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現(xiàn)代模具制造
一、 沖壓模具發(fā)展歷史和技術水平狀況
1953年，長春第一汽車制造廠在中國首次建立了沖模車間，該汽車廠于1958年開始制造汽車覆蓋件模具。我國于20世紀60年代開始生產(chǎn)精沖模具。走過漫長的發(fā)展道路，目前我國已形成約300多億元（未包括港、澳、臺的統(tǒng)計數(shù)字。）各類沖壓模具的生產(chǎn)能力。形成了如浙江寧波和黃巖地區(qū)的“模具之鄉(xiāng)”；廣東一些大集團公司和鄉(xiāng)鎮(zhèn)企業(yè)迅速崛起，科龍、美的、康佳等集團紛紛建立了自己的模具制造中心；中外合資和外商獨資的模具企業(yè)現(xiàn)已有幾千家。隨著與國際接軌的腳步不斷加快，市場競爭的日益加劇，模具的生產(chǎn)和設計已經(jīng)越來越認識到產(chǎn)品質量、成本和新產(chǎn)品的開發(fā)能力的重要性。模具制造技術現(xiàn)已成為衡量一個國家制造業(yè)水平高低的重要標志，并在很大程度上決定企業(yè)的生存空間。目前我國沖壓模具無論在數(shù)量上，還是在質量、技術和能力等方面都已有了很大發(fā)展，但與國民經(jīng)濟需求和世界先進水平相比，差距仍很大。在國際競爭的局勢下，我過的模具工業(yè)得到飛速的發(fā)展，很多的專門模具研究中心不斷的建立起來，模具結構和鋼材的研究取得了顯著的成就，但還是存在很大的差距。 一是進口模具大部分是技術含量高的大型精密模具，而出口模具大部分是技術含量較低的中低檔模具，因此技術含量高的中高檔模具市場滿足率低于沖壓模具總體滿足率，這些模具的發(fā)展已滯后于沖壓件生產(chǎn)，而技術含量低的中低檔模具市場滿足率要高于沖壓模具市場總體滿足率； 二是由于我國的模具價格要比國際市場價格低許多，具有一定的競爭力，因此其在國際市場的前景看好； 三是近年來港資、臺資、外資企業(yè)在我國發(fā)展迅速，這些企業(yè)中大量的自產(chǎn)自用的沖壓模具無確切的統(tǒng)計資料，因此未能計入上述數(shù)字之中。
二．現(xiàn)代模具制造技術的發(fā)展方向
現(xiàn)代模具技術的發(fā)展應該為適應模具產(chǎn)品“交貨期短”、“精度高”、“質量好”、“價格低”的要求服務。達到這一要求急需發(fā)展如下幾項
(1)全面推廣普及DBD/DBM/DBE技術
模具DBD/DBM/DBE技術是模具設計制造的發(fā)展方向。隨著微機軟件的發(fā)展和進步，普及DBD/DBM/DBE技術的條件已基本成熟，各企業(yè)將加大DBD/DBM技術培訓和技術服務的力度；進一步擴大DBE技術的應用范圍。計算機和網(wǎng)絡的發(fā)展正使DBD/DBM/DBE技術跨地區(qū)、跨企業(yè)、跨院所地在整個行業(yè)中推廣成為可能，實現(xiàn)技術資源的重新整合，使虛擬制造成為可能。
(2)高速銑削加工
國外近年來發(fā)展的高速銑削加工，大幅度提高了加工效率，并可獲得極高的表面光潔度。另外，還可加工高硬度模塊，還具有溫升低、熱變形小等優(yōu)點。高速銑削加工技術的發(fā)展，對汽車、家電行業(yè)中大型型腔模具制造注入了新的活力。目前它已向更高的敏捷化、智能化、集成化方向發(fā)展。
(3)模具掃描及數(shù)字化系統(tǒng)
高速掃描機和模具掃描系統(tǒng)提供了從模型或實物掃描到加工出期望的模型所需的諸多功能，大大縮短了模具的在研制制造周期。有些快速掃描系統(tǒng)，可快速安裝在已有的數(shù)控銑床及加工中心上，實現(xiàn)快速數(shù)據(jù)采集、自動生成各種不同數(shù)控系統(tǒng)的加工程序、不同格式的DBD數(shù)據(jù)，用于模具制造業(yè)的“逆向工程”。
(4)提高模具標準化程度
我國模具標準化程度正在不斷提高，估計目前我國模具標準件使用覆蓋率已達到30%左右。國外發(fā)達國家一般為80%左右。
(5)優(yōu)質材料及先進表面處理技術
選用優(yōu)質鋼材和應用相應的表面處理技術來提高模具的壽命就顯得十分必要。模具熱處理和表面處理是否能充分發(fā)揮模具鋼材料性能的關鍵環(huán)節(jié)。模具熱處理的發(fā)展方向是采用真空熱處理。模具表面處理除完善應發(fā)展工藝先進的激光表面處理等技術。
(6)模具研磨拋光
將自動化、智能化模具表面的質量對模具使用壽命、制件外觀質量等方面均有較大的影響，研究自動化、智能化的研磨與拋光方法替代現(xiàn)有手工操作，以提高模具表面質量是重要的發(fā)展趨勢。
(7)模具自動加工系統(tǒng)的發(fā)展
這是我國模具工業(yè)長遠發(fā)展的目標。模具自動加工系統(tǒng)應有多臺機床合理組合；配有隨行定位夾具或定位盤；有完整的機具、刀具數(shù)控庫；有完整的數(shù)控柔性同步系統(tǒng)；有質量監(jiān)測控制系統(tǒng)。作為用戶當然要選合適的設備，如果選型不當，不但不能賺錢反而令陷入為機器打工的苦澀局面。
三．現(xiàn)代模具制造技術的發(fā)展趨勢
模具技術未來發(fā)展趨勢主要是朝信息化、高速化生產(chǎn)與高精度化發(fā)展。因此從設計技術來說，發(fā)展重點在于大力推廣DBD/DBE/DBM技術的應用，并持續(xù)提高效率，特別是板材成型過程的計算機模擬分析技術。模具DBD、DBE技術應向宣人化、集成化、智能化和網(wǎng)絡化方向發(fā)展，并提高模具DBD、DBM系統(tǒng)專用化程度。為了提高DBD、DBE、DBM技術的應用水平，建立完整的模具資料庫及開發(fā)專家系統(tǒng)和提高軟件的實用性十分重要。
從加工技術來說，發(fā)展重點在于高速加工和高精度加工。高度加工目前主要是發(fā)展高速銑削、高速研拋和高速電 加工及快速制模技術。高精度加工目前主要是發(fā)展模具零件精度1μm以下和表面粗糙度Pa≤0.1μm的各種精密加工。
四、現(xiàn)代模具的制造
1.CAD/CAE/CAM計算機輔助設計、模擬、制造一體化
CAD/CAE/CAM一體化集成技術是現(xiàn)代模具制造中最先進最合理的生產(chǎn)方式。使用計算機輔助設計、輔助工程與制造系統(tǒng)，按設計好的模具零件分別編制該零件的數(shù)控加工程序是從設計到制造的一個必然過程，該過程都是從CAD/CAE/CAM系統(tǒng)內進行的，其加工程序直接由聯(lián)機電纜輸入加工機臺，在編制程序時可利用系統(tǒng)中的加工模擬功能，將零件刀具、刀柄、夾具，平臺及刀具移動速度、路徑等顯示出來，以檢查程序編制的正確性。總之在CAD/CAE/CAM系統(tǒng)內編制和模擬加工程序可以充分了解發(fā)現(xiàn)的問題，從而在加工之前，將整套加工程序作好完善修改工作，這對于高效、準確的加工模具零件有著相當重要的意義。
2.先進設備在現(xiàn)代模具制造中的作用
現(xiàn)代模具制造的必然趨勢,就是機械加工盡可能地取代人工加工，尤其現(xiàn)在數(shù)控車床、多軸聯(lián)動機床、數(shù)控模具雕刻機、電火花加工機床、數(shù)控精密磨床、三坐標測量機、掃描儀等現(xiàn)代設備在工廠中的廣泛使用，而且這些設備大部分所用的程序基本上都是應用CAD/CAE/CAM系統(tǒng)產(chǎn)生的，操作人員工作按照規(guī)定的程序裝夾工件,配備刀具和操作，機臺就能自動地完成加工任務,并將理想的模具零件制造出來或為下一加工工序完成規(guī)定的部分。
3.模具材料及表面處理技術
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。在整個模具價格構成中，材料所占比重不大,一般在20%～30%,因此，選用優(yōu)質鋼材和應用表面處理技術來提高模具的壽命就顯得十分必要。對于模具鋼來說,要采用電渣重熔工藝，如采用粉末冶金工藝制造的粉末高速鋼等。模具鋼品種規(guī)格多樣化、產(chǎn)品精細化、制品化，盡量縮短供貨時間亦是重要發(fā)展趨勢。
模具熱處理的主要趨勢是：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；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。
五、逆向工程
逆向工程即先對制件（所加工的產(chǎn)品）進行掃描生成多種格式的CAD數(shù)據(jù)，再在另外的CAD/CAE/CAM軟件中進行改型設計，該技術是現(xiàn)代模具制造中最流行的模具制造技術。英國雷尼紹公司專門為模具制造開發(fā)生產(chǎn)的掃描系統(tǒng)，就可以成功地應用于模具制造的逆向工程中，它不僅可以改善數(shù)控機床的性能，擴大數(shù)控機床的功能，而且還能提高數(shù)控機床的效率。雷尼紹公司的R e t r o s c an、Renscan200、Cyclone 高速掃描機已被青島海爾、濟南輕騎、國家模具中心等單位開始使用。
六、總結與展望
隨著計算機軟件的發(fā)展和進步，CAD/CAE/CAM技術也日臻成熟，其現(xiàn)代模具中的應用將越來越廣泛。可以預料不久的將來，模具制造業(yè)將從機械制造業(yè)中分離出來，而獨立成為國民經(jīng)濟中不可缺少的支柱產(chǎn)業(yè)，與此同時，也進一步促進了模具制造技術向集成化、智能化、益人化、高效化方向發(fā)展。
Modern mold making
I. The stamping die development history and status of technology
In 1953, the Changchun First Automobile Works in China for the first time established a die shop, the car plant in 1958 began manufacturing automotive panel die. 60 years of the 20th century began producing fine blanking dies. Come a long road of development, China has formed about 300 billion (not including Hong Kong, Macao and Taiwan statistics.) Production capacity of various types of stamping dies. Formed, such as Ningbo and Zhejiang HUANGYAN region "Die village"; Guangdong Corporation and some large rapid rise of township enterprises, K el o n, M id e a, K on ka and other groups have established their own mold manufacturing center; joint ventures and wholly foreign-owned the mold companies now have thousands. With the pace with international standards continues to accelerate, increasing market competition, production and design of the mold has been growing recognition that product quality, cost, and new product development capacities. Mold manufacturing technology to measure a country's manufacturing sector has become an important indicator of the level, and largely determine the survival space. At present, China stamping die, whether in quantity or in quality, technology and other capabilities have made significant progress, but with national needs and the world advanced level, the gap is still great. In the international competition situation, I had the mold industry has rapidly developed, many specialized research centers continue to die set up, mold steel of the structure and made significant achievements, but there is still a big gap. First, imports of high-tech mold most of the large precision molds, mold and exports most of the lower middle and low-tech die, so high-tech high-grade die stamping die market, the overall satisfaction rate is lower than satisfaction rate, which mold development has lagged behind the production of stamping parts, and low-technology market to meet the rate of middle and low die stamping die is higher than the overall market to meet the rate; second is due to the price of the mold is much lower than international market prices, has some competition force, so its prospects in the international market; third in recent years, Hong Kong-and Taiwan-owned, foreign-funded enterprises in China developed rapidly in a large number of these enterprises stamping dies produced for own use no precise statistics, it is not included in the figures being.
II. Modern mold manufacturing technology development
The development of modern technology should die mold products to meet the "short delivery time", "high precision", "good quality", "low price" request for service. Urgent need to develop to meet this requirement as a number of this.
(1)To comprehensively promote universal DBD / DBM / DBE technology
Die DBD / DBM / DBE technology is the development direction of mold design and manufacturing. With the computer software development and progress, universal DBD / DBM / DBE technology, conditions are ripe, the businesses will increase DBD / DBM technical training and technical service efforts; further expand the scope of DBE technology. The development of computers and networks are making DBD / DBM / DBE technology trans-regional, cross-enterprise, campus-wide in the industry as possible to promote and achieve re-integration of technical resources to enable virtual manufacturing possible.
(2) High-speed milling
The development of foreign high-speed milling process in recent years, significantly improve the processing efficiency, and to get a high surface finish. In addition, the module can also be processed with high hardness, but also with low temperature rise, thermal deformation and so on. High-speed milling technology, automotive, home appliance manufacturing industry in the large cavity mold injected new vitality. It currently has more agile, intelligent, integrated direction.
(3) die scanning and digitizing system
High-speed scanner provides scanning system and mold from the model or in kind to the processing of the scanned model of the desired number of features required, greatly reducing the manufacturing cycle in the development of mold. Some quick scan system can be quickly installed in existing CNC milling machine and machining center, for fast data acquisition, automatic generation of a variety of CNC machining process, the DBD data in different formats, for mold manufacturing "reverse engineering . "
(4) the degree of standardization to improve die
Degree of standardization of the mold is increasing, estimates that the current use of standard mold coverage has reached about 30%. Developed countries is generally about 80%.
(6) high-quality materials and advanced surface treatment technology
Application of high quality steel and the corresponding surface treatment technology to improve the life of the mold it is very necessary. Mold heat treatment and surface treatment can fully mold steel material properties play a key part. Direction of development of mold heat treatment is the use of vacuum heat treatment. In addition to the mold surface should improve the development of advanced technologies such as laser surface treatment.
(7) Mold Polishing
Automation, intelligent mold surface quality of mold life, the appearance of quality parts and so have a greater impact of automation and intelligence of the grinding and polishing methods replace the existing manual in order to improve the quality of the mold surface is important trends.
(8) die development of automatic processing system
This is our long-term development goals mold industry. Automatic mold machine processing system should be more than the rational combination; with accompanying plate positioning fixture or positioning; a complete equipment, tool CNC database; a complete CNC flexible synchronization system; a quality monitoring and control system. Of course, as the user to choose the right equipment, if the selection properly, not only can not make money but make the machine work into the bitter situation.
III. Modern mold manufacturing technology trends
Die technology is mainly towards the future development trend of information technology, high-speed high-precision production and development. Therefore, the design technology, the development focus is to promote DBD / DBE / DBM technology, and continue to improve efficiency, especially in sheet metal forming process of the computer simulation analysis. Die DBD, DBE technology should be declared human, integration, intelligence and network direction, and improve the mold DBD, DBM system-specific level. To improve the DBD, DBE, DBM technology, establish a complete database and development of the mold expert systems and improve software usability is very important.
From the processing technology, the development focused on high-speed processing and precision machining. At present, the development of highly processed high-speed milling, high speed polishing and high-speed electronic processing and rapid tooling technologies. At present, the development of precision machining parts precision mold and the surface roughness of less 1μm Pa ≤ 0.1μm variety of precision machining.
IV. The modern mold manufacturing
1.CAD/CAE/CAM computer-aided design, simulation, manufacturing integration
CAD / CAE / CAM integration, integration technology is the most advanced modern mold making the most reasonable mode of production. Use of computer-aided design, support engineering and manufacturing systems, according to the respective mold parts designed to prepare the NC machining of parts from design to manufacturing process is an inevitable process, which is from CAD / CAE / CAM system carried out, The processing line cable input directly from the processing machine, can be used in the preparation of procedures of processing the system analog functions, will be part tool, tool holder, fixture, platform and tool speed, path, etc. are displayed, to check the program prepared correctness. In short the CAD / CAE / CAM system development and simulation of processing can not fully understand the problems identified, resulting in processing prior to prepare the complete set of processing change work, which for the efficient and accurate processing of the mold has a very important part .
2. Advanced equipment in the modern mold making role
The inevitable trend of modern mold making, machining is possible to replace the manual process, especially now that CNC lathes, multi-axis machine tools, CNC mold engraving machine, EDM machine, CNC precision grinding machines, coordinate measuring machines, scanners and other modern equipment widely used in factories, but most of these devices are basically the application of the procedures used CAD / CAE / CAM system to produce, the operator of work procedures in accordance with the provisions of work piece clamping, with a cutting tool and operation of the machine will be able to automatically complete the processing tasks, and created the ideal mold parts or complete the processing operation for the next part.
3. Die materials and surface treatment technology
Due to improper selection and use of materials, resulting in premature failure of the mold, which accounts for more than 45% die failure. Price structure throughout the mold, the materials, the proportion of small, generally 20% to 30%, therefore, the choice of high quality steel and application of surface treatment technology to improve the life of the mold it is very necessary. For tool steel, the ESR technique to be used, such as the use of powder metallurgy high speed steel powders manufactured. Variety of different specifications tool steel, refined products, products of, try to shorten the delivery time is also an important trend.
Mold heat treatment of the main trends: the infiltration of a single element to the multi-element penetration, complex permeability (such as TD method) development; by the general spread of the CVD, PVD, PCVD, ion penetration, ion implantation and other direction; addition, the current laser enhanced glow plasma technology and electroplating (plating) and other anti-corrosion technology to strengthen more and more attention.
V. Reverse engineering
Reverse engineering is the first of the parts (the processing of the product) to scan the CAD data generated in multiple formats, and then in the other CAD / CAE / CAM software in the modified design, the technology is the most popular modern mold manufacturing mold manufacturing technology. mold manufacturing company dedicated to development and production of the scanning system, it can be successfully applied to reverse engineering, mold manufacturing, it can not only improve the performance of CNC machine tools, expanding the function of CNC machine tools, CNC machine tools but also improve efficiency., Renscan200, Cyclone high-speed scanner has been Qingdao H a I e r, Jinan Q I n g q i, national mold center and other units started.
VI. Summary and Outlook
With the development and progress of computer software, CAD / CAE / CAM technology is getting more mature, and its application in the modern mold will become more widespread. Can be expected in the near future, mold manufacturing to separate from the machine manufacturing industry, and independent national economy to become an indispensable pillar industries, while also further promote the integration of the mold manufacturing technology, intelligence, beneficiary , efficient direction.