In the modern mold form manufacturing, as shaped die face design increasingly complex, increasing the proportion of free surface, therefore, mold processing technology and a higher requirement, not only to ensure the manufacture of high precision and surface quality, to pursue processing of surface appearance, but also requires high stability and long mold life. Traditional modeling process hindered the development of molds to the precise direction. With the continuous processing technology for high-depth, especially in the CAE, CAD, CAM, CAPP software and related technology continues to develop, driven by more and more efficient processing technology has been used in mold manufacturing and processing, has changed the traditional mold processing using the "annealing heat treatment → → → milling EDM grinding → polishing →" and other complex and lengthy process, compression of the mold manufacturing cycle.



Efficient processing of high-speed cutting technology as an important means, the technology-intensive, involving a wide range of content, including fast and efficient NC programming, spatial multi-axis free-form surface machining, hard machining materials, cutting, NC process Standardization of programming in terms of reducing the past, EDM and manual repair mode of the workload, but also to ensure a high degree of consistency in mold manufacturing, to ensure that mold precision mold to reduce the number of test and shorten the manufacturing cycle, changing the past " dependent fitter "amendment assembly mode of thinking, in the" less loaded with only "or" install only unworthy of "the direction, to improve production efficiency, to achieve efficient processing.

Requirements on the tool

Research tool developed countries the average production costs and other expenses and relevant information known, the tool life increased by 50%, 1% can reduce the cost of production; and improve the processing efficiency of 20%, 15% can reduce the cost of production. This fully demonstrates the use of modern cutting technology, select high-speed, efficient tools, give full play to the performance and efficiency of machine tools, high-speed, efficient cutting, is to improve efficiency, reduce production costs of the correct way.

With the machine tool technology, the maximum spindle speed is also increasing significantly, tool rigidity and balance performance and progress to high-speed cutting tools laid a good foundation. To avoid tool unbalance in the centrifugal force generated under high speed cutting process the tool negative impact, resulting in tool life, surface quality and accuracy of drop shape, spindle and tool holder should consider the connection surface, and the longer part of the interfaces Arbor, the swing of particular importance is the radial accuracy, cantilever length. In order to achieve when the cylindrical holder in the radial swing precision finishing requirements, should use hydraulic chuck, chuck and force contraction compression chuck connection, and its radial swing accuracy can be achieved 0.001 ~ 0.003mm.

Use high-speed cutting tools, in addition to have a good general tool should have the hardness and wear resistance, high strength and toughness properties, but also should have higher reliability â‘  ensure cutting stability, consistent quality, fewer tool changes long life. â‘¡ higher accuracy and repeatability of positioning accuracy of installation, good interchangeability and quick-change resistance. â‘¢ serialization, standardization and universal, as far as possible Indexable machine tool and multi-function composite tool. â‘£ good chip breaking, performance on Chip and Chip to ensure the chip is not wrapped in the tool and the workpiece, not undermining the machined surface, without prejudice to the cutting fluid pouring.

Design requirements of the process

Many die enterprise resource management and use of the existence of some deficiencies, mainly in the mold Sheji manufacturing process of information sharing Bu full, numerical control technology and Pu Tong Technology conjugated poor, CAD / CAM software, the application level is not high, CNC 加工 processes and procedures standardized, low degree of standardization, as well as mold design, CNC technology, CNC programming small degree of realization of the parallel mode and so on. For the above shortcomings can be from the following aspects of work.

1. Mold design and process manufacturing technology information resources, information sharing is most important is the construction of the full use of mold design and graphics, and documentation of resources, such as the use of three-dimensional graphics can die Jianshao three-dimensional shape of NC programmers time, spent almost three-dimensional modeling CNC Programming 40% to 50% of the time. Full use of PDM and network resources to build internal process information management system, sharing of manufacturing information using all possible resources, can greatly improve programmer productivity.

2. CNC technology and a reasonable match for the ordinary process of mold design status, volume requirements, the production cycle, production costs, precision, and the different characteristics of different measures should be taken separately.

In the process design process, the response to design requirements, processing methods, fixture design and manufacture, tool selection, the combination of rough finishing methods, processes Jizhong division, corporate status and capacity of equipment such as synthetically to achieve NC perfect combination with traditional processing and matching, to play a variety of equipment, expertise and strengths.

3. Standardization of the preparation process and parameter of the reasonableness of the standardization of the preparation of numerical control technology to some extent, reflects the company's own level of CNC machining technology, standardized to constrain the NC program through diversification, and thus improve the quality of cutting tools, such as indicated positioning in the process baseline, on the knife base, tool parameters, cutting parameters and tool path pattern, will be mature and standardized CNC technology of immobilization, especially in the experience of a typical machining process based on the establishment of standardized processing NC program templates and template, can greatly improve the quality and mold process procedure of processing efficiency.

Also, according to the cut material should be used reasonably and step away from the tool, tool and step distance is too large or too small is not conducive to mold the process efficiency and manufacturing costs. Programming should be combined with materials and allowances for scientific processing of cutting parameters taken into account, the establishment of a variety of different mold materials and process parameters used cutting tool library for reference and use.

The requirements of processing equipment

High-speed machining equipment is of course an essential tool for efficient processing, Yao Zhi Shi does not achieve effective processing purchase Ji Taiwan high-speed processing equipment such 简单, but should Qiyeneibu (Shen Zhi business Waibu) the characteristics of the devices already Jinxing need to add good manufacturing process and capacity match. Similarly, the establishment of processing technology, can not be all eyes focused on high-speed processing equipment, a reasonable matching, full use can tap the potential of efficient processing.

(1) to die for business development and manufacturing process characteristics, functions to avoid redundancy and waste. Complex free surface in general mold, you can use five-axis machining center; for large complex mold free surface, can be used five-axis gantry machining center.

(2) select cost-effective equipment. As in the mold cavity and surface processing, the use of relatively small tool diameter, the requirements of the spindle high speed general to achieve 20000 ~ 40000r/min, or even higher, the feed rate of up to 40 ~ 80m/min; for the first time fixture rough, complete roughing and finishing, spindle power requirement is generally 10 ~ 40kW; as mold material strength and hardness are high, and called axis high precision and rigidity; same time, the machine must also have a high bed dynamic and static stiffness to improve positioning accuracy and vibration capability.

(3) software, also called speed CNC system operation, data processing capability, high control accuracy and response speed; CAM software, full automatic high-speed machining to prevent excessive Juyou cut and tool interference checking capabilities, thereby enhancing the complex surface machining accuracy .

(4) high-speed machining center can be divided to high-speed spindle-based HSM (HighSpeedMachining) high-speed machining center, and with high speed and acceleration-based HVM (HighVelocityMachining) high-speed machining center, you can choose according to need.

The requirements of the fixture

The reason why more and more universal modular fixture mold manufacturer's favor, because it greatly reduces the equipment downtime, can be completed in the shortest time simple assembly operations, also through a variety of positioning options, making fixture to meet mold needs. Meanwhile, the universal modular fixture can meet the bulk characteristics of mold, not only very flexible, but flexible, fast. Main features: portfolio component versatile, high hardness and wear resistance can be used repeatedly; with high dimensional accuracy and geometric precision, but also has a strong interchangeability; can adapt to mold design and manufacturing constantly changing, you can assemble a different station fixture.

Efficient processing is a systematic project to improve the cutting speed is not alone, it involves every aspect of production. Only the tool, is processed materials, cutting parameters and equipment selection and match reasonably, and through continuous exploration and summary, will be the best combination of various conditions in order to maximize their combined strengths to achieve the purpose of material removal efficiency. In addition, the use of information technology tools, optimization of process routes, reasonable choice fixture, between the secondary compression process time, speed up the mold making beats, in order to achieve efficient processing.