Mold manufacturing technology has developed rapidly and has become an important part of modern manufacturing technology. Luo Baihui, CEO of Mould Network and expert member of Shenzhen Mould Technology Society, said that modern mold manufacturing technology is developing in the direction of accelerating information driving, improving manufacturing flexibility, agile manufacturing and system integration. Specifically, it is represented by CAD/CAM technology of mold, laser rapid prototyping technology of mold, precision forming technology of mold, ultra-precision machining technology of mold, mold using finite element method and boundary element method for flow, cooling and heat transfer process. Dynamic simulation technology, mold CIMS technology, advanced mold manufacturing technology such as mold DNM technology and numerical control technology.
1. High-speed milling: The third-generation molding technology high-speed milling not only has high processing speed, good processing precision and surface quality, but also has a low temperature rise compared with the traditional cutting process (the workpiece is only increased by 3 ° C). The thermal deformation is small, so it is suitable for the processing of temperature and heat deformation sensitive materials (such as magnesium alloy); also because of the small cutting force, it can be applied to the processing of parts with thin wall and poor rigidity; reasonable selection of tools and cutting amount can realize hard materials. (HRC60) A series of advantages such as processing. Luo Baihui said that high-speed milling technology is still a hot topic at present, and it has developed into a higher agility, intelligence, and integration, becoming the third-generation molding technology.
2. EDM milling and “green†product technology From the perspective of foreign electric machining machines, the performance, process index, intelligence and automation have reached a very high level. At present, the new trend in foreign countries is to perform electric sparks. Research and development of milling technology (EDG machining technology), which is a new technology to replace the traditional cavity machining with shaped electrodes. It is a three-dimensional or two-dimensional contour machining with a simple tubular electrode rotating at high speed ( Like CNC milling, there is no longer a need to make complex shaped electrodes, which is clearly a major development in the field of EDM.
Recently, Mitsubishi Corporation of Japan has introduced new progress in the EDSCAN8E EDM machine. The machine can automatically compensate for electrode loss. The dedicated CAM system developed for this machine on Windows 95 can be linked with common CAD such as AutoCAD, and can measure online precision to ensure high precision machining. In order to confirm whether the shape of the machine is abnormal or defective, the CAM system can also realize simulation processing. At the same time as the advancement of EDM technology, the safety and protection technology of EDM has received more and more attention. Many electric machine tools have considered safety protection technology. At present, the European Community has stipulated that machine tools without the “CE†mark cannot enter the European Community market, and the international market is paying more and more attention to the requirements of safety protection technology.
At present, the main problem of EDM machine tools is radiation harassment, because it has a great impact on safety and environmental protection. In the case of more and more attention to "green" products in the international market, as the leading equipment for EDM processing of EDM machines Green "product technology" will be a problem that must be solved in the future.
3. New generation mold CAD/CAM software technology At present, the mold software developed by Britain, the United States, Germany and other countries and some universities and research institutes in China has the intelligence, integration and mold of the new generation mold CAD/CAM software. Features such as manufacturability evaluation. Luo Baihui said that the new generation of mold software should be based on a large amount of knowledge summarized from the mold design practice. This knowledge has been systematically and scientifically organized and stored in a specific form in the engineering knowledge base and can be easily called by the mold. With the support of intelligent software, mold CAD is no longer an imitation of traditional design and calculation methods, but under the guidance of advanced design theory, the full use of the rich knowledge and successful experience of experts in this field, the design results must be reasonable Sex and advanced.
The new generation of mold software designs the mold structure with three-dimensional thought and intuitive feeling. The generated three-dimensional structure information can be conveniently used for mold manufacturability evaluation and numerical control processing, which requires the mold software to shape and shape the parameters in three dimensions. Process simulation, CNC machining process simulation and information exchange and organization and management have achieved a fairly complete level and a high level of integration. Measuring the level of software integration depends not only on whether the functional modules are complete, but also whether these functional modules share the same data model, whether a global dynamic database is formed in a unified manner, and comprehensive management and sharing of information is realized to support mold design. The entire process of manufacturing, assembly, inspection, testing and commissioning.
The function of mold manufacturability evaluation is very important in the new generation of mold software. It is necessary to screen multiple plans, evaluate the rationality and economy of the mold design process, and provide modification basis for mold designers.
In the new generation of mold software, the manufacturability evaluation mainly includes the estimation of mold design and manufacturing cost, mold assembly evaluation, mold part manufacturing process evaluation, mold structure and forming performance evaluation. The new generation of software should also have an assembly-oriented function, because the function of the mold can only be realized through its assembly structure. After adopting the assembly-oriented design method, the mold assembly is no longer a simple assembly of parts by piece. The data structure can describe the function of the mold, and can define the assembly features of the relationship between the mold parts and realize the association of the parts. Can effectively guarantee the quality of the mold.
4, advanced rapid mold manufacturing technology (1), laser rapid prototyping technology (RPM) development speed, China has reached the international level, and gradually achieve commercialization. The rapid prototyping processes that have been commercialized in the world mainly include SLA (stereolithography), LOM (layered separation manufacturing), SLS (selective laser sintering), and 3D-P (three-dimensional printing).
Tsinghua University first introduced the SLA250 (stereolithography or laser-cured laser curing) equipment and technology of 3D Company of the United States and carried out research and development. After several years of efforts, it has improved and improved the M-RPMS-type. Functional rapid prototyping system" (with layered entity manufacturing - SSM, melt extrusion molding - MEM), this is the only system in China with two rapid prototyping processes (national patent) with good intellectual property rights, with good performance. Price ratio.
(2) The moldless multi-point forming technology is another advanced manufacturing technology for replacing the traditional mold with the height-adjustable punch group. The moldless multi-point forming system uses CAD/CAM/CAT technology as the main means. Automated forming of 3D surfaces quickly and economically. Jilin University of Technology has undertaken the national key scientific and technological research project on moldless forming, and has independently designed and manufactured the moldless multi-point forming equipment with international leading level.
Compared with the Massachusetts Institute of Technology in the United States, the University of Tokyo in Japan, and the Tokyo Institute of Technology in Japan, this technology is in a leading position in theoretical research and practical applications, and is currently developing for application. 3. The resin stamping die was successfully applied in the trial production of domestic cars for the first time. FAW Mould Manufacturing Co., Ltd. designed and manufactured 12 sets of resin molds for the modification of the new Xiaohongqi sedan. These 12 sets of molds are the drawing molds for large and complex internal and external coverings such as luggage, hood, front, rear, left and right fenders. The main feature is that the mold profile is based on the main model of CAD/CAM processing, and is cast by high-strength resin refined by Ciba. The gap between the convex and concave molds is accurately controlled by imported special wax sheets. The dimensional accuracy of the mold is high. The cycle can be shortened by one-half to two-thirds, and the manufacturing cost can be saved by about 10 million yuan (12 sets of molds). It has opened up a new way for China's car trial production and small batch production, which is the first in China. Experts from the Swiss Ciba Refinement believe that it can reach the international level in the 1990s. 5, on-site mold detection technology development of precision molds The requirements for measurement are getting higher and higher. Precision CMMs have long been limited by the environment and are rarely used in production sites. The new generation of three-coordinate measuring machine basically has temperature compensation and anti-vibration materials to improve dustproof measures, improve environmental adaptability and reliability, so that it can be easily installed in the workshop to achieve on-site measurement. .
5, mirror polishing mold surface engineering technology Mold polishing technology is an important part of the mold surface engineering, is an important process in the mold manufacturing process. At present, the polishing equipment and abrasive abrasives and processes of domestic mold polishing to Ra0.05μm can basically meet the needs, but the mirror polishing equipment, abrasive abrasives and technology of Ra0.025μm should be thrown to the stage of exploration. With the large-scale application of mirror injection molds in production, mold polishing technology has become a key issue in mold production. Due to certain problems in domestic polishing technology and materials, injection molds such as point-and-shoot lenses, CDs, VCDs, and tools with high transparency requirements still depend heavily on imports. Luo Baihui pointed out that the surface polishing of the mold is not only affected by the polishing equipment and process technology, but also affected by the mirror surface of the mold material. This has not attracted enough attention, that is, the polishing itself is restricted by the mold material. For example, when 45# carbon steel is used as an injection mold, when polishing to Ra0.2μm, obvious defects can be seen by the naked eye. Continued throwing can only increase the brightness, and the roughness is not expected to be improved. Therefore, it is currently in the production of mirror molds in China. Imported mold materials are often used, such as Sweden's Yishengbai 136, Japan's Datong PD555, etc. can get satisfactory mirror.
Mirror mold material is not only a chemical component problem, but also requires a series of advanced processes such as vacuum degassing, argon gas protection ingot casting, vertical continuous casting and rolling, and soft forging during smelting, so that the mirror mold steel has fewer internal defects. A series of advantages such as fine particle size, high degree of dispersion, fine metal grain size and good uniformity, in order to achieve the requirements of polishing to mirror mold steel.
1. High-speed milling: The third-generation molding technology high-speed milling not only has high processing speed, good processing precision and surface quality, but also has a low temperature rise compared with the traditional cutting process (the workpiece is only increased by 3 ° C). The thermal deformation is small, so it is suitable for the processing of temperature and heat deformation sensitive materials (such as magnesium alloy); also because of the small cutting force, it can be applied to the processing of parts with thin wall and poor rigidity; reasonable selection of tools and cutting amount can realize hard materials. (HRC60) A series of advantages such as processing. Luo Baihui said that high-speed milling technology is still a hot topic at present, and it has developed into a higher agility, intelligence, and integration, becoming the third-generation molding technology.
2. EDM milling and “green†product technology From the perspective of foreign electric machining machines, the performance, process index, intelligence and automation have reached a very high level. At present, the new trend in foreign countries is to perform electric sparks. Research and development of milling technology (EDG machining technology), which is a new technology to replace the traditional cavity machining with shaped electrodes. It is a three-dimensional or two-dimensional contour machining with a simple tubular electrode rotating at high speed ( Like CNC milling, there is no longer a need to make complex shaped electrodes, which is clearly a major development in the field of EDM.
Recently, Mitsubishi Corporation of Japan has introduced new progress in the EDSCAN8E EDM machine. The machine can automatically compensate for electrode loss. The dedicated CAM system developed for this machine on Windows 95 can be linked with common CAD such as AutoCAD, and can measure online precision to ensure high precision machining. In order to confirm whether the shape of the machine is abnormal or defective, the CAM system can also realize simulation processing. At the same time as the advancement of EDM technology, the safety and protection technology of EDM has received more and more attention. Many electric machine tools have considered safety protection technology. At present, the European Community has stipulated that machine tools without the “CE†mark cannot enter the European Community market, and the international market is paying more and more attention to the requirements of safety protection technology.
At present, the main problem of EDM machine tools is radiation harassment, because it has a great impact on safety and environmental protection. In the case of more and more attention to "green" products in the international market, as the leading equipment for EDM processing of EDM machines Green "product technology" will be a problem that must be solved in the future.
3. New generation mold CAD/CAM software technology At present, the mold software developed by Britain, the United States, Germany and other countries and some universities and research institutes in China has the intelligence, integration and mold of the new generation mold CAD/CAM software. Features such as manufacturability evaluation. Luo Baihui said that the new generation of mold software should be based on a large amount of knowledge summarized from the mold design practice. This knowledge has been systematically and scientifically organized and stored in a specific form in the engineering knowledge base and can be easily called by the mold. With the support of intelligent software, mold CAD is no longer an imitation of traditional design and calculation methods, but under the guidance of advanced design theory, the full use of the rich knowledge and successful experience of experts in this field, the design results must be reasonable Sex and advanced.
The new generation of mold software designs the mold structure with three-dimensional thought and intuitive feeling. The generated three-dimensional structure information can be conveniently used for mold manufacturability evaluation and numerical control processing, which requires the mold software to shape and shape the parameters in three dimensions. Process simulation, CNC machining process simulation and information exchange and organization and management have achieved a fairly complete level and a high level of integration. Measuring the level of software integration depends not only on whether the functional modules are complete, but also whether these functional modules share the same data model, whether a global dynamic database is formed in a unified manner, and comprehensive management and sharing of information is realized to support mold design. The entire process of manufacturing, assembly, inspection, testing and commissioning.
The function of mold manufacturability evaluation is very important in the new generation of mold software. It is necessary to screen multiple plans, evaluate the rationality and economy of the mold design process, and provide modification basis for mold designers.
In the new generation of mold software, the manufacturability evaluation mainly includes the estimation of mold design and manufacturing cost, mold assembly evaluation, mold part manufacturing process evaluation, mold structure and forming performance evaluation. The new generation of software should also have an assembly-oriented function, because the function of the mold can only be realized through its assembly structure. After adopting the assembly-oriented design method, the mold assembly is no longer a simple assembly of parts by piece. The data structure can describe the function of the mold, and can define the assembly features of the relationship between the mold parts and realize the association of the parts. Can effectively guarantee the quality of the mold.
4, advanced rapid mold manufacturing technology (1), laser rapid prototyping technology (RPM) development speed, China has reached the international level, and gradually achieve commercialization. The rapid prototyping processes that have been commercialized in the world mainly include SLA (stereolithography), LOM (layered separation manufacturing), SLS (selective laser sintering), and 3D-P (three-dimensional printing).
Tsinghua University first introduced the SLA250 (stereolithography or laser-cured laser curing) equipment and technology of 3D Company of the United States and carried out research and development. After several years of efforts, it has improved and improved the M-RPMS-type. Functional rapid prototyping system" (with layered entity manufacturing - SSM, melt extrusion molding - MEM), this is the only system in China with two rapid prototyping processes (national patent) with good intellectual property rights, with good performance. Price ratio.
(2) The moldless multi-point forming technology is another advanced manufacturing technology for replacing the traditional mold with the height-adjustable punch group. The moldless multi-point forming system uses CAD/CAM/CAT technology as the main means. Automated forming of 3D surfaces quickly and economically. Jilin University of Technology has undertaken the national key scientific and technological research project on moldless forming, and has independently designed and manufactured the moldless multi-point forming equipment with international leading level.
Compared with the Massachusetts Institute of Technology in the United States, the University of Tokyo in Japan, and the Tokyo Institute of Technology in Japan, this technology is in a leading position in theoretical research and practical applications, and is currently developing for application. 3. The resin stamping die was successfully applied in the trial production of domestic cars for the first time. FAW Mould Manufacturing Co., Ltd. designed and manufactured 12 sets of resin molds for the modification of the new Xiaohongqi sedan. These 12 sets of molds are the drawing molds for large and complex internal and external coverings such as luggage, hood, front, rear, left and right fenders. The main feature is that the mold profile is based on the main model of CAD/CAM processing, and is cast by high-strength resin refined by Ciba. The gap between the convex and concave molds is accurately controlled by imported special wax sheets. The dimensional accuracy of the mold is high. The cycle can be shortened by one-half to two-thirds, and the manufacturing cost can be saved by about 10 million yuan (12 sets of molds). It has opened up a new way for China's car trial production and small batch production, which is the first in China. Experts from the Swiss Ciba Refinement believe that it can reach the international level in the 1990s. 5, on-site mold detection technology development of precision molds The requirements for measurement are getting higher and higher. Precision CMMs have long been limited by the environment and are rarely used in production sites. The new generation of three-coordinate measuring machine basically has temperature compensation and anti-vibration materials to improve dustproof measures, improve environmental adaptability and reliability, so that it can be easily installed in the workshop to achieve on-site measurement. .
5, mirror polishing mold surface engineering technology Mold polishing technology is an important part of the mold surface engineering, is an important process in the mold manufacturing process. At present, the polishing equipment and abrasive abrasives and processes of domestic mold polishing to Ra0.05μm can basically meet the needs, but the mirror polishing equipment, abrasive abrasives and technology of Ra0.025μm should be thrown to the stage of exploration. With the large-scale application of mirror injection molds in production, mold polishing technology has become a key issue in mold production. Due to certain problems in domestic polishing technology and materials, injection molds such as point-and-shoot lenses, CDs, VCDs, and tools with high transparency requirements still depend heavily on imports. Luo Baihui pointed out that the surface polishing of the mold is not only affected by the polishing equipment and process technology, but also affected by the mirror surface of the mold material. This has not attracted enough attention, that is, the polishing itself is restricted by the mold material. For example, when 45# carbon steel is used as an injection mold, when polishing to Ra0.2μm, obvious defects can be seen by the naked eye. Continued throwing can only increase the brightness, and the roughness is not expected to be improved. Therefore, it is currently in the production of mirror molds in China. Imported mold materials are often used, such as Sweden's Yishengbai 136, Japan's Datong PD555, etc. can get satisfactory mirror.
Mirror mold material is not only a chemical component problem, but also requires a series of advanced processes such as vacuum degassing, argon gas protection ingot casting, vertical continuous casting and rolling, and soft forging during smelting, so that the mirror mold steel has fewer internal defects. A series of advantages such as fine particle size, high degree of dispersion, fine metal grain size and good uniformity, in order to achieve the requirements of polishing to mirror mold steel.
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