The molds are manufactured and used in various forms, with high technical content, unique production process, many production factors and wide application range. In addition, mold manufacturing technology has high requirements for producers' business and professional qualities. Mold manufacturing technology has the following two reasons: First, the mold is a single-piece product, that is, the mold is a special molding tool that is manufactured and manufactured according to the structural requirements between the finished products. Second, the key to mold manufacturing is mainly to make the convex. Special processes for molds, dies and related molded parts, as well as optimized design and high savings in the mold manufacturing process.
Second, mold design, processing several technologies
1. High speed machining technology
The concept of high-speed machining originated from the German cutting physicist Carl Salomon. He believes that the cutting temperature increases with the increase of the cutting speed in the conventional cutting range. When the cutting speed reaches the critical cutting speed, the cutting speed increases again, and the cutting temperature instead Drops, which greatly reduce machining time and double the productivity of machine tools. The characteristics of high speed machining and its application in the mold industry:
High processing efficiency Due to the high cutting speed, the feed rate is generally increased by 5-1 times, so that the material removal rate per unit time can be increased by 3-6 times, so the machining efficiency is greatly improved; the cutting force is small, the high speed machining is high, and the cutting speed is high. The speed of the outflow is fast, the friction between the chip and the front of the tool is reduced, and the cutting force is greatly reduced. During the high-speed machining process, 95% of the cutting heat is carried away by the chip due to the extremely high feed rate, and the workpiece is basically maintained. Cold state, so that the parts will not be deformed due to temperature rise; high precision machining and high-speed machining machine with high excitation frequency, far beyond the natural frequency range of the "machine-tool-to-work" process system, which makes the parts almost " The vibration-free state processing, while at high speed processing speed, the built-up edge, surface residual stress and work hardening are all suppressed, so the surface processed with high speed can be almost compared with grinding.
In addition, the process flow is simplified because the surface quality of high-speed milling can reach the effect of grinding. In some cases, high-speed machining can be used as a finishing process for parts, which simplifies the process and shortens the machining time of parts. High-speed machining is a processing technique characterized by high cutting speed, high feed rate and high machining accuracy. The workpiece has small thermal deformation, high processing precision and good surface quality; it is very suitable for thin-walled, poorly-rigid, and easily deformed parts in mold processing, and can directly process hardened materials used in molds, especially hardness in HRC46. Materials in the range of ~60.
2. Reverse engineering technology
According to the traditional product development process, the development process is a market research, a conceptual design, a general design, a detailed design, a process flow, a design fixture, a processing, inspection, assembly and performance testing. That is, from the product design process of "Design Idea One Product", this is called forward engineering or forward engineering. The reverse T-process applications in the mold industry can be roughly divided into the following cases:
In the absence of design drawings and incomplete or no CAD models, the design drawings or CAD models of the parts are formed on the basis of the measurement of the part prototypes; some objects that are difficult to directly use the computer for 3D geometric design are commonly used. The initial shape design of the clay, the material or the foam is carried out, and the physical model is transformed into a three-dimensional CAD model by reverse engineering; people often need to modify the existing products locally. The original design does not have the situation of three-dimensional cAD touch, and the reverse engineering technology is used to establish the CAD model, and then the CAD model is modified, which will shorten the product modification cycle and improve the production efficiency.
Third, the application of CAD / CAE technology
Mold design varies with the shape, size and dimensional accuracy of industrial product parts, surface quality requirements and molding process conditions, so each mold must be creatively designed. Mold design includes product part molding process optimization design and mechanical calculation and dimension and dimensional accuracy determination and design. Therefore, mold design is often divided into part process analysis and design, mold overall design, overall structure design, construction drawing design. four stages. CAD/CAE, computer-aided design and auxiliary engineering, including conceptual design, optimization design, finite element analysis, computer simulation, computer-aided drawing, and computer-aided design process management. CAD technology can be used to design the general structure of the product, and then structural analysis, feasibility evaluation and optimization design through CAE technology. After adopting the CAD/CAE integration technology of the mold, the parts generally do not need to be prototyped again. Geometric shape technology is adopted, and the shape of the parts can be accurately and realistically displayed on the computer screen. The finite element analysis program can detect the mechanical properties. . With the help of computers, automatic drawing replaces manual drawing, automatic retrieval replaces manual review, and rapid analysis replaces manual calculations, enabling mold designers to free themselves from cumbersome drawing and calculations, focusing on concepts such as solution design and structural optimization. Creative work. Before the mold is put into production, the CAE software can predict the correctness of the parameters related to the mold structure.
At present, the world's large CAD/CAE software systems, such as Pro/ENGINEER, UG, Solidworke, Alias, etc., provide system modules for early design of products, which we call industrial design modules or conceptual design modules. For example, Pro/ENGINEER includes an industrial design module, ProDesign, to support top-down projection design and automatic design of many complex tasks involved in complex product design. This module tool includes a two-dimensional, non-parameterized assembly layout editor for conceptual design. The application of these system modules greatly reduces the designer's workload, saves working time, improves work efficiency, and enables designers to devote more energy to the development and innovation of new products.
Fourth, the conclusion
With the development of the times, the globalization of mold manufacturing industry is an inevitable trend of development, and its competition is intensifying, which makes the current mold manufacturing industry face great challenges. This challenge mainly comes from the two major aspects of market and technology. Each technology unit is market-oriented and partners at the same time, and must be flexibly reorganized and integrated to complement each other. The combination of high-speed cutting, reverse engineering, rapid prototyping technology and CAD/CAE/CAM/RP virtual environment can shorten the design concept into products by several times or even several times, forming a comprehensive system for rapid product development and mold manufacturing. It can realize flexible and economical organization from product design, analysis, processing to management, and apply CAD/CAE technology to promote the rapid development of mold manufacturing technology.
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