外文翻译(现代模具制造技术工艺和发展前沿).doc

英文资料Modern Mold Manufacture And Development Of Cutting-edge TechnologyMaterials based on the role of mold in different ways, can be summed up modern processing methods for mold removal method, molding method and the cumulative three types of law. Removal Act - mold material was removed and the necessary forms; forming method - the same total amount of material through the flow of materials and get the body; cumulative law - by the material continue to increase, the accumulated the necessary physical . 1.1 Removal of Mold Processing This is the largest mold maker for a class of methods, including machining, EDM (EDM, wire cutting, electrolytic, etc.), chemical processing, such as corrosion. Characterized by the shape-size components is removed from the blank material to be redundant. 1.1.1 Machining About 90% of the mold by milling, turning, grinding and other machining methods. They are mainly used to mold parts of the final processing aids, as well as working parts of the pre-mold processing and final processing. (1) high-speed machining and milling technology Because the mold cavity often with a large number of free-form surfaces, the traditional hand-made has been unable to meet the needs of the linkage of the three-axis or multi-axis CNC milling machine can solve the maximum extent of the problem in this regard. Therefore, CNC milling and programming tool also naturally become the focus of advanced manufacturing technology. (2) die cutting and multi-axis joint coordinate processing mode Forming the work surface grinding is a traditional method of finishing with a high-precision, high-performance advantages of degrees. In the mold manufacture, die cut shape is mainly used Ruled Surface finishing punch, die pieces and EDM electrodes and other components used. (3) The mold and polishing After surface machining, surface roughness, regardless of their size must be polished again. Mold Polishing Mold current research is still mainly manually or with electric or pneumatic equipment, manually polished, low efficiency, labor intensity, and the quality of instability. China has imported three-dimensional surface can be automatic die polishing of the NC Institute mold. Developed humanoid intelligent automatic polishing technology has also been made, but fewer applications. Mold the future research will be towards the special mode, the composite, automation, intelligent direction. Extrusion die, such as research, study mode and laser polishing, EDM polishing, electrochemical polishing, as well as ultrasonic polishing compound polishing equipment and technology. 1.1.2 EDMMold processing technology of electricity mainly refers to wire cutting, EDM, piercing and electrolysis processing. (1) WEDM Cutting EDM spark discharge using metal melting or vaporization, and melting or vaporization of the metal to get rid of in order to achieve a variety of shapes metal parts processing. Wire-cutting for processing small precision, complex shapes, materials, special die parts, the more complex shapes, small precision dies, carbide dies in particular, its economic effects has become more significant. Micro-EDM and Wire Cutting walking is the main development of hot spots in recent years. (2) Cavity EDM EDM cavity forming a replication process, it is the use of spark discharge method to copy the shape of tool electrode in the blank mold cavity formed. EDM cavity mold in today's manufacturing industry has been to occupy the position can not be ignored, it can be sintered metal blocks and steel in the conventional methods of processing can not be processed or the shape of difficult processing complex, the size of the fine work, the right choice and the use of electrodes enables the cost of mold manufacturing method than conventional low-40%. Japan invented a new EDM method, that is, in the process of adding the right amount of liquid micro-silica powder, or aluminum powder, graphite powder may be, can make many times more than the surface of precision can be improved, the current processing methods corresponding EDM has also been commercialized. EDM technology can not be separated from the next three trends, namely, high-speed and high precision and high automation. (3) Electrochemical Machining ECM is based on the principle of electrolysis (the electrochemical anodic dissolution) will be the shape of the cathode tool for copying onto blank in the mold cavity of mold processing. As soon as the anode and cathode parts of the forming tool insert electrolyte, the effect of current, between the anode and cathode exchange of charge and materials, the result of dissolution of workpiece. In this way, can also be part of the surface area covered by the protection layer, only to other parts of the place of the oxide part of the material. 1.1.3 Die CAD / CAE / CAM (1) mold software integration, intelligent Mold software integrated software modules require relatively complete, while the function module using the same data model, in order to achieve comprehensive management and information sharing, to support the mold design, manufacturing, assembly, inspection, testing and production management of the entire process to achieve optimal benefits. Such as the United Kingdom's Deleam series software includes surface / solid geometry modeling, complex physical engineering graphics, industrial design of high-level rendering, plastic mold design expert system, the complexity of physical CAM, modeling and carving art automatic programming system, reverse engineering system and Online measurement of complex physical systems. (2) mold design, analysis and manufacture of three-dimensional Mold design, analysis, manufacturing three-dimensional and require a new generation of paperless software to three-dimensional mold, intuitive feel to the design of mold, using three-dimensional digital model can be easily used in the product structure of the CAE analysis, tooling manufacturing evaluation and CNC machining, forming process simulation and the management and sharing of information. Cimatron company, such as injection mold expert software can automatically generate parting direction in accordance with sub-type line and sub-surface, generated with the products corresponding to the core and cavity, the realization of the whole mold-related parts, and BOM is automatically generated for NC drilling process of the form, and capable of intelligent processing parameters, such as processing the results of calibration. (4) mold software applications networking trend With the mold in the enterprise competition, cooperation, production and management of globalization, internationalization, and computer hardware and software technology, the rapid development of network industries in the mold allows the virtual design, agile manufacturing technology both necessary and possible. The United States in its «21 Century Manufacturing Enterprise Strategy" that by 2006 the automotive industry to achieve agile manufacturing / virtual engineering solutions to automotive development cycle shortened from 40 months to four months. 1.1.4 chemical etching process Chemical etching process is based on the principle of metal in acid, alkali, soluble in salt solution, that is, the material of metallic materials because of their micro-region of the energy difference between the material and corrosion or the energy difference between the solvent and dissolution occurred. Metal atoms after the release of e-ion in the form of escape from the metal lattice, free ions and the existence of corrosion solution combined with anionic and cationic disappear. Removal of metal ions and anions combine to become insoluble salts, insoluble metal salts that must be the way to filter or centrifuge the solution from a corrosion separated. For example, etching.1.2 Of the forming mold processing In many cases, the need for the application of special steel, non-ferrous metal alloy or non-metallic materials, by forming various shapes to create the mold cavity. Forming method, including casting, plastic forming and so on, their common characteristic is the shape of parts from billet size of the transfer of material obtained during processing, the amount of the material will remain basically unchanged. 1.2.1 Die Casting Process Die casting process commonly used can be divided into three types, namely, sand casting, ceramics and foundry of EPC. Specific use depends on what kind of mold the size of type, precision, and a copy of the required to achieve the surface quality. Die casting manufacturers with the greatest advantage of almost immediately after casting the use of very small amount of follow-up processing. 1.2.2 the legal system of plastic extrusion die (1) Hot stamping method Hot stamping module is heated to forging temperature, the use of pre-prepared core module and the extrusion pressure of people out of the way to groove. Core parts can be used by itself or pre-processing core expertise. (2) cold extrusion method Extrusion die with the external parts to shape forming, after hardening, polishing, and then increase in a row under pressure, 0.1 10mm/min speed forced to squeeze into the soft annealed steel block, this block in the steel to form the first copy of the extrusion die concave model. This process limited to the most die under pressure and by about 3000MPa annealed steel yield strength limit. (3) Superplastic Extrusion Superplastic extrusion method is the use of materials in the superplastic state to the cavity forming punch extrusion method. At a high state of material plastic extrusion cavity, smooth surface, size precision; material deformation resistance low, compared with the cold extrusion can reduce the extrusion pressure of about one-tenth of a few; In addition, from design to machining molds have been simplified, material consumption reduction cost reduction die; die life high.1.3 cumulative mold processing method Law of cumulative mold parts processing refers to the shape is continuously added by a certain instruction materials, have been accumulated, including spraying, electroforming, laser processing, such as rapid prototyping and manufacturing processes. 1.3.1 Metal Spraying At high temperature and low temperature metal spraying, can be used for small-scale experimental mold. High-temperature coating (to be added to the oxygen-curable metal - acetylene flame in the melt), low temperature spray (low melting point alloy to spray release, in the electric components under the melting and spraying the surface of the model), the thickness of metal coating for the 1 - 3mm. When the coating after cooling down, the "mother mold" is removed from the model (model of at least 2 ° of angle) to the mold frame mosaic of the cushioning material, the liner can be a low melting point alloy, and can also be aluminum powder mixed with epoxy resin, structural foam mold, and sometimes also used as a cushioning material of cement. 1.3.2 Electroforming method Electroforming method, also known as electrolytic deposition, namely the use of electrochemical deposition of the principle of the cathode, in the model of the cathode electrolytic deposition of metal on the way to get the required cavity. When the model removed from the deposition layer, the sediment layer itself formed a shell; will add a layer of shell enhanced bush, you can Add a template, that is, forming an effective component. The advantages of electroforming method is that it can accurately reproduce the surface (even the deep narrow cavity can also be completed copy) and its dimensional accuracy, and a model can be used to create a number of the same cavity. Its shortcomings are more time-consuming, high cost. 1.3.3 Rapid prototyping and rapid tooling (RP / RT) Technology Rapid prototyping method is based on the principle of dispersion and accumulation of manufacturing technology. CAD model of parts of it by way of a certain discrete and become discrete machinable surface, discrete lines and discrete points, then the use of physical or chemical means, the face of these discrete, and the point segments formed by the accumulation of the overall shape of parts, the specific The method is: based on three-dimensional CAD model of parts, after the format conversion of its layered slices, the cross-section outline of the shape of each floor, and then use a laser beam selectively curing a layer of liquid photosensitive resin, or cutting a layer of layer of paper or metal foil, or layers of sintered powder materials, as well as the source of the selective use of jet injection layers of the Mongolian hot-melt binding agents or materials, forming the outline of the shape of the cross-section, and then gradually into a three-dimensional stacking three-dimensional parts. 1.4 Die Surface Treatment Technology The main trends are: the infiltration of a single element to the multi-element co-diffusion, complex permeability (such as the TD method) development; by the general spread of the CVD, PVD, PCVD, ion infiltration, such as the direction of the development of ion implantation; the coating may have TiC, TiN, TiCN, TiAlN, CrN, etc. At the same time, the atmosphere of heat treatment by means of heat treatment to the development of vacuum heat treatment. In addition, the current of the laser enhanced glow plasma nitriding technology and electroplating (plating) and other anti-corrosion technology to strengthen more and more attention. 1.5 Mold detection equipment and reverse engineering With the sophisticated, complex, large-scale mold the development of testing equipment have become increasingly demanding. The accuracy of precision molds now has up to 2 3m, the use of more domestic manufacturers are Italy, the United States, Japan and other countries of the high-precision coordinate measuring machine, with digital scanning. Such as Dongfeng Motor Die factory in Italy has a 3250mm × 3250mm coordinate measuring machine and digital photography optical scanners, the first in the domestic use of digital photography, the space of three-dimensional optical scanning as a means of information access, from the measurement of the physical realization of the establishment of mathematical model, the output engineering drawings to the whole process of mold manufacturing, the successful implementation of the reverse engineering technology development and applications.1.6 Modern Mold Industry trends (1) Die CAD/CAE/CAM are integrated, three-dimensional, intelligence and network direction. Die CAD/CAE/CAM technology is the mold design, manufacturing technology development direction of the detection of mold and the workpiece digitalization and integration of software functions mold, mold design, analysis and manufacture of three-dimensional, and die industry, as well as reverse engineering tool for software applications network is the main trend.