Mold Design and Manufacturing TechnologyCourse Title: Mold Design and Manufacturing TechnologyCourse Code:Credit: 3Lecture Hours: 46OverviewThis course is a compulsory course for students majoring in Mechanical Engineering and Automation. It is a comprehensive course with systematic combination of common mold design and manufacturing technology. This course focuses on the technological properties of materials, some typical mold designs and manufacture methods, and the manufacturing process and assembly process. It aims to help students master the typical mold design and manufacturing capability so as to form mould manufacturing concepts and industry knowledge, as well as lay foundation for graduation design and technical work in the future.Aims and ObjectivesOn successful completion of this course, students should be able to:*have a basic understanding of occupation quality in mold design and relevant manufacturing and carry out the mold design and manufacture of the actual product; *analyze the molding of material property as well as develop reasonable and feasible mould processing ability;*acquaint themselves with the mould design method so as to select standard parts for mould structure design with characteristics such as proper structure, convenient operation, convenient processing and assembling, and technique economic;*formulate the ability of correct mold manufacturing processing and assembly processing;*analyze and test generation processing related to technical problems;*develop their ability to learn to track the professional and technical development direction as well as explore latest knowledge on their own;*master the basic theory and methods for typical mould design and manufacture, and lay a theoretical basis for the graduation design and technical work further.Syllabus and Schedule of LecturesTheoretical Teaching:Chapter 1 Introduction: Basis of Stamping Process1.1An Overview of Moulds1.2Classification and Characteristics of Stamping1.3Properties of Sheet Stamping1.4Common Stamping Materials & Stamping EquipmentChapter 2 Blanking Process and Blanking Die2.1 Design Basis on Blanking Process & Typical Structure of Blanking Die2.2. Layout Design & Blanking Technology Calculation2.3. Structure Design of Blanking Die Parts & Integrated CasesChapter 3 Bending Process and Bending Die3.1 Bending Process and Bending Die Process & Typical Structure of Bending Die 3.2 Bending Quality Analysis & Bending Process Calculation3.3 Bending Die & Integrated CasesChapter 4 Drawing Process and Drawing Die4.1 Drawing Process and Drawing Parts Process;4.2 Typical Structure of Drawing Die & Wrinkling and Rupture of Drawing Parts4.3 Drawing Process Calculation & Drawing Die Design & Integrated Cases Chapter 5 Other Sheet Stamping and Process & Mould Design5.1 Bulging & Flanging5.2 Necking & Integrated CasesChapter 6 Stamping Die FEA Analysis Based on DTBAFIRN6.1 An Analysis of Software for Stamping;6.2 Case AnalysisChapter 7 Stamping Process Design7.1 Stamping Process Design & Analysis of Stamping Parts Processing7.2 Stamping Technology Program Development & Mold Design7.3 Stamping Equipment Selection & Process Documenting and Design Calculation ManualChapter 8 Fundamental Plastics Molding Process8.1Composition, Classification and Characteristics of Plastics8.2 Method and Process Characteristics of Plastic Forming;8.3 Structure Process of Plastic Pieces & Plastic Forming EquipmentChapter 9 Injection Molding Process and Injection Mold & Other Plastic Molding Process and Mold9.1 Principle and Process Conditions of Injection Molding Process & Structure of Injection Mold & Parting Surface9.2 Design of Gating System & Design Forming Part9.3 The Side Parting and Core Pulling Mechanism & Ejecting Mechanism Design & Clamping Mechanism9.4 Design Temperature Control System & Related Parameter Checking of Mould and Injection Machine9.5 Co-injection Molding Process & Design Flow of injection Mould & Integrated cases9.6 Compression Molding Process and Compression Mold & Pressure Injection Molding Process and Injection Mold & Extrusion Forming Process and Die & Hollow Blow Molding & Vacuum Forming & Compressed Forming & Air Foam Forming Chapter 10 Fundamental Mold Manufacturing10.1 Characteristics of Mold Manufacturing & Mold Manufacturing Process10.2 Process-scheduled Principles and Procedures for Mould and Die Manufacturing 10.3 Process Analysis of Mold Parts Diagram & Blank Selection of Mold Parts Chapter 11 Processing of Forming Die Surface11.1 Mechanical Process of Forming Die Surface11.2 Non-Traditional Machining (NTM) of Forming Die Surface11.3 Modern Technology for Mold Manufacturing & Processing of Mould Parts Chapter 12 Mold Assembly Process12.1 An Overview of Mold Assembly12.2 Dimension Chain of Assembly & Control Method of Die Clearance12.3 Assembly Process for Stamping and Injection Mould & Integrated Cases Practical Training (2 Hours)PrerequisitesMechanical Drawing and Computer Graphics, Fundamental Mechanical Design, Engineering Materials and Heat Treatment, Manufacturing Technology, NC Machining Technology, etc.TextbookTian Guanghui & Lin Hongqi. Mould Design and Manufacturing. Peking University Press, 2009.AssessmentsAssignment (including group work, course design report, homework, lecture participation and attendance) 50%Examination 50%。
塑料模具设计与制作要求1 范围本标准规定了本公司塑料模具的设计与制作要求。
本标准适用于本公司的塑料模具制作与验收。
2规范性引用标准下列文件中的条款通过本标准的引用而成为本标准的条款。
凡是注日期的引用文件，其随后所有的修改单(不包括勘误的内容)或修订版均不适用于本标准。
凡是不注日期的引用文件，其最新版本适用于本部分。
Q/MB05.003-2003 塑料模具设计制造规范3 技术要求3.1模具的设计要求3.1.1模具分类根据模架尺寸将模具分为大、中、小三类。
a）模架尺寸6060以上称为大型模具；b）模架尺寸3030～6060之间为中型模具；c）模架尺寸3030以下为小型模具。
3.1.2模架选用与设计的要求3.1.2.1优先选用标准模架，具体按《龙记标准模架》执行。
3.1.2.2若选用非标准模架，应优先选用标准板厚，具体参照《龙记标准模架》。
3.1.2.3大型非标模架，导柱直径不小于φ60mm,导套孔壁厚不得小于10mm，回针孔壁厚为 35～40mm，回针直径不小于φ30mm。
3.1.2.4大型非标模架A板、B板起吊螺丝孔为M36～M48。
3.1.2.5如有可能产生较大侧压力时（型腔深度超过50mm），非标大型模架应设计原身止口，以后模套住前模。
3.1.2.6模架3030以上就必须增加顶针板导柱2-4个。
3.1.2.7订购模架时必须注意方铁的高度。
3.1.3注塑参数校核方法3.1.3.1容模尺寸校核a）模具厚度+顶出距离+取出产品的距离＜最大开模距离；b）模具厚度＞注塑机模板最小闭合距离,而＜注塑机模板最大闭合距离；c）码模板尺寸小于注塑机模板的最大装夹尺寸。
3.1.3.2锁模力：F≥P.A.S10-²其中F：注射机的公称锁模力（t）；P：模内平均压力（25～40Mpa）；A：投影面积（包括产品、流道）cm²。
3.1.4型腔排位要求3.1.4.1型腔排位有利于各腔同时、均匀进胶；3.1.4.2多腔模各腔间距不小于20mm，大产品深腔根据强度面增加，模腔与镶件边不得少于20～25mm，多胶模的同一个产品保证进胶位置一致。
模具制作的验收标准产品要求：尺寸必须符合图纸要求。
塑件产品外观必须符合图纸要求或封样样品要求。
注塑产品不能出现冷料、气雾、缺料、收缩、溢料飞边、熔接痕、变形翘曲、顶白、斑痕、浇口雾斑等其它表观缺陷。
产品光面不能有划痕、细微麻点、波纹、桔皮纹。
产品砂面要求无砂眼、凹坑，纹理、疏密度应均匀一致。
产品内外表面棱角分明、工整一致。
产品上的字必须符合图纸所要求的字迹大小和深度,字迹必须清晰、棱角分明、工整一致、凹字底部平整光亮。
面板、面架熔接痕长度要小于5mm，盖板、基座、小件光面的产品（如按纽）不应有熔接痕,内件产品允许有不能避免的模具设计与注塑工艺上的熔接痕。
浇口去除后留下的痕迹不应影响产品的品质。
潜伏浇口处产品不应该有拉伤。
产品通过验收后，要对模具进行验收。
包括模具结构设计、外观、结构件、零件的加工精度、镶拼方式、材料、热处理手段等等.模具外观检查：1观察模板机械加工质量，模板平直,上下端面状况，外形尺寸整齐，周边2×450倒角，外观要给人感觉良好.60万模次以下生产的模具可按龙记模架的标准来自制模架或按龙记模架制作的其他标准模架；60万模次（含60万）以上生产用龙记标准模架。
注意：公司如无另外要求，二板模要用CI型模架,三板模要用DCI型模架，A、B板不能挖通框,B模与动模座板之间加设支承柱。
2模具起吊方向上要装吊环，可一次性将模具平衡吊起。
大中型模具在动定模之间要装有锁紧装置，防止模具起吊时开启.3冷却水的进出口位置应在注塑工操作的另一侧,其次是在注塑生产时在模具的下方。
热流道模具要配有接线板，并固定在模具上，传感器、加热元件电线通过快换插头迅速安装，要尽量简化安装。
电线导出后要用管子套上，防止散乱。
4模具及型腔的编号的要求按《模具编号的说明》及《模具型腔编号的说明》。
5模板的尺寸请按《模具制作的模板要求》。
6动模座板的顶出让位孔开孔直径40～42mm。
结构件状况检查:1导柱、导套应紧固，开合动作应灵活,表面无拉伤痕迹，无单侧受力。
