空調遙控器后殼體注塑模具設計,空調,遙控器,殼體,注塑,模具設計 模具的發(fā)展現狀及發(fā)展趨勢 1 模具簡介 模具是工業(yè)生產的基礎工藝裝備，已經取得了共識。模具生產技術水平的高低，已 成為衡量一個國家產品制造水平高低的重要標志，在很大程度上決定著產品的質量、效益和新產品的開發(fā)能力, 決定著一個國家制造業(yè)的國際競爭力.我國模具行業(yè)將向大型、精密、復雜、高效、長壽命和多功能方向發(fā)展。 塑料模具工業(yè)是隨塑料工業(yè)的發(fā)展而發(fā)展的。塑料工業(yè)是一門新興工業(yè)。自塑料問世后的幾十年以來，由于其原料豐富、制作方便和成本低廉，塑料工業(yè)發(fā)展很快，它在某些方面己取代了多種有色金屬、黑色金屬、水泥、橡膠、皮革、陶瓷、木材和玻璃等，成為各個工業(yè)部門不可缺少的材料。塑料模具的現代設計與制造和現代塑料工業(yè)的發(fā)展有極密切的關系。隨著塑料工業(yè)的飛速發(fā)展，塑料模具工業(yè)也隨之迅速發(fā)展。 在我國，隨著國民經濟的高速發(fā)展，模具工業(yè)的發(fā)展也十分迅速。2003年模具行業(yè)實現銷售收入162.03億元，比去年同期增長了41.57%；實現利潤總額為12.85億元，比去年同期增長了90.63%。我國模具行業(yè)得到了快速發(fā)展。從模具業(yè)規(guī)模上講，我國已經躍居世界第三位，僅次于日本和美國?？梢哉f我國已經成為模具生產大國，? 然而，就整個模具行業(yè)而言，大中型企業(yè)比較少，小型企業(yè)占絕大多數；與此同時，國內模具行業(yè)的企業(yè)存在著各種各樣的問題；與國外相關企業(yè)水平相比仍有很大的差距，因此國內企業(yè)不應當盲目樂觀，而應當努力發(fā)展、強壯自我，以應對來自各方面的挑戰(zhàn)。同時，把握住發(fā)展的機會，使我國早日成為模具的生產強國。 模具是制造業(yè)的重要工藝基礎，在我國，模具制造屬于專用設備制造業(yè)。中國雖然很早就開始制造模具和使用模具，但長期未形成產業(yè)。直到20世紀80年代后期，中國模具工業(yè)才駛入發(fā)展的快車道。近年，不僅國有模具企業(yè)有了很大發(fā)展，三資企業(yè)、鄉(xiāng)鎮(zhèn)（個體）模具企業(yè)的發(fā)展也相當迅速。據不完全統(tǒng)計，近10年全國（未含港、澳、臺統(tǒng)計數字，下同）模具生產及進出口發(fā)展情況如表1、表2的中國模具工業(yè)概況 表1 1995年以來中國歷年模具產值表 年份 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 產值（億元） 145 160 200 220 250 280 316 360 450 530 表2 1995年以來中國歷年模具進出口情況表 年份 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 進口（萬美元） 81100 91799 63000 66348 88274 97700 111174 127200 136930 181300 出口（萬美元） 4941 7000 9428 9591 13280 17374 18775 25234 33680 49100 由表可見，雖然中國模具工業(yè)發(fā)展迅速，但與需求相比，顯然供不應求，其主要缺口集中于精密、大型、復雜、長壽命模具領域。由于在模具精度、壽命、制造周期及生產能力等方面，中國與國際平均水平和發(fā)達國家仍有較大差距，因此，每年需要大量進口模具。 2 模具材料 根據成型方法和模具使用周期（即要生產的產品數量）的不同，塑料成型模具要滿足不同的需求，模具可以由多種材料制成，甚至于可以使比較特殊的材料如紙張和石膏。然而，由于大多數成型過程需要高壓，通常還有高溫條件限制，金屬迄今為止時最重要的材料，其中剛才居首位。很多時候，模具材料的選擇不僅關系到性能和最佳性價比，還影響到模具的加工方法，甚至是整體設計。 典型的例子是金屬鑄造模具的材料選擇，與機械加工模具相比，不同材料的金屬鑄造模具冷卻系統(tǒng)存在很大的差異。另外，不同的制造方法也會對材料的選擇產生影生產，原型模具的制造常常采用一些新技術，如計算機輔助設計和計算機集成制造，將固體毛配制成原型模具。與以前以模型為基礎的方法相比，用CAD和CIM方法會更經濟，這是因為這類模具廠家自身就能制作，而用其他技術，只能由外面的供應商來加工生產。 總之，雖然模具生產中經常會用到一些高性能材料，但用得最多的仍然是那些常規(guī)材料。像陶瓷這類高性能材料幾乎不能用于模具制造，這可能是因為其優(yōu)點（如高溫下性能不會改變）在模具中并不需要，相反，像燒結類陶瓷材料，具有低抗張強度和熱傳遞性差的缺點，在模具中也只有少量應用。這里所用的零件不是采用粉末冶金和熱等壓工藝生產，而是指燒結成的多空、透氣性零件。 在很多成型方法中，都必須將行腔中的氣體排出去，人們已經多次嘗試使用多孔金屬材料排氣。與專門設置的排氣裝置相比，其優(yōu)點是顯而易見的，尤其是在熔料前鋒處如有熔接線的地方，這里是最容易出現問題的區(qū)域：一方面能防止在制品表面有明顯的熔接線，還能避免溢流料等殘余物堵塞微孔。采用這類材料制造模具時，在設計和成型工藝上都會出現新的問題。 3 模具的發(fā)展趨勢 在現代機械制造業(yè)中,模具工業(yè)已成為國民經濟中的基礎工業(yè),許多新產品的開發(fā)和生產,在很大程度上依賴于模具制造技術,特別是在汽車、輕工、電子和航天等行業(yè)中尤顯重要。模具制造能力的強弱和模具制造水平的高低,已經成為衡量一個國家機械制造技術水平的重要標志之一,直接影響著國民經濟中許多部門的發(fā)展。模具CAD/CAM是在模具CAD和模具CAM分別發(fā)展的基礎上發(fā)展起來的,它是計算機技術在模具生產中綜合應用的一個新的飛躍。CAD/CAM技術的迅猛發(fā)展,軟件、硬件水平的進一步完善,為模具工業(yè)提供了強有力的技術支持,為企業(yè)的產品設計、制造和生產水平的發(fā)展帶來了質的飛躍,已經成為現代企業(yè)信息化、集成化、網絡化的最優(yōu)選擇。 ??? 中國模具產業(yè)除了要繼續(xù)提高生產能力，今后更要著重于行業(yè)內部結構的調整和技術發(fā)展水平的提高。結構調整方面，主要是企業(yè)結構向專業(yè)化調整，產品結構向著中高檔模具發(fā)展，向進出口結構的改進，中高檔汽車覆蓋件模具成形分析及結構改進、多功能復合模具和復合加工及激光技術在模具設計制造上的應用、高速切削、超精加工及拋光技術、信息化方向發(fā)展。 3.1 模具CAD/CAM技術發(fā)展趨勢 　　21世紀模具制造行業(yè)的基本特征是高度集成化、智能化、柔性化和網絡化,追求的目標是提高產品質量及生產效率,縮短設計周期及制造周期,降低生產成本,最大限度地提高模具制造業(yè)的應變能力,滿足用戶需求。具體表現出以下幾個特征。 （1）標準化　 CAD/CAM系統(tǒng)可建立標準零件數據庫,非標準零件數據庫和模具參數數據庫。標準零件庫中的零件在CAD設計中可以隨時調用,并采用GT(成組技術)生產。非標準零件庫中存放的零件,雖然與設計所需結構不盡相同,但利用系統(tǒng)自身的建模技術可以方便地進行修改,從而加快設計過程,典型模具結構庫是在參數化設計的基礎上實現的,按用戶要求對相似模具結構進行修改,即可生成所需要的結構。 （2）集成化技術　 現代模具設計制造系統(tǒng)不僅應強調信息的集成,更應該強調技術、人和管理的集成。在開發(fā)模具制造系統(tǒng)時強調“多集成”的概念,即信息集成、智能集成、串并行工作機制集成及人員集成,這更適合未來制造系統(tǒng)的需求?！　? 　 （3）智能化技術　 應用人工智能技術實現產品生命周期(包括產品設計、制造、使用)各個環(huán)節(jié)的智能化,實現生產過程(包括組織、管理、計劃、調度、控制等)各個環(huán)節(jié)的智能化,以及模具設備的智能化,也要實現人與系統(tǒng)的融合及人在其中智能的充分發(fā)揮。 　 （4）網絡技術的應用　 網絡技術包括硬件與軟件的集成實現,各種通訊協議及制造自動化協議,信息通訊接口,系統(tǒng)操作控制策略等,是實現各種制造系統(tǒng)自動化的基礎。目前早已出現了通過Internet實現跨國界模具設計的成功例子。 　 （5）多學科多功能綜合產品設計技術　 未來產品的開發(fā)設計不僅用到機械科學的理論與知識,而且還用到電磁學、光學、控制理論等知識。產品的開發(fā)要進行多目標全性能的優(yōu)化設計,以追求模具產品動靜態(tài)特性、效率、精度、使用壽命、可靠性、制造成本與制造周期的最佳組合。 （6）逆向工程技術的應用　 在許多情況下,一些產品并非來自設計概念,而是起源于另外一些產品或實物,要在只有產品原型或實物模型,而沒有產品圖樣的條件下進行模具的設計和制造以便制造出產品。此時需要通過實物的測量,然后利用測量數據進行實物的CAD幾何模型的重新構造,這種過程就是逆向工程RE(Reverse Engineering)。逆向工程能夠縮短從設計到制造的周期,是幫助設計者實現并行工程等現代設計概念的一種強有力的工具,目前在工程上正得到越來越廣泛的應用。 （7）快速成形技術　 快速成形制造技術RPM(Rapid Prototyping & Manufacturing)是基于層制造原理,迅速制造出產品原型,而與零件的幾何復雜程度絲毫無關,尤其在具有復雜曲面形狀的產品制造中更能顯示其優(yōu)越性。它不僅能夠迅速制造出原型供設計評估、裝配校驗、功能試驗,而且還可以通過形狀復制快速經濟地制造出產品模具(如制造電極用于EDM加工、作為模芯消失鑄造出模具等),從而避免了傳統(tǒng)模具制造的費時、高成本的NC加工,因而RPM技術在模具制造中日益發(fā)揮著重要的作用。 3.2 模具軟件功能集成化 ?模具軟件功能的集成化要求軟件的功能模塊比較齊全，同時各功能模塊采用同一數據模型，以實現信息的綜合管理與共享，從而支持模具設計、制造、裝配、檢驗、測試及生產管理的全過程，達到實現最佳效益的目的。如英國Delcam公司的系列化軟件就包括了曲面/實體幾何造型、復雜形體工程制圖、工業(yè)設計高級渲染、塑料模設計專家系統(tǒng)、復雜形體CAM、藝術造型及雕刻自動編程系統(tǒng)、逆向工程系統(tǒng)及復雜形體在線測量系統(tǒng)等。集成化程度較高的軟件還包括：Pro/ENGINEER、UG和CATIA等。 3.3 模具設計、分析及制造的三維化 ?? 傳統(tǒng)的二維模具結構設計已越來越不適應現代化生產和集成化技術要求。模具設計、分析、制造的三維化、無紙化要求新一代模具軟件以立體的、直觀的感覺來設計模具，所采用的三維數字化模型能方便地用于產品結構的CAE分析、模具可制造性評價和數控加工、成形過程模擬及信息的管理與共享。如Pro/ENGINEER、UG和CATIA等軟件具備參數化、基于特征、全相關等特點，從而使模具并行工程成為可能。另外，Cimatron公司的Mold expert，Delcam公司的Ps-mold及日立造船的Space-E/mold均是3D專業(yè)注塑模設計軟件，可進行交互式3D型腔、型芯設計、模架配置及典型結構設計。澳大利亞Mold flow公司的三維真實感流動模擬軟件Mold flow Advisers已經受到用戶廣泛的好評和應用。國內有華中理工大學研制的同類軟件HSC3D4.5F及鄭州工業(yè)大學的Z-mold軟件。面向制造、基于知識的智能化功能是衡量模具軟件先進性和實用性的重要標志之一。如Cimatron公司的注塑模專家軟件能根據脫模方向自動產生分型線和分型面，生成與制品相對應的型芯和型腔，實現模架零件的全相關，自動產生材料明細表和供NC加工的鉆孔表格，并能進行智能化加工參數設定、加工結果校驗等。 3.4 模具軟件應用的網絡化趨勢 ?? 隨著模具在企業(yè)競爭、合作、生產和管理等方面的全球化、國際化，以及計算機軟硬件技術的迅速發(fā)展，網絡使得在模具行業(yè)應用虛擬設計、敏捷制造技術既有必要，也有可能。美國在其《21世紀制造企業(yè)戰(zhàn)略》中指出，到2006年要實現汽車工業(yè)敏捷生產/虛擬工程方案，使汽車開發(fā)周期從40個月縮短到4個月。 3.5 模具標準化和技術化趨勢 近年，模具行業(yè)結構調整和體制改革步伐加大，主要表現在，大型、精密、復雜、長壽命、中高檔模具及模具標準件發(fā)展速度高于一般模具產品；塑料模和壓鑄模比例增大；專業(yè)模具廠數量及其生產能力增加；“三資”及私營企業(yè)發(fā)展迅速；股份制改造步伐加快等。 模具標準件的應用將日漸廣泛，模具標準化及模具標準件的應用能極大地影響模具制造周期。使用模具標準件不但能縮短模具制造周期，而且能提高模具質量和降低模具制造成本。同時，快速經濟模具的前景十分廣闊。由于人們要求模具的生產周期越短越好，因此開發(fā)快速經濟模具越來越引起人們的重視。例如研制各種超塑性材料來制作模具；用環(huán)氧、聚酯或在其中填充金屬、玻璃等增強物制作簡易模具。這類模具制造工藝簡單，精度易控制，收縮率較小，價格便宜，壽命較高。還可用水泥塑料制作汽車覆蓋件模具。中、低熔點合金模具，噴涂成型模具，電鑄模，精鑄模，層疊模，陶瓷吸塑模及光造型和使用熱硬化橡膠快速制造低成本模具等快速經濟模具將進一步發(fā)展?？鞊Q模架、快換沖頭等也將日益發(fā)展。另外采用計算機控制和機械手操作的快速換模裝置、快速試模裝置技術也會得到發(fā)展和提高。 我國模具行業(yè)要進一步發(fā)展多功能復合模具，一套多功能模具除了沖壓成型零件外，還擔負疊壓、攻絲、鉚接和鎖緊等組裝任務。通過這種多功能的模具生產出來的不再是成批零件，而是成批的組件，如觸頭與支座的組件、各種微小電機、電器及儀表的鐵芯組件等。多色和多材質塑料成形模具也將有較快發(fā)展。這種模具縮短了產品的生產周期，今后在不同領域將得到發(fā)展和應用。? 隨著熱流道技術的日漸推廣應用，熱流道模具在塑料模具中的比重將逐步提高。采用熱流道技術的模具可提高制件的生產率和質量，并能大幅度節(jié)約制件的原材料，這項技術的應用在國外發(fā)展很快，已十分普遍。國內熱流道模具也已經生產，有些企業(yè)已達30%左右，但總的來看，比例太低，亟待發(fā)展。隨著塑料成型工藝的不斷改進與發(fā)展，氣輔模具及適應高壓注射成型工藝的模具將隨之發(fā)展。 4 模具技術 模具技術集合了機械、電子、化學、光學、材料、計算機、精密監(jiān)測和信息網絡等諸多學科，是一個綜合性多學科的系統(tǒng)工程。模具技術的發(fā)展趨勢主要是模具產品向著更大型、更精密、更復雜及更經濟的方向發(fā)展，模具產品的技術含量不斷提高，模具制造周期不斷縮短，模具生產朝著信息化、無圖化、精細化、自動化的方向發(fā)展，模具企業(yè)向著技術集成化、設備精良化、產批品牌化、管理信息化、經營國際化的方向發(fā)展。 4.1 快速經濟制模技術 縮短產品開發(fā)周期是贏得市場競爭的有效手段之一。與傳統(tǒng)模具加工技術相比，快速經濟制模技術具有制模周期短、成本較低的特點，精度和壽命又能滿足生產需求，是綜合經濟效益比較顯著的模具制造技術，具體主要有以下一些技術。　 (1)快速原型制造技術(RPM)。它包括激光立體光刻技術(SLA) ；疊層輪廓制造技術(LOM) ；激光粉末選區(qū)燒結成形技術(SLS) ；熔融沉積成形技術(FDM) 和三維印刷成形技術(3D-P)等。 (2)表面成形制模技術。它是指利用噴涂、電鑄和化學腐蝕等新的工藝方法形成型腔表面及精細花紋的一種工藝技術。 (3)澆鑄成形制模技術。主要有鉍錫合金制模技術、鋅基合金制模技術、樹脂復合成形模具技術及硅橡膠制模技術等。 (4)冷擠壓及超塑成形制模技術。 (5)無模多點成形技術。 (6)KEVRON鋼帶沖裁落料制模技術。 (7)模具毛坯快速制造技術。主要有干砂實型鑄造、負壓實型鑄造、樹脂砂實型鑄造及失蠟精鑄等技術。 (8)其他方面技術。如采用氮氣彈簧壓邊、卸料、快速換模技術、沖壓單元組合技術、刃口堆焊技術及實型鑄造沖模刃口鑲塊技術等。 4.2 模具制造技術 在制造技術方面，首先是采用CAD/CAM技術，用計算機造型、編程并由數控機床加工己是主要手段，CAE軟件也得到應用。一般均采用內熱式或外熱式熱流道裝置。少數單位采用具有世界先進水平的高難度針閥式熱流道模具，完全消除了制件的澆口痕跡。氣體輔助注射技術已成功得到應用。在高效多色注射的應用和抽芯脫模機構的創(chuàng)新設計方面，也取得較大進展。在精度方面，塑件的尺寸精度可達IT6~7級，分型面接觸間隙為0.02~0.025mm，模板的彈性變形為0.05mm，分型面的表面粗糙度為Ra0.2μm ，塑料模壽命已達100萬次。 CAD/CAM/CAE技術的應用水平上了一個新臺階，以生產家用電器的企業(yè)為代表，陸續(xù)引進了相當數量的CAD/CAM系統(tǒng)，如美國EDS的UG II、美國Parametric Technology公司的Pro/Engineer、美國CV公司的CADS5、英國Deltacam公司的DOCT5、日本HZS公司的CRADE、以色列公司的Cimatron、美國AC-Tech公司的C-Mold及澳大利亞Moldflow公司的MPA塑模分析軟件等等。這些系統(tǒng)和軟件的引進，雖花費了大量資金，但在我國模具行業(yè)中，實現了CAD/CAM的集成，并能支持CAE技術對成型過程，如充模和冷卻等進行計算機模擬，取得了一定的技術經濟效益，促進和推動了我國模具CAD/CAM技術的發(fā)展。近年來，我國自主開發(fā)的塑料模CAD/CAM系統(tǒng)有了很大發(fā)展，主要有北航華正軟件工程研究所開發(fā)的CAXA系統(tǒng)、華中科技大學開發(fā)的注塑模HSC5.0系統(tǒng)及CAE軟件等，這些軟件具有適應國內模具的具體情況、能在微機上應用且價格較低等特點為進一步普及模具CAD/CAM技術創(chuàng)造了良好條件。 4.3 注射成型工藝技術 塑料注射成型技術是根據壓鑄原理從十九世紀末二十世紀初發(fā)展起來的,是目前塑料加工中最普遍采用的方法之一。該法適用于全部熱塑性塑料和部分熱固性塑料。在成形工藝方面，主要有沖壓模具功能復合化、超塑性成形、塑性精密成形技術、塑料模氣體輔助注射技術及熱流道技術、高壓注射成形技術等。另一方面，隨著先進制造技術的不斷發(fā)展和模具行業(yè)整體水平的提高，在模具行業(yè)出現了一些新的設計、生產、管理理念與模式。具體主要有：適應模具單件生產特點的柔性制造技術；創(chuàng)造最佳管理和效益的團隊精神，精益生產；提高快速應變能力的并行工程、虛擬制造及全球敏捷制造、網絡制造等新的生產哲理；廣泛采用標準件通用件的分工協作生產模式；適應可持續(xù)發(fā)展和環(huán)保要求的綠色設計與制造等。 注塑機的工作原理與打針用的注射器相似，它是借助螺桿（或柱塞）的推力，將已塑化好的熔融狀態(tài)（即粘流態(tài)）的塑料注射入閉合好的模腔內，經固化定型后取得制品的工藝過程。注射成型是一個循環(huán)的過程，每一周期主要包括：定量加料-熔融塑化-施壓注射-充模冷卻-啟模取件。取出塑件后又再閉模，進行下一個循環(huán)。 4.4 模具材料及表面處理技術 模具工業(yè)要上水平，材料應用是關鍵。因選材和用材不當，致使模具過早失效，大約占失效模具的45%以上。在模具材料方面，常用冷作模具鋼有CrWMn、Cr12、Cr12MoV和W6Mo5Cr4V2，火焰淬火鋼(如日本的AUX2、SX105V(7CrSiMnMoV)等；常用新型熱作模具鋼有美國H13、瑞典QRO80M、QRO90SUPREME等；常用塑料模具用鋼有預硬鋼(如美國P20)、時效硬化型鋼(如美國P21、日本NAK55等)、熱處理硬化型鋼(如美國D2，日本PD613、PD555、瑞典一勝白136等)、粉末模具鋼(如日本KAD18和KAS440)等；覆蓋件拉延模常用HT300、QT60-2、Mo-Cr、Mo-V鑄鐵等，大型模架用HT250。多工位精密沖模常采用鋼結硬質合金及硬質合金YG20等。在模具表面處理方面，其主要趨勢是：由滲入單一元素向多元素共滲、復合滲(如TD法)發(fā)展；由一般擴散向CVD、PVD、PCVD、離子滲入、離子注入等方向發(fā)展；可采用的鍍膜有：TiC、TiN、TiCN、TiAlN、CrN、Cr7C3、W2C等，同時熱處理手段由大氣熱處理向真空熱處理發(fā)展。另外，目前對激光強化、輝光離子氮化技術及電鍍(刷鍍)防腐強化等技術也日益受到重視。 4.5 我國模具行業(yè)共性技術 模具行業(yè)在“十二五”期間需要解決的重點關鍵技術應是模具信息化、數字化技術和精密、超精、高速、高效制造技術方面的突破。我國模具行業(yè)今后仍需提高的共性技術有： (1)建立在CAD/CAE平臺上的先進模具設計技術，提高模具設計的現代化、信息化、智能化、標準化水平。 (2)建立在CAM/CAPP基礎上的先進模具加工技術與先進制造技術相結合，提高模具加工的自動化水平與生產效率。 (3)模具生產企業(yè)的信息化管理技術。例如PDM（產品數據管理）、ERP（企業(yè)資源管理）、MIS（模具制造管理信息系統(tǒng)）及INTERMET平臺等信息網絡技術的應用、推廣及發(fā)展。 (4)高速、高精、復合模具加工技術的研究與應用。例如超精沖壓模具制造技術、精密塑料和壓鑄模具制造技術等。 (5)提高模具生產效率、降低成本和縮短模具生產周期的各種快速經濟模具制造技術。 (6)先進制造技術的應用。例如熱流道技術、氣輔技術、虛擬技術、納米技術、高速掃描技術、逆向工程、并行工程等技術在模具研究、開發(fā)、加工過程中的應用。 (7)原材料在模具中成形的仿真技術。 (8)先進的模具加工和專有設備的研究與開發(fā)。 (9)模具及模具標準件、重要輔件的標準化技術。 (10)模具及其制品的檢測技術。 (11)優(yōu)質、新型模具材料的研究與開發(fā)及其正確應用。 (12)模具生產企業(yè)的現代化管理技術。 5 存在問題和主要差距 雖然我國模具總量目前已達到相當規(guī)模，模具水平也有很大提高，但設計制造水平總體上落后于德、美、日、法、意等工業(yè)發(fā)達國家許多。當前存在的問題和差距主要表現在以下幾方面： (1)總量供不應求 國內模具自配率只有70%左右。其中低檔模具供過于求，中高檔模具自配率只有50%左右。 (2)企業(yè)組織結構、產品結構、技術結構和進出口結構均不合理 我國模具生產廠中多數是自產自配的工模具車間（分廠），自產自配比例高達60%左右，而國外模具超過70%屬商品模具。專業(yè)模具廠大多是“大而全”、“小而全”的組織形式，而國外大多是“小而?！?、“小而精”。國內大型、精密、復雜、長壽命的模具占總量比例不足30%，而國外在50%以上。2004年，模具進出口之比為3.7﹕1，進出口相抵后的凈進口額達13.2億美元，為世界模具凈進口量最大的國家。 (3)模具產品水平大大低于國際水平，生產周期卻高于國際水平 產品水平低主要表現在模具的精度、型腔表面粗糙度、壽命及結構等方面。 (4)開發(fā)能力較差，經濟效益欠佳 我國模具企業(yè)技術人員比例低，水平較低，且不重視產品開發(fā)，在市場中經常處于被動地位。我國每個模具職工平均年創(chuàng)造產值約合1萬美元，國外模具工業(yè)發(fā)達國家大多是15～20萬美元，有的高達25～30萬美元，與之相對的是我國相當一部分模具企業(yè)還沿用過去作坊式管理，真正實現現代化企業(yè)管理的企業(yè)較少。 造成上述差距的原因很多，除了歷史上模具作為產品長期未得到應有的重視，以及多數國有企業(yè)機制不能適應市場經濟之外，還有下列幾個原因： (5)國家對模具工業(yè)的政策支持力度還不夠 雖然國家已經明確頒布了模具行業(yè)的產業(yè)政策，但配套政策少，執(zhí)行力度弱。目前享受模具產品增值稅的企業(yè)全國只有185家，大多數企業(yè)仍舊稅負過重。模具企業(yè)進行技術改造引進設備要繳納相當數量的稅金，影響技術進步，而且民營企業(yè)貸款十分困難。 (6)人才嚴重不足，科研開發(fā)及技術攻關投入太少 模具行業(yè)是技術、資金、勞動密集的產業(yè)，隨著時代的進步和技術的發(fā)展，掌握并且熟練運用新技術的人才異常短缺，高級模具鉗工及企業(yè)管理人才也非常緊張。由于模具企業(yè)效益欠佳及對科研開發(fā)和技術攻關重視不夠，科研單位和大專院校的眼睛盯著創(chuàng)收，導致模具行業(yè)在科研開發(fā)和技術攻關方面投入太少，致使模具技術發(fā)展步伐不大，進展不快。 (7)工藝裝備水平低，且配套性不好，利用率低 近年來我國機床行業(yè)進步較快，已能提供比較成套的高精度加工設備，但與國外裝備相比，仍有較大差距。雖然國內許多企業(yè)已引進許多國外先進設備，但總體的裝備水平比國外許多企業(yè)低很多。由于體制和資金等方面的原因，引進設備不配套，設備與附件不配套現象十分普遍，設備利用率低的問題長期得不到較妥善的解決。 (8)專業(yè)化、標準化、商品化程度低，協作能力差 由于長期以來受“大而全”“小而全”影響，模具專業(yè)化水平低，專業(yè)分工不細致，商品化程度低。目前國內每年生產的模具，商品模具只占40﹪左右，其余為自產自用。模具企業(yè)之間協作不暢，難以完成較大規(guī)模的模具成套任務。模具標準化水平低，模具標準件使用覆蓋率低也對模具質量、成本有較大影響，特別是對模具制造周期有很大影響。 (9)模具材料及模具相關技術落后 模具材料性能、質量和品種問題往往會影響模具質量、壽命及成本，國產模具鋼與國外進口鋼材相比有較大差距。塑料、板材、設備性能差，也直接影響模具水平的提高。 6 模具行業(yè)發(fā)展規(guī)劃 目前，我國經濟仍處于高速發(fā)展階段，國際上經濟全球化發(fā)展趨勢日趨明顯，這為我國模具工業(yè)高速發(fā)展提供了良好的條件和機遇。一方面，國內模具市場將繼續(xù)高速發(fā)展，另一方面，模具制造也逐漸向我國轉移以及跨國集團到我國進行模具采購趨向也十分明顯。因此，放眼未來，國際、國內的模具市場總體發(fā)展趨勢前景看好，預計中國模具將在良好的市場環(huán)境下得到高速發(fā)展，我國不但會成為模具大國，而且一定逐步向模具制造強國的行列邁進?！笆濉逼陂g，中國模具工業(yè)水平不僅在量和質的方面有很大提高，而且行業(yè)結構、產品水平、開發(fā)創(chuàng)新能力、企業(yè)的體制與機制以及技術進步的方面也會取得較大發(fā)展。 根據“十二五”模具行業(yè)發(fā)展規(guī)劃，“十二五”期間模具產品發(fā)展重點主要有如下幾類： (1)汽車覆蓋件模具 沖壓模具占模具總量的40%以上。汽車覆蓋件模具主要為汽車配套，也包括為農用車、工程機械和農機配套的覆蓋件模具，它在沖壓模具中具有很大的代表性，模具大都是大中型，結構復雜，技術要求高。尤其是為轎車配套的覆蓋件模具，要求更高，可以代表沖壓模具的水平。此類模具我國已有一定的技術基礎，已為中檔轎車配套，但水平還不高，能力不足，目前滿足率只有一半左右。中高檔轎車覆蓋件模具主要依靠進口，已成為汽車發(fā)展的瓶頸，極大的影響著車型開發(fā)。 (2)精密沖壓模具 多工位級進模和精沖模代表了沖壓模具的發(fā)展方向，精度要求壽命要求極高，主要為電子工業(yè)、汽車、儀器儀表、電機電器等配套。這兩種模具，國內已有相當基礎，并已引進了國外技術及設備，個別企業(yè)生產的產品已達到世界水平，但大部分企業(yè)仍有較大差距，供應總量不足，進口很多。 (3)大型精密塑料模具 塑料模具占模具總量近40%，而且這個比例還在上升。塑料模具中為汽車和家電配套的大型注塑模具，為集成電路配套的塑封模，為電子信息產業(yè)和機械及包裝配套的多層、多腔、多材質、多色精密注塑模，為新型建材及節(jié)水農業(yè)配套的塑料異型材擠出模及管路和噴頭模具等，目前雖然已有相當技術基礎并正在快速發(fā)展，但技術水平與國外仍有較大差距，總量供不應求，每年的進口額達幾億美元。 (4)主要模具標準件 目前國內已有較大產量的模具標準件主要是模架、導向件、推桿推管、彈性元件等。這些產品不但國內配套大量需要，出口前景也很好，應繼續(xù)大力發(fā)展。氮氣缸和熱流道元件主要依靠進口，應在現有基礎上提高水平，形成標準并組織規(guī)?；a。 (5)其他高技術含量的模具 占模具總量給8%的壓鑄模具中，大型薄壁精密壓鑄技術含量高，難度大。鎂合金壓鑄模具目前雖然剛起步，但發(fā)展前景好，有代表性。子午線橡膠輪胎模具也是發(fā)展方向，其中活絡模技術難度最大。與快速成型技術相結合的一些快速制模技術及相應的快速經濟模具具有很好的發(fā)展前景。這些高技術含量的模具在“十二五”期間也應重點發(fā)展。? 7 模具行業(yè)發(fā)展對策 隨著國民經濟總量和工業(yè)產品技術的不斷發(fā)展，各行各業(yè)對模具的需求量越來越大，技術要求也越來越高。雖然模具種類繁多，但其發(fā)展重點應該是既能滿足大量需要，又有較高技術含量，特別是目前國內尚不能自給，需大量進口的模具和能代表發(fā)展方向的大型、精密、復雜、長壽命模具。模具標準件的種類、數量、水平、生產集中度等對整個模具行業(yè)的發(fā)展有重大影響。因此，一些重要的模具標準件也必須重點發(fā)展，而且其發(fā)展速度應快于模具的發(fā)展速度，這樣才能不斷提高我國模具標準化水平，從而提高模具質量，縮短模具生產周期，降低成本。由于我國的模具產品在國際市場上占有較大的價格優(yōu)勢，因此對于出口前景好的模具產品也應作為重點來發(fā)展。根據上述需要量大、技術含量高、代表發(fā)展方向、出口前景好的原則選擇重點發(fā)展產品，而且所選產品必須目前已有一定技術基礎，屬于有條件、有可能發(fā)展起來的產品特采取以下發(fā)展對策： (1)密切關注行業(yè)動態(tài)和政策導向，制定相應的對策。　 (2)依靠協會組織，結成共同聯盟，加強分工協作?！? (3)建立企業(yè)技術中心，走產學研聯合道路，提升自主創(chuàng)新能力?！? (4)打破行業(yè)界限，主動調整結構，面向新興模具市場，開拓新的業(yè)務領域?！? (5)加強人才培養(yǎng)，充分發(fā)揮人才在企業(yè)中的作用。 8　結語　　 ??? 經過這幾十年的發(fā)展,我國模具有了長足的發(fā)展,模具CAD/CAM技術已經被廣泛應用于我國企業(yè)。我國研制模具CAD/CAM軟件的開發(fā)水平也逐漸接近國外先進水平。在政府的大力支持下先后出現了一批先進的模具示范企業(yè),高校和企業(yè)也培養(yǎng)了一大批模具軟件開發(fā)及應用人才。但總的來說,我國目前模具軟件不管是從產品開發(fā)水平還是從商品化、市場化程度都與發(fā)達國家有不小的差距。模具技術水平還處于向高技術集成和向產業(yè)化商品化過渡的時期,研制的軟件在可靠性和穩(wěn)定性方面與國外工業(yè)發(fā)達國家的軟件尚有一些差距,還沒有針對性的軟件,使用一般都是通用性軟件。但是我們不但要看清我們的劣勢,也要看到我們的優(yōu)勢。與國外軟件相比我們的優(yōu)勢是:了解本國市場,便于提供技術支持,相對價格便宜等。另外,我們有政府的大力支持,各大高校也為CAD軟件的開發(fā)培養(yǎng)了大批的人才。在這些前提下,我國模具產業(yè)不僅要緊跟時代潮流,跟蹤國際最新動態(tài),遵守各種國際規(guī)范,形成自己獨特的優(yōu)勢,更要立足國內,結合國情,面向國內經濟建設的需要,開發(fā)出有自己特色,符合中國人習慣的CAD/CAM軟件。 12 Development situation and development trend of die ? 1? Die Introduction Mold is the basis for industrial production technology and equipment, consensus has been achieved. Mould production technology of high and low, Become an important symbol of national product manufacturing levels, to a large extent determine the quality of product, efficiency, and new product development capability, determine a country's international competitiveness in the manufacturing sector. China's mold industry will development to large, sophisticated, complex, high efficiency, long life span, and multi-functional direction. Plastic mould industry was developed along with the development of the plastics industry. Plastics industry is a new industry. Since the advent of plastic since decades, because of its rich, easy to make and low in cost of raw materials, plastics industry is developing rapidly, in some ways, it has been replaced by a variety of non-ferrous metals, ferrous metals, cement, rubber, wood, leather, ceramics and glass, become indispensable materials of various industrial sectors. Modern and contemporary in design and manufacturing of plastic mould plastic is very closely related to industrial development. With the rapid development of the plastics industry, plastic mould industry is rapidly developing. In our country, with the rapid development of the national economy, development of mold industry is very quickly. 2003 year mould industry sales 162.03 billion, over the same period last year increased by 41.57%; total profit to 12.85 billion, over the same period last year rose by 90.63%. China's mould industry has been rapid development. From the scale on the mould industry, China has leapt to third place in the world, second only to Japan and the United States. Can said in China has became die production powers, however, on entire die industry,, large and medium-sized enterprise comparison less, small enterprise accounted for most; Meanwhile, domestic die industry of enterprise exists with variety of problem; and abroad related enterprise level compared to still has is large of gap, so domestic enterprise does not should blind optimistic, and should efforts development, and strong self, to should from Parties surface of challenge. At the same time, to seize development opportunities, as the mould production of power as soon as possible. Mold is an important manufacturing base in China, mould manufacturing is dedicated device. China started to build mould and die very early, but in the long run do not form. Until 20 century 80 years later, China mould industry into the fast track of development. In recent years, not only the State-owned development of mould enterprises has been greatly, foreign-funded enterprises, towns (individual) very rapidly in the development of mould enterprises. Incomplete statistics show that nearly 10 years the country (not including Hong Kong, Macao, and Taiwan figures, the same below) mold production and import and export developments, such as table 1, table 2 China mould industry profiles ? Table 1 1995 Year over the die output table of China Year 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Value (billions of Yuan) 145 160 200 220 250 280 316 360 450 530 ? ? Table 2 1995 Year over the stencil in China since import and export tables Year 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Imports (USD) 81100 91799 63000 66348 88274 97700 111174 127200 136930 181300 Exports (USD) 4941 7000 9428 9591 13280 17374 18775 25234 33680 49100 ? Tables are visible, although China's mould industry has developed rapidly, but compared with the demand, clearly in short supply, its major gaps focused on precision, large-scale, complex, long-life areas of mold. Due to mould precision, long life, and production capacity of the manufacturing cycle, China and the international average, and is still a big gap between developed countries, therefore, need to import each year die. 2? Die Material Depending on the molding method and tool life cycle (that is, number of products manufactured by) different, plastic molding to meet different needs, molds can be made from a variety of materials, and even can make comparison of special materials such as paper and gypsum. However, because most of the molding process requires high pressures, usually also have high temperature conditions, so far the most important material of metal, which have topped. Most of the time, mould material choice is not only related to the performance and the best price/performance, also mould processing method, or even the whole design. A typical example is a metal casting mold material selection, compared with machined molds, different materials for metal casting mold cooling system there is a big difference. In addition, different manufacturing methods also can have a shadow on the choice of material production, manufacture of prototype tooling is often the use of new technologies, such as computer-aided design and computer-integrated manufacturing, solid preparation of prototype molds. Compared with the previous method based on the model of, CAD and CIM method will be more economical, this is because this type of mould manufacturers will be able to make itself, and other technologies, can only be processed by outside vendors. In short, while the mold is often used in high-performance materials, but most still are those of conventional materials. Almost cannot be used for high performance materials like ceramic molds, this may be because of its advantages (performance such as high temperature does not change) is not needed in a stencil, on the contrary, as a sintered ceramic material, has the disadvantage of low tensile strength and poor heat transfer, application and only a small amount of mold. Parts used here are not using hot press process and production of powder metallurgy, but fired into the air, and air permeability of parts. In many molding methods, you must use the tunes according to one ' s own understanding of gas discharge, there has been several attempts using porous metal exhaust. Compared to the exhaust and specifically set, its advantages are evident, especially in the melt forward like a melted wiring, here are the most prone to problem areas: on the one hand to prevent melting of surface there is a clear connection, allowing you to avoid overflow, and other remnants of plugging porous. With such material when you die, in design and new issues appear on the forming process. 3? Development trend of die In modern mechanical manufacturing , mould industry has become the basic industries of the national economy , many of the development and production of new products , to a large extent depend on the mold manufacturing technology , especially in the automobile industry, light industry, electronics and aerospace industries, such as especially important. Strength of mould manufacturing capabilities and moulds, high and low, has become one of the important measure of a national machinery manufacturing technology signs, directly affecting many sectors of the national economy development. Mould CAD/CAM is in die CAD and mould CAM developed on the basis of the development of, respectively, it is the application of computer technology in die and mold manufacturing a new leap forward. CAD/CAM the rapid development of technology , further improvement of the level of software, hardware , to mould industry has provided strong technical support , for the company's product design, manufacturing and development brought about a qualitative leap in production levels , has become a modern enterprise information, integration and optimal selection of networking. ??? Chinese mold industry, in addition to continuing to improve productivity, more focus on the adjustment of industry structure and raising the level of technology development. Structural adjustment, mainly to professional adjustment of enterprise structure, product mix towards the high-end tooling development, to the improvement of the structure of import and export, high-end analysis and structure improvement of automobile Panel die forming, multi-functional composite tooling and machining and the application of laser technology in mould design and manufacture, and super high speed cutting finishing and polishing technology, information technology development. 3.1 Mould CAD/CAM technology development trends 21 century of die and mold industry of basic characteristics is highly integrated, flexible and intelligent, networked , pursuit of the goals is to improve product quality and production efficiency , shorten the design cycle and manufacturing cycles , reduce production costs , maximize the responsiveness of die and mold manufacturing , To meet customer needs. We will show the following characteristics. (1) Standardized CAD/CAM system can establish a standard parts database, non-standard parts database and mould parameter database. Standard parts in the repository in CAD design parts can always accessible, and USES the GT (group technology) production. The standard parts library storage in parts, although and design in the required structure is not the same, but the use of the system itself modeling technology can easily be modified, so as to speed up the design process, the typical die structure in parametric design repository is the basis of the realized according to the request of users, die structure similar to modify, can generate need structure. (2)Integration technology Modern mold design and manufacturing system should not only emphasize information of integration, more should emphasize the integration of technology, and management. In the development of mould manufacturing system emphasize "much integration" concept, namely the information integration, intelligent integration, string of parallel mechanism of the integration and personnel integration, it is more suitable for the future of manufacturing system needs. (3) Intelligent technology Application of artificial intelligence technology to realize product life cycle (including product design, manufacture, use) each link intelligent, realize the production process (including organization, management, planning, scheduling, control, etc.) each link the intelligence of the intelligent equipment and mold, and to realize the integration of man and system and people in them intelligent of the full play. (4) Network technology application Network technology including hardware and software integration achieved, various communication protocol and manufacturing automation protocol, information communication interface, system operation control strategies, which is the basis of all kinds of manufacturing system automation. At present already appeared through the Internet realize across national borders the success of the die design example. (5) Multi-disciplinary and multi-function comprehensive product design technology The future product development design not only use mechanical scientific theory and knowledge, but also used electromagnetism, optical, control theory knowledge. The development of the product to the performance of multi-objective optimization design, mould products in pursuit of dynamic and static characteristic, efficiency, the precision and the service life, reliability, manufacturing costs and the best combination of manufacturing cycle. (6) The reverse engineering technology application In many cases, some products are not from design concept, but some other products from or physical, the only product prototype or physical model, and no product design under the condition of die design and manufacturing to make a product. This is a place for through the forms of measurement, and then the measurement data of the CAD models and physical structure again, this process is Reverse Engineering RE (Reverse Engineering). Reverse engineering can shorten the cycle of from design to manufacturing, is to help designers realized such modern concurrent engineering design concept of a powerful tool, currently in engineering is getting more and more widely. (7) Rapid forming technology Rapid Prototyping Manufacturing technology RPM (Rapid Prototyping & Manufacturing) is based on the principle of Manufacturing, Rapid Manufacturing a product prototype, and with parts of the geometry of the complex degree not least, especially in a complex curved surface to the shape of the product Manufacturing in can demonstrate its advantages. It not only to be able to quickly create prototype for design evaluation, assembly calibration, function test, and can also through the shape copy rapid economic to create products mould (such as manufacturing electrode for processing EDM, as punch mould casting out and disappear) so as to avoid the traditional mould manufacturing time consuming, the high cost of NC processing, thus RPM technology in mould manufacturing of increasingly played an important role. 3.2 Die software features integrated ?Die software features integrated requirements of functional modules of the software is complete, while the function module using the same data model, to achieve the integrated management and information sharing, to support the mold design, manufacture, Assembly, inspection, testing, and management of the entire process, achieve optimal efficiency purposes. United Kingdom Delcam company series of software including the surface / solid geometric modeling, rendering complex engineering drawing, industrial design, design expert system of plastic mold, complex body CAM, art and sculpture, reverse engineering system of automatic programming system and online measurement system of complex shapes. Higher degree of integration software include:Pro/ENGINEER, andUG and CATIA . 3.3 Mold design, analysis and manufacture of three-dimensional ?? ?? Traditional two-dimensional mold structure design has become increasingly unsuited to modern production and the integration of technical requirements. Mold design, analysis, fabrication of three dimensional, paper calls for new generation of die software to solid, intuitive feel to the design of the mold, using three dimensional digital model can be easily used in product structure of CAE analysis of manufacturability evaluation and numerical control machining, mold, forming process simulation and information management and sharing. Such as Pro / ENGINEER, UG and CATIA software with parameters, based on feature, all related to the characteristics, so that the mold concurrent engineering to become possible. In addition,Cimatron company Mold expert,Delcam company Ps-mold and Hitachi Space-E/mold is d professional injection mold design software, interactive d -shaped cavities, Core design, configuration and typical structure design of mould. Australia Mold flow simulation software company of three dimension realistic Mold flow Advisers has been widely praised by the user and the application. Huazhong University of Science and Technology in China developed similar software HSC3D4.5F and Zhengzhou University of technology Z-mold software. Manufacturing-oriented, knowledge-based intelligent function is a measure of software, one of the important symbols of the nature and relevance of the die. Cimatron injection molding experts of company software according to release automatically generate parting lines and parting surfaces, and products that correspond to the core and cavity, realize mould base parts, Automatic Bill of material and for NC machining drilling form, intelligent processing parameters setting, processing and results validation and so on. 3.4 Die software application networking trends ?? ??? As mold in Enterprise competition, cooperation, production and management of globalization and internationalization, as well as the rapid development of computer hardware and software technology, online agile manufacturing technology in die and mold industry application of virtual design, both necessary and also possible. United States in the21 century manufacturing enterprise strategy, pointed out that to 2006 years of auto industry agile production / virtual engineering solutions, the vehicle development cycle from 40 months to 4 months. 3.5 Die standardization and technical trend ??? In recent years, the mold industry structure adjustment and reform increased, mainly in, large, sophisticated, complex, long-life, high development faster than General mould of moulds and mould standard parts; plastic mold and die-scaled up; and productivity growth in the number of professional mold factory; "three-capital" and the rapid development of the private sector; joint-stock reform pace. ??? Die standard-applications will become more and more widespread, standardization of mold and mold standard parts can greatly influence the application of mould manufacturing cycle. Die standard-not only can reduce mold manufacturing cycles, and mold can improve quality and reduce tooling costs. At the same time, very broad prospects of rapid economic dies. As people require shorter production cycles, the better of molds, so rapid economic development die more and arouse people's attention. To create a mold for example development of superplastic; with epoxy, polyester, or in which the filler metal, glass and other enhancements make a simple mold. This type of mold manufacturing process is simple, precision control, less shrinkage, low price, high life. Also use a cement-plastic production of automobile Panel die. And low melting point alloy die in, spray molding, casting, precision casting, stacked die, ceramic vacuum forming mold and shape and low cost molds using heat hardening rubber rapid manufacturing, rapid economic dies will be further developed. Quick change die frame, quick change blow in first class are also growing. Quick die change equipment of computer control and robot operation, quick test mode device technologies will also be developed and improved. ??? China's mold industry to further develop the multifunctional complex moulds, apart from forming part of a multifunction die, also folding, locking, tapping, riveting and Assembly tasks. This versatile die are no longer mass produced parts, but a batch of components, such as contact and support components, various core components of micro-motors, electrical and instrument, and so on. The multi-color and multi-material plastic forming mold will also be rapid development. This mold to shorten the production cycle of the product, in different areas will be developed and applied in the future. Hot runner technology application, hot runner mould plastic mould's share will gradually increase. Hot runner technology mold can improve productivity and quality of products, substantial savings products and raw materials, application of this technology developed very rapidly in a foreign country, is very common. National hot runner molds are produced, some enterprises have reached about 30%, but in General, the ratio is too low and needs to be developed. With continuous improvement and development of plastic molding, gas assisted moulds and adapted to the high pressure injection molding process of mould will develop. 4? Mould technology Die collection of mechanical, chemical, optical, materials, electronics, computers, precision monitoring and information networks, and many other subjects, is a comprehensive multidisciplinary systems. Die technology of development trend main is die products towards more large, and more precision, and more complex and the more economic of direction development, die products of technology content constantly improve, die manufacturing cycle constantly shortened, die production towards information, and no figure of, and fine of, and automation of direction development, die Enterprise towards technology integrated of, and device excellent of, and production batch brand of, and management informati