The rapid development of mold manufacturing technology has become an important modern manufacturing technology component. If mold CAD / CAM technology, mold laser rapid prototyping technology, precision die forming technology, the ultra-precision processing technology of mold, mold in the design using finite element method, boundary element method to flow, cooling, heat transfer process of dynamic simulation technology, mold CIMS technology has been in the development of mold DNM technology and numerical control technology, covering nearly all of modern manufacturing technology.
Die Manufacturing Technology toward the speed of modern information-driven, increase manufacturing flexibility, agile manufacturing and systematic integration of direction.
1, high-speed milling: The third-generation tooling
High-speed milling process not only has high speed and excellent machining accuracy and surface quality, but also with the traditional cutting temperature compared to low (workpiece increased only 3 ℃), heat distortion is small, and thus suitable for temperature and thermal deformation sensitive materials (such as magnesium alloy, etc.) processing; also due to cutting force is small, thin-walled and rigid applicable to poor parts machining; reasonable selection of tools and cutting consumption, can be realized hard materials (HRC60) processing a series of advantages. Therefore, high-speed milling technology is still is the current hot topic, it has more agile, intelligent, integrated direction, to become the third-generation tooling.
2, EDM milling and "green" product technical
EDM from the foreign point of view, whether in performance, process indicators, intelligence, degree of automation have reached a very high level, currently abroad, the new trend is to EDM Milling Technology (EDM processing technology into a ) research and development, which is an alternative to the traditional processing of the cavity with the electrodes forming the new technology, which is high-speed rotation of the tubular electrode as a simple three-dimensional or two-dimensional contour machining (CNC milling, as the same), so no longer need to create complex forming electrodes, which is obviously EDM major developments in the field.
Recently, the Japanese launched a EDSCAN8E Mitsubishi EDM machines have become the new progress. The machine can automatically compensate for electrode wear, in the Windows95 machine developed for the dedicated CAM system to CAD with AutoCAD and other common linkage, and can on-line precision measurements, in order to ensure the realization of high-precision machining. In order to confirm whether the abnormal or incomplete processing of shape, CAM system can achieve the simulation process.
Technological advances in EDM, while EDM security and protection technology more and more attention has been paid, and many electric machines are considered a security protection technology. At present the EC has provision does not "CE" mark of the machine can not enter the EC market, while the international market is also increasing emphasis on security technology requirements.
At present, the main problem EDM machine is radiation harassment, because of its safety, environmental impact is greater in the international market, more and more emphasis on "green" products, cases, as the dominant mold processing equipment, EDM machine tools " green "product technology, will be in the future have to be solved.
Third, a new generation of die CAD / CAM software technology
At present, the United Kingdom, the United States, Germany and other countries and some of our universities and research institutes developed mold software, with a new generation of die CAD / CAM software for intelligent, integrated, mold manufacturability evaluation and so on.
Mold a new generation of software should be built from the mold design and practice, summarized a large number of knowledge. This knowledge through a systematic and scientific order, in the form of specific projects is stored in the Knowledge Base and can easily be called by mold. In the intelligent software support, CAD is no longer the mold of traditional design and calculation method of imitation, but in advanced design theory, under the guidance of experts in this field make full use of the wealth of knowledge and successful experiences, the design must have a reasonable result and advanced.
Mold a new generation of software to three-dimensional thinking, intuitive sense to design mold structure, the generated three-dimensional structural information can be easily used to mold manufacturability evaluation and numerical control machining, which requires the software dies in three-dimensional parametric feature modeling, molding process simulation, numerical control machining process simulation and exchange of information and organization and management reached a considerable degree of perfection and have a high level of integration. Measure of the degree of the level of software integration, not only depends on functional modules are complete, but also look at whether these function modules share the same data model, whether in a uniform manner to form the overall dynamic database to achieve the integrated management and sharing of information to support the mold design , manufacturing, assembly, inspection, testing and commissioning of the entire process.
Mold can produce a new generation of die nature of the evaluation function in the role of software is important, it is necessary for multi-program screening, but also to the mold design process, the rationality and economic assessment, and modify the basis for mold designers.
Die in the next generation software, manufacturability evaluation include mold design and manufacture of cost estimates, evaluation of mold can be assembled mold parts manufacturing process evaluation, mold structure and forming properties of the evaluation. there should be a new generation of software for the assembly function, because the mold features are available only through its assembly structure can be reflected. Assembly-oriented design methods, the mold assembly is no longer a simple by-part assembly, and its data structure, both the functions described in molds, but also define the relationship between the mold parts and components assembly features, parts and components to achieve the association which can effectively guarantee the quality of the mold.
4, advanced manufacturing technology Rapid Tooling
1, laser rapid prototyping technology (RPM) developing very rapidly, China has reached international level and the progressive realization of commercialization. The world has commercial Rapid Prototyping processes are mainly SLA (stereo lithography), LOM (Layered split manufacturing), SLS (selective laser sintering), 3D-P (3D printing).
Tsinghua University, the United States introduced the first 3D's SLA250 (stereo lithography, or laser curing said photosensitive resin) equipment and technology and conduct research and development, after years of hard work, many improvements, perfect, launched the "M-RPMS-Multi Functional Rapid Prototyping Manufacturing System "(with LOM-SSM, melt extrusion-MEM), which is China's own intellectual property rights has the world's only two kinds of rapid prototyping technology systems (national patent), with a better cost performance.
2, no multi-point forming technology is height-adjustable punch dies for sheet instead of the traditional groups of the surface forming another advanced manufacturing technology, multi-point forming system for CAD / CAM / CAT technology as the main means of rapid economic to achieve the automatic three-dimensional curved surface shape. Jilin Industry University assumed the non-die-formed national key scientific and technological projects have been independently designed and manufactured with international advanced level of the multi-point forming equipment.
This technology in China and the United States, Massachusetts Institute of Technology, Tokyo University, Tokyo Institute of Technology, compared the theoretical research and practical applications are a leader, is now moving to promote the use of sectors as well. 3, resin stamping die the first time in the trial of domestic cars has been successfully applied. FAW Die Manufacturing Co., Ltd. design and manufacture of 12 sets of resin molds for a new small red car modification trial, the 12 sets of molds are the trunk, hood, front and rear left-right sub-panels within and outside the coverage of large and complex pieces of Latin America extension of mold, its main feature is mold-type surfaces, CAD / CAM processing of master model as a benchmark, using the Swiss Ciba Specialty Chemicals of high-strength resin casting forming, punch and die clearance of imported special wax and accurate control of the dimensional accuracy of die high, manufacturing cycle can be shortened one-half to two-thirds, manufacturing costs can be saved about 10 million yuan (12 sets of molds). China's car prototype and small batch production has opened up a new way, is a national initiative. Switzerland, Ciba Specialty Chemicals, experts believe that up to 90 years with international standards.
5, field-based mold detection technology
Precision mold the development of measurement have become increasingly demanding. Precise coordinate measuring machine, a long time by environmental constraints, rarely used in the production site. Basically, a new generation of coordinate measuring machine has a temperature compensation and the use of anti-vibration material, to improve the dust control measures to improve environmental adaptation and use of reliability, so that it can be easily installed in the plant used to achieve the measurement of the characteristics of the site.
6, mirror-polished mold surface engineering technology
Mold Polishing Mold surface engineering technology is an important component part of the process of mold manufacturing an important post-processing technique. At present, the domestic mold polishing to Ra0.05μm polishing equipment, grinding and abrasive processes, can basically meet the demand, but to throw to Ra0.025μm mirror polishing equipment, grinding and abrasive processes Shangchu groping stage. With the mirror injection mold of large-scale applications in production, die mold polishing technology has become a key issue. Domestic polishing technology and materials so there is still a problem, such as the stupid camera lens injection mold, CD, VCD disc and tools for high transparency, a large part of the injection mold is still dependent on imports.
It is noteworthy that the mold surface polishing polishing equipment and processes are not affected by the impact of technology, but also by the degree of mold material mirror the impact of this has not attracted enough attention, that is, polishing itself constrained by the mold material. For example, to do with the 45 # carbon steel injection mold, the polishing to Ra0.2μm when the visible obvious defects, to continue throwing to only increase the brightness, while the roughness has no hope of improving it is the current domestic production in the mirror mold is often imported mold material, such as the Swedish one wins 100 136, Japanese Datong PD555, etc. access to the mirror degree of satisfaction.
Mirror mold material is not only chemical composition problem, but the main thing is to request use of a vacuum degassing refining, argon gas protection of ingots, vertical continuous casting and rolling, soft forging a series of advanced technology, so that mirror the internal defects die steel with less impurities fine grain, a high degree of dispersion of metal fine grain size, uniformity and good range of benefits to achieve the polished to the mirror surface of the die steel requirements. |
