外文翻譯--環(huán)保意識(shí)的設(shè)計(jì)和制造

第二篇譯文 環(huán)保意識(shí)的設(shè)計(jì)和制造 ECD M 研究的問題包括：產(chǎn)品與過程集成與材料選擇系統(tǒng)的設(shè)計(jì)，評(píng)估消費(fèi)者的需求和產(chǎn)品使用的集成模型的發(fā)展，處理或回收，改進(jìn)的方法，工具和對(duì)環(huán)境危害和成本或效益的風(fēng)險(xiǎn)評(píng)估程序，在加工或最終產(chǎn)品的材料，降低對(duì)環(huán)境的影響替代，在預(yù)測(cè)特定的政府法規(guī)的影響在整個(gè)產(chǎn)品生命周期技術(shù)的進(jìn)步，新的或改進(jìn)的制造過程，和增加的壽命，可以減少環(huán)境影響制造新的散裝材料和涂料的研制 1 能源，材料和資源的關(guān)注 關(guān)于在 ECD M 方法和技術(shù)的發(fā)展，在過去的十年里有了巨大的增長(zhǎng)的研究。國家制造科學(xué)中心創(chuàng)造了 一個(gè)對(duì)抗程序來識(shí)別和解決重大環(huán)境問題（例如，提高生活質(zhì)量，幫助合作解決環(huán)境問題，工業(yè)和環(huán)境安全的替代品取代過時(shí)的和有害的程序）。使用兩種方法來減少生產(chǎn)過程的環(huán)境影響：消除或減少有害物質(zhì)的使用過程，并分析不同替代生產(chǎn)過程的廢物的產(chǎn)生機(jī)制。在第一種方法中，大多數(shù)的研究主要集中在材料替代選擇，而第二種方法試圖改善制造過程的安全化學(xué)分離。在設(shè)計(jì)過程中，材料的選擇可以幫助回收過程。好的材料和制造工藝的選擇可以提高技術(shù)效率和生產(chǎn)力，以及 減少對(duì)環(huán)境的影響 。選擇最合適的材料和工藝的任務(wù)由于幾個(gè)原因非常復(fù)雜： 1）在材料和工藝 的可用數(shù)量快速增長(zhǎng)； 2）增加新的規(guī)格，數(shù)量應(yīng)滿足，包括經(jīng)濟(jì)和環(huán)境法規(guī)的限制； 3）材料短缺，這需要一個(gè)搜索一個(gè)兼容的替代。博克提供材料和工藝的選擇方法，使用一個(gè)交互式的專家系統(tǒng)，稱為營（計(jì)算機(jī)輔助材料工藝的選擇）。營設(shè)計(jì)者提供了一個(gè)工具選擇的材料和工藝組合。該系統(tǒng)，使用查詢和內(nèi)置的規(guī)則，對(duì)一個(gè)設(shè)計(jì)師的邏輯選擇一個(gè)特定的材料和工藝組合。 Whitmer 2，奧爾森，薩瑟蘭開發(fā)的兩兩比較的方法確定的設(shè)計(jì)時(shí)應(yīng)注重什么部分，影響產(chǎn)品的需求決定的。這種方法提供了一個(gè)層次決定生產(chǎn)環(huán)保意識(shí)的產(chǎn)品，和樣品進(jìn)行了比較。這些決定包 括： 1）對(duì)零件材料的選擇； 2）數(shù)和緊固件使用的類型； 3）接觸的零件的潤滑油； 4）部分在一個(gè)組件之間的幾何關(guān)系。從比較的結(jié)果被用來確定的設(shè)計(jì)工作，最大限度地提高相對(duì)于環(huán)境設(shè)計(jì)的有效性分布 。 2 回收拆卸模型 在 ECD M 文學(xué)，許多研究人員強(qiáng)調(diào)循環(huán)結(jié)束（ EOL）產(chǎn)品的重要性和產(chǎn)品拆卸回收的有效作用。循環(huán)是由 jovane 等人的定義。“回收材料或部件的產(chǎn)品使他們獲得新的產(chǎn)品?！绷硪粋€(gè)定義是由班克羅夫特為“產(chǎn)品設(shè)計(jì)以促進(jìn)產(chǎn)品和物料回收利用?！斑@些定義中的“閉合回路”的材料和組件重用他們?cè)诋a(chǎn)品生命周期不同階段的原材料或 輔助材料使用后。 (1)循環(huán) 狼和艾倫說，造紙行業(yè)將作為其輸出的 50%倍之多。然而，在塑料工業(yè)中，只有一小部分被回收。狼和愛倫還報(bào)道說，有 58000000000 磅的塑料樹脂在美國售出的小于 1%的回收。石井，尤邦克斯，他提出了一個(gè)用于回收廢舊產(chǎn)品產(chǎn)品退役模型設(shè)計(jì)。作者用“叢的概念，“這是一個(gè)集組件和組件共享一個(gè)共同的特點(diǎn)，根據(jù)設(shè)計(jì)者的意圖。一個(gè)無形的效益回收所產(chǎn)生的是“綠色”的形象?；厥諒U舊產(chǎn)品的其他重大利益會(huì)導(dǎo)致整個(gè)部件或組件的重用。例如，電子材料（如硅，鍺，鎵，銦）可以獲利的回收，因?yàn)樗麄兊母呱a(chǎn)成本。許 多工業(yè)過程已經(jīng)提出了從電子元件提取這些有價(jià)值的元素。 回收要求的材料，并在叢的緊固方法與現(xiàn)有技術(shù)兼容。綜述了各種金屬 henstack 回收為基礎(chǔ)的項(xiàng)目實(shí)踐，側(cè)重于廢鋼的汽車。研究產(chǎn)生的回收設(shè)計(jì)的一般性原則，包括簡(jiǎn)化機(jī)械拆卸，避免自我污染的材料組合，規(guī)范使用的材料，從鋼項(xiàng)目分離銅含量高的項(xiàng)目。 與回收設(shè)計(jì)相關(guān)的兩個(gè)工程問題拆解技術(shù)和回收成本。西蒙指出，拆除所需的知識(shí)的組成部件的目的地或拆卸回收的可能性。然而，從一個(gè)產(chǎn)品是為了達(dá)到其生命的結(jié)束時(shí)間，技術(shù)將在循環(huán)再造的先進(jìn)。這種現(xiàn)象揭示 EOL 產(chǎn)品的回收困難。西蒙提出 了解決該問題的兩個(gè)原則： 1）去除最有價(jià)值的部分的第一和 2）最大化“屈服”每個(gè)拆解操作。 維騰堡提出的一個(gè)部件和材料的循環(huán)路徑的概念，設(shè)想的寶馬。它需要一個(gè)“瀑布模型”降低價(jià)值，其中注意力首先集中在拆卸零件適合重用具有最高的價(jià)值。電子廢物的法令和二手車迫使制造商回收廢法令，重復(fù)使用可回收的餾分，和處理殘?jiān)Ｔ谄囆袠I(yè)，寶馬是回收和拆卸設(shè)計(jì)的領(lǐng)導(dǎo)者。 Z1 模型與一個(gè)塑料的皮膚，可以從金屬底盤 20 分鐘一二個(gè)座位的汽車。門，保險(xiǎn)杠，前，后，側(cè)面板是由可回收的熱塑性塑料采用 GE。的寶馬 3251 也使用可回收的塑料配件及目 標(biāo)市場(chǎng)環(huán)境意識(shí)的客戶。通過這些努力，寶馬已確定一些指引，使拆卸和回收容易。 材料識(shí)別是回收的另一個(gè)有趣的方法。它需要一個(gè)能夠識(shí)別材料技術(shù)，包括使用的比例和填充材料類型。理想的情況下，該技術(shù)應(yīng)該是廉價(jià)的，手持使用不同的部件，和用于在一個(gè)車間式環(huán)境顯著持久。一些研究人員已經(jīng)在這方面的工作取得了不同程度的成功。舍戈?duì)柕卤砻?，傅里葉變換紅外光譜的基礎(chǔ)設(shè)備，虎和鳥是善于識(shí)別塑料和一些填充材料。 這是不可能的或經(jīng)濟(jì)的回收產(chǎn)品完全；因此，回收利用的目的是最大限度地利用資源的質(zhì)量和剩余產(chǎn)品的潛力，減少污染。扎斯曼， Kriwet，和 Seliger 提出三個(gè)目標(biāo)應(yīng)該設(shè)計(jì)評(píng)估中考慮： 1）利潤最大化（效益）在一個(gè)產(chǎn)品的壽命； 2）使用的零件數(shù)量最大化；和 3）的量最小化（重量）的垃圾廢物。 （ 2）拆卸 人們已經(jīng)認(rèn)識(shí)到，使用過的產(chǎn)品的拆卸是必要使循環(huán)經(jīng)濟(jì)可行的處理技術(shù)現(xiàn)狀。 3 安全和健康問題 另一個(gè) ECD M 是安全和健康問題。在汽車、電子等行業(yè)，最常見的焊料的今天是由鉛和錫（ 37%的鉛和 63%的錫）。然而，由于鉛的極端毒性，它已被限制或禁止住宅油漆，汽油，和許多其他產(chǎn)品在過去的十年。因此，大量的研究集中在替代錫鉛焊料與無鉛或?qū)щ娔z。 第二篇英文原文 Environmentally Conscious Design and Manufacturing The research issues in ECD&M include: integration of product and process design with material selection systems,development of models for assessing the integration of consumer demand and product use,disposal or recycling,improvement in methods,tools and procedures for evaluation of the risks associated with environmental hazards and the cost or benefit,substitution of materials with lower environmental impact in processing or in the final product,advancement in techniques for forecasting the effects of specific governmental regulations over the complete product life cycle,new or improved manufacturing processes,and development of new bulk materials and coatings with increased life spans that can be manufactured with decreased environmental impact. 1.Energy,Materials,and Resource Concern Research concerning the development of methods and techniques in ECD&M has grown tremendously in the past decade.The National Center for Manufacturing Sciences created an ECM program to identify and solve major environmental problems(for example,to improve the quality of life,to help the industry collaboratively solving the environmental problem,and to replace obsolete and harmful procedures with environmentally safe alternatives). Two approaches are used to reduce the environmental impact of manufacturing processes: eliminate or reduce the use of hazardous substances in the processes,and analyze the mechanisms of waste generation in different alternative manufacturing processes.In the first approach,most research focuses on the material substitution and selection,while the second approach attempts to improve the safety of manufacturing process.Material selection during the design process for chemical separation can be an aid to the recycling process.Good material and manufacturing process selection can improve technical efficiency and productivity,as well as reduce the environmental impact.The task of selecting the most suitable material and process has become very complex due to several reasons:1) rapid growth in the number of materials and processes available；2) increase in the number of new specifications to be satisfied,including economic and environmental regulatory constraints；and 3) materials shortages,which require a search for a compatible substitution. Bock provided a material and process selection methodology using an interactive expert system, called CAMPS(Computer-Aided Material Process Selection).CAMPS provide the designer with a tool for selecting the material and process combination.This system,using queries and built-in rules,simulates a designers logic in choosing a particular material and process combination. Whitmer 2, Olson, and Sutherland developed the Pairwise Comparison Approach to determine what portion of the design time should be focused on decisions that affect the demand of products. This approach provides a hierarchy of decisions for producing an environmentally conscious product,and sample comparisons were made. These decisions include: 1)material selection for parts； 2)number and type of fasteners used； 3)lubricant used for parts in contact；and 4)geometrical relationship among parts within an assembly.Results from the comparisons are used to determine the distribution of the design effort that maximizes the effectiveness of the design with respect to the environment. 2.Recycling and Disassembly Modeling In the ECD&M literature,many researchers emphasize the importance of recycling end-of-life (EOL) products and the role of product disassembly for effective recycling. Recycling is defined by Jovane et al.asrecovering materials or components of a used product to make them available for new products. Another definition was given by Bancroft as the use of product design to facilitate the recovery and reuse of materials in the product. These definitions infer closing the loop of materials and components after usage by reusing them for raw materials or secondary materials at different stages of the products life cycle. (1) Recycling. Wolf and Ellen reported that the paper industry recycles as much as 50% of its output. However, in the plastics industry, only a small portion is recycled. Wolf and Ellen also reported that there were 58 billion pounds of plastic resin sold in the United States and less than 1% of this was recycled. Ishii, Eubanks, and Marco proposed a design for a product retirement model for recycling EOL products. The authors used the concept of clump, which is a collection of components and subassembly that share a common characteristic based on the designers intent. One intangible benefit arising from recycling is the green image. The other significant benefit of recycling EOL products would result from reusing whole parts or subassemblies. For example, electronic materials (such as gallium, germanium, silicon, and indium) can be profitably recycled because of their high production cost. Many industrial processes have been proposed for extracting these valuable elements from electronic components. Recycling requires that materials and fastening methods in the clump are compatible with existing technologies. Henstack reviewed recycling practices for various metal-based items, which focuses on steel scrap in automobiles. The study has generated some general principles of design for recyclability, including simplifying mechanical disassembly, avoiding self-contaminating combinations of materials, standardizing materials used, and separating high copper content items from steel items. Two engineering problems associated with design for recyclability are dismantling techniques and recycling costs. Simon pointed out that dismantling required the knowledge of the destination or recycling possibility of the component parts disassembled. However, from the time a product is designed to the time it reaches the end of its life, techniques will have advanced in recycling and reengineering. This phenomenon reveals the difficulties of recycling EOL products. Simon suggested two guidelines for dealing with this problem: 1)remove the most valuable parts first and 2) maximize the yield of each dismantling operation. Wittenburg proposed the concept of a recycling path of components and materials, as envisaged by BMW. It entails a cascade model of decreasing values, in which attention is first focused on the disassembled parts suitable for reuse that have the highest value. The Decree on Electronic Waste and the Decree on Used Cars forced manufacturers to reclaim waste, to reuse the recyclable fraction, and to dispose of the residue. In the automobile industry, BMW is the leader in design for recycling and disassembly. The Z1 model is a two-seat automobile with an all-plastic skin that can be removed from the metal chassis in 20 minutes. The doors, bumpers, and front, rear, and side panels are made of recyclable thermoplastics produced by GE. The BMW 3251 also uses recyclable plastic parts and target-markets to environmental conscious customers. Through these efforts, BMW has identified some guidelines that make disassembly and recycling easier. Material recognition is another interesting approach of recycling. It requires a technology capable of identifying materials, including the proportion and type of filler materials used. Ideally, the technology should be cheap, hand-held for use on different components,and significantly durable for use in a workshop-type environment. A number of researchers have been working in this area with varying success. Shergold indicated that the Fourier Transform Infrared-based equipment that Rover and Bird developed is good at identifying plastics and some filler materials. It is not possible or economical to recycle a product completely； therefore, the aim of recycling is to maximize the recycle resources and to minimize the mass and pollution potential of the remaining products. Zussman, Kriwet, and Seliger proposed three objectives that should be considered during the design evaluation: 1) maximization of profit (benefits-costs) over a products lifespan； 2) maximization of the number of parts reused； and 3) minimization of the amount (weight) of landfill waste. (2) Disassembly. It has been recognized that disassembly of used products is necessary to make recycling economically viable in the current state of the art of reprocessing technology. Disassembly is defined by Brennan, Gupta, and Taleb as the process of systematic removal of desirable constitute parts from an assembly while ensuring that there is no impairment of the parts due to the process. There are both economic and environmental sound reasons for disassembly. Many issues and research need to be addressed in the area of disassembly. The most significant technical challenge is how to design a product for easy disassembly. Designing a product with easydisassembly constraints as well as easy assembly constraints is likely to be a very difficult task. In the past, products and machines were designed with only the assembly operations considered. Some of the problems to be addressed during design stages are the following: 1) Ease of separation. Design for ease of separation, handling, and cleaning of all product components. 2) Fasteners. New fasteners should be developed, and the existing ones should be replaced by other fastening methods. Taking apart a snap-fitted or pop-in, pop-out product is much easier and requires less energy than taking apart a welded product. 3) Modularity design. The importance of using assemblies in a products design is to ease dealing with a product after its useful life. 4) Material selection. The variety of material types must be minimized to increase the recyclability of the product. Highly recyclable materials such as aluminum and thermoplastics should be encouraged, while the use of thermosets, which cannot be recycled, should be minimized. Research from the CIM Institute by Rose and Evans focused on disassembly-oriented lifecycle analyses, where recyclability of the product was evaluated under possible future trends in recycling technology and economy. At the Swiss Federal Institute of Technology, an evaluation procedure has been proposed to support product design according to conflicting design for disassembly criteria. Each criterion is weighted and the final decision made taken on the basis of scaling all relevant criteria. Leonard reported that two basic methods of disassembly were used: reverse assembly and brute force. For reverse assembly, if a fastener is screwed in, then it is screwed out； if two parts are snap-fit together, then they are snapped apart. For brute force,parts are just pulled or cut. Seliger, Zussman, and Kriwet stated that some obstacles make disassembly difficult for todays manufactured product. First, it is difficult to gain all the information necessary to plan the disassembly. Parts of the product might have been modified during repair, and wear can make joined elements difficult to remove. In addition, many consumer products are not designed for ease of disassembly. Engineers have done an outstanding job of meeting functional requirements and federal emission regulations. Traditionally, the engineers concentrated on improving productivity and made the product easier to be assembled. Fastening processes, such as welding and adhesive bonding, are permanent-type systems. However, engineers will now have to incorporate recyclability and disassembly into their designs when creating future products. Disassembly sequence is another problem encountered in the design for disassembly. The problems associated with the disassembly sequence are 1) freeing the part of all attachments； 2) finding the succeeding part in the disassembly sequence； and 3) disassembly of the succeeding part. 3.Safety and Health Issues Another area with ECD&M is safety and health issues. Within the automotive and electronic industries, the most common solder being used today is composed of lead and tin (37% Pb and 63% Sn). However, because of leads extreme toxicity, it has been restricted or banned from residential paints, gasoline, and numerous other products over the last decade. Therefore, much research has focused on the substitution of tin-lead solder with either non-lead or conductive adhesive. 第一篇譯文（中文） 2.3 注射模 2.3.1 注射模塑 注塑主要用于熱塑性制件的生 產(chǎn)，它也是最古老的塑料成型方式之一。目前，注塑占所有塑料樹脂消費(fèi)的 30%。典型的注塑產(chǎn)品主要有杯子器具、容器、機(jī)架、工具手柄、旋鈕（球形捏手）、電器和通訊部件（如電話接收器），玩具和鉛管制造裝置。 聚合物熔體因其較高的分子質(zhì)量而具有很高的粘性；它們不能像金屬一樣在重力流的作用下直接被倒入模具中，而是需要在高壓的作用下強(qiáng)行注入模具中。因此當(dāng)一個(gè)金屬鑄件的機(jī)械性能主要由模壁熱傳遞的速率決定，這決定了最終鑄件的晶粒度和纖維取向，也決定了注塑時(shí)熔體注入時(shí)的高壓產(chǎn)生強(qiáng)大的剪切力是物料中分子取向的主要決定力量。 由此所知，成品的機(jī)械性能主要受注射條件和在模具中的冷卻條件影響。 注塑已經(jīng)被應(yīng)用于熱塑性塑料和 熱固性塑料、泡沫部分，而且也已經(jīng)被改良用于生產(chǎn)反應(yīng)注塑過程，在此過程中，一個(gè)熱固樹脂系統(tǒng)的兩個(gè)組成部分在模具中同時(shí)被注射填充，然后迅速聚合。然而大多數(shù)注塑被用熱塑性塑料上，接下來的討論就集中在這樣的模具上。 典型的注塑周期或流程包括五個(gè)階段（見圖 2-1）： （ 1）注射或模具填充； （ 2）填充或壓緊； （ 3）定型； （ 4）冷卻； （ 5）零件頂出。 圖 2-1 注塑流程 塑料芯塊（或粉末）被裝入進(jìn)料斗，穿過一條在注射料筒中通過旋轉(zhuǎn)螺桿的作用下塑料芯塊（或粉末）被向前推進(jìn)的通道。螺桿的旋轉(zhuǎn)迫使這些芯塊在高壓下對(duì)抗使它們受熱融化的料筒加熱壁。加熱溫度在 265 至 500 華氏度之間。隨著壓力增強(qiáng)，旋轉(zhuǎn)螺桿被推向后壓直到積累了足夠的塑料能夠發(fā)射。注射活 塞迫使熔融塑料從料筒，通過噴嘴、澆口和流道系統(tǒng)，最后進(jìn)入 模具型腔。在注塑過程中，模具型腔被完全充滿。當(dāng)塑料接觸冰冷的模具表面，便迅速固化形成表層。由于型芯還處于熔融狀態(tài)，塑料流經(jīng)型芯來完成模具的填充。典型地，在注塑過程中模具型腔被填充至 95%98%。 然后模具成型過程將進(jìn)行至壓緊階段。當(dāng)模具型腔充滿的時(shí)候，熔融的塑料便開始冷卻。由于塑料冷卻過程中會(huì)收縮，這增加了收縮痕、氣空、尺寸不穩(wěn)定性等瑕疵。為了彌補(bǔ)收縮，額外的塑料就要被壓入型腔。型腔一旦被填充，作用于使物料熔化的壓力就會(huì)阻止模具型腔中的熔融塑 料由模具型腔澆口處回流。壓力一直作用到模具型腔澆口固化。這個(gè)過程可以分為兩步（壓緊和定型），或者一步完成（定型或者第二階段）。在壓緊過程中，熔化物通過補(bǔ)償收縮的保壓壓力來進(jìn)入型腔。固化成型過程中，壓力僅僅是為了阻止聚合物熔化物逆流。 固化成型階段完成之后，冷卻階段便開始了。在這個(gè)階段中，部件在模具中停留某一規(guī)定時(shí)間。冷卻階段的時(shí)間長(zhǎng)短主要取決于材料特性和部件的厚度。典型地，部件的溫度必須冷卻到物料的噴出溫度以下。 冷卻部件時(shí)，機(jī)器將熔化物塑煉以供下一個(gè)周期使用。高聚物受剪切作用和電熱絲的能量情況影響。一旦噴射成功，塑煉過程便停止了。這是在冷卻階段結(jié)束之前瞬間發(fā)生的。然后模具打開，部件便生產(chǎn)出來了。 2.3.2 注塑模具 注塑模具與它們的生產(chǎn)出來的產(chǎn)品一樣，在設(shè)計(jì)、精密度和尺寸方面各不相同。熱塑性模具的功能主要是把可塑性聚合物 制成人們想要的形狀，然后再將模制部件冷卻。 模具主要由兩個(gè)部件組成：（ 1）型腔和型芯，（ 2）固定型腔和型芯的底座。模制品的尺寸和重量限制了模具型腔的數(shù)量，同時(shí)也決定了所需設(shè)備的能力。從模具成型過程考慮，模具設(shè)計(jì)時(shí)要能安全合模、注射、脫模的作用力。此外，澆口和 流道的設(shè)計(jì)必須允許有效的流動(dòng)以及模具型腔均勻填充。 圖 2-2 舉例說明了典型注射模具中的部件。模具主要由兩部分組成：固定部分（型腔固定板），熔化的聚合物被注入的旁邊；在注塑設(shè)備結(jié)尾或排出旁邊的瓣合（中心板）部分。模具這兩部分之間的分隔線叫做分型線。注射材料通過一條叫做澆口的中心進(jìn)料通道被轉(zhuǎn)運(yùn)。澆口位于澆口軸套的上面，它逐漸縮小（錐形）是為了促進(jìn)模具打開時(shí)澆注材料的釋放。在多型腔模具中，主流道將高分子聚合熔化物提供到流道系統(tǒng)中，流道系統(tǒng)通過澆口流入每個(gè)模具型腔。 中心板支撐主型芯。主型芯的用途是確立部件的內(nèi)部 結(jié)構(gòu)。中心板有一個(gè)支持或支撐板。支撐板反過來被背對(duì)注塑模頂桿空間的 U 型結(jié)構(gòu)的柱子支撐，注塑模頂桿空間由背面的壓板和墊塊組成。被固定在中心板上的 U 型結(jié)構(gòu)，為也被叫做脫模行程的頂出行程提供了空間。在固化的過程中，部件從主型芯周圍收縮以至于當(dāng)模具打開的時(shí)候，部件和澆口隨著瓣合機(jī)構(gòu)一起被帶出來。接著，中央的起模桿被激活，引起脫模板向前移動(dòng)以至于頂桿能夠推動(dòng)部件離開型芯。帶有冷卻通道的上下模被提供，冷卻通道通過冷卻水循環(huán)流通來吸收熱塑性高分子聚合熔融物傳遞給模具的熱量。模具型腔也包含好的通風(fēng)口（對(duì)于 5 毫米而言，通風(fēng)口 應(yīng)該為 0.02 到 0.08 毫米）來確保填充過程中沒有空氣滯留在模具型腔內(nèi)。 1-頂桿 2-頂出板 3-導(dǎo)套 4-導(dǎo)柱 5-下頂針板 6-脫件銷 7-復(fù)位桿 8-限位桿 9-導(dǎo)柱 10-導(dǎo)柱 11-型腔板 12-澆口套 13-塑料工件 14-型芯 現(xiàn)在使用的有六種基本 注射模具類型。它們是：（ 1）雙板模；（ 2）三板模；（ 3）熱流道模具；（ 4）絕熱保溫流道模具；（ 5）溫流道模具；和（ 6）重疊壓塑模具。圖 2-3 和圖 2-4 闡明了這六種基本注射模具類型。 1.雙板模 一個(gè)雙板模具由每塊都帶有型腔和型芯的兩塊平板 組成。平板被固定在壓板上。瓣合機(jī)構(gòu)包含工件自動(dòng)拆卸機(jī)構(gòu)和流道系統(tǒng)。所有注射模具的基本設(shè)計(jì)都有這個(gè)思想。雙板模具是用來制作要求大型澆口制品的最合理的工具。 2.三板模 這種類型的模具由三塊板組成：（ 1）固定板或壓板被連接到固定壓盤上，通常包含主流道和分流道；（ 2）當(dāng)模具打開的時(shí)候，包含分流道和澆口中間板或型腔固定板是被允許浮動(dòng)的；（ 3）活動(dòng)板或陽模板包含模制件和用來除去模制件的頂出裝置。當(dāng)按壓進(jìn)行打開的時(shí)候，中間板和活動(dòng)板一起移動(dòng)，因此釋放了主流道和分流道系統(tǒng)和清除了澆口處模制品的贅物。當(dāng)模具打開的時(shí)候，這種設(shè)計(jì) 類型的模具使分離流道系統(tǒng)和模制件變成了可能。這種模具設(shè)計(jì)讓點(diǎn)澆口澆注系統(tǒng)能夠運(yùn)用。 3.熱流道模具 在這個(gè)注射模具的流程中，分流道要保持熱的，目的是使熔融的塑料一直處于流動(dòng)的狀態(tài)。實(shí)際上，這是一個(gè)“無流道”模具流程，有時(shí)候它也被叫做無流道模具。在無流道模具中，分流道被包含在自己的板中。熱流道模具除了模塑周期中模具的分流道部分不被打開這點(diǎn)外，其他地方與三板注射模具相似。加熱流道板與剩下的冷卻部分的模具是絕緣的。分流道中除了熱加板，模具中剩余部分是一個(gè)標(biāo)準(zhǔn)的兩板模具。 無流道模具相比傳統(tǒng)的澆口流道模具有幾個(gè)優(yōu)點(diǎn)。無 流道模具沒有模具副產(chǎn)品（澆口，分流道，主流道）被處理或者再利用，也沒有澆口與制件的分離。周期僅僅要求制件被冷卻和從模具中脫離。在這個(gè)系統(tǒng)中，從注射料筒到模具型腔，溫度能夠達(dá)到統(tǒng)一。 4.絕熱保溫流道模具 絕熱流道模具是熱流道模具的一種演變。在這種類型的模具中，分流道材料的外表面充當(dāng)了絕緣體來讓熔融材料通過。在隔熱的模具中，通過保留自己的溫度使模具中的物料一直是熔化的。有時(shí)候，一個(gè)分料梭和熱探測(cè)器被加入模具中來增加柔韌性。這種類型的模具對(duì)于多孔中心澆口的制件來說是理想的。 5.溫流道模具 它是熱流道模具的一種演變。在 這種模具中，流道而不是流道板被加熱。這是通過電子芯片嵌入探測(cè)器實(shí)現(xiàn)的。 6.重疊壓塑模具 重疊壓塑注射模具顧名思義。一個(gè)多重兩板模具其中的一塊板被放在另一塊板的上面。這種結(jié)構(gòu)也可以用在三板模具和熱流道模具上。兩板重疊結(jié)構(gòu)使單一的擠壓輸出量加倍，與一個(gè)型腔數(shù)量相同的兩板模具相比，還減少了一半的合模壓力。這種方式也被叫做“雙層模塑”。 2.3.3 壓膜機(jī) 1.傳統(tǒng)的注塑機(jī) 在這個(gè)流程中，塑料顆粒或粉末被倒入一個(gè)機(jī)器料斗中，然后被送入加熱料筒室。一個(gè)活塞壓縮物料，迫使物料漸進(jìn)地通過加熱料筒中物料被分料梭慢慢散開的加熱區(qū)域。 分料梭被安裝在料筒的中心，目的是加速塑料體中心的加熱。分料梭也有可能被加熱，以便塑料能夠內(nèi)外一起被加熱。 物料從加熱料斗流經(jīng)噴嘴進(jìn)入模具。噴嘴是料斗和模具之間的密封裝置它被用來阻止因?yàn)槭Ｓ鄩毫Χ鸬奈锪闲孤?。模具在注塑機(jī)的末端被夾具夾緊閉合。對(duì)于聚苯乙烯而言，機(jī)器末端兩三噸的壓力通常用在之間和流道系統(tǒng)中每個(gè)小的投影面積上。傳統(tǒng)的活塞式機(jī)器是唯一能生產(chǎn)斑點(diǎn)部分的類型的機(jī)器。另一種類型的注塑機(jī)將塑料材料充分地混合，以至于僅有一種顏色被生產(chǎn)出來。 2.柱塞式預(yù)塑機(jī) 這種機(jī)器使用了分料梭活塞加熱器來預(yù)塑塑料顆粒。塑料 顆粒變成熔化狀態(tài)之后，液態(tài)的塑料被倒入一個(gè)蓄料室，直到塑料準(zhǔn)備好被壓入模具。這種類型的機(jī)器比傳統(tǒng)的機(jī)器生產(chǎn)零件的速度更快，因?yàn)樵谥萍鋮s的時(shí)間中，模具腔被填滿進(jìn)行噴射。由于注射活塞在流動(dòng)的物料中工作，因此在壓縮顆粒的時(shí)候沒有壓力損失。這種現(xiàn)象能夠應(yīng)用在帶有更多投影面積的大型制件上。柱塞式預(yù)塑機(jī)的其他特點(diǎn)與傳統(tǒng)的單一活塞式注塑機(jī)是一樣的。圖 2-5舉例說明了柱塞式預(yù)塑機(jī)。 3.螺桿式預(yù)塑機(jī) 在這種注塑機(jī)中，用擠壓機(jī)來塑化塑料物料。旋轉(zhuǎn)的螺桿使塑料芯塊向前，提供給擠壓機(jī)料筒的加熱內(nèi)壁。熔融的，塑化的物料從擠壓機(jī)移動(dòng)到一個(gè)蓄料室，然后通過注射活塞移動(dòng)到模具中。螺桿的應(yīng)用有以下優(yōu)勢(shì)：（ 1）便于物料更好的混合及塑料溶化后的剪切作用；（ 2）流動(dòng)物料硬度的范圍更廣及熱敏材料可以流動(dòng)；（ 3）能在更短的時(shí)間內(nèi)進(jìn)行色澤改變；（ 4）模具制件中的應(yīng)力更小 4.往復(fù)式螺桿注塑機(jī) 這種類型的注塑機(jī)使用了一個(gè)水平的擠壓機(jī)來代替加熱室。螺桿的旋轉(zhuǎn)使塑料物料向前移動(dòng)通過擠壓機(jī)料筒。隨著物料流經(jīng)帶螺桿的加熱料筒，物料從顆粒狀態(tài)變?yōu)樗芰先廴跔顟B(tài)。螺桿往復(fù)的過程中，傳遞給模制物料的熱量是由螺桿和擠壓機(jī)的料筒壁之間的摩擦和傳導(dǎo)引起的。當(dāng)物料向前移動(dòng)的時(shí)候，螺桿返回到在擠壓機(jī)料筒前方?jīng)Q定物料容量的行程開關(guān)處。 在這個(gè)時(shí)候，與典型擠壓機(jī)類似的擠壓過程結(jié)束了。當(dāng)物料注射到模具 中，螺桿向前移動(dòng)來轉(zhuǎn)移料筒中的物料。在這個(gè)注塑機(jī)中，螺桿既充當(dāng)活塞，又充當(dāng)螺桿。模具中的澆口截面凍結(jié)阻止回流之后，螺桿開始旋轉(zhuǎn)并且向后移動(dòng)，進(jìn)行下一個(gè)周期。圖 2-5 展示了往復(fù)式螺桿注塑機(jī)。 這種形式的注塑有幾個(gè)優(yōu)點(diǎn)。它更有效地塑化熱敏感材料，由于螺桿的混合作用更快地混合色澤。給材料加熱的文都能夠更低，并且整個(gè)周期時(shí)間可以更短。 第一篇英文原文 2.3 Injection Molds 2.3.1 Injection Molding Injection molding is principally used for the production of thermoplastic parts, and it is also one of the oldest. Currently injection-molding accounts for 30% of all plastics resin consumption. Typical injection-molded products are cups, containers, housings, tool handles, knobs, electrical and communication components (such as telephone receivers), toys, and plumbing fittings. Polymer melts have very high viscosities due to their high molecular weights； they cannot be poured directly into a mold under gravity flow as metals can, but must be forced into the mold under high pressure. Therefore while the mechanical properties of a metal casting are predominantly determined by the rate of heat transfer from the mold walls, which determines the grain size and grain orientation in the final casting, in injection molding the high pressure during the injection of the melt produces shear forces that are the primary cause of the final molecular orientation in the material. The mechanical properties of the finished product are therefore affected by both the injection conditions and the cooling conditions within the mold. Injection molding has been applied to thermoplastics and thermosets, foamed parts, and has been modified to yield the reaction injection molding (RIM) process, in which the two components of a thermosetting resin system are simultaneously injected and polymerize rapidly within the mold. Most injection molding is however performed on thermoplastics, and the discussion that follows concentrates on such moldings. A typical injection molding cycle or sequence consists of five phases (see Fig. 2-1): (1) Injection or mold filling； (2) Packing or compression； (3) Holding； (4) Cooling； (5) Part ejection. Fig. 2-1 Injection molding process Plastic pellets (or powder) are loaded into the feed hopper and through an opening in the injection cylinder where they are carried forward by the rotating screw. The rotation of the screw forces the pellets under high pressure against the heated walls of the cylinder causing them to melt. Heating temperatures range from 265 to 500 F. As the pressure builds up, the rotating screw is forced backward until enough plastic has accumulated to make the shot. The injection ram (or screw) forces molten plastic from the barrel, through the nozzle, sprue and runner system, and finally into the mold cavities. During injection, the mold cavity is filled volumetrically. When the plastic contacts the cold mold surfaces, it solidifies (freezes) rapidly to produce the skin layer. Since the core remains in the molten state, plastic flows through the core to complete mold filling. Typically, the cavity is filled to 95%98% during injection. Then the molding process is switched over to the packing phase. Even as the cavity is filled, the molten plastic begins to cool. Since the cooling plastic contracts or shrinks, it gives rise to defects such as sink marks, voids, and dimensional instabilities. To compensate for shrinkage, addition plastic is forced into the cavity. Once the cavity is packed, pressure applied to the melt prevents molten plastic inside the cavity from back flowing out through the gate. The pressure must be applied until the gate solidifies. The process can be divided into two steps (packing and holding) or may be encompassed in one step (holding or second stage). During packing, melt forced into the cavity by the packing pressure compensates for shrinkage. With holding, the pressure merely prevents back flow of the polymer melt. After the holding stage is completed, the cooling phase starts. During cooling, the part is held in the mold for specified period. The duration of the cooling phase depends primarily on the material properties and the part thickness. Typically, the part temperature must cool below the materials ejection temperature. While cooling the part, the machine plasticates melt for the next cycle. The polymer is subjected to shearing action as well as the condition of the energy from the heater bands. Once the shot is made, plastication ceases. This should occur immediately before the end of the cooling phase. Then the mold opens and the part is ejected. 2.3.2 Injection Molds Molds for injection molding are as varied in design, degree of complexity, and size as are the parts produced from them. The functions of a mold for thermoplastics are basically to impart the desired shape to the plasticized polymer and then to cool the molded part. A mold is made up of two sets of components: (1) the cavities and cores, and (2) the base in which the cavities and cores are mounted. The size and weight of the molded parts limit the number of cavities in the mold and also determine the equipment capacity required. From consideration of the molding process, a mold has to be designed to safely absorb the forces of clamping, injection, and ejection. Also, the design of the gates and runners must allow for efficient flow and uniform filling of the mold cavities. Fig.2-2 illustrates the parts in a typical injection mold. The mold basically consists of two parts: a stationary half (cavity plate), on the side where molten polymer is injected, and a moving half (core plate) on the closing or ejector side of the injection molding equipment. The separating line between the two mold halves is called the parting line. The injected material is transferred through a central feed channel, called the sprue. The sprue is located on the sprue bushing and is tapered to facilitate release of the sprue material from the mold during mold opening. In multicavity molds, the sprue feeds the polymer melt to a runner system, which leads into each mold cavity through a gate. The core plate holds the main core. The purpose of the main core is to establish the inside configuration of the part. The core plate has a backup or support plate. The support plate in turn is supported by pillars against the U-shaped structure known as the ejector housing, which consists of the rear clamping plate and spacer blocks. This U-shaped structure, which is bolted to the core plate, provides the space for the ejection stroke also known as the stripper stroke. During solidification the part shrinks around the main core so that when the mold opens, part and sprue are carried along with the moving mold half. Subsequently, the central ejector is activated, causing the ejector plates to move forward so that the ejector pins can push the part off the core. Both mold halves are provided with cooling channels through which cooled water is circulated to absorb the heat delivered to the mold by the hot thermoplastic polymer melt. The mold cavities also incorporate fine vents (0.02 to 0.08 mm by 5 mm) to ensure that no air is trapped during filling. Fig. 2-2 Injection mold 1-ejector pin 2-ejector plate 3-guide bush 4-guide pillar 5-ejector base plate 6-sprue puller pin 7-push-back pin 8-limit pin 9-guide pillar 10-guide pillar 11-cavity plate 12-sprue bushing 13-plastic workpiece 14-core There are six basic types of injection molds in use today. They are: (1) two-plate mold； (2) three-plate mold, (3) hot-runner mold； (4) insulated hot-runner mold； (5) hot-manifold mold； and (6) stacked mold. Fig. 2-3 and Fig. 2-4 illustrate these six basic types of injection molds. Fig. 2-3 This illustrates three of the six basic types of injection molding dies (1) Two-plate injection mold (2) Three-plate injection mold (3) Hot-runner mold See Fig. 2-4 for the other three types. Fig. 2-4 This illustrates three of the six basic types of injection molding dies (1) Insulated runner injection mold (2) Hot manifold injection mold (3) Stacked injection mold See Fig. 2-3 for the other three types. 1. Two-Plate Mold A two-plate mold consists of two plates with the cavity and cores mounted in either plate. The plates are fastened to the press platens. The moving half of the mold usually contains the ejector mechanism and the runner system. All basic designs for injection molds have this design concept. A two-plate mold is the most logical type of tool to use for parts that require large gates. 2. Three-Plate Mold This type of mold is made up of three plates: (1) the stationary or runner plate is attached to the stationary platen, and usually contains the sprue and half of the runner； (2) the middle plate or cavity plate, which contains half of the runner and gate, is allowed to float when the mold is open； and (3) the movable plate or force plate contains the molded part and the ejector system for the removal of the molded part. When the press starts to open, the middle plate and the movable plate move together, thus releasing the sprue and runner system and degating the molded part. This type of mold design makes it possible to segregate the runner system and the part when the mold opens. The die design makes it possible to use center-pin-point gating. 3. Hot-Runner Mold In this process of injection molding, the runners are kept hot in order to keep the molten plastic in a fluid state at all times. In effect this is a runnerless molding process and is sometimes called the same. In runnerless molds, the runner is contained in a plate of its own. Hot runner molds are similar to three-plate injection molds, except that the runner section of the mold is not opened during the molding cycle. The heated runner plate is insulated from the rest of the cooled mold. Other than the heated plate for the runner, the remainder of the mold is a standard two-plate die. Runnerless molding has several advantages over conventional sprue runner-type molding. There are no molded side products (gates, runners, or sprues) to be disposed of or reused, and there is no separating of the gate from the part. The cycle time is only as long as is required for the molded part to be cooled and ejected from the mold. In this system, a uniform melt temperature can be attained from the injection cylinder to the mold cavities. 4. Insulated Hot-Runner Mold This is a variation of the hot-runner mold. In this type of molding, the outer surface of the material in the runner acts like an insulator for the melten material to pass through. In the insulated mold, the molding material remains molten by retaining its own heat. Sometimes a torpedo and a hot probe are added for more flexibility. This type of mold is ideal for multicavity center-gated parts. 5. Hot-Manifold This is a variation of the hot-runner mold. In the hot-manifold die, the runner and not the runner plate is heated. This is done by using an electric-cartridge-insert probe. 6. Stacked Mold The stacked injection mold is just what the name implies. A multiple two-plate mold is placed one on top of the other. This construction can also be used with three-plate molds and hot-runner molds. A stacked two-mold construction doubles the output from a single press and reduces the clamping pressure required to one half, as compared to a mold of the same number of cavities in a two-plate mold. This method is sometimes called “two-level molding”. 2.3.3 Mold Machine 1. Conventional Injection-Molding Machine In this process, the plastic granules or pellets are poured into a machine hopper and fed into the chamber of the heating cylinder. A plunger then compresses the material, forcing it through progressively hotter zones of the heating cylinder, where it is spread thin by a torpedo. The torpedo is installed in the center of the cylinder in order to accelerate the heating of the center of the plastic mass. The torpedo may also be heated so that the plastic is heated from the inside as well as from the outside. The material flows from the heating cylinder through a nozzle into the mold. The nozzle is the seal between the cylinder and the mold； it is used to preve