Rapid development of mold manufacturing technology has become an important part of modern manufacturing technology. Such as mold CAD/CAM technology, mold laser rapid prototyping technology, mold precision forming technology, mold ultra-precision machining technology, mold design using finite element method, boundary element method for flow, cooling, heat transfer process dynamic simulation technology, mold CIMS technology, The DNM technology and numerical control technology have been developed, covering almost all modern manufacturing technologies. Modern mold manufacturing technology is developing in the direction of accelerating information drive, improving manufacturing flexibility, agile manufacturing, and systematic integration. First, high-speed milling: the third generation of mold making technology High-speed milling not only has high machining speed and surface quality with good machining accuracy, but also has low temperature rise compared to traditional cutting (workpieces only increase by 3°C) and small thermal deformation, so it is suitable for temperature thermal deformation sensitive materials (such as Magnesium alloy, etc.) processing; also due to the small cutting force, can be applied to the processing of thin-walled and rigid parts; reasonable choice of tool cutting amount, can achieve a series of advantages of hard materials (HRC60) processing. Therefore, high-speed milling machining technology is still a hot topic. It has developed toward the direction of higher agility, intelligence, and integration, and it has become the third generation of mold making technology. Second, EDM milling "green" product technology From the point of view of foreign electric machine tools, the performance, process indicators, intelligence, and automation have reached a very high level. At present, new trends in foreign countries are being researched and developed on EDM milling technology (EDM creation technology). An alternative to the traditional new technology for forming cavities with molded electrodes, it uses high-speed rotating simple tubular electrodes for three-dimensional or two-dimensional contouring (like CNC milling), eliminating the need to manufacture complex shaped electrodes, which is clearly in the field of EDM machining. Major developments. Recently, Mitsubishi Corporation of Japan has made new progress in the development of the EDSCAN8E EDM machine tool. This machine can perform automatic compensation of electrode loss. A dedicated CAM system is developed for this machine on Windows 95. It can be linked with general-purpose CAD such as AutoCAD, and can perform line accuracy measurement to ensure high-precision machining. In order to confirm whether the processing shape is abnormal or incomplete, the CAM system can also perform simulation processing. The progress of EDM technology At the same time, EDM protection technology has received more and more attention, and many EDM machines have considered safety protection technology. At present, the European Community has stipulated that no "CE" marking machine tool can not enter the European Community market, and the international market is also paying more and more attention to technical requirements for safety protection. At present, the major problems of EDM machine tools are radiation harassment, because it has a greater impact on safety and environmental protection, and the international market places more and more emphasis on the “green†products. As the leading tool for mold processing, the “green†product technology for EDM machines will The problem must be solved in the future. Third, a new generation of mold CAD/CAM software technology At present, the United Kingdom, the United States, Germany and other countries and China's colleges and universities research institutes to develop mold software, with a new generation of mold CAD / CAM software intelligent, integrated, mold manufacturability evaluation and other characteristics. A new generation of mold software should establish a lot of knowledge from the mold design practice. This knowledge has been systematically and scientifically organized to store the engineering knowledge base in a specific form and can be easily invoked by the mold. Under the support of intelligent software, mold CAD is no longer imitating traditional design and calculation methods. Under the guidance of advanced design theory, experts in this field are fully used to enrich knowledge and successful experience, and their design results must be reasonable and advanced. The new generation of mold software designs the mold structure with three-dimensional thoughts and intuitive sensations. The generated three-dimensional structure information can be conveniently used for the evaluation of the manufacturability of the mold. This requires three-dimensional parametric modeling of the mold software, simulation of the molding process, and numerical control processing. Process simulation and information exchange organization and management have reached a fairly complete level and have a higher level of integration. To measure the degree of software integration, not only depends on whether the functional modules are complete, but also whether these functional modules share the same data model, whether to form a global dynamic database in a unified manner, and achieve integrated management and sharing of information to support the design and manufacture of molds. Assembly, inspection, testing and commissioning of the entire process. Mould manufacturability evaluation function The function of the new generation mold software is very important. It is not only necessary to screen multiple projects, but also to evaluate the rationality and economy of the mold design process, and provide the mold designer with the basis for modification. The new generation of mold software, manufacturability evaluation mainly includes mold design and manufacturing cost estimation, mold assembly evaluation, mold parts manufacturing process evaluation, mold structure and forming performance evaluation. The new generation of software should also have an assembly-oriented function, because the mold function can only be reflected through its assembly structure. After adopting the assembly-oriented design method, the mold assembly is no longer assembled simply by parts. The data structure can not only describe the function of the mold, but also define the relationship between the mold parts and the assembly features, and realize the parts correlation, thus effectively guaranteeing the mold quality. Fourth, advanced rapid mold manufacturing technology 1. Rapid development of laser rapid prototyping (RPM) technology. China has reached the international level and gradually realizes commercialization. The world's most commercially available rapid prototyping processes are SLA (stereolithography), LOM (Layered Fabrication), SLS (Selective Laser Sintering), and 3D-P (Three-Dimensional Printing). Tsinghua University first introduced the 3D company SLA250 (stereolithography or photosensitive resin laser curing) equipment and technology and carried out research and development. After several years of hard work, it has repeatedly improved, perfected and introduced the "M- RPMS-type multifunctional Rapid Prototyping Manufacturing System (has layered solid manufacturing - SSM, melt extrusion molding - MEM), which is the only country in the world with independent intellectual property rights. It has two rapid prototyping process systems (national patents) with a good performance to price ratio. 2. Dieless multi-point forming technology uses advanced adjustable punch groups to replace the traditional die for surface forming of sheet and another advanced manufacturing technology. The dieless multi-point forming system takes CAD/CAM/CAT technology as the main means to quickly and economically realize 3D. The surface is automatically shaped. Jilin University of Technology undertook the state key scientific and technological projects related to moldless molding, and has independently designed and manufactured an internationally leading level of moldless multi-point forming equipment. Compared with the Massachusetts Institute of Technology, the University of Tokyo in Japan, and the Tokyo Institute of Technology in Japan, the technology of our country is in a leading position in the practical application of theoretical research. Currently, it is developing towards application. 3. The successful application of the trial production of the first domestically produced car for resin stamping dies. FAW Mold Manufacturing Co., Ltd. designed and manufactured 12 sets of resin molds for the new small red flag sedan modified prototype. The 12 sets of molds were respectively used for the drawing of large complex inner and outer cover parts such as trunk, engine hood, left, right and left fenders. Features Mold face is based on the CAD/CAM process master model, using Swiss Ciba refined high-strength resin casting molding, convex and concave mold gaps are controlled by imported special wax, precision mold size, manufacturing cycle can be shortened by half To two-thirds, manufacturing costs can save about 10 million yuan (12 sets of mold). It has opened up a new avenue for pilot production of small cars in China, and it is a domestic initiative. Experts of Ciba refinement in Switzerland believe that it can reach the international level in the 1990s. Fifth, on-site mold testing technology The development of precision molds requires more and more measurement. Precision coordinate measuring machines have long been limited by the environment and are rarely used on site. The new generation of three-coordinate measuring machines basically have temperature compensation and use of anti-vibration materials to improve dust-proof measures, improve the reliability of environmental adaptability, make it easy to use in the installation workshop, in order to achieve the characteristics of the measurement site. Six, mirror polishing mold surface engineering technology Mold Polishing Technology Mould surface engineering is an important part of the mold manufacturing process, after processing important processes. At present, the domestic mold polishing to Ra0.05μm polishing equipment, abrasives abrasives and processes, can basically meet the needs, but to throw to Ra0.025μm mirror polishing equipment, grinding abrasives and technology are still at the stage of exploration. With the large-scale application of mirror injection molds, mold polishing technology has become a key issue for mold production. Due to certain problems in domestic polishing process technology and materials, there are still a large number of injection molds, such as point-and-shoot lens injection molds, CD, VCD discs and tools, which are still heavily dependent on imports. It is worth noting that the polishing of the mold surface is not only affected by the polishing equipment process technology, but also affected by the mirror surface of the mold material, which has not attracted enough attention. In other words, the polishing itself is restricted by the mold material. For example, when using 45# carbon steel as an injection mold, when polishing to Ra0.2μm, visible defects are visible to the naked eye. Continuing to throw away can only increase the brightness, and the roughness has no hope of improvement. Therefore, domestic mirror mold production is often imported. Mold materials, such as Sweden Shengbai 136, Japan Datong PD555, etc. can get a satisfactory degree of mirror. The mirror mold material is not only a matter of chemical composition, but also a series of advanced techniques such as vacuum degassing, argon gas protection ingot casting, vertical continuous casting and rolling, and soft forging are required in the smelting process, so that the internal defects of the mirror surface mold steel tool are small and the impurity particles are fine. High degree of dispersion, fine metal grain size, good uniformity and a series of advantages, in order to achieve the polishing to the mirror mold steel requirements.
Aluminum sand casting production technology
process:
The precision of the Aluminum sand casting: ±1mm;
Smoothness of surface of rough part: Ra6.4;
Shrinkage rate of aluminum sand casting products: 2%;
Material wastage rate: 7%;
General aluminum sand casting machining allowance: 2mm~3mm;
Surface preparation methods: Sand blasted, Shot blasting, Powder coating,
Painting, Plating, Electrophoresis, Polishing.
Advantages and disadvantages of aluminum sand casting
part:
Generally use wooden and aluminum mold, far cheaper than metal
mold casting mould. The price advantage is particularly prominent in small
batch and bulk production. But the production efficiency is low; Low dimension
accuracy of castings, the surface is rough.
The production of aluminum sand casting parts
Aluminum Sand Casting Part, Aluminum Foundry Casting Part, A356 Sand Casting Part, ZL101 Sand Casting Product, Aluminum Sand Cast Part, A356 T6 Sand Casting NINGBO BEILUN LEMA MACHINERY TECHNOLOGY CO.,LTD , http://www.china-lema.com
