New technology promotes the development of mold manufacturing industry.
Core tip: high speed cutting machine has the advantages of high speed, intelligence and precision: the spindle speed is high and the table is moving fast. Mainly using the main shaft structure, the maximum speed of spindle is higher than the mechanical structure. For example, a type of high-speed five-axis gantry machining center, with the maximum rotational speed of 42 000r/min, and the fast moving speed of the table is 42m/min. The X/Y axis is driven by linear motor. Compared with the traditional ball screw drive, the advantages are: direct transmission, high path accuracy and no backspace.
1. Application of high speed cutting machine.
High-speed cutting machine has the advantages of high speed, intelligence and precision: the spindle speed is high and the table is moving fast. Mainly using the main shaft structure, the maximum speed of spindle is higher than the mechanical structure. For example, a type of high-speed five-axis gantry machining center, with the maximum rotational speed of 42 000r/min, and the fast moving speed of the table is 42m/min. The X/Y axis is driven by linear motor. Compared with the traditional ball screw drive, the advantages are: direct transmission, high path accuracy and no backspace. The bed adopts the skycar structure, all the axial moving parts are moved above the column, the workpiece is fixed on the workbench, so that the workpiece quality does not affect the machining performance of the machine. Intelligent thermal compensation system can real-time dynamic compensation, the operators don't have to wait a long time or for machine tool thermal stable state to processing, can be directly started but was turned on precision milling processing, machine tool automatic compensation for the thermal displacement of tool center point, improves the processing precision of the workpiece, enhance the stability and reliability of the machining process; The one-piece bed structure design improves the rigidity of the whole body and ensures the stability of precision and mechanical performance.
My company USES 3 r rapid positioning clamping system, ensure the repositioning precision of the workpiece fixture to 2 microns, cumulative error from the source control, at the same time greatly reduce machine down time and the labor intensity of workers, the utilization rate of equipment at its highest point. All the workpiece and the electrode are formed in closed to install, closed to determine the offset value, programmed in advance, realize overall by the processing center to edm mould processing process flexibility, automation and standardization.
High-speed machine tool, and the application of precision tool system, makes high speed machining compared with ordinary milling has incomparable advantages: can be quickly removed a lot of excess material when rough machining, and can achieve the high surface quality in finish machining, reduce the time of subsequent polishing processing. For example, with the ball end milling cutter with 10mm, the milling spacing is 0.2mm, and the theoretical residual height of the workpiece surface is only 0.001mm. For some stamping dies, polishing is not required, and can be debugged directly. The application of high speed machining simplifies the machining process and saves some cost, and there is no surface hardening caused by electroprocessing. High speed machining take very small feed rate and cutting depth, can obtain high quality of processing surface, can use a smaller diameter cutter for smaller rounded corners and die detail processing, sometimes can save fitter polishing process, prevents damage to the human factors on the accuracy of mold.
2. Application of CAD/CAM/CAE technology.
CAD/CAM/CAE technology to product design, mold design, mold manufacturing, and data analysis of organic combination, greatly improving the quality of mold design, mold design and shorten the manufacturing cycle, reduces the product cost, is of great significance to improve the level of mold development and competitiveness.
Synchronization of product research and development, the company I used the synchronous structure design, mould making and synchronization process development process, the mold development process is: the product 3 d CAD design, CAE analysis (see figure 1), DL figure 3 d design to mould 3 d design, mould CAM numerical control processing (see figure 2), mould and parts of three dimensional coordinates, testing and commissioning of qualified samples (see figure 3). For example, Moldflow Moldflow analysis software is used to select the best position of the product and fill the cavity quickly. Analyze the warp, welding marks, stoma and stress marks of the product, thus reducing the maintenance after the mold opening.
Using Catia V5R20, CimatronE11, UG NX8.0, PowerMill, Moldflow and professional CAD/CAM/CAE tools such as Nastran software, make my company has cover parts, bumper (see figure 4) and complex functions, such as perfect design experience and solutions.
3. Establishment of process database.
Mature experience refined into the database technology, such as forming surface are not equal in all parts of the gap, rolling model of surface deformation caused by the expansion and press backlash compensation, etc., the amount of compensation in nc machining processing come out ahead of time, by forming CAE analysis, test results and the parts compensation processing data, and so on, summarizes formation forming mold process database, reduce mould debugging work, promote efficiency of mould manufacturing.
4. Application of injection mold ejection test machine.
In terms of the injection mold ejection mechanism: mold ejection machine can fully simulate the movement process of mold in injection molding machine, dynamic, cold more than 2, 500 times, make the mold ejection and sliding smoothly and smoothly and efficiently improved the mould production efficiency and product quality, extend the die life, reduce the mold and injection molding machine working cost, shorten the mold production cycle, for better mold production security.
5. Conclusion
Under the new situation, the market is more and more high to the requirement of mould manufacturing, the application of new technology and new equipment to promote the development of the domestic mold manufacturing industry, narrowing the gap with international advanced mold manufacturing areas, but there are still many aspects in the mold technology and management level need to be improved.