The production method of processing pl房書astic materials into a large number時高 of uniformly shaped parts is the學多 cornerstone of modern manufacturing.作用 In fact, every market-oriented c腦知ommodity has at least one s家山hape defined by a mold.姐低 However, with the continuous deve務場lopment of the manufacturi議讀ng industry, molds have become more 從很and more complex, and the required 問自firmness has become higher些河 and higher. The tech還一nical difficulty is getting higher雨街 and higher, and the pro說司duct life cycle is getting shorter a民兵nd shorter. Users also put for美討ward more requirements 樂長for mold products, such as: m校樂aintenance-free can run for票務 a long time, low energy consumption, w都我ear resistance, easy t雜還o install Replacement商體 and greater flexibility, 她從etc.
Under the pressure of market輛現 competition and increasing us錯就er requirements, mold manufact科低urers have to choose more 山請practical and effective mold pro件唱cessing methods and adopt more favora暗也ble market strategies. As a resul司刀t, the mold processing industry has我人 shown the following d舞亮evelopment trends.
1. Globalization
The globalization of the mold mar笑習ket and development is one 道業of the most important characte務家ristics of today's mold indus國吃try. Buyers of molds are all ove在們r the world, and mold manufacturers a家農re equally ubiquitous厭嗎. The global development o學就f the mold industry has caused m市間old processing companies w分森ith simple production processes a站風nd low precision to migrate to相一 developing countries w知黑ith relatively backward techno器看logy and low productivity.能答 The mold manufacturers tha聽會t still remain in the United State輛朋s, Europe and Japan are positioned 能林to produce high-level molds. Th生子is is not only a technical requ購慢irement, but also a result of相請 competition. Mold manufa愛機cturers must face glob用低al market competition, whic計開h is the driving force for mold ma麗花nufacturers to pursue efficient applic吧會ation technology.
2. Shorten the productio站報n cycle
As we all know, under the場道 same conditions, users are wil問從ling to choose products with a short用離er delivery time, because小這 users can save more pro笑制duction time, so mold manufac下我turers have to do every房視thing possible to speed up the produc放這tion schedule, and strive to simplify 對匠and abolish unnecessary Pro水弟duction process.
3. High-speed processing
The "high-speed machinin劇行g" developed in recen友遠t years has had an important impact o笑志n the mold manufacturing 友書industry. "High-speed mac民南hining" is achieved by a very場習 small stepping distance and a報但 large feed rate. Gener下少ally, a high spindle s多會peed can enable the tool to 微拍obtain sufficient chip resistance. 話河In rough machining, the use of obl麗來ique tools for small畫時 width cutting tends t師報o have a higher metal removal rate,遠國 and this effect can be achie慢山ved even with small tools.吃器 In many cases, the su師麗rface accuracy of the workpiece數人 after high-speed roughing is very 小土close to the required level你船, so semi-finishing operations 呢如can be omitted.
High-speed machining makes the work唱得piece obtain a smooth surface and 舞東saves machining time. The t可從ypical stepping distance is醫看 only 0.001in, and the sharp poin討討t is only 0.00005in h水子igh. Most of the workpiece surfac樹行e after high-speed proc物些essing is very smooth an民遠d no need for further work by fitt刀知er Processing.
In the finishing process, the in市弟crease of the feed rate can avoid 拍農the extension of the con笑我struction period due to the reduction o廠舊f the step distance, and the abolition 土行or reduction of the subsequent北員 polishing or grinding proc來理ess is beneficial to the protection長器 of the processed surface.
Under normal circumstances, the ma黃呢chining tool should reach at least購就 1200 surface feet per minute, and低新 the spindle speed should not 微個be lower than 8000r/min. The sp動可indle of the old machi房票ne tool can reach this lev現媽el after trimming, but it錯這s stability is limited. At present, mac用近hining tool manufacturers are 朋看keen to produce machining centers sp跳器ecially designed for h和國igh-speed machining. In the United年能 States, the use of high-sp舞國eed processing technology to reduce海大 or eliminate fitter procedures is 去舞a measure of considerable benefit, 拿喝and this technology is also很下 popular in Europe an器個d Japan.
4. Hard milling
Using fully hardened materials to爸鄉 process mold cavities is an輛畫other important trend in the developmen視去t of mold processing i懂事ndustry. This is especially筆筆 valuable for forging dies, because for工拿ging dies often require要相 higher hardness than other dies.如湖 Roughing and finishing are performed 低年continuously on a machine tool.現章 In the roughing process, 北睡the light cutting with high spind費什le speed and small t樹現ool radius forms suf吃人ficient torque, whic議船h can be used to machi少少ne hardness up to 64RC Metal materi舞聽als; in the finishing process, the sma開土ller stepping distance ensures 兵樂that the workpiece can obtain呢技 an excellent surface fi人一nish.
Because the material itself has a ce的鐘rtain degree of hardness, electri煙老cal discharge machining (EDM) can be r朋聽educed or eliminated a線哥ltogether. Because the material i外歌s already hard enough, no heat treat那雜ment is required. Not only that, but北個 also the tempering after h視知eat treatment and the 都歌grinding process to offset the東慢 geometric deformation caused by the妹土 heat treatment. This technology 司知is very popular in Jap花習an, and now it has also體短 received widespread attention in明照 the United States and is being spr土司ead to Europe.
The high-speed machining of harde些雪ned materials puts forward highe雪麗r requirements for processin美白g tools. Therefore, many machi算分ne tool manufacturers have s了好pecially designed and deve計們loped special grinde草和rs for this kind of processing. I工懂n the case of high spindle speed家車 and high feed rate, the tool need讀吧s to perform light cutting,裡內 but thermal stability and high mech些是anical hardness are also very ne從用cessary. In this type弟門 of machining, high-pr新錯essure coolant is another n到文ecessary condition, but there are also笑身 some tool manufacturers 務市that use dry cutting to prevent thermal北人 shock to the tool. At the草南 same time, dry cutting can also黑機 reduce environmental pollution. Most o行和f these machines are suita亮山ble for processing forging d家國ies and small and medium-siz廠月ed dies.
The forging die used to manufac藍城ture the operating rods p工機roduced by Japan Asda is made of har金快dened materials throug樹影h typical high-speed processing. The 線城size of the workpiece is 1兵開64mm×106mm×32mm, and the mate一對rial hardness is 60RC.作信 Using cemented carb樹東ide milling cutter and oil mis秒科t coolant, it takes 109 minutes to mi聽外ll the mold cavity. Although hard 人費milling technology is inclu間話ded, the price of this type of machine船制 tool is relatively high, b長如ut only one such machine技新 tool can complete the entire視高 process of rough machining, finish南唱ing and electrical discharg器樂e machining, which is undoubtedly q微朋uite comparable to developed countri體醫es like Japan Attractive. It is worth n文著oting that the machining direction o醫風f such machine tools i廠跳s gradually becoming horizontal rather慢鄉 than vertical, which is also a new和車 feature.
5. CAD/CAM tends to be fast and inte姐家lligent
CAD/CAM has three obvio房章us development trends, namely: hybr水時id model, design and manufacturing syst習空em database, and workshop si為又te 3D programming.
The demand for hybrid models by indust如費rial companies has been pa生綠rticularly significant in r術森ecent years. The use of solid 店廠model is of great benefit. It enab樂會les material entities with compl爸女ex structures to be easily expresse煙文d and adjusted in the form of an indepe雪謝ndent entity, and it allo秒購ws addition and subtraction between 但書entities to generate new solid models匠錢. For mechanical engineers, the道術 main advantage of the請頻 solid model is that i討話t enables engineers to design produ睡鄉cts composed of relatively standardi老購zed physical elements, su離看ch as standard holes, bosses, sleeves, 你唱flanges, etc.
The solid model is also of great use t舞劇o the tool designer. 懂購In some cases, the inserted 3D頻著 product model can be simply sub相妹tracted from the mold c會事avity in a single operation. H亮子ybrid models allow users to build懂路 solids, surfaces, and o讀北ther graphical elements in a從愛 single geometric model. With s睡紅ome CAM systems, users can freely deco笑南mpose these solid model草雨s, or combine all the solids t術冷ogether and process them a海玩s a complete solid.
Many American manufacturers have b坐司ecome accustomed to dealing 在從with physical models 照城provided by users, while Europe and遠兒 Japan are still relatively backwa山姐rd in this regard. However, rapid吃購 product updates require the United Sta用數tes, Europe, and Japan to jointly作志 support the development of physical mo河文del technology.
6. Database system
For many tool manufacturers,是有 the automated CAD/CAM th木一at can ultimately bring them practical 有男benefits is more important. In terms o劇微f mold design, some CAD/CAM syste暗日m vendors such as American 生舞Cimatron Technology Company, Briti動間sh Vero International Company an亮還d American Bentley Syst身子em Company have added corresponding mod外能ules to the system to impl件紙ement conventional CAD/CAM systems T木器he automation function.
At any time during the machini現為ng process, because the solid mod亮票el always exists, the CAM system can師動 compare the workpiece with the s機來olid model at any time. Using th樂拿e database system, the CAM syst雪綠em can identify where the step dist個視ance is too wide in th音影e area between the two tool paths. Thes對子e areas with too wide stepping 不現distance should be reprocessed in th那北e direction perpendicular to兒子 the original processing axi學用s to ensure the best sur花上face quality. Moreover, th化數e continuous existence of t劇地he entity database is extremely impo友地rtant for high-speed mach化金ining, and for semi-finishing ma去員chining, the existence化很 of a permanent entity datab微如ase is the most ideal thing.
The database system is a highly auto校劇mated expert system, it 光內contains nearly 10 yea愛錢rs of CAM expert experience, it章不 is completed by senior developers, 熱個machining tool manufacturers an相一d a large number of user feedback.懂數 As a system based on rich exp工睡erience, the library also provides 日船users with flexible stora女上ge functions so that users can add 拍白their own manufacturing technolog弟醫y.
7. Workshop on-site program銀師ming
In recent years, the CAM system is gr東議adually becoming easier to use,間藍 because the CAM system is return市醫ing to the workshop site from 鐵們the CAM design room. Automated 她算tool manufacturers in Detroi他農t and Ontario in North Amer綠飛ica have shown the most obviou紙風s advantages in this regard.
In the past 20 years, many manufacturer厭綠s initially tried to transfer pr飛費ogramming to the CAD身懂/CAM design room where the p間姐rogramming is easier to control. H有費owever, with the increasi城睡ng complexity of cutting tools, NC pr男船ogramming has become a bottl師亮eneck restricting industrial devel農吃opment. After the programming was r放謝e-transferred to the works飛睡hop site, this development barrier was 火票quickly removed, so th畫司at combined with practice, program外業ming tools became very easy to us東舊e.
In the Detroit area, this new t事媽ype of on-site programmin低現g has led to rapid deve司機lopment of workshop programmin個吧g. Appropriate use of programming tool事低s cuts down a lot of NC 輛間programming time, bec懂數ause most tool paths are created sy人生nchronously with the m西坐achining process. It sa現歌ves the repeated correction proces民從s between CAD and CAM, enables the prod到冷uction part to obtain an妹他 effective NC program,舊作 and can give full play t要匠o the role of workers 工不and equipment on the production line子冷. More importantly, 光個now the person who creates t工車he tool path is the per行近son who performs the pro子雨cessing. This also gave the machinist分外s the opportunity to 筆年implement their machining資中 methods, which made them v不現ery satisfied. This helps 秒為them make better on-site decisions報朋, choose the most op水校timized processing metho花喝d, and modify the proc美影essing method in time.
8. Automation
Another important developme件窗nt trend of mold processing is a錯生utomation, which sounds we商雜ird, because most molds are produced拿嗎 in a single piece, it seems that it sh路匠ould require a flexible processing s麗友ystem instead of an autom技你ated processing system.校訊 But in fact, mold processing has但火 shown the characteri美窗stics of small batch product是街ion in many aspects.
Recently, many manufacturers have黃制 shown a keen interest in an au日業tomation system. This kind of automati說到on equipment can continuously an路歌d automatically execute街這 operation steps during the manufactur裡去ing process without human interventi草樂on. The robot automatio你光n system is used to load and unload wo自技rkpieces and Cutting tool東厭s are the next goal of many厭地 mold manufacturers&弟草#39; automation development.
Nick, President of 3R Systems in New Je黃音rsey, USA, said: “Many companies ar也討e looking for ways to improve p可大roduction efficiency and output wi中中thout increasing fixed costs. D事子ue to the tight labor market 黃少and the lack of skilled operat物外ors, the fixed production costs o山年f companies are high. In order to農和 improve, automation can 山大increase output through個雨 inherent production pr來湖ocesses instead of using operators笑票."
9. Electrical discharge machining (EDM厭子)
Electrical discharge machining i現外s known for its excellent ability to是街 handle mold cavities. 近事Wired electrical discharge machini拿體ng is also widely used in 匠雨mold production, as long as the m輛跳old manufacturer almost 愛嗎has at least one electri城熱cal discharge processing equipment.她購 In the past few years, electr城街ical discharge machining t影金echnology has develop放拍ed rapidly, which makes車村 the role and position of electric紅門al discharge machining techn生家ology in the mold processi人長ng industry more prom還她inent.
Compared with previous years, whether 子購it is stamping electrical d土東ischarge machining o紙得r wired electrical discharge mach話會ining, the development and 身金changes are quite rapid,短近 and their "burning"可什 time has been reduced a lot.土自 In order to achieve unattended cont理和inuous operation, the electr道畫ical discharge machining sys謝視tem must provide automatic workpie謝劇ce transposition and elect請行rode transformation functi到弟ons. This is the main purpose of the 紙放mold processing plant to install a筆體n automated robot operating syste笑習m on the electrical discharge問機 processing unit.
The robot automation system u喝還sed in the fast combustion elec畫影trical discharge machining unit 煙新consumes electrodes very 門書quickly, so the demand for electr校子odes is greatly increased, resulting i熱內n a lack of electrodes.湖木 In the United States, the high-物校speed processing tech藍票nology of graphite electrodes is in會腦creasingly popular. The reduction and a吃件bolition of fitter and polish黑地ing techniques have made electr動你ode machining valuable t跳花ime. More importantly, the abolit工體ion of manual work means th鐵又at the geometric model defined b體分y the machining and CAD will never be l在兵ost, and high-speed machining allo房秒ws manufacturers to follow the 那友user’s requirements. The actual d飛年esign requires the production of 他樂electrodes. If more than one elec鄉你trode is to be produce術麗d, the same product 兵錢can be "replicated" by th不拍e processing system. With sufficient 機他electrodes, EDM can show i要如ts skills in mold processing, whi白懂ch is an important advancement in河大 multi-cavity mold processi做事ng.
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