外文翻譯--在注塑模應(yīng)用方面外形電鑄鎳的技術(shù)注釋

1、<p>　　畢業(yè)設(shè)計(論文)外文資料翻譯</p><p>　　系　　部： 機(jī)械工程系 </p><p>　　專 業(yè)： 機(jī)械工程及自動化 </p><p>　　姓 名： </p><p>　

2、　學(xué) 號： </p><p>　　外文出處： 中國機(jī)械資訊網(wǎng) </p><p>　　BBS.CMIW.CN </p><p>　　附 件： 1.外文資料翻譯譯文；2.外文原文。 </p&g

3、t;<p>　　附件1：外文資料翻譯譯文</p><p>　　在注塑模應(yīng)用方面，外形電鑄鎳的技術(shù)注釋</p><p>　　摘要 在過去幾年，快速成型技術(shù)及快速模具在發(fā)達(dá)國家已廣泛應(yīng)用。在這篇文章中,作為一種范例，分析電芯塑料注射模具。通過快速成型，利用差分系統(tǒng)得到鎳殼模型。主要目的是分析鎳殼力學(xué)特征，學(xué)習(xí)不同方面的金相組織、硬度、內(nèi)壓，失敗的可能性。以這些特色的有關(guān)參數(shù)生產(chǎn)

4、鎳殼電設(shè)備，終于得到了一個注塑模具核心部分。</p><p>　　關(guān)鍵詞：電鍍； 電制；顯微組織； 鎳</p><p><b>　　文章概要</b></p><p><b>　　1. 引言</b></p><p>　　2. 注塑模具制造過程</p><p>　　3. 電鑄殼獲

5、?。涸O(shè)備</p><p><b>　　4. 獲得硬度</b></p><p><b>　　5. 金相組織</b></p><p><b>　　6. 內(nèi)壓</b></p><p>　　7. 測試的注塑模具</p><p><b>　　8. 結(jié)論&

6、lt;/b></p><p><b>　　1．引言</b></p><p>　　現(xiàn)代工業(yè)遇到的最重要的挑戰(zhàn)之一是在很短的時間內(nèi)向消費(fèi)者提供更好的產(chǎn)品。因此,現(xiàn)代工業(yè)必須有更強(qiáng)的競爭性和適應(yīng)更合理的生產(chǎn)成本。 毫無疑問，結(jié)合時間和質(zhì)量并不容易,因?yàn)樗麄兘?jīng)?；ハ嘧儞Q。生產(chǎn)系統(tǒng)的科技進(jìn)步，在方式將可更有效和可行的促進(jìn)組合,例如,如果是演化的觀測系統(tǒng)和注塑技術(shù)、我們得出

7、的結(jié)論是事實(shí)上可以用很少的時間和高質(zhì)量把新產(chǎn)品推向市場。在模具制造領(lǐng)域中，先進(jìn)的快速模具制造技術(shù)有可能改善設(shè)計和制造過程注入部分。快速模具制造技術(shù)基本上是由程序集中組成，在短短的時間里，以可接受的精度水平使我們獲取小型系列的塑料模具零件。其應(yīng)用領(lǐng)域不僅包括制作塑膠件注，而且他們研制并創(chuàng)造了最高產(chǎn)量。</p><p>　　本文包括在廣泛試圖研究確定分析測試和建議的科研第一線，在產(chǎn)業(yè)層次形成從注塑模具獲取鎳殼核心的可

8、能性，同時用差分模型快速成型設(shè)備取得了初步的模型。</p><p>　　也將不得不說，無數(shù)業(yè)內(nèi)人士事前并沒有應(yīng)用任何新電鑄技術(shù)，但很大程度上，在快速模具的生產(chǎn)技術(shù)上使用這種試圖調(diào)查研究工作.，運(yùn)用所有準(zhǔn)確，制度化的方式方法并提出了工作。</p><p>　　2．注塑模具制造過程</p><p>　　核心是透過電進(jìn)程的鎳殼。這是一個主管充滿金屬環(huán)氧樹脂的一核心板塊。模

9、具(圖1)制造時可以直接注射A型多用標(biāo)本，確定SO3167標(biāo)準(zhǔn)的甲狀旁腺恩目的是要確定這個試樣的力學(xué)性能和通過常規(guī)手段收集工業(yè)材料。</p><p>　　圖1注塑模具制造與電核心</p><p>　　根據(jù)這一方法研制工作，該階段取得核心有以下幾方面：</p><p>　　(一) CAD系統(tǒng)預(yù)期目標(biāo)的設(shè)計</p><p>　　(二) 快速原型設(shè)

10、備制造模型(頻分多路復(fù)用)。該材料將被用于ABS塑料</p><p>　　(三) 以以往的模式生產(chǎn)事前已經(jīng)涂了導(dǎo)電涂料的鎳電殼(必須有導(dǎo)電)</p><p>　　(四) 從模型中清理殼牌</p><p>　　(五) 生產(chǎn)背面填充著隨著銅管與冷凍槽流動具有抗高溫殼牌環(huán)氧樹脂的核</p><p><b>　　心 </b>&l

11、t;/p><p>　　注塑模具有兩個空洞，他們一個是電加工的核心，另一個是直接在機(jī)械上移動壓板。因此，它獲得了與同一工具及同一工藝條件同時在空洞里注入兩種不同的標(biāo)本制造技術(shù)。</p><p>　　3．電鑄殼獲?。涸O(shè)備</p><p>　　電鍍是一個電化學(xué)過程中的化學(xué)變化, 當(dāng)電流通過，它起源于電解質(zhì)。該電解槽是由金屬鹽溶液淹沒兩個電極，一個陽極(鎳)、陰極(示范)。通過

12、來自一定強(qiáng)度的直流電。當(dāng)電流流經(jīng)電路，目前在溶液中金屬離子轉(zhuǎn)化為原子，堆積于陰極或多或少的創(chuàng)造沉淀層。</p><p>　　這項(xiàng)工作采用的鍍液是由鎳、磺酸集中在400 毫升/公升，氯化鎳(10微克/公升)、硼酸(50微克/公升),allbrite SLA (30立方厘米/公升),703allbrite(2立方厘米/公升)。這種合成物的選擇主要取決于我們打算的應(yīng)用類型即注塑模具，即使注射了玻璃纖維?；撬徭囎屛覀儷@得

13、可以接受的殼內(nèi)壓 (測試結(jié)果，不同工藝條件，不高于50兆帕和2兆帕左右最佳條件)。 不過這種程度的內(nèi)部壓力也是使用添加劑Allbrite SLA強(qiáng)硝酸脂、甲醛水溶液產(chǎn)生的后果。這種添加劑當(dāng)允許較小殼顆粒增加阻力。703allbrite是降解水溶液以減少表面腐蝕。氯化鎳,盡管內(nèi)壓有害，增強(qiáng)導(dǎo)電溶液中的金屬均勻分布在陰極。硼酸作為pH值的緩沖。一旦已確定浴，有效驗(yàn)的參數(shù)測試改變不同條件過程的電流密度(在1至22a/立方分米)，溫度(35至5

14、5℃)和pH值, 部分的改變鍍液組成。</p><p><b>　　4．獲得硬度</b></p><p>　　在測試期間已獲得一個非常有趣的結(jié)論，對不同程度硬度的鎳殼一直保持在相當(dāng)高的穩(wěn)定價值。在圖2，在pH4±0.2，攝氏45℃時，可以觀察到電流密度值為2.5和22℃之間。硬度值的范圍從高壓540至580。如果pH值降為3.5，氣溫下降55℃，硬度值的范圍

15、從高壓520以上至高壓560以下。由磺酸鎳組成的這一特點(diǎn)使得測試不同于其他傳統(tǒng)業(yè)務(wù)，觀念是允許經(jīng)營范圍更廣；然而這種有限性的將取決于其他因素。例如內(nèi)應(yīng)力，因?yàn)槠涔ぷ鳡顟B(tài)可能在某些變性的pH值、電流密度和溫度下。在另一方面，傳統(tǒng)的硬度介于200-250高壓磺酸浴，遠(yuǎn)低于在測試中獲得的。有必要要考慮到對于注塑模具，接受300高壓硬度。其中最常見的材料就可以找到注塑模具鋼(高壓290)，積分硬化鋼(高壓520-595)，casehardene

16、d鋼(高壓760-800)等。這樣可以觀察到中高幅度硬度水平的鎳殼注塑模具材料，有償殼牌是反對用低延性的環(huán)氧樹脂填充。因?yàn)樽⑺苁且粋€內(nèi)壓控制進(jìn)程， 這也是為什么必須要?dú)ず穸缺M可能均勻(以上最低值)，避免重大失誤。如圖：</p><p>　　圖2．硬度變化與電流密度．4+0.2pH值．45℃</p><p><b>　　5．金相組織</b></p><

17、;p>　　主要是為了改良而分析金相結(jié)構(gòu)、電流密度、溫度值。樣品分析、橫向部分(垂直于沉積)為實(shí)現(xiàn)準(zhǔn)備便捷，樹脂被方便的封裝在含有硝酸，醋酸混合物的瓶子，進(jìn)行每隔15，25，40，50秒收盤后擦拭。為了事后在奧林匹斯金相顯微鏡碲下觀察PME3-ADL 3.3×/10×。</p><p>　　在評論文中的照片之前，有必要討論用差分快速成型機(jī)械制造逐層貫通的熔融塑料 (ABS) 殼模具。 每一

18、層擠出模具留下的螺紋直徑約0.15毫米即橫向和縱向的中間媒介。因此，在機(jī)器的主要表面可以觀察到薄線標(biāo)明的道路。這些線路將作為參考解決水平鎳重復(fù)性顯示。重復(fù)性模式將是一個評估注塑模具基本內(nèi)容的基本要素：表面紋理。</p><p>　　該系列測試表1所示：</p><p><b>　　表1．</b></p><p><b>　　檢驗(yàn)系列&

19、lt;/b></p><p>　　圖3顯示第一次蝕刻的系列表面樣本。它顯示了頻分多路復(fù)用機(jī)的原理，也就是說有一個良好的重復(fù)性。 它仍無法察覺圓形的顆粒結(jié)構(gòu)，在圖4系列2之后的第二蝕刻可以觀察到一條線道較前明顯減少。在圖5系列2°和3，雖然這時路徑很難查出，蝕刻已開始出現(xiàn)了一批顆粒結(jié)構(gòu)。另外，最黑暗的地方顯示含有合成物浴的蝕刻過程。</p><p>　　圖 3. 系列1(&#

20、215;150)、蝕刻1</p><p>　　圖 4. 系列2(×300), 蝕刻2</p><p>　　圖 5. 系列3(×300),蝕刻2</p><p>　　這一行為表明，工作在低電流密度、高溫下，殼以良好的再現(xiàn)能力獲得粒度即適當(dāng)?shù)膽?yīng)用。如果進(jìn)行了平面沉積的橫向分析，它可以在所有的樣品和一切條件下測試，沉淀物的增長結(jié)構(gòu)是由薄片組成的(圖6)

21、。雖然延展性低，但是取得了高機(jī)械阻力。這取決于質(zhì)量,，首先存在添加劑。因?yàn)榛撬徭囋]有添加劑，通常制造纖維和非層結(jié)構(gòu)[5]。更正直到近似于空值的潤濕劑，在任何情況下保持層結(jié)構(gòu)表明這種結(jié)構(gòu)的應(yīng)力消脂(allbrite習(xí)得)。在另一方面，據(jù)測試根據(jù)不同層結(jié)構(gòu)層厚度的計算電流密度。</p><p>　　圖 6. 機(jī)橫向系列2 (×600),蝕刻2.</p><p><b>　

22、　6．內(nèi)壓</b></p><p>　　其中一個主要特征是殼的應(yīng)用像輸入低水平內(nèi)壓。用陰極張力法在不同電流密度和鍍液溫度測量系統(tǒng)下做不同的測試。鋼鐵被用來測試與控制自由和固定(160毫米長度 寬度12.7毫米,厚度0.3毫米)。因?yàn)槌练e金屬是唯一允許檢測控制機(jī)械應(yīng)變(拉伸或壓應(yīng)力)和計算內(nèi)壓。對于部分鋼鐵來說，從彈性的角度來看Stoney模型應(yīng)用被假定鎳底層厚度不夠，表面影響小(3微米)。在所有測試情

23、形中最佳條件是內(nèi)部壓力50和極端條件下為2兆帕，為所需的可接受值。最后的結(jié)論是在不同的條件和工作參數(shù)下電鍍浴允許無明顯變化內(nèi)壓。</p><p><b>　　7．測試的注塑模具</b></p><p>　　試驗(yàn)已在各種代表性熱塑性材料中進(jìn)行如聚丙烯、鎂、高密度聚乙烯和PC。分析零件的性能，如注射大小、重量、抗延性僵化。測試?yán)炝W(xué)性能和分析光破壞性。這一核心進(jìn)行約50

24、0注射量，其余條件下經(jīng)受更多。</p><p>　　一般而言，重大分歧都是未察覺樣本核心之間的行為。從加工腔到一整套的材料，但是在分析光彈性時(圖七)發(fā)現(xiàn)了兩種不同張標(biāo)本，基本上是取決于炎熱劃轉(zhuǎn)、澆注腔的剛度。這種差異說明延性變化較突出的部分材料，如聚乙烯、六鎂。</p><p>　　圖 7．分析光注入標(biāo)本</p><p>　　在所有分析化驗(yàn)中發(fā)現(xiàn)高密度聚乙烯管案例

25、是一個較低延性標(biāo)本。所得鎳核心，量化30%左右。在這種情況下六鎂值也接近50%。</p><p><b>　　8．結(jié)論</b></p><p>　　經(jīng)過連續(xù)的測試和不同的條件下已經(jīng)清查磺酸鎳浴已獲準(zhǔn)使用添加劑。鎳殼將獲得一些可以接受的注塑模具的機(jī)械性能。也就是說，重復(fù)性好，高硬度及良好的機(jī)械阻力。因而機(jī)械層結(jié)構(gòu)不足的部分將取代鎳殼的環(huán)氧樹脂飾面。核心為注塑塑造，允許注

26、入可接受質(zhì)量水平中型系列塑料零件。</p><p>　　附件2：外文原文（復(fù)印件）</p><p>　　A technical note on the characterization of electroformed nickel shells for their application to injection molds </p><p>　　Abstract

27、 The techniques of rapid prototyping and rapid tooling have been widely developed during the last years. In this article, electroforming as a procedure to make cores for plastics injection molds is analysed. Shells are

28、obtained from models manufactured through rapid prototyping using the FDM system. The main objective is to analyze the mechanical features of electroformed nickel shells, studying different aspects related to their metal

29、lographic structure, hardness, internal stresses and</p><p>　　Keywords: Electroplating; Electroforming; Microstructure; Nickel </p><p>　　Article Outline</p><p>　　1. Introduction <

30、;/p><p>　　2. Manufacturing process of an injection mold </p><p>　　3. Obtaining an electroformed shell: the equipment </p><p>　　4. Obtained hardness </p><p>　　5. Metallogra

31、phic structure </p><p>　　6. Internal stresses </p><p>　　7. Test of the injection mold </p><p>　　8. Conclusions </p><p>　　1. Introduction</p><p>　　One of th

32、e most important challenges with which modern industry comes across is to offer the consumer better products with outstanding variety and time variability (new designs). For this reason, modern industry must be more and

33、more competitive and it has to produce with acceptable costs. There is no doubt that combining the time variable and the quality variable is not easy because they frequently condition one another; the technological advan

34、ces in the productive systems are going to permit t</p><p>　　This paper is included within a wider research line where it attempts to study, define, analyze, test and propose, at an industrial level, the pos

35、sibility of creating cores for injection molds starting from obtaining electroformed nickel shells, taking as an initial model a prototype made in a FDM rapid prototyping equipment. </p><p>　　It also would h

36、ave to say beforehand that the electroforming technique is not something new because its applications in the industry are countless but this research work has tried to investigate to what extent and under which paramete

37、rs the use of this technique in the production of rapid molds is technically feasible. All made in an accurate and systematized way of use and proposing a working method. </p><p>　　2. Manufacturing process o

38、f an injection mold</p><p>　　The core is formed by a thin nickel shell that is obtained through the electroforming process, and that is filled with an epoxic resin with metallic charge during the integration

39、 in the core plate 。 This mold (Fig. 1) permits the direct manufacturing by injection of a type a multiple use specimen, as they are defined by the UNE-EN ISO 3167 standard. The purpose of this specimen is to determine t

40、he mechanical properties of a collection of materials representative industry, injected in these tools</p><p>　　Fig. 1. Manufactured injection mold with electroformed core.</p><p>　　The sta

41、ges to obtain a core, according to the methodology researched in this work, are the following: </p><p>　　(a) Design in CAD system of the desired object.</p><p>　　(b) Model manufacturing in a rap

42、id prototyping equipment (FDM system). The material used will be an ABS plastic.</p><p>　　(c) Manufacturing of a nickel electroformed shell starting from the previous model that has been coated with a conduc

43、tive paint beforehand (it must have electrical conductivity).</p><p>　　(d) Removal of the shell from the model.</p><p>　　(e) Production of the core by filling the back of the shell with epoxy re

44、sin resistant to high temperatures and with the refrigerating ducts made with copper tubes.</p><p>　　The injection mold had two cavities, one of them was the electroformed core and the other was directly mac

45、hined in the moving platen. Thus, it was obtained, with the same tool and in the same process conditions, to inject simultaneously two specimens in cavities manufactured with different technologies. </p><p>

46、　　3. Obtaining an electroformed shell: the equipment</p><p>　　Electrodeposition is an electrochemical process in which a chemical change has its origin within an electrolyte when passing an electric current

47、 through it. The electrolytic bath is formed by metal salts with two submerged electrodes, an anode (nickel) and a cathode (model), through which it is made to pass an intensity coming from a DC current. When the current

48、 flows through the circuit, the metal ions present in the solution are transformed into atoms that are settled on the cathode creating </p><p>　　The plating bath used in this work is formed by nickel sulfama

49、te and at a concentration of 400 ml/l, nickel chloride (10 g/l), boric acid (50 g/l), Allbrite SLA (30 cc/l) and Allbrite 703 (2 cc/l). The selection of this composition is mainly due to the type

50、 of application we intend, that is to say, injection molds, even when the injection is made with fibreglass. Nickel sulfamate allows us to obtain an acceptable level of internal stresses in the shell (the tests gave resu

51、lts, for different proc</p><p>　　Once the bath has been defined, the operative parameters that have been altered for testing different conditions of the process have been the current density (between 1 and 2

52、2 A/dm2), the temperature (between 35 and 55 °C) and the pH, partially modifying the bath composition. </p><p>　　4. Obtained hardness</p><p>　　One of the most interesting conclusi

53、ons obtained during the tests has been that the level of hardness of the different electroformed shells has remained at rather high and stable values. In Fig. 2, it can be observed the way in which for current density va

54、lues between 2.5 and 22 A/dm2, the hardness values range from 540 and 580 HV, at pH 4 ± 0.2 and with a temperature of 45 °C. If the pH of the bath is reduced at 3.5 and the temperature

55、is 55 °C those values are above 520 HV and below 560 HV. Th</p><p>　　Fig. 2. Hardness variation with current density. pH 4 ± 0.2, T = 45 °C.</p&

56、gt;<p>　　5. Metallographic structure</p><p>　　In order to analyze the metallographic structure, the values of current density and temperature were mainly modified. The samples were analyzed in frontal

57、 section and in transversal section (perpendicular to the deposition). For achieving a convenient preparation, they were conveniently encapsulated in resin, polished and etched in different stages with a mixture of aceti

58、c acid and nitric acid. The etches are carried out at intervals of 15, 25, 40 and 50 s, after being polished again, in order t</p><p>　　Before going on to comment the photographs shown in this article,

59、it is necessary to say that the models used to manufacture the shells were made in a FDM rapid prototyping machine where the molten plastic material (ABS), that later solidifies, is settled layer by layer. In each layer,

60、 the extruder die leaves a thread approximately 0.15 mm in diameter which is compacted horizontal and vertically with the thread settled inmediately after. Thus, in the surface it can be observed thin lines that in&

61、lt;/p><p>　　The tested series are indicated in Table 1. </p><p><b>　　Table 1. </b></p><p>　　Tested series </p><p>　　Fig. 3 illustrates the surface of a sample

62、of the series after the first etch. It shows the roads originated by the FDM machine, that is to say that there is a good reproducibility. It cannot be still noticed the rounded grain structure. In Fig. 4, series 2, afte

63、r a second etch, it can be observed a line of the road in a way less clear than in the previous case. In Fig. 5, series 3 and 2° etch it begins to appear the rounded grain structure although it is very difficult to

64、check the roads at thi</p><p>　　Fig. 3. Series 1 (×150), etch 1.</p><p>　　Fig. 4. Series 2 (×300), etch 2.</p><p>　　Fig. 5. Series 3 (×300), etch 2.<

65、;/p><p>　　This behavior indicates that, working at a low current density and a high temperature, shells with a good reproducibility of the model and with a small grain size are obtained, that is, adequate for t

66、he required application. </p><p>　　If the analysis is carried out in a plane transversal to the deposition, it can be tested in all the samples and for all the conditions that the growth structure of the dep

67、osit is laminar (Fig. 6), what is very satisfactory to obtain a high mechanical resistance although at the expense of a low ductibility. This quality is due, above all, to the presence of the additives used because a nic

68、kel sulfamate bath without additives normally creates a fibrous and non-laminar structure. The modification </p><p>　　Fig. 6. Plane transversal of series 2 (×600), etch 2.</p><p>　　6.

69、Internal stresses</p><p>　　One of the main characteristic that a shell should have for its application like an insert is to have a low level of internal stresses. Different tests at different bath temperatur

70、es and current densities were done and a measure system rested on cathode flexural tensiometer method was used. A steel testing control was used with a side fixed and the other free (160 mm length, 12.7 mm widt

71、h and thickness 0.3 mm). Because the metallic deposition is only in one side the testing control has a mechani</p><p>　　7. Test of the injection mold</p><p>　　Tests have been carried out wi

72、th various representative thermoplastic materials such as PP, PA, HDPE and PC, and it has been analysed the properties of the injected parts such as dimensions, weight, resistance, rigidity and ductility. Mechanical prop

73、erties were tested by tensile destructive tests and analysis by photoelasticity. About 500 injections were carried out on this core, remaining under conditions of withstanding many more. </p><p>　　In general

74、 terms, important differences were not noticed between the behavior of the specimens obtained in the core and the ones from the machined cavity, for the set of the analysed materials. However in the analysis by photoelas

75、ticiy (Fig. 7) it was noticed a different tensional state between both types of specimens, basically due to differences in the heat transference and rigidity of the respective mold cavities. This difference explains the

76、ductility variations more outstanding in the parti</p><p>　　Fig. 7. Analysis by photoelasticity of injected specimens.</p><p>　　For the case of HDPE in all the analysed tested tubes it was

77、noticed a lower ductility in the specimens obtained in the nickel core, quantified about 30%. In the case of PA 6 this value was around 50%. </p><p>　　8. Conclusions</p><p>　　After consecutive t

78、ests and in different conditions it has been checked that the nickel sulfamate bath, with the utilized additives has allowed to obtain nickel shells with some mechanical properties acceptable for the required application

79、, injection molds, that is to say, good reproducibility, high level of hardness and good mechanical resistance in terms of the resultant laminar structure. The mechanical deficiencies of the nickel shell will be partiall