Method of filling simulated muscles for limb of crash test dummy for automobile

A method of filling simulated muscles for a limb of an automobile crash test dummy, wherein the simulated muscles are molded with foaming in an inner cavity of a mold;

• the mold comprises an upper mold, a mold core, a lower mold, a sprue port and an exhaust port;
• and the upper mold and the lower mold are buckled to form the inner cavity of the mold;
• the method comprises the following steps:
• step 1:
• obtaining a filling volume of the inner cavity of the mold by using a liquid casting method, and then calculating a total mass of a filler according to the filling volume and a known density of foamed sponge obtained after foaming of the filler, wherein the filler is composed of a first material and a second material;
• and obtaining masses of the first material and the second material according to the obtained total mass of the filler and a preset hardness of the limb, wherein a skin layer is prefabricated on an inner surface of the mold in an attaching manner;
• and the inner cavity of the mold herein refers to a space except for the skin layer in the mold, and the inner cavity mold is empty at this time;
• wherein, the step 1 specifically comprises the following steps:
• S101:
• fully pouring a sufficient amount of measuring liquid into the inner cavity, with the skin layer, of the mold, and obtaining the filling volume of the inner cavity of the mold by using the liquid casting method:
• V
• liquid
• (
• cm
• 3
• )
• =
• M
• ρ
• (
• 1
• )
• wherein ρ is a density of the measuring liquid, and M is a weight of the measuring liquid;
• and
• the measuring liquid is volatile and nontoxic liquid, and the liquid has the viscosity of 1.1-1.5 cP, and preferably, is anhydrous ethanol;
• S102:
• taking a cup residue loss in a process of dumping the filler into consideration, setting a mass redundancy coefficient, and calculating the total mass of the actually used filler in the inner cavity of the mold:
• Vfiller=Vliquid
• Mfiller=ρfillerVfiller
• Mactuallyusedfiller=KMfiller (2)
• wherein ρfiller is a density of the foamed sponge obtained after foaming of the filler;
• Vfiller is the filling volume, calculated in S101 of the inner cavity of the mold;
• K is the mass redundancy coefficient;
• Mfiller is the total mass of the filler just fully filled in the inner cavity of the mold;
• and Mactuallyusedfiller used filler is the total mass of the actually used filler;
• S103:
• calculating masses of various components of the filler, wherein
• the filler is composed of the first material and the second material, a mass ratio of the first material to the second material is set according to the preset hardness of the limb so as to deduce the masses of the first material and the second material, and a calculation formula is as follows:
• m
• A
• =
• M
• actually
• ⁢
• used
• ⁢
• filler
• ×
• A
• A
• +
• B
• (
• 3
• )
• m
• B
• =
• M
• actually
• ⁢
• used
• ⁢
• filler
• ×
• B
• A
• +
• B
• wherein mA is the mass of the first material;
• mB is the mass of the second material;
• and A:B is the mass ratio of the first material to the second material.
• step 2:
• preparing an adhesive liquid film layer fully pouring an adhesive liquid into the inner cavity of the mold for stilling for 20-40 s, and pouring out a residual adhesive liquid in the inner cavity of the mold to form an adhesive liquid film layer on the inner wall of the skin layer of the inner cavity of the mold;
• step 3:
• preparing a filler pouring a weighed first material and second material into a stirring cup for stirring for 9-12 s at a room temperature and a rotating speed of 2500-3000 r/min so as to form the filler with mixing;
• injecting the mixed filler into the inner cavity of the mold;
• enabling the filler to gradually be foamed in the mold to form foamed sponge;
• allowing the foamed sponge to stand for 5-8 min until the foamed sponge is foamed to the exhaust port and does not overflow from an end part of the exhaust port;
• and then completing the filling process;
• step 4:
• conducting demolding detection on the limb taking out a manufactured dummy limb member after separating the upper mold from the lower mold, detecting whether the dummy limb has a bulge or collapse or not by using an appearance vision;
• and if there is no bulge or collapse, then selecting the middle portion of the limb, and measuring the outside diameter of the middle portion with a measuring tape to judge whether the outside diameter accord with a dimension of the inner surface of the mold or not so as to complete detection on the limb.