CN111241699B - Method for improving warping deformation of automobile headlamp mask - Google Patents
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- 238000004088 simulation Methods 0.000 claims abstract description 27
- 238000001746 injection moulding Methods 0.000 claims abstract description 18
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- 238000012360 testing method Methods 0.000 claims abstract description 8
- 230000007547 defect Effects 0.000 claims description 10
- 238000012545 processing Methods 0.000 claims description 8
- 238000005259 measurement Methods 0.000 claims description 7
- 238000013102 re-test Methods 0.000 claims description 6
- 238000011156 evaluation Methods 0.000 claims description 3
- 238000004458 analytical method Methods 0.000 claims 1
- 238000012937 correction Methods 0.000 abstract description 5
- 238000003754 machining Methods 0.000 abstract description 2
- 238000013461 design Methods 0.000 description 8
- 239000002994 raw material Substances 0.000 description 6
- 238000005206 flow analysis Methods 0.000 description 4
- 238000004364 calculation method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000012938 design process Methods 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
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Abstract
The invention relates to a method for improving the buckling deformation of a front lamp mask of an automobile, belonging to the field of automobile lamp manufacturing, and the method comprises the following specific steps: designing a product, designing a mold, optimizing the mold, testing the mold, confirming the stability of an injection molding process, analyzing and correcting the deviation of a mold flow, manufacturing pre-deformation data, copying a mold core and testing the mold again. By analyzing factors influencing the warpage deformation of the automobile headlight and carrying out simulation and reciprocating correction on injection molding process parameters, the warpage deformation of the automobile headlight mask in the manufacturing process is overcome, the component yield of the automobile headlight mask is improved, the machining process precision of the automobile headlight mask is greatly improved, the production cost is reduced, and the economic benefit is increased.
Description
Technical Field
The invention belongs to the field of automobile lamp manufacturing, and particularly relates to a method for improving the warping deformation of an automobile headlamp mask.
Background
The automobile headlamp is an important component of an automobile, is arranged at the front end of an automobile body, and has high functional requirements and appearance requirements. The headlight mask is completely of a curved irregular contour, needs to be matched with parts such as a grille, a fender, a top cover, a front bumper and the like, some vehicles also need to be matched with a grille lamp, and the requirement on matching precision is particularly high. Therefore, a particularly high dimensional accuracy of the individual pieces of the automobile headlight mask is required. However, since the automobile headlamp mask is made of polycarbonate material by injection molding, the inherent characteristics of the plastic material cause the part to shrink and warp. The larger the degree of the curved surface of the part is, the more the space is avoided and the more serious the warping is. These characteristics and limitations are difficult to eliminate, and therefore, the headlamp cover is warped and deformed.
At present, a mainstream finished automobile customer generally requires that the deviation amount of a matching surface is +/-0.5 mm, the prior art cannot completely make the part deviation within +/-0.5 mm, the only method is to adjust the process to the limit, and then the customer performs deviation approval, so that the design of a designer is greatly discounted, and the actually produced automobile cannot achieve the perfect design effect.
Therefore, a method for improving the warpage of the front lamp mask is urgently needed, so that the warpage of the parts is greatly reduced, and the requirements of customers are met.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a method for improving the buckling deformation of an automobile headlamp mask, which has the following specific technical scheme that the method comprises the following steps:
designing a product, designing a product structure, and determining a product matching surface and requirements so as to determine a measuring point and a positioning point of the product;
designing a mold, and designing a detachable and replaceable mold core according to the product matching surface designed in the step one;
step three, optimizing the die structure and solving the die defects;
testing the mold, solving the appearance defect of the product, and determining the mold structure and the injection molding process parameters;
fifthly, confirming the stability of the injection molding process, establishing a coordinate system according to the positioning points determined in the first step, measuring the measuring points of the N product parts to obtain the measuring value of each measuring point of the N product parts and the range value of the measuring value, comparing the range value of the measuring value with the client-given tolerance value, determining that the measuring value is qualified when the range value of the measuring value is less than 20% of the client-given tolerance value, analyzing reasons to find out influencing factors when the range value of the measuring value is more than or equal to 20% of the client-given tolerance value, and optimizing until the measuring result meets the condition that the range value of the measuring value is less than 20% of the client-given tolerance value and is determined to be qualified;
step six, correcting the module flow analysis deviation, performing analog simulation by using module flow analysis software, evaluating the buckling deformation, evaluating each measuring point of the product part by taking the positioning point in the step one as an evaluation standard of the deformation, comparing the deviation value of the obtained measuring point with the average value of the measured value of each measuring point in the step five to obtain a difference value, determining the difference value to be a qualified simulation result when the difference value is less than 20% of the customer given tolerance value, analyzing reasons to find out influence factors when the difference value is more than or equal to 20% of the customer given tolerance value, modifying simulation parameters, and optimizing until the difference value is less than 20% of the customer given tolerance value and determining the difference value to be a qualified simulation result;
seventhly, pre-deformation data manufacturing, namely turning the matching surface in the step one by taking a theoretical position as a central point according to the qualified simulation result in the step six, exporting result data, utilizing CATIA software to conduct smoothing treatment on the matching surface again to generate entity data, importing the entity data into the module flow analysis software again, simulating again to obtain a new simulation result, comparing the new simulation result with the theoretical data to obtain a deformation value, determining the matching surface as qualified data when the deformation value is less than 20% of a client given tolerance value, and repeating the steps five to seven when the deformation value is greater than or equal to 20% of the client given tolerance value until the deformation value is less than 20% of the client given tolerance value and determining the matching surface as qualified data;
step eight, copying the mold core, copying and processing the mold core according to the qualified data in the step seven to obtain a standard mold core, respectively measuring the standard mold core and the mold core in the step two according to a reference point, comparing the deviation values of the measurement results of the two mold cores, determining the mold core as a qualified mold core when the deviation value is less than 0.01mm, and re-processing the mold core until the deviation value is less than 0.01mm compared with the measurement result of the standard mold core, and determining the mold core as a qualified mold core;
and step nine, re-testing the mold, namely mounting the qualified mold core in the step eight to the mold, re-testing the mold, producing product parts, establishing a coordinate system by utilizing the positioning points, measuring the T values of the measuring points of the M product parts, determining the M product parts as the qualified parts when the T values are less than 85% of the customer given tolerance value, and repeating the step five until the T values are less than 85% of the customer given tolerance value, and determining the M product parts as the qualified parts.
And step five, the N value is 10.
Step six the modeling flow analysis software is moldflow2019 version.
According to the technical scheme, by analyzing the factors influencing the warping deformation of the automobile headlamp and carrying out simulation and reciprocating correction on the injection molding process parameters, the warping deformation generated in the manufacturing process of the automobile headlamp mask is overcome, the component yield of the automobile headlamp mask is improved, the machining process precision of the automobile headlamp mask is greatly improved, the production cost is reduced, and the economic benefit is increased.
Drawings
The invention will be further described with reference to the following description and embodiments in conjunction with the accompanying drawings:
FIG. 1 is a flow chart of a method implementation
FIG. 2 automobile headlight cover
Detailed Description
The invention is further described in detail below with reference to the drawings and examples. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
A method for improving the warping deformation of a front lamp mask of an automobile comprises the following steps as shown in a specific flow chart shown in figure 1:
designing a product, designing a product structure, and determining a product matching surface and requirements so as to determine measuring points and positioning points of the product, wherein the step is normal product structure design, the product matching surface and requirements are well defined in the design process, and the measuring points and RPS points of the product are determined;
step two, design the mould, match the face according to the product that designs in step one, design detachable, removable mould benevolence, this step is according to the product that step definition matches the face, and replaceable mould benevolence can be dismantled in the design, mould benevolence design point: 1 is as small as possible, 2 can be flexibly disassembled, and 3 has a measuring reference;
step three, optimizing the die structure and solving the die defects;
testing the mold, solving the appearance defect of the product, determining the mold structure and the injection molding process parameters, mainly solving the appearance defect of the product, and locking the mold structure and the injection molding process parameters after optimizing the appearance defect of the product;
step five, confirming the stability of the injection molding process, establishing a coordinate system according to the positioning points determined in the step one, measuring the measuring points of N product parts to obtain the measured value of each measuring point of the N product parts and the range value of the measured value, comparing the range value of the measured value with the client-given tolerance value, when the range value of the measured value is less than 20% of the client-given tolerance value, determining the measured value as qualified, when the range value of the measured value is more than or equal to 20% of the client-given tolerance value, analyzing the reasons to find out influencing factors, optimizing until the measured value meets the range value that the range value of the measured value is less than 20% of the client-given tolerance value, determining the measured value as qualified, normally, continuously and stably producing a batch of parts without defects in appearance, wherein the number of the parts is 10, the process parameters can be adjusted in a reasonable range on the basis of the process parameters locked in the step four, establishing the coordinate system according to the RPS point defined in the step one, measuring the measuring points, measuring the T value, evaluating the extreme value of each measuring point of 10 pieces, comparing the extreme value with the tolerance given by the client, if the result is less than the tolerance given by the client, 1/5 is acceptable, otherwise, analyzing the reason to find out the influencing factor, and optimizing until the measuring result is acceptable;
step six, correcting the module flow analysis deviation, performing analog simulation by using module flow analysis software, evaluating the buckling deformation, evaluating each measuring point of the product part by taking the positioning point in the step one as an evaluation standard of the deformation, comparing the deviation value of the obtained measuring point with the average value of the measured value of each measuring point in the step five to obtain a difference value, determining the difference value to be a qualified simulation result when the difference value is less than 20% of the customer given tolerance value, analyzing reasons to find out influence factors when the difference value is more than or equal to 20% of the customer given tolerance value, modifying simulation parameters, and optimizing until the difference value is less than 20% of the customer given tolerance value and determining the difference value to be a qualified simulation result;
seventhly, pre-deformation data manufacturing, namely turning the matching surface in the step one according to the qualified simulation result in the step six by taking the theoretical position as a central point, for example, a point A is used, the simulation value T is-3.75, the value of the turned point A' is T3.75, the result data is exported, the matching surface is subjected to fairing treatment again by CATIA software to generate entity data, the entity data is imported into the analog flow analysis software again, simulation is performed again, the new simulation result is obtained and compared with the theoretical data to obtain a deformation value, when the deformation value is less than 20% of the customer given tolerance value, the matching surface is determined as qualified data, when the deformation value is greater than or equal to 20% of the customer given tolerance value, the steps five to seven are repeated until the deformation value is less than 20% of the customer given tolerance value, and the matching surface is determined as qualified data;
eighthly, copying a mold core, copying and processing the mold core according to the qualified data in the seventeenth step to obtain a standard mold core, respectively measuring the standard mold core and the mold core in the second step according to a reference point, comparing the deviation values of the measurement results of the two mold cores, determining the mold core as a qualified mold core when the deviation value is less than 0.01mm, and re-processing the mold core when the deviation value is greater than or equal to 0.01mm until the deviation value is less than 0.01mm of the measurement result of the standard mold core, and determining the mold core as a qualified mold core;
and step nine, re-testing the mold, namely mounting the qualified mold core in the step eight to the mold, re-testing the mold, producing product parts, establishing a coordinate system by utilizing the positioning points, measuring the T values of the measuring points of the M product parts, determining the M product parts as the qualified parts when the T values are less than 85% of the customer given tolerance value, and repeating the step five until the T values are less than 85% of the customer given tolerance value, and determining the M product parts as the qualified parts.
The factors influencing the buckling deformation mainly include the uncontrollable factors of the performance of raw materials, injection molding process parameters, part structures, pouring gate positions and external environments. Wherein the properties of the raw materials are controlled by different types, brands and processes of manufacturers. The actual values of the injection molding process parameters are determined by the set values and the precision of the injection molding machine. The part structure cannot be changed depending on the shape of the customer. The gate location is defined in terms of product structure.
Now, the warpage deformation amount of the headlight mask is defined as y, the property of the raw material itself is defined as x1, the injection molding process parameter is defined as x2, the part structure is defined as a, the gate position is defined as x3, and the external environment is defined as x4., then the warpage deformation amount y of the headlight mask is a function of the property of the raw material itself x1, the injection molding process parameter x2, the part structure a, the gate position x3 and the external environment x4, and is recorded as y ═ kxf (x1, x2, x3, x4, a).
The performance of the raw materials can be measured through tests, and the set values of the injection molding process parameters are finally determined through mold testing. The gate position and the overmould flow analysis may determine an optimum position.
The deviation m1 between the actual value of the raw material property and the test measurement value, the deviation m2 between the set process parameter and the actual process parameter due to the precision of the injection molding equipment, and the external environment x4 are the root causes of the deviation between the mold flow analysis simulation result and the actual warpage deformation. And m1, m2, and x4 are all uncertain random quantities. The effect of these random variables on the amount of warp deformation is not controllable. In order to eliminate the influence of these uncontrollable factors, the influence is reduced by a correction value k. Meanwhile, after the uncontrollable factors are corrected, the fluctuation range of the warpage deformation amount of the headlamp mask is proved to be far smaller than the required value of a customer through experiments, and +/-0.5 mm is generally considered to be far smaller than 20% of the required value of the customer and is considered to be acceptable.
After finding out the correction parameters through experiments, the correction parameters K and data such as x1, x2, x3, x4, a and the like are taken into analog flow analysis software to obtain the approximately accurate buckling deformation amount of the headlamp mask. In this case, the determined warpage amount is not optimized by means such as adjusting a process or a mold gate, and is a relatively stable warpage amount.
The outer contour surface of the front lamp cover is divided into a plurality of curved surfaces with approximately the same vector directions, the curved surfaces with matching requirements are subjected to inversion calculation, and the moldflow2019 has the function of obtaining a curved surface which has the same actual warping amount as a part but is completely opposite to the warping direction. And then outputting the curved surface data, and generating an entity by using CATIA software again. And (4) carrying out warping deformation simulation on the generated new part by using Moldflow again, comparing warping deformation with original data, and if the warping deformation does not meet the requirement of less than 20% of the customer requirement value, carrying out inversion calculation, outputting a curved surface, generating an entity and the like. Until the simulated warp deformation is less than 20% of the customer requirement. And (5) using the parts meeting the requirements for die processing.
When the mold is designed, the mold core part related to the curved surface is designed to be as small as possible, the mold core can be flexibly disassembled and assembled, the mold core is convenient to copy, and unnecessary waste of re-opening the mold is reduced.
This concludes the description of the embodiments of the present invention.
Claims (3)
1. A method of improving warpage of an automotive headlamp housing, comprising the steps of:
designing a product, designing a product structure, and determining a product matching surface and requirements so as to determine a measuring point and a positioning point of the product;
designing a mold, and designing a detachable and replaceable mold core according to the product matching surface designed in the step one;
step three, optimizing the die structure and solving the die defects;
testing the mold, solving the appearance defect of the product, and determining the mold structure and the injection molding process parameters;
fifthly, confirming the stability of the injection molding process, establishing a coordinate system according to the positioning points determined in the first step, measuring the measuring points of the N product parts to obtain the measured value of each measuring point of the N product parts and the range value of the measured value, comparing the range value of the measured value with the tolerance value given by a customer, determining the measured value to be qualified when the range value of the measured value is less than 20% of the tolerance value given by the customer, analyzing reasons to find out influence factors when the range value of the measured value is greater than or equal to 20% of the tolerance value given by the customer, and optimizing until the measured value meets the condition that the range value of the measured value is less than 20% of the tolerance value given by the customer and determining the measured value to be qualified;
step six, correcting the analysis deviation of the mold flow, performing analog simulation by using mold flow analysis software, evaluating the buckling deformation amount, evaluating each measuring point of the product part by taking the positioning point in the step one as an evaluation standard of the deformation amount, comparing the deviation value of the obtained measuring point with the average value of the measured value of each measuring point in the step five to obtain a difference value, determining the difference value to be a qualified simulation result when the difference value is less than 20% of the customer given tolerance value, analyzing reasons to find out influence factors, modifying simulation parameters and optimizing until the difference value is less than 20% of the customer given tolerance value and determining the difference value to be a qualified simulation result when the difference value is greater than or equal to 20% of the customer given tolerance value;
step seven, pre-deformation data manufacturing, namely turning over the matching surface in the step one by taking a theoretical position as a central point according to the qualified simulation result in the step six, exporting result data, performing fairing processing on the matching surface by using CATIA software to generate entity data, importing the entity data into the module flow analysis software again, performing simulation again to obtain a new simulation result, comparing the new simulation result with the theoretical data to obtain a deformation value, determining the matching surface as qualified data when the deformation value is less than 20% of a customer given tolerance value, and repeating the step five to the step seven when the deformation value is greater than or equal to 20% of the customer given tolerance value until the deformation value is less than 20% of the customer given tolerance value and determining the matching surface as qualified data;
eighthly, copying a mold core, copying and processing the mold core according to the qualified data in the seventeenth step to obtain a standard mold core, respectively measuring the standard mold core and the mold core in the second step according to a reference point, comparing the deviation values of the measurement results of the two mold cores, determining the mold core as a qualified mold core when the deviation value is less than 0.01mm, and re-processing the mold core when the deviation value is greater than or equal to 0.01mm until the deviation value is less than 0.01mm of the measurement result of the standard mold core, and determining the mold core as a qualified mold core;
and step nine, re-testing the mold, namely mounting the qualified mold core in the step eight to the mold, re-testing the mold, producing product parts, establishing a coordinate system by utilizing the positioning points, measuring the T values of the measuring points of the M product parts, determining the M product parts as the qualified parts when the T values are less than 85% of the customer given tolerance value, and repeating the step five until the T values are less than 85% of the customer given tolerance value, and determining the M product parts as the qualified parts.
2. The method of improving the warpage of an automotive headlamp mask as claimed in claim 1, wherein in step five, the value of N is 10.
3. A method of improving warpage of an automotive headlamp mask as claimed in claim 1, wherein the mold flow analysis software of step six is moldflow 2019.
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| CN114516137B (en) * | 2020-11-19 | 2023-04-14 | 美的集团股份有限公司 | Design method of injection mold, injection molding method and injection mold |
| CN114654623B (en) * | 2020-12-22 | 2023-06-23 | 青岛海信模具有限公司 | Method for correcting reverse deformation of injection mold |
| CN113021816B (en) * | 2021-03-04 | 2023-03-07 | 上海泰客诺信息科技有限公司 | Method and system for improving anti-deformation accuracy of injection molding product |
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Address after: Block D, Hongda Optoelectronic Industrial Park, 789 Shunda Road, Changchun hi tech Economic Development Zone, Jilin Province, 130000 Patentee after: Changchun Hella Faway Automotive Lighting Co.,Ltd. Address before: Block D, Hongda Optoelectronic Industrial Park, 789 Shunda Road, Changchun hi tech Economic Development Zone, Jilin Province, 130000 Patentee before: CHANGCHUN FAW FUWEI HAILA AUTO LIGHT Co.,Ltd. |
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