發(fā)布時間：2018-06-10 02:02

  本文選題：電連接器 + 注塑成型�。� 參考：《江蘇大學(xué)》2017年碩士論文

【摘要】：隨著電子連接器的迅速發(fā)展,市場對電連接器接觸件的注塑成型表面質(zhì)量、尺寸精度、裝配性能等提出了較以往更高的要求。在成型過程中,因收縮變形而導(dǎo)致尺寸精度產(chǎn)生誤差是常見且棘手的工程問題。工程師在新產(chǎn)品開發(fā)設(shè)計中根據(jù)產(chǎn)品結(jié)構(gòu)與成型工藝特點(diǎn)進(jìn)行產(chǎn)品設(shè)計,但其結(jié)果往往是難以準(zhǔn)確預(yù)測的,由于材料收縮率因材料與成型工藝的差異有著不同的收縮結(jié)果,此外,注塑件收縮越大,其翹曲變形量、表面縮痕等質(zhì)量缺陷出現(xiàn)的可能性就越大。如何運(yùn)用CAE在新產(chǎn)品開發(fā)設(shè)計階段進(jìn)行成型質(zhì)量缺陷預(yù)測以提高電子連接器的表面質(zhì)量及其性能成為該領(lǐng)域研究的重要課題。本文以昆山科信成電子有限公司生產(chǎn)的Audio Jack連接器插件母座為研究對象,研究了在注塑機(jī)、塑件材料及模具結(jié)構(gòu)等確定情況下,工藝參數(shù)對成型質(zhì)量的影響;通過優(yōu)化成型工藝參數(shù),從而改善了由于收縮變形引起的成型尺寸精度不夠?qū)е碌慕M裝不良問題;最后通過試模驗證了組裝的可行性。論文研究的主要內(nèi)容與成果如下:(1)基于Moldflow軟件,進(jìn)行了澆口位置優(yōu)化、有限元模型創(chuàng)建及仿真試驗結(jié)果分析:繪制連接器三維實(shí)體,將其導(dǎo)入軟件中進(jìn)行網(wǎng)格劃分與修復(fù)。利用Moldflow中的“澆口位置”分析序列選項尋找最佳澆口位置,模擬多處出現(xiàn)短射,因此不能作為最佳澆口位置。根據(jù)該連接器結(jié)構(gòu)與澆口設(shè)計原則,設(shè)計了三種澆口位置方案,在相同工藝條件下模擬比較各項指標(biāo),綜合得出側(cè)面澆口為最優(yōu)方案,與實(shí)際生產(chǎn)澆口一致。按照實(shí)際連接器成型生產(chǎn)設(shè)計了澆注系統(tǒng)與冷卻系統(tǒng),對其進(jìn)行網(wǎng)格劃分,運(yùn)用流動與冷卻功能進(jìn)行分析,驗證了建立的有限元模型的可行性。對翹曲變形功能分析,結(jié)果表明,引起連接器變形量最大的因素為收縮不均,占所有因素引起變形量的98.01%,冷卻不均及取向因素影響較小,且Y方向收縮變形量最大,對連接器的裝配有重要影響。(2)基于正交試驗設(shè)計,分析了不同工藝參數(shù)對連接器注塑成型質(zhì)量的影響,優(yōu)化了成型工藝參數(shù),運(yùn)用加權(quán)綜合評分法獲得了成型連接器綜合質(zhì)量最優(yōu)的工藝參數(shù)組合:以模具溫度、熔體溫度、保壓壓力、保壓時間、注射時間、冷卻時間為主要成型工藝參數(shù),以頂出時體積收縮率、翹曲變形量、縮痕深度為質(zhì)量指標(biāo),建立了六因素五水平25組正交試驗,運(yùn)用軟件模擬了不同工藝參數(shù)組合下的質(zhì)量指標(biāo),并對試驗結(jié)果進(jìn)行了信噪比函數(shù)計算。通過信噪比的均值與極差分析得出了各質(zhì)量指標(biāo)最優(yōu)的工藝參數(shù)組合及工藝參數(shù)影響趨勢,優(yōu)化了成型工藝參數(shù)。通過信噪比的方差分析得到了工藝參數(shù)對各質(zhì)量指標(biāo)的影響程度及其大小,結(jié)果表明,頂出時體積收縮率、翹曲變形量及縮痕深度顯著性影響因素均為保壓壓力與熔體溫度,模具溫度、保壓時間、注射時間及冷卻時間影響相對較小,但也需要適當(dāng)?shù)墓に噮?shù)水平�；诩訖�(quán)綜合評分法,對頂出時體積收縮率、翹曲變形量及縮痕深度進(jìn)行了綜合質(zhì)量評價,通過綜合評分的均值與極差分析得到了綜合質(zhì)量最優(yōu)的成型工藝參數(shù)組合及工藝參數(shù)對綜合評分的影響程度。(3)基于變異系數(shù)法與逼近理想解法相結(jié)合優(yōu)化了工藝參數(shù)多目標(biāo)質(zhì)量,進(jìn)一步細(xì)化與優(yōu)化了工藝參數(shù),建立了工藝參數(shù)與多目標(biāo)質(zhì)量間的BP神經(jīng)網(wǎng)絡(luò)預(yù)測模型:以正交試驗結(jié)果為樣本,對其進(jìn)行了去量綱化處理,運(yùn)用變異系數(shù)法確定了各質(zhì)量指標(biāo)權(quán)重后,結(jié)合逼近理想解法計算了各質(zhì)量指標(biāo)在不同工藝參數(shù)組合下的相對接近度。通過均值與極差分析了不同成型工藝參數(shù)對相對接近度的影響,初步獲得了兼顧多質(zhì)量指標(biāo)最優(yōu)的工藝參數(shù)組合,在此基礎(chǔ)上進(jìn)行了工藝參數(shù)細(xì)化正交試驗,進(jìn)一步分析得出了成型質(zhì)量更加優(yōu)越的工藝參數(shù),試驗結(jié)果表明,各質(zhì)量指標(biāo)相比工藝參數(shù)未細(xì)化前取得了進(jìn)一步的優(yōu)化。因工藝參數(shù)與成型質(zhì)量間的非線性復(fù)雜關(guān)系難以用具體數(shù)學(xué)函數(shù)表達(dá),建立了工藝參數(shù)與多目標(biāo)質(zhì)量間的BP神經(jīng)網(wǎng)絡(luò)預(yù)測模型。以正交試驗結(jié)果作訓(xùn)練樣本,訓(xùn)練不同隱含層節(jié)點(diǎn)數(shù)對網(wǎng)絡(luò)的影響,得出了誤差最小的節(jié)點(diǎn)數(shù)。對工藝參數(shù)細(xì)化試驗結(jié)果進(jìn)行了訓(xùn)練與預(yù)測,預(yù)測值接近模擬值,表明建立的網(wǎng)絡(luò)映射關(guān)系模型有較好的預(yù)測功能,在誤差許可內(nèi)可替代軟件較長時間的模擬,為方便快速優(yōu)化工藝參數(shù)提供了理論指導(dǎo)。(4)連接器注塑成型工藝試模驗證:根據(jù)研究得到的最佳工藝參數(shù)組合進(jìn)行了試模驗證,試模所得的尺寸測量符合圖面設(shè)計尺寸規(guī)格,試模塑件與端子組裝良好,表明優(yōu)化后的工藝參數(shù)組合能很好的改善連接器生產(chǎn)中因收縮變形導(dǎo)致的尺寸精度不夠問題。為滿足生產(chǎn)出的連接器達(dá)到客戶提出的插拔接觸特性要求,進(jìn)行了塑件組裝端子后的插拔力測試,插拔力曲線結(jié)果顯示滿足設(shè)計規(guī)格,間接驗證了優(yōu)化后的成型工藝參數(shù)的可靠性。以上研究表明,CAE分析結(jié)合優(yōu)化方法及工藝試模驗證的研究思路,對改善成型質(zhì)量缺陷、優(yōu)化工藝參數(shù)、減少產(chǎn)品量試后的試模與修模次數(shù)等具有重要的現(xiàn)實(shí)指導(dǎo)意義。
[Abstract]:With the rapid development of electronic connectors, the market has put forward higher requirements on the surface quality, size accuracy and assembly performance of the contact parts of electrical connector. In the forming process, the error of the size accuracy caused by the shrinkage deformation is a common and difficult engineering problem. The engineer is in the design of the new product development. The product design is carried out according to the product structure and molding process characteristics, but the result is often difficult to predict accurately, because the shrinkage of material has different shrinkage results because of the difference between material and molding process. In addition, the greater the shrinkage of the injection parts, the more possibility of the quality defects, such as the warpage deformation, the surface shrinkage, and so on. How to use the CAE It is an important subject in this field to predict the quality defects of the molding quality in the new product development and design stage to improve the surface quality and performance of the electronic connector. This paper studies the Audio Jack connector plug-in base of the Kunshan Kexin Electronics Co., Ltd. as the research object, and studies the injection molding machine, the plastic material and the die structure, etc. To determine the effect of process parameters on the quality of the molding, by optimizing the molding process parameters, the problem of poor assembly caused by the lack of precision caused by the shrinkage deformation is improved. Finally, the feasibility of the assembly is verified by the test model. The main contents and results of the paper are as follows: (1) based on the Moldflow software, The optimization of gate position, the creation of finite element model and the result analysis of simulation test: draw the three-dimensional connector of the connector and introduce it into the software to divide and repair the grid. Using the "gate position" in Moldflow to find the best gate position and simulate several short shots, so it can not be used as the best gate position. This connector structure and gate design principle, designed three kinds of gate position scheme, simulated comparison of various indexes under the same technological conditions, and synthetically concluded that the side gate was the best scheme, which was the same as the actual production gate. According to the actual connector molding production, the gating system and cooling system were designed, and the grid was divided and the flow was used. The feasibility of the finite element model is verified with the analysis of the cooling function. The analysis of the warping deformation function shows that the biggest factor causing the deformation of the connector is the unequal shrinkage, 98.01% of the deformation amount caused by all factors, the less influence of the cooling uneven and the orientation factors, and the largest shrinkage deformation in the Y direction, to the connector. The assembly has important influence. (2) based on the orthogonal test design, the influence of different process parameters on the quality of the connector injection molding is analyzed, the molding process parameters are optimized, and the optimum combination quality of the forming connector is obtained by using the weighted comprehensive scoring method. The molding tool temperature, melt temperature, pressure holding pressure, pressure holding time, injection time, injection molding are used. Time and cooling time are the main forming process parameters, with the volume shrinkage rate, warpage quantity and shrinkage depth as quality indexes, six factors and five levels orthogonal test is set up. The quality indexes of different process parameters are simulated by software, and the signal to noise ratio function is calculated for the test results. The signal to noise ratio is all calculated. The combination of process parameters and the influence trend of process parameters are obtained, and the process parameters are optimized. The influence degree and size of the process parameters on each quality index are obtained by the variance analysis of the signal to noise ratio. The results show that the volume shrinkage, the warpage and the shrinkage depth are significant when the ejection is ejecting. The influence factors are pressure retaining pressure and melt temperature, mould temperature, pressure holding time, injection time and cooling time are relatively small, but appropriate technological parameters are needed. Based on the weighted comprehensive scoring method, the volume shrinkage, warpage and shrinkage depth are evaluated and the mean value of the comprehensive score is evaluated. The influence degree of the optimum combination of forming process parameters and process parameters on the comprehensive score is obtained. (3) based on the combination of the variation coefficient method and the approach ideal solution, the multi target quality of the process parameters is optimized, the process parameters are further refined and optimized, and the BP nerve between the process parameters and the multi-objective mass is established. The network prediction model: Taking the orthogonal test results as the sample, it is dimensionally processed, the weight of each quality index is determined by the method of variation coefficient, and the relative proximity of the quality indexes under the combination of different process parameters is calculated with the approximate ideal solution. The relative parameters of different molding process are analyzed by the mean and the extreme difference. On the basis of the influence of proximity, the optimum combination of multi quality indexes is obtained. On this basis, the orthogonal experiment of process parameters refinement is carried out. Further analysis has been made to obtain the better process parameters of the molding quality. The test results show that the quality indexes have been further optimized before the technical parameters are not refined. The nonlinear complex relationship between process parameters and molding quality is difficult to express with specific mathematical functions. The BP neural network prediction model between process parameters and multi-objective mass is established. The orthogonal test results are used as training samples to train the influence of the number of hidden layer nodes on the network, and the number of nodes with the smallest error is obtained. The result of the experiment is trained and predicted. The predicted value is close to the simulated value. It shows that the established network mapping relationship model has better prediction function. It can replace the software for a long time in the error license, and provides theoretical guidance for the convenience and rapid optimization of the process parameters. (4) the test model verification of the connector injection molding process: Based on the research The optimum combination of the process parameters was verified. The size measurement obtained by the test model was in accordance with the size specification of the surface. The test mould and the terminal assembly were well assembled. It showed that the optimized combination of the process parameters could improve the lack of dimension precision caused by the shrinkage deformation in the connector production. To the requirements of the contact characteristics proposed by the customer, the plug force test after the plastic part assembly terminal is carried out. The result of the pluggable force curve shows the design specification, and the reliability of the optimized molding process parameters is indirectly verified. The above research shows that the CAE analysis combines the optimization method and the process test verification of the process to improve the molding quality. It is of great practical significance to optimize the process parameters and reduce the number of trial and repair dies after testing.
【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TM503.5

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