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畢業(yè)設(shè)計 論文 開題報告 題目 加熱器底座塑料模具設(shè)計 系 別 機(jī)電信息系 專 業(yè) 機(jī)械設(shè)計制造及其自動化 班 級 姓 名 學(xué) 號 導(dǎo) 師 2012 年 12 月 24 日 1 畢業(yè)設(shè)計 論文 綜述 題目背景 研究意義及國內(nèi)外相關(guān)研究情況 1 1 題目背景與研究意義 我國塑料模工業(yè)從起步到現(xiàn)在 歷經(jīng)半個多世紀(jì) 有了很大發(fā)展 模具水平 有了較大提高 尤其是塑料模具發(fā)展速度將高于其它模具 在模具行業(yè)中的比例 將逐步提高 本設(shè)計題目涉及目標(biāo)均為工程實際零件 通過對塑件的實體測繪 完成基本參數(shù)的采集 然后運(yùn)用 塑料模具設(shè)計 塑料成型工藝 等知識 指導(dǎo) 學(xué)生利用 CAD 等軟件完成模具結(jié)構(gòu)的設(shè)計 并進(jìn)行相關(guān)的計算 本設(shè)計旨在鍛煉 學(xué)生在技術(shù)應(yīng)用能力上達(dá)到培養(yǎng)目標(biāo)的基本要求 在塑料成型工藝與塑料模具設(shè) 計技術(shù)方面得到全面提高 1 2 國內(nèi)外相關(guān)研究情況 塑料模具增長迅速 比重不斷提高 目前 塑料模具在整個模具行業(yè)中所占 比重約為 30 在未來模具市場中 塑料模具的發(fā)展速度將高于其他模具 模具 的精度將越來越高 10 年前精密模具的精度一般為 5 微米 現(xiàn)已達(dá)到 2 3 微米 1 微米精度的模具也將上市 多功能復(fù)合模具將進(jìn)一步發(fā)展 新型多功能復(fù)合模具 除了沖壓成型零件外 還擔(dān)負(fù)疊壓 攻絲 鉚接和鎖緊等組裝任務(wù) 對鋼材的性 能要求越來越高 熱流道模具在塑料模具中的比重也將逐漸提高 隨著塑料成型 工藝的不斷改進(jìn)與發(fā)展 氣輔模具及適應(yīng)高壓注塑成型等工藝的模具也將隨之發(fā) 展 標(biāo)準(zhǔn)件的應(yīng)用將日益廣泛 模具標(biāo)準(zhǔn)化及模具標(biāo)準(zhǔn)件的應(yīng)用將極大地影響模 具制造周期 還能提高模具的質(zhì)量和降低模具制造成本 快速經(jīng)濟(jì)模具的前景十 分廣闊 以塑代鋼 以塑代木的進(jìn)程進(jìn)一步加快 塑料模具的比例將不斷增大 由于機(jī)械零件的復(fù)雜程度和精度的不斷提高 對塑料模具的要求也越來越高 模 具技術(shù)含量將不斷提高 2 本課題研究的主要內(nèi)容和擬采用的研究方案 研究方法或措施 2 1 主要內(nèi)容 2 1 1 本設(shè)計是以工程實際零件 加熱器底座塑料模具設(shè)計為對象 用于電熱 器元件的固定支撐放置 該零件一邊有橫向側(cè)孔 必須考慮測抽芯機(jī)構(gòu)才能完成 因此需要學(xué)生充分運(yùn)用所學(xué)知識進(jìn)行模具結(jié)構(gòu)設(shè)計 2 1 2 確定模具的設(shè)計方案 進(jìn)行整體設(shè)計 2 1 3 主要部件設(shè)計計算及校核 2 1 4 繪制塑料件零件圖與模具裝配圖 2 1 5 編寫設(shè)計說明書 2 2 研究方法和步驟 本設(shè)計題目涉及目標(biāo)均為工程實際零件 通過對塑件的實體測繪 完成基本參數(shù) 的采集 然后運(yùn)用 注塑模具設(shè)計 塑料模具設(shè)計 塑料成型工藝 等知識 利 用 AutoCAD 和 Pro E 或 soildworks 等軟件完成模具結(jié)構(gòu)的設(shè)計 并進(jìn)行相關(guān)的校核計 算 完成包括選材熱處理 制造工藝規(guī)程 可行性分析等工作 本設(shè)計旨在鍛煉我們 在專業(yè)技術(shù)應(yīng)用能力上達(dá)到培養(yǎng)目標(biāo)的基本要求 在塑料成型工藝與塑料模具設(shè)計技 術(shù)方面得到全面提高 圖 1 加熱器底座零件圖 2 3 擬采用的研究方案 方案一 選用臥式注射機(jī) 壓塊加螺釘固定 澆注系統(tǒng)選用側(cè)澆口 方案二 選用立式注射機(jī) 螺釘固定 澆注系統(tǒng)選用點澆口 方案比較 臥式注射機(jī)適合于高速化生產(chǎn) 模具裝拆及調(diào)整容易 采用螺釘 加壓塊固定更加安全 側(cè)澆口形狀簡單 尺寸容易掌握 綜上所述 初步選用方 案一 3 本課題研究的重點及難點 前期已開展工作 3 1 本課題研究的重點及難點 此制品用于電熱器元件的固定支撐放置 制品材料為 ABS 丙烯腈 丁二 烯 苯乙烯共聚物 此材料有良好的耐化學(xué)腐蝕 表面硬度 加工性和染色性 制品的壁厚 熔料溫度對收縮率影響極小 ABS 有較強(qiáng)的抗沖擊強(qiáng)度 且在低溫 下也不迅速下降 ABS 有一定的硬度和尺寸穩(wěn)定性 易于成型加工 經(jīng)過調(diào)色可 配成任何顏色 此制品是批量生產(chǎn) 所以我將設(shè)計一套塑料成型模具 在設(shè)計模具時需要考 慮制品的一些特點 制品的主要特點是該零件一邊有橫向側(cè)孔 兩側(cè)有兩個上下 通孔 且上下孔形狀不規(guī)則 注塑時很復(fù)雜 塑件的尺寸精度有一定的要求 外 型需光潔不得有劃傷 總體尺寸大小適中 取塑件的最大截面為分型面 底座上 面的左右小孔和主體上左右相同的不規(guī)則通孔需要抽芯 開模后 塑件包緊動模 型芯的力比較大 采用推管推出 推出力比較平穩(wěn) 塑件不易發(fā)生變形 3 2 前期已開展工作 3 2 1 已簡單查閱了資料 對注塑模具設(shè)計的流程有了一定的了解 3 2 2 已對塑件結(jié)構(gòu)有了了解 并繪制了 CAD 圖 4 完成本課題的工作方案及進(jìn)度計劃 按周次填寫 第1周 查閱和收集資料 初步了解課題 第2 4周 塑件結(jié)構(gòu)分析與繪制 初步計劃了設(shè)計方案 完成開題報告 第5 8周 澆注系統(tǒng)等結(jié)構(gòu)的選擇和尺寸計算 完成中期報告 第9 12 周 繪制裝配圖及零件圖 第13 14 周 編寫論文 第15周 提交論文并進(jìn)行終期答辯 參考文獻(xiàn) 1 曹宏深 趙仲治主編 塑料成型工藝與模具設(shè)計 北京 機(jī)械工業(yè)出版社 1993 2 李秦蕊主編 塑料模具設(shè)計 西安 西北工業(yè)大學(xué)出版社 1995 3 洪慎章主編 實用注塑模具結(jié)構(gòu)圖集 化學(xué)工業(yè)出版社 2009 4 孫玲主編 塑料成型工藝與模具設(shè)計 清華大學(xué)出版社 2008 5 孫錫紅 我國塑料模具發(fā)展現(xiàn)狀及發(fā)展建議 期刊電加工與模具 2010 6 我國模具發(fā)展趨勢 期刊模具制造 2003 7 蔣繼宏 王效岳主編 注射模具典型結(jié)構(gòu) 100 例 中國輕工業(yè)出版社 2000 8 顏智偉主編 塑料模具設(shè)計與結(jié)構(gòu)設(shè)計 北京 國防工業(yè)出版社 2006 9 廖念釗 莫雨松 互換性與技術(shù)測量 M 中國計量出版社 2000 10 宋滿倉主編 注塑模具設(shè)計 北京 電子工業(yè)出版社 2010 11 王永平主編 注塑模具設(shè)計經(jīng)驗點評 機(jī)械工業(yè)出版社 3003 12 張中元編 塑料成型工藝與模具設(shè)計 北京 航空工業(yè)出版社 2005 13 徐進(jìn)編 模具材料應(yīng)用手冊 北京 機(jī)械工業(yè)出版社 2008 14 Mita T Yamaguchi T Kashiwase T and Kawase T Realization og speed biped using modern control theory Int J Control 1984 40 107 119 15 Eldukhri E E Design and control of a biped walking robot phD thesis Department of Electronic and Electrical Engineering Univerity of Salford UK 16 Medrano Xenda G A and Eldukhri E E Biped robot locomotiong in the sagittal plane Trans Trans Inst Mcasmt and Control 1997 19 38 49 5 指導(dǎo)教師意見 對課題的深度 廣度及工作量的意見 指導(dǎo)教師 年 月 日 6 所在系審查意見 系主管領(lǐng)導(dǎo) 年 月 日 畢業(yè)設(shè)計 論文 中期報告 題目 加熱器底座塑料模具設(shè)計 系 別 機(jī)電信息系 專 業(yè) 機(jī)械設(shè)計制造及其自動化 班 級 姓 名 學(xué) 號 導(dǎo) 師 2013 年 3 月 20 日 1 設(shè)計 論文 進(jìn)展?fàn)顩r 1 1 本次設(shè)計的塑料件為一長方形半封閉樣式的加熱器底座 產(chǎn)品特點為 底座必須 棱廓分明且外表面光滑 底部有兩個空心圓柱 頂部有兩個不規(guī)則柱孔且對稱分布 兩 側(cè)壁有圓孔 分模時要考慮側(cè)向抽芯 最后要求外表無明顯澆口痕跡 座體內(nèi)部不規(guī)則 柱體要求與側(cè)壁之間光滑過度 在結(jié)構(gòu)設(shè)計時需整體考慮模具的合理性 圖 1 加熱器底座零件二維圖 圖 2 加熱器底座零件三維圖 1 2 在開題的基礎(chǔ)上進(jìn)行了部分零件的計算和設(shè)計 已調(diào)整了結(jié)構(gòu)方案 修改了零件 圖的不合理結(jié)構(gòu) 并進(jìn)一步的完成了模具裝配草圖的繪制 1 3 通過計算塑料件的體積及查閱相關(guān)模具設(shè)計手冊完成了注塑機(jī)的選擇 選型為 G54 S 200 400 型 相關(guān)參數(shù)如下 理論注射量 200 400cm 3 最大注射面積 645cm 2 最大模具厚度 406mm 鎖模力 2540KN 最小模具厚度 165mm 定位孔直徑 125mm 模板行程 260mm 拉桿空間 290 368mm 噴嘴球半徑 18mm 噴嘴孔徑 4mm 1 4 確定主流道 分流道的形式和尺寸 其澆口套的尺寸如圖 3 所示 分流道截面形狀及尺寸如圖 4 所示 圖 3 澆口套形式與尺寸 圖 4 分流道截面形狀 1 5 確定模腔數(shù)量及其排列方式 澆口形式 加熱器底座的尺寸不太大 為了降低注射成本 根據(jù)所選注塑機(jī)的注射量 采用一 模兩型腔的模具 為了滿足較高的外觀要求 確定采用側(cè)澆口 其選用的側(cè)澆口結(jié)構(gòu)形 式如圖 5 所示 圖 5 側(cè)澆口結(jié)構(gòu)形式 1 6 計算并校核型腔部分的強(qiáng)度和剛度 根據(jù)圓形端蓋的高度確定型腔板的側(cè)壁厚度 型芯固定板的厚度 并確動模板 頂出板 支塊厚度及其模具安裝方法 1 7 完成了對模具工作部分尺寸進(jìn)行設(shè)計計算 1 8 完成了模具零件結(jié)構(gòu)設(shè)計 比如 導(dǎo)柱 導(dǎo)套 拉料桿 復(fù)位桿 頂 桿 滑塊 推板導(dǎo)柱導(dǎo)套等等 1 9 初步繪制模具裝配圖如圖 6 所示 圖 6 模具裝配圖 注 1 正文 宋體小四號字 行距 22 磅 標(biāo)題 加粗 宋體四號字 2 中期報告由各系集中歸檔保存 不裝訂入冊 2 存在問題及解決措施 2 1 未考慮到模具冷卻問題 解決措施 在模具內(nèi)添加了冷卻系統(tǒng) 2 2 中間型芯的固定存在問題 未限制周向轉(zhuǎn)動 解決措施 在老師的指導(dǎo)下 查閱了相關(guān)手冊 在動模固定板和型芯的交界處安裝 騎縫螺釘 防止其周向轉(zhuǎn)動 3 后期工作安排 12 周 13 周 完善模具結(jié)構(gòu)裝配圖 并完成所有零件圖的繪制工作 14 周 15 周 完成模具零件的選材 工藝規(guī)程的編制 16 周 17 周 對所有圖紙進(jìn)行校核 編寫設(shè)計說明書 所有資料提請指導(dǎo)教師檢 查 18 周 準(zhǔn)備答辯 指導(dǎo)老師簽字 年 月 日 1 外文翻譯 Treating and the modern mould make high speed One summarizes 1 the present situation that the mould makes at present and trend The mould is important handicraft equipment occupies decisive position in industrid departments such as consumer goods electrical equipment electron automobile aircraft fabrication The mould is important handicraft equipment occupies decisive position in industrid departments such as consumer goods electrical equipment electron automobile aircraft fabrication Industrial product part rough process 75 the finish machining 50 and plastic part 90 will be completed from the mould The Chinese mould market demand already reaches scale of 500 hundred million yuan at present The automobile mould the annual growth rate covering piece of mould especially will exceed 20 Also prompt building material mould development various heterotype material the mould wall surface and floor mould become new mould growth point plastic doors and windows and plastic drain pipe increase to exceeding 30 by in the upcoming several years The home appliance mould annual growth rate will exceed 10 The IT industry year increases speed equally exceeding 20 the need to the mould accounts for 20 of mould marketplace 2004 annual Chinese machine tools implements industry output value will continue to increase Our country mould fabrication market potential is enormous The basis data counts in recent years our country mould year gross output value reaches 3 billion U S dollar entrance exceeds 1 billion U S dollar exceed 100 million U S dollar outlet Increase by from 25 to increase to 2005 50 of 1995 The expert foretells that abroad Asia portion being occupied by in mould fabrication in the whole world will from 25 to increase to 2005 50 of 1995 Chinese mould industry has been expanding by leaps and bounds has formed east China and two big South China bases and has expanded gradually arriving at other province In 2002 Shandong Anhui Sichuan in 1996 mould manufacturing industry output value annual average growth 14 grows by 25 in 2003 In 2003 our country mould output value is 45 billion RMB The gross product place occupies the world the 3rd exports a mould increases 33 5 compared to last year 336 800 000 U S dollar But contents low our country technology moulds already pile up in excess of requirement very most support of accurate complicated top grade mould imports Every year the entrance mould exceeds 1 billion U S dollar Exceed 100 million U S dollar outlet Precise mould accuracy requires that 3 mu ms large scale moulds require that 8000 satisfied kN agree well with model force injection machine request in 2 The minitype mould needs the request satisfying the diameter 1 mm silent stock tube At present adopt quick cutting to produce a mould already becoming the general trend that the mould makes a few moulds have produced a manufacturer in abroad high speed machine tool large area has substituted the electric spark machine tool quick cutting has improved the mould efficacy greatly Machine tool enterprise aims at mould manufacturing enterprises some treating centres 60 all above of the machine tool producing a factory sells treating enterprise to a mould The mould fabrication enterprise substituting the electric spark finish machining mould gradually in abroad has adopt quick cutting already commonly quick cutting has produced a mould already becoming the general trend that the mould makes gradually has improved the mould efficacy and mass greatly Adopt quick cutting to replace electric spark producing a mould can get on the stick obviously improves mould accuracy life time growing 2 high speed processes application in making in the mould 2 1 quick cutting merit 1 cutter high rotation rate and the machine tool height enter be given to and high acceleration improve metal excision rate greatly 2 2 quick cutting diminutions cut a force 3 quick cutting heat major part generate heat from the cuttings entrainment workpiece being short 4 quick cutting cut down vibration improve treating mass 2 2 high speed treating apply to the beneficial result that the mould processes 1 fleetness rough process and half finish machining improve treating efficiency 2 high speed high accuracy finish machining replace only entire the height processing indicating mass form accuracy rise 50 cuts down repair a mill by hand than EDM processes a potentiation 3 cuts the surface processing final molding stiffly improve surface mass form accuracy the treating not only being that surface harshness is low and the surface radiance is high being used for complicated surface has more advantage 4 the surface loss that EDM treating produces improve mould life span 20 5 processes an electrode rapidly combining with the CAD CAM technology especially the form is complicated thin wall is similar to an electrode 3 adopt quick cutting to process a mould needing the problem solving In in the homeland since the aspect cause such as fund technology the quick cutting applying produce a mould be in the initial stage stage Return the machine tool cutter handicraft back to existence as well as some problem of aspect needs to proceed orderly other solve The shortcoming is that finished cost is high correct cutter sigmatism have comparatively high demand can not have used big cutters need to have the complicated computer programming technology to be used for support equipment running cost height Two the high speed processing a mould s processes a machine tool Mould finish machining and hard cutting treating require that the numerical control high speed machine tool form board model put up the precision processing need high effect numerical control machine tool etc The mould aiming at produces a lot of machine tool enterprise some treating centres 60 all above of the machine tool producing a factory sells enterprise to a mould The fixed assets having 5 billion yuan without exception in the upcoming several years throws into mould industry 80 is the machine tool buying a mould process equipment just saying every year having 4 billion yuan of RMB to buy Jinqie among them At present average our country numerical control machine tool utilization ratio approximately 20 the high speed machine tool utilization ratio 3 5 Also mould enterprise has the unit suitable to buy a high speed machine tool complies with 6000 40000 rmp s to have 1 high speed machine tool technology parameter demands Process centre chief axis high power high rotation rate satisfied rude finish machining The finish machining mould wants to need to reach 15000 20000 rmp like the cutter the machine tool with minor diameter Generally the chief axis rotation rate machine tool under 10000 rpm can carry out rough process and half finish machining cannot reach the finish machining accuracy Have no way to reach 400 the above m min cutting speed 2 five scrolls of machine tools application increases a trend 1 treating route is nimble the surface form is complicated 2 treating range is big the various type mould suitable processes 3 cuts life span of condition easy to cut down cutter wear to raise a cutter 3 the softwares buying CAD CAM and high speed machine tools assort On the grounds of the machine tool major part counting having several billions U S dollar to be used to enter port every year the electromachining machine tool and the high speed machine tool need to import Three quick cutting mould cutter technology 3 Quick cutting processes the cutter needing allocating proper quick cutting Progressing processing cutter material s in high speed has urged development of high speed treating The cutter knife edge headquarter and high tenacity base gathering crystal strengthening the ceramics cutter being able to be used giving consideration to high hardness experience and observe carbide alloy coating becoming possibility Gather the crystal cube nitriding boron PCBN bit whose hardness may amount to 3500 4500 HV Gather crystal miamond PCD it s hardness but amount to 6000 10000 HV Germany SCS Japan Mitsubishi magical steel and Sumitomo Switzerland Shanteweike USA Kenna are in recent years swiftly large wait for the famous abroad cutter company to successively have debuted the respective quick cutting cutter not only cutter having average structural steel of quick cutting the ceramics cutter still having direct quick cutting of energy quenching hard steel is waiting for an effect to surpass the hard cutter especially the coating cutter appears all of a sudden bringing into play in quenching half finish machining and finish machining of hard steel New cutter material and cutter technology appearing already make the bottleneck problem that high speed has processed no longer be able to appear on the cutter But expensive entrance cutter price also blocks quick cutting mould key factor Above to come to saying the cutter and the cutter holder acceleration reach 3 gs the sort the cutter circular runout needs to be smaller than 0 015 mm but the knife length is unable greater than 4 times cutters diameter The reality according to SANDVIK company has counted the carbide alloy has stood on in the entirety using carbon nitriding titanium TICN coating when milling cutters 58 HRC carry out high speed bright metal chopping rough process cutter linear speed has been 100 m min about whose linear speed has exceeded but 280 m min when finish machining and microstoning Such demands to cutter material include the hardness tenacity red hardness keep the form include row of crumbs function surface accuracy dynamic balance sex etc cutting the function the cutter under high temperature state as well as cutter life span all has very highly Experience according to in the homeland mould high speed finish machining linear speed has exceeded 400 800 m min when adopt the young diameter ball head milling cutter to carry out mould finish machining The machine tool choosing sufficient high speed s cuts mould finish machining stiffly Delcam adopt 0 8 mm diameter cutter to process the narrow slot rotation rate 40000 rpm 0 1 mm depth feed speed 30 m min 1 chooses the cutter parameter the cutter waits if shouldering an anterior angle The cutter requires that the ability processing request shock resistance tenacity more highly requiring that heat resistance pounds than average is strong 2 adopts various method improving cutter life span reduces cutter cost 3 adopt the high speed hilt HSK hilt heat pressing applying the most being at present to pretend to grip a cutter Pay attention to a cutter pretend to grip overall in the day afer tomorrow dynamic balance 4current cutter enterprise has already done many jobs in the field of the technology resolving the quick cutting cutter serving facing the cutter processing may help to solve much problem the cutter has produced a manufacturer becoming the main body the reference cutter has produced the technology parameter that the manufacturer provides Four improve quick cutting mould efficiency technology 1 cutter diameter and the length choice 2 HSM and the EDM choice 3 does cutting and the lubricating cooling 4 feeds choice Move forward generally giving amounts milling cutter diameters 10 move forward giving a width milling cutter diameter 40 According to material condition chooses the parameter processing handicraft rationally High speed bright metal cuts the mass processing part material abroad fairly good material quality level is 4 identical the treating function comparison is stable But the cutter that the company produces abroad is also that the standard makes an experiment with their material The treating being recommended by is suitable to their standard comparatively like the parameter material quality has the certain difference with domestic part this difference shows comparatively obviously some parameters can apply directly but some effect dispatches right away comparatively during the period of high speed bright metal chops if using their cutter But select and use part material quality in the homeland like enterprise having the certain standard what be put into use part material can use the part material quality that high speed processes especially the general meeting is limited in some part material range inner that this applies the high speed processing technology to us has also provided advantageous condition has been able to apply to less treating material within range Being needing to emphasize that here must choose the treating technological parameter optimizing out a set of capital suitable enterprise on these material is brought into company standard and The technology selecting and using the domestic cutter seldom having the bright metal recommending high speed to chop parametric is necessary making an experiment get the comparatively satisfied parameter produce a manufacturer had better to select and use the fixed cutter cut down the number of times testing that the standard forming a processing technology such can improve effective utilization ratio of equipment lowers production costs can get the fairly good economic effect Five quick cutting route processing a cutter and programming 1 flat surface feeds the route choice 2 2 outlines process the route choice 3 Keep cutting loading stable 4 keeps relatively stable moving forward giving amounts and feed speed 5 keeps the garden corner in flat surface cutting 6 chooses the finish machining margin rationally Programming demand of HSC finish machining to CAM 1 the bright metal avoiding a corner to the full cuts motion 2 tries one s best to avoid external feed of workpiece and enter next depth return knife motion direct from the outline Or adopt a helical line or being sure enter slanting to moving forward 3 constant each edge feed improve the quality prolongs cutter life span 4 outline treating are kept waiting in level surface Quick cutting CAM software Several years ago will have started quick cutting processing programming technology research the Delcam company has developed the quick cutting automation programming software module Lately the MasterCAM company has also developed the quick cutting automation programming software module You also are in in the homeland north navigation developing the quick cutting automation programming software module Six high speed machine tool numerical control system characteristic 1 high speed data is processed 2 corner forecasts are handled 3 NURBS are not justified appearance strip runin curve treating Seven safe quick cutting mould problem 1 Monitoring wearing a cutter away and destroying 2 Intensity that the bit links 3 Strict with the machine tool and the cutter examination is very important and before the average machine tool processing diversity safety protects and starts up Eight there exists problem in our country at present in adopt high speed to process the mould technology 1 machine tool 5 1 domestic high speed machine tool overall function still has the gap the function component function to be able to not satisfy a request Power and rotation rate including the electricity chief axis entrance machine tool price is high 2 Under the machine tool high speed the dynamic behaviour studies the function being not enough to affect a complete machine as a result 3 The five scroll of machine tool is not enough mature entrance machine tool price is very high 4 supporting technology and equipment are fairly incomplete 2 cutters 1 domestic cutter is not able to adapt to the quick cutting application high speed cuts only entire treating especially stiffly Entrance cutter price is high The cutter technology is to affect quick cutting processing a key factor of mould 2 supporting technologies are not enough to include hilt online dynamic balance in complete set etc 3 high speed moulds process the technology and the experiment 1 Be short of the accumulation applying experience since high speed processes the mould history comparatively shortly 2 The comparison studying comparison stops throwing into lack sets up a project to quick cutting handicraft is difficult 3 Be short of the quick cutting data base or the handbook is still blank space at present 4 moulds produce the manufacturer cognition lack to quick cutting the analysis contrast being short of long range beneficial result 4 Be short of the quick cutting automation programming software 5 Be short of a five scroll of gear quick cutting automation programming CAM software Concluding remark The mould marketplace has the intense need but technology to be unable to keep abreast with to high speed treating Starting is late the basis is relatively poor overall engineering level not being taller than develops slowlyRequire that one by one aspect coordinated growth the product mimic inkstone throwing into combining with enlarging each comprehensive utilization aspect strengths drive quick cutting application in making in the mould Our hope effort passing every aspect before the market demand push go down pass technological progress look like automobile machine tool home appliance before long not only our country being going to become a mould producing Great Power and be going to become a mould producing the powerful country References 1 Jin Diecheng Song Fangzhi The modern mould makes the technology Beijing Mechanical industry press 2001 2 Xu Hefeng The digitization mould makes the technology Beijing Chemical industry press 2001 3 Zhao Bo High speed processes the forward position technology that the mould processes Mould technology 2000 2 4 Zhang Haiou The fleetness mould makes the technology current situation and their developing trend Mould technology 2000 6 5 Guo Dongming Wang Xiaoming Be geared to the needs of the particular kind processing technology that the fleetness creates Chinese mechanical engineering 2000 11 6 高速加工和現(xiàn)代模具制造 一 概述 1 目前模具制造的發(fā)展現(xiàn)狀和趨勢 模具作為重要的工藝裝備 在消費(fèi)品 電器電子 汽車 飛機(jī)制造等工業(yè)部門中 占有舉足輕重的地 位 工業(yè)產(chǎn)品零件粗加工的 75 精加工的 50 及塑料零件的 90 將由模具完成 目前中國模具市場需求 已達(dá) 500 億元之規(guī)模 汽車模具 特別是覆蓋件模具年增長速度將超過 20 建材模具也迅速發(fā)展 各種異型材模具 墻面和地面模具成為模具的新增長點 今后幾年塑料門窗和塑料排水管增長將超過 30 家電模具年增長速度將超過 10 IT 業(yè)年均增長速度超過 20 對模具的需求占模具市場的 20 2004 年中國機(jī)床工具工業(yè)產(chǎn)值將繼續(xù)增長 我國模具制造市場潛力巨大 根據(jù)資料統(tǒng)計 近年 來 我國模具的年總產(chǎn)值達(dá)到 30 億美元 進(jìn)口超過 10 億美元 出口超過 1 億美元 增長從 1995 年的 25 增加到 2005 年的 50 國外專家預(yù)言 亞洲在全球模具制造中占據(jù)的份額 將從 1995 年的 25 增加至 2005 年的 50 中國模具工業(yè)發(fā)展迅速 形成了華東和華南兩大基地 并且逐漸擴(kuò)大到其他省份 山東 安徽 四川 1996 年 2002 年 模具制造業(yè)產(chǎn)值年平均增長 14 2003 年增長 25 2003 年我國模具產(chǎn)值為 450 億人 民幣 總產(chǎn)量位居世界第 3 出口模具 3 368 億美元 比上年增長 33 5 但是 我國技術(shù)含量低的模具 已供過于求 精密 復(fù)雜的高檔模具很大部分依靠進(jìn)口 每年進(jìn)口模具超過 10 億美元 出口超過 1 億美 元精密模具精度要求在 2 3 m 大型模具需要滿足 8000kN 合模力注塑機(jī)的要求 小型模具需滿足直徑 1mm 塑料管的要求 目前 采用高速切削生產(chǎn)模具已經(jīng)成為模具制造的大趨勢 在國外一些模具生產(chǎn)廠家 高速機(jī)床大面積取代電火花機(jī)床 高速切削大大提高了模具生產(chǎn)效率 機(jī)床企業(yè)瞄準(zhǔn)模具生產(chǎn)企業(yè) 有的 加工中心生產(chǎn)廠機(jī)床的 60 以上賣給模具加工企業(yè) 高速切削逐漸取代電火花精加工模具在國外的模具制 造企業(yè)已經(jīng)普遍采用 高速切削生產(chǎn)模具已經(jīng)成為逐漸模具制造的大趨勢 大大提高了模具生產(chǎn)效率和質(zhì) 量 采用高速切削替代電火花生產(chǎn)模具 可以明顯提高效率 提高模具精度 使用壽命長 2 高速加工在模具制造中的應(yīng)用 2 1 高速切削的優(yōu)點 1 刀具的高轉(zhuǎn)速和機(jī)床的高進(jìn)給以及高加速度 大大提高金屬切除率 2 高速切削減小切削力 3 高速切削熱大部分由切屑帶走 工件發(fā)熱少 4 高速切削減少振動 提高加工質(zhì)量 2 2 高速加工應(yīng)用于模具加工的效益 1 快速粗加工和半精加工 提高加工效率 2 高速高精度精加工硬切削代替光整加工 表明質(zhì)量高 形狀精度提高 比 EDM 加工提高效率 50 減少手工修磨 3 硬切削加工最后成型表面 提高表面質(zhì)量 形狀精度 不僅是表面粗糙度低 而且表面光亮度 高 用于復(fù)雜表面的加工更具優(yōu)勢 4 避免 EDM 加工產(chǎn)生的表面損傷 提高模具壽命 20 5 結(jié)合 CAD CAM 技術(shù)快速加工電極 特別是形狀復(fù)雜 薄壁類電極 3 采用高速切削加工模具需要解決的問題 在國內(nèi) 由于資金 技術(shù)等方面的原因 應(yīng)用高速切削生產(chǎn)模具還處于初期階段 還存在機(jī)床 刀 具 工藝以及其他方面的一些問題需要逐步解決 缺點是加工成本高 對刀具的使用有較高的要求 不 能使用過大的刀具 要有復(fù)雜的計算機(jī)編程技術(shù)做支持 設(shè)備運(yùn)行成本高 二 加工模具的高速加工機(jī)床 模具精加工和硬切削加工需要數(shù)控高速機(jī)床 模板 模架加工需要精密 高效數(shù)控機(jī)床等 許多機(jī)床企 業(yè)瞄準(zhǔn)模具生產(chǎn) 有的加工中心生產(chǎn)廠機(jī)床的 60 以上賣給模具企業(yè) 模具行業(yè)今后幾年年均有 50 億元 7 的固定資產(chǎn)投入 其中 80 是購買模具加工設(shè)備 也就是說每年有 40 億元人民幣要購買金切機(jī)床 目前 我國數(shù)控機(jī)床的平均利用率大約 20 高速機(jī)床的利用率 3 5 模具企業(yè)也有相當(dāng)?shù)膯挝毁徺I高速機(jī)床 從 6000 40000rmp 的都有 1 高速機(jī)床的技術(shù)參數(shù)要求 加工中心主軸大功率 高轉(zhuǎn)速 滿足粗精加工 精加工模具要用小直徑刀具 機(jī)床一般要達(dá)到 15000 20000rmp 通常主軸轉(zhuǎn)速在 10000rpm 以下的機(jī)床可以進(jìn)行粗加工和半精加工 達(dá)不到精加工的精 度 無法達(dá)到 400m min 以上的切削速度 2 五軸機(jī)床的應(yīng)用增加趨勢 1 加工路線靈活 表面形狀復(fù)雜 2 加工范圍大 適合多種類型模具加工 3 切削條件好 減少刀具磨損 提高刀具壽命 3 購買 CAD CAM 軟件和高速機(jī)床配套 據(jù)統(tǒng)計 每年有幾十億美元用于進(jìn)口機(jī)床 大部分電加工機(jī)床和高速機(jī)床需要進(jìn)口 三 高速切削模具的刀具技術(shù) 高速切削加工還需配備適宜高速切削的刀具 高速加工刀具材料的進(jìn)展促使了高速加工的發(fā)展 硬質(zhì) 合金涂層刀具 聚晶增強(qiáng)陶瓷刀具使得兼顧高硬度的刀刃部和高韌性的基體成為可能 聚晶立方氮化硼 PCBN 刀片 其硬度可達(dá) 3500 4500HV 聚晶金剛石 PCD 其硬度可達(dá) 6000 10000HV 近年來德國 SCS 日本三菱 神鋼 及住友 瑞士山特維克 美國肯納飛碩等國外著名刀具公司都先后推出了各自的高 速切削刀具 不僅有高速切削普通結(jié)構(gòu)鋼的刀具 還有能直接高速切削淬硬鋼的陶瓷刀具等超硬刀具 尤其 是涂層刀具異軍突起 在淬硬鋼