基于CAD/CAE集成模型的塑料注射模优化设计系统
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摘要
随着计算机技术在注射模设计领域的应用不断深入，研究将注射模一体化设计技术、数值模拟技术、综合评价技术、优化设计技术与专业的CAD平台进行无缝集成，减少设计和分析过程中模型的转换，降低设计方案评价对技术人员经验的依赖性，对促进注射模设计的自动化和智能化具有重要的意义。本文在广东省科技计划工业攻关项目“注射模CAD/CAE系统的开发与应用示范”(2007B010400082)和国家支撑计划项目“先进注塑成形工艺与新型模具结构开发及应用推广”(2011BAF16B00)的资助下，对注射模CAD/CAE集成及优化设计方法进行了深入研究，开发了基于CAD/CAE集成模型的注射模优化设计系统。
建立统一的数据模型是实现CAD/CAE集成的关键。本文将有限元模型的定义作为分析特征添加到基于B-Rep结构表达的几何模型中，提出了包含几何造型数据和有限元特征属性数据的参数化注射模CAD/CAE集成模型。并在专业的CAD平台上利用参数化混合造型、有限元网格自动划分、工程属性分派技术实现了有限元模型的自动提取及与集成模型的动态联动。在此基础上，构建了集设计、分析、评价和优化功能为一体的注射模优化设计系统框架。
针对目前注射模CAD设计无法兼顾CAE分析等问题，本文从制品、浇注系统、冷却系统、模具结构件四个方面对注射模CAD/CAE一体化建模方法进行了深入研究。同时，将特征识别技术应用于注射模CAD/CAE集成，通过对制品细节特征和冷却系统特征的识别，实现了制品几何模型的理想化以及冷却系统CAE模型的自动重构，为注射模CAD/CAE集成模型的实现提供了有力的技术支持。
对注射成形CAE分析结果进行可视化的显示和科学自动的评价，是实现注射模设计方案自动优化的基础。本文提出了一种在CAD平台上实现CAE分析结果数据场的可视化方法。并通过对注射成形设计方案评价目标的分析，建立了面向设计优化的开放式评价指标集，重点对指标集中优化指标的计算以及约束指标的数学判定方法进行了研究。在此基础上提出了基于成形模拟的注射模设计优化流程和设计优化方法。
对注射成形过程中模具的受力变形进行分析可以优化模具结构、减少模具重量、降低原材料成本。本文在对注射模结构优化目标、约束条件和设计变量进行详细分析的基础上，提出了基于结构分析的注射模设计优化流程。重点研究了注射模结构分析数值模型的建立方法，通过对注射模具的结构进行了不同形式的简化生成了相应的受力分析模型，将制品CAE充模分析所得的熔体压力场数据与模具网格单元信息进行合理匹配完成了型腔载荷的准确加载，在注射模CAD/CAE集成系统中实现了模具结构分析，并通过实验对比确定了最优的模具结构简化方案。
在上述研究成果的基础上，本文开发了基于CAD/CAE集成模型的注射模优化设计原型系统，并通过应用实例对系统功能进行了介绍，证明了系统的有效性和可行性。
With the further application of computer technology in the field of injection molddesign, there are more and more researches focusing on integration of integrativemodeling, numerical simulation, comprehensive evaluation and optimal design techniqueswith professional CAD platform, which contributes to avoid model conversion betweendesign and analysis software, reduces dependence on experience in analysis resultevaluation, and promotes automation and intelligence of design process. With the financialsupport from the Technology Project of Guangdong Province (2007B010400082) and theNational Key Technology R&D Program of China (2011BAF16B00), the methodologiesof CAD/CAE integration and design optimization have been studied in this paper, and anoptimization design system of injection mold based on CAD/CAE integrated model hasalso been developed.
It is the key for the integration of CAD and CAE to construct a unified data model.Therefore, this paper, which proposes a CAD/CAE integrated model combining thedefinition of finite element model with boundary representative geometric model, achievesseamless integration between geometric and finite element modeling on professional CADplatform by using parametric composite modeling, mesh generation and engineeringproperties mapping techniques. Based on this integrated model, an injection moldoptimization design system, including design, analysis, evaluation and optimizationfunction, is designed. And the framework and component modules of the system arediscussed.
In order to solve the problem of relative isolation of the design and analysis process,this paper proposes an integrated design method for CAD/CAE integration of the injectionmold, and conducts in-depth study for the aspects of product, filling system, coolingsystem and mold structure. Meanwhile, the feature recognition technology is studied tohelp realizing CAD/CAE integration. By recognition of detailed features of product andcooling system, the product geometric model is idealized and the cooling system CAEmodel is automatically extracted, which provides a strong support for the creation of theCAD/CAE integrated model.
Visual display and comprehensive evaluation of injected molding CAE analysisresults are very important to the automatic optimization of design schemes. For this reason,an approach to achieve visualization of data field calculated by CAE software on CADplatform is proposed. Through the analysis of injection mold design objectives, this paperestablishes an open set of evaluation criteria for design optimization, which focuses on theresearch of calculation of optimization criterions and mathematical judgment method ofconstraint criterions. On this basis, a design optimization process and design optimizationmethod based on injection molding simulation is proposed.
The mold deformation simulation in the process of injection molding is greatsignificance to the mold structure optimization, weight reduction and cost saving.According to this reason, by the detailed analysis of optimization objective, constraintconditions and design variable, this paper proposes an injection mold design optimizationprocess based on structure analysis and focuses on the construction of structural analysismodel of injection mold. Several kinds of structural analysis models of injection mold areestablished through simplifying mechanical model, and the pressure analysis result of theproduct is imported as the mold cavity load by matching mesh. Based on these studies, themold structural analysis is carried out in the CAD/CAE integrated system. By comparingthe deformation simulation results of the box injection mold with the experiments, the bestsimplified scheme of injection mold structure is presented.
On the basis of the above theoretic achievement, a prototype system based onCAD/CAE integrated model has been developed. And some practical cases are studied toillustrate the system function and demonstrate the usefulness and feasibility of the system.
建立统一的数据模型是实现CAD/CAE集成的关键。本文将有限元模型的定义作为分析特征添加到基于B-Rep结构表达的几何模型中，提出了包含几何造型数据和有限元特征属性数据的参数化注射模CAD/CAE集成模型。并在专业的CAD平台上利用参数化混合造型、有限元网格自动划分、工程属性分派技术实现了有限元模型的自动提取及与集成模型的动态联动。在此基础上，构建了集设计、分析、评价和优化功能为一体的注射模优化设计系统框架。
针对目前注射模CAD设计无法兼顾CAE分析等问题，本文从制品、浇注系统、冷却系统、模具结构件四个方面对注射模CAD/CAE一体化建模方法进行了深入研究。同时，将特征识别技术应用于注射模CAD/CAE集成，通过对制品细节特征和冷却系统特征的识别，实现了制品几何模型的理想化以及冷却系统CAE模型的自动重构，为注射模CAD/CAE集成模型的实现提供了有力的技术支持。
对注射成形CAE分析结果进行可视化的显示和科学自动的评价，是实现注射模设计方案自动优化的基础。本文提出了一种在CAD平台上实现CAE分析结果数据场的可视化方法。并通过对注射成形设计方案评价目标的分析，建立了面向设计优化的开放式评价指标集，重点对指标集中优化指标的计算以及约束指标的数学判定方法进行了研究。在此基础上提出了基于成形模拟的注射模设计优化流程和设计优化方法。
对注射成形过程中模具的受力变形进行分析可以优化模具结构、减少模具重量、降低原材料成本。本文在对注射模结构优化目标、约束条件和设计变量进行详细分析的基础上，提出了基于结构分析的注射模设计优化流程。重点研究了注射模结构分析数值模型的建立方法，通过对注射模具的结构进行了不同形式的简化生成了相应的受力分析模型，将制品CAE充模分析所得的熔体压力场数据与模具网格单元信息进行合理匹配完成了型腔载荷的准确加载，在注射模CAD/CAE集成系统中实现了模具结构分析，并通过实验对比确定了最优的模具结构简化方案。
在上述研究成果的基础上，本文开发了基于CAD/CAE集成模型的注射模优化设计原型系统，并通过应用实例对系统功能进行了介绍，证明了系统的有效性和可行性。
With the further application of computer technology in the field of injection molddesign, there are more and more researches focusing on integration of integrativemodeling, numerical simulation, comprehensive evaluation and optimal design techniqueswith professional CAD platform, which contributes to avoid model conversion betweendesign and analysis software, reduces dependence on experience in analysis resultevaluation, and promotes automation and intelligence of design process. With the financialsupport from the Technology Project of Guangdong Province (2007B010400082) and theNational Key Technology R&D Program of China (2011BAF16B00), the methodologiesof CAD/CAE integration and design optimization have been studied in this paper, and anoptimization design system of injection mold based on CAD/CAE integrated model hasalso been developed.
It is the key for the integration of CAD and CAE to construct a unified data model.Therefore, this paper, which proposes a CAD/CAE integrated model combining thedefinition of finite element model with boundary representative geometric model, achievesseamless integration between geometric and finite element modeling on professional CADplatform by using parametric composite modeling, mesh generation and engineeringproperties mapping techniques. Based on this integrated model, an injection moldoptimization design system, including design, analysis, evaluation and optimizationfunction, is designed. And the framework and component modules of the system arediscussed.
In order to solve the problem of relative isolation of the design and analysis process,this paper proposes an integrated design method for CAD/CAE integration of the injectionmold, and conducts in-depth study for the aspects of product, filling system, coolingsystem and mold structure. Meanwhile, the feature recognition technology is studied tohelp realizing CAD/CAE integration. By recognition of detailed features of product andcooling system, the product geometric model is idealized and the cooling system CAEmodel is automatically extracted, which provides a strong support for the creation of theCAD/CAE integrated model.
Visual display and comprehensive evaluation of injected molding CAE analysisresults are very important to the automatic optimization of design schemes. For this reason,an approach to achieve visualization of data field calculated by CAE software on CADplatform is proposed. Through the analysis of injection mold design objectives, this paperestablishes an open set of evaluation criteria for design optimization, which focuses on theresearch of calculation of optimization criterions and mathematical judgment method ofconstraint criterions. On this basis, a design optimization process and design optimizationmethod based on injection molding simulation is proposed.
The mold deformation simulation in the process of injection molding is greatsignificance to the mold structure optimization, weight reduction and cost saving.According to this reason, by the detailed analysis of optimization objective, constraintconditions and design variable, this paper proposes an injection mold design optimizationprocess based on structure analysis and focuses on the construction of structural analysismodel of injection mold. Several kinds of structural analysis models of injection mold areestablished through simplifying mechanical model, and the pressure analysis result of theproduct is imported as the mold cavity load by matching mesh. Based on these studies, themold structural analysis is carried out in the CAD/CAE integrated system. By comparingthe deformation simulation results of the box injection mold with the experiments, the bestsimplified scheme of injection mold structure is presented.
On the basis of the above theoretic achievement, a prototype system based onCAD/CAE integrated model has been developed. And some practical cases are studied toillustrate the system function and demonstrate the usefulness and feasibility of the system.
引文
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