新技術促進模具制造業發展
1. 高速切削機床(chuang)的應用
高(gao)(gao)(gao)(gao)速(su)(su)(su)切(qie)削(xue)機(ji)床(chuang)具有(you)高(gao)(gao)(gao)(gao)速(su)(su)(su)化(hua)、智能化(hua)和精密(mi)化(hua)的(de)(de)優點:機(ji)床(chuang)主(zhu)(zhu)(zhu)軸(zhou)(zhou)(zhou)轉(zhuan)速(su)(su)(su)高(gao)(gao)(gao)(gao)，工(gong)作臺移(yi)動(dong)(dong)速(su)(su)(su)度(du)快。主(zhu)(zhu)(zhu)要采(cai)用(yong)電(dian)主(zhu)(zhu)(zhu)軸(zhou)(zhou)(zhou)結(jie)構，主(zhu)(zhu)(zhu)軸(zhou)(zhou)(zhou)的(de)(de)最高(gao)(gao)(gao)(gao)轉(zhuan)速(su)(su)(su)較機(ji)械結(jie)構顯著提高(gao)(gao)(gao)(gao)。如某型號跨軌式(shi)高(gao)(gao)(gao)(gao)速(su)(su)(su)五軸(zhou)(zhou)(zhou)龍門加(jia)(jia)工(gong)中(zhong)心(xin)， 其主(zhu)(zhu)(zhu)軸(zhou)(zhou)(zhou)最高(gao)(gao)(gao)(gao)轉(zhuan)速(su)(su)(su)可(ke)達42 000r/min，工(gong)作臺的(de)(de)快速(su)(su)(su)移(yi)動(dong)(dong)速(su)(su)(su)度(du)為42m/min。X/Y軸(zhou)(zhou)(zhou)采(cai)用(yong)直線電(dian)動(dong)(dong)機(ji)驅動(dong)(dong)，與(yu)傳(chuan)統(tong)滾珠絲杠傳(chuan)動(dong)(dong)相比的(de)(de)優點是(shi):直接(jie)傳(chuan)動(dong)(dong)、路(lu)徑精度(du)較高(gao)(gao)(gao)(gao)，無背隙。床(chuang)身采(cai)用(yong)天車式(shi)結(jie)構，所有(you)軸(zhou)(zhou)(zhou)向(xiang)動(dong)(dong)件(jian)皆于立(li)柱(zhu)上(shang)方移(yi)動(dong)(dong)，工(gong)件(jian)固(gu)定于工(gong)作臺上(shang)，使工(gong)件(jian)質量不影響機(ji)械的(de)(de)加(jia)(jia)工(gong)表現；智能熱(re)補(bu)(bu)償系統(tong)可(ke)進行實時動(dong)(dong)態補(bu)(bu)償，操(cao)作人員不必等很長時間(jian)或待機(ji)床(chuang)達到熱(re)穩(wen)定狀態才開(kai)始(shi)加(jia)(jia)工(gong)，而是(shi)一開(kai)機(ji)就可(ke)直接(jie)開(kai)始(shi)精密(mi)銑削(xue)加(jia)(jia)工(gong)，機(ji)床(chuang)自動(dong)(dong)對(dui)刀具中(zhong)心(xin)點熱(re)位移(yi)進行補(bu)(bu)償，提高(gao)(gao)(gao)(gao)了(le)加(jia)(jia)工(gong)工(gong)件(jian)的(de)(de)精度(du)，增強了(le)加(jia)(jia)工(gong)過(guo)程中(zhong)的(de)(de)穩(wen)定性(xing)(xing)；一體式(shi)床(chuang)身結(jie)構設計，提升了(le)整(zheng)體機(ji)構剛性(xing)(xing)，確保精度(du)及機(ji)械表現的(de)(de)穩(wen)定性(xing)(xing)。
高速(su)機床以及精(jing)密(mi)工(gong)(gong)(gong)(gong)(gong)具系統的(de)應用，使高速(su)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)與普(pu)通(tong)銑削加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)相比具有無可(ke)比擬的(de)優點:既(ji)可(ke)以在粗加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)時(shi)(shi)快速(su)切(qie)除大量(liang)的(de)多(duo)余(yu)材料，又(you)可(ke)以在精(jing)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)時(shi)(shi)達到(dao)很高的(de)表面(mian)質量(liang)，減少了后(hou)續拋(pao)光加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)的(de)時(shi)(shi)間。如(ru)用φ 10mm的(de)球頭銑刀(dao)(dao)(dao)，銑削間距為(wei)0.2mm走刀(dao)(dao)(dao)，工(gong)(gong)(gong)(gong)(gong)件(jian)表面(mian)的(de)理論殘留高度僅為(wei)0.001mm。對于一些(xie)沖壓成形(xing)模具就不(bu)需要(yao)拋(pao)光打(da)磨，可(ke)以直接進行調試。應用高速(su)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)簡(jian)化了加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)序， 節省了部(bu)分費用，而且不(bu)會(hui)出現電加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)所導致的(de)表面(mian)硬化。高速(su)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)采取非(fei)常小(xiao)的(de)進給(gei)速(su)度和切(qie)深，可(ke)獲得高質量(liang)的(de)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)表面(mian)，可(ke)以使用更小(xiao)直徑(jing)刀(dao)(dao)(dao)具對更小(xiao)的(de)圓角(jiao)及模具進行細節加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)，有時(shi)(shi)可(ke)省去(qu)鉗工(gong)(gong)(gong)(gong)(gong)拋(pao)光的(de)工(gong)(gong)(gong)(gong)(gong)序，防止了人(ren)為(wei)因素對模具精(jing)度的(de)破(po)壞。
2. CAD/CAM/CAE技術的應用
CAD/CAM/CAE技術將產品(pin)設(she)(she)計、模(mo)具(ju)(ju)設(she)(she)計、模(mo)具(ju)(ju)制(zhi)造和數據分析(xi)有機(ji)結合, 大(da)大(da)提(ti)(ti)高(gao)了(le)模(mo)具(ju)(ju)產品(pin)的設(she)(she)計質(zhi)量，縮短了(le)模(mo)具(ju)(ju)設(she)(she)計與制(zhi)造周期，降(jiang)低(di)了(le)產品(pin)成本(ben),對于提(ti)(ti)高(gao)模(mo)具(ju)(ju)開發水平和競爭力具(ju)(ju)有重要(yao)意義。
利用Catia V5R20、CimatronE11、UG NX8.0、PowerMill、Moldflow及Nastran等(deng)專(zhuan)業CAD/CAM/CAE工具軟件，使(shi)我公(gong)司具有覆蓋件、保險杠(見圖4)及復(fu)雜功能件等(deng)完善(shan)的(de)設計經(jing)驗和解(jie)決方案。
3. 工藝(yi)數據庫的建立(li)
成(cheng)熟的(de)(de)經驗提煉成(cheng)工藝數據(ju)庫，如成(cheng)形(xing)(xing)(xing)面各(ge)處的(de)(de)不相等(deng)(deng)間隙(xi)、壓(ya)延模(mo)(mo)型(xing)面膨脹處理及壓(ya)力機變形(xing)(xing)(xing)引起的(de)(de)間隙(xi)補(bu)償等(deng)(deng)，這(zhe)些補(bu)償量在數控加工時(shi)提前加工出(chu)來，通過CAE成(cheng)形(xing)(xing)(xing)分析(xi)、試模(mo)(mo)結(jie)果(guo)及各(ge)零件(jian)補(bu)償加工數據(ju)等(deng)(deng)，總結(jie)形(xing)(xing)(xing)成(cheng)成(cheng)形(xing)(xing)(xing)模(mo)(mo)具(ju)(ju)工藝數據(ju)庫，減少(shao)模(mo)(mo)具(ju)(ju)的(de)(de)調試工作量，提升模(mo)(mo)具(ju)(ju)制(zhi)造效率。
4. 注塑模具頂出試(shi)驗機(ji)的(de)應用
注塑模具(ju)(ju)頂出機(ji)構的(de)(de)磨合(he):模具(ju)(ju)頂出試驗機(ji)可完(wan)全模擬模具(ju)(ju)在注塑機(ji)中的(de)(de)運動(dong)過程，動(dong)態、冷研(yan)2 500次以上，使模具(ju)(ju)的(de)(de)頂出和(he)滑(hua)動(dong)平穩(wen)、順(shun)暢，高效提高了模具(ju)(ju)的(de)(de)生產效率(lv)和(he)產品(pin)質量，延長模具(ju)(ju)壽命，減少(shao)模具(ju)(ju)與注塑機(ji)磨合(he)成(cheng)本，縮短模具(ju)(ju)制作周期，使模具(ju)(ju)生產得到更好的(de)(de)安全保(bao)障。
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