摘要
提出了一种线圈嵌入式感应加热辅助变模温注塑方法。通过将感应线圈直接嵌入模具型腔板基体内部,在高频电流激励下激发交变电磁场,使线圈周围金属区域迅速感应出高密度涡流并产生大量焦耳热,从而实现模腔表面的快速加热。针对不同类型注塑制品对变模温工艺技术指标的差异化需求,分别建立了以模腔表面加热效率优先和加热均匀性优先为目标的模具感应加热系统优化模型,并提出一种结合有限元分析(FEA)与粒子群优化(PSO)算法的联合求解策略。优化结果表明:对加热效率优先模型,优化后的模具加热效率提升了41.8%、加热均匀性提高了76.9%;而对加热均匀性优先模型,优化后的模具加热效率和加热均匀性分别提高了34%和91%。基于优化设计参数,构建了用于实际变模温注塑的线圈嵌入式感应加热模具原型,并以某电子产品的塑料面板为研究对象开展实验验证。结果表明:所成型面板的表面无明显色差且呈现均匀的镜面光泽,其平均表面粗糙度仅为26.13 nm,该面板无需打磨、喷涂、抛光等后处理即可直接满足装配要求。这不仅验证了FEA-PSO优化策略的有效性,同时还证明了所提出的变模温注塑方法在实际生产中的应用可行性。
A coil-embedded induction heating-assisted variotherm injection molding method is proposed.By embedding the induction coil directly into the mold cavity plate,a high-frequency alternating electromagnetic field is generated under current excitation,inducing high-density eddy currents,producing substantial Joule heat in the surrounding metal region,and rapid heating the cavity surface.Considering the varying technical priorities of different injection-molded products,two optimization models for the mold induction heating system were established,focusing respectively on heating efficiency and temperature uniformity.A hybrid solution strategy of combining the finite element analysis(FEA)and particle swarm optimization(PSO)was proposed.The optimization results show that,for the efficiency-priority model,the heating efficiency of the mold was improved by 41.8%,while the temperature uniformity was also enhanced by 76.9%.For the uniformity-priority model,the heating efficiency and uniformity were improved by 34%and 91%,respectively.Based on the optimized parameters,a prototype mold with an embedded induction heating system was constructed for variotherm injection molding,and experimental validation was carried out using a plastic panel from an electronic product as the test case.The results demonstrate that the front surface of the molded panel exhibited no visible color difference and a uniform mirror-like gloss,with an average surface roughness of only 26.13 nm.The panel required no post-processing such as sanding,painting,or polishing to meet assembly requirements.These findings validate not only the effectiveness of the FEA-PSO optimization strategy but also the practical feasibility of the proposed variotherm injection molding method.
作者
肖成龙
胡灿
曾广胜
XIAO Chenglong;HU Can;ZENG Guangsheng(School of Materials Science and Engineering,Hunan Institute of Technology,Hengyang 421002,China)
出处
《工程塑料应用》
北大核心
2025年第11期138-145,共8页
Engineering Plastics Application
基金
湖南省教育厅科学基金重点项目(23A0632)
国家重点研发计划项目(2024YFD2101000)
国家自然科学基金项目(52173034)。
关键词
变模温注塑成型
嵌入式感应加热系统
优化设计
有限元分析
粒子群优化
variotherm injection molding
embedded induction heating system
optimal design
finite element analysis
particle swarm optimization
