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編號
無錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
相關(guān)資料
題目： 側(cè)彎支架冷沖壓工藝及級進(jìn)模設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動化專業(yè)
學(xué) 號： 0923262
學(xué)生姓名： 趙 安
指導(dǎo)教師： 鐘建剛（職稱：副教授 ）
（職稱： ）
2013年5月25日
目 錄
一、畢業(yè)設(shè)計(jì)（論文）開題報(bào)告
二、畢業(yè)設(shè)計(jì)（論文）外文資料翻譯及原文
三、學(xué)生“畢業(yè)論文（論文）計(jì)劃、進(jìn)度、檢查及落實(shí)表”
四、實(shí)習(xí)鑒定表
無錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
開題報(bào)告
題目： 側(cè)彎支架冷沖壓工藝及級進(jìn)模設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動化 專業(yè)
學(xué) 號： 0923262
學(xué)生姓名： 趙 安
指導(dǎo)教師： 鐘建剛 （職稱：副教授）
（職稱： ）
2012年11月25日
課題來源
來源于無錫毅立模具有限公司，是電器產(chǎn)品上的一個(gè)零件。
科學(xué)依據(jù)（包括課題的科學(xué)意義；國內(nèi)外研究概況、水平和發(fā)展趨勢；應(yīng)用前景等）
（1）課題科學(xué)意義
模具是制造業(yè)中的一種重要的加工工藝裝備，是現(xiàn)代工業(yè)發(fā)展的基石，廣泛應(yīng)用于汽車、航空航天、家電、工程設(shè)備等方面。沒有高水平的模具，也就沒有高水平的工業(yè)產(chǎn)品，因此模具設(shè)計(jì)與制造技術(shù)水平的高低，是衡量一個(gè)國家產(chǎn)品制造水平高低的重要標(biāo)志之一，在很大程度上決定著產(chǎn)品的質(zhì)量、效益和新產(chǎn)品的開發(fā)能力。近年來我國模具產(chǎn)業(yè)總產(chǎn)值保持15%的年增長率。以沖壓模具為例，占國內(nèi)模具生產(chǎn)總量40%的沖壓模具，其制品覆蓋了汽車、電子、通訊、機(jī)械、電機(jī)電器、儀器儀表和家電等產(chǎn)品范圍，在汽車輕量化、新能源、自動化裝備、醫(yī)療器械、航空航天、節(jié)能減排等領(lǐng)域的模具發(fā)展勢頭強(qiáng)勁。級進(jìn)模的特點(diǎn)：1、級進(jìn)模是多任務(wù)序沖模，在一幅模具內(nèi)，可以包括沖裁，彎曲成型和拉伸等多種多道工序，具有很高的生產(chǎn)率。2、級進(jìn)模操作安全。3、易于自動化。4、可以采用高速沖床生產(chǎn)。5、可以減少沖床、場地面積，減少半成品的運(yùn)輸和倉庫占用。6、尺寸要求較高的零件不宜采用級進(jìn)模生產(chǎn)。
（2）研究狀況及其發(fā)展前景
近幾年來，我國模具技術(shù)有了很大發(fā)展，模具水平有了較大提高。體現(xiàn)在大型、精密、復(fù)雜、高效和長壽命模具方面。還有模具材料方面的技術(shù)進(jìn)步都很快，模具水平得以提高，模具國產(chǎn)化取得了可喜的成就。歷年來進(jìn)口模具不斷增長的勢頭有所控制，模具出口穩(wěn)步增長。1、沖模2、產(chǎn)品結(jié)構(gòu)、企業(yè)結(jié)構(gòu)等方面。3、產(chǎn)品水平。4、工藝裝備水平。當(dāng)前，我國工業(yè)生產(chǎn)的特點(diǎn)是產(chǎn)品品種多、更新快和市場競爭激烈。在這種情況下，用戶對模具制造的要求是交貨期短、精度高、質(zhì)理好、價(jià)格低。
因此，模具工業(yè)的發(fā)展的趨勢是非常明顯的。1、模具產(chǎn)品發(fā)展將大型化、精密化。2、多功能復(fù)合模具將進(jìn)一步發(fā)展。3、模具標(biāo)準(zhǔn)件的應(yīng)用將日漸廣泛。4、模具使用優(yōu)質(zhì)材料及應(yīng)用先進(jìn)的表面處理技術(shù)將進(jìn)一步受重視。5、在模具設(shè)計(jì)制造中將全面推廣CAD等技術(shù)。6、高速銑削加工將得到更廣泛的應(yīng)用。7、模具高速掃描及數(shù)字化系統(tǒng)將發(fā)揮更大的作用。8、模具自動加工系統(tǒng)的研制和發(fā)展。
研究內(nèi)容
沖壓級進(jìn)模是在條料的送料方向上，具有兩個(gè)以上的工位，并在壓力機(jī)一次行程中，在不同的工位上完成兩道或兩道以上的沖壓工序的沖模。它在一副模具上的不同區(qū)域完成多道沖壓成型工序的一種精密、高效、復(fù)雜的沖壓模具，在一副模具內(nèi)可以完成零件的沖裁、翻邊、彎曲、拉深、立體成形等工藝。
擬采取的研究方法、技術(shù)路線、實(shí)驗(yàn)方案及可行性分析
1沖裁的工藝性分析，包括結(jié)構(gòu)、尺寸、基準(zhǔn)及表面粗糙度的分析計(jì)算
2工藝方案的確定，包括工序的性質(zhì)、數(shù)目、順序及其種類組合，確定沖壓設(shè)備編寫沖壓工藝過程卡片。
3具體的計(jì)算分析，毛胚、排樣圖、搭邊值等具體的計(jì)算分析，計(jì)算是否合理。
4完成相關(guān)數(shù)據(jù)成形的圖形繪制。
實(shí)驗(yàn)完全由計(jì)算數(shù)據(jù)決定整套模具裝配圖及其零件圖的優(yōu)劣，完全以數(shù)據(jù)為依據(jù)進(jìn)行的實(shí)驗(yàn)分析，行之有效，對于整套設(shè)計(jì)有完整的設(shè)計(jì)思路，具體的設(shè)計(jì)計(jì)算完全可以通過查表或者公式書籍可以獲得，完全有可行性。
研究計(jì)劃及預(yù)期成果
研究計(jì)劃：
2012年11月12日-2012年12月2日：按照任務(wù)書要求查閱論文相關(guān)參考資料，填寫畢業(yè)設(shè)計(jì)開題報(bào)告書。
2012年12月3日-2013年3月1日：工作計(jì)劃、進(jìn)度。
2013年3月4日-2013年3月8日：查閱參考資料，學(xué)習(xí)并翻譯一篇與畢業(yè)設(shè)計(jì)相關(guān)的英文材料。
2013年3月9日-2013年4月12日：沖壓工藝設(shè)計(jì)，模具結(jié)構(gòu)設(shè)計(jì)，刃口尺寸和主要零件結(jié)構(gòu)設(shè)計(jì)和尺寸計(jì)算。
2013年4月13日-2013年5月3日：繪制模具裝配圖和零件圖。
2013年5月4日-2013年5月25日：工藝文件、畢業(yè)論文撰寫和修改工作。
預(yù)期成果：
1．完成模具裝配圖：1張（A0或A1）；
2．零件圖：主要非標(biāo)準(zhǔn)件零件圖（不少于5張）；
3．冷沖壓工藝卡片：1張；
4．設(shè)計(jì)說明書：1份；
5．翻譯8000以上外文印刷字符或譯出約5000左右漢字的有關(guān)技術(shù)資料或?qū)I(yè)文獻(xiàn)，內(nèi)容要盡量結(jié)合課題。
特色或創(chuàng)新之處
側(cè)彎支架冷沖壓工藝及級進(jìn)模設(shè)計(jì)改變以往的多個(gè)單個(gè)工藝加工，采用一步完成，不須再次進(jìn)行加工。落料，折彎等工藝之間存在各自偏差，一個(gè)工藝出現(xiàn)數(shù)據(jù)問題，則前面的數(shù)道加工完全報(bào)廢，后續(xù)加工沒辦法完成，致使嚴(yán)重影響產(chǎn)品的交期，嚴(yán)重影響企業(yè)經(jīng)濟(jì)效率。
采用冷沖壓工藝及級進(jìn)模設(shè)計(jì)，模具的設(shè)計(jì)和制造成為關(guān)鍵，只需對產(chǎn)品進(jìn)行初次多個(gè)檢驗(yàn)以及后期抽檢即可保證企業(yè)所生產(chǎn)出來產(chǎn)品的質(zhì)量，可大量的使用，極大的提高了生產(chǎn)效率，為企業(yè)的生產(chǎn)提供了強(qiáng)大的競爭力。側(cè)彎支架冷沖壓工藝及級進(jìn)模設(shè)計(jì)會在未來的市場上得到更多的應(yīng)用。
已具備的條件和尚需解決的問題
已具備的條件：
① 實(shí)驗(yàn)方案思路已經(jīng)非常明確，已經(jīng)具備落料、沖孔、翻遍連續(xù)模設(shè)計(jì)計(jì)算的基本知識及理論。
② 能夠使用相關(guān)三維軟件繪制裝配圖及其零件圖。
尚需解決的問題：
對設(shè)計(jì)的每個(gè)環(huán)節(jié)考慮不是很周全。連續(xù)模結(jié)構(gòu)因素設(shè)計(jì)連續(xù)模時(shí)，要準(zhǔn)確掌握加工速度、沖材材質(zhì)、沖壓力、工位數(shù)、模具間隙等各主要因素，否則就不能發(fā)揮模具的效用和綜合加工方法，特別是在高速沖壓精密件時(shí)，模具損傷多，工件精度低，得不到滿意效果。
指導(dǎo)教師意見
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見
教研室主任簽名：
年 月 日
系意見
主管領(lǐng)導(dǎo)簽名：
年 月 日
英文原文
1 Die position in industrial production
Mold is a high-volume products with the shape tool, is the main process of industrial production equipment.
With mold components, with high efficiency, good quality, low cost, saving energy and raw materials and a series of advantages, with the mold workpieces possess high accuracy, high complexity, high consistency, high productivity and low consumption , other manufacturing methods can not match. 已成為當(dāng)代工業(yè)生產(chǎn)的重要手段和工藝發(fā)展方向。 Have already become an important means of industrial production and technological development. 現(xiàn)代經(jīng)濟(jì)的基礎(chǔ)工The basis of the modern industrial economy.
The development of modern industrial and technological level depends largely on the level of industrial development die, so die industry to national economic and social development will play an increasing role. 1989 年 3 月國務(wù)院頒布的《關(guān)于當(dāng)前產(chǎn)業(yè)政策要點(diǎn)的決定》中，把模具列為機(jī)械工業(yè)技術(shù)改造序列的第一位、生產(chǎn)和基本建設(shè)序列的第二位 ( 僅次于大型發(fā)電設(shè)備及相應(yīng)的輸變電設(shè)備 ) ，確立模具工業(yè)在國民經(jīng)濟(jì)中的重要地位。 March 1989 the State Council promulgated "on the current industrial policy decision points" in the mold as the machinery industry transformation sequence of the first, production and capital construction of the second sequence (after the large-scale power generation equipment and the corresponding power transmission equipment), establish tooling industry in an important position in the national economy. 1997 年以來，又相繼把模具及其加工技術(shù)和設(shè)備列入了《當(dāng)前國家重點(diǎn)鼓勵(lì)發(fā)展的產(chǎn)業(yè)、產(chǎn)品和技術(shù)目錄》和《鼓勵(lì)外商投資產(chǎn)業(yè)目錄》。 Since 1997, they have to mold and its processing technology and equipment included in the "current national focus on encouraging the development of industries, products and technologies catalog" and "to encourage foreign investment industry directory." 經(jīng)國務(wù)院批準(zhǔn)，從 1997 年到 2000 年，對 80 多家國有專業(yè)模具廠實(shí)行增值稅返還 70% 的優(yōu)惠政策，以扶植模具工業(yè)的發(fā)展。 Approved by the State Council, from 1997 to 2000, more than 80 professional mold factory owned 70% VAT refund of preferential policies to support mold industry. 所有這些，都充分體現(xiàn)了國務(wù)院和國家有關(guān)部門對發(fā)展模具工業(yè)的重視和支持。 All these have fully demonstrated the development of the State Council and state departments tooling industry attention and support. 目前全世界模具年產(chǎn)值約為 600 億美元，日、美等工業(yè)發(fā)達(dá)國家的模具工業(yè)產(chǎn)值已超過機(jī)床工業(yè)，從 1997 年開始，我國模具工業(yè)產(chǎn)值也超過了機(jī)床工業(yè)產(chǎn)值。 Mold around the world about the current annual output of 60 billion U.S. dollars, Japan, the United States and other industrialized countries die of industrial output value of more than machine tool industry, beginning in 1997, China's industrial output value has exceeded the mold machine tool industry output.
According to statistics, home appliances, toys and other light industries, nearly 90% of the parts are integrated with production of chopsticks; in aircraft, automobiles, agricultural machinery and radio industries, the proportion exceeded 60%. 例如飛機(jī)制造業(yè)，某型戰(zhàn)斗機(jī)模具使用量超過三萬套，其中主機(jī)八千套、發(fā)動機(jī)二千套、輔機(jī)二萬套。 Such as aircraft manufacturing, the use of a certain type of fighter dies more than 30,000 units, of which the host 8000 sets, 2000 sets of engines, auxiliary 20 000 sets. 從產(chǎn)值看， 80 年代以來，美、日等工業(yè)發(fā)達(dá)國家模具行業(yè)的產(chǎn)值已超過機(jī)床行業(yè)，并又有繼續(xù)增長的趨勢。 From the output of view, since the 80's, the United States, Japan and other industrialized countries die industry output value has exceeded the machine tool industry, and there are still rising. 據(jù)國際生產(chǎn)技術(shù)協(xié)會預(yù)測，到 2000 年，產(chǎn)品盡件粗加工的 75% 、精加工的 50 ％將由模具完成；金屬、塑料、陶瓷、橡膠、建材等工業(yè)制品大部分將由模具完成， 50 ％以上的金屬板材、 80 ％以上的塑料都特通過模具轉(zhuǎn)化成制品。 Production technology, according to the International Association predicts that in 2000, the product best pieces of rough 75%, 50% will be finished mold completed; metals, plastics, ceramics, rubber, building materials and other industrial products, most of the mold will be completed in more than 50% metal plates, more than 80% of all plastic products, especially through the mold into.
模具的歷史發(fā)展 2 The historical development of mold
The emergence of mold can be traced back thousands of years ago, pottery and bronze foundry, but the large-scale use is with the rise of modern industry and developed.
The 19th century, with the arms industry (gun's shell), watch industry, radio industry, dies are widely used. 二次大戰(zhàn)后，隨著世界經(jīng)濟(jì)的飛速發(fā)展，它又成了大量生產(chǎn)家用電器、汽車、電子儀器、照相機(jī)、鐘表等零件的最佳方式。 After World War II, with the rapid development of world economy, it became a mass production of household appliances, automobiles, electronic equipment, cameras, watches and other parts the best way. 從世界范圍看，當(dāng)時(shí)美國的沖壓技術(shù)走在前列——許多模具先進(jìn)技術(shù)，如簡易模具、高效率模具、高壽命模具和沖壓自動化技術(shù)，大多起源于美國；而瑞士的精沖、德國的冷擠壓技術(shù)，蘇聯(lián)對塑性加工的研究也處于世界先進(jìn)行列。 From a global perspective, when the United States in the forefront of stamping technology - many die of advanced technologies, such as simple mold, high efficiency, mold, die and stamping the high life automation, mostly originated in the United States; and Switzerland, fine blanking, cold in Germany extrusion technology, plastic processing of the Soviet Union are at the world advanced. 50 年代，模具行業(yè)工作重點(diǎn)是根據(jù)訂戶的要求，制作能滿足產(chǎn)品要求的模具。 50's, mold industry focus is based on subscriber demand, production can meet the product requirements of the mold. 模具設(shè)計(jì)多憑經(jīng)驗(yàn)，參考已有圖紙和感性認(rèn)識，對所設(shè)計(jì)模具零件的機(jī)能缺乏真切了解。 Multi-die design rule of thumb, reference has been drawing and perceptual knowledge, on the design of mold parts of a lack of real understanding of function. 從 1955 年到 1965 年，是壓力加工的探索和開發(fā)時(shí)代——對模具主要零部件的機(jī)能和受力狀態(tài)進(jìn)行了數(shù)學(xué)分橋，并把這些知識不斷應(yīng)用于現(xiàn)場實(shí)際，使得沖壓技術(shù)在各方面有飛躍的發(fā)展。 From 1955 to 1965, is the pressure processing of exploration and development of the times - the main components of the mold and the stress state of the function of a mathematical sub-bridge, and to continue to apply to on-site practical knowledge to make stamping technology in all aspects of a leap in development. 其結(jié)果是歸納出模具設(shè)計(jì)原則，并使得壓力機(jī)械、沖壓材料、加工方法、梅具結(jié)構(gòu)、模具材料、模具制造方法、自動化裝置等領(lǐng)域面貌一新，并向?qū)嵱没姆较蛲七M(jìn)，從而使沖壓加工從儀能生產(chǎn)優(yōu)良產(chǎn)品的第一階段。 The result is summarized mold design principles, and makes the pressure machine, stamping materials, processing methods, plum with a structure, mold materials, mold manufacturing method, the field of automation devices, a new look to the practical direction of advance, so that pressing processing apparatus capable of producing quality products from the first stage.
Into the 70's to high speed, launch technology, precision, security, development of the second stage. 在這個(gè)過程中不斷涌現(xiàn)各種高效率、商壽命、高精度助多功能自動校具。 Continue to emerge in this process a variety of high efficiency, business life, high-precision multi-functional automatic school to help with. 其代表是多達(dá)別多個(gè)工位的級進(jìn)模和十幾個(gè)工位的多工位傳遞模。 Represented by the number of working places as much as other progressive die and dozens of multi-station transfer station module. 在此基礎(chǔ)上又發(fā)展出既有連續(xù)沖壓工位又有多滑塊成形工位的壓力機(jī)—彎曲機(jī)。 On this basis, has developed both a continuous pressing station there are more slide forming station of the press - bending machine. 在此期間，日本站到了世界最前列——其模具加工精度進(jìn)入了微米級，模具壽命，合金工具鋼制造的模具達(dá)到了幾千萬次，硬質(zhì)合金鋼制造的模具達(dá)到了幾億次 p 每分鐘沖壓次數(shù)，小型壓力機(jī)通常為 200 至 300 次，最高為 1200 次至 1500 次。 In the meantime, the Japanese stand to the world's largest - the mold into the micron-level precision, die life, alloy tool steel mold has reached tens of millions of times, carbide steel mold to each of hundreds of millions of times p minutes for stamping the number of small presses usually 200 to 300, up to 1200 times to 1500 times. 在此期間，為了適應(yīng)產(chǎn)品更新快、用期短 ( 如汽車改型、玩具翻新等 ) 的需要，各種經(jīng)濟(jì)型模具，如鋅落合金模具、聚氨酯橡膠模具、鋼皮沖模等也得到了很大發(fā)展。 In the meantime, in order to meet product updates quickly, with the short duration (such as cars modified, refurbished toys, etc.) need a variety of economic-type mold, such as zinc alloy die down, polyurethane rubber mold, die steel skin, also has been very great development.
From the mid-70s so far can be said that computer-aided design, supporting the continuous development of manufacturing technology of the times. 隨著模具加工精度與復(fù)雜性不斷提高，生產(chǎn)周期不斷加快，模具業(yè)對設(shè)備和人員素質(zhì)的要求也不斷提高。 With the precision and complexity of mold rising, accelerating the production cycle, the mold industry, the quality of equipment and personnel are required to improve. 依靠普通加工設(shè)備，憑經(jīng)驗(yàn)和手藝越來越不能滿足模具生產(chǎn)的需要。 Rely on common processing equipment, their experience and skills can not meet the needs of mold. 90 年代以來，機(jī)械技術(shù)和電子技術(shù)緊密結(jié)合，發(fā)展了 NC 機(jī)床，如數(shù)控線切割機(jī)床、數(shù)控電火花機(jī)床、數(shù)控銑床、數(shù)控坐標(biāo)磨床等。 Since the 90's, mechanical and electronic technologies in close connection with the development of NC machine tools, such as CNC wire cutting machine, CNC EDM, CNC milling, CNC coordinate grinding machine and so on. 而采用電子計(jì)算機(jī)自動編程、控制的 cNc 機(jī)床提高了數(shù)控機(jī)床的使用效率和范圍。 The use of computer automatic programming, control CNC machine tools to improve the efficiency in the use and scope. 近年來又發(fā)展出由一臺計(jì)算機(jī)以分時(shí)的方式直接管理和控制一群數(shù)控機(jī)床的 nNc 系統(tǒng)。 In recent years, has developed a computer to time-sharing by the way a group of direct management and control of CNC machine tools NNC system.
With the development of computer technology, computers have gradually into the mold in all areas, including design, manufacturing and management. 國際生產(chǎn)研究協(xié)會預(yù)測，到 2000 年，作為設(shè)計(jì)和制造之間聯(lián)系手段的圖紙將失去其主要作用。 International Association for the Study of production forecasts to 2000, as a means of links between design and manufacturing drawings will lose its primary role. 模具自動設(shè)計(jì)的最根本點(diǎn)是必須確立模具零件標(biāo)準(zhǔn)及設(shè)計(jì)標(biāo)準(zhǔn)。 Automatic Design of die most fundamental point is to establish the mold standard and design standards. 要擺脫過去以人的思考判斷和實(shí)際經(jīng)驗(yàn)為中心所組成的設(shè)計(jì)方法，就必須把過去的經(jīng)驗(yàn)和思考方法，進(jìn)行系列化、數(shù)值化、數(shù)式化，作為設(shè)計(jì)準(zhǔn)則儲存到計(jì)算機(jī)中。 To get rid of the people of the past, and practical experience to judge the composition of the design center, we must take past experiences and ways of thinking, for series, numerical value, the number of type-based, as the design criteria to the computer store. 因?yàn)槟＞邩?gòu)成元件也干差萬別，要搞出一個(gè)能適應(yīng)各種零件的設(shè)計(jì)軟件幾乎不可能。 Components are dry because of mold constitutes a million other differences, to come up with a can adapt to various parts of the design software almost impossible. 但是有些產(chǎn)品的零件形狀變化不大，模具結(jié)構(gòu)有一定的規(guī)律，放可總結(jié)歸納，為自動設(shè)計(jì)提供軟件。 But some products do not change the shape of parts, mold structure has certain rules, can be summed up for the automatic design of software. 如日本某公司的 CDM 系統(tǒng)用于級進(jìn)模設(shè)計(jì)與制造，其中包括零件圖形輸入、毛坯展開、條料排樣、確定模板尺寸和標(biāo)準(zhǔn)、繪制裝配圖和零件圖、輸出 NC 程序 ( 為數(shù)控加工中心和線切割編程 ) 等，所用時(shí)間由手工的 20% 、工時(shí)減少到 35 小時(shí)；從 80 年代初日本就將三維的 cad ／ cam 系統(tǒng)用于汽車覆蓋件模具。 If a Japanese company's CDM system for progressive die design and manufacturing, including the importation of parts of the figure, rough start, strip layout, determine the size and standard templates, assembly drawing and parts, the output NC program (for CNC machining Center and line cutting program), etc., used in 20% of the time by hand, reduce their working hours to 35 hours; from Japan in the early 80s will be three-dimensional cad / cam system for automotive panel die. 目前，在實(shí)體件的掃描輸入，圖線和數(shù)據(jù)輸入，幾何造形、顯示、繪圖、標(biāo)注以及對數(shù)據(jù)的自動編程，產(chǎn)生效控機(jī)床控制系統(tǒng)的后置處理文件等方面已達(dá)到較高水平；計(jì)算機(jī)仿真 (CAE) 技術(shù)也取得了一定成果。 Currently, the physical parts scanning input, map lines and data input, geometric form, display, graphics, annotations and the data is automatically programmed, resulting in effective control machine tool control system of post-processing documents have reached a high level; computer Simulation (CAE) technology has made some achievements. 在高層次上， CAD ／ CAM ／ CAE 集成的，即數(shù)據(jù)是統(tǒng)一的，可以互相直接傳輸信息． At high levels, CAD / CAM / CAE integration, that data is integrated, can transmit information directly with each other. 實(shí)現(xiàn)網(wǎng)絡(luò)化。 Achieve network. 目前． Present. 國外僅有少數(shù)廠家能夠做到。 Only a few foreign manufacturers can do it.
3我國模具工業(yè)現(xiàn)狀及發(fā)展趨勢 China's mold industry and its development trend
模具工業(yè)現(xiàn)狀 Die & Mould Industry Status
Due to historical reasons for the formation of closed, "big and complete" enterprise features, most enterprises in China are equipped with mold workshop, in factory matching status since the late 70s have a mold the concept of industrialization and specialization of production. 生產(chǎn)效率不高，經(jīng)濟(jì)效益較差。 Production efficiency is not high, poor economic returns. 模具行業(yè)的生產(chǎn)小而散亂，跨行業(yè)、投資密集，專業(yè)化、商品化和技術(shù)管理水平都比較低。 Mold production industry is small and scattered, cross-industry, capital-intensive, professional, commercial and technical management level are relatively low.
據(jù)不完全統(tǒng)計(jì)，全國現(xiàn)有模具專業(yè)生產(chǎn)廠、產(chǎn)品廠配套的模具車間（分廠）近17000家，約60萬從業(yè)人員，年模具總產(chǎn)值達(dá)200億元人民幣。 According to incomplete statistics, there are now specialized in manufacturing mold, the product supporting mold factory workshop (factory) near 17 000, about 600 000 employees, annual output value reached 20 billion yuan mold. 但是，我國模具工業(yè)現(xiàn)有能力只能滿足需求量的60％左右，還不能適應(yīng)國民經(jīng)濟(jì)發(fā)展的需要。 However, the existing capacity of the mold and die industry can only meet the demand of 60%, still can not meet the needs of national economic development. 目前，國內(nèi)需要的大型、精密、復(fù)雜和長壽命的模具還主要依靠進(jìn)口。 At present, the domestic needs of large, sophisticated, complex and long life of the mold also rely mainly on imports. 據(jù)海關(guān)統(tǒng)計(jì)，1997年進(jìn)口模具價(jià)值6.3億美元，這還不包括隨設(shè)備一起進(jìn)口的模具；1997年出口模具僅為7800萬美元。 According to customs statistics, in 1997 630 million U.S. dollars worth of imports mold, not including the import of mold together with the equipment; in 1997 only 78 million U.S. dollars export mold. 目前我國模具工業(yè)的技術(shù)水平和制造能力，是我國國民經(jīng)濟(jì)建設(shè)中的薄弱環(huán)節(jié)和制約經(jīng)濟(jì)持續(xù)發(fā)展的瓶頸。 At present the technological level of China Die & Mould Industry and manufacturing capacity, China's national economy in the weak links and bottlenecks constraining sustainable economic development.
1、模具工業(yè)產(chǎn)品結(jié)構(gòu)的現(xiàn)狀 3.1 Research on the Structure of industrial products mold
In accordance with the division of China Mould Industry Association, China mold is divided into 10 basic categories, which, stamping die and plastic molding two categories accounted for the main part. 按產(chǎn)值計(jì)算，目前我國沖壓模占50％左右，塑料成形模約占20％，拉絲模（工具）約占10％，而世界上發(fā)達(dá)工業(yè)國家和地區(qū)的塑料成形模比例一般占全部模具產(chǎn)值的40％以上。 Calculated by output, present, China accounts for about 50% die stamping, plastic molding die about 20%, Wire Drawing Die (Tool) about 10% of the world's advanced industrial countries and regions, the proportion of plastic forming die die general of the total output value 40%.
我國沖壓模大多為簡單模、單工序模和符合模等，精沖模，精密多工位級進(jìn)模還為數(shù)不多，模具平均壽命不足100萬次，模具最高壽命達(dá)到1億次以上，精度達(dá)到3～5um，有50個(gè)以上的級進(jìn)工位，與國際上最高模具壽命6億次，平均模具壽命5000萬次相比，處于80年代中期國際先進(jìn)水平。 Most of our stamping die mold for the simple, single-process mode and meet the molds, precision die, precision multi-position progressive die is also one of the few, die less than 100 million times the average life of the mold reached 100 million times the maximum life of more than accuracy 3 ~ 5um, more than 50 progressive station, and the international life of the die 600 million times the highest average life of the die 50 million times compared to the mid 80s at the international advanced level.
我國的塑料成形模具設(shè)計(jì)，制作技術(shù)起步較晚，整體水平還較低。 China's plastic molding mold design, production technology started relatively late, the overall level of low. 目前單型腔，簡單型腔的模具達(dá)70％以上，仍占主導(dǎo)地位。 Currently a single cavity, a simple mold cavity 70%, and still dominant. 一模多腔精密復(fù)雜的塑料注射模，多色塑料注射模已經(jīng)能初步設(shè)計(jì)和制造。A sophisticated multi-cavity mold plastic injection mold, plastic injection mold has been able to multi-color preliminary design and manufacturing. 模具平均壽命約為80萬次左右，主要差距是模具零件變形大、溢邊毛刺大、表面質(zhì)量差、模具型腔沖蝕和腐蝕嚴(yán)重、模具排氣不暢和型腔易損等，注射模精度已達(dá)到5um以下，最高壽命已突破2000萬次，型腔數(shù)量已超過100腔，達(dá)到了80年代中期至90年代初期的國際先進(jìn)水平。 Mould is about 80 million times the average life span is about, the main difference is the large deformation of mold components, excess burr side of a large, poor surface quality, erosion and corrosion serious mold cavity, the mold cavity exhaust poor and vulnerable such as, injection mold 5um accuracy has reached below the highest life expectancy has exceeded 20 million times, the number has more than 100 chamber cavity, reaching the mid 80s to early 90s the international advanced level.
2、模具工業(yè)技術(shù)結(jié)構(gòu)現(xiàn)狀 3.2 mold Present Status of Technology
Technical level of China's mold industry currently uneven, with wide disparities. 從總體上來講，與發(fā)達(dá)工業(yè)國家及港臺地區(qū)先進(jìn)水平相比，還有較大的差距。 Generally speaking, with the developed industrial countries, Hong Kong and Taiwan advanced level, there is a large gap.
在采用CAD/CAM/CAE/CAPP等技術(shù)設(shè)計(jì)與制造模具方面，無論是應(yīng)用的廣泛性，還是技術(shù)水平上都存在很大的差距。 The use of CAD / CAM / CAE / CAPP and other technical design and manufacture molds, both wide application, or technical level, there is a big gap between both. 在應(yīng)用CAD技術(shù)設(shè)計(jì)模具方面，僅有約10%的模具在設(shè)計(jì)中采用了CAD，距拋開繪圖板還有漫長的一段路要走；在應(yīng)用CAE進(jìn)行模具方案設(shè)計(jì)和分析計(jì)算方面，也才剛剛起步，大多還處于試用和動畫游戲階段；在應(yīng)用CAM技術(shù)制造模具方面，一是缺乏先進(jìn)適用的制造裝備，二是現(xiàn)有的工藝設(shè)備（包括近10多年來引進(jìn)的先進(jìn)設(shè)備）或因計(jì)算機(jī)制式（IBM微機(jī)及其兼容機(jī)、HP工作站等）不同，或因字節(jié)差異、運(yùn)算速度差異、抗電磁干擾能力差異等，聯(lián)網(wǎng)率較低，只有5%左右的模具制造設(shè)備近年來才開展這項(xiàng)工作；在應(yīng)用CAPP技術(shù)進(jìn)行工藝規(guī)劃方面，基本上處于空白狀態(tài)，需要進(jìn)行大量的標(biāo)準(zhǔn)化基礎(chǔ)工作；在模具共性工藝技術(shù)，如模具快速成型技術(shù)、拋光技術(shù)、電鑄成型技術(shù)、表面處理技術(shù)等方面的CAD/CAM技術(shù)應(yīng)用在我國才剛起步。 In the application of CAD technology design molds, only about 10% of the mold used in the design of CAD, aside from drawing board still has a long way to go; in the application of CAE design and analysis of mold calculation, it was just started, most of the game is still in trial stages and animation; in the application of CAM technology manufacturing molds, first, the lack of advanced manufacturing equipment, and second, the existing process equipment (including the last 10 years the introduction of advanced equipment) or computer standard (IBM PC and compatibles, HP workstations, etc.) different, or because of differences in bytes, processing sp