The mold speed milling Technical Overview-Part1

I. Introduction 

In the modern  mold production, with increasing high aesthetics and functional requirements of the plastic parts, plastic parts internal structure is designed to be more and more complex, the exterior design of the mold are becoming increasingly complex, free-form surface increasing proportion corresponding mold structure is also designed to be more and more complicated. Mold Accessories processing technology put forward higher requirements, should not only ensure the manufacture of high precision and surface quality, but also to the pursuit of the beauty of the machined surface. With the deepening of the high-speed processing technology, especially in promoting the development of machine tools, CNC system, tool systems, CAD / CAM software and other related technology, high-speed processing technology has been increasingly used in the mold cavity processing and manufacturing. 
CNC high-speed machining as the most important one in the mold manufacturing advanced manufacturing technology, is a set of efficient, high-quality, low power consumption at an advanced manufacturing technology. Compared to conventional machining, the cutting speed and feed speed has been greatly improved, and the cutting mechanism is not the same. Cutting speed cutting essential leap unit power metal removal rate of 30% to 40%, a 30% reduction in cutting forces and tool cutting life expectancy has increased by 70% to stay in the workpiece, cutting heat The amplitude decreased low-level cutting vibration almost disappeared. With the increase in cutting speed, rough material removal rate per unit time, cutting the time to reduce the processing efficiency, so as to shorten the product manufacturing cycle, improve the market competitiveness of the products. At the same time, high-speed processing of a small amount of fast-forward the cutting force reduces the chip's high-speed discharge to reduce the the workpiece cutting forces and heat stress deformation, increase the possibility of poor rigidity and thin-walled parts machining. Due to the reduction of the cutting forces, the speed increases so that the cutting system frequency away from the low-order natural frequency of the machine, while the surface roughness of the workpiece is most sensitive to low-level frequency, thereby reducing the surface roughness. Electrical processing and the step of grinding and polishing can be substituted in the mold high-hardened steel (HRC45 ~ HRC65) during processing, the use of high-speed cutting, thereby avoiding the manufacturing of the electrodes and time-consuming electrical processing, significantly reduce the fitter grinding and polishing amount. A growing need in the market for thin-walled mold workpiece, high-speed milling can also be successfully completed, and in high-speed milling CNC machining centers, a mold clamping can complete the multi-step processing. 
High speed machining of the mold process to produce a huge impact, changing the traditional mold used annealing → ​​milling machining → ​​heat treatment → grinding or EDM → hand sanding, polishing "complex and lengthy process, and can even be used to replace all of the original high-speed machining process. High-speed machining techniques can be applied to the the hardened mold cavity directly processing (especially semi-finishing and finishing), EDM electrode machining, Rapid Prototyping Manufacturing has also been widely used. Mass production practice shows that the application of high speed cutting technology can save about 80% of the mold in the subsequent processing manual grinding time, saving nearly 30% of the processing costs, the mold surface machining accuracy of up to 1 m, the tool cutting efficiency can be increased by 1. 

Second, high-speed milling machine 

Speed ​​cutting technology is one of the main development direction of cutting technology to a higher level with the development of the basic technology of CNC technology, microelectronic technology, new materials and new structure. Due to the mold special processing and high-speed processing technology, the technology and process systems for high-speed machining of molds (machine tools, CNC system, tool, etc.) put forward higher requirements than the traditional punch and die. 
　 A high stability of the machine tool support member 
High-speed cutting machine tool bed support member should have a good dynamic and static stiffness the the hot stiffness and damping characteristics. Most of the machines are high-quality, high rigidity and high tensile gray iron as a support member material, add some machine tool companies still base a high damping characteristics of polymer concrete to increase its vibration resistance and thermal stability This will not only ensure the machine accuracy and stability, but also prevents the cutting tool chatter. The closed bed design, overall casting bed, symmetrical structure of the bed with clouds of ribs is also an important measure to improve machine stability. The company's R & D departments of some machine tools in the design process, but also using modal analysis and finite element structural calculations to optimize the structure of the machine more stable and reliable support member. 
　 2. Machine spindle 
The performance of high-speed machine tool spindle is an important condition for achieving high-speed machining. High-speed cutting machine tool spindle speed range to 10000 ~ 100000m/min, and 15kW spindle power greater than. Axial gap between the shank and spindle control spindle compressed air or cooling system is not greater than 0.005mm. Also requires the spindle performance (that has a very high angular acceleration and deceleration) with rapid acceleration, rapid accurate stop at the specified location, high-speed spindle often hydrostatic bearings, aerostatic bearing, hot-pressed silicon nitride (Si3N4) ceramic bearings magnetic bearing type structure. Lubrication to use more oil lubrication and jet lubrication technology. Spindle cooling generally use the spindle internal water-cooled or air-cooled. 
　 3. Machine drive system 
To meet the needs of high speed machining of the mold, the high speed machining machine tool drive system should have the following characteristics: 
(1) a high feed rate. Studies have shown that, for small diameter tool to improve the speed and the amount of feed per tooth helps reduce tool wear. The feed rate range of 20 ~ 30m/min, such as the use of a large lead ball screw drive, feed rate up to 60m/min; linear motor allows speeds of up to 120m/min feed. 
(2) a high acceleration. Three-dimensional complex surface contour of the high-speed machining requirements drive system has good acceleration characteristics, to provide high-speed feed drive (fast forward speed of 40m/min, 3D contouring speed of 10m/min) to provide 0.4m/s2 to 10m/s2 acceleration and deceleration. 
Most machine manufacturers closed loop position servo control lead to large-size, high-quality ball screw or lead screw bulls. With the development of motor technology, advanced linear motor has come out, and successfully applied to theCNC machine tools. No mass inertia advanced linear motor driven CNC machine tools, advanced, hysteresis and vibration problems faster servo response speed and improve the the servo control accuracy and precision machining. 
　 4. CNC system 
Advanced CNC system is a key factor to ensure the quality and efficiency of high-speed machining of mold complex surface, the basic requirements of the numerical control system of high-speed machining of the mold: 
(1) high-speed digital control loop (Digital CONTROL loop), including: a 32-bit or 64-bit parallel processor and 1.5Gb more hard disk drives; very short sampling time of a linear motor 
(2) the velocity and acceleration feedforward control (Feed forward control); crawl control of the digital drive system (Jerk control). 
(3) advanced interpolation method (based on NURBS spline interpolation), to obtain a good surface quality, precise dimensions and high geometric accuracy. 
(4) pretreatment (Look-ahead) function. Requires a large capacity buffer register, pre-reading and checking more than one block (such as DMG machine can block up to 500 the Simens block system up to 1000 to 2000), in order to be processed surface shape (curvature) occurs change to take timely measures to change the feed rate to avoid excessive cutting. 
(5) error compensation function, including fever caused by thermal error compensation due to the linear motor spindle quadrant error compensation, the measuring system error compensation. In addition the requirements of high-speed machining of the mold on the data transmission speed is also high. 
(6) data interface, such as RS232 serial port transmission speed of 19.2kb, while many state-of-the-art machining centers have adopted Ethernet LAN (Ethernet) for data transfer speeds of up to 200kb. 
　 5. Cooling lubrication 
High-speed machining using coated carbide cutting tools without cutting fluid, in the case of high-speed, high-temperature, efficient cutting. This is because: the high speed rotation of the milling spindle, cutting fluid to reach the cutting area must first overcome a great centrifugal force; even if it overcomes the centrifugal force into the cutting area, may also be due to the high temperature of the cutting area and immediately evaporated, the cooling effect is small even not; cutting fluid causes the intense temperature changes of the cutter blade, easily lead to cracks, so dry cutting oil / gas cooling and lubricating. This manner can be provided with high pressure gas quickly blown away by the cutting of the cutting zone, so that the large amount of cutting tropical go, while the atomizing the lubricant can be provided in the the tool blade portion and the workpiece surface to form a thin layer of micro-protective film, can be effectively extend tool life and improve the quality of the parts of the surface. 

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The application of high-speed stamping technology

With the rapid development of electronic communications, electrical appliances, automobiles and home appliances and other products, the growing demand for precision stampings, technical requirements are also increasing, and the application surface more and more widely, so a large number of ordinary presses can not meet the production and super mass production, production and technical requirements. High-speed precision press high speed, automation and continuous punching is an effective way to improve press productivity. Due to the number of times per minute than the tonnage of high-speed precision presses slide stroke similar to the ordinary presses more than five times higher, so high-speed precision presses not only high precision stamping parts, surface quality, and long mold life. 

In recent years, the stamping technology to keep the speed, precision and intelligent direction, the momentum of development of advanced high-speed presses, and therefore the emergence of a number of high-speed precision press and ultra-high-speed precision presses, such as Germany Las special company, Münster, Switzerland nbsp, Schuler, Germany, Japan, the rate of energy and electricity production companies, the development of small-tonnage high-speed precision presses, Number of strokes up to 2,000 times / minute, 3,000 beats / minute, 4,000 times / minute. In the load state, but also up to the standard super precision requirements. This indicates that high-speed precision press technology has developed to the ultra-high-speed ultra-precision stage. 

Some foreign companies of small tonnage of high-speed precision presses Number of strokes divided into four speed grades: normal speed ≦ 250 beats / min, times high speed> 250 to 400 beats / min, high-speed> 400 to 1,000 times / min, super- speed ≧ 1,000 times / minute. Large tonnage of high-speed precision press slide the relatively low number of trips, such as 300 tons of large-scale high-speed precision presses, the number of slide stroke range is only about 160 to 400 beats / min, 100 tons of fin dedicated high-speed precision presses The slide stroke number range is generally about 150 to 250 beats / min. 

Punching speed presses tonnage, slide stroke length and the number of products, process structure and materials process performance, automatic feeding speed and precision of many different elements, it is difficult to use simple numbers as the divided each grade boundaries, Therefore, the international high-speed precision presses range of rapid change is still yet to make a clear definition, usually the punching speed of 5 to 10 times higher than ordinary presses speed collectively referred to as high-speed precision stamping. From the situation of most enterprises in China's high-speed precision press, Chong times speed according to the the average slider minimum and maximum number of strokes or greater than the mean of 10 to 20% of the impulse rate is more reasonable and reference significance standards. Because the maximum number of strokes of the high-speed precision presses slider generally refers to the number of load-stroke. Imbalance presses running significantly increased when the number of trips up to a certain value, the dynamic changes of the dead under the slider, must be resolved so that the quality of the coil material feeding speed, mold performance and life equipment strength, stiffness and precision, the failure of automatic monitoring and stability, vibration and noise as well as lubrication and cooling system and a series of technical problems. Therefore, the application of high-speed precision presses the red times speed is critical. 

Type and technical characteristics of the high-speed precision stamping parts 

High-speed precision stamping parts industry, purpose and process characteristics can be divided into a class of electronic components, IC integrated circuit lead frame class motor core, electrical core heat exchanger fin class, car parts, home appliances parts and other types like. Part consists mainly of connected devices, connectors, brush, electrical terminals, flexible parts. 

IC IC lead frame contains the leadframe discrete devices and integrated circuit lead frame. The motor core consists mainly of single phase series motor core domestic motor core, single-phase, single phase shaded pole motor core, permanent magnet DC motor core industrial motor core, plastic stator core, etc.. The electrical core mainly contains the E-shaped transformer core, EI-shaped transformer core-shaped transformer core and transformer iron chips, etc.. The heat exchanger the fin consists mainly of industrial heat exchanger fins, household heat exchanger fin, automotive heat exchanger fins. Car parts include automotive structural parts, automotive functional parts. Appliance parts contains a large home appliance parts, such as CPT electron gun parts and small appliance parts, all kinds of structural parts and functional parts. Other types of parts contains parts of the instrumentation, IT parts, acoustic class and cameras class parts, with parts of the modern office, as well as hardware. 

The technology has many varieties, the diversity of materials, material roll sheet automated production batch, high precision, complex shape, high technology content and added value of high-speed precision stamping parts. 

Typical high-speed precision stamping production technology overview 

Motor core production technology overview 

The core is an important component of the motor products, generally made ​​of 0.35mm, 0.5mm thick silicon steel sheet. In all aspects of motor production, core red chip production is key. China's high-speed precision stamping iron chips and core automatically stack riveting three core with twisted groove stack riveting core with twisted trunks and swivel stack riveting dual rotary core stack riveting the core double row giant slalom stack riveting large outer rotor core with a twist slot stack riveting the stator core semicircle combination stack riveting, multi-block stator core portfolio stack riveting, long straight stator core rolling portfolio stack riveting high-speed precision stamping production technology and international advanced technology compared favorably. 

Where the typical core three band twisted groove stack riveting products production technology of high-speed precision stamping the Profile core material 50W470 silicon steel sheet, strip material thickness of 0.5mm, 307.5mm wide material. With the material by uncoiling device, S-type leveling device, feeding equipment, materials, lubrication system, high-speed precision presses, large precision progressive die such as the integration of high-speed running, and the automatic stamping rectify nail holes rotor sheet stack riveting process hole , the rotor piece mark hole, measured at the rotor film hole rotor Slotted rotor piece stepped hole, rotor film stack riveting holes in the rotor chip the rotor film blanking stack riveting and twisting slot, the stator chip gap stator chip mark hole the stator chip metering orifice stator Slotted stator sheet stack riveting hole in the stator chip the stator sheet blanking stack riveting multi-station and multi-process cross Continuous stamping, once completed three sets of stator and rotor core products, The core automatically stacked riveting a thickness of 105mm, and the stator core outer diameter 110.52 0.02mm, an outer diameter of 55.1 0.01/0.02 mm. Products produced 300 tons of large-scale high-speed precision presses, pumping speed change from 280 to 320 beats / min, and automatic output core products in the stamping process. 

The heat exchanger fin production technology overview 

The fins are the main components of the air-conditioning products are generally made ​​of 0.105mm thick aluminum foil. In recent years, China's high-speed stamping heat exchanger fins production technology has been significantly improved, such as home air conditioning heat exchanger fins, automobile air conditioning heat exchanger fin, industrial air conditioning heat exchangers, the overall ducted air-conditioning heat exchangers fins, the new Hole air conditioning heat exchanger fin, and a large cold storage radiator fin high speed precision stamping production technology has been close to the international advanced level. China R & D 12, 24, 36, 42, 48, 60, 72, 76 fins and other high-speed precision stamping production technology has reached the international level of similar products. Typical Φ 5.2 72 column 2 stepper finned high-speed precision stamping production technology overview: fin material is aluminum foil 1,000-8H22, including material thickness of 0.105 mm, exhibition rack over oil installations, feeding device, high-speed precision presses, large-scale precision progressive die, suction aggregate device fin automatic production line, with high-speed precision stamping material pressing device, extended engineering, punch and die engineering, flanging works, blinds Engineering, Central Shaped Cut works, ends profiled cut engineering side cut works, different positive project, slitting Engineering, feeding projects, cross-cutting works 12 forming engineering continuous stamping, once out of 72 fins, fin shape complexity, accuracy higher require smooth, flat surface, no scratches, no glitches, flanging without cracking and other technical requirements. Φ 5 series, 72 the number of fins and 2 stepper produced 100 tons of high-speed precision dedicated press sprint speed of 260 times / min, and products while aggregate side reclaimer fin stamping process.

IC IC lead frame production technology overview 

The lead frame is a vector of discrete devices and integrated circuits. Lead frame chip carrier semiconductor devices, its main features are many kinds, large-volume, high precision, small shape thin material, the surface needs local plating as well as the appearance of demanding. In recent years, with the development of science and technology, China's high-speed precision stamping leadframe production technology than in the past has been greatly enhanced, such as discrete devices TO-220, SOT, SOD series lead frame production technology has reached the level of similar foreign products. SSOP-024 IC lead frame production technology of high-speed precision stamping Overview: C194 copper alloy lead frame material, the thickness of 0.152 mm coil stock by volume rack, feed mechanism, guide feeding mechanism, high-speed precision presses, precision level into the mold, roll rewinding device such as the composition of the lead frame high-speed precision stamping automated production lines, the stamping process contains typing, stamping gneissic point, punch positioning holes and inserts given hole, rushed inside the lead A, rushed inside the lead B, Chong within leads C, separated from the pieces, the static pressure within the lead school cross bend, extracurricular lead school step, the inner leads leveling, finishing 32 station continuous stamping, once out of the 4 rows, each row in the 11mm 9mm the size of the surface of the inner and outer lead pin 24 out, the minimum spacing of the inner lead coplanarity of 0.17mm, is required to control other technical requirements within the 0.01mm. The lead frame on the production of 80 tons of high-speed precision presses, the red times the speed of 450 to 500 beats / minute. SSOP-24 IC lead frames set micro molding, meager, multiple feet of high-density, small pitch, diversification of the overall level of close to the international advanced level of similar products.

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The direction of development of the mold processing technology

China's mold is divided into 10 major categories and 46 subcategories. There are different processing methods, different types of mold similar mold can also be accomplished using different processing techniques to. Mold tooling work is mainly focused on the mold surface processing, surface processing and assembling, processing method precision casting, metal machining, electrical discharge machining, electrochemical machining, laser and other high-energy beam processing, as well as sets of two or more processing methods as one of the composite processing. CNC and computer technology continues to evolve, so that they get to a wide range of applications in many tooling method. In the case of varieties of industrial products and personalized increasingly obvious product replacement fast, to the fierce competition in the market, user requirements mold making short delivery time, high accuracy, good quality, low price, driven mold processing technology to the following aspects of development.

High-speed milling technology

China mold manufacturing backbone of key enterprises in recent years, has introduced high-speed milling and high speed machining centers, they have played a good role in the mold processing. The current highest speed machine tools spindle speed 100000r/min, rapid feed speeds of up to 120m/min, acceleration up to 1-2g tool change time can be increased to 1-2s. This can greatly improve the processing efficiency, and to obtain a surface roughness Ra ≤ 1 processing, the high-hardness material can be cut more than 60HRC EDM challenge. With the improvement of the spindle speed, the machine structure and configuration of the system and its key components and spare parts, cutting tools are must tie in greatly improved, so that the machine cost. The Chinese imports maximum spindle speed of high-speed machine tools mainly in the short term will continue to 10000-20000r/min, few will reach about 40000r/min. Although to a higher speed development is the inevitable direction, but the most important thing to promote.

The high-speed machining cutting process of revolutionary change, from the perspective of technology development, high-speed milling with ultra-precision machining, hard machining combination, opening up the field of milling and grinding, and greatly reduce mold polishing amount, shorten the mold manufacturing cycle, mold companies in China will be more applications. Parallel machine tool, also known as virtual axis machine tools, and 3D laser the birth of the 6-axis milling machine, and open CNC system application more add luster to high-speed machining.

EDM technology

Electrical discharge machining (EDM) has been subject to severe challenges of high-speed milling, but some of the inherent characteristics of the EDM technology and unique advantage of high-speed milling can not entirely replace the complex surfaces, such as mold, deep narrow cavity, sharp corners, machining slit grooves on pit etc.. High-speed milling can meet the processing requirements of some of these, but the cost is much higher than the EDM. Compared to milling, EDM easier to automate. Complex, precision small cavities and the fine cavity and remove knife marks, the completion of the sharp corners, narrow grooves on, deep processing and pattern processing, will be the focus of future EDM applications. In order to further play its unique role in the mold processing, is the EDM the future direction of development:

Continue to improve the efficiency of the EDM, surface integrity of the degree of automation and processing;

　　 * EDM precision equipment and large;

　　 * EDM equipment processing stability, easy operation and excellent performance and low cost;

　　 * Research and development of energy-efficient to meet different requirements and anti-electrolysis new pulse power, the power waveform detection and treatment and control technology development;

　　 * Research and development of high-performance integrated expert system technology continues to evolve and EDM intelligent and adaptive control, fuzzy control, multi-axis control, automatic exchange electrode, two-lane automatic switching anti-electrolysis and discharge energy distribution technology development;

　　 * Powder mixed processing mirror light processing technology development;

　　 * Development of micro EDM technology, including three-dimensional micro-contour CNC EDM milling and micro-EDM grinding and micro EDM technology;

　　 * WEDM in the use of artificial intelligence techniques, to go wire systems, and wear silk technology improvements;

　　 * EDM milling technology and machine tools and EDM machining centers (including molding machine and cutting machine) will be developed;

　　 * As a strategy of sustainable development, green EDM new technology is an important development trend in the future.

Rapid prototyping and manufacturing (RPM) and rapid tooling (RT) technologies

Mold the future of the largest competitive factors, how to quickly create a user needed to mold. The RPM technology may directly or indirectly for the RT. Metal mold rapid manufacturing technology goals, direct manufacturing can be used for the industrial production of high-precision of durable metal hard mold. Indirect legal mold technology is the key to the development of the short process technology to reduce the loss of accuracy, cost-laminated and surface finishing technology integration. The combination of the RPM technology with RT Technology, is the traditional rapid tooling technology (such as the low melting point alloy casting, spraying, electroforming, casting, layer, rubber poured solid, etc.) in the direction of further development. RPM technology and ceramic precision casting precision casting mold cavity forming a new way. Application the RPM / RT technology, the concept from mold design to fabrication, only about 1/4 of 1/3 of the time and cost required to the traditional processing methods, and has broad prospects for development. RT technology to further improve the competitiveness, the need to develop the data and processing the data easier to generate, high precision, small size and material restrictions direct rapid manufacturing of metal mold.

Ultra-precision machining, micromachining and composite processing technology

With the mold to provide the precision and direction of large-scale development of ultra-precision machining, micromachining and collector, chemical, ultrasonic, laser technology will be developed in one of the complex processing. Ultra-precision machining achieve submicron nano-precision ultra-precision machining technology has also been applied to the production. Electric machining, electrochemical machining, beam machining and other processing technology has become an important part of the microfabrication technology, the Global more with a wavelength of 0.5 nm radiation wave manufacturing a nano-grade plastic mold. A machine combining laser milling and high-speed milling, mold processing technology has been a new development.

Advanced surface treatment technology

Mold heat treatment and surface treatment, is the key to the ability to give full play to the performance of the mold material. Vacuum heat treatment, cryogenic treatment, including vapor deposition PVD and CVD (TiN, TiC, etc.), the ions penetrate, such as plasma spraying, and TRD surface treatment technology, diamond film covering technology, high wear-resistant high-precision processing technology, no adhesions surface processing technology in the mold manufacturing applications, and presents good prospects for development. Technical and other mold surface of the mold surface laser heat treatment, welding, strengthen and repair to strengthen and repair techniques, and will also be subject to further attention.

Mold polishing

Mold polishing still mainly manual, inefficient, labor-intensive, unstable quality. China has introduced a CNC grinding machine can achieve a three-dimensional surface mold Auto Polishing own study of humanoid intelligent automatic polishing techniques have certain results, but few current applications are expected to be developed. Should continue to pay attention to the development of special grinding and polishing techniques, such as extrusion honing, of laser honing and polishing, EDM polishing, electrochemical polishing, ultrasonic polishing compound polishing technology and process equipment.

Mold automatic processing system

With the rapid development of new technology, foreign molds automatic processing system. Mold automatic processing system should have the following characteristics: the rational combination of more than one machine; with accompanying positioning jig or positioning plate; complete jig and tool CNC library; the complete CNC flexible synchronization system and quality monitoring and control system. The person at the same time to complete the roughing and finishing machines for mold processing system. These will be developed.

Mold CAM / DNC technology and software

With CNC technology and the rapid development of computer technology, CAM / DNC technology has been widely used mold companies in China. Many software development of dedicated software for mold machining characteristics much less for high-speed machining software. Adapt to the characteristics of the mold, with a high level of CNC machining capacity, and post-processing procedures, precision machining and high-speed processing functions, user-friendly, easy to learn, offers a variety of data format conversion software and system integration preparation conditions will The direction of future development.

In addition to the above-mentioned direction of development, as well as the correct selection of the cutting tool. According to statistics, accounted for 3-5% of the total cost of the mold production tool, the correct selection of the tool, improve production efficiency more than 20%.

Mold manufacturing technology development direction

Mold manufacturing, mold for stamping parts design and mold processing often can not be divided. Therefore, in addition to the design and processing technology, but also must pay attention to the number of integrated technologies, the development direction will mold making a significant impact. Microelectronic technology, software technology as the core IT features into a digital, networked, strong penetration affect all areas of society, traditional manufacturing information is imperative.

Mold CAD / CAE / CAM integration technology

Mold CAD / CAE / CAM technology has evolved into a more mature common technology, hardware and software prices have dropped to a the SMEs generally acceptable level, coupled with the introduction of the popularization and application of microcomputer and microcomputer version of the software, the popularity of the mold industry CAD / CAM, the conditions are ripe for the rapid development of the future will. Mould CAD / CAE / CAM integration and pleasant software, integrated, intelligent, networked future direction of development. Qualified enterprises should actively carry out the CAD / CAE / CAM technology deepening application, that application of KBE technology and implementation of enterprise information engineering. From CAPP → PDM → CIMS → VM gradually deepen and improve, there are a lot of people think that the implementation of C3PCAD/CAE/CAM/PDM) technology may be more effective.

Precision measurement and high-speed scanning and digitizing systems will play a greater role in reverse engineering and concurrent engineering

With the development of high-precision molds, mold measurement techniques seem to be important. The mold stress, magnetic measurement techniques and three-dimensional measurement technology and R parts of the shape and size accuracy, surface roughness measurement techniques are mold measuring technology focus. Available shortly 4D laser measuring machine can be self-calibration, 3D measurement can be performed not only to quality indicators, and can be drawn, indicating that the accuracy of each measurement point. Online laser measurement of the CNC machining process, not only to help assure the quality of the processing of the workpiece, but also greatly enhance the safety of the operation of the NC machine. The high-speed scanner and mold scan system provides a number of features of the desired model from the model or in-kind scanning to processing required, can greatly reduce the mold manufacturing cycle. Reverse engineering and concurrent engineering mold production in the future, play an important role to.

Mold continuously improve the level of standardization

Correct and reasonable selection of mold standard parts and mold degree of standardization, can effectively reduce the mold manufacturing cycle, improve quality and reduce costs, and therefore, mold degree of standardization will continue to improve.

Virtual technology will be developed

The development of the computer and information networks, virtual technology to become a reality. Virtual technology can form a virtual space environment,, mold within enterprises virtual assembly, virtual collaborative design between enterprises, manufacturing, research and development cooperation, resulting in the establishment of a virtual enterprise.

The rapid development of management techniques

The third of seven management machinery industry often say "the importance of the management. Mold companies in the modern enterprise system, and the establishment and operation of various innovative mechanisms, both core management technology, is also mold manufacturing, insurance and corporate development. Mold manufacturing management information system (MIS), product information management (PDM) to establish the platform for the Internet e-commerce (EC) as the means of communication and contact and mold manufacturing, though not discussed in this article Wai, but they are also the mold enterprise management technology direction of development, and the importance attached by the industry.

In the development of information technology to stimulate industrialization, China's mold design and processing and manufacturing technology lagged behind the international level, enterprise management technology behind the international level, is the fact that the industry can not be ignored. To quickly raise the level of China's mold industry, all workers must study hard, firmly grasp the development direction of the world mold technology, give full play to the initiative, down to earth, with confidence to create a better future.

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mould design

Continue to improve the efficiency of the EDM, surface integrity of the degree of automation and processing;

　　 * EDM precision equipment and large;

　　 * EDM equipment processing stability, easy operation and excellent performance and low cost;

　　 * Research and development of energy-efficient to meet different requirements and anti-electrolysis new pulse power, the power waveform detection and treatment and control technology development;

　　 * Research and development of high-performance integrated expert system technology continues to evolve and EDM intelligent and adaptive control, fuzzy control, multi-axis control, automatic exchange electrode, two-lane automatic switching anti-electrolysis and discharge energy distribution technology development;

　　 * Powder mixed processing mirror light processing technology development;

　　 * Development of micro EDM technology, including three-dimensional micro-contour CNC EDM milling and micro-EDM grinding and micro EDM technology;

　　 * WEDM in the use of artificial intelligence techniques, to go wire systems, and wear silk technology improvements;

　　 * EDM milling technology and machine tools and EDM machining centers (including molding machine and cutting machine) will be developed;

　　 * As a strategy of sustainable development, green EDM new technology is an important development trend in the future.

Rapid prototyping and manufacturing (RPM) and rapid tooling (RT) technologies

Mold for stamping parts the future of the largest competitive factors, how to quickly create a user needed to mold. The RPM technology may directly or indirectly for the RT. Metal mold rapid manufacturing technology goals, direct manufacturing can be used for the industrial production of high-precision of durable metal hard mold. Indirect legal mold technology is the key to the development of the short process technology to reduce the loss of accuracy, cost-laminated and surface finishing technology integration. The combination of the RPM technology with RT Technology, is the traditional rapid tooling technology (such as the low melting point alloy casting, spraying, electroforming, casting, layer, rubber poured solid, etc.) in the direction of further development. RPM technology and ceramic precision casting precision casting mold cavity forming a new way. Application the RPM / RT technology, the concept from mold design to fabrication, only about 1/4 of 1/3 of the time and cost required to the traditional processing methods, and has broad prospects for development. RT technology to further improve the competitiveness, the need to develop the data and processing the data easier to generate, high precision, small size and material restrictions direct rapid manufacturing of metal mold.

Ultra-precision machining, micromachining and composite processing technology

With the mold to provide the precision and direction of large-scale development of ultra-precision machining, micromachining and collector, chemical, ultrasonic, laser technology will be developed in one of the complex processing. Ultra-precision machining achieve submicron nano-precision ultra-precision machining technology has also been applied to the production. Electric machining, electrochemical machining, beam machining and other processing technology has become an important part of the microfabrication technology, the Global more with a wavelength of 0.5 nm radiation wave manufacturing a nano-grade plastic mold tooling. A machine combining laser milling and high-speed milling, mold processing technology has been a new development.

Advanced surface treatment technology

Mold heat treatment and surface treatment, is the key to the ability to give full play to the performance of the mold material. Vacuum heat treatment, cryogenic treatment, including vapor deposition PVD and CVD (TiN, TiC, etc.), the ions penetrate, such as plasma spraying, and TRD surface treatment technology, diamond film covering technology, high wear-resistant high-precision processing technology, no adhesions surface processing technology in the mold manufacturing applications, and presents good prospects for development. Technical and other mold surface of the mold surface laser heat treatment, welding, strengthen and repair to strengthen and repair techniques, and will also be subject to further attention.

Mold polishing

Mold polishing still mainly manual, inefficient, labor-intensive, unstable quality. China has introduced a CNC grinding machine can achieve a three-dimensional surface mold Auto Polishing own study of humanoid intelligent automatic polishing techniques have certain results, but few current applications are expected to be developed. Should continue to pay attention to the development of special grinding and polishing techniques, such as extrusion honing, of laser honing and polishing, EDM polishing, electrochemical polishing, ultrasonic polishing compound polishing technology and process equipment.

Mold manufacturing technology, including the design and processing, the paper analyzed from both the technical development direction of China's mold industry. The article pointed out that the CAD / CAE, CAPP and KBE first mold design technology trend; access to explore the development direction of the mold processing technology, such as high-speed milling, EDM, rapid prototyping made ​​rapid mold and other. Finally, analysis of the prospects of the mold-made integrated technology.

From a technical point of view, the mold manufacturing (including design and processing) technology can be broadly divided into five stages of development: manual operation stage, the stage of manual plus mechanization (ordinary general machine tools), digital control stage, computerized stage and CAD / CAE / CAM information network technology integration stage.

China has a vast territory, large mold manufacturing enterprises, technology development levels, at all stages coexist, but mainly digitally controlled phase-based, some the backbone key enterprises have developed computerized stage. But at the same time there are many enterprises still remain in the manual plus mechanized stage. Purely manual stage basically has become history, CAD / CAE / CAM integration phase of the horizon of information network technology. Most mold manufacturing enterprises, the future direction of development should be to improve the level of numerical control and computerized-based, active use of high-tech, gradually moving towards the integration of CAD / CAE / CAM information network technology. Mold the paperless manufacturing will gradually replace the traditional design and processing.

Mold design and technology development direction

Mold design have long relied on the experience and mechanical drawing. Since the 1980s the development of mold computer-aided design (CAD) technology, this technology has been recognized, and to fast development. The nineties began development of mold technology of computer-aided engineering (CAE), now also for many enterprise applications, it shortened the mold manufacturing cycle and improve the quality of the mold have a significant role. Some industrial countries the mold enterprise applications CAD technology, from two-dimensional design development to the three-dimensional design, three-dimensional design has reached more than 70%. Most Chinese enterprises still remain on the level of the two-dimensional design, three-dimensional design companies less than 20%. CAE software abroad more common domestic applications is still relatively small, used to predict parts forming process defects may occur in the level is still relatively low.

Mold design and CAD and CAE software, should raise the level in the following aspects:

　　 * Mold design database and knowledge-based systems;

　　 * The mold engineering planning and design;

　　 * Mold material and reasonable choice of standard parts;

　　 * Mold rigidity, strength, flow channel and the design of the cooling passage;

Plastic mold plastic forming process simulation analysis (injection molding, plastic mold filling, packing, cooling, warpage, shrinkage, fiber orientation simulation analysis), the analysis of the thermal conductivity and cooling process, solidification and structural stress analysis. The calculated gating system and mold cavity pressure field, temperature field, velocity field, shear strain rate field and shear stress field distribution and analysis of the results is very complex and time-consuming. This simulation technology from surface flow technology development to the two-sided flow technology, and soon both right and quickly entity streaming technology can be developed to produce to meet the plastic pieces of virtual manufacturing requirements of the three-dimensional the injection flow simulation software;

　　 * The die metal forming process simulation, wrinkling and rupture analysis, stress-strain and springback analysis;

　　 * Die-casting mold casting forming flow simulation, heat transfer and solidification analysis;

　　 * Forging die forging forming process simulation and metal flow and filling analysis;

To improve the design and analysis software, intelligent and integrated level, and to strengthen their capabilities to adapt to the continuous development of the mold.

In addition to mold CAD / CAE technology, mold process design is also very important. Computer Aided Process Planning (CAPP) application technology has begun to mold companies in China. As most of the molds are single-piece production, the process rules different from the mass-produced products, the technical difficulty of the application of CAPP CAPP software for all types of mold and mold companies also difficult. CAPP technology application in order to better mold companies must be prepared to develop and research. Although CAPP technology application and promotion of difficulty is higher than the CAD and CAE, but also must pay attention to the direction of this development.

Knowledge-based engineering (KBE) technology is an important tool of modern design-oriented decision-making automation has become an important way to promote the engineering design intelligent attention in recent years, will mold the smart, optimizing the design to have an important impact.

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