0125-拉鉤的冷沖模設(shè)計(jì)【全套5張CAD圖+文獻(xiàn)翻譯+說(shuō)明書(shū)】
0125-拉鉤的冷沖模設(shè)計(jì)【全套5張CAD圖+文獻(xiàn)翻譯+說(shuō)明書(shū)】,全套5張CAD圖+文獻(xiàn)翻譯+說(shuō)明書(shū),拉鉤,沖模,設(shè)計(jì),全套,cad,文獻(xiàn),翻譯,說(shuō)明書(shū),仿單
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題 目： 拉鉤的冷沖模設(shè)計(jì)
一、模具工業(yè)的分類(lèi)
我國(guó)模具設(shè)計(jì)與制造技術(shù)的發(fā)展經(jīng)歷了手工作坊制造階段、工業(yè)化生產(chǎn)階段和現(xiàn)代化生產(chǎn)階段。伴隨著計(jì)算機(jī)技術(shù)的快速發(fā)展, 數(shù)字化、信息化CADCAE/CAM技術(shù)和數(shù)控加工機(jī)床已普遍采用, 模具產(chǎn)業(yè)正處于高速發(fā)展階段。
模具是制造業(yè)的重要基礎(chǔ)工藝裝備。模具總體上可分為兩大類(lèi): 金屬材料制件成形模具，如沖壓模具、鍛造模具、壓鑄模具、擠壓模具、拉絲模具、粉末冶金模具等; 非金屬材料制件成形模具, 如塑料注射模具、壓鑄模具、擠出模具, 橡膠制件、玻璃制件和陶瓷制件成形模具等。模具的具體分類(lèi)方法很多, 如按模具結(jié)構(gòu)形式分, 沖壓模具可分為簡(jiǎn)單模、連續(xù)模和復(fù)合模, 注塑模具可分為單分型面和雙分型面注塑模具等; 按工藝性質(zhì)分, 沖壓模具可分為沖孔模、落料模、拉深模、彎曲模，塑模具可分為壓塑模、傳遞模、注射模等。[1]
其中沖壓模具、塑料模具、鑄造模具、鍛壓模具、橡膠模具、粉末冶金模具、拉絲模具、無(wú)機(jī)材料成形模具等是最主要的八大類(lèi), 用于制造業(yè)中的幾乎所有產(chǎn)品的生產(chǎn)。[7]
二、模具工業(yè)的地位
模具是以其特定的形狀通過(guò)一定的方式使原材料成型。隨著社會(huì)的發(fā)展和科技的進(jìn)步， 模具行業(yè)越來(lái)越被重視，模具技術(shù)在國(guó)民經(jīng)濟(jì)各個(gè)部門(mén)都得到廣泛的應(yīng)用，它不僅與整個(gè)機(jī)械行業(yè)密切相關(guān)，而且與人們的生活密切相關(guān)。模具工業(yè)是國(guó)民經(jīng)濟(jì)的基礎(chǔ)產(chǎn)業(yè)，是“百
業(yè)之母”，是永不衰亡的行業(yè)，模具工業(yè)的發(fā)展水平標(biāo)志著一個(gè)國(guó)家的工業(yè)水平及產(chǎn)品開(kāi)發(fā)的能力?！笆濉?規(guī)劃指出，模具是生產(chǎn)各種工業(yè)產(chǎn)品的重要基礎(chǔ)工藝裝備，國(guó)民經(jīng)濟(jì)的五大支柱產(chǎn)業(yè)—機(jī)械、電子、汽車(chē)、石化、建筑等都要求模具工業(yè)的發(fā)展與之相適應(yīng)。
模具因其生產(chǎn)效率高、產(chǎn)品質(zhì)量好、材料消耗低、操作簡(jiǎn)單、生產(chǎn)過(guò)程易于實(shí)現(xiàn)機(jī)械化與自動(dòng)化、生產(chǎn)成本低而獲得廣泛應(yīng)用，利用模具可以加工出薄壁、重量輕、剛性好、形狀復(fù)雜的零件；產(chǎn)品質(zhì)量有模具保證，具有一模一樣的的特點(diǎn)；這是其它加工制造業(yè)所無(wú)法完成的；模具是現(xiàn)代工業(yè)，特別是汽車(chē)、摩托車(chē)、航空、儀表、儀器、醫(yī)療器械、電子通信、兵器、家用電器、五金工具、日用品等工業(yè)必不可少的工藝裝備。據(jù)資料統(tǒng)計(jì)，利用模具制造的零件數(shù)量，在飛機(jī)、汽車(chē)、摩托車(chē)、拖拉機(jī)、電機(jī)、電器、儀器儀表等機(jī)電產(chǎn)品中占80%以上；在電腦、電視機(jī)、攝像機(jī)、照相機(jī)、錄像機(jī)等電子產(chǎn)品中占85%以上；在電冰箱、洗衣機(jī)、空調(diào)、電風(fēng)扇、自行車(chē)、手表等輕工業(yè)產(chǎn)品中占90%以上；在子彈、槍支等兵器產(chǎn)品中占95%以上；在日用金屬產(chǎn)品中占95%以上?？梢?jiàn)，研究和發(fā)展模具技術(shù)，對(duì)于促進(jìn)國(guó)民經(jīng)濟(jì)的發(fā)展具有特別重要的意義。目前，模具技術(shù)已成為衡量一個(gè)國(guó)家產(chǎn)品制造水平的重要標(biāo)志之一。[2]
起步到現(xiàn)在，我國(guó)模具工業(yè)經(jīng)歷了半個(gè)多世紀(jì)的發(fā)展，已有了較大的提高，與國(guó)外的差距正在進(jìn)一步縮小。而中國(guó)模具對(duì)世界的影響也在不斷擴(kuò)大, 主要表現(xiàn)在以下幾點(diǎn):
1、ISTMA 和FADMA 及其他國(guó)家的模協(xié)和有關(guān)國(guó)際組織已越來(lái)越重視中國(guó)模協(xié), 他們邀請(qǐng)中國(guó)模協(xié)出席國(guó)際會(huì)議和參加國(guó)際行業(yè)活動(dòng)越來(lái)越多, 他們到中國(guó)來(lái)考察和交流也越來(lái)越多, 中國(guó)模具已經(jīng)成為國(guó)際模具中的一個(gè)不可忽視的力量。
2、隨著國(guó)際交往的日益增多和外資(包括港資、合資) 在中國(guó)模具行業(yè)的投入日漸增加, 中國(guó)模具正表現(xiàn)得越來(lái)越融入世界, 并已逐步與國(guó)際接軌, 三資企業(yè)已對(duì)中國(guó)模具的發(fā)展作出了很大貢獻(xiàn),中國(guó)模具和世界模具已越來(lái)越密不可分。
3、無(wú)論是出口還是在中國(guó)國(guó)內(nèi)使用, 中國(guó)模具已經(jīng)為境外企業(yè)和境內(nèi)三資企業(yè)降低了不少生產(chǎn)成本, 也就是說(shuō), 為世界的進(jìn)步做出了一些貢獻(xiàn),而且這一貢獻(xiàn)將隨著中國(guó)模具的進(jìn)一步發(fā)展而不斷增大。中國(guó)模具與世界正在實(shí)現(xiàn)共贏。
4、由于中國(guó)的過(guò)去、現(xiàn)在和不久的將來(lái)一直有較為優(yōu)秀且豐富和廉價(jià)的人力資源、龐大的市場(chǎng)及其他許多有利條件, 外資在中國(guó)模具中已經(jīng)并且將進(jìn)一步占據(jù)越來(lái)越重要的地位, 中國(guó)已成為承接工業(yè)發(fā)達(dá)國(guó)家模具業(yè)轉(zhuǎn)移的良好目的地, 確實(shí)加速了世界模具產(chǎn)業(yè)的轉(zhuǎn)移, 從而也為通過(guò)這種轉(zhuǎn)移而使工業(yè)發(fā)達(dá)國(guó)家向更高層次發(fā)展做出了貢獻(xiàn)。
5、中國(guó)龐大的模具市場(chǎng)促進(jìn)了世界模具的發(fā)展。
從上述情況來(lái)看, 中國(guó)模具確實(shí)已經(jīng)與世界模具密不可分, 而且中國(guó)模具在世界模具中的地位將會(huì)越來(lái)越重要, 其影響也會(huì)越來(lái)越大。中國(guó)模具加速融入世界并實(shí)現(xiàn)國(guó)際共贏的局面將會(huì)進(jìn)一步發(fā)展下去。在當(dāng)今的信息社會(huì)和世界經(jīng)濟(jì)進(jìn)一步全球化的發(fā)展過(guò)程中,世界在促進(jìn)中國(guó)模具的發(fā)展,中國(guó)模具也正在并將進(jìn)一步促進(jìn)世界的發(fā)展。[9]
三、我國(guó)模具工業(yè)的現(xiàn)狀
模具屬于邊緣科學(xué)，它涉及機(jī)械設(shè)計(jì)制造、塑性加工、鑄造、金屬材料及其熱處理、高分子材料、金屬物理、凝固理論、粉末冶金、塑料、橡膠、玻璃等諸多學(xué)科、領(lǐng)域和行業(yè)。
從中國(guó)模具工業(yè)協(xié)會(huì)獲悉, 近年來(lái)在國(guó)民經(jīng)濟(jì)中占有重要地位的模具工業(yè)得到了迅速發(fā)展。模具是工業(yè)生產(chǎn)的基礎(chǔ)工藝裝備在電子、汽車(chē)、電機(jī)電器、儀表、家電和通訊等產(chǎn)品中, 一般的零部件都依靠模具成型。國(guó)民經(jīng)濟(jì)的五大支柱產(chǎn)業(yè), 機(jī)械, 電子、汽車(chē)、石化、建筑都要求模具工業(yè)的發(fā)展與之相適應(yīng), 模具是“ 效益放大器”, 用模具生產(chǎn)的最終產(chǎn)品價(jià)值, 往往是模具自身價(jià)值的幾十倍、上百倍。模具生產(chǎn)水平的高低, 己成為衡量一個(gè)國(guó)家產(chǎn)品制造水平高低的重要標(biāo)志, 在很大程度上決定著產(chǎn)品的質(zhì)量、效益和新產(chǎn)品的開(kāi)發(fā)能力。因此, 振興和發(fā)展我國(guó)的模具工業(yè),日益受到人們的重視和關(guān)注國(guó)務(wù)院頒布的《關(guān)于當(dāng)前產(chǎn)業(yè)政策要點(diǎn)的丸定》也把模具列為機(jī)械工業(yè)改造序列的第一位、生產(chǎn)和基本建設(shè)序列的第二位。由于我國(guó)模具工業(yè)發(fā)展迅速, 前景廣闊, 國(guó)內(nèi)外模具及模具加工設(shè)備廠商已普遍看好中國(guó)市場(chǎng)?？v觀我國(guó)的模具工業(yè)，既有高速發(fā)展的良好勢(shì)頭，又存在精度低、結(jié)構(gòu)欠合理、壽命短等一系列不足，無(wú)法滿(mǎn)足整個(gè)工業(yè)迅速發(fā)展的迫切要求。[3]
近年來(lái)，我國(guó)模具工業(yè)的迅速發(fā)展是大家有目共睹的，中國(guó)模具工業(yè)的現(xiàn)狀大致可以從以下3個(gè)方面來(lái)講：
1、模具的產(chǎn)值與出口量增長(zhǎng)明顯。從整體情況來(lái)看，我國(guó)已經(jīng)步入模具工業(yè)大國(guó)之列，但是距模具強(qiáng)國(guó)還有相當(dāng)差距。
2、模具制造水平不斷提高。近幾年，以大型、精密、復(fù)雜、長(zhǎng)壽命模具為代表的、技術(shù)含量較高的中高檔模具的比重進(jìn)一步提高，現(xiàn)在中高檔模具所占比重已經(jīng)達(dá)到35% 以上。模具的設(shè)計(jì)和制造水平也有了很大的發(fā)展，很多先進(jìn)的模具設(shè)計(jì)與制造技術(shù)在我國(guó)的模具企業(yè)中得到應(yīng)用，如CAD/CAE/CAM 等計(jì)算機(jī)輔助技術(shù)、高速加工技術(shù)、熱流道技術(shù)、氣輔技術(shù)、逆向工程等新技術(shù)得到廣泛應(yīng)用，E R P、P D M 等信息化管理技術(shù)正得到積極推廣，這些先進(jìn)技術(shù)的應(yīng)用和信息化管理的實(shí)施極大地提高了模具企業(yè)的生產(chǎn)效率，縮短了生產(chǎn)周期。
3、我國(guó)模具行業(yè)已經(jīng)形成了自己的骨干隊(duì)伍。目前，我國(guó)約有模具生產(chǎn)廠點(diǎn)3 萬(wàn)余家，從業(yè)人員100余萬(wàn)人，在各個(gè)模具行業(yè)的骨干企業(yè)隊(duì)伍中也涌現(xiàn)出了本行業(yè)的龍頭企業(yè)。他們的生產(chǎn)裝備先進(jìn)，生產(chǎn)達(dá)到了一定規(guī)模，技術(shù)水平較高，而且產(chǎn)品具有自己的特點(diǎn)。[10]
目前，中國(guó)約有模具生產(chǎn)廠2萬(wàn)余家，從業(yè)人員50多萬(wàn)人，全年模具產(chǎn)值達(dá)450億元人民幣以上。近年來(lái)，模具行業(yè)結(jié)構(gòu)調(diào)整步伐加快，主要表現(xiàn)為大型、精密、復(fù)雜、長(zhǎng)壽命模具和模具標(biāo)準(zhǔn)件發(fā)展速度高于行業(yè)的總體發(fā)展速度；塑料模和壓鑄模比例增大；面向市場(chǎng)的專(zhuān)業(yè)模具廠家數(shù)量及能力增加較快。隨著經(jīng)濟(jì)體制改革的不斷深入，“三資”及民營(yíng)企業(yè)的發(fā)展很快。[5]
在模具產(chǎn)值產(chǎn)量和進(jìn)出口迅速發(fā)展的同時(shí), 近年來(lái)中國(guó)在模具行業(yè)技術(shù)進(jìn)步和模具水平的提高方面也取得了可喜的成績(jī)?，F(xiàn)在, 我國(guó)已能生產(chǎn)精度達(dá)到詳?shù)亩喙の患?jí)進(jìn)模, 壽命可達(dá)億沖次以上。個(gè)別企業(yè)生產(chǎn)的多工位級(jí)進(jìn)模已可在次的高速?zèng)_床上使用, 精度可達(dá)林。在大型塑料模具方面, 我國(guó)已能生產(chǎn)英寸大屏幕彩電和英寸背投式電視的塑殼模具、大容量洗衣機(jī)全套塑料件模具以及汽車(chē)保險(xiǎn)杠、整體儀表板塑料模具等。在精密塑料模具方面, 我國(guó)已能生產(chǎn)照相機(jī)和手機(jī)塑料件模具、多型腔小模數(shù)齒輪模具及精度達(dá)林的腔塑封模具等,精度達(dá)到林的光盤(pán)模也已能夠生產(chǎn)了。塑料模具的熱流道和氣輔等技術(shù)水平不斷提高。在大型精密復(fù)雜壓鑄模方面, 國(guó)內(nèi)已能生產(chǎn)自動(dòng)扶梯整體踏板壓鑄模、汽車(chē)后橋齒輪箱壓鑄模以及汽車(chē)發(fā)動(dòng)機(jī)殼體的鑄造模具等。在汽車(chē)覆蓋件模具方面,國(guó)內(nèi)已能生產(chǎn)中檔新型轎車(chē)的覆蓋件模具, 高檔轎車(chē)的部分覆蓋件模具也已能夠生產(chǎn)了。子午線(xiàn)輪胎活絡(luò)模具、鋁合金和塑料門(mén)窗異型材擠出成形模、精鑄或樹(shù)脂快速成型拉延模等, 也已達(dá)到相當(dāng)高的水平, 制造出來(lái)的模具可與進(jìn)口模具媲美。國(guó)內(nèi)生產(chǎn)的最大模具單套重量已超過(guò)100t我國(guó)模具企業(yè)CAD、CAM、CAE、CAPP、PDM、PLM、ERP等數(shù)字、化信息化技術(shù)的使用面正在不斷擴(kuò)大, 水平也在不斷提高。
中國(guó)模具工業(yè)產(chǎn)值僅次于日本和美國(guó), 排在世界前三位。中國(guó)經(jīng)濟(jì)的高速發(fā)展同樣對(duì)模具工業(yè)提出了越來(lái)越高的要求, 也為其發(fā)展提供了巨大的空間。現(xiàn)今, 國(guó)內(nèi)的模具生產(chǎn)廠家已增至2 萬(wàn)余家, 模具制造從業(yè)人員已超過(guò)50 多萬(wàn)人, 模具的年產(chǎn)值達(dá)到534 億元人民幣。近10 年來(lái), 國(guó)內(nèi)模具在數(shù)量、質(zhì)量、技術(shù)等方面有了很大的跨躍; 現(xiàn)正以每年15 %左右的增長(zhǎng)速度穩(wěn)步發(fā)展。[4]
四、現(xiàn)代模具設(shè)計(jì)與制造方法
現(xiàn)代模具制造業(yè)已成為技術(shù)密集型和資金密集型的產(chǎn)業(yè), 它與高新技術(shù)已形成相互依托的關(guān)系。一方面, 模具是直接為高新技術(shù)產(chǎn)業(yè)化服務(wù)的不可缺少的裝備另一方面, 模具生產(chǎn)本身又大量采用高新技術(shù)及裝備, 因此, 模具制造已成為高新技術(shù)產(chǎn)業(yè)的重要組成部分。模具成形零件時(shí)實(shí)現(xiàn)快速、優(yōu)質(zhì)、低耗是國(guó)家可持續(xù)發(fā)展戰(zhàn)略的要求。[7]
我國(guó)模具制造技術(shù)發(fā)展迅速，逐漸由單一、具體、細(xì)節(jié)的設(shè)計(jì)及各道工序的加工過(guò)程向設(shè)計(jì)、制造技術(shù)的系統(tǒng)化、集成化過(guò)程轉(zhuǎn)變，已成為現(xiàn)代先進(jìn)制造技術(shù)的重要組成部分。
1、模具CAD/CAE/CAM技術(shù)：以三維造型為主的模具設(shè)計(jì)、制造、工藝信息的數(shù)字化傳遞及轉(zhuǎn)換所形成的CAD/CAE/CAM一體化技術(shù)在我國(guó)已大量推廣應(yīng)用。例如，汽車(chē)大型覆蓋件模具已普遍應(yīng)用CAD/CAM技術(shù)，實(shí)現(xiàn)了模具設(shè)計(jì)、制造、沖壓一體化、數(shù)控編程和數(shù)控加工實(shí)現(xiàn)了DNC，計(jì)算機(jī)軟硬件配置已接近國(guó)際水平；在塑料模具方面也已廣泛應(yīng)用CAD/CAE/CAM技術(shù)，多項(xiàng)國(guó)內(nèi)自主開(kāi)發(fā)的軟件推廣之中，如北航華正的CAXA軟件系列和華中理工大學(xué)的HSC2.0等；在壓鑄模方面，CAD/CAM同樣得到了廣泛應(yīng)用，并已開(kāi)始應(yīng)用CAE軟件進(jìn)行澆道系統(tǒng)和工藝參數(shù)等方面的優(yōu)化分析。
2、模具先進(jìn)制造工藝及裝備：模具由功能件和支持件組成。在塑料模和壓鑄模中，功能件為型腔和型芯，在鍛模中為型腔，在沖壓模具中為型孔和沖頭，支持件一般為標(biāo)準(zhǔn)件，因此，模具加工的主要部件可分為兩類(lèi)，即型腔，型芯加工和型孔加工。
（1）高速銑削加工
高速銑削加工在模具制造中具有以下特點(diǎn)：高效，高速銑削加工的主軸轉(zhuǎn)速一般為15000-40000r/min,最高可達(dá)100000r/min。切削鋼時(shí)，其切削速度約為400m/min，比傳統(tǒng)的銑削加工高5~10倍；在加工型腔模時(shí)與傳統(tǒng)的加工方法相比起效率提高4-5倍；與完全采用EDM加工相比，其加工速度提高了4-8倍；高精度，一般加工精度為10m，有的精度更高；高表面質(zhì)量，由于高速銑削的工具溫度小，姑表面沒(méi)有變質(zhì)層及微裂紋，熱變形也小。最好的表面粗糙度R小于1m；可加工高硬材料，可銑削50~54HRC。
（2）NCEDM加工
NCEDM的多軸聯(lián)動(dòng)控制、電極自動(dòng)交換、C軸加工、數(shù)控?cái)[動(dòng)等功能能完成各種復(fù)雜型腔的精密加工，采用自適應(yīng)控制、模糊控制、各種專(zhuān)家系統(tǒng)、新型脈沖電源燈優(yōu)化加工狀態(tài)，自動(dòng)完成全部加工過(guò)程。NCEDM在中小型腔模、復(fù)雜精密型腔模等加工方面發(fā)揮著越來(lái)越重要的作用。
（3）虛擬軸數(shù)控加工
在模具復(fù)雜型腔銑削加工中采用五軸數(shù)控銑床可提高加工質(zhì)量和效率。五軸數(shù)控加工還可在三軸聯(lián)動(dòng)加工不易接近的地方進(jìn)行加工，以避免銑刀中心銑削工作帶來(lái)的弊端，并能在一次裝夾中完成五面加工，因此更適合于模具制造。虛擬軸五軸數(shù)控機(jī)床突破了傳統(tǒng)的串聯(lián)式床身滑臺(tái)結(jié)構(gòu)，由于采用了高級(jí)軟件、降低了傳統(tǒng)五軸數(shù)控銑床結(jié)構(gòu)的復(fù)雜性，因此，結(jié)構(gòu)簡(jiǎn)單，成本低。虛擬軸五軸數(shù)控機(jī)床也可實(shí)現(xiàn)高速加工，尤其適合復(fù)雜型腔的銑削、磨削和測(cè)量，是我國(guó)模具制造工藝及裝備的重要發(fā)展方向。
（4）復(fù)合加工
復(fù)合加工時(shí)指在一臺(tái)機(jī)床上進(jìn)行兩種或兩種以上不同加工工藝的復(fù)合，以實(shí)現(xiàn)不同加工工藝優(yōu)勢(shì)互補(bǔ)的作用。其發(fā)展方向又可分為兩個(gè)方向：銑削加工與激光加工復(fù)合技術(shù)，銑削加工與EDM復(fù)合技術(shù)。
（5）型孔加工工藝及裝備
沖壓模等型孔加工主要依靠磨削加工及數(shù)控電火花線(xiàn)切割加工（WEDM）。在磨削加工中，成形磨、坐標(biāo)磨、光曲磨等精密加工工藝及裝備在我國(guó)已廣泛應(yīng)用。WEDM在沖壓模等型孔加工中已起到不可替代的作用。國(guó)內(nèi)外沖壓模等加工都離不開(kāi)WEDM。主要方向有：磨削加工、WEDM加工。[6]
五、我國(guó)模具行業(yè)存在的問(wèn)題
目前, 我國(guó)模具總量雖然已達(dá)到相當(dāng)大的規(guī)模, 模具水平也已有了很大提高, 但在總體上, 我國(guó)模具生產(chǎn)的商品化、專(zhuān)業(yè)化、標(biāo)淮化程度還較低, 商品化模具只占左右, 模具標(biāo)準(zhǔn)件使用覆蓋率還不到, 專(zhuān)業(yè)模具企業(yè)只占模具生產(chǎn)廠點(diǎn)的少數(shù), 而且裝備也比較落后。由于資金缺乏, 我國(guó)的模具企業(yè)大都只能購(gòu)買(mǎi)較低檔的國(guó)產(chǎn)設(shè)備和來(lái)自我國(guó)臺(tái)灣的設(shè)備, 而少用歐美和日本的高檔設(shè)備, 設(shè)備數(shù)控化程度遠(yuǎn)低于國(guó)際水平。我國(guó)模具設(shè)計(jì)制造水平在總體上要比工業(yè)發(fā)達(dá)國(guó)家落后許多。
主要存在以下幾點(diǎn)問(wèn)題：
1、產(chǎn)品質(zhì)量不高：當(dāng)前我國(guó)模具生產(chǎn)廠中多數(shù)是“大而全”、“小而全”，國(guó)外模具企業(yè)大多是“小而專(zhuān)”、“小而精”。國(guó)內(nèi)模具總量中屬大型、精密、復(fù)雜、長(zhǎng)壽命模具的比例只有30% 左右，國(guó)外在50%以上。國(guó)內(nèi)模具生產(chǎn)廠家，工藝條件參差不齊，差距很大?，F(xiàn)代模具工業(yè)早已走出以前手工制模的時(shí)代，進(jìn)入了數(shù)字化時(shí)代，實(shí)現(xiàn)了無(wú)圖化生產(chǎn)，通過(guò)電腦輸入數(shù)據(jù)加工制作模具。我國(guó)不少?gòu)S家由于設(shè)備不配套很多工作依賴(lài)手工完成，嚴(yán)重影響了精度和質(zhì)量。
2、標(biāo)準(zhǔn)化水平不高：模具是專(zhuān)用成形工具產(chǎn)品，雖然個(gè)性化強(qiáng)，但也是工業(yè)產(chǎn)品，所以標(biāo)準(zhǔn)化工作十分重要。模具標(biāo)準(zhǔn)化工作主要包括模具技術(shù)標(biāo)準(zhǔn)的制訂和執(zhí)行、模具標(biāo)準(zhǔn)件的生產(chǎn)和應(yīng)用以及有關(guān)標(biāo)準(zhǔn)的宣傳、貫徹和推廣等工作。中國(guó)模具標(biāo)準(zhǔn)化工作起步較晚，因此模具標(biāo)準(zhǔn)化落后于生產(chǎn)，更落后于世界上許多工業(yè)發(fā)達(dá)的國(guó)家。由于中國(guó)模具標(biāo)準(zhǔn)化工作起步較晚，模具標(biāo)準(zhǔn)件生產(chǎn)、銷(xiāo)售、推廣和應(yīng)用工作也比較落后，因此，模具標(biāo)準(zhǔn)件品種規(guī)格少、供應(yīng)不及時(shí)、配套性差等問(wèn)題長(zhǎng)期存在，從而使模具標(biāo)準(zhǔn)件使用覆蓋率一直較低。
3、CAD/CAE/CAM 技術(shù)剛起步：CAD/CAE/CAM 是面向制造的工程設(shè)計(jì)技術(shù)群中的核心技術(shù)，是提高企業(yè)產(chǎn)品自主開(kāi)發(fā)能力和產(chǎn)品檔次的重要手段，也是提高企業(yè)對(duì)市場(chǎng)的應(yīng)變能力和快速響應(yīng)能力的重要途徑，是現(xiàn)階段應(yīng)大力推廣應(yīng)用的關(guān)鍵共性技術(shù)，是模具設(shè)計(jì)的發(fā)展方向。
4、缺乏相關(guān)人才：當(dāng)今世界正進(jìn)行著新一輪的產(chǎn)業(yè)調(diào)整，一些模具制造逐漸向發(fā)展中國(guó)家轉(zhuǎn)移，中國(guó)正成為世界模具大國(guó)，但我國(guó)模具行業(yè)人才緊缺成為一個(gè)迫在眉睫的問(wèn)題。模具行業(yè)是一個(gè)需長(zhǎng)期積累經(jīng)驗(yàn)的行業(yè)，現(xiàn)在的年輕人能堅(jiān)持下來(lái)而有所成就的很少。由于最初的學(xué)習(xí)非?？菰铮虼嗽S多初學(xué)者常半途而廢。此外，我國(guó)傳統(tǒng)教育方式對(duì)模具人才的培養(yǎng)存在不足。一些高校盡管在近幾年內(nèi)設(shè)立了模具專(zhuān)業(yè)，但由于受軟硬件設(shè)施限制，培養(yǎng)出的學(xué)員實(shí)際技能不夠。而社會(huì)上各種各樣的模具培訓(xùn)班，由于缺乏規(guī)范的職業(yè)標(biāo)準(zhǔn)，因此學(xué)員質(zhì)量良莠不齊。
5、受到外資的挑戰(zhàn)：目前世界制造業(yè)生產(chǎn)基地加速向中國(guó)轉(zhuǎn)移，中國(guó)制造業(yè)又正邁向更高的發(fā)展階段，對(duì)優(yōu)質(zhì)精密模具的需求不斷上升。國(guó)際模具工業(yè)巨頭繼20世紀(jì)90 年代中期進(jìn)入中國(guó)后，再掀投資熱潮，目的正為搶占先機(jī)，中國(guó)本土模具工業(yè)面臨國(guó)外先進(jìn)技術(shù)與高質(zhì)量制品的挑戰(zhàn)，生存空間受擠壓。
6、缺乏自有品牌：企業(yè)開(kāi)發(fā)能力弱、沒(méi)有品牌，導(dǎo)致了經(jīng)濟(jì)效益欠佳，在市場(chǎng)中常處于被動(dòng)地位。[8]
六、參考文獻(xiàn)
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[6]陳德忠.我國(guó)模具先進(jìn)制造技術(shù)的發(fā)展[J].發(fā)展前沿，2000,09
[7]周永泰.中國(guó)模具工業(yè)的現(xiàn)狀與發(fā)展[J].行業(yè)展望，2007,12
[8]屈偉平.我國(guó)模具制造業(yè)發(fā)展現(xiàn)狀、存在的問(wèn)題及對(duì)策[J].模具技術(shù)，2006,05
[9]周永泰.中國(guó)模具正在加速融入世界并實(shí)現(xiàn)國(guó)際共贏[J].模具工業(yè)，2006,04
[10]曉霏等.中國(guó)模具工業(yè)發(fā)展現(xiàn)狀與展望[J].航空制造技術(shù)，2008,08
[11] A. Y. C. Nee and M. W. Fu, “Determination of optimal parting directions in plastic injection mold design”, Annals CIRP, 46(1),pp. 429–432, 1997.
9
開(kāi)題報(bào)告
題 目： 拉鉤的冷沖模設(shè)計(jì)
一、課題意義
1、模具工業(yè)的分類(lèi)
我國(guó)模具設(shè)計(jì)與制造技術(shù)的發(fā)展經(jīng)歷了手工作坊制造階段、工業(yè)化生產(chǎn)階段和現(xiàn)代化生產(chǎn)階段。伴隨著計(jì)算機(jī)技術(shù)的快速發(fā)展, 數(shù)字化、信息化CADCAE/CAM技術(shù)和數(shù)控加工機(jī)床已普遍采用, 模具產(chǎn)業(yè)正處于高速發(fā)展階段。
模具是制造業(yè)的重要基礎(chǔ)工藝裝備。模具總體上可分為兩大類(lèi): 金屬材料制件成形模具，如沖壓模具、鍛造模具、壓鑄模具、擠壓模具、拉絲模具、粉末冶金模具等; 非金屬材料制件成形模具, 如塑料注射模具、壓鑄模具、擠出模具, 橡膠制件、玻璃制件和陶瓷制件成形模具等。模具的具體分類(lèi)方法很多, 如按模具結(jié)構(gòu)形式分, 沖壓模具可分為簡(jiǎn)單模、連續(xù)模和復(fù)合模, 注塑模具可分為單分型面和雙分型面注塑模具等; 按工藝性質(zhì)分, 沖壓模具可分為沖孔模、落料模、拉深模、彎曲模，塑模具可分為壓塑模、傳遞模、注射模等。其中沖壓模具、塑料模具、鑄造模具、鍛壓模具、橡膠模具、粉末冶金模具、拉絲模具、無(wú)機(jī)材料成形模具等是最主要的八大類(lèi), 用于制造業(yè)中的幾乎所有產(chǎn)品的生產(chǎn)。[7]
2、模具工業(yè)的地位
隨著社會(huì)的發(fā)展和科技的進(jìn)步， 模具行業(yè)越來(lái)越被重視，模具技術(shù)在國(guó)民經(jīng)濟(jì)各個(gè)部門(mén)都得到廣泛的應(yīng)用，它不僅與整個(gè)機(jī)械行業(yè)密切相關(guān)，而且與人們的生活密切相關(guān)。模具工業(yè)是國(guó)民經(jīng)濟(jì)的基礎(chǔ)產(chǎn)業(yè)，模具工業(yè)的發(fā)展水平標(biāo)志著一個(gè)國(guó)家的工業(yè)水平及產(chǎn)品開(kāi)發(fā)的能力。模具是生產(chǎn)各種工業(yè)產(chǎn)品的重要基礎(chǔ)工藝裝備，國(guó)民經(jīng)濟(jì)的五大支柱產(chǎn)業(yè)—機(jī)械、電子、汽車(chē)、石化、建筑等都要求模具工業(yè)的發(fā)展與之相適應(yīng)。
模具因其生產(chǎn)效率高、產(chǎn)品質(zhì)量好、材料消耗低、操作簡(jiǎn)單、生產(chǎn)過(guò)程易于實(shí)現(xiàn)機(jī)械化與自動(dòng)化、生產(chǎn)成本低而獲得廣泛應(yīng)用，利用模具可以加工出薄壁、重量輕、剛性好、形狀復(fù)雜的零件；產(chǎn)品質(zhì)量有模具保證，具有一模一樣的的特點(diǎn)；這是其它加工制造業(yè)所無(wú)法完成的；模具是現(xiàn)代工業(yè)，特別是汽車(chē)、摩托車(chē)、航空、儀表、儀器、醫(yī)療器械、電子通信、兵器、家用電器、五金工具、日用品等工業(yè)必不可少的工藝裝備。據(jù)資料統(tǒng)計(jì)，利用模具制造的零件數(shù)量，在飛機(jī)、汽車(chē)、摩托車(chē)、拖拉機(jī)、電機(jī)、電器、儀器儀表等機(jī)電產(chǎn)品中占80%以上；在電腦、電視機(jī)、攝像機(jī)、照相機(jī)、錄像機(jī)等電子產(chǎn)品中占85%以上；在電冰箱、洗衣機(jī)、空調(diào)、電風(fēng)扇、自行車(chē)、手表等輕工業(yè)產(chǎn)品中占90%以上；在子彈、槍支等兵器產(chǎn)品中占95%以上；在日用金屬產(chǎn)品中占95%以上?？梢?jiàn)，研究和發(fā)展模具技術(shù)，對(duì)于促進(jìn)國(guó)民經(jīng)濟(jì)的發(fā)展具有特別重要的意義。目前，模具技術(shù)已成為衡量一個(gè)國(guó)家產(chǎn)品制造水平的重要標(biāo)志之一。[2]
3、我國(guó)模具工業(yè)的現(xiàn)狀
近年來(lái)，我國(guó)模具工業(yè)的迅速發(fā)展是大家有目共睹的，中國(guó)模具工業(yè)的現(xiàn)狀大致可以從以下3個(gè)方面來(lái)講：
（1）模具的產(chǎn)值與出口量增長(zhǎng)明顯。從整體情況來(lái)看，我國(guó)已經(jīng)步入模具工業(yè)大國(guó)之列，但是距模具強(qiáng)國(guó)還有相當(dāng)差距。
（2）模具制造水平不斷提高。近幾年，以大型、精密、復(fù)雜、長(zhǎng)壽命模具為代表的、技術(shù)含量較高的中高檔模具的比重進(jìn)一步提高，現(xiàn)在中高檔模具所占比重已經(jīng)達(dá)到35% 以上。模具的設(shè)計(jì)和制造水平也有了很大的發(fā)展，很多先進(jìn)的模具設(shè)計(jì)與制造技術(shù)在我國(guó)的模具企業(yè)中得到應(yīng)用，如CAD/CAE/CAM 等計(jì)算機(jī)輔助技術(shù)、高速加工技術(shù)、熱流道技術(shù)、氣輔技術(shù)、逆向工程等新技術(shù)得到廣泛應(yīng)用，E R P、P D M 等信息化管理技術(shù)正得到積極推廣，這些先進(jìn)技術(shù)的應(yīng)用和信息化管理的實(shí)施極大地提高了模具企業(yè)的生產(chǎn)效率，縮短了生產(chǎn)周期。
（3）我國(guó)模具行業(yè)已經(jīng)形成了自己的骨干隊(duì)伍。目前，我國(guó)約有模具生產(chǎn)廠點(diǎn)3 萬(wàn)余家，從業(yè)人員100余萬(wàn)人，在各個(gè)模具行業(yè)的骨干企業(yè)隊(duì)伍中也涌現(xiàn)出了本行業(yè)的龍頭企業(yè)。他們的生產(chǎn)裝備先進(jìn)，生產(chǎn)達(dá)到了一定規(guī)模，技術(shù)水平較高，而且產(chǎn)品具有自己的特點(diǎn)。[10]
目前，中國(guó)約有模具生產(chǎn)廠2萬(wàn)余家，從業(yè)人員50多萬(wàn)人，全年模具產(chǎn)值達(dá)450億元人民幣以上。近年來(lái)，模具行業(yè)結(jié)構(gòu)調(diào)整步伐加快，主要表現(xiàn)為大型、精密、復(fù)雜、長(zhǎng)壽命模具和模具標(biāo)準(zhǔn)件發(fā)展速度高于行業(yè)的總體發(fā)展速度；塑料模和壓鑄模比例增大；面向市場(chǎng)的專(zhuān)業(yè)模具廠家數(shù)量及能力增加較快。隨著經(jīng)濟(jì)體制改革的不斷深入，“三資”及民營(yíng)企業(yè)的發(fā)展很快。中國(guó)模具工業(yè)的發(fā)展在地域分布上存在不平衡性，東南沿海地區(qū)發(fā)展快于中西部地區(qū)，南方的發(fā)展快于北方。模具生產(chǎn)最集中的地區(qū)在珠江三角和長(zhǎng)江三角地區(qū)，其模具產(chǎn)值約占全國(guó)產(chǎn)值的2/3以上。[5]
二、現(xiàn)代模具的發(fā)展前景
為了制造高精度、長(zhǎng)壽命、高效的復(fù)雜腔結(jié)構(gòu)的現(xiàn)代模具，需解決以下３個(gè)方面的問(wèn)題：
1、模具材料及其表面處理技術(shù)。模具工業(yè)要上水平，材料應(yīng)用是關(guān)鍵。因選材和用材不當(dāng)，致使模具過(guò)早失效，大約占失效模具的45%以上。在模具材料方面常用的冷作模具鋼有CrWMn、Cr12、Cr12MoV 和W6Mo5Cr4V2，新型冷作模具鋼有65Nb、O12Al、CG-2、LD、GD、GM等；常用新型熱作模具鋼有美國(guó)H 1 3、瑞典QRO 80M、QRO 90SUPREME 等；常用塑料模具用鋼有預(yù)硬鋼(P20、SM1 B30)、時(shí)效硬化型鋼(P21、PMS、SM2、日本NAK55等)、熱處理硬化型鋼(MnCrWV、日本S-STAR、瑞典－勝百S-136 等)、粉末模具鋼(日本DEX40 等);多工位精度沖模硬質(zhì)合金(YG20、YG25 等)以及鋼結(jié)構(gòu)硬質(zhì)合金( T L M W 5 0 、GW50 等)。在模具表面處理方面，主要趨勢(shì)是：由滲入單一元素向多元素共滲、復(fù)合滲(如TD 法)發(fā)展；由一般擴(kuò)散向CVD 、P V D、P C V D、離入滲入、離子注入等方向發(fā)展;可采用的鍍膜有：TiC、TiN、TiCN、TiAN、CrN、Cr7C3、W2C 等，同時(shí)熱處理手段由大氣熱處理向真空熱處理發(fā)展。另外，激光強(qiáng)化、輝光離子氮化技術(shù)也日益受到重視。
2、提高設(shè)計(jì)制造技術(shù)水平。當(dāng)代模具的設(shè)計(jì)與制造已廣泛采用計(jì)算機(jī)輔助設(shè)計(jì)與制造( C A D /CAM)，設(shè)計(jì)過(guò)程程序化和自動(dòng)化，使用程序模擬成形過(guò)程，采用交互式設(shè)計(jì)方法，發(fā)揮人和計(jì)算機(jī)的各自特長(zhǎng)。數(shù)據(jù)庫(kù)和計(jì)算機(jī)網(wǎng)絡(luò)技術(shù)使設(shè)計(jì)人員擁有大量資料和信息。設(shè)計(jì)與制造之間的直接信息傳輸便于設(shè)計(jì)的反復(fù)修改。
3、專(zhuān)業(yè)化生產(chǎn)及標(biāo)準(zhǔn)化。專(zhuān)業(yè)化生產(chǎn)是現(xiàn)代化工業(yè)生產(chǎn)的重要特征之一，工業(yè)先進(jìn)國(guó)家模具專(zhuān)業(yè)化生產(chǎn)已達(dá)到75% 以上。標(biāo)準(zhǔn)化是實(shí)現(xiàn)模具專(zhuān)業(yè)化生產(chǎn)的基本前提，也是系統(tǒng)提高整個(gè)模具行業(yè)技術(shù)水平和經(jīng)濟(jì)效益的重要手段，這是機(jī)械制造業(yè)向深層次發(fā)展的必由之路。國(guó)外企業(yè)都極為重視模具的標(biāo)準(zhǔn)化，我國(guó)的模具標(biāo)準(zhǔn)化程度不足30%，而且標(biāo)準(zhǔn)品種少、質(zhì)量低、交貨期長(zhǎng)，嚴(yán)重阻礙了模具的合理流向和效能的發(fā)揮，需盡快制訂標(biāo)準(zhǔn)化規(guī)范Windows 用戶(hù)界面。[3]
目前, 國(guó)內(nèi)模具市場(chǎng)不斷擴(kuò)大, 國(guó)際上將模具制造逐漸向我國(guó)轉(zhuǎn)移的趨勢(shì)和跨國(guó)集團(tuán)到我國(guó)進(jìn)行模具國(guó)際采購(gòu)的趨向十分明顯。因此,展望未來(lái), 國(guó)際、國(guó)內(nèi)模具市場(chǎng)總體發(fā)展前景美好。我國(guó)模具工業(yè)將會(huì)有一個(gè)繼續(xù)高速發(fā)展的機(jī)遇期。只要我們把握這個(gè)機(jī)遇期, 中國(guó)模具工業(yè)不但會(huì)在量和質(zhì)的方面繼續(xù)有一個(gè)很大的提高, 而且一定會(huì)在行業(yè)結(jié)構(gòu)、產(chǎn)品水平、開(kāi)發(fā)創(chuàng)新能力、企業(yè)的體制與機(jī)制的方方面面取得較大進(jìn)展。
模具技術(shù)集合了機(jī)械、電子、化學(xué)、光學(xué)、材料、計(jì)算機(jī)、精密檢測(cè)和信息網(wǎng)絡(luò)等諸多學(xué)科, 是一個(gè)綜合性多學(xué)科的系統(tǒng)工程。模具技術(shù)的發(fā)展趨勢(shì)主要是模具產(chǎn)品向著更大型、更精密、更復(fù)雜及更經(jīng)濟(jì)快速的方向發(fā)展, 模具產(chǎn)品的技術(shù)含量不斷提高, 模具制造周期不斷縮短, 模具生產(chǎn)朝著信息化、無(wú)圖化、精細(xì)化、自動(dòng)化的方向發(fā)展, 模具企業(yè)向著技術(shù)集成化、設(shè)備精良化、產(chǎn)品品牌化、管理信息化、經(jīng)營(yíng)國(guó)際化的方向發(fā)展。[7]
三、課題研究方法與計(jì)劃
課題的主要內(nèi)容是沖壓模具的設(shè)計(jì)，所以我首先應(yīng)該深入學(xué)習(xí)機(jī)械設(shè)計(jì)、機(jī)械CAD/CAM、冷沖壓技術(shù)等相關(guān)知識(shí)。沖壓模具是模具類(lèi)別中應(yīng)用最廣泛的一種，通過(guò)模具對(duì)金屬的直接加壓使其產(chǎn)生塑性變形，從而金屬材料分離，以此來(lái)獲得一定尺寸和性能的金屬零件。模具的設(shè)計(jì)過(guò)程是和實(shí)際生產(chǎn)分不開(kāi)的。我們應(yīng)該充分研究設(shè)計(jì)任務(wù)書(shū)，了解產(chǎn)品用途，并進(jìn)行沖壓件的工藝性及尺寸公差等級(jí)分析，對(duì)于一些沖壓件結(jié)構(gòu)不合理或工藝性不好的，必須征詢(xún)指導(dǎo)教師的意見(jiàn)后進(jìn)行改進(jìn)。在初步明確設(shè)計(jì)要求的基礎(chǔ)上，可按以下步驟進(jìn)行沖壓總體方案的論證。
1、主要任務(wù)與目標(biāo)
圖1為某電器元件—拉鉤。該零件的制造方法為冷沖壓成型，本課題要求分析封蓋沖壓件的成形工藝，設(shè)計(jì)模具，畫(huà)出模具裝配圖及所有零部件的工程圖，寫(xiě)出畢業(yè)論文。
圖1 掛鉤
2、主要內(nèi)容與基本要求
（1）分析墊片的沖壓成形工藝。
（2）模具設(shè)計(jì)。此零件厚度小，形狀簡(jiǎn)單，要求設(shè)計(jì)的模具具有高精度和高成型效率。
（3）打印圖紙，寫(xiě)出畢業(yè)論文。
（4）要求學(xué)生熟悉冷沖模具設(shè)計(jì)工藝，具有較強(qiáng)的機(jī)械設(shè)計(jì)能力。設(shè)計(jì)圖紙的正確與否是評(píng)定本次設(shè)計(jì)水平的關(guān)鍵。
四、參考文獻(xiàn)
[1]劉國(guó)勝.黃石理工學(xué)院學(xué)報(bào). Journal of Huangshi Institute of Technology，2007，01
[2]蔣桂芝.模具技術(shù)在國(guó)民經(jīng)濟(jì)中的地位[J].機(jī)電產(chǎn)品開(kāi)發(fā)與創(chuàng)新，2009，05
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外文文獻(xiàn)翻譯譯文
題 目： 拉鉤的冷沖模設(shè)計(jì)
一、 外文原文
A Parametric-Controlled Cavity Layout Design System for a Plastic Injection Mould
M. L. H. Low and K. S. Lee
Department of Mechanical Engineering, National University of Singapore, Singapore
Today, the time-to-market for plastic products is becoming shorter, thus the lead time available for making the injection mould is decreasing. There is potential for timesaving in the mould design stage because a design process that is repeatable for every mould design can be standardised. This paper presents a methodology for designing the cavity layout for plastic injection moulds by controlling the geometrical parameters using a standardisation template. The standardization template for the cavity layout design consists of the configurations for the possible layouts. Each configuration of the layout design has its own layout design table of all the geometrical parameters. This standardisation template is pre-defined at the layout design level of the mould assembly design. This ensures that the required configuration can be loaded into the mould assembly design very quickly, without the need to redesign the layout. This makes it useful in technical discussions between the product designers and mould designers prior to the manufacture of the mould. Changes can be made to the 3D cavity layout design immediately during the discussions, thus saving time and avoiding miscommunication. This standardisation template for the cavity layout design can be customised easily for each mould making company to their own standards.
Keywords: Cavity layout design; Geometrical parameters;
Mould assembly; Plastic injection mould design; Standardisation
template
1. Introduction
Plastic injection moulding is a common method for the mass production of plastic parts with good tolerances. There are two main items that are required for plastic injection moulding. They are the injection-moulding machine and the injection mould. The injection-moulding machine has the mould mountedon it and provides the mechanism for molten plastic transfer from the machine to the mould, clamping the mould by the application of pressure and the ejection of the formed plastic part. The injection mould is a tool for transforming the molten plastic into the final shape and dimensional details of the plastic part. Today, as the time-to-market for plastic parts is becoming shorter, it is essential to produce the injection mould in a shorter time.
Much work had been done on applying computer technologies to injection mould design and the related field. Knowledge-based systems (KBS) such as IMOLD [1,2], IKMOULD[3], ESMOLD [4], the KBS of the National Cheng Kang University, Taiwan [5], the KBS of Drexel University [6], etc. were developed for injection mould design. Systems such as HyperQ/Plastic [7], CIMP [8], FIT [9], etc. are developed for the selection of plastic materials using a knowledge-based approach. Techniques have also been developed for parting design in injection moulding [10–12].
It has been observed that although mould-making industries are using 3D CAD software for mould design, much time is wasted in going through the same design processes for every project. There is great potential for timesaving at the mould design stage if the repeatable design processes can be standardized to avoid routine tasks. A well-organised hierarchical design tree in the mould assembly is also an important factor [13,14].However, little work has been done in controlling the parameters in the cavity layout design; thus this area will be our main focus. Although there are many ways of designing the cavity layout [15,16], mould designers tend to use only conventional designs, thus there is a need to apply standardisation at the cavity layout design level.
This paper presents a methodology for designing the cavity layout for plastic injection moulds by controlling the parameters based on a standardisation template. First, a well-organised mould assembly hierarchy design tree had to be established. Then, the classification of the cavity layout configuration had to be made to differentiate between those with standard configurations and those with non-standard configurations. The standard configurations will be listed in a configuration database and each configuration has its own layout design table that controls its own geometrical parameters. This standardization template is pre-defined at the layout design level of the mould assembly design.
2. Cavity Layout Design for a Plastic Injection Mould
An injection mould is a tool for transforming molten plastic into the final shape and dimensional details of a plastic part. Thus, a mould contains an inverse impression of the final part. Most of the moulds are built up of two halves: the front insert and the back insert. In certain mould-making industries, the front insert is also known as the cavity and the back insert is known as the core. Figure 1 shows a front insert (cavity) and a back insert (core). Molten plastic is injected into the impression to fill it. Solidification of the molten plastic then forms the part. Figure 2 shows a simple two-plate mould assembly.
2.1 Difference Between a Single-Cavity and a Multi-Cavity Mould
Very often, the impression in which molten plastic is being filled is also called the cavity. The arrangement of the cavities is called the cavity layout. When a mould contains more than one cavity, it is referred to as a multi-cavity mould. Figures 3(a) and 3(b) shows a single-cavity mould and a multi-cavity mould.
A single-cavity mould is normally designed for fairly large parts such as plotter covers and television housings. For smaller parts such as hand phone covers and gears, it is always more economical to design a multi-cavity mould so that more parts can be produced per moulding cycle. Customers usually determine the number of cavities, as they have to balance the investment in the tooling against the part cost.
2.2 Multi-Cavity Layout
A multi-cavity mould that produces different products at the same time is known as a family mould. However, it is not usual to design a mould with different cavities, as the cavities may not all be filled at the same time with molten plastic of the same temperature.
On the other hand, a multi-cavity mould that produces the same product throughout the moulding cycle can have a balanced layout or an unbalanced layout. A balanced layout is one in which the cavities are all uniformly filled at the same time under the same melt conditions [15,16]. Short moulding can occur if an unbalanced layout is being used, but this can be overcome by modifying the length and cross-section of the runners (passageways for the molten plastic flow from the sprue to the cavity). Since this is not an efficient method, it is avoided where possible. Figure 4 shows a short moulding situation due to an unbalanced layout.
A balanced layout can be further classified into two categories: linear and circular. A balanced linear layout can accommodate 2, 4, 8, 16, 32 etc. cavities, i.e. it follows a 2n series. A balanced circular layout can have 3, 4, 5, 6 or more cavities, but there is a limit to the number of cavities that can be accommodated in a balanced circular layout because of space constraints. Figure 5 shows the multi-cavity layouts that have been discussed.
3. The Design Approach
This section presents an overview of the design approach for the development of a parametric-controlled cavity layout design system for plastic injection moulds. An effective working method of mould design involves organising the various subassemblies and components into the most appropriate hierarchy design tree. Figure 6 shows the mould assembly hierarchy design tree for the first level subassembly and components. Other subassemblies and components are assembled from the second level onwards to the nth level of the mould assembly hierarchy design tree. For this system, the focus will be made only on the “cavity layout design”.
3.1 Standardisation Procedure
In order to save time in the mould design process, it is necessary to identify the features of the design that are commonly used. The design processes that are repeatable for every mould design can then be standardised. It can be seen from Fig. 7 that there are two sections that interplay in the standardization procedure for the “cavity layout design”: component assembly standardisation and cavity layout configuration standardisation.
3.1.1 Component Assembly Standardisation
Before the cavity layout configuration can be standardised, there is a need to recognise the components and subassemblies that are repeated throughout the various cavities in the cavity layout. Figure 8 shows a detailed “cavity layout design” hierarchy design tree. The main insert subassembly (cavity) in thesecond level of the hierarchy design tree has a number of subassemblies and components that are assembled directly to it from the third level onwards of the hierarchy design tree. They can be viewed as primary components and secondary components. Primary components are present in every mould design. The secondary components are dependent on the plastic part that is to be produced, so they may or may not be present
in the mould designs.
As a result, putting these components and subassemblies directly under the main insert subassembly, ensures that every repeatable main insert (cavity) will inherit the same subassemblies and components from the third level onwards of the hierarchy design tree. Thus, there is no need to redesign similar subassemblies and components for every cavity in the cavity layout.
3.1.2 Cavity Layout Configuration Standardisation
It is necessary to study and classify the cavity layout configurations into those that are standard and those that are nonstandard. Figure 9 shows the standardisation procedure of the cavity layout configuration.
A cavity layout design, can be undertaken either as a multicavity layout or a single-cavity layout, but the customers always determine this decision. A single-cavity layout is always considered as having a standard configuration. A multi-cavity mould can produce different products at the same time or the same products at the same time. A mould that produces different products at the same time is known as a family mould, which is a non-conventional design. Thus, a multicavity family mould has a non-standard configuration.
A multi-cavity mould that produces the same product can contain either a balanced layout design or an unbalanced layout design. An unbalanced layout design is seldom used and, as a result, it is considered to possess a non-standard configuration. However, a balanced layout design can also encompass either a linear layout design or a circular layout design. This depends on the number of cavities that are required by the customers. It must be noted, however, that a layout design that has any other non-standard number of cavities is also classified as having a non-standard configuration.
After classifying those layout designs that are standard, their detailed information can then be listed into a standardization template. This standardisation template is pre-defined in the cavity layout design level of the mould assembly design and supports all the standard configurations. This ensures that the required configuration can be loaded very quickly into the mould assembly design without the need to redesign the layout.
3.2 Standardisation Template
It can be seen from Fig. 10 that there are two parts in the standardisation template: a configuration database and a layoutde sign table. The configuration database consists of all the standard layout configurations, and each layout configuration has its own layout design table that carries the geometrical parameters. As mould-making industries have their own standards, the configuration database can be customised to take into account those designs that are previously considered as non-standard.
3.2.1 Configuration Database
A database can be used to contain the list of all the different standard configurations. The total number of configurations in this database corresponds to the number of layout configurations available in the cavity layout design level of the mould design assembly. The information listed in the database is the configuration number, type, and the number of cavities. Table 1 shows an example of a configuration database. The configuration number is the name of each of the available layout configurations with the corresponding type and number of cavities. When a particular type of layout and number of cavities is called for, the appropriate layout configuration will be loaded into the cavity layout design.
3.2.2 Layout Design Table
Each standard configuration listed in the configuration database has its own layout design table. The layout design table contains the geometrical parameters of the layout configuration and is independent for every configuration. A more complex layout configuration will have more geometrical parameters to control the cavity layout.
Figures 11(a) and 11(b) show the back mould plate (core plate) with a big pocket and four small pockets for assembling the same four-cavity layout. It is always more economical and easier to machine a large pocket than to machine individual smaller pockets in a block of steel. The advantages of machining a large pocket are:
1. More space between the cavities can be saved, thus a smaller block of steel can be used.
2. Machining time is faster for creating one large pocket compared to machining multiple small pockets.
3. Higher accuracy can be achieved for a large pocket than for multiple smaller pockets.
As a result, the default values of the geometrical parameters in the layout design table results in there being no gap between the cavities. However, to make the system more flexible, the default values of the geometrical parameters can be modified to suit each mould design where necessary.
3.3 Geometrical Parameters
There are three variables that establish the geometrical parameters:
1. Distances between the cavities (flexible). The distances between the cavities are listed in the layout design table and they can be controlled or modified by the user. The default values of the distances are such that there are no gaps between the cavities.
2. Angle of orientation of the individual cavity (flexible). The angle of orientation of the individual cavity is also listed in the layout design table which the user can change. For a multi-cavity layout, all the cavities have to be at the same angle of orientation as indicated in the layout design table. If the angle of orientation is modified, all the cavities will be rotated by the same angle of orientation without affecting the layout configuration.
3. Assembly mating relationship between each cavities (fixed). The orientation of the cavities with respect to each other is pre-defined for each individual layout configuration and is controlled by the assembly mating relationship between cavities. This is fixed for every layout configuration unless it is customised.
Figure 12 shows an example of a single-cavity layout configuration and its geometrical parameters. The origin of the main insert/cavity is at the centre. The default values of X1 and Y1 are zero so that the cavity is at the centre of the layout (both origins overlap each other). The user can change the values of X1 and Y1, so that the cavity can be offset appropriately.
Figure 13 shows an example of an eight-cavity layout configuration and its geometrical parameters. The values of X and Y are the dimensions of the main insert/cavity. By default, the values of X1 and X2 are equal to X, the value of Y1 is equal to Y, and thus there is no gap between the cavities. The values of X1, X2, and Y1 can be increased to take into account the gaps between the cavities in the design. These values are listed in the layout design table.
If one of the cavities has to be oriented by 90°, the rest of the cavities will be rotated by the same angle, but the layout design remains the same. The user is able to rotate the cavities by changing the parameter in the layout design table. The resultant layout is shown in Fig. 14.
A complex cavity layout configuration, which has more geometrical parameters, must make use of equation to relate the parameters.
4. System Implementation
A prototype of the parametric-controlled cavity layout design system for a plastic injection mould has been implemented using a Pentium III PC-compatible as the hardware. This prototype system uses a commercial CAD system (SolidWorks 2001) and a commercial database system (Microsoft Excel?) as the software. The prototype system is developed using the Microsoft Visual C++ V6.0 programming language and the SolidWorks API (Application Programming Interface) in a Windows NT? environment. SolidWorks is chosen primarily for two reasons:
1. The increasing trend in the CAD/CAM industry is to move towards the use of Windows-based PCs instead of UNIX workstations mainly because of the cost involved in purchasing the hardware.
2. The 3D CAD software is fully Windows-compatible, thus it is capable of integrating information from Microsoft Excel files into the CAD files (part, assembly, and drawing) smoothly [17].
This prototype system has a configuration database of eight standard layout configurations that are listed in an Excel file. This is shown in Fig. 15(a). Corresponding to this configuration database, the layout design level, which is an assembly file in SolidWorks (layout.sldasm), has the same set of layout configurations. The configuration name in the Excel file corresponds to the name of the configurations in the layout assembly file, which is shown in Fig. 15(b).
Every cavity layout assembly file (layout.sldasm) for each project will be pre-loaded with these layout configurations. When a required layout configuration is requested via the user interface, the layout configuration will be loaded. The user interface shown in Fig. 16 is prior to the loading of the requested layout configuration. Upon loading the requested layout configuration, the current layout configuration information will be listed in the list box.
The user is then able to change the current layout configuration to any other available layout configurations that are found in the configuration database. This is illustrated in Fig. 17.
The layout design table for the current layout configuration that contains the geometrical parameters can be activated when the user triggers the push button at the bottom of the user interface. When the values of the geometrical parameters are changed, the cavity layout design will be updated accordingly. Figure 18 shows the activation of the layout design table of the current layout configuration.
5. A Case Study
A CAD model of a hand phone cover, shown in Fig. 19, is used in the following case study.
Prior to the cavity layout design stage, the original CAD model has to be scaled according to the shrinkage value of the moulding resin to be used. The main insert is then created to encapsulate the shrunk part. This entire subassembly is known as the main insert subassembly (xxx cavity. sldasm), where “xxx” is the project name. Figure 20 shows the main insert subassembly. After the main insert subassembly is created, the cavity layout design system can be used to prepare the cavity layout of the mould assembly.
5.1 Scenario 1: Initial Cavity Layout Design
In a mould design, the number of cavities to be built in a mould is always suggested by the customers, as they have to balance the investment in the tooling against the part cost. Initially, the customers had requested a two-cavity mould to be designed for this hand phone cover. After the creation of the main insert subassembly, the mould designer loads a layout configu
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