附录
Mold high speed milling processing technology First，foreword
In the modern mold production, along with to models artistic and the function must obtain more and more high, models the internal structure to design more and more complex, the mold contour design day by day is also complex, the free curved surface accounts for the proportion to increase unceasingly, the corresponding mold structure also designs more and more complex. These all set a higher request to the mold processing technology, not only should guarantee the high manufacture precision and the surface quality, moreover must pursue the processing surface artistic. Along with is unceasingly thorough to the high speed processing engineering research, is processing the engine bed, the numerical control system, the cutting tool system, CAD/ especially Correlation technology and so on CAM software develops unceasingly under the impetus, high speed processes the technology more and more many to apply in the mold cavity processing and the manufacture.
The numerical control high-speed cutting processing took in the mold manufacture a most important advanced manufacture technology, is the collection is highly effective, high quality, the low consumption in a body advanced manufacture technology. Is opposite in the traditional machining, its cutting speed, entered to the speed had the very big enhancement, moreover cut the mechanism not to be same. The high-speed cutting caused the machining to have the leap, its specific power metal excision rate enhanced 30%~40%, the cutting force reduced 30%, the cutting tool working durability enhanced 70%, remained hotly large scale reduces in the work piece cutting, the low step shudder vanished nearly. Along with the cutting speed enhancement, unit time semi-finished materials material removing rate increased, the cutting time reduced, the processing efficiency enhanced, thus reduced the product manufacture cycle, enhanced the product market competitive power. At the same time, the high speed processing small amount entered quickly causes the cutting force to reduce, the scrap high speed discharged reduced the work piece cutting force and the thermal load distorts, enhances the rigidity
to be bad and the thin wall components machining possibility. Because cutting force reducing, the rotational speed enhancement causes the cutting system the operating frequency to be far away the engine bed the low step natural frequency, but the work piece surface roughness is most sensitive to the low step frequency, from this reduced the surface roughness. In mold high hard steel stock (HRC45~HRC65) in the processing process, uses the high-speed cutting to be possible to substitute for the working procedure which the electrical finishing and rubs truncates polishes, thus has avoided the electrode manufacture and the time-consuming electrical finishing, large scale reduced fitter's polishing with to throw the light quantity. Thin wall mold work piece more and more needs which regarding some markets in, the high speed milling also may smoothly complete, moreover in the high speed milling CNC processing center, a mold attire clamps may complete the multiplex step of processing.
The high speed processing technology has had the huge influence to the mold processing craft, changed the traditional mold processing to use "the annealing -> milling processing -> heat treatment -> to rub truncates" or "the electric spark machining -> manually polishes, polishes" and so on the complex long technical process, even might use the high-speed cutting processing substitution original complete working procedure. The high speed processing technology besides may apply in the hard mold cavity direct processing (in particular half precision work and precision work), in EDM aspect and so on electrode processing, fast type manufacture also obtained the widespread application. The mass productions practice indicated that, the application high-speed cutting technology may save in the mold following processing 80% handwork to grind the time approximately, saves the processing cost expense nearly 30%, the mold face work precision may reach 1 m, the cutting tool cutting efficiency may enhance 1 time. Second, high speed milling processing engine bed
The high-speed cutting technology is one of machining technology main development directions, it along with foundation technology the and so on CNC technology, microelectronic technology, new material and new structure development but steps a higher stair. Because the mold processes particular as well as high speed processing technology own characteristic, (processed engine bed, numerical control system, cutting
tool to the mold high speed processing related technology and the craft system and so on) proposed processed a higher request compared to the traditional mold.
1. High stable engine bed strut part
The high-speed cutting engine lathe and so on supports the part to be supposed to have very well moves, the static rigidity, hot rigidity and best damping characteristic. The majority of engine beds all use high grade, the high rigidity and Gao Kangzhang the gray iron took the strut part material, some engine bed companies also increase the high damping characteristic in the foundation polymer concrete, by increases its vibration-proof and the thermo-stability, this not only may guarantee the engine bed precision is stable, also may prevent when cutting the cutting tool inspires trembles. Uses the enclosed lathe bed design, the overall casting lathe bed, the symmetrical lathe bed structure and has the densely covered stiffener and so on also enhances the engine bed stable important measure. Some engine bed companies' research and development departments in design process, but also uses the modality analysis and the finite element structure computation and so on, optimized the structure, stably causes the engine bed strut part to be reliable.
2. Engine bed main axle
The high speed engine bed main axle performance is the realization high-speed cutting processing important condition. The high-speed cutting engine bed main axle rotational speed scope is 10000~100000m/Min, the main axle power is bigger than 15kW. Is not bigger than 0.005mm through the main axle compressed air or axial play between the cooling system control hilt and the main axle. Also requests the main axle to have the fast vertical speed, to assign the performance which the position is fast stops (namely to have extremely high angle addition and subtraction speed), therefore the high speed main axle often uses the liquid static pressure bearing type, the air static pressure bearing type, the thermo-compression nitriding silicon (Si3N4) the ceramic bearing magnetism aerosol bearing type iso-structuralism form. Lubricates uses technology and so on oil gas lubrication, splash lubrication. The main axle cools uses the main axle interior water cooling generally or air cooled.
3. The engine bed actuates the system
In order to satisfy the mold high speed processing the need, high speed processes the engine bed the actuation system to be supposed to have the following characteristic:
(1) high entering for speed. The research indicated that, regarding the minor diameter cutting tool, enhances the rotational speed and each tooth enters for the quantity is advantageous in reduces the cutting tool attrition. At present commonly used entering for the speed range is 20~30m/Min, like uses leads greatly the ball bearing guide screw transmission, enters may reach 60m/ min; Uses the straight line electrical machinery then may enable to achieve 120m/min.
(2) high acceleration. Has the good acceleration characteristic to the three dimensional complex curved surface silhouette high speed processing request actuation system, the request provides the driver which the high rapid advance or progress gives (to enter speed approximately 40m/ min, the 3D outline processing speed is 10m/Min), can provide 0.4m/S2 to 10m/The s2 acceleration and reduces the speed.
The engine bed manufacturer mostly uses the entire closed loop position servo-control slightly to lead, the great size, the high grade ball bearing guide screw or leads greatly many guide screws. Along with the electrical machinery technology development, the advanced straight line electric motor already was published, and the success applied in the CNC engine bed. The advanced straight line direct motor drive enable the CNC engine bed no longer to have the mass inertia, in advance, question and so on lag and vibration, sped up the servo speed of response, increased the servo-control precision and the engine bed processing precision.
4. Numerical control system
The advanced numerical control system is guaranteed the mold complex curved surface high speed processing quality and the efficiency key aspect, the mold high-speed cutting processing to the numerical control system basic request is:
(1) high speed numerical control return route (Digital control loop), including: 32 or above 64 bit parallel processors and 1.5Gb hard disk; Extremely short straight line electrical machinery sampling time.
(2) speed and acceleration feed-forward control (Feed forward control); Digital actuation system crawling control (Jerk control).
(3) advanced inserts makes up the method (to insert based on the NURBS transect makes up), by obtains the good surface quality, the precise size and the high geometry precision.
(4) pretreats (Look-ahead) the function. The request has the large capacity cushion register, may read in advance and inspects many segments (for example the DMG engine bed to be possible to reach 500 segments, the Simens system may reach a 1000~2000 segment), in order to when is processed the superficial shape (curvature) changes may promptly adopt changes for measure and so on speed by avoids cutting and so on.
(5) the error compensatory function, including because the straight line electrical machinery, the main axle and so on gives off heat the hot error which causes to compensate, the quadrantal error compensates, the measurement system error compensates and so on the function. In addition, the mold high-speed cutting processing very is also high to the data transmission speed request.
(6) the traditional data connection, like the RS232 serial mouth transmission speed is 19.2kb, but many advanced processings centers have used the ether local area network (Ethernet) to carry on the data transmission, the speed may reach 200kb.
5. Cooling lubrication
The high speed processing uses the belt coating the hard alloy tools, in high speed, the high temperature situation does not need the cutting compound, the cutting efficiency to be higher. This is because: The milling main axle high speed revolves, the cutting compound if achieved the cutting area, first must overcome the enormous centrifugal force; Even if it overcame the centrifugal force to enter the cutting area, also was possible as a result of the cutting area high temperature but to evaporate immediately, the cooling effect very small did not even have; At the same time the cutting compound can cause the cutting tool edge of a sword the temperature intense change, is easy to cause the crack the production, therefore must pick the oil used/Gas cooling lubrication dry type cutting way. This way may use the compressed gas rapidly the cutting which the cutting area produces, thus the massive cuttings hotly will carry off, at the same time might forms extremely thin microscopic protective film after the atomization lubricating oil in the cutting tool edge of a sword and the work piece surface, but effectively will lengthen the cutting tool life and enhances the components the surface quality.
Third, high-speed cutting processing hilt and cutting tool Because time high-speed cutting processing the centrifugal force and the vibration influence, requests the cutting tool to have the very high geometry precision and the attire clamps the repetition pointing accuracy as well as the very high rigidity and the high speed transient equilibrium security reliability. Because time high-speed cutting processing big characteristic and so on centrifugal force and vibration, the traditional
7:24 taper hilt system is carrying on the high-speed cutting to watch appears the obvious rigidity insufficient, the redundant pointing accuracy is not high, the axial size not steadily grades the flaw, the main axle inflation causes the cutting tool and clamps the organization nature heart the deviation, affects the cutting tool the transient equilibrium ability. At present applies many is the HSK high speed hilt and the overseas nowadays popular fastening -like hilt. the fastening -like hilt has the heating system, the hilt all uses the awl department to contact generally with the main axle end surface also, its rigidity is good, but the cutting tool commutactivity misses, a hilt only can install one kind of connection diameter the cutting tool. Because this kind of heating system quite is expensive, when initial period uses the HSK kind of hilt system then. When enterprise's high speed engine bed quantity surpasses above 3, uses the fastening -like hilt quite to be appropriate.
The cutting tool is in the high-speed cutting processing one of most active important factors, it is affecting the processing efficiency, the production cost and the product processing precision directly. The cutting tool must withstand load and so on high temperature, high pressure, friction, impact and vibration in the high speed processing process, the high-speed cutting cutting tool should have the good machine capability and the thermostability, namely has the good anti- impact, the wearability and resists heat the weary characteristic. The high-speed cutting processing cutting tool technological development speed is very quick, application many like diamonds (PCD), cubic boron nitride (CBN), ceramic cutting tool, coating hard alloy, (carbon) titanium nitrides hard alloy TIC (N) and so on.
In the processing cast iron and in the alloy steel cutting tool, the hard alloy is the most commonly used cutting tool material. Hard alloy tools resistance to wear good, but the solidity ratio cube boron nitride and the ceramics are low. In order to enhance degree
of hardness and the superficially attractive fineness, uses the cutting tool coating technology, the coating material for the titanium nitrides (TIN), the aluminium nitride titanium (TIALN) and so on. The coating technology causes the coating by the sole coating development for multilayered, the many kinds of coating material coating, has become one of enhancement high-speed cutting ability essential technical. The diameter in the 10~40mm scope, also has the carbon titanium nitrides coating the hard alloy bit to be able to process the Luo river degree of hardness to be smaller than 42 materials, but the titanium nitrides aluminum coating cutting tool can process the Luo river degree of hardness is 42 even higher materials. When high-speed cutting steel products, the cutting tool material should select the hot rigidity and the fatigue strength high P kind of hard alloy, the coating hard alloy, the cubic boron nitride (CBN) and the CBN compound cutting tool material (WBN) and so on. Cuts Truncates the cast iron, should select the fine grain K kind of hard alloy to carry on the rough machining, selects the compound nitrided silicon ceramics or the crystal combination cube boron nitride (PCNB) the compound cutting tool carries on the precision work. When precise processing non-ferrous metal or nonmetallic material, should select crystal combination diamond PCD or the CVD diamond coating cutting tool. When choice cutting parameter, in view of the circular shear blade and a ball milling cutter, should pay attention to the effective diameter the concept. The high speed milling cutting tool should press the balance design manufacture. The cutting tool front angle must be smaller than the conventional cutting tool front angle, the clearance angle is slightly big. The host vice- cutting edge attachment point should the cavetto or the lead angle, increases the vertex angle, prevents the knife point place hot attrition. Should enlarge nearby the knife point the cutting edge length and the cutting tool material volume, enhances the cutting tool rigidity. Is safe in the guarantee and satisfies the processing request under the condition, the cutting tool hangs extends as far as possible short, cutter body central toughness is friends with. The hilt must be sturdier than the cutting tool diameter, connects the handle to assume but actually the pyramidal, by increases its rigidity. As far as possible central the refrigerant hole in the cutting tool and the cutting tool system. A ball end mill must consider effectively cuts the length, the cutting edge must be as far as possible short, two spiral
grooves balls end mill usually uses in the thick mill complex curved surface, four spiral grooves balls end mill usually uses in the fine mill complex curved surface.
Fouth, mold high speed processing craft and strategy The high speed processing including take removes the remainder as the goal rough machining, the residual rough machining, as well as take gains the high grade processing surface and the slight structure as the goal half precision work, the precision work and the mirror surface processing and so on.
1. Rough machining
The mold rough machining essential target is pursues in the unit time material removing rate, and is half precision work preparation work piece geometry outline. In the high speed processing rough machining should adopt the craft plan is the high cutting speed, Gao Jin giving rate and the small cutting specifications combination. The contour processing way is one processing way which the multitudinous CAM software uses generally. Using is spiral contour and so on the Z axis contour two ways which are many, also is in processes the region only time to feed, in does not lift the knife in the situation to produce continuously the smooth cutting tool way, enters, draws back the knife way to use the circular arc to cut into, to cut. The spiral contour way characteristic is, has not waited the high level between the knife road migration, may avoid frequently lifting the knife, feeding to the components surface quality influence and mechanical device nonessential consuming. To is steep and the flat site processes separately, the computation suits contour and suits the use similar 3D bias the region, and may use the spiral way, in very little lifts the cutting tool way which the knife in the situation produces optimizes, obtains the better surface quality. In the high speed processing, certainly must adopt the circular arc to cut into, to cut the connection way, as well as the circular arc transition, avoids changing the cutting tool to enter suddenly for the direction, the prohibition use direct under knife connection way, avoids burying the cutting tool the work piece. When processes the mold cavity, should avoid the cutting tool vertical insertion work piece under, but should use inclines the knife way (commonly used angle of bank for 20°~30°), best uses the screw type under knife by to reduce the cutting tool load. When processes the mold core, should under the knife then level cut into the work piece as far as possible first from the work piece. The cutting tool cuts into, cuts when the
work piece should use as far as possible inclines the type (or round arc-type) cuts into, cuts, vertically avoids cutting into, cutting. Uses climbs up the type cutting to be possible to reduce the cutting heat, reduces the cutting tool stress and the work hardening degree, improves the processing quality.
2. Half precision work
The mold half precision work essential target is causes the work piece outline shape smoothly, surface finish remainder even, this especially is important regarding the tool steel mold, because it will affect time the precision work cutting tool layer of cutting area change and cutting tool load change, thus influence cutting process stability and precision work surface quality.
The rough machining is based on the volume model, the precision work then is based on the face mold. Before develops CAD/The CAM system to the components geometry description is not continual, after because has not described in front of the rough machining, the precision work processes the model the average information, therefore the rough machining surface surplus processing remainder distribution and the great surplus processing remainder is unknown. Therefore should fifty-fifty the precision work strategy carry on the optimization after to guarantee half precision work the work piece surface has the even surplus processing remainder. The optimized process includes: After the rough machining the outline computation, the great surplus processing remainder computation, the biggest permission processing remainder determination, is bigger than the biggest permission processing remainder the profile district (for example transition radius and so on scoop channel, corner is smaller than rough machining cutting tool radius region) as well as when half precision work the knife heart path computation to the surplus processing remainder and so on.
The existing mold high speed processes C A D/The CAM software has the surplus processing remainder analysis function mostly, and can act according to the surplus processing remainder the size and the distribution situation uses the reasonable half precision work strategy. After like the MasterCAM software provided has tied the shape milling (Pencil milling) and the surplus milling (Rest milling) and so on the method eliminates the rough machining the surplus processing remainder big quoin by to guarantee the following working procedure even processing remainder.
3. Precision work
The mold high speed precision work strategy is decided by the cutting tool and the work piece contact point, but the cutting tool and the work piece contact point but changes along with the processing surface curved surface slope and the cutting tool effective radius change. Regarding by the complex curved surface processing which many curved surface combination but becomes, should carry on the continuous treating as far as possible in a working procedure, but is not carries on the processing separately to each curved surface, by reduces lifts the knife, under the knife number of times. However, because processes the superficial slope change, if only defines the processing the side to eat the knife quantity (Step over), possibly creates on the slope different surface the actual step of distance non-uniformity, thus influence processing quality.
In the ordinary circumstances, the precision work curved surface radius of curvature should be bigger than the cutting tool radius 1.5 times, by evades the no admittance to the direction suddenly transformation. In the mold high speed precision work, when each time cuts into, cuts the work piece, enters for the direction change should as far as possible use the circular arc or the curve switches over, avoids using the straight line to switch over, by maintains the cutting process the stability.
High speed precision work strategy including three dimensional strategy and so on bias, contour precision work and best contour precision work, spiral contour precision work. These strategies may guarantee the cutting process light along, is stable, guarantees can fast excise on the work piece the material, obtains the high accuracy, the smooth cutting surface. The precision work basic request is needs to obtain the very high precision, the smooth components surface quality, relaxed realization fine region processing, like small fillet, trench and so on. Said to many shapes that, the precision work most effective strategy is the use three dimensional spiral strategy. Uses this kind of strategy to be possible to avoid the frequent direction change which uses the parallel strategy and in the bias precision work strategy can appear, thus the enhancement processing speed, reduces the cutting tool attrition. This strategy may in very little lift the knife in the situation to produce continuously the smooth cutting tool way. This kind of processing technology synthesized the spiral processing and the contour processing strategy merit, the cutting tool load stabler, proposes the knife number of times to be
less, may reduce the process period, reduces the cutting tool damage probability. It also may improve the processing surface quality, after the most predestined time of death reduces the need which the precision work manually polishes. Needs unifies in many situations the steep region contour precision work and the flat site three dimensional equal-space precision work method the use.
The numerical control programming also must consider the geometry design and the craft arrangement, when uses the CAM system carries on the high speed processing numerical control programming, besides the cutting tool and the processing parameter basis special details choice, the programming strategy which the processing method choice and uses has become the key. Splendid use CAD/The CAM workstation programs engineer to be supposed at the same time also to be a qualified design and the technologist, he should have a correct understanding to the components geometry structure, has knowledge and concept which designs regarding the ideal working procedure arrangement as well as the reasonable cutting tool path.
Fifth, high-speed cutting numerical control programming The high speed milling processing is more and more high to the numerical control programming system request, the price expensive high speed processing equipment proposed a higher secure and the valid request to the software. The high-speed cutting has compared to the traditional cutting special technological requirement, besides must have the high-speed cutting engine bed and the high-speed cutting cutting tool, has the appropriate CAM programming software also is very important. The numerical control processing numerical control instruction has contained all technological process, outstanding high speed processes the CAM programming system to be supposed to have the very high computation speed, strong inserts makes up the function, the entire journey is automatic has cut the inspection and the handling ability, the automatic hilt and the jig interference inspection, enters for rate the optimized processing function, treats the processing path monitoring function, the cutting tool path edition optimization function and the processing remaining analysis function and so on. The high-speed cutting programming first must pay attention to the processing method the security and the validity; Next, must guarantee with utmost effort the cutting tool path smooth is steady, this can affect components the directly and so on processing quality and engine bed main
axle life; Finally, must cause the cutting tool load to be even as far as possible, this can affect the cutting tool directly the life.
1. The CAM system should have the very high computation programming speed
In the high speed processing uses extremely small entering and cuts the depth for the quantity, its NC procedure must be much bigger than to the traditional numerical control processing procedure, thus requests the software computation speed to have to be quick, by saves the cutting tool path edition and the optimized programming time.
2. The entire journey automatically guards against has cut the handling ability and the automatic hilt interference inspection ability
The high speed processing processes the nearly 10 time of cuttings speeds by the tradition to carry on the processing, once will occur has cut to the engine bed, the product and the cutting tool has the calamity consequence, therefore will request its CAM system to have to have the entire journey automatically to guard against has cut processing the ability and the automatic hilt and the jig interference inspection, circles evades the function. The system can automatically prompt short supports on both sides the cutting tool length, and automatically carries on the cutting tool interference inspection.
3. Rich high-speed cutting cutting tool path strategy
The high speed processing to processes the craft to feed the way to have the special request compared to the traditional way, in order to can guarantee the maximum cutting efficiency, also guaranteed when high-speed cutting processes the security, the CAM system ought to be able to act according to processes the instantaneous remainder the size automatically to enter for rate carries on optimized processing, can automatically carry on the cutting tool path edition to optimize, the processing remaining analysis and the treatment processing path monitoring, by guarantees the high speed processing cutting tool stressful condition the stability, enhances the cutting tool the service life.
After uses the high speed processing equipment, will be able to increase to programmers' demand, because high speed will process the technological requirement strictly, has cut the protection to be more important, therefore will have to spend the much time to carry on the simulation examination to the NC instruction. In the ordinary circumstances, high speed processes the programming time the to be ordinary than processing programming time to have to be much longer. In order to guarantee the high speed processing equipment enough utilization ratio, must dispose the more CAM
personnel. The existing CAM software, like PowerMILL, MasterCAM, UnigraphicsNX, Cimatron and so on have all provided the correlation function high speed milling cutting tool path strategy.
Sixth, concluding remark
The high-speed cutting technology is one of machining technology main development directions, at present mainly applies in the automobile industry and the mold profession, in the processing complex curved surface domain, work piece itself or the cutting tool system rigidity request high processing domain and so on, is the many kinds of advanced processings technology integration in particular, its is highly effective high grade, esteems for the people. It not only involves to the high speed processing craft, moreover also includes high speed processes the engine bed, the numerical control is systematic, the high-speed cutting cutting tool and CAD/CAM technology and so on. The mold high speed processing technology generally has applied at present in the developed country mold manufacturing industry, but still waited for in our country's application scope and the application level the enhancement, because it had the tradition to process the incomparable superiority, still will be the next processing technology inevitable development direction.
中文翻译
模具高速铣削加工技术
一、前言
在现代模具生产中，随着对塑件的美观度及功能要求得越来越高，塑件内部结构设计得越来越复杂，模具的外形设计也日趋复杂，自由曲面所占比例不断增加，相应的模具结构也设计得越来越复杂。这些都对模具加工技术提出了更高要求，不仅应保证高的制造精度和表面质量，而且要追求加工表面的美观。随着对高速加工技术研究的不断深入，尤其在加工机床、数控系统、刀具系统、CAD/CAM软件等相关技术不断发展的推动下，高速加工技术已越来越多地应用于模具型腔的加工与制造中。
数控高速切削加工作为模具制造中最为重要的一项先进制造技术，是集高效、优质、低耗于一身的先进制造技术。相对于传统的切削加工，其切削速度、进给速度有了很大的提高，而且切削机理也不相同。高速切削使切削加工发生了本质性的飞跃，其单位功率的金属切除率提高了30%~40%，切削力降低了30%，刀具的切削寿命提高了70%，留于工件的切削热大幅度降低，低阶切削振动几乎消失。随着切削速度的提高，单位时间毛坯材料的去除率增加了，切削时间减少了，加工效率提高了，从而缩短了产品的制造周期，提高了产品的市场竞争力。同时，高速加工的小量快进使切削力减少了，切屑的高速排出减少了工件的切削力和热应力变形，提高了刚性差和薄壁零件切削加工的可能性。由于切削力的降低，转速的提高使切削系统的工作频率远离机床的低阶固有频率，而工件的表面粗糙度对低阶频率最为敏感，由此降低了表面粗糙度。在模具的高淬硬钢件(HRC45~HRC65)的加工过程中，采用高速切削可以取代电加工和磨削抛光的工序，从而避免了电极的制造和费时的电加工，大幅度减少了钳工的打磨与抛光量。对于一些市场上越来越需要的薄壁模具工件，高速铣削也可顺利完成，而且在高速铣削CNC加工中心上，模具一次装夹可完成多工步加工。
高速加工技术对模具加工工艺产生了巨大影响，改变了传统模具加工采用的“退火→铣削加工→热处理→磨削”或“电火花加工→手工打磨、抛光”等复杂冗长的工艺流程，甚至可用高速切削加工替代原来的全部工序。高速加工技术除可应
用于淬硬模具型腔的直接加工(尤其是半精加工和精加工)外，在EDM电极加工、快速样件制造等方面也得到了广泛应用。大量生产实践表明，应用高速切削技术可节省模具后续加工中约80%的手工研磨时间，节约加工成本费用近30%，模具表面加工精度可达1 m，刀具切削效率可提高1倍。
二、高速铣削加工机床
高速切削技术是切削加工技术的主要发展方向之一，它随着CNC技术、微电子技术、新材料和新结构等基础技术的发展而迈上更高的台阶。由于模具加工的特殊性以及高速加工技术的自身特点，对模具高速加工的相关技术及工艺系统(加工机床、数控系统、刀具等)提出了比传统模具加工更高的要求。
1. 高稳定性的机床支撑部件
高速切削机床的床身等支撑部件应具有很好的动、静刚度，热刚度和最佳的阻尼特性。大部分机床都采用高质量、高刚性和高抗张性的灰铸铁作为支撑部件材料，有的机床公司还在底座中添加高阻尼特性的聚合物混凝土，以增加其抗振性和热稳定性，这不但可保证机床精度稳定，也可防止切削时刀具振颤。采用封闭式床身设计，整体铸造床身，对称床身结构并配有密布的加强筋等也是提高机床稳定性的重要措施。一些机床公司的研发部门在设计过程中，还采用模态分析和有限元结构计算等，优化了结构，使机床支撑部件更加稳定可靠。
2. 机床主轴
高速机床的主轴性能是实现高速切削加工的重要条件。高速切削机床主轴的转速范围为10000~100000m/min，主轴功率大于15kW。通过主轴压缩空气或冷却系统控制刀柄和主轴间的轴向间隙不大于0.005mm。还要求主轴具有快速升速、在指定位置快速准停的性能(即具有极高的角加减速度)，因此高速主轴常采用液体静压轴承式、空气静压轴承式、热压氮化硅（Si3N4）陶瓷轴承磁悬浮轴承式等结构
形式。润滑多采用油气润滑、喷射润滑等技术。主轴冷却一般采用主轴内部水冷或气冷。
3. 机床驱动系统
为满足模具高速加工的需要，高速加工机床的驱动系统应具有下列特性：
(1) 高的进给速度。研究表明，对于小直径刀具，提高转速和每齿进给量有利于降低刀具磨损。目前常用的进给速度范围为20~30m/min，如采用大导程滚珠丝杠传动，进给速度可达60m/min；采用直线电机则可使进给速度达到
120m/min。
(2)高的加速度。对三维复杂曲面廓形的高速加工要求驱动系统具有良好的加速度特性，要求提供高速进给的驱动器(快进速度约40m/min，3D轮廓加工速度为10m/min)，能够提供0.4m/s2到10m/s2的加速度和减速度。
机床制造商大多采用全闭环位置伺服控制的小导程、大尺寸、高质量的滚珠丝杠或大导程多头丝杠。随着电机技术的发展，先进的直线电动机已经问世，并成功应用于CNC机床。先进的直线电动机驱动使CNC机床不再有质量惯性、超前、滞后和振动等问题，加快了伺服响应速度，提高了伺服控制精度和机床加工精度。
4. 数控系统
先进的数控系统是保证模具复杂曲面高速加工质量和效率的关键因素，模具高速切削加工对数控系统的基本要求为：
(1) 高速的数字控制回路(Digital control loop)，包括：32位或64位并行处理器及1.5Gb以上的硬盘；极短的直线电机采样时间。
(2)速度和加速度的前馈控制(Feed forward control)；数字驱动系统的爬行控制(Jerk control)。
(3) 先进的插补方法( 基于NURBS的样条插补)，以获得良好的表面质量、精确的尺寸和高的几何精度。
(4)预处理(Look-ahead)功能。要求具有大容量缓冲寄存器，可预先阅读和检查多个程序段(如DMG机床可多达500个程序段，Simens系统可达1000~2000个
程序段)，以便在被加工表面形状(曲率)发生变化时可及时采取改变进给速度等措施以避免过切等。
(5)误差补偿功能，包括因直线电机、主轴等发热导致的热误差补偿、象限误差补偿、测量系统误差补偿等功能。此外，模具高速切削加工对数据传输速度的要求也很高。
(6) 传统的数据接口，如RS232串行口的传输速度为19.2kb，而许多先进的加工中心均已采用以太局域网(Ethernet)进行数据传输，速度可达200kb。
5. 冷却润滑
高速加工采用带涂层的硬质合金刀具，在高速、高温的情况下不用切削液，切削效率更高。这是因为：铣削主轴高速旋转，切削液若要达到切削区，首先要克服极大的离心力；即使它克服了离心力进入切削区，也可能由于切削区的高温而立即蒸发，冷却效果很小甚至没有；同时切削液会使刀具刃部的温度激烈变化，容易导致裂纹的产生，所以要采用油/气冷却润滑的干式切削方式。这种方式可以用高压气体迅速吹走切削区产生的切削，从而将大量的切削热带走，同时经雾化的润滑油可以在刀具刃部和工件表面形成一层极薄的微观保护膜，可有效地延长刀具寿命并提高零件的表面质量。
三、高速切削加工的刀柄和刀具
由于高速切削加工时离心力和振动的影响，要求刀具具有很高的几何精度和装夹重复定位精度以及很高的刚度和高速动平衡的安全可靠性。由于高速切削加工时较大的离心力和振动等特点，传统的7:24锥度刀柄系统在进行高速切削时表现出明显的刚性不足、重复定位精度不高、轴向尺寸不稳定等缺陷，主轴的膨胀引起刀具及夹紧机构质心的偏离，影响刀具的动平衡能力。目前应用较多的是HSK高速刀柄和国外现今流行的热胀冷缩紧固式刀柄。热胀冷缩紧固式刀柄有加热系统，刀柄一般都采用锥部与主轴端面同时接触，其刚性较好，但是刀具可换性较差，一
个刀柄只能安装一种连接直径的刀具。由于此类加热系统比较昂贵，在初期时采用HSK类的刀柄系统即可。当企业的高速机床数量超过3台以上时，采用热胀冷缩紧固式刀柄比较合适。
刀具是高速切削加工中最活跃重要的因素之一，它直接影响着加工效率、制造成本和产品的加工精度。刀具在高速加工过程中要承受高温、高压、摩擦、冲击和振动等载荷，高速切削刀具应具有良好的机械性能和热稳定性，即具有良好的抗冲击、耐磨损和抗热疲劳的特性。高速切削加工的刀具技术发展速度很快，应用较多的如金刚石(PCD)、立方氮化硼(CBN)、陶瓷刀具、涂层硬质合金、(碳)氮化钛硬质合金TIC(N)等。
在加工铸铁和合金钢的切削刀具中，硬质合金是最常用的刀具材料。硬质合金刀具耐磨性好，但硬度比立方氮化硼和陶瓷低。为提高硬度和表面光洁度，采用刀具涂层技术，涂层材料为氮化钛(TiN)、氮化铝钛(TiALN)等。涂层技术使涂层由单一涂层发展为多层、多种涂层材料的涂层，已成为提高高速切削能力的关键技术之一。直径在10~40mm范围内，且有碳氮化钛涂层的硬质合金刀片能够加工洛氏硬度小于42的材料，而氮化钛铝涂层的刀具能够加工洛氏硬度为42甚至更高的材料。高速切削钢材时，刀具材料应选用热硬性和疲劳强度高的P类硬质合金、涂层硬质合金、立方氮化硼（CBN）与CBN复合刀具材料（WBN）等。切削铸铁，应选用细晶粒的K类硬质合金进行粗加工，选用复合氮化硅陶瓷或聚晶立方氮化硼（PCNB）复合刀具进行精加工。精密加工有色金属或非金属材料时，应选用聚晶金刚石PCD或CVD金刚石涂层刀具。选择切削参数时，针对圆刀片和球头铣刀，应注意有效直径的概念。高速铣削刀具应按动平衡设计制造。刀具的前角比常规刀具的前角要小，后角略大。主副切削刃连接处应修圆或导角，来增大刀尖角，防止刀尖处热磨损。应加大刀尖附近的切削刃长度和刀具材料体积，提高刀具刚性。在保证安全和满足加工要求的条件下，刀具悬伸尽可能短，刀体中央韧性要好。刀柄要比刀具直径粗壮，连接柄呈倒锥状，以增加其刚性。尽量在刀具及刀具系统中央留有冷却液孔。球头立铣刀要考虑有效切削长度，刃口要尽量短，两螺旋槽球头立铣刀通常用于粗铣复杂曲面，四螺旋槽球头立铣刀通常用于精铣复杂曲面。
四、模具高速加工工艺及策略
高速加工包括以去除余量为目的的粗加工、残留粗加工，以及以获取高质量的加工表面及细微结构为目的的半精加工、精加工和镜面加工等。
1. 粗加工
模具粗加工的主要目标是追求单位时间内的材料去除率，并为半精加工准备工件的几何轮廓。高速加工中的粗加工所应采取的工艺方案是高切削速度、高进给率和小切削用量的组合。等高加工方式是众多CAM软件普遍采用的一种加工方式。应用较多的是螺旋等高和等Z轴等高两种方式，也就是在加工区域仅一次进刀，在不抬刀的情况下生成连续光滑的刀具路径，进、退刀方式采用圆弧切入、切出。螺旋等高方式的特点是，没有等高层之间的刀路移动，可避免频繁抬刀、进刀对零件表面质量的影响及机械设备不必要的耗损。对陡峭和平坦区域分别处理，计算适合等高及适合使用类似3D偏置的区域，并且可以使用螺旋方式，在很少抬刀的情况下生成优化的刀具路径，获得更好的表面质量。在高速加工中，一定要采取圆弧切入、切出连接方式，以及拐角处圆弧过渡，避免突然改变刀具进给方向，禁止使用直接下刀的连接方式，避免将刀具埋入工件。加工模具型腔时，应避免刀具垂直插入工件，而应采用倾斜下刀方式(常用倾斜角为20°~30°)，最好采用螺旋式下刀以降低刀具载荷。加工模具型芯时，应尽量先从工件外部下刀然后水平切入工件。刀具切入、切出工件时应尽可能采用倾斜式(或圆弧式)切入、切出，避免垂直切入、切出。采用攀爬式切削可降低切削热，减小刀具受力和加工硬化程度，提高加工质量。
2. 半精加工
模具半精加工的主要目标是使工件轮廓形状平整，表面精加工余量均匀，这对于工具钢模具尤为重要，因为它将影响精加工时刀具切削层面积的变化及刀具载荷的变化，从而影响切削过程的稳定性及精加工表面质量。
粗加工是基于体积模型，精加工则是基于面模型。以前开发的CAD/CAM系统对零件的几何描述是不连续的，由于没有描述粗加工后、精加工前加工模型的中间信息，故粗加工表面的剩余加工余量分布及最大剩余加工余量均是未知的。因此应对半精加工策略进行优化以保证半精加工后工件表面具有均匀的剩余加工余量。优化过程包括：粗加工后轮廓的计算、最大剩余加工余量的计算、最大允许加工余量的确定、对剩余加工余量大于最大允许加工余量的型面分区(如凹槽、拐角等过渡半径小于粗加工刀具半径的区域)以及半精加工时刀心轨迹的计算等。
现有的模具高速加工C A D /CAM软件大都具备剩余加工余量分析功能，并能根据剩余加工余量的大小及分布情况采用合理的半精加工策略。如MasterCAM软
件提供了束状铣削(Pencil milling)和剩余铣削(Rest milling)等方法来清除粗加工后剩余加工余量较大的角落以保证后续工序均匀的加工余量。
3. 精加工
模具的高速精加工策略取决于刀具与工件的接触点，而刀具与工件的接触点随着加工表面的曲面斜率和刀具有效半径的变化而变化。对于由多个曲面组合而成的复杂曲面加工，应尽可能在一个工序中进行连续加工，而不是对各个曲面分别进行加工，以减少抬刀、下刀的次数。然而，由于加工中表面斜率的变化，如果只定义加工的侧吃刀量(Step over)，就可能造成在斜率不同的表面上实际步距不均匀，从而影响加工质量。
一般情况下，精加工曲面的曲率半径应大于刀具半径的1.5倍，以避免进给方向的突然转变。在模具的高速精加工中，在每次切入、切出工件时，进给方向的改变应尽量采用圆弧或曲线转接，避免采用直线转接，以保持切削过程的平稳性。
高速精加工策略包括三维偏置、等高精加工和最佳等高精加工、螺旋等高精加工等策略。这些策略可保证切削过程光顺、稳定，确保能快速切除工件上的材料，得到高精度、光滑的切削表面。精加工的基本要求是要获得很高的精度、光滑的零件表面质量，轻松实现精细区域的加工，如小的圆角、沟槽等。对许多形状来说，精加工最有效的策略是使用三维螺旋策略。使用这种策略可避免使用平行策略和偏置精加工策略中会出现的频繁的方向改变，从而提高加工速度，减少刀具磨损。这个策略可以在很少抬刀的情况下生成连续光滑的刀具路径。这种加工技术综合了螺旋加工和等高加工策略的优点，刀具负荷更稳定，提刀次数更少，可缩短加工时间，减小刀具损坏机率。它还可以改善加工表面质量，最大限地减小精加工后手工打磨的需要。在许多场合需要将陡峭区域的等高精加工和平坦区域三维等距精加工方法结合起来使用。
数控编程也要考虑几何设计和工艺安排，在使用CAM系统进行高速加工数控编程时，除刀具和加工参数根据具体情况选择外，加工方法的选择和采用的编程策略就成为了关键。一名出色的使用CAD/CAM工作站的编程工程师应该同时也是一名合格的设计与工艺师，他应对零件的几何结构有一个正确的理解，具备对于理想工序安排以及合理刀具轨迹设计的知识和概念。
五、高速切削数控编程
外文资料翻译 资料来源：《模具设计与制造专业英语》 文章名：Chapter 3 Casting Dies 书刊名：《English for Die & Mould Design and Manufacturing》 作者：刘建雄王家惠廖丕博主编 出版社：北京大学出版社，2002 章节：Chapter 3 Casting Dies 页码：P51~P60 文章译名：铸造模具
Chapter 3 Casting Dies 3.1Casting The first castings were made during the period 4000~3000 B.C., using stone and metal molds for casting copper. Various casting processes have been developed over a long period of time, each with its own characteristics and applications, to meet specific engineering and service requirements. Many parts and components are made by casting, including cameras, carburetors, engine blocks, crankshafts, automotive components, agricultural and railroad equipment, pipes and plumbing fixtures, power tools, gun barrels, frying pans, and very large components for hydraulic turbines. Casting can be done in several ways. The two major ones are sand casting, in which the molds used are disposable after each cycle, and die casting, or permanent molding, in which the same metallic die is used thousands or even millions of times. Both types of molds have three common features. They both have a “plumbing” system to channel molten alloy into the mold cavity. These channels are called sprues, runners, and gates (Fig. 3-1). Molds may be modified by cores which form holes and undercuts or inserts that become an integral part of the casting. Inserts strengthen and reduce friction, and they may be more machinable than the surrounding metal. For example, a steel shaft when properly inserted into a die cavity results in an assembled aluminum step gear after the shot. After pouring or injection, the resulting castings require subsequent operations such trim-ming, inspection, grinding, and repairs to a greater or lesser extent prior to shipping. Premium-quality castings from alloys of aluminum or steel require x-ray soundness that will be acceptable by the customer. Certain special casting processes are precision-investment casting, low-pressure casting, and centrifugal casting.
压力铸造模具设计说明 一、压铸简介压力铸造简称压铸，是一种将熔融合金液倒入压室内，以高速充填钢制模具的型腔，并使合金液在压力下凝固而形成铸件的铸造方法。压铸区别于其它铸造方法的主要特点是高压和高速。①金属液是在压力下填充型腔的，并在更高的压力下结晶凝固，常见的压力为15—100MPa。②金属液以高速充填型腔，通常在10—50米/秒，有的还可超过80米/秒，（通过内浇口导入型腔的线速度—内浇口速度），因此金属液的充型时间极短，约0.01—0.2秒（须视铸件的大小而不同）内即可填满型腔。压铸机、压铸合金与压铸模具是压铸生产的三大要素，缺一不可。所谓压铸工艺就是将这三大要素有机地加以综合运用，使能稳定地有节奏地和高效地生产出外观、内在质量好的、尺寸符合图样或协议规定要求的合格铸件，甚至优质铸件。1、压铸机（1）压铸机的分类压铸机按压室的受热条件可分为热压室与冷压室两大类。而按压室和模具安放位置的不同，冷室压铸机又可分为立式、卧式和全立式三种形式的压铸机。热室压铸机立式 冷室卧室全立式（2）压铸机的主要参数a合型力（锁模力）（千牛）————————KN b压射力（千牛）—————————————KN c动、定型板间的最大开距——————————mm d动、定型板间的最小开距——————————mm e动型板的行程———————————————mm f大杠内间距（水平×垂直）—————————mm g大杠直径—————————————————mm h顶出力——————————————————KN i顶出行程—————————————————mm j压射位置（中心、偏心）——————————mm k一次金属浇入量（Zn、Al、Cu）———————Kg l压室内径（Ф）——————————————mm m空循环周期————————————————s n铸件在分型面上的各种比压条件下的投影面积注：还应有动型板、定型板的安装尺寸图等。2、压铸合金压铸件所采用的合金主要是有色合金，至于黑色金属（钢、铁等）由于模具材料等问题，目前较少使用。而有色合金压铸件中又以铝合金使用较广泛，锌合金次之。下面简单介绍一下压铸有色金属的情况。（1）、压铸有色合金的分类 受阻收缩混合收缩自由收缩铅合金 -----0.2-0.3% 0.3-0.4% 0.4-0.5% 低熔点合金锡合金 锌合金--------0.3-0.4% 0.4-0.6% 0.6-0.8% 铝硅系--0.3-0.5% 0.5-0.7% 0.7-0.9% 压铸有色合金铝合金铝 铜系铝镁系---0.5-0.7% 0.7-0.9% 0.9-1.1% 高熔点合金铝锌系镁合金----------0.5-0.7% 0.7-0.9% 0.9-1.1% 铜合金（2）、各类压铸合金推荐的浇铸温度合金种类铸件平均壁厚≤3mm 铸件平均壁厚>3mm 结构简单结构复杂结构简单结构复杂 铝合金铝硅系610-650℃640-680℃600-620℃610-650℃ 铝铜系630-660℃660-700℃600-640℃630-660℃ 铝镁系640-680℃660-700℃640-670℃650-690℃ 铝锌系590-620℃620-660℃580-620℃600-650℃
前言 在目前激烈的市场竞争中，产品投入市场的迟早往往是成败的关键。模具是高质量、高效率的产品生产工具，模具开发周期占整个产品开发周期的主要部分。因此客户对模具开发周期要求越来越短，不少客户把模具的交货期放在第一位置，然后才是质量和价格。因此，如何在保证质量、控制成本的前提下加工模具是值得认真考虑的问题。模具加工工艺是一项先进的制造工艺，已成为重要发展方向，在航空航天、汽车、机械等各行业得到越来越广泛的应用。模具加工技术，可以提高制造业的综合效益和竞争力。研究和建立模具工艺数据库，为生产企业提供迫切需要的高速切削加工数据，对推广高速切削加工技术具有非常重要的意义。本文的主要目标就是构建一个冲压模具工艺过程，将模具制造企业在实际生产中结合刀具、工件、机床与企业自身的实际情况积累得高速切削加工实例、工艺参数和经验等数据有选择地存储到高速切削数据库中，不但可以节省大量的人力、物力、财力，而且可以指导高速加工生产实践，达到提高加工效率，降低刀具费用，获得更高的经济效益。 1.冲压的概念、特点及应用 冲压是利用安装在冲压设备（主要是压力机）上的模具对材料施加压力，使其产生分离或塑性变形，从而获得所需零件（俗称冲压或冲压件）的一种压力加工方法。冲压通常是在常温下对材料进行冷变形加工，且主要采用板料来加工成所需零件，所以也叫冷冲压或板料冲压。冲压是材料压力加工或塑性加工的主要方法之一，隶属于材料成型工程术。 冲压所使用的模具称为冲压模具，简称冲模。冲模是将材料（金属或非金属）批量加工成所需冲件的专用工具。冲模在冲压中至关重要，没有符合要求的冲模，批量冲压生产就难以进行；没有先进的冲模，先进的冲压工艺就无法实现。冲压工艺与模具、冲压设备和冲压材料构成冲压加工的三要素，只有它们相互结合才能得出冲压件。 与机械加工及塑性加工的其它方法相比，冲压加工无论在技术方面还是经济方面都具有许多独特的优点，主要表现如下； (1) 冲压加工的生产效率高，且操作方便，易于实现机械化与自动化。这是
Injection Molding The basic concept of injection molding revolves around the ability of a thermoplastic material to be softened by heat and to harden when cooled .In most operations ,granular material (the plastic resin) is fed into one end of the cylinder (usually through a feeding device known as a hopper ),heated, and softened(plasticized or plasticized),forced out the other end of the cylinder, while it is still in the form of a melt, through a nozzle into a relatively cool mold held closed under pressure.Here,the melt cools and hardens until fully set-up. The mold is then opened, the piece ejected, and the sequence repeated. Thus, the significant elements of an injection molding machine become: 1) the way in which the melt is plasticized (softened) and forced into the mold (called the injection unit); 2) the system for opening the mold and closing it under pressure (called the clamping unit);3) the type of mold used;4) the machine controls. The part of an injection-molding machine, which converts a plastic material from a sold phase to homogeneous seni-liguid phase by raising its temperature .This unit maintains the material at a present temperature and force it through the injection unit nozzle into a mold .The plunger is a combination of the injection and plasticizing device in which a heating chamber is mounted between the plunger and mold. This chamber heats the plastic material by conduction .The plunger, on each stroke; pushes unbelted plastic material into the chamber, which in turn forces plastic melt at the front of the chamber out through the nozzle The part of an injection molding machine in which the mold is mounted, and which provides the motion and force to open and close the mold and to hold the mold close with force during injection .This unit can also provide other features necessary for the effective functioning of the molding operation .Moving
(此文档为word格式，下载后您可任意编辑修改！) 冷冲模具使用寿命的影响及对策 冲压模具概述 冲压模具--在冷冲压加工中，将材料(金属或非金属)加工成零件(或半成品)的一种特殊工艺装备，称为冷冲压模具(俗称冷冲模)。冲压--是在室温下，利用安装在压力机上的模具对材料施加压力，使其产生分离或塑性变形，从而获得所需零件的一种压力加工方法。 冲压模具的形式很多，一般可按以下几个主要特征分类： 1?根据工艺性质分类 (1)冲裁模沿封闭或敞开的轮廓线使材料产生分离的模具。如落料模、冲孔模、切断模、切口模、切边模、剖切模等。 (2)弯曲模使板料毛坯或其他坯料沿着直线(弯曲线)产生弯曲变形，从而获得一定角度和形状的工件的模具。 (3)拉深模是把板料毛坯制成开口空心件，或使空心件进一步改变形状和尺寸的模具。 (4)成形模是将毛坯或半成品工件按图凸、凹模的形状直接复制成形，而材料本身仅产生局部塑性变形的模具。如胀形模、缩口模、扩口模、起伏成形模、翻边模、整形模等。2?根据工序组合程度分类 (1)单工序模在压力机的一次行程中，只完成一道冲压工序的模具。 (2)复合模只有一个工位，在压力机的一次行程中，在同一工位上同时完成两道或两道以上冲压工序的模具。 (3)级进模(也称连续模) 在毛坯的送进方向上，具有两个或更多的工位，在压力机的一次行程中，在不同的工位上逐次完成两道或两道以上冲压工序的模具。 冲冷冲模全称为冷冲压模具。 冷冲压模具是一种应用于模具行业冷冲压模具及其配件所需高性能结构陶瓷材料的制备方法，高性能陶瓷模具及其配件材料由氧化锆、氧化钇粉中加铝、错元素构成，制备工艺是将氧化锆溶液、氧化钇溶液、氧化错溶液、氧化铝溶液按一定比例混合配成母液，滴入碳酸氢铵，采用共沉淀方法合成模具及其配件陶瓷材料所需的原材料，反应生成的沉淀经滤水、干燥，煅烧得到高性能陶瓷模具及其配件材料超微粉，再经过成型、烧结、精加工，便得到高性能陶瓷模具及其配件材料。本发明的优点是本发明制成的冷冲压模具及其配件使用寿命长，在冲压过程中未出现模具及其配件与冲压件产生粘结现象，冲压件表面光滑、无毛刺，完全可以替代传统高速钢、钨钢材料。 冷冲模具主要零件冷冲模具是冲压加工的主要工艺装备，冲压制件就是靠上、下模具的相对运动来完成的。 加工时由于上、下模具之间不断地分合，如果操作工人的手指不断进入或停留在模具闭合区，便会对其人身安全带来严重威胁。 1
济南大学泉城学院 毕业设计外文资料翻译 题目现代快速经济制造模具技术 专业机械制造及其自动化 班级专升本1302班 学生刘计良 学号2013040156 指导教师刘彦 二〇一五年三月十六日
Int J Adv Manuf Technol ,(2011) 53:1–10DOI 10.1007/s00170-010-2796-y Modular design applied to beverage-container injection molds Ming-Shyan Huang & Ming-Kai Hsu Received: 16 March 2010 / Accepted: 15 June 2010 / Published online: 25 June 2010 # Springer-Verlag London Limited 2010 Modular design applied to beverage-container injection molds The Abstract: This work applies modular design concepts to designating beverage-container injection molds. This study aims to develop a method of controlling costs and time in relation to mold development, and also to improve product design. This investigation comprises two parts: functional-ity coding, and establishing a standard operation procedure, specifically designed for beverage-container injection mold design and manufacturing. First, the injection mold is divided into several modules, each with a specific function. Each module is further divided into several structural units possessing sub-function or sub-sub-function. Next, dimen-sions and specifications of each unit are standardized and a compatible interface is constructed linking relevant units. This work employs a cup-shaped beverage container to experimentally assess the performance of the modular design approach. The experimental results indicate that the modular design approach to manufacturing injection molds shortens development time by 36% and reduces costs by 19 23% compared with the conventional ap-proach. Meanwhile, the information on
模具工业是国民经济的基础工业，是国际上公认的关键工业，工业发达国家称之为“工业之母”。模具成型具有效率高，质量好，节省原材料，降低产品成本等优点。采用模具制造产品零件已成为当今工业的重要工艺手段。模具在机械，电子，轻工，纺织，航空，航天等工业领域里，已成为使用最广泛的工业化生产的主要工艺装备，它承担了这些工业领域中60%--80%产品零件，组件和部件的加工生产。“模具就是产品质量”，“模具就是经济效益”的观念已被越来越多的人所认识和接受。在中国，人们已经认识到模具在制造业中的重要基础地位，认识更新换代的速度，新产品的开发能力，进而决定企业的应变能力和市场竞争能力。在目前用薄钢板制造发动机罩盖的传统还是会持续相当一段时间，所以有必要在钢板的基础上通过利用计算机软件的功能分析零件的工艺性能（结构合理，受力，是否容易冲出破面、、、），发现现有零件的不足之处，讨论并确定改进这些不足之处，进而改善模具的设计，改良冲裁方式；最终实现产品的改良，改善产品的力学性能，外观，使用效果，和造价等等。冲压加工是通过模具来实现的，从模具角度来看，模具生产技术水平的高低，已成为衡量一个国家产品制造水平高低的重要标志，因为模具在很大程度上决定着产品的质量、效益和新产品的开发能力。“模具是工业生产的基础工艺装备”也已经取得了共识。据统计，在电子、汽车、电机、电器、仪器、仪表、家电和通信等产品中，60%～80%的零部件都要依靠模具成形。用模具生产制件所具备的高精度、高复杂程度、高一致性、高生产率和低消耗，是其他加工制造方法所不能比拟的。同时，冲压加工也创造了巨大的价值增值，模具是“效益放大器”，用模具生产的最终产品的价值，往往是模具自身价值的几十倍、上百倍。目前全世界模具年产值约为600亿美元，日、美等工业发达国家的模具工业产值已超过机床工业，从1997年开始，我国模具工业产值也超过了机床工业产值。其中冲压模具在所有模具（锻造模、压铸模、注塑模等）中，无论从数量、重量或者是从价值上都位居榜首。 由此可见，板料冲压加工及其模具制造技术对国民经济的发展已经并将继续作出重大的贡献。随着我国经济的发展，对这种生产技术的发展及专业技术人才的需求将与日俱增。因此，加强对板料冲压加工及其模具制造技术的研究，具有重要的意义。 现状和发展趋势：经过了100多年的发展,目前小型汽车发动机的罩壳的设计技术已经相当成熟的了，但是随着各式各样的小型发动机的开发，发动机的前后罩也做了很大的改进。现在，对小型汽车发动机的罩壳的改进主要表现在对其构造材料的改进；例如用树脂基复合材料替代传统的薄钢板，用 RTM制造发动机水箱、隔热罩、发动机罩等等，由于用复合材料来取代原有金属的发动机壳体类零件，重量会有所减轻，且成本也将大大降低，对制造商而言，这个改进创造了很大了利润空间，所以这方面的技术进步还会持续相当长一段时间。就目前而言，我国冲压模具还存在许多问题，其中模具生产周期、质量和数量仍旧是关键。与国际水平相比，一般来说，我国冲压模具生产周期要比国外先进水平长、寿命约
冷冲模具使用寿命的影响及对策 冲压模具概述 冲压模具--在冷冲压加工中，将材料（金属或非金属）加工成零件（或半成品）的一种特殊工艺装备，称为冷冲压模具（俗称冷冲模）。冲压--是在室温下，利用安装在压力机上的模具对材料施加压力，使其产生分离或塑性变形，从而获得所需零件的一种压力加工方法。 冲压模具的形式很多，一般可按以下几个主要特征分类： １．根据工艺性质分类 （1）冲裁模沿封闭或敞开的轮廓线使材料产生分离的模具。如落料模、冲孔模、切断模、切口模、切边模、剖切模等。 （2）弯曲模使板料毛坯或其他坯料沿着直线（弯曲线）产生弯曲变形，从而获得一定角度和形状的工件的模具。 （3）拉深模是把板料毛坯制成开口空心件，或使空心件进一步改变形状和尺寸的模具。 （4）成形模是将毛坯或半成品工件按图凸、凹模的形状直接复制成形，而材料本身仅产生局部塑性变形的模具。如胀形模、缩口模、扩口模、起伏成形模、翻边模、整形模等。 ２．根据工序组合程度分类 （1）单工序模在压力机的一次行程中，只完成一道冲压工序的模具。 （2）复合模只有一个工位，在压力机的一次行程中，在同一工位上同时完成两道或两道以上冲压工序的模具。 （3）级进模（也称连续模）在毛坯的送进方向上，具有两个或更多的工位，在压力机的一次行程中，在不同的工位上逐次完成两道或两道以上冲压工序的模具。 冲冷冲模全称为冷冲压模具。 冷冲压模具是一种应用于模具行业冷冲压模具及其配件所需高性能结构陶瓷材料的制备方法，高性能陶瓷模具及其配件材料由氧化锆、氧化钇粉中加铝、镨元素构成，制备工艺是将氧化锆溶液、氧化钇溶液、氧化镨溶液、氧化铝溶液按一定比例混合配成母液，滴入碳酸氢铵，采用共沉淀方法合成模具及其配件陶瓷材料所需的原材料，反应生成的沉淀经滤水、干燥，煅烧得到高性能陶瓷模具及其配件材料超微粉，再经过成型、烧结、精加工，便得到高性能陶瓷模具及其配件材料。本发明的优点是本发明制成的冷冲压模具及其配件使用寿命长，在冲压过程中未出现模具及其配件与冲压件产生粘结现象，冲压件表面光滑、无毛刺，完全可以替代传统高速钢、钨钢材料。 冷冲模具主要零件 冷冲模具是冲压加工的主要工艺装备，冲压制件就是靠上、下模具的相对运动来完成的。加工时由于上、下模具之间不断地分合，如果操作工人的手指不断进入或停留在模具闭合区，便会对其人身安全带来严重威胁。
毕业设计论文外文翻译
模具的发展 1模具在工业生产中的地位 模具是大批量生产同形产品的工具，是工业生产的主要工艺装备。 采用模具生产零部件，具有生产效率高、质量好、成本低、节约能源和原材料等一系列优点，用模具生产制件所具备的高精度、高复杂程度、高一致性、高生产率和低消耗，是其他加工制造方法所不能比拟的。已成为当代工业生产的重要手段和工艺发展方向。现代经济的基础工业。现代工业品的发展和技术水平的提高，很大程度上取决于模具工业的发展水平，因此模具工业对国民经济和社会发展将起越来越大的作用。1989年3月国务院颁布的《关于当前产业政策要点的决定》中，把模具列为机械工业技术改造序列的第一位、生产和基本建设序列的第二位(仅次于大型发电设备及相应的输变电设备)，确立模具工业在国民经济中的重要地位。1997年以来，又相继把模具及其加工技术和设备列入了《当前国家重点鼓励发展的产业、产品和技术目录》和《鼓励外商投资产业目录》。经国务院批准，从1997年到2000年，对80多家国有专业模具厂实行增值税返还70%的优惠政策，以扶植模具工业的发展。所有这些，都充分体现了国务院和国家有关部门对发展模具工业的重视和支持。目前全世界模具年产值约为600亿美元，日、美等工业发达国家的模具工业产值已超过机床工业，从1997年开始，我国模具工业产值也超过了机床工业产值。 据统计，在家电、玩具等轻工行业，近90％的零件是综筷具生产的；在飞机、汽车、农机和无线电行业，这个比例也超过60％。例如飞机制造业，某型战斗机模具使用量超过三万套，其中主机八千套、发动机二千套、辅机二万套。从产值看，80年代以来，美、日等工业发达国家模具行业的产值已超过机床行业，并又有继续增长的趋势。据国际生产技术协会预测，到2000年，产品尽件粗加工的75%、精加工的50％将由模具完成；金属、塑料、陶瓷、橡胶、建材等工业制品大部分将由模具完成，50％以上的金属板材、80％以上的塑料都特通过模具转化成制品。
第一篇译文（中文） 2.3注射模 2.3.1注射模塑 注塑主要用于热塑性制件的生产，它也是最古老的塑料成型方式之一。目前，注塑占所有塑料树脂消费的30%。典型的注塑产品主要有杯子器具、容器、机架、工具手柄、旋钮（球形捏手）、电器和通讯部件（如电话接收器），玩具和铅管制造装置。 聚合物熔体因其较高的分子质量而具有很高的粘性；它们不能像金属一样在重力流的作用下直接被倒入模具中，而是需要在高压的作用下强行注入模具中。因此当一个金属铸件的机械性能主要由模壁热传递的速率决定，这决定了最终铸件的晶粒度和纤维取向，也决定了注塑时熔体注入时的高压产生强大的剪切力是物料中分子取向的主要决定力量。由此所知，成品的机械性能主要受注射条件和在模具中的冷却条件影响。 注塑已经被应用于热塑性塑料和热固性塑料、泡沫部分，而且也已经被改良用于生产反应注塑过程，在此过程中，一个热固树脂系统的两个组成部分在模具中同时被注射填充，然后迅速聚合。然而大多数注塑被用热塑性塑料上，接下来的讨论就集中在这样的模具上。 典型的注塑周期或流程包括五个阶段（见图2-1）： （1）注射或模具填充； （2）填充或压紧； （3）定型； （4）冷却； （5）零件顶出。 图2-1 注塑流程 塑料芯块（或粉末）被装入进料斗，穿过一条在注射料筒中通过旋转螺杆的作用下塑料芯块（或粉末）被向前推进的通道。螺杆的旋转迫使这些芯块在高压下对抗使它们受热融化的料筒加热壁。加热温度在265至500华氏度之间。随着压力增强，旋转螺杆被推向后压直到积累了足够的塑料能够发射。注射活塞迫使熔融塑料从料筒，通过喷嘴、浇口和流道系统，最后进入模具型腔。在注塑过程中，模具型腔被完全充满。当塑料接触冰冷的模具表面，便迅速固化形成表层。由于型芯还处于熔融状态，塑料流经型芯来完成模具的填充。典型地，在注塑过程中模具型腔被填充至95%~98%。 然后模具成型过程将进行至压紧阶段。当模具型腔充满的时候，熔融的塑料便开始冷却。由于塑料冷却过程中会收缩，这增加了收缩痕、气空、尺寸不稳定性等瑕疵。为了弥补收缩，额外的塑料就要被压入型腔。型腔一旦被填充，作用于使物料熔化的压力就会阻止模具型腔中的熔融塑料由模具型腔浇口处回流。压力一直作用到模具型腔浇口固化。这个过程可以分为两步（压紧和定型），或者一步完成（定型或者第二阶段）。在压紧过程中，熔化物通过补偿收缩的保压压力来进入型腔。固化成型过程中，压力仅仅是为了阻止聚合物熔化物逆流。
注射模具的介绍 1.模具基本知识 1.1引言 我们日常生产、生活中所使用到的各种工具和产品，大到机床的底座、机身外壳，小到一个胚头螺丝、纽扣以及各种家用电器的外壳，无不与模具有着密切的关系。模具的形状决定着这些产品的外形，模具的加工质量与精度也就决定着这些产品的质量。因为各种产品的材质、外观、规格及用途的不同，模具分为了铸造模、锻造模、压铸模、冲压模等非射胶模具，以及射胶模具。近年来，随着射料工业的飞速发展和通用与工程射料在强度和精度等方面的不断提高，射料制品的应用范围也在不断扩大，如：家用电器、仪器仪表，建筑器材，汽车工业、日用五金等众多领域，射料制品所占的比例正迅猛增加。一个设计合理的射料件往往能代替多个传统金属件。工业产品和日用产品射料化的趋势不断上升。 1.2 模具的一般定义 在工业生产中，用各种压力机和装在压力机上的专用工具，通过压力把金属或非金属材料制出所需形状的零件或制品，这种专用工具统称为模具。 1.3 模具的一般分类 可分为射胶模具及非射胶模具：（1）非射胶模具有：铸造模、锻造模、冲压模、压铸模等。 A．铸造模——水龙头、生铁平台 B．锻造模——汽车身 C．冲压模——计算机面板 D．压铸模——超合金，汽缸体（2）射胶模具根据生产工艺和生产产品的不同又分为：A．注射成型模——电视机外壳、键盘按钮（应用最普遍） B．吹气模——饮料瓶 C．压缩成型模——电木开关、科学瓷碗碟 D．转移成型模——集成电路制品 E．挤压成型模——胶水管、射胶袋 F．热成型模——透明成型包装外壳 G．旋转成型模——软胶洋娃娃玩具 注射成型是射料加工中最普遍采用的方法。该方法适用于全部热射性射料和部分热固性射料，制得的射料制品数量之大是其它成型方法望尘莫及的，作为注射成型加工的主要工具之一的注射模具，在质量精度、制造周期以及注射成型过程中的生产效率等方面水平高低，直接影响产品的质量、产量、成本及产品的更新，同时也决定着企业在市场竞争中的反应能力和速度。注射模具是由若干块钢板配合各种零件组成的，基本分为： A 成型装置（凹模，凸模） B 定位装置（导柱，导套） C 固定装置（工字板，码模坑） D 冷却系统（运水孔） E 恒温系统（加热管，发热线） F 流道系统（唧咀孔，流道槽，流道孔） G 顶出系统（顶针，顶棍） 1.4 模具的类型
快速成型制作铸造模具 快速成形制造技术是目前国际上成型工艺中备受关注的焦点。铸造作为一项传统的工艺，制造成本低、工艺灵活性大，可以获得复杂形状和大型的铸件。充分发挥两者的特点和优势，可以在新产品试制中取得客观的经济效益。 快速成形制造技术又称为快速原型制造技术(Rapid Prototyping Manufacturing，简称RPM)，是一项高科技成果。它包括SLS、SLA、SLM等成型方法,集成了CAD技术、数控技术、激光技术和材料技术等现代科技成果，是先进制造技术的重要组成部分。与传统制造方法不同，快速成型从零件的CAD几何模型出发，通过软件分层离散和数控成型系统，用激光束或其他方法将材料堆积而形成实体零件，所以又称为材料添加制造法(Material Additive Manufacturing 或 Material Increase Manufacturing)。由于它把复杂的三维制造转化为一系列二维制造的叠加，因而可以在不用模具和工具的条件下几乎能够生成任意复杂形状的零部件，极大地提高了生产效率和制造柔性。与数控加工、铸造、金属冷喷涂、硅胶模等制造手段一起，快速自动成型已成为现代模型、模具和零件制造的强有力手段，是目前适合我国国情的实现金属零件的单件或小批量敏捷制
造的有效方法，在航空航天、汽车摩托车、家电等领域得到了广泛应用。 快速成型技术能够快捷地提供精密铸造所需的蜡模或可消失熔模以及用于砂型铸造的木模或砂模，解决了传统铸造中蜡模或木模等制备周期长、投入大和难以制作曲面等复杂构件的难题。而精密铸造技术（包括石膏型铸造）和砂型铸造技术，在我国是非常成熟的技术，这两种技术的有机结合，实现了生产的低成本和高效益，达到了快速制造的目的。 RPM技术的特点 快速成型的过程是首先生成一个产品的三维CAD实体模型或曲面模型文件，将其转换成特定的文件格式，再用相应的软件从文件中“切”出设定厚度的一系列片层，或者直接从CAD文件切出一系列的片层。这些片层按次序累积起来仍是所设计零件的形状。然后，将上述每一片层的资料传到快速自动成型机中去，用材料添加法并以激光为加热源，依次将每一层烧结或熔结并同时连结各层，直到完成整个零件。成型材料为各种可烧结粉末，如石蜡、塑料、低熔点金属粉末或它们的混合粉末。 快速成型技术与传统方法相比具有独特的优越性，其特点如下：
注塑成型智能模具设计工具 摘要 注塑成型是一个生产热塑性塑料制品最流行的制造工艺，而模具设计是这个过程的一个重要方面。模具设计需要专业的知识、技能，最重要的是拥有该领域的经验。三者缺一不可。生产塑料组件需要选择恰当的模具，如果缺乏其中之一，这种选择就得在反复试验的基础上进行。这会增加生产成本，并造成设计上的不一致。本文介绍了智能模具设计工具的发展。该工具捕获模具设计过程的知识，并且以符合逻辑的方式将这些知识反映出来。所获得的知识将是确定性的，但模具设计过程中的信息是非确定的。一旦开发了模具设计工具，它将指导使用者根据不同客户的要求，为其塑料零件选择合适的模具。 导言 注塑成型工艺过程需要专业的知识、技能，最重要的是需要它成功的实践经验。通常是工艺参数控制过程的效率。在制造过程中，有效地控制和优化这些参数能实现一致性，这种一致性会在零件质量和零件成本上表现出来的问题。 1 智能化工程模块注塑成型工艺（IKEM） 基于知识的智能化工程模块的注塑成型工艺（IKEM）是一种软件技术，它领先于并行工程和 CAD / CAM 系统。它集成工程的设计和制造工艺的最新知识，给用户各种设计方面的指示，通过减少在产品开发设计阶段的工程变更，有助于减少一些工时。该系统将用于注塑设计，设计迭代和流程整合。目前的过程由许多手工计算、CAD 图形结构和从以前项目取得的经验三部分组成。一旦工程师完成设计，这将是性能评估。该 IKEM 项目已分为三大模块。 1 费用估算模块 2 模具设计模块 3 生产模块 IKEM 系统有两种形式输入。在一个 CAD 模型的形式（Pro/E 文件）下输入，和在给出的用户界面形式下输入。制造商的经验水平将决定如何有效地控制工艺参数。有时这就导致人为错误引起的不一致性。还有经验不足，时间、资源短缺和创新的空间不大的情况。通过创造所谓的“智能模型”的问题，工程学知识提供了一个可行的方案去解决所有这样用户输入形式模架设计制造用户输出形式语法分析程 CAD 模型成本估计 2 智能模具设计工具 在它的基本形式中模具设计工具是一个从文本文件中提取输入的 Visual Basic 应用程序，这种文本文件包含关于零件和用户输入程序。该文本文件包含来自 Pro/E 的一个信息文件的零件的几何解析。输入是用来估测模具得尺寸和其它各种特性。 2.1 文献回顾 模具设计的是另一种注塑成型过程的阶段，有经验的工程师在很大程度上有助于自动化进程，提高其效率。这个问题需要注意的是深入研究设计模具的时间。通常情况下，当设计工程师设计模具时，他们会参阅表格和标准手册，这会消耗大量的时间。另外，在标准的CAD 软件中需要大量的时间去考虑模具的建模组件。不同的研究人员已经解决了缩短用不同的方式来设计模具所花费的时间的问题。凯尔奇和詹姆斯采用成组技术来减少模具设计时间。聚合一类注塑成型件的独特的编码系统和在注射模具中所需的工具已开发，它可以适用于其它产品生产线。实施编码系统的软件系统也已经被开发。通过获取在这方面领域的工程师的经验和知识，尝试直接使模具设计过程的自动化。并行模具设计系统的研究开发就是这样的一个过程，在并行工程环境中试图制定一个系统的注塑模具设计流程。他们的研究目标是研制一个有利于并行工程实践的模具开发的进程，和研制开发一个以知识为基础的为注塑模具设计提供工艺问题和产品要求的辅助设计。通过各种方式获取关于模具设计过程的确定信息和
外文原文 Abstract：Die designing is a demanding and hard work．To design a separate die for each product is time consuming and expensive task．This paper presents an idea of sets of standard reference dies．it gives a concept of flexible die designing using a reference standard die designed in a popular commercial CAD／CAM software—Pro／Engineer．Rather than designing a separate die for each part，just update the die design by selecting the die dimensions as required．The use of this concept will prove to reduce time and cost of product in manufacturing industry． Key words：die；flexible die designing system ；standardization；Pro/E；secondary development At present, the industrial developed countries and regions in the mold industry has been gradually standardize and serialization. In China, although the majority die within the enterprises have business standards, but generally not high degree of standardization, standardization of stamping die in the die-limited parts of the parts. To achieve real savings stamping die design time and shorten the processing cycle, cost savings, reduce design and manufacturing staff workload purposes, it needs to develop a flexible stamping die design system. At the same time, stamping die serialization of the scope of standardization and can not be confined to die-part of the fixed panels, boards, the top plate unloading device commonly used components such as stamping or even die structure, we should achieve serialization and standardization. As CAD / CAM technology in the design and manufacture die in the course of extensive application, it should first be standardized stamping die from the CAD system began. Some large-scale commercialization of the CAD / CAM software, such as Pro / E, UG, and so on. Have developed a specialized injection mold design package. And stamping die design for the special software, users need to be developed. l The application tools Pro / E in stamping die design flexibility in the system development Pro / Engineer by the United States has developed a set of PTC CAD / cAM / CAE software. Pro / E using a single database And feature-based, the design parameters of the model, provides users with 1 The development is very convenient for stamping die flexible system of tools juice 1.1 Family Table Fanaily Fable known as the Family Table, the structure used to create the same or similar parts of the size and characteristics of the standardized database tables, is devoted to the establishment of a standard parts library tool. The use of the former