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1、附录2IntegratedsimulationoftheinjectionmoldingprocesswithstereolithographymoldsAbstractFunctionalpartsareneededfordesignverificationtesting,fieldtrials,customerevaluation,andproductionplanning.Byeliminatingmultiplesteps,thecreationoftheinjectionmolddirec

2、tlybyarapidprototyping(RP)processholdsthebestpromiseofreducingthetimeandcostneededtomoldlow-volumequantitiesofparts.ThepotentialofthisintegrationofinjectionmoldingwithRPhasbeendemonstratedmanytimes.Whatismissingisthefundamentalunderstandingofhowthemo

3、dificationstothemoldmaterialandRPmanufacturingprocessimpactboththemolddesignandtheinjectionmoldingprocess.Inaddition,numericalsimulationtechniqueshavenowbecomehelpfultoolsofmolddesignersandprocessengineersfortraditionalinjectionmolding.Butallcurrentsi

4、mulationpackagesforconventionalinjectionmoldingarenolongerapplicabletothisnewtypeofinjectionmolds,mainlybecausethepropertyofthemoldmaterialchangesgreatly.Inthispaper,anintegratedapproachtoaccomplishanumericalsimulationofinjectionmoldingintorapid-prot

5、otypedmoldsisestablishedandacorrespondingsimulationsystemisdeveloped.Comparisonswithexperimentalresultsareemployedforverification,whichshowthatthepresentschemeiswellsuitedtohandleRPfabricatedstereolithography(SL)molds.KeywordsInjectionmoldingNumerical

6、simulationRapidprototyping1IntroductionIninjectionmolding,thepolymermeltathightemperatureisinjectedintothemoldunderhighpressure[1].Thus,themoldmaterialneedstohavethermalandmechanicalpropertiescapableofwithstandingthetemperaturesandpressuresofthemoldi

7、ngcycle.Thefocusofmanystudieshasbeentocreatetheinjectionmolddirectlybyarapidprototyping(RP)process.Byeliminatingmultiplesteps,thismethodoftoolingholdsthebestpromiseofreducingthetimeandcostneededtocreatelow-volumequantitiesofpartsinaproductionmaterial

8、.ThepotentialofintegratinginjectionmoldingwithRPtechnologieshasbeendemonstratedmanytimes.ThepropertiesofRPmoldsareverydifferentfromthoseoftraditionalmetalmolds.Thekeydifferencesarethepropertiesofthermalconductivityandelasticmodulus(rigidity).Forexamp