【正文】 通過(guò)實(shí)驗(yàn)結(jié)果表明，目前這個(gè)方法非常適合處理快速成型模具中的問(wèn)題。 但目前所有的做常規(guī)注塑模具的模擬包已經(jīng)不再適合這種新型的注塑模具，這主要是因?yàn)槟＞卟牧系某杀咀兓艽?。 無(wú)論是模具設(shè)計(jì)還是注塑成型的過(guò)程中，缺少的是對(duì)如何修改這個(gè)模具材料和快速成型 制造過(guò)程的影響有最根本的認(rèn)識(shí) 。 在小批量生產(chǎn)零件的時(shí)候，通過(guò)消除多重步驟，建立了有快速成型形成的注塑模具，這種方法可以保證縮短時(shí)間和節(jié)約成本 。 and a cooling time of 48 s. The SL material used, Dupont SOMOSTM 6110 resin, has the ability to resist temperatures of up to 300 ?C temperatures. As mentioned above, thermal conductivity of the mold is a major factor that differentiates between an SL and a traditional mold. Poor heat transfer in the mold would produce a nonuniform temperature distribution, thus causing 14 warpage that distorts the pleted parts. For an SL mold, a longer cycle time would be expected. The method of using a thin shell SL mold backed with a higher thermal conductivity metal (aluminum) was selected to increase thermal conductivity of the SL mold. Fig. 4. Experimental cavity model Fig. 5. A parison of the distortion variation in the X direction for different thermal conductivity。 an injection pressure of MPa。 and polypropylene was used as the injection material. The injection machine was a production level ARGURY Hydronica 320210750 with the following process parameters: a melt temperature of 250 ?C。 u, v are the average wholegap thicknesses。 1 附錄 2 Integrated simulation of the injection molding process with stereolithography molds Abstract Functional parts are needed for design veri?cation testing, ?eld trials, customer evaluation, and production planning. By eliminating multiple steps, the creation of the injection mold directly by a rapid prototyping (RP) process holds the best promise of reducing the time and cost needed to mold lowvolume quantities of parts. The potential of this integration of injection molding with RP has been demonstrated many times. What is missing is the fundamental understanding of how the modi?cations to the mold material and RP manufacturing process impact both the mold design and the injection molding process. In addition, numerical simulation techniques have now bee helpful tools of mold designers and process engi neers for traditional injection molding. But all current simulation packages for conventional injection molding are no longer applicable to this new type of injection molds, mainly because the property of the mold material changes greatly. In this paper, an integrated approach to acplish a numerical simulation of injection molding into rapidprototyped molds is established and a corresponding simulation system is developed. Comparisons with experimental results are employed for veri?cation, which show that the present scheme is well suited to handle RP fabricated stereolithography (SL) molds. Keywords Injection molding Numerical simulation Rapid prototyping 1 Introduction In injection molding, the polymer melt at high temperature is injected into the mold under high pressure [1]. Thus, the mold material needs to have thermal and mechanical properties capable of withstanding the temperatures and pressures of the molding cycle. The focus of many studies has been to create the injection mold directly by a rapid prototyping (RP) process. By eliminating multiple steps, this method of tooling holds the best promise of reducing the time and cost needed to create lowvolume quantities of parts in a production material. The potential of integrating injection molding with RP technologies has been demonstrated many times. The properties of RP molds are very different from those of traditional metal molds. The key differ ences are the properties of thermal conductivity and elastic modulus (rigidity). For example, the polymers used in RPfabricated stereolithography (SL) molds have a thermal conductivity that is less than one 2 thousandth that of an aluminum tool. In using RP technologies to create molds, the entire mold design and injectionmolding process parameters need to be modi?ed and optimized from traditional methodologies due to the pletely different tool material. However, there is still not a fundamental understanding of how the modi?cations to the mold tooling method and material impact both the mold design and the injection molding process parameters. One cannot obtain reasonable results by simply changing a few material properties in current models. Also, using traditional approaches when making actual parts may be generating suboptimal results. So there is a dire need to study the interaction between the rapid tooling (RT) process and material and injection molding, so as to establish the mold design criteria and techniques for an RToriented injection molding process. In addition, puter simulation is an effective approach for predicting the quality of molded parts. Commercially available simulation packages of the traditional injection molding process have now bee routine tools of the mold designer and process engineer [2]. Unfortunately, current simulation programs for conventional injection molding are no longer applicable to RP molds, because of the dramatically dissimilar tool material. For instance, in using the existing simulation software with aluminum and SL molds and paring with experimental results, though the simulation values of part distortion are reasonable for the aluminum mold, results are unacceptable, with the error exceeding 50%. The distortion during injection molding is due to shrinkage and warpage of the plastic part, as well as the mold. For ordinarily molds, the main factor is the shrinkage and warpage of the plastic part, which is modeled accurately in current simulations. But for RP molds, the distortion of the mold has potentially more in?uence, which have been neglected in current models. For instance, [3] used a simple threestep simulation process to consider the mold distortion, which had too much deviation. In this paper, based on the above a