the injection mold process, a pressure gradient exists from the polymer entrance to the last-fill location. At different planar locations of a part, when the polymer melt cools down to the transition temperature and freezes (changes from liquid to solid) at different pressures, shrinkage at the various locations will be different. If cooling channels are not arranged properly, the mold wall temperatures on the cavity and core sides can be different. This unbalanced cooling can also cause the melt at the upper and lower halves of the cavity to shrink differently, because they freeze at different times and different pressures. These two types of non-uniform shrinkage will cause parts to warp. Reducing shrinkage and warpage is one of the top priorities for improving the quality of injection molded parts. In addition to part design and material properties, process conditions are the most important determinants of part quality. In this paper, the relationship between process conditions and in-cavity residual stress will be studied. In-cavity residual stress is the driving force that causes parts to deform after they are taken out of the mold. The effects of process conditions on injection-molded part quality (in terms of shrinkage and warpage) will be discussed. Different packing pressure levels, together with unbalanced cooling from mold wall temperatures, will be examined. Deformation of injection molded parts will be measured. Comparisons between experimental and numerical simulation results will be reported.
在注射模过程中,从聚合物入口到最后填充位置存在压力梯度。在零件的不同平面位置,当聚合物熔体冷却到转变温度并在不同压力下冻结(由液体变为固体)时,不同位置的收缩率会有所不同。如果冷却通道布置不当,则型腔和芯侧的模壁温度可能不同。这种不平衡的冷却也会导致腔体上下半部分的熔体收缩不同,因为它们在不同的时间和不同的压力下冻结。这两种不均匀收缩会导致零件翘曲。减少收缩和翘曲是提高注塑件质量的首要任务之一。除了零件设计和材料性能外,工艺条件是零件质量的最重要决定因素。本文将研究工艺条件与腔内残余应力之间的关系。型腔内残余应力是零件出模后产生变形的驱动力。将讨论工艺条件对注塑件质量的影响(在收缩和翘曲方面)。将检查不同的包装压力水平,以及模具壁温度的不平衡冷却。将测量注塑件的变形。将报告实验和数值模拟结果的比较。
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引用次数: 1
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