A CADCAEintegrated injection mold design system for plastic products.docx
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A CADCAEintegrated injection mold design system for plastic products.docx
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ACADCAEintegratedinjectionmolddesignsystemforplasticproducts
ACAD/CAE-integratedinjectionmolddesignsystemforplasticproducts
IvanMatin&MiodragHadzistevic&JankoHodolic
&DjordjeVukelic&DejanLukic
Abstract:
Molddesignisaknowledge-intensiveprocess.Thispaperdescribesaknowledge-basedoriented,parametric,modularandfeature-basedintegratedcomputer-aideddesign/computer-aidedengineering(CAD/CAE)systemformolddesign.DevelopmentofCAxsystemsfornumericalsimulationofplasticinjectionmoldingandmolddesignhasopenednewpossibilitiesofproductanalysisduringthemolddesign.TheproposedsystemintegratesPro/ENGINEERsystemwiththespeciallydevelopedmoduleforthecalculationofinjectionmoldingparameters,molddesign,andselectionofmoldelements.ThesysteminterfaceusesparametricandCAD/CAEfeature-baseddatabasetostreamlinetheprocessofdesign,editing,andreviewing.AlsopresentedaregeneralstructureandpartofoutputresultsfromtheproposedCAD/CAE-integratedinjectionmolddesignsystem.
Keywords:
Molddesign.Numericalsimulation.CAD.CAE
1Introduction
Injectionmoldingprocessisthemostcommonmoldingprocessformakingplasticparts.Generally,plasticinjectionmoldingdesignincludesplasticproductdesign,molddesign,andinjectionmoldingprocessdesign,allofwhichcontributetothequalityofthemoldedproductaswellasproductionefficiency[1].Thisisprocessinvolvingmanydesignparametersthatneedtobeconsideredinaconcurrentmanner.Molddesignforplasticinjectionmoldingaidedbycomputershasbeenfocusedbyanumberofauthorsworldwideforalongperiod.Variousauthorshavedevelopedprogramsystemswhichhelpengineerstodesignpart,mold,andselectionparametersofinjectionmolding.Duringthelastdecade,manyauthorshavedevelopedcomputer-aideddesign/computer-aidedengineering(CAD/CAE)molddesignsystemsforplasticinjectionmolding.Jongetal.developedacollaborativeintegrateddesignsystemforconcurrentmolddesignwithintheCADmoldbaseontheweb,usingPro/E.Lowetal.developedanapplicationforstandardizationofinitialdesignofplasticinjectionmolds.Thesystemenableschoiceandmanagementofmoldbaseofstandardmoldplates,butdoesnotprovidemoldandinjectionmoldingcalculations.Theauthorsproposedamethodologyofstandardizingthecavitylayoutdesignsystemforplasticinjectionmoldsuchthatonlystandardcavitylayoutsareused.Whenstandardlayoutsareused,theirlayoutconfigurationscanbeeasilystoredinadatabase.Linatal.describeastructuraldesignsystemfor3Ddrawingmoldbasedonfunctionalfeaturesusingaminimumsetofinitialinformation.Inaddition,itisalsoapplicabletoassignthefunctionalfeaturesflexiblybeforeaccomplishingthedesignofasolidmodelforthemainpartsofadrawingmold.Thisdesignsystemincludesmodulesforselectionandcalculationofmoldcomponents.ItusesPro/EmodulesPro/ProgramandPro/Toolkit,andconsistsofmodulesformoldselection,modificationanddesign.Dengetal.analyzeddevelopmentoftheCAD/CAEintegration.TheauthorsalsoanalyzedsystemsandproblemsofintegrationbetweenCADandCAEsystemsfor
Fig.1Generalstructureofintegratedinjectionmolddesignsystemforplasticproducts
Fig.2Structureofmodulefornumericalsimulationofinjectionmoldingprocess
numericalsimulationofinjectionmoldingandmolddesign.AuthorsproposeafeatureontologyconsistingofanumberofCAD/CAEfeatures.Thisfeaturerepresentsnotonlythegeometricinformationofplasticpart,butalsothedesignintentisorientedtowardsanalysis.Partfeaturescontaintheoverallproductinformationofaplasticpart,wallfeatures,developmentfeatures(suchaschamfer,ribs,boss,hole,etc.),treatmentfeatureswhichcontainanalysis-relateddesigninformationandsubwall/developedfeatures.Wallanddevelopmentfeaturesaresocalled“componentfeatures”.Godecetal.developedaCAEsystemformolddesignandinjectionmoldingparameterscalculations.Thesystemisbasedonmorphologymatrixanddecisiondiagrams.Thesystemisusedforthermal,rheologicalandmechanicalcalculation,andmaterialbasemanagement,butnointegrationwithcommercialCAxsoftwareisprovided.。
Huangetal.
developedamold-basedesignsystemforinjectionmolding.Thedatabasetheyusedwasparametricandfeature-basedoriented.ThesystemusedPro/Eformodelingdatabasecomponents.Kongetaldevelopedaparametric3Dplasticinjectionmolddesignsystemintegratedwithsolidworks.Otherknowledge-basedsystems,suchasIMOLD,ESMOLD,IKMOULD,andIKBMOULD,havebeendevelopedforinjectionmolddesign.IMOLDdividesmolddesignintofourmajorsteps;partingsurfacedesign,impressiondesign,runnersystemdesign,andmold-basedesign.Thesoftwareusesaknowledge-basedCADsystemtoprovideaninteractiveenvironment,assistdesignersintherapidcompletionofmolddesign,andpromotethestandardizationofthemolddesignprocess.IKB-MOULDapplicationconsistsofdatabasesandknowledgebasesformoldmanufacturing.Louetal.developedanintegratedknowledge-basedsystemformoldbasedesign.Thesystemhasmoduleforimpressioncalculation,dimensioncalculation,calculationofthenumberofThispaperdescribesKBSandkeytechnologies,suchasproductmodeling,theframe-rulemethod,CBS,andtheneuralnetworks.AmultilayerneuralnetworkhasbeentrainedbybackpropagationBP.moldplatesandselectionofinjectionmachine.ThesystemusesPro/MoldBaselibrary.Thisneuralnetworkadoptslength,width,heightandthenumberofpartsinthemoldasinputandnineparameters(length,width,andheightofupanddownset-in,moldbasessidethickness,bottomthicknessofthecore,andcavityplates)asoutput.Moketal.[13,14]developed
anintelligentcollaborativeKBSforinjectionmolds.Mokatelhasdevelopedaneffectivereuseandretrievalsystemthatcanregistermodeledstandardpartsusingasimplegraphicaluserinterfaceeventhoughdesignersmaynotknowtherulesofregistrationforadatabase.ThemolddesignsystemwasdevelopedusinganOpenAPIandcommercialCAD/computeraidedmanufacturing(CAM)/CAEsolution.ThesystemwasappliedtostandardizemoldbasesandmoldpartsinHyundaiHeavyIndustry.Thissystemadoptedthemethodofdesignediting,whichimplementsthemastermodelusingfeatures.Thedevelopedsystemprovidesmethodswherebydesigners
Canregisterthemastermodel,whichisdefinedasafunctionof3DCAD,asstandardpartsandeffectivelyreusestandardpartseventhoughtheydonotrecognizetherulesofthedatabase.Todicetal.developedasoftwaresolutionforautomatedprocessplanningformanufacturingofplasticinjectionmolds.ThisCAD/CAPP/CAMsystemdoesnotprovideCAEcalculationofparametersofinjectionmoldingandmolddesign.Maicanetal.usedCAEformechanical,thermal,andrheologicalcalculations.Theyanalyzedphysical,mechanical,andthermalpropertiesofplasticmaterials.Theydefinedthecriticalparametersofloadedpart.Nardinetal.triedtodevelopthesystemwhichwouldsuitalltheneedsoftheinjectionmoldingforselectionofthepartmold–technologysystem.Thesimulationresultsconsistofgeometricalandmanufacturingdata.Onthebasisofthesimulationresults,partdesignerscanoptimizepartgeometry,whilemolddesignerscanoptimizetherunningandthecoolingsystemofthemold.Theauthorsdevelopedaprogramwhichhelpstheprogrammersoftheinjectionmoldingmachinetotransfersimulationdatadirectlytothemachine.Zhouetaldevelopedavirtualinjectionmoldingsystembasedonnumericalsimulation.Maetaldevelopedstandardcomponentlibraryforplasticinjectionmolddesignusinganobject-orientedapproach.Thisisanobjectoriented,librarymodelfordefiningmechanicalcomponentsparametrically.Theydevelopedanobject-orientedmoldcomponentlibrarymodelforincorporatingdifferentgeometrictopologiesandnon-geometricinformation.Overtheyears,manyresearchershaveattemptedtoautomateawholemolddesignprocessusingvariousknowledge-basedengineering(KBE)approaches,suchasrule-basedreasoning(RBR),andcasebase(CBR)andparametricdesigntemplate(PDT).Chanatal.[20]developeda3DCADknowledge-based-assistedinjectionmolddesignsystem(IKBmold).Intheirresearch,designrulesandexpertknowledgeofmolddesignwereobtainedfromexperiencedmolddesignersand
Fig.3Formstodefinethemoldgeometry
handbooksthroughvarioustraditionalknowledgeacquisitionprocesses.hetraditionalKBEapproaches,suchasRBR,CBR,andsimplePDThavebeensuccessfullyappliedtomoldcavityandrunnerlayoutdesignautomationoftheoneproductmold.Yeetal.proposedafeature-basedandobject-orientedhierarchicalrepresentationandsimplifiedsymbolicgeometryapproachforautomationmoldassemblymodeling.Thepreviouslymentionedanalysisofvarioussystemsshowsthatauthorsuseddifferentwaystosolvetheproblemsofmolddesignbyreducingittomoldconfigurator(selector).TheyusedCAD/CAEintegrationforcreatingprecisionrulesfor
mold-baseselection.ManyauthorsusedCAEsystemfornumericalsimulationofinjectionmoldingtodefineparametersofinjectionmolding.SeveralalsodevelopedoriginalCAEmodulesformoldandinjectionmoldingprocesscalculation.However,commontoallpreviouslymentionedsystemsisthelackofmoduleforcalculationofmoldandinjectionmoldingparameterswhichwouldallowintegrationwiththeresultsofnumericalsimulation.Thisleadstoconclusionthatthereisaneedtocreateasoftwaresystemwhichintegratesparametersofinjectionmoldingwiththeresultobtainedbynumericalsimulationofinjectionmolding
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