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汽车手套箱盖板模具如何设计？

How to design the die for the cover plate of the glove box?

1

One

塑件外观要求及模具结构分析

Analysis of appearance requirements and die structure of plastic parts

图1所示为某品牌汽车手套箱盖板零件图，材料为PP。外表面需皮纹，塑件为外观件，表面要求高。塑件尺寸为：555.5*200.4*300.5mm。塑件特点如下：（1）外观面要求高，塑件外观面需皮纹，塑件外观面不允许有斑点，浇口痕迹，更不允许有收缩凹陷.熔接痕.飞边等缺陷。（2）塑件为皮纹件，塑件外观面（A面）脱模斜度设计要合理（一般至少设计5度以上）。（3）塑件外形复杂，曲面光洁度高，本塑件内外侧面无倒扣。（4）塑件内侧面只有锁扣位置有倒扣，塑件内侧面因塑件结构与焊接工艺的原因无法设计加强筋，因此塑件有应力变形与内缩缺陷。（5）塑件外观夹线要求高，塑件外观需防止出现段差。

Figure 1 shows a brand car glove box cover part drawing, material PP. The outer surface needs leather pattern, plastic parts are exterior parts, and the surface requirements are high. The size of the plastic part is: 555.5*200.4*300.5mm. The features of the plastic parts are as follows: (1) the requirements of the appearance surface are high, the appearance of the plastic parts need skin lines, the appearance surface of the plastic parts is not allowed to have spots, gate marks, and no shrinkage sag, weld mark. Flims and other defects. (2) the plastic parts are made of leather, and the design of the outward appearance (A surface) of the plastic parts should be reasonable (usually at least 5 degrees or more). (3) plastic parts are complex in shape and high in surface finish. (4) the inner side of the plastic part only has the locking position, and the inner surface of the plastic part cannot design the reinforcement because of the structure of the plastic parts and the welding process. Therefore, the plastic parts have stress and deformation and internal shrinkage defects. (5) the appearance of the plastic parts is highly demanding, and the appearance of the plastic parts needs to be prevented from occurring.

2

Two

模具结构分析

Analysis of die structure

根据手套箱盖板的结构特点，模具优先采用热流道注塑模结构，采用3点开放式热嘴进胶。图1所示塑件外侧无倒扣，内侧有2个倒扣，因为是在内侧，从位置空间考虑首选做斜顶结构。本模具外形尺寸为：1100*730*840（mm）,总重量约3吨，属于中型注塑模具。详细结构见图2与图3。

According to the structural characteristics of the glove box cover plate, the hot runner injection mold structure is preferred, and the 3 point open type hot nozzle is used for glue injection. Figure 1 shows that the outer part of the plastic part is not buckled, and the inner side has 2 buckles, because it is in the inner side, and the oblique top structure is preferred for the location space. The die size is 1100*730*840 (mm) and the total weight is about 3 tons, which belongs to the medium-sized injection mold. The detailed structure is shown in Figure 2 and figure 3.

图2 汽车手套箱盖板注塑模具结构图1

Figure 2 the structure diagram of the injection mold for the cover plate of the glove box 1

图3 汽车手套箱盖板注塑模具结构图2

Figure 3 the structure diagram of the injection mold for the cover plate of the glove box 2

3

Three

成型零件设计

Design of forming parts

汽车手套箱盖板注塑模具成型零件设计必须解决以下两个问题。

The following two problems must be solved in the design of injection moulds for automobile glove box covers.

（1）模板和镶件采用一体式还是分体式?

(1) are templates and inserts integrated or split?

一体式俗称原身出，分体式俗称镶钶（core）。一体式模具的优点是结构紧凑，强度刚性好，避免了开框、配框和制造斜楔等繁琐的工序。分体式的优点是工序分散，便于分科加工，由于模板比内模镶件材料便宜，故可节省成本。

One is commonly known as the original body, and the other is called core. The advantages of the integrated die are compact structure, high strength and rigidity, avoiding the tedious processes such as frame opening, frame matching and Wedge manufacturing. The advantage of the split type is that the process is dispersed, and it is easy to separate the processing. As the template is cheaper than the internal model insert, it can save cost.

本模具定动模采用一体式，常用材料为：P20。

The mold is fixed in one mold, and the commonly used material is P20.

（3）塑件如何进胶？型腔如何排位？或者说塑件在型腔中如何摆放？

(3) how do plastic parts get into glue? How do the cavities be arranged? Or how do the plastic parts be placed in a cavity?

由于塑件为汽车手套箱盖板，型腔排位方式是：1*1。本塑件外侧倒扣，外侧不需设计抽芯系统，内侧有两个倒扣，采用斜推块结构。本塑件外形落差大，在模具设计时要注意防倾斜设计，模具管位设计尺寸要大，要壮实。本模具采用四面围边周圈做5度斜度来防止倾斜，保证定位精确。

Because the plastic part is the glove box cover plate, the cavity arrangement is 1*1. The outer part of the plastic part is buckled, and the outer side does not need to design a core pulling system. The inner side has two reverse buttons, and the oblique pushing block structure is adopted. The shape of the plastic part is large, so we should pay attention to the anti tilt design when designing the mould, and the size of the die must be large and strong. The mold is made of 5 sides of the circumference of the four sides to prevent inclination and ensure accurate positioning.

在模具设计中，塑件的进胶方式决定了模具的排位方式与模具类型。在汽车模具设计中客户一般会提供在那些位置进胶的信息作为参考，所有汽车模具都需要做模流分析（利用MOLDFLOW软件等）来验证塑件的进胶方式。确定进胶的位置，浇口形式，尺寸大小。一般会选取多种方案进行模流分析，做好后发给客户确认，与客户一起选取最优与最合适的方案设计浇注系统。

In the mold design, the way of injection of plastic parts determines the position and type of mold. In the design of the automobile die, the customer usually provides information as a reference in those positions. All automobile molds need to do model flow analysis (using MOLDFLOW software etc.) to verify the molding method of the plastic parts. Determine the location of the glue, the form and size of the gate. In general, a variety of options will be selected for mold flow analysis. After that, the customer will be confirmed, and the best and most appropriate scheme will be selected together with the customer to design gating system.

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Four

模流分析

Model flow analysis

在汽车模具设计中，根据以往类似塑件的经验首先确定浇口的大概位置，然后应用MolFlow软件对浇口进行模拟分析，根据分析结果优化浇口的形状与位置。由于汽车塑件同一塑件形状与结构大多类似，以往的设计为模具提供了参考，根据以往成功的案例作为参照，往往起到事半功倍的作用。

In the design of automobile die, the approximate position of the gate is determined according to the experience similar to the plastic parts, and then the gate is simulated and analyzed with MolFlow software, and the shape and position of the gate are optimized according to the analysis results. Since the shape and structure of the same plastic parts of the automobile plastic parts are mostly similar, the previous design provides the reference for the mold. According to the previous successful cases, it often plays a double role.

图4 汽车手套箱盖板进胶方案

Figure 4 injection scheme for cover plate of automobile glove box

如图4所示：塑件采用2点顺序阀热流道，从塑件侧边进胶，主流道尺寸为16mm。为避免外观缺陷，采用潜伏式浇口（俗称牛角浇口）进胶。

As shown in Figure 4, the plastic parts adopt the 2 point sequence valve hot runner, from the side of the plastic part, and the main flow path is 16mm. To avoid appearance defects, use latent gate (commonly known as horn gate) to glue.

图5 汽车手套箱盖板填充分析

Figure 5 filling analysis of cover plate of automobile glove box

如图5所示：塑件采用2点顺序阀热流道，从塑件侧边进胶，填充时间为4.6秒，塑件填充效果良好。

As shown in Figure 5, the plastic parts adopt 2 point sequence valve hot runner, from the side of the plastic parts to glue, filling time is 4.6 seconds, plastic parts filling effect is good.

图6 汽车手套箱盖板填充等高线分析

Figure 6 contour analysis of cover plate filling of automobile glove box

图7 汽车手套箱盖板注射压力曲线分析

Figure 7 analysis of the injection pressure curve of the cover plate of a car glove box

图8 汽车手套箱盖板锁模力曲线分析

Figure 8 analysis of the clamping force curve of the cover plate of a car glove box

图9 汽车手套箱盖板熔接痕与包风分析

Figure 9 analysis of weld lines and air cladding of the cover plate of automobile glove box

根据图4-图9所示分析结果，得出结论。塑件填充流动平衡，无缺胶困气现象，塑件填充压力均匀。经过模流分析结果，本模具采用上述进胶方案。

According to the analysis results of figure 4-, figure 9, the conclusion is drawn. Plastic parts filled with flow balance, without glue trapped gas phenomenon, plastic parts filling pressure uniform. After the mold flow analysis results, the mold adopts the above glue injection scheme.

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Five

浇注系统设计

Gating system design

本模具浇注系统采用热流道进胶，采用两点开放式热嘴的进胶方式，塑件材料为PP,。

The mold runner system adopts hot runner glue, and adopts two point open type hot nozzle to enter glue, and the plastic material is PP.

由于塑件为PP料，料流动好，流道设计范围广些，但热嘴至塑件边缘的流道长度尽量设计在60mm以内，如果实在不行也尽量控制在100mm以内，避免冷流道过长与避免压力损失大。本模具采用2点顺序阀热流道，从塑件侧边进胶，主流道尺寸为16mm。为避免外观缺陷，采用潜伏式浇口（俗称牛角浇口）进胶，如图10所示。

Because the plastic part is PP material, the material flow well, the flow path design range is wide, but the pipe length of the hot mouth to the plastic part is designed within 60mm as far as possible. If it is not true, it can not also be controlled within 100mm as far as possible, avoiding the long cold flow passage and the great loss of pressure. This mold adopts 2 point sequence valve hot runner, glue from the side of plastic parts, and the main road size is 16mm. To avoid appearance defects, use latent gate (commonly known as cattle horn gate) to glue, as shown in Figure 10.

图10 汽车手套箱盖板浇注系统设计

Figure 10 design of the gating system for the cover plate of a glove box

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Six

侧向抽芯机构设计

Design of lateral core pulling mechanism

本模具无侧向抽芯（滑块）机构，故本节不作讨论。塑件内侧有2处倒扣，由于在塑件内侧，因此优先采用“斜顶杆+斜顶”结构。本模具斜顶较小，采用D12

The die has no lateral core pulling mechanism, so this section will not be discussed. The inner part of the plastic part has 2 reversing buckles. Because of the inner part of the plastic part, the "inclined roof + oblique top" structure is preferred. The slanted top of the mold is small, and the D12 is used