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WAC Lighting Bath Wall Sconces & Low Profile ADA
Wall Sconces
Vie LED Vanities in
Brushed Nickel
Vie LED Vanities in Chrome and Brushed Nickel
Lighting WS-6614, WS-6620, WS-6618, WS-6624, WS-6636 Vie LED Vanities & Sconces
Sleek understated elegance in a unique format perfect for narrow
bath applications and niches. Utilizing proprietary LED technology, the
bath light operates without a driver or transformer and dims
beautifully with an ELV dimmer. Cool contemporary Brushed Nickel and
Chrome finishes.
Sleek elegance for narrow applications
Bath lights have 3 inch wide format for narrow applications
Screened white glass
Vertical or horizontal mount
Bath lights are ADA compliant
Meets 2013 California Title 24 Efficiency
Conversion plate for 4 inch J box included
Smooth and continuous ELV dimming
ETL & cETL damp location listed
No driver or transformer needed
277V available (special order)
Finish: BN - Brushed Nickel,
CH -Chrome
Color Temp: 2700K
Dimming : 100% - 10%
Rated Life : 80,000 hours
Horizontal Vanity
Horizontal
WS-6618-BN
Small 18& Vie Bath Vanity Sconce
WS-6618-CH
Small 18& Vie Bath Vanity Sconce
WS-6624-BN
Medium 24& Vie Bath Vanity Sconce
WS-6624-CH
Medium 24& Vie Bath Vanity Sconce
WS-6636-BN
Large 36& Vie Bath Vanity Sconce
WS-6636-CH
Large 36& Vie Bath Vanity Sconce
WS-6618-CH Small 18& Vie Bath Vanity Sconce
LED Lumens: 1845
Delivered Lumens:
WS-6624-BN Medium 24& Vie Bath Vanity Sconce
LED Lumens: 2580
Delivered Lumens:
WS-6636-CH Large 36& Vie Bath Vanity Sconce
LED Lumens:
Delivered Lumens:
Vertical Vanity (shown below)
WS-6614-BN
Small 14& Vie Wall Vanity Sconce
WS-6614-CH
Small 14& Vie Wall Vanity Sconce
WS-6620-BN
Large 20& Vie Wall Vanity Sconce
WS-6620-CH
Large 20& Vie Wall Vanity Sconce
WS-6614-CH Small 14& Vie Wall Vanity Sconce
Watt: 18.5W
LED Lumens: 1462
Delivered Lumens:
WS-6620-BN Large 20& Vie Wall Vanity Sconce
LED Lumens: 1845
Delivered Lumens:
Mount vertically or horizontal
Lighting WS-6312, WS-6320, WS-6327
Sonoma Vanities & Sconces
An upscale transitional design to complement many bath renovations. Mouth blown etched opal glass shines at the forefront of a stunning natural seashell mosaic artfully tiled by hand for visual depth and attention to detail. Mount vertically or horizontal for various locations and applications.
Hand applied natural shell tiles over plated mirror chrome
Mouth blown etched triplex glass
ADA compliant
Meets 2013 California Title 24 Efficiency
No driver or transformer needed
Vertical or horizontal mount
Smooth and continuous ELV dimming
ETL & cETL damp location listed
277V available (special order)
WS-6312-CH
Sonoma Vanity Sconce
WS-6320-CH
Medium 20&
Sonoma Vanity Sconce
WS-6327-CH
Sonoma Vanity Sconce
WS-6312 Small 12& Sonoma Vanity Sconce Watt: 7.5W
LED Lumens: 592
Delivered Lumens:
WS-6320 Medium 20& Sonoma Vanity Sconce Watt: 13.5W
LED Lumens: 980
Delivered Lumens:
WS-6327 Large 27& Sonoma Vanity Sconce Watt: 17.5W
LED Lumens: 1346
Delivered Lumens: 865
CH- Chrome
Color Temp: 2700K
Dimming : 100% - 10%
Rated Life : 80,000 hours
WS-6718, WS-6724, WS-6736 Line Vanities and Sconces
Line takes edge-lit LED technology inside a thin rotary panel to softly provide uniform illumination for flattering facial rendering.
The rotating panel can be tilted for direct light in the daytime or indirect light at night. Offered in 2700K and 3000K
with variety of related products to complement room interiors.
Super thin,
edge-lit LED panel
Vertical or horizontal mount with 330&
adjustment
Meets 2013 California Title 24 Efficiency
Smooth and continuous ELV dimming
ETL & cETL damp location listed
Transformer located in J box
277V available (special order)
WS-6718-27-AL
Small 18& Line Vanity Sconce - 2700K
WS-6718-30-AL
Small 18& Line Vanity Sconce - 3000K
WS-6724-27-AL
Medium 24& Line Vanity Sconce- 2700K
WS-6724-30-AL
Medium 24& Line Vanity Sconce - 3000K
WS-6736-27-AL
Large 36& Line Vanity Sconce- 2700K
WS-6736-30-AL
Large 36& Line Vanity Sconce - 3000K
AL- Brushed Aluminum
Color Temp: 2700K, 3000K
Dimming : 100% - 10%
Rated Life : 80,000 hours
WS-7213 Small 13& Elemental Sconce
Watt: 15.5W
LED Lumens: 1118
Delivered Lumens:
WS-7222 Medium 22& Elemental Vanity
Watt: 30.5W
LED Lumens: 2236
Delivered Lumens:
WS-7230 Large 30& Elemental Vanity
Watt: 39.5W
LED Lumens: 2925
Delivered Lumens:
Mount Horizontally or Vertical
WAC Lighting WS-7012, WS-7022, WS-7027 Astoria Vanities and Sconces
Mouth blown and acid etched 3-layer glass combined with casted and plated hardware and proprietary LED technology designed for powerful lumen output and excellent color rendering. A fit and finish to complement today's bath hardware and traditional lighting finishes.
Understated elegance that transitions old world charm to modern day styling
Mouth blown etched triplex glass
Vertical or horizontal mount
ADA Compliant
Meets 2013 California Title 24 Efficiency
No driver or transformer needed
Smooth and continuous ELV dimming
ETL & cETL damp location listed
277V available (special order)
WS-7012-AN
Small 12& Astoria Vanity Sconce
WS-7012-BB
Small 12& Astoria Vanity Sconce
WS-7012-BO
Small 12& Astoria Vanity Sconce
WS-7012-PN
Small 12& Astoria Vanity Sconce
WS-7022-AN
Medium 22& Astoria Vanity Sconce
WS-7022-BB
Medium 22& Astoria Vanity Sconce
WS-7022-BO
Medium 22& Astoria Vanity Sconce
WS-7022-PN
Medium 22& Astoria Vanity Sconce
WS-7027-AN
Large 27& Astoria Vanity Sconce
WS-7027-BB
Large 27& Astoria Vanity Sconce
WS-7027-BO
Large 27& Astoria Vanity Sconce
WS-7027-PN
Large 27& Astoria Vanity Sconce
AN- Antique Nickel,
BB- Burnished Brass,
BO- Brushed Bronze,
PN- Polished Nickel
Color Temp: 2700K
Dimming : 100% - 10%
Rated Life : 80,000 hours
Call us at 800-585-1285 to order securely
Ask about Discounts or Sales
WS-7012 Small 12& Astoria Sconce
LED Lumens: 1118
Delivered Lumens: 655
WS-7022 Medium 22& Astoria Vanity
Watt: 31.5W
LED Lumens: 2236
Delivered Lumens: 1610
WS-7027 Large 27& Astoria Vanity
LED Lumens: 2925
Delivered Lumens: 1950
WAC Lighting
WS-7316, WS-7322, WS-7334 Svelte Vanities and Sconces
The uniform cylinder transitions from cased etched opal glass to perfectly plated metal seamlessly.
Wall mounted vertically on either side of a mirror or place one horizontally above for flattering diffuse illumination.
A streamlined light sealed to meet healthcare facility requirements
IP65 rated, ETL & cETL wet location listed for indoor application
Mouth blown etched triplex glass
Vertical or horizontal mount
ADA Compliant
Meets 2013 California Title 24 Efficiency
No driver or transformer needed
Smooth and continuous ELV dimming
277V available (special order)
WS-7316-BN
Small 16& Svelte Vanity Sconce
WS-7316-CH
Small 16& Svelte Vanity Sconce
WS-7322-BN
Medium 22& Svelte Vanity Sconce
WS-7322-CH
Medium 22& Svelte Vanity Sconce
WS-7334-BN
Large 34& Svelte Vanity Sconce
WS-7334-CH
Large 34& Svelte Vanity Sconce
BN- Brushed Nickel,
CH- Chrome
Color Temp: 2700K
Dimming : 100% - 10%
Rated Life : 80,000 hours
WS-7316 Small 16& Svelte Sconce
Watt: 24.5W
LED Lumens: 1845
Delivered Lumens: 875
WS-7322 Medium 22& Svelte Vanity
Watt: 34.5W
LED Lumens: 2580
Delivered Lumens: 1350
WS-7334 Large 34& Svelte Vanity
LED Lumens: 4043
Delivered Lumens: 2100
WAC Lighting
WS-7115, WS-7120, WS-7128 Bristol
Vanities and Sconces
Handsome traditional styling upgraded with modern LED technology make for a beautiful light, with energy savings and zero-maintenance.
Etched blown glass with soft square edges illuminates with unparalleled uniformity and efficacy.
Cast metal decorative transitional end caps and matching rectangular back plate complete the masculine design. Four designer finishes available to complement popular bath hardware and art frames.
Modern technology, masculine traditional
Mouth blown etched triplex glass
Four finishes to complement most bath hardware
Vertical or horizontal mount
ADA compliant
Meets 2013 California Title 24 Efficiency
No driver or transformer needed
Smooth and continuous ELV dimming
ETL & cETL damp location listed
277V available (special order)
WS-7115-AN
Small 15& Bristol Vanity Sconce
WS-7115-BB
Small 15& Bristol Vanity Sconce
WS-7115-BO
Small 15& Bristol Vanity Sconce
WS-7115-PN
Small 15& Bristol Vanity Sconce
WS-7120-AN
Medium 20& Bristol Vanity Sconce
WS-7120-BB
Medium 20& Bristol Vanity Sconce
WS-7120-BO
Medium 20& Bristol Vanity Sconce
WS-7120-PN
Medium 20& Bristol Vanity Sconce
WS-7128-AN
Large 28& Bristol Vanity Sconce
WS-7128-BB
Large 28& Bristol Vanity Sconce
WS-7128-BO
Large 28& Bristol Vanity Sconce
WS-7128-PN
Large 28& Bristol Vanity Sconce
AN- Antique Nickel,
BB- Burnished Brass,
BO- Brushed Bronze,
PN- Polished Nickel
Color Temp: 2700K
Dimming : 100% - 10%
Rated Life : 80,000 hours
Call us at 800-585-1285 to order securely
Ask about Discounts or Sales
WS-7115 Small 15& Bristol
LED Lumens: 1462
Delivered Lumens: 990
WS-7120 Medium 20& Bristol Vanity
Watt: 25.5W
LED Lumens: 1845
Delivered Lumens: 1345
WS-7128 Large 28& Bristol Vanity
Watt: 37.5W
LED Lumens: 2925
Delivered Lumens: 1935
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外文翻译--一个描述电铸镍壳在注塑模具的应用的技术研究
桂林电子科技大学毕业设计（论文）外文翻译译文第1页共28页technicalnoteonthecharacterizationofelectroformednickelshellsfortheirapplicationtoinjectionmoldsaUniversidaddeLasPalmasdeGranCanaria,DepartamentodeIngenieriaMecanica,SpainAbstractThetechniquesofrapidprototypingandrapidtoolinghavebeenwidelydevelopedduringthelastyears.Inthisarticle,electroformingasaproceduretomakecoresforplasticsinjectionmoldsisanalysed.ShellsareobtainedfrommodelsmanufacturedthroughrapidprototypingusingtheFDMsystem.Themainobjectiveistoanalyzethemechanicalfeaturesofelectroformednickelshells,studyingdifferentaspectsrelatedtotheirmetallographicstructure,hardness,internalstressesandpossiblefailures,byrelatingthesefeaturestotheparametersofproductionoftheshellswithanelectroformingequipment.Finallyacorewastestedinaninjectionmold.KeywordsElectroplatingElectroformingMicrostructureNickel1.IntroductionOneofthemostimportantchallengeswithwhichmodernindustrycomesacrossistooffertheconsumerbetterproductswithoutstandingvarietyandtimevariabilitynewdesigns.Forthisreason,modernindustrymustbemoreandmorecompetitiveandithastoproducewithacceptablecosts.Thereisnodoubtthatcombiningthetimevariableandthequalityvariableisnoteasybecausetheyfrequentlyconditiononeanotherthetechnologicaladvancesintheproductivesystemsaregoingtopermitthatcombinationtobemoreefficientandfeasibleinawaythat,forexample,ifitisobservedtheevolutionofthesystemsandtechniquesofplasticsinjection,wearriveattheconclusionthat,infact,ittakeslessandlesstimetoputanewproductonthemarketandwithhigherlevelsofquality.Themanufacturingtechnologyofrapidtoolingis,inthisfield,oneofthosetechnologicaladvancesthatmakespossibletheimprovementsintheprocessesofdesigningandmanufacturinginjectedparts.Rapidtoolingtechniquesarebasicallycomposedofacollectionofproceduresthataregoingtoallowustoobtainamoldofplasticparts,insmallormediumseries,inashortperiodoftimeandwithacceptableaccuracylevels.Theirapplicationisnotonlyincludedinthefieldofmakingplasticinjectedpieces1,2and3,however,itistruethatitiswheretheyhavedevelopedmoreandwheretheyfindthehighestoutput.Thispaperisincludedwithinawiderresearchlinewhereitattemptstostudy,define,analyze,testandpropose,atanindustriallevel,thepossibilityofcreatingcoresfor桂林电子科技大学毕业设计（论文）外文翻译译文第2页共28页injectionmoldsstartingfromobtainingelectroformednickelshells,takingasaninitialmodelaprototypemadeinaFDMrapidprototypingequipment.Italsowouldhavetosaybeforehandthattheelectroformingtechniqueisnotsomethingnewbecauseitsapplicationsintheindustryarecountless3,butthisresearchworkhastriedtoinvestigatetowhatextentandunderwhichparameterstheuseofthistechniqueintheproductionofrapidmoldsistechnicallyfeasible.Allmadeinanaccurateandsystematizedwayofuseandproposingaworkingmethod.2.ManufacturingprocessofaninjectionmoldThecoreisformedbyathinnickelshellthatisobtainedthroughtheelectroformingprocess,andthatisfilledwithanepoxicresinwithmetallicchargeduringtheintegrationinthecoreplate4ThismoldFig.1permitsthedirectmanufacturingbyinjectionofatypeamultipleusespecimen,astheyaredefinedbytheUNEENISO3167standard.Thepurposeofthisspecimenistodeterminethemechanicalpropertiesofacollectionofmaterialsrepresentativeindustry,injectedinthesetoolsanditscoMParisonwiththepropertiesobtainedbyconventionaltools.Fig.1.Manufacturedinjectionmoldwithelectroformedcore.Thestagestoobtainacore4,accordingtothemethodologyresearchedinthiswork,arethefollowingaDesigninCADsystemofthedesiredobject.bModelmanufacturinginarapidprototypingequipmentFDMsystem.ThematerialusedwillbeanABSplastic.cManufacturingofanickelelectroformedshellstartingfromthepreviousmodelthathasbeencoatedwithaconductivepaintbeforehanditmusthaveelectricalconductivity.dRemovaloftheshellfromthemodel.桂林电子科技大学毕业设计（论文）外文翻译译文第3页共28页eProductionofthecorebyfillingthebackoftheshellwithepoxyresinresistanttohightemperaturesandwiththerefrigeratingductsmadewithcoppertubes.Theinjectionmoldhadtwocavities,oneofthemwastheelectroformedcoreandtheotherwasdirectlymachinedinthemovingplaten.Thus,itwasobtained,withthesametoolandinthesameprocessconditions,toinjectsimultaneouslytwospecimensincavitiesmanufacturedwithdifferenttechnologies.3.ObtaininganelectroformedshelltheequipmentElectrodeposition5and6isanelectrochemicalprocessinwhichachemicalchangehasitsoriginwithinanelectrolytewhenpassinganelectriccurrentthroughit.Theelectrolyticbathisformedbymetalsaltswithtwosubmergedelectrodes,ananodenickelandacathodemodel,throughwhichitismadetopassanintensitycomingfromaDCcurrent.Whenthecurrentflowsthroughthecircuit,themetalionspresentinthesolutionaretransformedintoatomsthataresettledonthecathodecreatingamoreorlessuniformdepositlayer.Theplatingbathusedinthisworkisformedbynickelsulfamate7and8ataconcentrationof400ml/l,nickelchloride10g/l,boricacid50g/l,AllbriteSLA30cc/landAllbrite7032cc/l.Theselectionofthiscompositionismainlyduetothetypeofapplicationweintend,thatistosay,injectionmolds,evenwhentheinjectionismadewithfibreglass.Nickelsulfamateallowsustoobtainanacceptablelevelofinternalstressesintheshellthetestsgaveresults,fordifferentprocessconditions,notsuperiorto50MPaandforoptimumconditionsaround2MPa.Nevertheless,suchlevelofinternalpressureisalsoaconsequenceofusingasanadditiveAllbriteSLA,whichisastressreducerconstitutedbyderivativesoftoluenesulfonamideandbyformaldehydeinaqueoussolution.Suchadditivealsofavourstheincreaseoftheresistanceoftheshellwhenpermittingasmallergrain.Allbrite703isanaqueoussolutionofbiodegradablesurfaceactingagentsthathasbeenutilizedtoreducetheriskofpitting.Nickelchloride,inspiteofbeingharmfulfortheinternalstresses,isaddedtoenhancetheconductivityofthesolutionandtofavourtheuniformityinthemetallicdistributioninthecathode.TheboricacidactsasapHbuffer.TheequipmentusedtomanufacturethenickelshellstestedhasbeenasfollowsPolypropylenetank600mm400mm500mminsize.Threeteflonresistors,eachonewith800W.Mechanicalstirringsystemofthecathode.Systemforrecirculationandfiltrationofthebathformedbyapumpandapolypropylenefilter.桂林电子科技大学毕业设计（论文）外文翻译译文第4页共28页Chargingrectifier.Maximumintensityincontinuous50Aandcontinuouscurrentvoltagebetween0and16V.TitaniumbasketwithnickelanodesIncoSRoundsElectrolyticNickelwithapurityof99.Gasesaspirationsystem.Oncethebathhasbeendefined,theoperativeparametersthathavebeenalteredfortestingdifferentconditionsoftheprocesshavebeenthecurrentdensitybetween1and22A/dm2,thetemperaturebetween35and55°CandthepH,partiallymodifyingthebathcomposition.4.ObtainedhardnessOneofthemostinterestingconclusionsobtainedduringthetestshasbeenthatthelevelofhardnessofthedifferentelectroformedshellshasremainedatratherhighandstablevalues.InFig.2,itcanbeobservedthewayinwhichforcurrentdensityvaluesbetween2.5and22A/dm2,thehardnessvaluesrangefrom540and580HV,atpH4±0.2andwithatemperatureof45°C.IfthepHofthebathisreducedat3.5andthetemperatureis55°Cthosevaluesareabove520HVandbelow560HV.Thisfeaturemakesthetestedbathdifferentfromotherconventionalonescomposedbynickelsulfamate,allowingtooperatewithawiderrangeofvaluesnevertheless,suchoperativitywillbelimiteddependingonotherfactors,suchasinternalstressbecauseitsvariabilitymayconditiontheworkatcertainvaluesofpH,currentdensityortemperature.Ontheotherhand,thehardnessofaconventionalsulfamatebathisbetween200–250HV,muchlowerthantheoneobtainedinthetests.Itisnecessarytotakeintoaccountthat,foraninjectionmold,thehardnessisacceptablestartingfrom300HV.Amongthemostusualmaterialsforinjectionmoldsitispossibletofindsteelforimprovement290HV,steelforintegralhardening520–595HV,casehardenedsteel760–800HV,etc.,insuchawaythatitcanbeobservedthatthehardnesslevelsofthenickelshellswouldbewithinthemedium–highrangeofthematerialsforinjectionmolds.Theobjectiontothelowductilityoftheshelliscompensatedinsuchawaywiththeepoxyresinfillingthatwouldfollowitbecausethisistheoneresponsibleforholdinginwardlythepressurechargesoftheprocessesofplasticsinjectionthisisthereasonwhyitisnecessaryfortheshelltohaveathicknessashomogeneousaspossibleaboveaminimumvalueandwithabsenceofimportantfailuressuchaspitting.Fig.2.Hardnessvariationwithcurrentdensity.pH4±0.2,T45°C.桂林电子科技大学毕业设计（论文）外文翻译译文第5页共28页5.MetallographicstructureInordertoanalyzethemetallographicstructure,thevaluesofcurrentdensityandtemperatureweremainlymodified.Thesampleswereanalyzedinfrontalsectionandintransversalsectionperpendiculartothedeposition.Forachievingaconvenientpreparation,theywereconvenientlyencapsulatedinresin,polishedandetchedindifferentstageswithamixtureofaceticacidandnitricacid.Theetchesarecarriedoutatintervalsof15,25,40and50s,afterbeingpolishedagain,inordertobeobservedafterwardsinametallographicmicroscopeOlympusPME3ADL3.3/10.Beforegoingontocommentthephotographsshowninthisarticle,itisnecessarytosaythatthemodelsusedtomanufacturetheshellsweremadeinaFDMrapidprototypingmachinewherethemoltenplasticmaterialABS,thatlatersolidifies,issettledlayerbylayer.Ineachlayer,theextruderdieleavesathreadapproximately0.15mmindiameterwhichiscompactedhorizontalandverticallywiththethreadsettledinmediatelyafter.Thus,inthesurfaceitcanbeobservedthinlinesthatindicatetheroadsfollowedbytheheadofthemachine.Theselinesaregoingtoactasareferencetoindicatethereproducibilitylevelofthenickelsettled.Thereproducibilityofthemodelisgoingtobeafundamentalelementtoevaluateabasicaspectofinjectionmoldsthesurfacetexture.ThetestedseriesareindicatedinTable1.Table1.TestedseriesSeriespHTemperature°CCurrentdensityA/dm214.2±0.±0.±0..0±0.24522.22Fig.3illustratesthesurfaceofasampleoftheseriesafterthefirstetch.ItshowstheroadsoriginatedbytheFDMmachine,thatistosaythatthereisagoodreproducibility.Itcannotbestillnoticedtheroundedgrainstructure.InFig.4,series2,afterasecondetch,itcanbeobservedalineoftheroadinawaylessclearthaninthepreviouscase.InFig.5,series3and2°etchitbeginstoappeartheroundedgrain桂林电子科技大学毕业设计（论文）外文翻译译文第6页共28页structurealthoughitisverydifficulttochecktheroadsatthistime.Besides,themostdarkenedareasindicatethepresenceofpittingbyinadequateconditionsofprocessandbathcomposition.Fig.3.Series1150,etch1.Fig.4.Series2300,etch2.Fig.5.Series3300,etch2.桂林电子科技大学毕业设计（论文）外文翻译译文第7页共28页Thisbehaviorindicatesthat,workingatalowcurrentdensityandahightemperature,shellswithagoodreproducibilityofthemodelandwithasmallgrainsizeareobtained,thatis,adequatefortherequiredapplication.Iftheanalysisiscarriedoutinaplanetransversaltothedeposition,itcanbetestedinallthesamplesandforalltheconditionsthatthegrowthstructureofthedepositislaminarFig.6,whatisverysatisfactorytoobtainahighmechanicalresistancealthoughattheexpenseofalowductibility.Thisqualityisdue,aboveall,tothepresenceoftheadditivesusedbecauseanickelsulfamatebathwithoutadditivesnormallycreatesafibrousandnonlaminarstructure9.Themodificationuntilanearlynullvalueofthewettingagentgaveasaresultthatthelaminarstructurewasmaintainedinanycase,thatmatterdemonstratedthatthedeterminantforsuchstructurewasthestressreducerAllbriteSLA.Ontheotherhand,itwasalsotestedthatthelaminarstructurevariesaccordingtothethicknessofthelayerintermsofthecurrentdensity.Fig.6.Planetransversalofseries2600,etch2.6.InternalstressesOneofthemaincharacteristicthatashellshouldhaveforitsapplicationlikeaninsertistohavealowlevelofinternalstresses.Differenttestsatdifferentbathtemperaturesandcurrentdensitiesweredoneandameasuresystemrestedoncathodeflexuraltensiometermethodwasused.Asteeltestingcontrolwasusedwithasidefixedandtheotherfree160mmlength,12.7mmwidthandthickness0.3mm.Becausethemetallicdepositionisonlyinonesidethetestingcontrolhasamechanicalstraintensileorcompressivestressthatallowstocalculatetheinternalstresses.Stoneymodel10wasappliedandwassupposedthatnickelsubstratumthicknessisenoughsmall3μmtoinfluence,inanelasticpointofview,tothestrainedsteelpart.Inallthetestedcasesthemostvalueofinternalstresswasunder50MPaforextremeconditionsand2MPaforoptimalconditions,anacceptablevaluefortherequiredapplication.Theconclusionisthattheelectroliticbathallowstoworkatdifferentconditionsandparameterswithoutasignificantvariationofinternalstresses.桂林电子科技大学毕业设计（论文）外文翻译译文第8页共28页7.TestoftheinjectionmoldTestshavebeencarriedoutwithvariousrepresentativethermoplasticmaterialssuchasPP,PA,HDPEandPC,andithasbeenanalysedthepropertiesoftheinjectedpartssuchasdimensions,weight,resistance,rigidityandductility.Mechanicalpropertiesweretestedbytensiledestructivetestsandanalysisbyphotoelasticity.About500injectionswerecarriedoutonthiscore,remainingunderconditionsofwithstandingmanymore.Ingeneralterms,importantdifferenceswerenotnoticedbetweenthebehaviorofthespecimensobtainedinthecoreandtheonesfromthemachinedcavity,forthesetoftheanalysedmaterials.HoweverintheanalysisbyphotoelasticiyFig.7itwasnoticedadifferenttensionalstatebetweenbothtypesofspecimens,basicallyduetodifferencesintheheattransferenceandrigidityoftherespectivemoldcavities.ThisdifferenceexplainstheductilityvariationsmoreoutstandinginthepartiallycrystallinematerialssuchasHDPEandPA6.Fig.7.Analysisbyphotoelasticityofinjectedspecimens.ForthecaseofHDPEinalltheanalysedtestedtubesitwasnoticedalowerductilityinthespecimensobtainedinthenickelcore,quantifiedabout30.InthecaseofPA6thisvaluewasaround50.8.ConclusionsAfterconsecutivetestsandindifferentconditionsithasbeencheckedthatthenickelsulfamatebath,withtheutilizedadditiveshasallowedtoobtainnickelshellswithsomemechanicalpropertiesacceptablefortherequiredapplication,injectionmolds,thatistosay,goodreproducibility,highlevelofhardnessandgoodmechanicalresistanceintermsoftheresultantlaminarstructure.Themechanicaldeficienciesofthenickelshellwillbepartiallyreplacedbytheepoxyresinthatfinishesshapingthecorefortheinjectionmold,allowingtoinjectmediumseriesofplasticpartswithacceptablequalitylevels.桂林电子科技大学毕业设计（论文）外文翻译译文第9页共28页References1A.E.W.Rennie,C.E.BockingandG.R.Bennet,Electroformingofrapidprototypingmandrelsforelectrodischargemachiningelectrodes,J.Mater.Process.Technol.1102001,pp.186–196.2P.K.D.V.Yarlagadda,I.P.IlyasandP.Chrstodoulou,Developmentofrapidtoolingforsheetmetaldrawingusingnickelelectroformingandstereolithographyprocesses,J.Mater.Process.Technol.1112001,pp.286–294.3J.Hart,A.Watson,ElectroformingAlargelyunrecognisedbutexpandingvitalindustry,Interfinish96,14WorldCongress,Birmingham,UK,1996.4M.Monzónetal.,Aplicacióndelelectroconformadoenlafabricaciónrápidademoldesdeinyección,RevistadePlásticosModernos.842002,p.557.桂林电子科技大学毕业设计（论文）外文翻译译文第10页共28页5L.F.Hamiltonetal.,CálculosdeQuímicaAnalítica,McGrawHill1989.6E.Julve,Electrodeposicióndemetales,2000E.J.S..7A.Watson,NickelSulphamateSolutions,NickelDevelopmentInstitute1989.8A.Watson,AdditionstoSulphamateNickelSolutions,NickelDevelopmentInstitute1989.9J.Dini,ElectrodepositionMaterialsScienceofCoatingandSubstrates,NoyesPublications1993.10J.W.Judy,Magneticmicroactuatorswithpolysiliconflexures,MastersReport,DepartmentofEECS,UniversityofCalifornia,Berkeley,1994.cap′.3.HowSurfaceTreatmentsKeepMoldsOperatingLongerImportanttipsandinformationaboutmoldcoatingstohelpyouachievethelevelofproductionthatyouandyourcustomersdesire.BySteven.BalesMoldmakingtechnologyJanuary2006AbstractTheresanawfullottoknowthesedaysaboutmoldingplasticandhowtogettheverybestperformancefromthevaluabletoolsyoubuildorrun.Thisguidehasbeenwrittentoprovideimportanttipsandinformationaboutmoldcoatings.Afterreadingthis,youshouldhaveaverygoodideaofwhatcoatingsfromtheverytraditionaltotheverylatestwillhelpyoutoachievethelevelofproductionyouandyour桂林电子科技大学毕业设计（论文）外文翻译译文第11页共28页customersdesire.Afterall,thesetoolsareaninvestmentandtheyneedtobeprotectedforthelifeoftheproductstheymold.KeyWordsmoldcoatingspreventivemaintenancePMprogrambenefitnickelCobaltdiamondchromenickelPTFEnickelboronnitrideelectrolessnickeltextureTheKeyRoleofCoatingsBeforeintroducingyoutothewiderangeofcoatingsonthemarkettoday,itsimportanttonotetherolecoatingscanplayinaneffectivepreventivemaintenancePMprogram.PMisreallythekeytoprotectingyourtooling,yourinvestment.WhyBecauseitsavestimeandmoney.Onceyouinvestinamoldcoatingtoimprovetoolperformance,thenaPMprogramisalwaysagoodideatoensureyougetthemaximumbenefit.Thesetwostepsshouldbeagiveninanyshop.Remember,nocoatinglastsforever,andproducingsubstandardpartsfromamoldwithaworncoatingisnowaytowincustomersandstayprofitable.PMisprobablythemostcosteffectivestrategyyoucanputinplace.Thekeyistoeducateyourpersonnelonhowmoldcoatingswearduringproduction.Everycoatingisdifferent,soitsofbenefittohaveemployeeslearnhowtotellwhenthecoatingisshowingdeterioration,especiallyinhighwearareassuchasgatesandrunners.Forexample,wearinandaroundgateareasplatedwithhardchromeisthefirstsignthatyourmoldneedsservicing.HowcanyoutellthereiswearThechromecoatingisapproximately20RCpointsharderthanthebasesteel,soexposedsteelwillwearmuchfasterthanthecoatedsurfacessurroundingit,causingaslightorpronouncededgeorsteponthesurface.Conversely,nickelwillwearalmostevenly,causingakindoffeatheringeffect,makingitmoredifficulttorecognizewear.Amoreidentifiabledifferencewillbethecolorbecausewhennickelcoatingwears,itproducesashadoworhaloeffectonthesteel.Nosteporedgewillbeevident.Thesteelalsowillhaveamoresilverappearancecomparedtothesomewhattarnishedlookofthenickelcoating.ThisknowledgemakespullingamoldformaintenancebeforethecoatingwearsthroughanultraimportantaspectofaPMprogram.Tomissimportantwearsignalsmeansmorecostlyrepairsandadditionalpolishingexpense.桂林电子科技大学毕业设计（论文）外文翻译译文第12页共28页MeasuringWearArecommendedtoolformeasuringthewearlevelofanycoatingisanelectronicthicknessgaugethatusesacombinationofmagnetismandeddycurrenttoaccuratelymeasuresurfacethickness.Whenthemoldfirstarrivesinyourplant,takethetimetomeasurethesurfacethicknessespeciallyinhighwearareasusingthisspecializedtool.Asyourunproductiononthemold,occasionallypausetoremeasurethoseareas.Whenyouhavedeterminedthatthefinishiswearingtoacriticallevel,pullthemoldandsenditoutformaintenance.PartCountsBesuretorecordthemeasurementstakenwiththethicknessgaugeandusethenotestocreateahistoryofmaintenancerequirementsforthetool.Acyclecounterinstalledonthemoldwillallowyourtoolingengineertorecordwearlevelsascomparedtopiecepartcounts,therebydoublingtheeffectivenessofyourPMprogram.Partcountsareagreatwaytodeterminemaintenanceneeds,especiallywithhighvolumemoldingprojects.Fromtheveryfirsttimeyourunthemold,keepanaccuratepiececountuntilitisreadyforitsfirstmaintenancework.Usethatcountasagaugeforwhenthenextmaintenanceisdue.Becauseyouknowapproximatelywhenthemoldwillbereadytoberefurbished,youcanarrangetheserviceinadvancewithyourcoatingvendor.Thisnotonlygiveshimampletimetoscheduleyourmoldmaintenance,butitalsoallowsyoutooptimizetheuseofthemoldandthemachinethatsrunningit.CoatingChallengesEventoday,therearethosewhoquestionthebenefitsofusingfancysometimesmoreexpensivecoatingstoprolongtoolinglifeorenhanceperformance.Tosome,thetriedandtruehardchromeorelectrolessnickelarealltheylleverneedtoaccomplishthosegoals.Butweallknowthattodaysengineeredplasticmaterialscanbeprettyroughoninjectionmolds.Challengestomoldmaintenanceextendbeyondglassandmineralfillerstoincludericehulls,woodfibers,metalpowders,flameretardantsandotheradditivesnottomentiontheresinsthemselves.Inaddition,outgassingandmoistureacidityoftenaccompanyabrasivewear,takinganevenbiggertollonexpensivetooling.Inaddition,growingcomplexityinmolddesigninvolvestinier,moreintricateflowpassagesandmorefrequentuseofmovingcoresandslides.Allofthesecircumstanceshavepromptedthedevelopmentofawidervarietyofmoldcoatingsthatcankeepmoldsoperatinglongerbetweenrepairs.NewCoatingScience桂林电子科技大学毕业设计（论文）外文翻译译文第13页共28页Ifyouaremoldinghighlyintricatepartsusingglassfilledmaterials,youmightthinkusinghardchromewillbesufficientbecauseitisaclassic,reliablewaytoprotectyourmoldfrombothcorrosionandabrasion.However,hardchrome,forallitsbenefits,doesnottendtoplateuniformlyindetailedareaslikeribsandbosses.Thereisanewersolutionanickelcobaltalloycoatingthatcanovercomethatlimitation.NickelCobaltNickelcobaltcanbeaneconomicalalternativetohardchrome.Hardchromerequiresconstructionofaconforminganodetocoatthemold.Themoredetailinthemold,themoretimeittakestobuildtheanodeandthemoreexpensivetheprocessbecomes.Thisnickelcobaltalloycoatingrequiresnoanode,andbecauseofitselectrolessproperties,itplatesmuchmoreuniformly.Thecobaltgivesitgoodabrasionresistance,butitshardnessis62RC,10pointslowerthanhardchrome.IsitworthpayingextraforhardchromessuperiorwearprotectionYouhavetoconsiderthematerialbeingruninthemold.WhatsthepercentageofglassIscorrosionagreaterconcernthanabrasionDiamondChromeHardchromeandanickelcobaltalloycoatingoffertwoverygoodsolutionsforabrasionresistance,butforveryhighwearconditions,anevennewerproductcalleddiamondchromeoffersexceptionalprotection.IthasanRCratinggreaterthan85andisachromiummatrixcompositecoatingwithadispersionofnanometersize,sphericaldiamondparticles.Sincediamondsareunmatchedforhardness,thiscoatingoffersprotectionbeyondthenorm.ThoughtheirRockwellratingsarecomparable,diamondchromeoutperformstitaniumnitrideTiNcoatingbecauseitwontcompromisethedimensionalintegrityoftheplatedtool.Thedifferenceisthatitisappliedatonlyabout130oFwhileTiNrequiresapplicationtemperaturesof800oForhigher.Diamondchromecanplateprehardened,heattreatedornitridedsteelandotherbasematerialssuchasaluminum,berylliumcopper,brassandstainlesssteel.Recommendedusesincludecores,cavities,slides,ejectorsleeves,androtatingandunscrewingcores.Itsantigallingpropertiesareadvantageousonmovingcoresandslides.Diamondchromealsoisverystrippableandhasnoadverseeffectonthebasematerial,savingtimeandmoneywhenmaintenanceisneeded.TiNisstrippableaswell,butitcantakeuptoseveraldaystoremovewithaperoxidebasedsolution.Diamondchromecanbestrippedinminutesusingreverseelectrolysisinacausticsolution.桂林电子科技大学毕业设计（论文）外文翻译译文第14页共28页Inaddition,diamondchromecanbedepositedatanycontrolledthicknessfrom20millionthsofaninchto0.001in.TiNisgenerallyonlyappliedinthindepositsofafewmillionthsofaninch.Diamondchromecancoatcomplexdetails,whileTiNhasverylimitedcoverageofcomplexdetails.WhileTiNisverylubricious,withacoefficientoffrictionCOFof0.4againststeel,diamondchromehasaCOFof0.15nearlythreetimesmorelubricious.NickelBoronNitrideWhenitcomestomoldersneedsforaspecialtycoatingthatoffersexcellentreleasepropertiesandhighresistancetowear,heat,andcorrosion,anelectrolessnickelphosphorusmatrixcontainingboronnitrideparticlesshouldbeconsidered.IthasaverylowCOF0.05againststeelandanRChardnessof54,whichcanbeincreasedto67RCafterheattreatingauniquecharacteristic.Nickelboronnitridecanbeappliedtoanysubstrateatonly185oFandcanbeeasilystrippedwithoutcompromisingthebasematerial.Thoughitisapproximately20percentmoreexpensivethannickelPTFE,thiscoatingwilloutperformnickelPTFEatupto1250oF,whichfarsurpassesthe500oFmaximumlimitforallPTFEbasedcoatings.Becauseapplyingnickelboronnitrideisanautocatalyticprocess,itrequiresnoanode,thereforesavingtimeandmoney.Inaddition,itwillnotcompromisethermalconductivityofthemold.Applicationsincludeunscrewingcoresforclosures,wherereducedcycletimesareessential.Wherelubricityisneededforbetterreleasefromdeepribs,zerodraftcores,texturedsurfacesandstickypolymers,anickelPTFEcompositewillgreatlyimprovepartreleaseandenhanceresinflowbyasmuchas4to8percentforshortercycletimes.COFis0.10againststeel.ItshouldbenotedthatapplyingpurePTFEtothemoldaddshighlubricity,butonlyaveryshorttermbenefit.PTFEbyitselfhasnohardness,soitwontlast.Butadispersionof25percentPTFEbyvolumeinacodepositwithnickelresultsin45RChardnessforaddedwearandcorrosionprotection.TriedandTrueDespitethenewcoatingscience,wecannotthrowouttheold,reliablecoatingssuchaslikehardchromeorelectrolessnickeljustyet.Theresnoquestionthattheystillhavetheiruses.HardChromeForexample,hardchromestopadvantageisthatithasahardnessof72RockwellCRCandisappliedatthelowtemperatureof130oF.Whenappliedinitspurestform,itallowsyoutoachieveanySPIfinishonyourtooling.桂林电子科技大学毕业设计（论文）外文翻译译文第15页共28页Hardchromeisoftenagoodchoiceforelectricalcircuitbreakermoldssincetheyusematerialscontainingasmuchas40percentglass.Tohelpcombaterosionandpreventseverelydamaginggatesandsurroundingmoldareas,itisusuallyrecommendtouseahighdiamondpolish,followedbyahardchromecoatingof0.5inchesforaddedprotection.Thedownsidecanbecost,sincechromeplatingislimitedtoareasaccessiblebyananode.Ifyourmoldhascomplexdetails,itcouldrequireextraconforminganodeconstructionandthataddstimeandexpensetotheproject.Anotherpossibledrawbackischromesenvironmentalimpactchromiumisacarcinogen.Somecompaniesareattemptingtodevelopbetter,cleaneralternatives,butsofarnothingmatcheshardchromesbenefitsfromatoolingperspective.ElectrolessNickelLikehardchrome,electrolessnickelhasbeenusedsuccessfullyforyears,particularlytoprotectmoldswherecorrosiveoffgassingiscreatedbymaterialssuchasPVCorhalogenatedfireretardants.Itisnotuncommontoseesuchresinsproduceanorangerust,corrodingtheunprotectedmoldalmostrightbeforeyoureyes.Productsmoldedofsuchmaterialsfortheelectronicormedicalindustryoftencannottoleratethepresenceofanyoxidationbyproducts.Electrolessnickeldoesanexcellentjobofresistingoxidationbecauseitplatesveryuniformlyinthindepositsof0.3inches.Evenintightareasofdetailedparts,electrolessnickelat50RChardnessisidealforcorrosionprotection.Itcanbedepositedinveryaccuratethicknessesof0.002to0.003inchesandcanbegroundorEDMed.Thus,electrolessnickeloftenisusedfordimensionalbuildupsunderflashchromeandforenlargingthreadedcoresandinsertsorpreciselysizingcavities.Italsoworksverywellonentiremoldbases,AandBplates,ejectorbasehousings,pinplatesandpillarsupports,providingyearsoflowmaintenance,rustfreeoperation.KnowYourMoldFinishesBeforedeterminingwhatcoatingtouseifoneisneededthemoldfinishmustbetakenintoaccountbecause,asnotedearlier,certainfinishesmayactuallyincreasetheneedforamoldcoating,andsomecombinationsworkextremelywelltogetherimprovinglubricityandreleaseproperties.TherearefourstandardSPIfinishesdiamond,stone,paperandblast.Eachgivesthemoldingsurfaceadifferentappearance,fromaglossy,mirrorlikesurfaceA1Diamondtoafairlyrough,grittytexturefromblastingwithglassbeadsoraluminumoxide.Eachofthefourfinisheshasthreegradesaswell.DiamondTheA1Diamondfinishisthemostperfectfinishavailable,whichmeansithasthelowestRAvalueroughnessaverage.Therearenohighorlowridges.Forexample,a桂林电子科技大学毕业设计（论文）外文翻译译文第16页共28页paperscratchonsteelcanratea2to4RAfinish,whereasanA1Diamondislensqualitysmoothness,generally1RAorless.Roughnessisalmostimmeasurable.Butanumberofplasticmaterialstendtosticklikegluetotheflawless,mirrorlikefinish,makingsuchperfectsmoothnessalmostdetrimentalinmanymoldingapplications.Onegoodexampleismoldingpolystyreneonapolishedstraightwallcorewith1dorlessdraft.Streakordraglinescanappearontheparts.Thiscanbesolvedbyflashchromeplatingthecore,whichcreatesasurfacewithmicrocracks.ImpregnatingthosecrackswithPTFEandthenreestablishingtheA1Diamondfinishsolvestheprobleminmorethan95percentofcases.Inthinwallmoldingapplicationssuchasthese,alightbeadblastfinishisappliedjustenoughtoveryslightlyinterrupttheflawlessA2Diamondsurface.Thesurfaceisbuffedagain,leavingjustabitofalmostinvisiblestipple.binethatwithahard,protectivecoatinglikechromeordiamondchrome,binethatwithahard,protectivecoatinglikechromeordiamondchrome,andyouwillstrengthenthemoldssurfaceandoptimizerelease.TextureandReleaseTherearemanytexturedsurfacestoday,includingfauxleatherforautomobiledashboards,woodgrains,geometricpatternsandstipplepatternsfoundonpagers,cellphonesandcomputercomponents.Aplatedmoldcoatingisoftenessentialtoobtainingatexturedsurfacewithadequatelubricity.Texturedsurfacesrequireprotection.Thepeaksofthetexturedsurfacesarethefirstareasofmolddetailtoexperiencewear,makingitveryimportanttocheckthemoldperiodicallywithaprofilometertomeasuregraindepthandpeakcounts.Moldcoatingshelpdecreasethefrequencyofrepairsandrefurbishmentbymaintainingtheintegrityofthetexturedsurface.Ifadiamondfinishpresentsreleaseproblems,ablastfinishcanbetheanswerparticularlywhenmoldingtexturedpartsusingmaterialssuchassiliconerubber,flexiblePVC,TPESandsomesoftpolypropylenes.Theseproductstendtoclingtoapolishedfinish,butbreakingupthesurfacewithalightblastingimprovesrelease.AddacoatingofnickelPTFEandyougetevenbetterrelease.桂林电子科技大学毕业设计（论文）外文翻译译文第17页共28页Hardchromeandelectrolessnickelplatingwillhelpprotecttexturedsurfaces,aswillanickelcobaltcoating.Unlikehardchrome,electrelessnickelcobaltplatesuniformly,whichmakesitidealforverydetailedmoldswithdeepribsandbosses.Itcombinesthecorrosionprotectionandlubricityofelectrolessnickelwiththestrengthofcobalt.SummaryIfyourelookingforenhancedperformanceinyourmolds,thepropercombinationofsurfacetreatmentandfinishcanprovideadditionalbenefitbyextendingproductiontimesbetweenpreventivemaintenance.Yourcoatingsvendorcanbeavaluableresourceforeducatingyourpersonnelonhowcoatingsyouusewillwearovertime,aswellasawaytoreducedowntimeandcutcosts.AutomatedsurfacefinishingofplasticinjectionmoldsteelwithsphericalgrindingandballburnishingprocessesAbstractThisstudyinvestigatesthepossibilitiesofautomatedsphericalgrindingandballburnishingsurfacefinishingprocessesinafreeformsurfaceplasticinjectionmoldsteelPDS5onaCNCmachiningcenter.Thedesignandmanufactureofagrinding桂林电子科技大学毕业设计（论文）外文翻译译文第18页共28页toolholderhasbeenaccomplishedinthisstudy.TheoptimalsurfacegrindingparametersweredeterminedusingTaguchisorthogonalarraymethodforplasticinjectionmoldingsteelPDS5onamachiningcenter.TheoptimalsurfacegrindingparametersfortheplasticinjectionmoldsteelPDS5werethecombinationofanabrasivematerialofPAAl2O3,agrindingspeedof18000rpm,agrindingdepthof20μm,andafeedof50mm/min.ThesurfaceroughnessRaofthespecimencanbeimprovedfromabout1.60μmto0.35μmbyusingtheoptimalparametersforsurfacegrinding.SurfaceroughnessRacanbefurtherimprovedfromabout0.343μmto0.06μmbyusingtheballburnishingprocesswiththeoptimalburnishingparameters.Applyingtheoptimalsurfacegrindingandburnishingparameterssequentiallytoafinemilledfreeformsurfacemoldinsert,thesurfaceroughnessRaoffreeformsurfaceregiononthetestedpartcanbeimprovedfromabout2.15μmto0.07μm.KeywordsAutomatedsurfacefinishingBallburnishingprocessGrindingprocessSurfaceroughnessTaguchismethod1IntroductionPlasticsareimportantengineeringmaterialsduetotheirspecificcharacteristics,suchascorrosionresistance,resistancetochemicals,lowdensity,andeaseofmanufacture,andhaveincreasinglyreplacedmetalliccomponentsinindustrialapplications.Injectionmoldingisoneoftheimportantformingprocessesforplasticproducts.Thesurfacefinishqualityoftheplasticinjectionmoldisanessentialrequirementduetoitsdirecteffectsontheappearanceoftheplasticproduct.Finishingprocessessuchasgrinding,polishingandlappingarecommonlyusedtoimprovethesurfacefinish.桂林电子科技大学毕业设计（论文）外文翻译译文第19页共28页Themountedgrindingtoolswheelshavebeenwidelyusedinconventionalmoldanddiefinishingindustries.Thegeometricmodelofmountedgrindingtoolsforautomatedsurfacefinishingprocesseswasintroducedin.Afinishingprocessmodeofsphericalgrindingtoolsforautomatedsurfacefinishingsystemswasdevelopedin.Grindingspeed,depthofcut,feedrate,andwheelpropertiessuchasabrasivematerialandabrasivegrainsize,arethedominantparametersforthesphericalgrindingprocess,asshowninFig.1.Theoptimalsphericalgrindingparametersfortheinjectionmoldsteelhavenotyetbeeninvestigatedbasedintheliterature.Fig.1.SchematicdiagramofthesphericalgrindingprocessInrecentyears,someresearchhasbeencarriedoutindeterminingtheoptimalparametersoftheballburnishingprocessFig.2.Forinstance,ithasbeenfoundthatplasticdeformationontheworkpiecesurfacecanbereducedbyusingatungstencarbideballoraroller,thusimprovingthesurfaceroughness,surfacehardness,andfatigueresistance.Theburnishingprocessisaccomplishedbymachiningcentersandlathes.Themainburnishingparametershavingsignificanteffectsonthesurfaceroughnessareballorrollermaterial,burnishingforce,feedrate,burnishingspeed,桂林电子科技大学毕业设计（论文）外文翻译译文第20页共28页lubrication,andnumberofburnishingpasses,amongothers.TheoptimalsurfaceburnishingparametersfortheplasticinjectionmoldsteelPDS5wereacombinationofgreaselubricant,thetungstencarbideball,aburnishingspeedof200mm/min,aburnishingforceof300N,andafeedof40μm.Thedepthofpenetrationoftheburnishedsurfaceusingtheoptimalballburnishingparameterswasabout2.5microns.Theimprovementofthesurfaceroughnessthroughburnishingprocessgenerallyrangedbetween40and90.Fig.2.SchematicdiagramoftheballburnishingprocessTheaimofthisstudywastodevelopsphericalgrindingandballburnishingsurfacefinishprocessesofafreeformsurfaceplasticinjectionmoldonamachiningcenter.TheflowchartofautomatedsurfacefinishusingsphericalgrindingandballburnishingprocessesisshowninFig.3.Webeganbydesigningandmanufacturingthesphericalgrindingtoolanditsalignmentdeviceforuseonamachiningcenter.TheoptimalsurfacesphericalgrindingparametersweredeterminedbyutilizingaTaguchisorthogonalarraymethod.FourfactorsandthreecorrespondinglevelswerethenchosenfortheTaguchisL18matrixexperiment.Theoptimalmountedsphericalgrindingparametersforsurfacegrindingwerethenappliedtothesurfacefinishofafreeformsurfacecarrier.Toimprovethesurfaceroughness,thegroundsurfacewasfurtherburnished,usingtheoptimalballburnishingparameters.桂林电子科技大学毕业设计（论文）外文翻译译文第21页共28页Fig.3.Flowchartofautomatedsurfacefinishusingsphericalgrindingandballburnishingprocesses桂林电子科技大学毕业设计（论文）外文翻译译文第22页共28页2DesignofthesphericalgrindingtoolanditsalignmentdeviceTocarryoutthepossiblesphericalgrindingprocessofafreeformsurface,thecenteroftheballgrindershouldcoincidewiththezaxisofthemachiningcenter.Themountedsphericalgrindingtoolanditsadjustmentdevicewasdesigned,asshowninFig.4.SchematicillustrationofthesphericalgrindingtoolanditsadjustmentdeviceFig.4.Theelectricgrinderwasmountedinatoolholderwithtwoadjustablepivotscrews.Thecenterofthegrinderballwaswellalignedwiththehelpoftheconicgrooveofthealignmentcomponents.Havingalignedthegrinderball,twoadjustablepivotscrewsweretightenedafterwhich,thealignmentcomponentscouldberemoved.Thedeviationbetweenthecentercoordinatesoftheballgrinderandthatoftheshankwasabout5μm,whichwasmeasuredbyaCNCcoordinatemeasuringmachine.Theforceinducedbythevibrationofthemachinebedisabsorbedbyahelicalspring.Themanufacturedsphericalgrindingtoolandballburnishingtoolweremounted,asshowninFig.5.Thespindlewaslockedforboththesphericalgrindingprocessandtheballburnishingprocessbyaspindlelockingmechanism.桂林电子科技大学毕业设计（论文）外文翻译译文第23页共28页Fig.5.aPhotoofthesphericalgrindingtoolbPhotooftheballburnishingtool3Planningofthematrixexperiment3.1ConfigurationofTaguchisorthogonalarrayTheeffectsofseveralparameterscanbedeterminedefficientlybyconductingmatrixexperimentsusingTaguchisorthogonalarray.Tomatchtheaforementionedsphericalgrindingparameters,theabrasivematerialofthegrinderballwiththediameterof10mm,thefeedrate,thedepthofgrinding,andtherevolutionoftheelectricgrinderwereselectedasthefourexperimentalfactorsparametersanddesignatedasfactorAtoDseeTable1inthisresearch.Threelevelssettingsforeachfactorwereconfiguredtocovertherangeofinterest,andwereidentifiedbythedigits1,2,and3.Threetypesofabrasivematerials,namelysiliconcarbideSiC,whitealuminumoxideAl2O3,WA,andpinkaluminumoxideAl2O3,PA,wereselectedandstudied.Threenumericalvaluesofeachfactorweredeterminedbasedontheprestudyresults.TheL18orthogonalarraywasselectedtoconductthematrixexperimentforfour3levelfactorsofthesphericalgrindingprocess.Table1.Theexperimentalfactorsandtheirlevels桂林电子科技大学毕业设计（论文）外文翻译译文第24页共28页3.2DefinitionofthedataanalysisEngineeringdesignproblemscanbedividedintosmallerthebettertypes,nominalthebesttypes,largerthebettertypes,signedtargettypes,amongothers8.ThesignaltonoiseS/Nratioisusedastheobjectivefunctionforoptimizingaproductorprocessdesign.Thesurfaceroughnessvalueofthegroundsurfaceviaanadequatecombinationofgrindingparametersshouldbesmallerthanthatoftheoriginalsurface.Consequently,thesphericalgrindingprocessisanexampleofasmallerthebettertypeproblem.TheS/Nratio,η,isdefinedbythefollowingequationη-10log10meansquarequalitycharacteristic-10log10????????niiyn121whereyiobservationsofthequalitycharacteristicunderdifferentnoiseconditionsnnumberofexperimentAftertheS/NratiofromtheexperimentaldataofeachL18orthogonalarrayiscalculated,themaineffectofeachfactorwasdeterminedbyusingananalysisofvarianceANOVAtechniqueandanFratiotest.Theoptimizationstrategyofthesmallerthebetterproblemistomaximizeη,asdefinedbyEq.1.Levelsthatmaximizeηwillbeselectedforthefactorsthathaveasignificanteffectonη.Theoptimalconditionsforsphericalgrindingcanthenbedetermined.4ExperimentalworkandresultsThematerialusedinthisstudywasPDS5toolsteelequivalenttoAISIP20,whichiscommonlyusedforthemoldsoflargeplasticinjectionproductsinthefieldofautomobilecomponentsanddomesticappliances.ThehardnessofthismaterialisaboutHRC33HS46.Onespecificadvantageofthismaterialisthataftermachining,themoldcanbedirectlyusedforfurtherfinishingprocesseswithoutheattreatmentduetoitsspecialpretreatment.Thespecimensweredesignedandmanufacturedsothattheycouldbemountedonadynamometertomeasurethereactionforce.ThePDS5specimenwasroughlymachinedandthenmountedonthedynamometertocarryoutthefinemillingonathreeaxismachiningcentermadebyYangIronCompanytypeMV3A,equippedwithaFUNUCCompanyNCcontrollertype0M.Thepremachinedsurfaceroughnesswasmeasured,usingHommelwerkeT4000桂林电子科技大学毕业设计（论文）外文翻译译文第25页共28页equipment,tobeabout1.6μm.Figure6showstheexperimentalsetupofthesphericalgrindingprocess.AMP10touchtriggerprobemadebytheRenishawCompanywasalsointegratedwiththemachiningcentertoolmagazinetomeasureanddeterminethecoordinatedoriginofthespecimentobeground.TheNCcodesneededfortheballburnishingpathweregeneratedbyPowerMILLCAMsoftware.ThesecodescanbetransmittedtotheCNCcontrollerofthemachiningcenterviaRS232serialinterface.Fig.6.ExperimentalsetuptodeterminetheoptimalsphericalgrindingparametersTable2summarizesthemeasuredgroundsurfaceroughnessalueRaandthecalculatedS/NratioofeachL18orthogonalarraysingEq.1,afterhavingexecutedthe18matrixexperiments.TheaverageS/NratioforeachlevelofthefouractorsisshowngraphicallyinFig.7.Table2.GroundsurfaceroughnessofPDS5specimenExp.InnerarraycontrolfactorsMeasuredsurfaceroughnessvalueRaResponsenoABCD??my?1??my?2??my?3S/NηdBMean??my?_.350.359.20.370.360.388.30.410.440.407.30.630.650.643.10.730.770.782.20.450.420.397.桂林电子科技大学毕业设计（论文）外文翻译译文第26页共28页.310.329.30.270.250..320.329.220.350.390.408.330.410.500.436.110.400.390.427.130.330.340.319.210.480.500.476.320.570.610.534.310.590.550.545.120.360.360.358.230.570.530.535.Fig.7.PlotsofcontrolfactoreffectsThegoalinthesphericalgrindingprocessistominimizethesurfaceroughnessvalueofthegroundspecimenbydeterminingtheoptimallevelofeachfactor.Since-logisamonotonedecreasingfunction,weshouldmaximizetheS/Nratio.Consequently,wecandeterminetheoptimallevelforeachfactorasbeingthelevelthathasthehighestvalueofη.Therefore,basedonthematrixexperiment,theoptimalabrasivematerialwaspinkaluminumoxidetheoptimalfeedwas50mm/mintheoptimaldepthofgrindingwas20μmandtheoptimalrevolutionwas18000rpm,asshowninTable3.TheoptimalparametersforsurfacesphericalgrindingobtainedfromtheTaguchismatrixexperimentswereappliedtothesurfacefinishofthefreeformsurfacemoldinserttoevaluatethesurfaceroughnessimprovement.Aperfumebottle桂林电子科技大学毕业设计（论文）外文翻译译文第27页共28页wasselectedasthetestedcarrier.TheCNCmachiningofthemoldinsertforthetestedobjectwassimulatedwithPowerMILLCAMsoftware.Afterfinemilling,themoldinsertwasfurthergroundwiththeoptimalsphericalgrindingparametersobtainedfromtheTaguchismatrixexperiment.Shortlyafterwards,thegroundsurfacewasburnishedwiththeoptimalballburnishingparameterstofurtherimprovethesurfaceroughnessofthetestedobjectseeFig.8.ThesurfaceroughnessofthemoldinsertwasmeasuredwithHommelwerkeT4000equipment.TheaveragesurfaceroughnessvalueRaonafinemilledsurfaceofthemoldinsertwas2.15μmonaveragethatonthegroundsurfacewas0.45μmonaverageandthatonburnishedsurfacewas0.07μmonaverage.Thesurfaceroughnessimprovementofthetestedobjectongroundsurfacewasabout2.15-0.45/2.1579.1,andthatontheburnishedsurfacewasabout2.15-0.07/2.1596.7.Fig.8.Finemilled,groundandburnishedmoldinsertofaperfumebottle桂林电子科技大学毕业设计（论文）外文翻译译文第28页共28页5ConclusionInthiswork,theoptimalparametersofautomatedsphericalgrindingandballburnishingsurfacefinishingprocessesinafreeformsurfaceplasticinjectionmoldweredevelopedsuccessfullyonamachiningcenter.Themountedsphericalgrindingtoolanditsalignmentcomponentswasdesignedandmanufactured.TheoptimalsphericalgrindingparametersforsurfacegrindingweredeterminedbyconductingaTaguchiL18matrixexperiments.TheoptimalsphericalgrindingparametersfortheplasticinjectionmoldsteelPDS5werethecombinationoftheabrasivematerialofpinkaluminumoxideAl2O3,PA,afeedof50mm/min,adepthofgrinding20μm,andarevolutionof18000rpm.ThesurfaceroughnessRaofthespecimencanbeimprovedfromabout1.6μmto0.35μmbyusingtheoptimalsphericalgrindingconditionsforsurfacegrinding.Byapplyingtheoptimalsurfacegrindingandburnishingparameterstothesurfacefinishofthefreeformsurfacemoldinsert,thesurfaceroughnessimprovementsweremeasuredtobegroundsurfacewasabout79.1intermsofgroundsurfaces,andabout96.7intermsofburnishedsurfaces.
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