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1、射出成型CAE分析的技巧TechniquesforInjectionMoldingCAEAnalysis產品分析PartAnalysis1壁厚不均Non-uniformWallThickness壁厚不均是注塑成形中最大的麻煩製造者。這對薄壁零件尤然。這些麻煩包括了遲滯現象、短射、凹陷、發赤、噴流、翹曲及長冷卻時間等；目前都可用CAE以直接或間接的方式預測。Non-uniformwallthicknessisthebiggesttroublemakerinplasticinjectionmolding.Thisisespeciallytruetothin-wallpart.Thetroub
2、les,includinghesitation,shortshot,sinkmark,blush,jetting,warpageandlongcoolingtimeetc.,canbepredicted,directlyorindirectly,byusingCAE.壁厚不均Non-uniformWallThickness遲滯現象和短射、冷卻時間和翹曲可以充填、冷卻和收縮翹曲的模擬程式直接預測。發赤、噴流和凹陷可以充填和保壓的模擬程式間接預測。Hesitationandshortshot,coolingtime,andwarpagecanbepredicted,directly,byfi
3、lling,coolingandshrinkage/warpagesimulations,respectively.Blushandjetting,andsinkmark,canbepredicted,indirectly,byfillingandpackingsimulations,respectively.2空洞或/和凹陷Voidor/andSinkMark空洞(Void)凹陷(SinkMark)突出件尺寸DimensionsoftheProjection一個錯誤設計的突出件(例如肋和螺柱)可能顯現遲滯痕、焦痕、短射、凹陷、空洞和/或翹曲。突出件厚度、高度、脫模角和內圓角半徑可以充填
4、、保壓、冷卻和收縮/翹曲模擬進行確認。Anerroneousdesignedprojection(e.g.ribandboss,etc.)wouldshowhesitationmark,burnmark,shortshot,sinkmark,voids,and/orwarpage.Theselectionofthickness,height,draftangleandradiusofthefilletofaprojectioncanbeverifiedbyfilling,packing,coolingandshrinkage/warpagesimulations.3孔Holes從易於成型
5、的觀點來看，相鄰二孔緣的距離，或是孔緣和產品邊緣的距離，至少要有壁厚的兩倍，而絕對不可小於壁厚。Fromaneaseofmoldingperspective,thedistancefromoneholetothenext,ortotheedgeofapart,mustbeataminimumtwotimesthepart’swallthickness,andneverlessthanthepart’swallthickness孔Holes當一個孔的形狀、尺寸和位置不對時，熔接線、翹曲和開裂等問題勢必產生。妥善的作法是以模擬程式確認孔的尺寸等。Whentheshape,dimensions
6、,orlocationofaholeisnotcorrect,theproblemsofweldline,warpageandcrackingwouldbeencountered.Itisadvisedtoverifyyourholedimensions,etc.,usingsimulation.4模具分析MoldAnalysis典型的澆注系統TypicalFillingSystem豎澆道Sprue澆口成品GatePart主流道MainRunner冷料井ColdSlugWell支流道BranchRunner5澆口位置LocationofGate澆口位置的決定可以依循流動平衡的原則；流動平
7、衡的定義是所有的熔膠波前在同一個時間到達型腔的末端。Thelocationofgatescanbedeterminedbasedontheprincipleofflowbalance.Thedefinitionofflowbalanceisthatallthemeltfrontsreachtheendofthecavityatthesametime.澆口數目NumberofGates在型腔能夠完滿充填的前提下，澆口數目是愈少愈好。為
