Automobile front-end module PP-LGF40 insert injection molding rapid molding process method head

Abstract

The invention discloses an injection molding rapid molding process method for a PP-LGF40 insert of an automobile front-end module, and belongs to the technical field of automobile part manufacturing. The method comprises the following steps: a raw material pretreatment step: carrying out hot air drying on a PP-LGF40 material at 80-90 DEG C for 1-2 hours; the temperature of a screw rod of an injection molding machine is set to be 240 DEG C from the first area to the seventh area in sequence, PP-LGF40 is adopted as a raw material, and through optimized equipment configuration, a full-automatic mechanical arm system and refined technological parameter control, key technologies such as multi-section quick mold opening and closing, multi-section injection and pressure maintaining are adopted, so that the temperature of the screw rod of the injection molding machine is set to be 240 DEG C; and the insert injection molding period of the front-end module is greatly shortened to be less than 65 seconds from the traditional 90-100 seconds. The problems that in the prior art, the forming period is long, and the cost is high are effectively solved, and the production efficiency and the market competitiveness are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing technology, and in particular to a rapid prototyping process for PP-LGF40 automotive front-end module inserts via injection molding. Background Technology With the growing demand for lightweight vehicles, front-end modules in automobiles are now widely adopting injection molding processes that combine long glass fiber reinforced plastics with metal inserts. Parts manufactured using this process offer advantages such as light weight, high strength, good integration, and low cost.

[0002] However, existing front-end module insert injection molding technologies, such as those using PA-GF30 material, generally suffer from excessively long molding cycles, with most products having cycles as long as 90 to 100 seconds. This directly leads to high processing costs and seriously affects the market competitiveness of enterprises.

[0003] A search revealed that Chinese patent CN106079234A discloses "an injection molding process for a front-end module covered with sheet metal using PA-GF30 material." While this process provides a feasible technical solution, it has significant shortcomings: First, the processing temperature of the raw material PA-GF30 is high, resulting in high energy consumption; second, the patent does not involve a fully automated robotic arm operation scheme, limiting the degree of automation; and finally, the overall molding cycle remains relatively long, failing to meet the current industry's competitive demand for high efficiency.

[0004] Therefore, it is necessary to provide a rapid prototyping process for the PP-LGF40 automotive front-end module insert injection molding to solve the above-mentioned technical problems. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides a rapid prototyping process for the injection molding of PP-LGF40 automotive front-end module inserts.

[0006] This invention provides a rapid prototyping process for PP-LGF40 automotive front-end module inserts via injection molding, characterized by the following steps: S1. Raw material pretreatment steps: Dry the PP-LGF40 material with hot air at 80~90℃ for 1~2 hours; S2. Equipment Pre-treatment Steps: Set the screw temperature of the injection molding machine from Zone 1 to Zone 7 as follows: 240℃, 235℃, 230℃, 225℃, 220℃, 215℃, 200℃, with a tolerance of ±10℃; hot runner temperature: 240±10℃; mold stationary water temperature: 40±10℃; moving mold water temperature: 35±10℃. S3. Plasticizing step: Plasticize the dried raw material in the injection molding machine, set the plasticizing end position to 260±10mm, release 10±5mm, plasticizing speed to 50±10rpm / min, and plasticizing back pressure to 10±10bar. S4. Insert placement step: The metal insert is picked up by a tooling controlled by a robotic arm. S5. Rapid mold closing procedure: Multi-segment speed control is used for mold closing, and the total mold closing time is controlled within 6±1 seconds; S6. Injection procedure: A multi-segment injection process is adopted, with an overall injection pressure of 100±10 bar and an injection time of 6±1 seconds. S7. Pressure holding step: A multi-stage pressure holding process is adopted, with a total pressure holding time of 9±1 seconds; S8. Cooling step: Cooling time 25±10 seconds; S9. Rapid mold opening procedure: Multi-segment speed control is used for mold opening, and the total mold opening time is controlled within 6±1 seconds; S10. Synchronous operation steps: After the mold is opened, the robotic arm controls the tooling to simultaneously place the metal inserts and grasp the molded products; The entire injection molding cycle is controlled within 65 seconds.

[0007] Preferably, the rapid mold closing step employs five-stage speed control, with the following parameters: Mold closing section: Position 1500±50mm, speed 60±10%; Two-stage mold closing: Position 1300±50mm, speed 100%; Three-stage mold closing mechanism: Position 300±50mm, Speed ​​100%; Four-stage mold closing mechanism: Position 100±50mm, Speed ​​40±10%; Five-stage mold closing mechanism: position 20±10mm, speed 15±5%.

[0008] Preferably, the rapid mold opening step employs five-stage speed control, with the following parameters: Mold opening section: Position 0mm, speed 15±5%; Two-stage mold opening: Position 100±50mm, speed 25±5%; Three-stage mold opening: position 300±50mm, speed 100%; Four-stage mold opening: Position 1300±50mm, speed 100%; Five-stage mold opening: position 1500±50mm, speed 50±10%.

[0009] Preferably, the injection step employs a five-stage injection method with the following parameters: Injection point: 270mm, speed 35±10%; Injection stage two: Position 225±10mm, speed 50±10%; Injection in three stages: position 100±10mm, speed 45±5%; Injection in four segments: position 60±10mm, speed 25±10%; Injection in five stages: position 35mm, speed 20±5%.

[0010] Preferably, the pressure holding step employs a three-stage pressure holding method, with the following parameters: Pressure holding stage: Pressure 40±10 bar, time 2±1 seconds; Pressure holding stage 2: Pressure 50±10 bar, time 2±1 seconds; Three pressure holding stages: pressure 60±10 bar, time 5±1 seconds.

[0011] Preferably, the injection molding machine is an injection molding machine with a clamping force of 3200 tons and a screw diameter of 150mm, and uses an alloy hardened screw.

[0012] Preferably, the core and cavity of the mold are made of 1.2738TSHH steel, the water channel spacing inside the mold is 60~70mm, and the vertical distance between the water channel and the mold surface is 25~40mm.

[0013] Preferably, the metal insert includes a metal reinforcing plate, a metal nut, and a metal bushing, wherein the surface of the metal reinforcing plate is electrophoretically treated, and the surfaces of the metal nut and bushing are galvanized.

[0014] Preferably, the robotic arm is a 6-axis robotic arm, and the tooling for picking and placing parts is in a two-sided operation mode, with one side used to pick up metal inserts and the other side used to pick up injection molded products, and is equipped with a detection signal device.

[0015] Preferably, in the synchronous operation step, the time for placing the metal insert is controlled at 7±2 seconds, and the time for grasping the product is controlled at 6±2 seconds.

[0016] Compared with related technologies, the present invention provides the following beneficial effects: This method uses PP-LGF40 as raw material and, through optimized equipment configuration, a fully automated robotic arm system, and precise process parameter control, including key technologies such as multi-stage rapid mold opening and closing, and multi-stage injection and holding pressure, significantly reduces the injection molding cycle of the front-end module inserts from the traditional 90-100 seconds to less than 65 seconds. This invention effectively solves the problems of long molding cycles and high costs associated with existing technologies, significantly improving production efficiency and market competitiveness. Attached Figure Description

[0018] Figure 1 This is a process flow diagram of the present invention. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0020] See Figure 1 A rapid prototyping process for PP-LGF40 inserts for automotive front-end modules, including production preparation: Injection molding raw materials: PP-LGF40 (polypropylene with 40% long glass fiber), pellet length 8~10mm, material density 1.22±0.02 g / cm3, flexural modulus of the sample >8000MPa, heat distortion temperature >160℃.

[0021] Metal inserts: The surface of the reinforcing plate is electrophoretically treated, and the surface of the nuts and bushings is galvanized to prevent the metal parts from rusting.

[0022] Injection molding machine: 3200 tons, screw diameter 150mm, alloy hardened screw Mold: 1.2738TSHH steel, water channel spacing 65mm, water channel distance from mold surface 30mm.

[0023] Includes the following steps: S1. Raw material pretreatment steps: Add PP-LGF40 material into the hot air drying drum using a feeder, and dry it with hot air at 80~90℃ for 1~2 hours; S2. Equipment Pre-treatment Steps: Set the screw temperature of the injection molding machine from Zone 1 to Zone 7 as follows: 240℃, 235℃, 230℃, 225℃, 220℃, 215℃, 200℃, with a tolerance of ±10℃; hot runner temperature: 240±10℃; mold stationary water temperature: 40±10℃, moving mold water temperature: 35±10℃, water pipe pressure: 0.6±0.1MPa, water pipe flow rate: >6m³ / h; S3. Plasticizing step: Plasticize the dried raw material in the injection molding machine, set the plasticizing end position to 260±10mm, release 10±5mm, plasticizing speed to 50±10rpm / min, and plasticizing back pressure to 10±10bar. S4. Insert placement step: The metal insert is picked up by a tooling controlled by a robotic arm. S5. Rapid mold closing procedure: Multi-segment speed control is used for mold closing, and the total mold closing time is controlled within 6±1 seconds; S6. Injection procedure: A multi-segment injection process is adopted, with an overall injection pressure of 100±10 bar and an injection time of 6±1 seconds. S7. Pressure holding step: A multi-stage pressure holding process is adopted, with a total pressure holding time of 9±1 seconds; S8. Cooling step: Cooling time 25±10 seconds; S9. Rapid mold opening procedure: Multi-segment speed control is used for mold opening, and the total mold opening time is controlled within 6±1 seconds; S10. Synchronous operation steps: After the mold is opened, the robotic arm controls the tooling to simultaneously place the metal inserts and grasp the molded products; The entire injection molding cycle is controlled within 65 seconds.

[0024] The rapid mold closing step employs five-stage speed control, with the following parameters: Mold closing section: Position 1500±50mm, speed 60±10%; Two-stage mold closing: Position 1300±50mm, speed 100%; Three-stage mold closing mechanism: Position 300±50mm, Speed ​​100%; Four-stage mold closing mechanism: Position 100±50mm, Speed ​​40±10%; Five-stage mold closing mechanism: position 20±10mm, speed 15±5%.

[0025] The rapid mold opening step employs five-stage speed control, with the following parameters: Mold opening section: Position 0mm, speed 15±5%; Two-stage mold opening: Position 100±50mm, speed 25±5%; Three-stage mold opening: position 300±50mm, speed 100%; Four-stage mold opening: Position 1300±50mm, speed 100%; Five-stage mold opening: position 1500±50mm, speed 50±10%.

[0026] The injection procedure employs a five-stage injection process with the following parameters: Injection point: 270mm, speed 35±10%; Injection stage two: Position 225±10mm, speed 50±10%; Injection in three stages: position 100±10mm, speed 45±5%; Injection in four segments: position 60±10mm, speed 25±10%; Injection in five stages: position 35mm, speed 20±5%.

[0027] The pressure holding step employs a three-stage pressure holding method, with the following parameters: Pressure holding stage: Pressure 40±10 bar, time 2±1 seconds; Pressure holding stage 2: Pressure 50±10 bar, time 2±1 seconds; Three pressure holding stages: pressure 60±10 bar, time 5±1 seconds.

[0028] Sequence valve switch settings: The No. 1 gate is set to open at 220±10mm and close at 0mm, with a holding time of 6±2 seconds.

[0029] The No. 2 gate is set to open at 100±10mm and close at 0mm, with a holding time of 6±2 seconds.

[0030] The No. 3 gate is set to open at 145±10mm and close at 0mm, with a holding time of 6±2 seconds.

[0031] The No. 4 gate is set to open at 200±10mm and close at 0mm.

[0032] The No. 5 gate is set to open at 270±10mm and close at 0mm.

[0033] The No. 6 gate is set to open at 200±10mm and close at 0mm.

[0034] Gate 7 is set to open at 145±10mm and close at 0mm, with a holding pressure time of 6±2 seconds. The No. 8 gate is set to open at 170±10mm and close at 0mm.

[0035] 10. Core pulling parameter settings: The inlet pressure is 90±10 bar, and the flow rate is 45±10%.

[0036] Extraction pressure 80±10 bar, flow rate 40±10%.

[0037] 11. Set the clamping pressure to 2000±200 tons and the cooling time to 25±10 seconds.

[0038] The injection molding machine is a 3200-ton clamping force injection molding machine with a screw diameter of 150mm, and uses an alloy-hardened screw to reduce the corrosion of the screw surface by long-wave fibers. The equipment has a built-in plasticizing motor to reduce plasticizing waiting time.

[0039] The mold core and cavity are made of 1.2738TSHH steel to reduce the erosion and corrosion of the mold surface by glass fiber. The water channel spacing inside the mold is 60~70mm, and the vertical distance between the water channel and the mold surface is 25~40mm. CAE tools are used in the early stage of design to analyze the product deformation and shrinkage rate, and reduce the pressure holding and cooling time during production.

[0040] The metal insert includes a metal reinforcing plate, a metal nut, and a metal bushing, wherein the surface of the metal reinforcing plate is electrophoretically treated, and the surfaces of the metal nut and bushing are galvanized.

[0041] The robotic arm is a 6-axis robotic arm with a two-sided operation configuration for picking and placing parts. One side is used to grip metal inserts, and the other side is used to grip injection molded products. It is also equipped with a detection signal device to help the robot determine whether the picking and placing of parts has been completed.

[0042] In the synchronous operation steps, the time for placing the metal insert is controlled within 7±2 seconds, and the time for grasping the product is controlled within 6±2 seconds.

[0043] Working principle: 1. Use a centralized feeding system to pump the pre-dried PP-LGF40 material into the buffer hopper of the injection molding machine.

[0044] 2. Using the set plasticizing parameters (set screw plasticizing parameters: plasticizing end position 260±10mm, subsequent retraction 10±5mm, plasticizing speed 50±10rpm / min, plasticizing back pressure 10±10bar), heat and shear the raw material to a molten state.

[0045] 3. The pick-and-place fixture uses a connecting device to be fixed to a 6-axis robotic arm. The robotic arm controls the pick-and-place fixture to grab the metal insert at the pick-up point. After grabbing, it waits above the mold for the injection molding machine to open the mold.

[0046] 4. Use the pre-set mold closing parameters (set mold opening and closing parameters: The mold closing section is 1500±50mm, and the speed is 60±10%.

[0047] The mold closing section is located at 1300±50mm, and the speed is 100%.

[0048] The mold closing position is 300±50mm in three stages, and the speed is 100%.

[0049] The mold closing position is 100±50mm in four stages, and the speed is 40±10%.

[0050] The mold closing position is 20±10mm at the fifth stage, and the speed is 15±5%.

[0051] The mold opening position is 0mm, and the speed is 15±5%.

[0052] The mold opening section is 100±50mm at the second stage and the speed is 25±5%.

[0053] The mold opening position is 300±50mm in three stages, and the speed is 100%.

[0054] The mold opening position is 1300±50mm in four stages, and the speed is 100%.

[0055] The mold opens at five positions (1500±50mm) with a speed of 50±10%, quickly closing the mold to a clamping force of 2000 tons. The mold closing time is 6±1 seconds.

[0056] 5. Apply the plasticized molten material (set screw temperatures: Zone 1 240℃, Zone 2 235℃, Zone 3 230℃, Zone 4 225℃, Zone 5 220℃, Zone 6 215℃, Zone 7 200℃, temperature tolerance ±10℃) using the set injection process parameters (set injection parameters: The overall injection pressure is 100±10 bar.

[0057] Inject at a depth of 270mm at a speed of 35±10%.

[0058] The injection site was 225±10mm, and the injection speed was 50±10%.

[0059] The injection sites were 100±10mm apart, and the injection speed was 45±5%.

[0060] The injection sites were 60±10mm apart, and the injection speed was 25±10%.

[0061] Set the injection position to 35mm and the speed to 20±5%. Inject the molten material into the mold's hot runner system. —Injection time: 6±1 seconds. 6. When the material enters the hot runner system, the injection molding machine controls the mold valve pins to open in a set sequence (setting injection parameters: The overall injection pressure is 100±10 bar.

[0062] Inject at a depth of 270mm at a speed of 35±10%.

[0063] The injection site was 225±10mm, and the injection speed was 50±10%.

[0064] The injection sites were 100±10mm apart, and the injection speed was 45±5%.

[0065] The injection sites were 60±10mm apart, and the injection speed was 25±10%.

[0066] Fill the five injection points at a depth of 35mm and a speed of 20±5%.

[0067] 7. When the raw material fills approximately 98% of the mold cavity, the injection molding machine uses the set parameters (holding pressure stage 1: 40±10 bar, holding time 2±1 seconds; holding pressure stage 2: 50±10 bar, holding time 2±1 seconds; holding pressure stage 3: 60±10 bar, holding time 5±1 seconds) for holding. — Holding time 9±1 seconds. 8. After the pressure holding period is completed, the product cooling time stage begins (clamping pressure set at 2000±200 tons, cooling time 25±10 seconds). — Cooling time 25±10 seconds.

[0068] 9. After the cooling stage is completed, the injection molding machine is set with the mold opening parameters (1500±50mm at the first mold closing position, speed 60±10%).

[0069] The mold closing section is located at 1300±50mm, and the speed is 100%.

[0070] The mold closing position is 300±50mm in three stages, and the speed is 100%.

[0071] The mold closing position is 100±50mm in four stages, and the speed is 40±10%.

[0072] The mold closing position is 20±10mm at the fifth stage, and the speed is 15±5%.

[0073] The mold opening position is 0mm, and the speed is 15±5%.

[0074] The mold opening section is 100±50mm at the second stage and the speed is 25±5%.

[0075] The mold opening position is 300±50mm in three stages, and the speed is 100%.

[0076] The mold opening position is 1300±50mm in four stages, and the speed is 100%.

[0077] The mold opening process is completed at five positions (1500±50mm) and a speed of 50±10%. The mold opening time is 6±1 seconds.

[0078] 10. After the injection molding machine completes mold opening, the robot controls the placement and removal of parts on the fixed mold, simultaneously placing one metal plate, two metal nuts, and six metal bushings. — Placement time for metal inserts: 7±2 seconds.

[0079] 11. After the fixed mold metal insert is placed, the robotic arm controls the pick-and-place fixture to grab the front-end module part and safely return to the placement point. — Grabbing the front-end module product takes 6±2 seconds.

[0080] The entire process takes about 65 seconds for the injection molding machine to complete, which is much shorter than the injection molding cycle time for front-end module inserts in the industry.

[0081] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A rapid prototyping process for injection molding of PP-LGF40 inserts for automotive front-end modules, characterized in that, Includes the following steps: S1. Raw material pretreatment steps: Dry the PP-LGF40 material with hot air at 80~90℃ for 1~2 hours; S2. Equipment Pre-treatment Steps: Set the screw temperature of the injection molding machine from Zone 1 to Zone 7 as follows: 240℃, 235℃, 230℃, 225℃, 220℃, 215℃, 200℃, with a tolerance of ±10℃; hot runner temperature: 240±10℃; mold stationary water temperature: 40±10℃; moving mold water temperature: 35±10℃. S3. Plasticizing step: Plasticize the dried raw material in the injection molding machine, set the plasticizing end position to 260±10mm, release 10±5mm, plasticizing speed to 50±10rpm / min, and plasticizing back pressure to 10±10bar. S4. Insert placement step: The metal insert is picked up by a tooling controlled by a robotic arm. S5. Rapid mold closing procedure: Multi-segment speed control is used for mold closing, and the total mold closing time is controlled within 6±1 seconds; S6. Injection procedure: A multi-segment injection process is adopted, with an overall injection pressure of 100±10 bar and an injection time of 6±1 seconds. S7. Pressure holding step: A multi-stage pressure holding process is adopted, with a total pressure holding time of 9±1 seconds; S8. Cooling step: Cooling time 25±10 seconds; S9. Rapid mold opening procedure: Multi-segment speed control is used for mold opening, and the total mold opening time is controlled within 6±1 seconds; S10. Synchronous operation steps: After the mold is opened, the robotic arm controls the tooling to simultaneously place the metal inserts and grasp the molded products; The entire injection molding cycle is controlled within 65 seconds.

2. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The rapid mold closing step employs five-stage speed control, with the following parameters: Mold closing section: Position 1500±50mm, speed 60±10%; Two-stage mold closing: Position 1300±50mm, speed 100%; Three-stage mold closing mechanism: Position 300±50mm, Speed ​​100%; Four-stage mold closing mechanism: Position 100±50mm, Speed ​​40±10%; Five-stage mold closing mechanism: position 20±10mm, speed 15±5%.

3. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The rapid mold opening step employs five-stage speed control, with the following parameters: Mold opening section: Position 0mm, speed 15±5%; Two-stage mold opening: Position 100±50mm, speed 25±5%; Three-stage mold opening: position 300±50mm, speed 100%; Four-stage mold opening: Position 1300±50mm, speed 100%; Five-stage mold opening: position 1500±50mm, speed 50±10%.

4. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The injection procedure employs a five-stage injection process with the following parameters: Injection point: 270mm, speed 35±10%; Injection stage two: Position 225±10mm, speed 50±10%; Injection in three stages: position 100±10mm, speed 45±5%; Injection in four segments: position 60±10mm, speed 25±10%; Injection in five stages: position 35mm, speed 20±5%.

5. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The pressure holding step employs a three-stage pressure holding method, with the following parameters: Pressure holding stage: pressure 40±10 bar, time 2±1 seconds; Pressure holding stage 2: Pressure 50±10 bar, time 2±1 seconds; Three-stage pressure holding: pressure 60±10 bar, time 5±1 seconds.

6. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The injection molding machine is a 3200-ton clamping force injection molding machine with a screw diameter of 150mm, and uses an alloy hardened screw.

7. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The mold core and cavity are made of 1.2738TSHH steel. The water channel spacing inside the mold is 60~70mm, and the vertical distance between the water channel and the mold surface is 25~40mm.

8. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The metal insert includes a metal reinforcing plate, a metal nut, and a metal bushing, wherein the surface of the metal reinforcing plate is electrophoretically treated, and the surfaces of the metal nut and bushing are galvanized.

9. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, The robotic arm is a 6-axis robotic arm with a two-sided operation mode for picking up and placing parts. One side is used to pick up metal inserts, and the other side is used to pick up injection molded products. It is also equipped with a detection signal device.

10. The rapid prototyping process for the PP-LGF40 insert of the automotive front-end module according to claim 1, characterized in that, In the synchronous operation steps, the time for placing the metal insert is controlled within 7±2 seconds, and the time for grasping the product is controlled within 6±2 seconds.

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