基于联合仿真的极端工况下聚合物薄壁圆筒注塑工艺优化

吉建华; 李忠捷; 马艺涛; 谢飞鹏; 谢鹏程

doi:10.3969/j.issn.1674-6457.2025.11.012

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (11) : 136-144. DOI: 10.3969/j.issn.1674-6457.2025.11.012

先进材料智能成形技术

基于联合仿真的极端工况下聚合物薄壁圆筒注塑工艺优化

吉建华^1a, 李忠捷^1a, 马艺涛^1a, 谢飞鹏², 谢鹏程^1a,1b,*

作者信息 +

Optimization of Polymer Thin-walled Cylinder Injection Molding Process under Extreme Conditions Based on Co-simulation

JI Jianhua^1a, LI Zhongjie^1a, MA Yitao^1a, XIE Feipeng², XIE Pengcheng^1a,1b,*

Author information +

文章历史 +

摘要

目的针对高温、高压服役工况下聚合物薄壁圆筒构件的注射成型质量引发结构性能下降的问题,探究注射成型工艺对其结构性能的影响规律,确定构件的最优注射成型工艺。方法采用Moldex3D、Digimat-MAP及Abaqus数值仿真软件,对成型工艺和结构性能进行联合仿真分析。首先进行注射成型模拟并获取热残余应力分布,再将残余应力场映射至结构网格中,作为初始条件进行动态结构仿真。通过正交试验,探究了注射速度、熔体温度、模具温度、保压压力与保压时间5个关键工艺参数对残余应力的影响规律。结果模具温度、保压压力和保压时间是影响薄壁圆筒构件残余应力的主要因素,经工艺优化后,圆筒最大热残余应力降低98.37%,应力分布均匀性显著改善。动态结构仿真结果表明,残余应力对圆筒在压力加载初期的应力分布具有影响,是极端服役工况初期诱发结构失效的主要原因。结论建立了多物理场联合仿真方法与工艺优化策略,提高了聚合物薄壁圆筒结构成型工艺与结构性能的预测准确性,确定了薄壁圆筒的最优注射成型工艺参数,大幅降低残余应力水平,改善了薄壁圆筒在极端服役工况下的力学响应行为。

Abstract

To address the degradation of structural properties in polymer thin-walled cylindrical components caused by injection molding quality under high-temperature and high-pressure service conditions, the work aims to investigate the effect of injection molding processes on structural performance and determine the optimal molding process for these components. Moldex3D, Digimat-MAP, and Abaqus numerical simulation software were employed to conduct coupled simulation analyses of molding processes and structural properties. Firstly, injection molding simulations were conducted to obtain thermal residual stress distributions. These residual stress fields were then mapped onto the structural mesh as initial conditions for dynamic structural simulations. Orthogonal experiments were carried out to study the effect of five key process parameters including injection speed, melt temperature, mold temperature, holding pressure, and holding time, on residual stresses. Mold temperature, holding pressure, and holding time were identified as the primary factors affecting residual stresses in thin-walled cylindrical components. Following process optimization, the maximum thermal residual stress in the cylinder decreased by 98.37%, with significantly improved stress distribution uniformity. Dynamic structural simulation results indicated that residual stresses affected the stress distribution during the initial stage of pressure loading, constituting the primary cause of structural failure initiation under extreme service conditions. A multi-physics coupled simulation method and a process optimization strategy are established, which improves the prediction accuracy of the forming process and structural performance of polymer thin-walled cylindrical structures. Optimal injection molding process parameters for thin-walled cylinders are determined, substantially reducing residual stress levels and improving the mechanical response behavior of thin-walled cylinders under extreme service conditions.

导出引用

吉建华, 李忠捷, 马艺涛, 谢飞鹏, 谢鹏程. 基于联合仿真的极端工况下聚合物薄壁圆筒注塑工艺优化[J]. 精密成形工程. 2025, 17(11): 136-144 https://doi.org/10.3969/j.issn.1674-6457.2025.11.012

JI Jianhua, LI Zhongjie, MA Yitao, XIE Feipeng, XIE Pengcheng. Optimization of Polymer Thin-walled Cylinder Injection Molding Process under Extreme Conditions Based on Co-simulation[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 136-144 https://doi.org/10.3969/j.issn.1674-6457.2025.11.012

中图分类号： TH164

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