手機(jī)上蓋注塑模具設(shè)計與仿真加工
手機(jī)上蓋注塑模具設(shè)計與仿真加工,手機(jī),注塑,模具設(shè)計,仿真,加工
畢業(yè)設(shè)計（論文）開題報告
題目 手機(jī)上蓋注塑模具設(shè)計與仿真加工
1、 選題的依據(jù)及意義：
隨著科學(xué)的發(fā)展，各種產(chǎn)品的更新?lián)Q代速度越來越快，而產(chǎn)品的更新是以新產(chǎn)品的造型設(shè)計和模具的設(shè)計、制造與更新為前提的。模具的設(shè)計是模具更新的基礎(chǔ)，模具設(shè)計工作與產(chǎn)品的更新信息相關(guān)。傳統(tǒng)的手工設(shè)計模式已經(jīng)不能很好地適應(yīng)時代的需要，計算機(jī)輔助設(shè)計與制造已成為許多大型CAD/CAM/CAE軟件追求的目標(biāo)。而在眾多輔助設(shè)計制造軟件中，Unigraphics 軟件是當(dāng)今世界較先進(jìn)、面向制造業(yè)的綜合軟件。
該軟件的功能覆蓋了整個產(chǎn)品的開發(fā)過程，即覆蓋了從概念設(shè)計、功能工程、工程分析、加工制造到產(chǎn)品發(fā)布的全過程，在模具、航空、汽車、機(jī)械、電器電子等各工業(yè)領(lǐng)域的應(yīng)用非常廣泛。UG軟件在產(chǎn)品造型、注塑模設(shè)計和沖壓級進(jìn)模設(shè)計中的應(yīng)用，將體現(xiàn)該軟件在產(chǎn)品造型和模具設(shè)計中的強(qiáng)大功能，展現(xiàn)它的靈活性和工程設(shè)計嚴(yán)謹(jǐn)性的特點(diǎn)和優(yōu)點(diǎn)。
二、國內(nèi)外研究概況及發(fā)展趨勢：
模具是現(xiàn)代工業(yè)生產(chǎn)中的重要工藝裝備之一，模具工業(yè)是國民經(jīng)濟(jì)中重要的基礎(chǔ)工業(yè)，模具設(shè)計與制造水平的高低是衡量一個國家綜合制造能力的重要標(biāo)志。工業(yè)發(fā)達(dá)國家對模具工業(yè)都極為重視，早在 50年代開始就己使模具擺脫了產(chǎn)品更新?lián)Q代的重要工藝裝備，模具對工業(yè)的發(fā)展具有重要意義。從工業(yè)產(chǎn)值對比來看，經(jīng)濟(jì)發(fā)達(dá)國家的模具總產(chǎn)值早己超過了機(jī)床的總產(chǎn)值。如日本，1987年模具總產(chǎn)值為124億美元，而其機(jī)床總產(chǎn)值為102億美元;1991年前者為131億美元，后者為120億美元151。在各種模具產(chǎn)品中，塑料模和沖壓模是用量最大涉及領(lǐng)域最廣的兩種。據(jù)統(tǒng)計，日本一萬多家模具企業(yè)中，生產(chǎn)塑料模和沖壓模的各占40%左右;韓國模具專業(yè)廠中生產(chǎn)塑料模的占43.9%，生產(chǎn)沖壓模的占44.8%。在塑料模具中，由于注塑模具能夠一次成型形狀復(fù)雜、尺寸精確的制品，適用于高效率、大批量的自動化生產(chǎn)方式，使其在塑料模中的占用量超過了5%。
我國塑料模工業(yè)從起步到現(xiàn)在，歷經(jīng)半個多世紀(jì)，有了很大發(fā)展，模具水平有了較大提高。在大型模具方面已能生產(chǎn)48英寸大屏幕彩電塑殼注射模具、6.5kg大容量洗衣機(jī)全套塑料模具以及汽車保險杠和整體儀表板等塑料模具；精密塑料模具方面，已能生產(chǎn)照相機(jī)塑料件模具、多型腔小模數(shù)齒輪模具及塑封模具。注塑模型腔制造精度可達(dá)0.02～0.05mm，表面粗糙度Ra0.2μm，模具質(zhì)量、壽命明顯提高了，非淬火鋼模壽命可達(dá)10～30萬次，淬火鋼模達(dá)50～1000萬次，交貨期較以前縮短，但和國外相比仍有較大差距。
成型工藝方面，多材質(zhì)塑料成型模、高效多色注射模、鑲件互換結(jié)構(gòu)和抽芯脫模機(jī)構(gòu)的創(chuàng)新設(shè)計方面也取得較大進(jìn)展。氣體輔助注射成型技術(shù)的使用更趨成熟。熱流道模具開始推廣，有的廠采用率達(dá)20%以上，一般采用內(nèi)熱式或外熱式熱流道裝置，少數(shù)單位采用具有世界先進(jìn)水平的高難度針閥式熱流道裝置，少數(shù)單位采用具有世界先進(jìn)水平的高難度針閥式熱流道模具。但總體上熱流道的采用率達(dá)不到10%，與國外的50～80%相比，差距較大。
在制造技術(shù)方面，CAD/CAM/CAE技術(shù)的應(yīng)用水平上了一個新臺階，以生產(chǎn)家用電器的企業(yè)為代表，陸續(xù)引進(jìn)了相當(dāng)數(shù)量的CAD/CAM系統(tǒng)，如美國EDS的UGⅡ、美國Parametric Technology公司的Pro/Engineer、美國CV公司的CADS5、英國Deltacam公司的DOCT5、日本HZS公司的CRADE、以色列公司的Cimatron、美國AC-Tech公司的C-Mold及澳大利亞Moldflow公司的MPA塑模分析軟件等等。這些系統(tǒng)和軟件的引進(jìn)，雖花費(fèi)了大量資金，但在我國模具行業(yè)中，實(shí)現(xiàn)了CAD/CAM的集成，并能支持CAE技術(shù)對成型過程，如充模和冷卻等進(jìn)行計算機(jī)模擬，取得了一定的技術(shù)經(jīng)濟(jì)效益，促進(jìn)和推動了我國模具CAD/CAM技術(shù)的發(fā)展。近年來，我國自主開發(fā)的塑料模CAD/CAM系統(tǒng)有了很大發(fā)展，主要有北航華正軟件工程研究所開發(fā)的CAXA系統(tǒng)、華中理工大學(xué)開發(fā)的注塑模HSC5.0系統(tǒng)及CAE軟件等，這些軟件具有適應(yīng)國內(nèi)模具的具體情況、能在微機(jī)上應(yīng)用且價格較低等特點(diǎn)，為進(jìn)一步普及模具CAD/CAM技術(shù)創(chuàng)造了良好條件。?
據(jù)有關(guān)方面預(yù)測，模具市場的總體趨熱是平穩(wěn)向上的，在未來的模具市場中，塑料模具的發(fā)展速度將高于其它模具，在模具行業(yè)中的比例將逐步提高。隨著塑料工業(yè)的不斷發(fā)展，對塑料模具提出越來越高的要求是正常的，因此，精密、大型、復(fù)雜、長壽命塑料模具的發(fā)展將高于總量發(fā)展速度。同時，由于近年來進(jìn)口模具中，精密、大型、復(fù)雜、長壽命模具占多數(shù)，所以，從減少進(jìn)口、提高國產(chǎn)化率角度出發(fā)，這類高檔模具在市場上的份額也將逐步增大。建筑業(yè)的快速發(fā)展，使各種異型材擠出模具、PVC塑料管材管接頭模具成為模具市場新的經(jīng)濟(jì)增長點(diǎn)，高速公路的迅速發(fā)展，對汽車輪胎也提出了更高要求，因此子午線橡膠輪胎模具，特別是活絡(luò)模的發(fā)展速度也將高于總平均水平；以塑代木，以塑代金屬使塑料模具在汽車、摩托車工業(yè)中的需求量巨大；家用電器行業(yè)在“十一五”期間將有較大、空調(diào)器和微波爐發(fā)展，特別是電冰箱等的零配件的塑料模需求很大；而電子及通訊產(chǎn)品方面，除了彩電等音像產(chǎn)品外，筆記本電腦和網(wǎng)機(jī)頂盒將有較大發(fā)展，這些都是塑料模具市場的增長點(diǎn)。
3、 研究內(nèi)容及實(shí)驗(yàn)方案：
3.1 畢業(yè)設(shè)計的研究內(nèi)容：
（1）使用的原始資料可以是實(shí)物或自行設(shè)計。
（2）根據(jù)零件實(shí)物或模型在CAD/CAM/UG軟件中進(jìn)行數(shù)字化三維設(shè)計，完成鼠標(biāo)上蓋的建模。
（3） 進(jìn)行手機(jī)上蓋凸凹模型面設(shè)計，并且設(shè)計模架、定位環(huán)、推桿、澆注系統(tǒng)、冷卻系統(tǒng)等，完成模具的設(shè)計。
（4）生成手機(jī)上蓋零件的NC加工程序，進(jìn)行仿真加工。
（5）繪制手機(jī)上蓋的注塑模具凸凹模的工程圖和模具總裝配圖；
（6）繪制圖紙，撰寫畢業(yè)論文。
3.2 畢業(yè)設(shè)計的實(shí)驗(yàn)方案:
手機(jī)上蓋及其模具設(shè)計的步驟：
（1）參照手機(jī)的實(shí)物，以人機(jī)工程學(xué)、注塑模具的制造和工藝性為原則，自行設(shè)計出一款手機(jī)上蓋。
（2）手機(jī)產(chǎn)品開發(fā)過程中要全面貫徹數(shù)字化設(shè)計和制造的理論，進(jìn)行無紙化設(shè)計制造：
A、CAD建模過程中運(yùn)用UG NX 5.0軟件為基礎(chǔ)進(jìn)行數(shù)字化三維設(shè)計，完成手機(jī)的建模；
B、模型設(shè)計完成后利用UG NX 5.0的Mold?Wizard模塊進(jìn)行手機(jī)上蓋模具的凸凹模型面設(shè)計，選擇材料和注塑機(jī)，進(jìn)行模架、定位環(huán)、推桿等模具標(biāo)準(zhǔn)件的加載和澆注系統(tǒng)、冷卻系統(tǒng)的設(shè)計。
C、手機(jī)上蓋的模具設(shè)計完成后利用Solid Edge軟件進(jìn)行數(shù)字預(yù)裝配。
D、利用UG NX 5.0軟件進(jìn)行手機(jī)上蓋上下模型芯和型腔的CAM編程，生成NC加工程序，并在計算機(jī)中模擬加工過程。如果可能，在數(shù)控機(jī)床上加工出手機(jī)上蓋上下模型芯和型腔的實(shí)物。
（3）利用前面已建立的手機(jī)模型和模具設(shè)計中加載和設(shè)計的數(shù)字模型生成工程圖數(shù)據(jù)，完成模具的總裝配圖，進(jìn)行工程圖的輸出和打印。
（4）設(shè)計完成過程中，進(jìn)行畢業(yè)論文的編寫。
模具設(shè)計實(shí)驗(yàn)所用到的軟件和工具：
UG NX 5.0、Solid Edge、AUTOCAD 2006等軟件和測量工具等。
4、 目標(biāo)、主要特色及工作進(jìn)度
4.1 通過手機(jī)上蓋的模具設(shè)計所要達(dá)到的目標(biāo)：
（1）較深入的了解注塑模具的數(shù)字化設(shè)計和生產(chǎn)工程中的現(xiàn)狀和發(fā)展趨勢；
（2）通過這次設(shè)計，深入學(xué)習(xí)UG NX 5.0（包括建模模塊、CAM模塊、工程圖模塊、Mold?Wizard（模塊）、Solid Edge（包括建模模塊、工程圖模塊）、AUTOCAD 2006等軟件的高級命令；
（3）深入學(xué)習(xí)注塑模具設(shè)計和制造過程中所用的理論知識，掌握模具設(shè)計師應(yīng)該具備的知識。查閱資料，詢問老師，爭取使模具產(chǎn)品最優(yōu)化；
（4）通過這次畢業(yè)設(shè)計，學(xué)會學(xué)習(xí)新知識和網(wǎng)上檢索信息的能力；
（5）通過與老師、同學(xué)的溝通和交流，掌握團(tuán)隊(duì)合作的能力；
4.2 手機(jī)上蓋的模具畢業(yè)設(shè)計的主要特色：
(1)結(jié)合現(xiàn)代制造業(yè)已成為主流的數(shù)字化技術(shù)，在純數(shù)字化技術(shù)支持下自行設(shè)計一款鼠標(biāo)上蓋的注塑模具。設(shè)計過程中，用到UG NX 5.0、Solid Edge、AUTOCAD 2006等國際流行的機(jī)械專業(yè)軟件，進(jìn)行無紙化設(shè)計制造，以縮短研發(fā)周期，降低成本。
(2)在模型設(shè)計過程中利用人機(jī)工程學(xué)理論，如上蓋的曲率偏小，使人對鼠標(biāo)的感覺最好，減輕操作人員長時間工作帶來的疲憊感。
4.3 畢業(yè)設(shè)計(論文)工作內(nèi)容及完成時間：
1．查閱資料，英文資料翻譯，撰寫開題報告。 第1周～第2周
2. 手機(jī)上蓋的三維建模。 第3周～第5周
3. 凸凹模型面設(shè)計。 第6周～第8周
4. 注塑模具設(shè)計，繪制圖紙。 第9周～第11周
5. 生成手機(jī)上蓋零件的數(shù)控加工程序。 第12周～第14周
6. 撰寫畢業(yè)論文。 第15周～第16周
7. 答辯準(zhǔn)備及畢業(yè)答辯 第17周
主要參考文獻(xiàn)
[1].張洪興等.數(shù)控機(jī)床編程、操作、維修，北京：航空工業(yè)出版社，2001.10
[2].曾向陽，謝國明. UG NX基礎(chǔ)及應(yīng)用教程（建模、裝配、制圖）. 北京：電子工業(yè)出版社，2003.
[3].盛曉敏等. 先進(jìn)制造技術(shù)，北京：機(jī)械工業(yè)出版社，2000.9
[4].李鯉，劉善春.基于UG下的數(shù)控加工快速編程，大眾科技，2005.7
[5].F.BACKS. Concurrent manufacturing of parts and tools for the sheet-metal Industry.
Intelligent Manufacturing(1998)9,347-352
[6].C. K. Mok, K. S. Chin and John K. L. Ho. An Interactive Knowledge-Based CAD System For Mould
Design in Injection Moulding Processes. Int J Adv Manuf Technol (2001) 17:27–38
手機(jī)上蓋注塑模具設(shè)計與仿真加工
摘要：注塑模具CAD技術(shù)是指在注塑模具設(shè)計過程中采用CAD系統(tǒng)來輔助設(shè)計人員進(jìn)行模具設(shè)計，以便提高模具設(shè)計的水平和效率。注塑模具CAD系統(tǒng)是在通用CAD系統(tǒng)的基礎(chǔ)上，加載了注塑模具知識和設(shè)計經(jīng)驗(yàn)?zāi)K，支持注塑模具設(shè)計的基本流程。
隨著科學(xué)的發(fā)展，各種產(chǎn)品的更新?lián)Q代速度越來越快，而產(chǎn)品的更新是以新產(chǎn)品的造型設(shè)計和模具的設(shè)計、制造與更新為前提的。模具的設(shè)計是模具更新的基礎(chǔ)，模具設(shè)計工作與產(chǎn)品的更新信息相關(guān)。傳統(tǒng)的手工設(shè)計模式已經(jīng)不能很好地適應(yīng)時代的需要，計算機(jī)輔助設(shè)計與制造已成為許多大型CAD/CAM/CAE軟件追求的目標(biāo)。而在眾多輔助設(shè)計制造軟件中，Unigraphics 軟件是當(dāng)今世界較先進(jìn)、面向制造業(yè)的綜合軟件。
本設(shè)計首先采用UG軟件進(jìn)行注塑件的三維實(shí)體造型,針對手機(jī)上蓋的具體外形尺寸,應(yīng)用基于特征的實(shí)體建模和自由形狀建模等知識,使用體素特征、掃描特征、成形特征、特征操作等具體的操作步驟逐步生成手機(jī)上蓋。其次,利用UG軟件中的Mold wizard工具對手機(jī)上蓋進(jìn)行拆模，并且對手機(jī)上蓋模具的模架、定位環(huán)、推桿、澆口、合模導(dǎo)向機(jī)構(gòu)、抽芯機(jī)構(gòu)、澆注系統(tǒng)、冷卻系統(tǒng)等進(jìn)行了設(shè)計。最后，利用UG軟件中的CAM功能對凸模進(jìn)行仿真加工并生成手機(jī)上蓋凸模的NC加工程序。
關(guān)鍵詞：注塑模具 UG 手機(jī)上蓋 凸模
Injection mold design mobile phone cover and process
Abstract: CAD technology is the injection mold injection mold design process in the CAD system used to assist designers to mold design, mold design in order to improve the level and efficiency. Injection Mold CAD system is based on the general CAD system, load the injection mold design knowledge and experience in modules support the basic process of injection mold design.
With the development of science, the upgrading of various products faster and faster, while the product update is a new product modeling design and mold design, manufacturing and updated as the prerequisite. Mold mold design is the basis for updating, mold design and product-related updates. The traditional manual design model has not well adapted to the needs of the times, computer-aided design and manufacturing has become many large CAD / CAM / CAE software goal. Assisted in the design and manufacturing of many software, Unigraphics software is the world's more advanced and comprehensive software for the manufacturing industry.
The design of the first injection molded parts using UG software three-dimensional solid modeling,mobile shelters for the specific dimensions,application of feature-based modeling and free modeling the shape of knowledge, use of voxel features, scanning features, shape features, feature operation and other concrete steps to gradually build mobile phone cover. Secondly, the use of UG software Mold wizard tools mobile phone cover for form removal, and mold on the mobile phone cover mold, positioning ring, putter,gate, mold-oriented institutions, core pulling mechanism, gating system, cooling system is designed. Finally, UG CAM software features simulation of the punch process and generate the NC cell phone cover punch processing.
Keywords: Injection Mold UG Mobile phone cover Punch
目 錄
1 引言
1.1 課題的依據(jù)和意義………………………………………………………（1）
1.2 注塑模具CAD技術(shù)概述…………………………………………………（1）
1.3 國內(nèi)外塑料工業(yè)的發(fā)展概況……………………………………………（5）
1.4 塑料模國內(nèi)外研究概況及發(fā)展趨勢……………………………………（7）
1.5 模具加工CAM現(xiàn)狀………………………………………………………（9）
1.6 UG軟件在模具制造中的應(yīng)用特點(diǎn)………………………………………（9）
1.7 本設(shè)計任務(wù)………………………………………………………………（10）
2 手機(jī)上蓋的設(shè)計
2.1 建立外形…………………………………………………………………（11）
2.2 建立殼體…………………………………………………………………（16）
2.3 建立缺口特征……………………………………………………………（17）
2.4 建立鑲邊…………………………………………………………………（24）
3 注塑模具設(shè)計
3.1 注射模設(shè)計的基本原則…………………………………………………（26）
3.2 分型面的選擇……………………………………………………………（26）
3.3 確定型腔布置及型芯和型腔的建立……………………………………（30）
3.4 結(jié)構(gòu)零件的設(shè)計…………………………………………………………（31）
3.5 澆注系統(tǒng)的設(shè)計…………………………………………………………（34）
3.6 推出機(jī)構(gòu)的設(shè)計…………………………………………………………（35）
3.7 澆口設(shè)計…………………………………………………………………（36）
3.8 冷卻系統(tǒng)設(shè)計……………………………………………………………（36）
3.9 排氣系統(tǒng)的設(shè)計…………………………………………………………（37）
3.10 模具設(shè)計的有關(guān)計算 …………………………………………………（37）
4 數(shù)控仿真加工工藝
4.1 零件的分析………………………………………………………………（40）
4.2 零件鋼材的選用…………………………………………………………（41）
4.3 加工方案…………………………………………………………………（42）
4.4 手機(jī)凸模的CAM…………………………………………………………（42）
結(jié)論 ……………………………………………………………………………（59）
參考文獻(xiàn)………………………………………………………………………（60）
致 謝………………………………………………………………………（61）
附錄（圖表）…………………………………………………………………（62）
畢業(yè)設(shè)計（論文）任務(wù)書
I、畢業(yè)設(shè)計(論文)題目：
手機(jī)上蓋注塑模具設(shè)計與仿真加工
II、畢 業(yè)設(shè)計(論文)使用的原始資料(數(shù)據(jù))及設(shè)計技術(shù)要求：
1.使用的原始資料可以是實(shí)物或自行設(shè)計。
2.根據(jù)零件實(shí)物或模型在CAD/CAM軟件中進(jìn)行數(shù)字化三維設(shè)計，完成鼠標(biāo)上蓋的建模。
3. 進(jìn)行手機(jī)上蓋凸凹模型面設(shè)計，并且設(shè)計模架、定位環(huán)、推桿、澆注系統(tǒng)、冷卻
系統(tǒng)等，完成模具的設(shè)計。
4.生成手機(jī)上蓋零件的NC加工程序，進(jìn)行仿真加工。
III、畢 業(yè)設(shè)計(論文)工作內(nèi)容及完成時間：
1．查閱資料，英文資料翻譯，撰寫開題報告。 第1周～第2周
2. 手機(jī)上蓋的三維建模。 第3周～第5周
3. 凸凹模型面設(shè)計。 第6周～第8周
4. 注塑模具設(shè)計，繪制圖紙。 第9周～第11周
5. 生成手機(jī)上蓋零件的數(shù)控加工程序。 第12周～第14周
6. 撰寫畢業(yè)論文。 第15周～第16周
7. 答辯準(zhǔn)備及畢業(yè)答辯 第17周
Ⅳ 、主 要參考資料：
[1].張洪興等.數(shù)控機(jī)床編程、操作、維修，北京：航空工業(yè)出版社，2001.10
[2].曾向陽，謝國明. UG NX基礎(chǔ)及應(yīng)用教程（建模、裝配、制圖）. 北京：電子工業(yè)出
版社，2003.
[3].盛曉敏等. 先進(jìn)制造技術(shù)，北京：機(jī)械工業(yè)出版社，2000.9
[4].李鯉，劉善春.基于UG下的數(shù)控加工快速編程，大眾科技，2005.7
[5].F.BACKS. Concurrent manufacturing of parts and tools for the sheet-metal Industry.
Intelligent Manufacturing(1998)9,347-352
[6].C. K. Mok, K. S. Chin and John K. L. Ho. An Interactive Knowledge-Based CAD System For Mould
Design in Injection Moulding Processes. Int J Adv Manuf Technol (2001) 17:27–38
航空與機(jī)械工程系 學(xué)院（系） 機(jī)械設(shè)計制造及其自動化 專業(yè)類 0781053 班
學(xué)生（簽名）：
日期： 自2011年 3月 1日至 2011年 6月 2日
指導(dǎo)教師（簽名）：
助理指導(dǎo)教師(并指出所負(fù)責(zé)的部分)：
航空與機(jī)械工程 系（室）主任（簽名）：
附注:任務(wù)書應(yīng)該附在已完成的畢業(yè)設(shè)計說明書首頁。
The mold designing and manufacturing
The mold is the manufacturing industry important craft foundation, in our country, the mold manufacture belongs to the special purpose equipment manufacturing industry. China although very already starts to make the mold and the use mold, but long-term has not formed the industry. Straight stabs 0 centuries 80's later periods, the Chinese mold industry only then drives into the development speedway. Recent years, not only the state-owned mold enterprise had the very big development, the three investments enterprise, the villages and towns (individual) the mold enterprise's development also rapid quietly.
Although the Chinese mold industrial development rapid, but compares with the demand, obviously falls short of demand, its main gap concentrates precisely to, large-scale, is complex, the long life mold domain. As a result of in aspect and so on mold precision, life, manufacture cycle and productivity, China and the international average horizontal and the developed country still had a bigger disparity, therefore, needed massively to import the mold every year .
The Chinese mold industry must continue to sharpen the productivity, from now on will have emphatically to the profession internal structure adjustment and the state-of-art enhancement. The structure adjustment aspect, mainly is the enterprise structure to the specialized adjustment, the product structure to center the upscale mold development, to the import and export structure improvement, center the upscale automobile cover mold forming analysis and the structure improvement, the multi-purpose compound mold and the compound processing and the laser technology in the mold design manufacture application, the high-speed cutting, the super finishing and polished the technology, the information direction develops .
The recent years, the mold profession structure adjustment and the organizational reform step enlarges, mainly displayed in, large-scale, precise, was complex, the long life, center the upscale mold and the mold standard letter development speed is higher than the common mold product; The plastic mold and the compression casting mold proportion increases; Specialized mold factory quantity and its productivity increase; "The three investments" and the private enterprise develops rapidly; The joint stock system transformation step speeds up and so on. Distributes from the area looked, take Zhejiang Delta and Yangtze River delta as central southeast coastal area development quickly to mid-west area, south development quickly to north. At present develops quickest, the mold produces the most centralized province is Guangdong and Zhejiang, places such as Jiangsu, Shanghai, Anhui and Shandong also has a bigger development in recent years.
Although our country mold total quantity had at present achieved the suitable scale, the mold level also has the very big enhancement, after but design manufacture horizontal overall rise and fall industry developed country and so on Yu De, America, date, France, Italy many. The current existence question and the disparity mainly display in following several aspects:
(1) The total quantity falls short of demand
Domestic mold assembling one rate only, about 70%. Low-grade mold, center upscale mold assembling oneself rate only has 50% about.
(2) the enterprise organizational structure, the product structure, the technical structure and the import and export structure does not gather
in our country mold production factory to be most is from the labor mold workshop which produces assembles oneself (branch factory), from produces assembles oneself the proportion to reach as high as about 60%, but the overseas mold ultra 70% is the commodity mold. The specialized mold factory mostly is "large and complete", "small and entire" organization form, but overseas mostly is "small but", "is specially small and fine". Domestic large-scale, precise, complex, the long life mold accounts for the total quantity proportion to be insufficient 30%, but overseas in 50% above 2004 years, ratio of the mold import and export is 3.7:1, the import and export balances the after net import volume to amount to 1.32 billion US dollars, is world mold net import quantity biggest country .
(3) The mold product level greatly is lower than the international standard
The production cycle actually is higher than the international water broad product level low mainly to display in the mold precision, cavity aspect and so on surface roughness, life and structure.
(4) Develops the ability badly, economic efficiency unsatisfactory our country mold enterprise technical personnel proportion low
The level is lower, also does not take the product development, and is frequent in the passive position in the market. Our country each mold staff average year creation output value approximately, ten thousand US dollars, overseas mold industry developed country mostly 15 to10, 000 US dollars, some reach as high as 25 to10, 000 US dollars, relative is our country quite part of molds enterprises also continues to use the workshop type management with it, truly realizes the enterprise which the modernized enterprise manages few
To create the above disparity the reason to be very many, the mold long-term has not obtained the value besides the history in as the product which should have, as well as the most state-owned enterprises mechanism cannot adapt the market economy, but also has the following several reasons: .
(1) Country to mold industry policy support dynamics also insufficiently
Although the country already was clear about has promulgated the mold profession industrial policy, but necessary policy few, carried out dynamics to be weak. At present enjoyed the mold product increment duty enterprise nation 185; the majority enterprise still the tax burden is only overweight. The mold enterprise carries on the technological transformations introduction equipment to have to pay the considerable amount the tax money, affects the technology advancement, moreover privately operated enterprise loan extremely difficult.
(2) Talented person serious insufficient, the scientific research development and the technical attack investment too urine
mold profession is the technology, the fund, the work crowded industry, along with the time progress and the technical development, grasps the talented person which and skilled utilizes the new technology exceptionally short, the high-quality mold fitter and the enterprise management talent extremely is also anxious. Because the mold enterprise benefit unsatisfactory and takes insufficiently the scientific research development and the technical attack, the scientific research unit and the universities, colleges and institutes eye stares at is creating income, causes the mold profession invests too few in the scientific research development and the technical attack aspect, causes the mold technological development step doe not to be big, progresses does not be quick.
(3) The craft equipment level is low, also is not good, the using factor is low. Recent years ,our country engine bed profession progressed quickly, has been able to provide the quite complete precision work equipment, but compared with the overseas equipment, still had a bigger disparity. Although the domestic many enterprises have introduced many overseas advanced equipment, but the overall equipment level low are very more than the overseas many enterprises. As a result of aspect the and so on system and fund reason, introduces the equipment not necessary, the equipment and the appendix not necessary phenomenon are extremely common, the equipment utilization rate low question cannot obtain the comparatively properly solution for a long time .
(4) Specialization, standardization, commercialized degree low, the cooperation ability
Because receives "large and complete" "small and entire" the influence since long ago, mold specialization level low, the specialized labor division is not careful, the commercialized degree is low. At present domestic every year produces mold, commodity mold minister 40% about, other for from produce uses for oneself. Between the molds enterprise cooperates impeded, completes the comparatively large-scale mold complete task with difficulty. Mold standardization level low, mold standard letter use cave rare is low also to the mold quality, the cost has a more tremendous influence, specially has very tremendous influence.
(5) To the mold manufacture cycle) the mold material and the mold correlation technology fall
The mold material performance, the quality and the variety question often can affect the mold quality, the life and the cost, the domestically produced molding tool steel and overseas imports the steel products to compare has a bigger disparity. Plastic, plate, equipment energy balance, also direct influence mold level enhancement.
At present, our country economy still was at the high speed development phase, on the international economical globalization development tendency is day by day obvious, this has provided the good condition and the opportunity for the our country mold industry high speed development. On the one hand, the domestic mold market will continue high speed to develop, on the other hand, the mold manufacture also gradually will shift as well as the transnational group to our country carries on the mold purchase trend to our country extremely to be also obvious. Therefore, will take a broad view the future, international, the domestic mold market overall development tendency prospect will favor, estimated the Chinese mold will obtain the high speed development under the good market environment, our country not only can become the mold great nation, moreover certainly gradually will make the powerful nation to the mold the ranks to make great strides forward. "15" period, the Chinese mold industry level not only has the very big enhancement in the quantity and the archery target aspect, moreover the profession structure, the product level, the development innovation ability, enterprise's system and the mechanism as well as the technology advancement aspect also can obtain a bigger development .
The mold technology has gathered the machinery, the electron, chemistry, optics, the material, the computer, the precise monitor and the information network and so on many disciplines, is a comprehensive nature multi-disciplinary systems engineering. The mold technology development tendency mainly is the mold product to larger-scale, precise, more complex and a more economical direction develops, the mold product technical content unceasingly enhances, the mold manufacture cycle unceasingly reduces, the mold production faces the information, is not having the chart, is fine, the automated direction develops, the mold enterprise to the technical integration, the equipment excellent, is producing approves the brand, the management information, the management internationalization direction develops.
Mold profession in "十15" period needs to solve the key essential technology should be the mold information, the digitized technology and precise, ultra fine, high speed, the highly effective manufacture technology aspect breakthrough
Along with the national economy total quantity and the industry product technology unceasing development, all the various trades and occupations to the mold demand quantity more and more big, the specification more and more is also high.
Although mold type many, but its development should be with emphasis both can meet the massive needs, and has the comparatively high-tech content, specially at present domestic still could not be self-sufficient, needs the massive imports the mold and can represent the development direction large-scale, precise, is complex, the long life mold. Standard letter type, quantity, level and the production of the mold have significant influence to the entire mold profession development. Therefore, some important mold standard letters also must prioritize, moreover its development speed should quickly to the mold development speed, like this be able unceasingly to raise our country mold standardization level, thus improves the mold quality, reduces the mold production cycle, reduces the cost. Because our country mold product holds the bigger price superiority in the international market, therefore regarding the exportation prospect good mold product also should take key develops. According to the above required quantity big, the technical content is high, represents the development direction, the export prospect good principle choice prioritize product, moreover chooses the product to have at present to have the certain technology base, belongs has the condition, has the product which the possibility develops .
Die trend
1. Mold CAD / CAE / CAM being integrated, three-dimensional, intelligent and network direction
(1) Mold software features integrated
Die software features of integrated software modules required relatively complete, while the function module using the same data model, in order to achieve Syndicated news management and sharing of information to support the mold design, manufacture, assembly, inspection, testing and production management of the entire process to achieve optimal benefits. Series such as the UK Delcam's software will include a surface / solid geometric modeling, engineering drawing complex geometry, advanced rendering industrial design, plastic mold design expert system, complex physical CAM, artistic design and sculpture automatic programming system, reverse engineering and complex systems physical line measurement systems. A higher degree of integration of the software includes: Pro / ENGINEER, UG and CATIA, etc.. Shanghai Jiao tong University, China with finite element analysis of metal plastic forming systems and Die CAD / CAM systems; Beijing Beihang Haier Software Ltd. CAXA Series software; Jilin Gold Grid Engineering Research Center of the stamping die mold CAD / CAE / CAM systems .
(2) Mold design, analysis and manufacture of three-dimensional
Two-dimensional mold of traditional structural design can no longer meet modern technical requirements of production and integration. Mold design, analysis, manufacturing three-dimensional technology, paperless software required to mold a new generation of three-dimensional, intuitive sense to design the mold, using three-dimensional digital model can be easily used in the product structure of CAE analysis, tooling manufacturability evaluation and CNC machining, forming process simulation and information management and sharing. Such as Pro / ENGINEER, UG and CATIA software such as with parametric, feature-based, all relevant characteristics, so that mold concurrent engineering possible. In addition, Cimatran company Mold expert, Delcam's Ps-mold and Hitachi Shipbuilding of Space-E/mold are professional injection mold 3D design software, interactive 3D cavity, core design, mold base design configuration and typical structure . Australian company Moldflow realistic three-dimensional flow simulation software MoldflowAdvisers been widely praised by users and applications. China Huazhong University of Science have developed similar software HSC3D4.5F and Zhengzhou University, Z-mold software. For manufacturing, knowledge-based intelligent software function is a measure of die important sign of advanced and practical one. Such as injection molding experts Cimatron's software can automatically generate parting direction based parting line and parting surface, generate products corresponding to the core and cavity, implementation of all relevant parts mold, and for automatically generated BOM Form NC drilling process, and can intelligently process parameter setting, calibration and other processing results.
(3) Mold software applications, networking trend
With the mold in the enterprise competition, cooperation, production and management, globalization, internationalization, and the rapid development of computer hardware and software technology, the Internet has made in the mold industry, virtual design, agile manufacturing technology both necessary and possible. The United States in its "21st Century Manufacturing Enterprise Strategy" that the auto industry by 2006 to achieve agile manufacturing / virtual engineering solutions to automotive development cycle shortened from 40 months to 4 months.
2. mold testing, processing equipment to the precise, efficient, and multi-direction
(1) mold testing equipment more sophisticated, efficient
Sophisticated, complex, large-scale mold development, testing equipment have become increasingly demanding. Precision Mould precision now reached 2 ~ 3μm, more domestic manufacturers have to use Italy, the United States, Japan and other countries in the high-precision coordinate measuring machine, and with digital scanning. Such as Dongfeng Motor Mould Factory not only has the capacity 3250mm × 3250mm Italian coordinate measuring machine, also has a digital photography optical scanner, the first in the domestic use of digital photography, optical scanning as a means of spatial three-dimensional access to information, enabling the establishment from the measurement of physical → model output of engineering drawings → → the whole process of mold making, reverse engineering a successful technology development and applications. This equipment include: second-generation British Renishaw high-speed scanners (CYCLON SERIES2) can be realized and contact laser probe complementary probe, laser scanner accuracy of 0.05mm, scanning probe contact accuracy of 0.02 mm. Another German company GOM ATOS portable scanners, Japan Roland's PIX-30, PIX-4 desktop scanner and the United Kingdom Taylor Hopson's TALYSCAN150 multi-sensor, respectively Three-dimensional scanner with high speed, low-cost and functional composite and so on.
(2) CNC EDM
Japan Sodick linear motor servo drive using the company's AQ325L, AQ550LLS-WEDM have driven fast response, transmission and high positioning accuracy, the advantages of small thermal deformation. Switzerland Chanmier company NCEDM with P-E3 adaptive control, PCE energy control and automatic programming expert systems. Others also used the powder mixed EDM machining technology, micro-finishing pulse power and fuzzy control (FC) technologies.
(3) high-speed milling machine (HSM)
Milling is an important means of cavity mold. The low-temperature high-speed milling with the workpiece, cutting force is small, smooth processing, processing quality, processing efficiency (for the general milling process 5 to 10 times) and can process hard materials (<60HRC) and many other advantages. Thus in the mold processing more and more attention. Ruishikelang company UCP710-type five-axis machining center, machine tool positioning accuracy up to 8μm, home-made closed-loop vector control spindle with a maximum speed 42000r/min. Italy RAMBAUDI's high-speed milling, the processing range of up to 2500mm × 5000mm × 1800mm, speed up 20500r/min, cutting feed speed of 20m/min. HSM generally used large, medium-sized mold, such as motor cover mold, die casting mold, large plastic surface machining, the surface precision up to 0.01mm.
模具設(shè)計與制造
模具是制造業(yè)的重要工藝基礎(chǔ)，在我國模具制造屬于專用設(shè)備制造業(yè)。中國雖然很早就開始制造模具和使用模具，但長期未形成產(chǎn)業(yè)。直到20世紀(jì)80年代后期，中國模具工業(yè)才駛?cè)氚l(fā)展的快車道。近年，不僅國有模具企業(yè)有了很大發(fā)展，三資企業(yè)、鄉(xiāng)鎮(zhèn)（個體）模具企業(yè)的發(fā)展也相當(dāng)迅速。
雖然中國模具工業(yè)發(fā)展迅速，但與需求相比，顯然供不應(yīng)求，其主要缺口集中于精密、大型、復(fù)雜、長壽命模具領(lǐng)域。由于在模具精度、壽命、制造周期及生產(chǎn)能力等方面，中國與國際平均水平和發(fā)達(dá)國家仍有較大差距，因此，每年需要大量進(jìn)口模具。
中國模具產(chǎn)業(yè)除了要繼續(xù)提高生產(chǎn)能力，今后更要著重于行業(yè)內(nèi)部結(jié)構(gòu)的調(diào)整和技術(shù)發(fā)展水平的提高。結(jié)構(gòu)調(diào)整方面，主要是企業(yè)結(jié)構(gòu)向?qū)I(yè)化調(diào)整，產(chǎn)品結(jié)構(gòu)向著中高檔模具發(fā)展，向進(jìn)出口結(jié)構(gòu)的改進(jìn)，中高檔汽車覆蓋件模具成形分析及結(jié)構(gòu)改進(jìn)、多功能復(fù)合模具和復(fù)合加工及激光技術(shù)在模具設(shè)計制造上的應(yīng)用、高速切削、超精加工及拋光技術(shù)、信息化方向發(fā)展。
近年，模具行業(yè)結(jié)構(gòu)調(diào)整和體制改革步伐加大，主要表現(xiàn)在，大型、精密、復(fù)雜、長壽命、中高檔模具及模具標(biāo)準(zhǔn)件發(fā)展速度高于一般模具產(chǎn)品；塑料模和壓鑄模比例增大；專業(yè)模具廠數(shù)量及其生產(chǎn)能力增加；“三資”及私營企業(yè)發(fā)展迅速；股份制改造步伐加快等。從地區(qū)分布來看，以珠江三角洲和長江三角洲為中心的東南沿海地區(qū)發(fā)展快于中西部地區(qū)，南方的發(fā)展快于
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