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Modern fast economy manufacture mold technology
Along with the global economy development, the new technological revolution made the new progress and the breakthrough unceasingly, the technical leap development already becomes the important attribute which the impetus world economics grew. The market economy unceasing development, urges the industry product more and more to the multi- varieties, high grade, the low cost direction to develop, in order to maintain and strengthens the product in market competitive power, product development cycle, production cycle more and more short, thereupon to makes each kind of product the essential craft equipment mold request to be more and more harsh. On the one hand the enterprise for the pursue scale benefit, causes the mold to turn towards high speed, is precise, the long life direction develops; On the other hand enterprise in order to satisfy the multi- varieties,, the product renewal quickly, wins the market the need, requests the mold to turn towards the manufacture cycle to be short, the cost low fast economy direction develops. The computer, the laser, electronic, the new material, the new technical development, causes the fast economical pattern making technology even more powerful, the application scope expands unceasingly, the type increases unceasingly, the creation economic efficiency and the social efficiency are more and more remarkable. The fast economical pattern making technology and the traditional machine-finishing compares, has the pattern making cycle short, the cost is low, the precision and the life can satisfy in the production the operation requirements, is synthesizes an economic efficiency quite remarkable kind to make the mold the technology, summarizes below, has several types to leave.
1 fast prototypes manufactures technology The fast prototype manufacture technology is called RPM, is one kind of new manufacture technology which the 80's later period develops. US, Japan, England, Israel, Germany, China have all promoted own commercialization product, and has formed the new industry gradually.RPM is the computer, the laser, the optical scanning, the advanced new material, the computer-aided design (CAD), the computer assistance processing (CAM), the numerical control (CNC) synthesizes the application the high technology and new technology. In takes shape in the concept take the plane separate, piles up as the instruction, in the control take the computer and the numerical control as the foundation, take biggest flexibility as general goals. It has abandoned the traditional machine-finishing method, to the manufacturing industry transformation is a significant breakthrough, uses the RPM technology to be possible directly or indirectly the fast pattern making, this technology already by profession widespread application and so on automobile, aviation, electrical appliances, ships, medical service, mold.
2 surfaces take shape the pattern making technology The surface takes shape the pattern making technology, mainly is the use spurts spreads, the electrolytic casting, chemistry corrosion and so on the new technique formation cavity surface and the fine pattern one kind of craft technology, in the practical application including following several kind of types.
electric arcs spurt spread take shape the pattern making technology The electric arc spurts spreads takes shape the technical principle is: Has the electric arc quantity of heat using between 2 circular telegrams tinsel to melt the tinsel, depends upon the compressed gas its full atomization, and gives the certain kinetic energy, high speed sprays in the type mold surface, layer upon layer mounts, forms a metal shell, namely the cavity internal surface, uses to fill the substrate material again (generally for metal silt and resin compound materials) performs to support the reinforcement, enhances its intensity and the rigidity, combines the mold together with the metal pattern frame. This kind of pattern making technology craft simple, cost low, manufacture cycle extremely short, the cavity surface takes shape only needs for several hours, saves the energy and the metal material, general cavity surface 2-3mm is only thick, simulation greatly strengthened, the pattern precision may achieve 0.5 mu m. At present this technology widely uses in superficial shape and so on airplane, automobile mold, electrical appliances, furniture, shoemaking, fine arts handicraft is complex and the pattern fine each kind of polyurethane product blow molding, attracts models, the PVC injection, PU becomes spongy and each kind of injection takes shape in the mold.
electrolytic castings take shape the technology The electrolytic casting takes shape the technical principle to be same with the galvanization, is according to model the mold (ready-made product or female mold which makes according to product blueprint) is the datum (negative pole), places in the electrolytic casting fluid (anode), causes in the electrolytic casting fluid the metallic ion to return to original state a latter place deposition on the type mold, forms the metal shell, after strips it, contacts the surface with the type mold namely for the mold the cavity internal surface. This technical main characteristic is saves material, the mold manufacture cycle short, electrolytic casting level degree of hardness may reach 40HRC, enhanced the resistance to wear and the life, roughness, the size precision is completely consistent with the type mold, is suitable for the injection, attracts models, the blow molding, keeps out models, mold cavity and the electric spark and so on bakelite mold, glass mold, compression casting mold takes shape the electrode manufacture.
cavities surfaces fine pattern takes shape etching technology The etching technology is optics, chemistry, the machining synthesis application one kind of technology, its basic principle is makes first the pattern design the film, then in has spread the film on pattern design duplication the photosensitive material on the mold cavity surface, process chemistry processing, the mold cavity surface does not form by the etching partial protectors, then acts according to the mold material quality, the choice corresponding etching craft, pattern design etching in mold internal surface.This technical main characteristic is the time short, the expense is low, patching damages the pattern design to be possible to achieve flawlessly.
3 sprinkle to cast into the type system mold technique Sprinkling to cast into technical and common characteristics of the type system mold is according to the kind piece for basis, sprinkle a convex and cave mold, a surface do not need the machine to process.Make physically to mainly have following several categories type in the mold.
4 extrusions takes shape the technology Using the berylliuim copper alloy good thermal conductivity and the stability, after the solid melt aging treatment of metal, use the swaging pressure to make the mold concave model cavity. Its characteristic is makes the cycle short, the cavity precision is high (the IT7 level), surface roughness Ra=0.025 mu m, The intensity is high, the life may reach 500,000 times, does not have the environmental pollution. This technology is using the metal material in the thin crystal grain, certainly takes shape the temperature, under the low distortion speed condition, when the material has the best superplasticity, toes attend to carry out raised mold which the initiative finishes, then may extrude the concave mold with the small strength one kind of fast economical pattern making technology. Ultra models takes shape material typical representative is Zn-22%AL.
5 does not have the mold multi- spots forming technology Does not have the mold multi- spots fast forming technology is by CAD/CAM/CAT The technology is the main method about, may adjust the base main body group highly using the computer control to form forms the surface, replaces the traditional mold to carry on the three dimensional curved surface forming to the sheet an modern advanced manufacture technology. This technology may change the distortion way and the stressful condition at will, enhances the material the formed limit, may form repeatedly, by this elimination material interior remaining stress, the realization does not have the snapping back forming
6 triumphant Uygur bright steel belt blanking falls the material pattern making technology The new steel belt blanking falls the material pattern making technology is one kind is different with has raised, the concave mold structure steel belt mold generally, it is with specially makes the new fast economical pattern making technology by the single edge steel belt which the backing strip is composed. This kind of mold weight is light, only then 200kg, the processing precision for ±0.35-0.50mm, may suit each kind of black and the non-ferrous metal 0.5-0.65mm thick sheet processing generally. The life may achieve 5-25 ten thousand, the production cost is low.
7 molds semifinished materials fast manufacture technology solid casting Because the massive molds are belong to the single unit or the production, the mold semifinished materials manufacture quality and the cycle and the cost to the final mold quality and cyclical and the cost influence are very important. The modern mold semifinished materials widely have used the seeds casting technology, the so-called solid casting is (polystyrene PS either polymethacrylate PMMA) manufactures using the foam plastics replaces traditional the wooden mold or the metal pattern, after the modelling does not have to take out the model, then may the casting, under the foam plastics model high temperature liquid metal function, deflagrate the gasification but to vanish, the molten metal substitution original foam plastics model holds the position, after the condensation forms the casting.
8 other aspects technologies in order to simplify the mold the structural design, reduces the mold cost, reduces the mold manufacture cycle, in domestic and foreign also successively appeared some other aspects new technology application, like trades the mold frame, the ramming unit, the cutting edge built-up welding quickly, inlays the block casting, the nitrogen spring and so on.
nitrogen springs on mold application The nitrogen spring is one kind of new elastic function part, replaces the spring, the rubber, the polyurethane or the air cushion with it side, it can accurately provide presses the strength, then may have the greatly initial ball pressure in the small space, does not need pre- tightly, is basically hit the pressure basically in the mold entire work process to be constant. The ball pressure size and the working point position may, accurate, conveniently adjust as necessary, simplifies the mold to stretch, nearby the pressure, ex-denning isostructuralism, simplifies the mold design, reduces the pattern making cycle, debugs the mold to be convenient, reduces the replacement mold time, enhances the production efficiency.
fast trades the mold technology Because product variety increasing, causes the mold in the production the transmutation extremely frequently, how thereupon reduces the ramming equipment the down time, enhances the production efficiency, fast traded the mold technology to receive people's attention. At present developed industrial nation some big companies traded the mold speed to achieve astonishing degree, whether had fast trades the mold technology to become for an enterprise technology advancement sign. The always tendency is reduces the mold to install on the equipment, to be fixed, the adjustment time, this both must give in the equipment structural design to consider, and must in the mold structural design, the standardized aspect consider, machine on work as far as possible placing machine under will do.
ramming units combination technology The ramming unit combination technology is dies a resolve into each one simple unit the convention to die, according to the working procedure request, the arrangement combination, completes the many kinds of ramming working procedure when the identical inferior stroke the new craft equipment, the work the ramming unit not with the punch press slide joint, only needs the slide attack then to complete the ramming work. When independent employment it is 1 complete mold. It may use for to process the sheet or the molding punch holes, falls the material, cuts the angle, the grooving, shuts off and the shallow stretch and so on. Has the assembly strongly, the easy to operate, the versatility, the efficiency is quickly good and so on the characteristic, suits the multi- varieties specially, center the production.
may process the plastic in mold manufacture application May process the plastic to be common in the developed industrial nation application, specially in manufacturing industry and so on automobile, airplane, mainly replaces the lumber or the metal manufacture automobile body host model, the profile, examines has and the casting model and so on. May process the plastic the main characteristic is has both the lumber and the metal fine workability, the manufacture craft simple and direct (may use compression molding, pour, spells sticks, method well and so on sculpture), the size stability, does not distort, bears moistly, anti-corrosive, is easy to repair, the easy modification, the weight light, the manufacture cycle short, the cost to be low. Fast economical pattern making technology type very many, its has the characteristic, the application scope are various, this article only can broadly make some simple introductions, each kind of technology still had many concrete technological processes, the craft parameter and its the technical characteristic in the concrete application and the implementation process.
The mold is one of foundation industries, in the globalization market economy and under each kind of high technology and new technology swift and violent development situation, the fast economical mold has entrusted with the new mission and the brand-new connotation, the classification increases unceasingly, the fast economical pattern making material turns towards the multi- varieties seriation to make great strides forward, the craft has the new innovation and the breakthrough unceasingly, is published one after another with it supplementary equipment, the service domain in opens up unceasingly, the creation economic efficiency is more and more remarkable. Along with the commodity economy development, the intense market competition, the product renewal acceleration, is reducing the cycle to the fast economical pattern making technology, reduces the cost, will increase the precision and lengthens the life aspect the request to be able to be more and more high inevitably. Because it can cause the enterprise to win the market, creates the remarkable economic efficiency, more and more receives entrepreneur's favor and the concerned leader department's enormous attention and the policy fund support. Each kind of fast economical pattern making technology also can consummate mature and the development unceasingly in the promoted application process, as a result of the high technology and new technology development, each kind of technical bonding with the seepage, for the adaption production in different demand, surely will be able to form some, the frugal energy, the frugal material fast pattern making technology new from now on.
譯文：
現(xiàn)代快速經(jīng)濟(jì)制造模具技術(shù)?
????隨著全球經(jīng)濟(jì)的發(fā)展，新的技術(shù)革命不斷取得新的進(jìn)展和突破，技術(shù)的飛躍 發(fā)展已經(jīng)成為推動世界經(jīng)濟(jì)增長的重要因素。市場經(jīng)濟(jì)的不斷發(fā)展，促使工業(yè)產(chǎn)品越來越向多品種、小批量、高質(zhì)量、低成本的方向發(fā)展，為了保持和加強(qiáng)產(chǎn)品在市場上的競爭力，產(chǎn)品的開發(fā)周期、生產(chǎn)周期越來越短，于是對制造各種產(chǎn)品的關(guān)鍵工藝裝備——模具的要求越來越苛刻。?一方面企業(yè)為追求規(guī)模效益，使得模具向著高速、精密、長壽命方向發(fā)展；另一方面企業(yè)為了滿足多品種、小批量、產(chǎn)品更新?lián)Q代快、贏得市場的需要，要求模具向著制造周期短、成本低的快速經(jīng)濟(jì)的方向發(fā)展。計算機(jī)、激光、電子、新材料、新技術(shù)的發(fā)展，使得快速經(jīng)濟(jì)制模技術(shù)如虎添翼，應(yīng)用范圍不斷擴(kuò)大，類型不斷增多，創(chuàng)造的經(jīng)濟(jì)效益和社會效益越來越顯著。??快速經(jīng)濟(jì)制模技術(shù)與傳統(tǒng)的機(jī)械加工相比，具有制模周期短、成本低、精度與壽命又能滿足生產(chǎn)上的使用要求，是綜合經(jīng)濟(jì)效益比較顯著的一類制造模具的技術(shù)，概括起來，有以下幾種類別。??
1快速原型制造技術(shù)?快速原型制造技術(shù)簡稱RPM，是80年代后期發(fā)展起來的一種新型制造技術(shù)。美國、日本、英國、以色列、德國、中國都推出了自己的商業(yè)化產(chǎn)品，并逐漸形成了新型產(chǎn)業(yè)。?RPM是電腦、激光、光學(xué)掃描、先進(jìn)的新型材料、計算機(jī)輔助設(shè)計(CAD)、計算機(jī)輔助加工(CAM)、數(shù)控(CNC)綜合應(yīng)用的高新技術(shù)。在成型概念上以平面離散、堆積為指導(dǎo)，在控制上以計算機(jī)和數(shù)控為基礎(chǔ)，以最大柔性為總體目標(biāo)。它摒棄了傳統(tǒng)的機(jī)械加工方法，對制造業(yè)的變革是一個重大的突破，利用RPM技術(shù)可以直接或間接地快速制模，該技術(shù)已被汽車、航空、家電、船舶、醫(yī)療、模具等行業(yè)廣泛應(yīng)用。??
??? 2表面成型制模技術(shù)??表面成型制模技術(shù)，主要是利用噴涂、電鑄、化學(xué)腐蝕等新的工藝方法形成型腔表面及精細(xì)花紋的一種工藝技術(shù)，實際應(yīng)用中包括以下幾種類型。??
電弧噴涂成型制模技術(shù)??電弧噴涂成型技術(shù)的原理是：利用2根通電的金屬絲之間產(chǎn)生電弧的熱量將金屬絲熔化，依靠高壓氣體將其充分霧化，并給予一定的動能，高速噴射在樣模表面，層層鑲嵌，形成一金屬殼體，即型腔的內(nèi)表面，再用充填基體材料(一般為金屬粉粒與樹脂的復(fù)合材料)加以支撐加固，提高其強(qiáng)度和剛性，連同金屬模架組合成模具。這種制模技術(shù)工藝簡單、成本低，制造周期非常短，型腔表面的成型僅需幾個小時，節(jié)省能源和金屬材料，一般型腔表面僅2-3mm厚，仿真性極強(qiáng)，花紋精度可達(dá)到0.5μm。?目前該技術(shù)被廣泛地用于飛機(jī)、汽車的內(nèi)飾件模具、家電、家俱、制鞋、美術(shù)工藝品等表面形狀復(fù)雜及花紋精細(xì)的各種聚氨酯制品的吹塑、吸塑、PVC注射、PU發(fā)泡及各類注射成型模具中。??
?? 電鑄成型技術(shù)?電鑄成型技術(shù)的原理同電鍍一樣，是依樣模(現(xiàn)成制品或按制品圖紙制成的母模)為基準(zhǔn)(陰極)，置放在電鑄液中(陽極)，使電鑄液中的金屬離子還原后一層一層地沉積在樣模上，形成金屬殼體，將其剝離后，與樣模接觸的表面即為模具的型腔內(nèi)表面。該技術(shù)主要特點(diǎn)是節(jié)省材料、模具制造周期短，電鑄層硬度可達(dá)40HRC，提高了耐磨性和壽命，粗糙度、尺寸精度與樣模完全一致，適用于注射、吸塑、吹塑、搪塑、膠木模、玻璃模、壓鑄模等模具型腔及電火花成型電極的制造。??
型腔表面精細(xì)花紋成型的蝕刻技術(shù)蝕刻技術(shù)是光學(xué)、化學(xué)、機(jī)加工綜合應(yīng)用的一種技術(shù)，它的基本原理是先把花紋圖案制成膠片，再把膠片上的花紋圖案復(fù)制在已涂上光敏材料的模具型腔表面上，經(jīng)過化學(xué)處理，模具型腔表面形成不被蝕刻部分的保護(hù)層，再根據(jù)模具材質(zhì)，選擇相應(yīng)蝕刻工藝，將花紋圖案蝕刻在模具內(nèi)表面上。??該技術(shù)的主要特點(diǎn)是時間短、費(fèi)用低，修補(bǔ)破損花紋圖案可做到天衣無縫。
3澆鑄成型制模技術(shù)澆鑄成型制模技術(shù)的共同特點(diǎn)是依樣件為基準(zhǔn)，澆鑄出凸、凹模，型腔表面不需要機(jī)械加工。
4擠壓成型技術(shù)???利用鈹銅合金的良好的導(dǎo)熱性和穩(wěn)定性，經(jīng)固熔時效處理后，采用冷擠壓制造模具凹模型腔。其特點(diǎn)是制造周期短，型腔精度高(IT7級)，表面粗糙度Ra=0.025μm,強(qiáng)度高，壽命可達(dá)50萬次，無環(huán)境污染。該技術(shù)是利用金屬材料在細(xì)化晶粒、一定成型溫度、低變形速率條件下，材料具有最佳超塑性時，將事先制作好的凸模，用較小的力便可擠壓出凹模的一種快速經(jīng)濟(jì)制模技術(shù)。超塑成型材料的典型代表是Zn-22%AL。??
5無模多點(diǎn)成形技術(shù)??無模多點(diǎn)快速成形技術(shù)是以CAD/CAM/CAT技術(shù)為主要手段，利用計算機(jī)控制高度可調(diào)基本體群形成上下成形面，代替?zhèn)鹘y(tǒng)模具對板料進(jìn)行三維曲面成形的又一現(xiàn)代先進(jìn)制造技術(shù)。此項技術(shù)可以隨意改變變形路徑與受力狀態(tài)，提高材料的成形極限，可反復(fù)成形，以此消除材料內(nèi)部的殘余應(yīng)力，實現(xiàn)無回彈成形。??
? 6凱維朗(KEVRON)鋼帶沖裁落料制模技術(shù)??新型鋼帶沖裁落料制模技術(shù)是一種不同于一般具有凸、凹模結(jié)構(gòu)的鋼帶模，它是由單刃鋼帶與特制墊板組成的新型快速經(jīng)濟(jì)制模技術(shù)。這種模具重量輕，一般只有200kg，加工精度為?±0.35-0.50mm，可適合各種黑色和有色金屬的0.5-0.65mm厚的板料加工。壽命可達(dá)到5-25?萬次，制造成本低。??
??? 7模具毛坯的快速制造技術(shù)—實型鑄造由于大量的模具是屬于單件或小批量生產(chǎn)，模具毛坯的制造質(zhì)量和周期及成本對最終的模具質(zhì)量和周期及成本的影響是至關(guān)重要的。??
????現(xiàn)代模具毛坯已廣泛地采用子實型鑄造技術(shù)，所謂實型鑄造就是利用泡沫塑料制作代替?zhèn)鹘y(tǒng)的木?；蚪饘倌＃煨秃蟛恍枞〕瞿Ｐ?，便可以澆鑄，泡沫塑料模型的高溫液體金屬作用下，迅速燃燒氣化而消失，金屬液取代原來泡沫塑料模型所占有的位置，冷凝后形成鑄件。??
? 8其它方面技術(shù)為了簡化模具的結(jié)構(gòu)設(shè)計，降低模具成本，縮短模具制造周期，在國內(nèi)外也先后出現(xiàn)了一些其它方面新技術(shù)的應(yīng)用，如快換模架、沖壓單元、刃口堆焊、鑲塊鑄造、氮?dú)鈴椈傻?。??
???? 氮?dú)鈴椈稍谀＞呱系膽?yīng)用??氮?dú)鈴椈墒且环N新型彈性功能部件，用它代替彈簧、橡膠、聚氨酯或者氣墊，它能夠準(zhǔn)確地提供壓邊力，在較小空間便可產(chǎn)生較大初始彈壓力，不需預(yù)緊，在模具整個工作過程中彈壓力基本恒定。彈壓力大小及受力點(diǎn)位置可隨時、準(zhǔn)確、方便地調(diào)整，簡化模具拉伸、壓邊、卸料等結(jié)構(gòu)，簡化模具設(shè)計，縮短制模周期，調(diào)試模具方便，縮短更換模具時間，提高生產(chǎn)效率。??
快速換模技術(shù)?由于產(chǎn)品品種的增多，使模具在生產(chǎn)中更換變得十分頻繁，于是如何縮短沖壓設(shè)備的停機(jī)時間，提高生產(chǎn)效率，快速換模技術(shù)受到了人們的關(guān)注。目前發(fā)達(dá)工業(yè)國家的一些大公司換模速度達(dá)到了驚人的程度，是否具有快速換模技術(shù)已成為企業(yè)技術(shù)進(jìn)步的一項標(biāo)志?？偟内厔菥褪菧p少模具在設(shè)備上安裝、固定、調(diào)整的時間，這既要在設(shè)備結(jié)構(gòu)設(shè)計上予以考慮，又要在模具的結(jié)構(gòu)設(shè)計、標(biāo)準(zhǔn)化方面予以考慮，將機(jī)上的作業(yè)盡可能地放在機(jī)下做。??
沖壓單元組合技術(shù)?沖壓單元組合技術(shù)是將常規(guī)的沖模分解為一個個簡單的單元沖模，根據(jù)工序件的要求，排列組合，在同一次沖程內(nèi)完成多種沖壓工序的新型工藝裝備，工作時沖壓單元不與沖床滑塊聯(lián)接，只需滑塊打擊即可完成沖壓工作。單獨(dú)使用時它就是1副完整模具。它可以用來加工板料或型材的沖孔、落料、切角、切槽、切斷及淺拉伸等。具有組裝快捷、使用方便、通用性強(qiáng)、經(jīng)濟(jì)性好等特點(diǎn)，特別適合多品種、中小批量生產(chǎn)。??
?? 可加工塑料在模具制造中的應(yīng)用??可加工塑料在發(fā)達(dá)的工業(yè)國家應(yīng)用較普遍，特別是在汽車、飛機(jī)等制造業(yè)中，主要代替木材或金屬制作汽車車身主模型、靠模、檢具和鑄造模型等?？杉庸に芰系闹饕攸c(diǎn)是兼?zhèn)淠静暮徒饘俚膬?yōu)良加工性能，制作工藝簡捷(可采用模塑、澆注、拼粘、雕塑等方法)、尺寸穩(wěn)定性好、不變形、耐潮濕、耐腐蝕、易修復(fù)、易改型、重量輕、制作周期短、成本低。??
?????快速經(jīng)濟(jì)制模技術(shù)種類很多，其所具有的特點(diǎn)、應(yīng)用范圍各不相同，本文僅能概括地做一些簡單介紹，每種技術(shù)在具體應(yīng)用和實施過程中尚有許多具體的工藝過程、工藝參數(shù)及其技術(shù)特性。?模具是基礎(chǔ)工業(yè)之一，在全球化市場經(jīng)濟(jì)和各種高新技術(shù)的迅猛發(fā)展形勢下，快速經(jīng)濟(jì)模具賦予了新的使命和全新的內(nèi)涵，分類不斷增加，快速經(jīng)濟(jì)制模材料向著多品種系列化邁進(jìn)，工藝不斷有新的創(chuàng)新和突破，與之配套設(shè)備相繼問世，服務(wù)領(lǐng)域在不斷地拓寬，創(chuàng)造的經(jīng)濟(jì)效益越來越顯著。隨著商品經(jīng)濟(jì)的發(fā)展，激烈的市場競爭，產(chǎn)品更新?lián)Q代的加速，對快速經(jīng)濟(jì)制模技術(shù)在縮短周期、降低成本，提高精度和延長壽命方面的要求勢必會越來越高。由于它能使企業(yè)贏得市場，創(chuàng)造顯著的經(jīng)濟(jì)效益，越來越受到企業(yè)家的青睞和有關(guān)領(lǐng)導(dǎo)部門的極大關(guān)注與政策資金的支持。各種快速經(jīng)濟(jì)制模技術(shù)在推廣應(yīng)用過程中也會不斷完善成熟和發(fā)展，由于高新技術(shù)的發(fā)展，各種技術(shù)的復(fù)合與滲透，為適應(yīng)生產(chǎn)中的不同需求，今后必定會形成一些新型、節(jié)約能源、節(jié)約材料的快速制模技術(shù)。
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