721 電器旋鈕注射模設(shè)計(jì)【優(yōu)秀含9張CAD圖+PROE模型+文獻(xiàn)翻譯+說(shuō)明書(shū)】
721 電器旋鈕注射模設(shè)計(jì)【優(yōu)秀含9張CAD圖+PROE模型+文獻(xiàn)翻譯+說(shuō)明書(shū)】,優(yōu)秀含9張CAD圖+PROE模型+文獻(xiàn)翻譯+說(shuō)明書(shū),721,電器旋鈕注射模設(shè)計(jì)【優(yōu)秀含9張CAD圖+PROE模型+文獻(xiàn)翻譯+說(shuō)明書(shū)】,電器,旋鈕,注射,設(shè)計(jì),優(yōu)秀,優(yōu)良,cad,proe,模型,文獻(xiàn),翻譯
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題 目
電器旋鈕CAD注射模設(shè)計(jì)
學(xué)生姓名
班級(jí)學(xué)號(hào)
專(zhuān)業(yè)
畢業(yè)設(shè)計(jì)（論文）課題名稱(chēng)：電器旋鈕CAD注射模設(shè)計(jì)
一、選題背景與意義
塑料制品之所以能夠在各行各業(yè)得到大規(guī)模的應(yīng)用,是由于他們本身具有一系列特點(diǎn)。塑料相對(duì)金屬，密度小，但是比強(qiáng)度高，絕緣性能優(yōu)良，具有非常優(yōu)良的抗化學(xué)腐蝕性，在機(jī)械、化工汽車(chē)、航空航天等領(lǐng)域，塑料已經(jīng)大規(guī)模的取代了金屬。目前塑料制件幾乎在工業(yè)、日常生活的各個(gè)領(lǐng)域里無(wú)處不在。塑料作為一種新的工程材料，發(fā)展勢(shì)頭極其迅猛，躋身于金屬、纖維材料和硅酸鹽三大材料之列。其仍在不斷的開(kāi)發(fā)與應(yīng)用，并且隨著成型工藝的不斷成熟與發(fā)展，大大促進(jìn)了塑料成型模具的開(kāi)發(fā)與制造。隨著新產(chǎn)品的不斷開(kāi)發(fā)，產(chǎn)品的更新?lián)Q代不斷加快，這就促進(jìn)CAD/CAM/CAE技術(shù)的在模具行業(yè)中的應(yīng)用。隨著生產(chǎn)技術(shù)水平的提高，電器模具應(yīng)用越來(lái)越普遍，如何開(kāi)發(fā)DVD相關(guān)結(jié)構(gòu)的模具成為相關(guān)企業(yè)面臨的重要問(wèn)題。本課題采用CAD/CAM/CAE技術(shù)完成2132front-P注射模設(shè)計(jì)模具的結(jié)構(gòu)設(shè)計(jì)和模具設(shè)計(jì)，通過(guò)完成此次畢業(yè)設(shè)計(jì)的意義在于將我大學(xué)所學(xué)的知識(shí)進(jìn)行歸納性總結(jié)，提高我的專(zhuān)業(yè)實(shí)踐能力，通過(guò)對(duì)整個(gè)設(shè)計(jì)過(guò)程的實(shí)際操作來(lái)發(fā)現(xiàn)問(wèn)題解決問(wèn)題，從而為將來(lái)在工作崗位工作打下了良好的基礎(chǔ)。
隨著生產(chǎn)技術(shù)水平的提高，電器模具應(yīng)用越來(lái)越普遍，如何開(kāi)發(fā)電器模具成為相關(guān)企業(yè)面臨的重要問(wèn)題。本課題采用CAD/CAM/CAE技術(shù)完成電器旋鈕模具的結(jié)構(gòu)設(shè)計(jì)和模具設(shè)計(jì)，通過(guò)完成此次畢業(yè)設(shè)計(jì)的意義在于將我大學(xué)所學(xué)的知識(shí)進(jìn)行歸納總結(jié)，提高我的專(zhuān)業(yè)實(shí)踐能力，通過(guò)對(duì)整個(gè)設(shè)計(jì)過(guò)程的實(shí)際操作來(lái)發(fā)現(xiàn)解決問(wèn)題，從而為將來(lái)在工作崗位工作打下良好的基礎(chǔ)。
二、課題關(guān)鍵問(wèn)題及難點(diǎn)
該塑料制品選用的是ABS塑料，ABS是丙烯晴、丁二烯和苯乙烯三種單體的三元共聚物，ABS具有較高的強(qiáng)度、硬度、耐熱性及耐化學(xué)腐蝕性；它具有優(yōu)良的介電性能及成型加工性能等綜合的優(yōu)良性能，且價(jià)格便宜，原料易得。ABS在比較寬廣的溫度范圍內(nèi)具有較高的沖擊強(qiáng)度，熱變形溫度比PA、PVC高，尺寸穩(wěn)定性好，收縮率在0.4%~0.8%范圍內(nèi)，若經(jīng)玻纖增強(qiáng)后可以減少到0.2%～0.4%，而且絕少出現(xiàn)塑后收縮。ABS具有良好的成型加工性，制品表面光潔度高，且具有良好的涂裝性和染色性，可電鍍成多種色澤。ABS尚具有良好的配混性，可與多種樹(shù)脂配混成合金(共混物)，如PC/ABS、ABS/PC、ABS/PVC、PA/ABS、PBT/ABS等，使之具有新的性能和新的應(yīng)用領(lǐng)域，ABS若與MMA摻混可制成透明ABS，透光率可達(dá)80%。
ABS是吸水的塑料，于室溫下，24小時(shí)可吸收0.2%~0.35%水分，雖然這種水分不至于對(duì)于機(jī)械性能構(gòu)成重大影響，但注塑時(shí)若濕度超過(guò)0.3%，塑料表面會(huì)受大的影響，所以對(duì)ABS進(jìn)行成型加工時(shí)，一定要事先干燥，而且干燥后的水分含量應(yīng)小于0.3%。
注塑成型時(shí)的主要缺陷為容易產(chǎn)生溢料飛邊、氣泡、熔接痕、燒焦及黑紋、光澤不良；采取相關(guān)的消除措施為增大注射壓力、提高模具溫度、加排氣槽、充分預(yù)干燥。結(jié)構(gòu)上該塑件總體形狀為長(zhǎng)方形，塑件壁厚均勻，邊緣過(guò)度圓滑。尺寸精度無(wú)特殊要求，右上方分布6個(gè)直徑為7mm的通孔，右下方對(duì)稱(chēng)分布有4個(gè)6毫米的孔，同時(shí)還有幾處下沉的階梯結(jié)構(gòu)，所以應(yīng)設(shè)計(jì)抽芯機(jī)構(gòu)。該塑件要求表面光澤，無(wú)飛邊、毛刺、縮孔、留痕。所以在成型時(shí)要注意控制成型溫度，澆注系統(tǒng)應(yīng)緩慢散熱，冷卻速度不宜過(guò)快。
三、文獻(xiàn)綜述
近年來(lái)，由于我國(guó)國(guó)民經(jīng)濟(jì)的高速、穩(wěn)定的增長(zhǎng)，促進(jìn)了我國(guó)模具工業(yè)的迅速發(fā)展壯大，因此，模具設(shè)計(jì)與制造專(zhuān)業(yè)或者相關(guān)的材料成型與控制專(zhuān)業(yè)已經(jīng)成為我國(guó)國(guó)內(nèi)具有優(yōu)勢(shì)的熱門(mén)專(zhuān)業(yè)之一。進(jìn)入新世紀(jì)以來(lái)，我國(guó)模具銷(xiāo)售額以年平均20%左右的速度增長(zhǎng)，2006年模具銷(xiāo)售額達(dá)到720億元人民幣，居日本、美國(guó)之后第三位；模具出口突破了10億美元。我國(guó)模具生產(chǎn)廠(chǎng)、點(diǎn)達(dá)到了約3萬(wàn)家，從業(yè)人員近100萬(wàn)人。這些都說(shuō)明我國(guó)模具工業(yè)有了相當(dāng)?shù)囊?guī)模。期中，塑料模具在整個(gè)模具行業(yè)中約占30%左右。國(guó)內(nèi)塑料模具市場(chǎng)對(duì)注塑模具需求量日益增長(zhǎng)。專(zhuān)家普遍預(yù)測(cè)，在未來(lái)的模具市場(chǎng)中，塑料模具在模具總量中的比例將逐步提高，且發(fā)展速度將高于其他模具。所以，越來(lái)越多的人開(kāi)始從事塑料模具行業(yè)的設(shè)計(jì)。大大的促進(jìn)了我國(guó)注塑模具技術(shù)的發(fā)展。但是我國(guó)目前和發(fā)達(dá)國(guó)家相比仍有較大差距，主要表現(xiàn)在模具加工的制造精度和表面粗糙度，加工模具的復(fù)雜程度、 模具的使用壽命和制造周期等。所以，我們?nèi)孕璨粩嗟呐^斗，用我們國(guó)家人民的聰明才智去開(kāi)發(fā)模具行業(yè)，使我國(guó)的模具設(shè)計(jì)得到進(jìn)一步的發(fā)展，逐漸縮短與發(fā)達(dá)國(guó)家的差距。
目前塑料模具主要分為種類(lèi)很多，一般按照制品的成型材料性質(zhì)可分為熱固性塑料膜和熱塑性塑料膜；按照產(chǎn)品的成型工藝劃分又可分為壓縮模、壓注模和注射模，其中注射模在塑料模具應(yīng)用面中較為廣泛；還有按照模具裝卸方式分類(lèi)、按照模具行腔數(shù)目分類(lèi)、按照分型面特征分類(lèi)等多種分類(lèi)方式。
塑料產(chǎn)品成型材料有很多種，目前世界投入生產(chǎn)的大約有300多種，其中常用的有40余種。名稱(chēng)多以其所有合成樹(shù)脂作為名稱(chēng)來(lái)稱(chēng)呼：聚乙烯、聚丙烯、聚氯乙烯。酚醛樹(shù)脂、氧樹(shù)脂,俗稱(chēng)：電木（酚醛樹(shù)脂）,有機(jī)玻璃（聚甲基丙烯酸甲脂）,玻璃鋼（熱固性樹(shù)脂用玻璃纖維增強(qiáng)）;英文名稱(chēng)：尼龍（聚酰胺）PA 聚乙烯 PE 等。一般根據(jù)受熱后其性質(zhì)不同可分為熱塑性塑料和熱固性塑料。
模具生產(chǎn)的過(guò)程一般包括：接受任務(wù)書(shū)（通常模具設(shè)計(jì)任務(wù)書(shū)由塑料制件工藝員根據(jù)成型塑料制件的任務(wù)書(shū)提出，模具設(shè)計(jì)人員以成型塑料制件任務(wù)書(shū)、模具設(shè)計(jì)任務(wù)書(shū)為依據(jù)來(lái)設(shè)計(jì)模具）；收集整理有關(guān)制件設(shè)計(jì)、成型工藝、成型設(shè)備、機(jī)械加工及特殊加工數(shù)據(jù)，例如塑料制件在外表形狀、顏色透明度、使用性能方面的要求是什么，塑件的幾何結(jié)構(gòu)是否合理等；消化工藝數(shù)據(jù)，分析工藝任務(wù)書(shū)所提出的成型方法、設(shè)備型號(hào)、材料規(guī)格、模具結(jié)構(gòu)類(lèi)型等要求是否恰當(dāng)；確定成型方式，采用直壓法、鑄壓法還是注射法；選擇成型設(shè)備，初步估計(jì)模具外形尺寸，判斷模具能否在所選的注射機(jī)上安裝和使用；確定模具類(lèi)型，選擇理想的模具結(jié)構(gòu)在于確定必需的成型設(shè)備，理想的型腔數(shù)。其中有型腔的布置、分型面的確定、選擇頂出方式、確定澆注系統(tǒng)脫模方式、主要成型零部件計(jì)算等；繪制模具結(jié)構(gòu)草圖為正式繪圖做準(zhǔn)備；最后模具的校核，包括基本結(jié)構(gòu)方面和設(shè)計(jì)圖紙方面[6]。
現(xiàn)代經(jīng)濟(jì)的飛速發(fā)展,推動(dòng)了我國(guó)模具工業(yè)的前進(jìn)。CAD/CAM/CAE技術(shù)的日臻完善和在模具制造上的應(yīng)用,使其在現(xiàn)代模具的制造中發(fā)揮越來(lái)越重要的作用, CAD/CAM/CAE技術(shù)已成為現(xiàn)代模具的制造的必然趨勢(shì)[7]。CAD/CAM/CAE計(jì)算機(jī)輔助設(shè)計(jì)、模擬與制造一體化, CAD/CAM/CAE一體化集成技術(shù)是現(xiàn)代模具制造中最先進(jìn)、最合理的生產(chǎn)方式。使用計(jì)算機(jī)輔助設(shè)計(jì)、輔助工程與制造系統(tǒng),按設(shè)計(jì)好的模具零件分別編制該零件的數(shù)控加工程序是從設(shè)計(jì)到制造的一個(gè)必然過(guò)程。總之,CAD/CAM/CAE集成技術(shù)就是在這種情況下應(yīng)運(yùn)而生的,它已成為現(xiàn)代模具制造技術(shù)發(fā)展的必然趨勢(shì),并以科學(xué)合理的方法給模具制造者提供了一種行之有效的輔助工具。這技術(shù)的應(yīng)用大大減少了設(shè)計(jì)師的工作量,節(jié)約了工作時(shí)間,提高了工作效率,使設(shè)計(jì)師把更多的精力用在新產(chǎn)品的開(kāi)發(fā)及創(chuàng)新上。
參考文獻(xiàn)
[1] 高軍，李熹平，高玉田，褚興榮. 注塑成型工藝分析及模具設(shè)計(jì)[M]. 北京：化學(xué)工業(yè)出版社. 2009.
[2] 葉久新，王群. 塑料成型工藝及模具設(shè)計(jì)[M]. 北京：機(jī)械工業(yè)出版社. 2007.
[3] 伍先明，張蓉. 塑料模具設(shè)計(jì)指導(dǎo)[M]. 北京：國(guó)防工業(yè)出版社. 2006.
[4] 石富安，龔云表. 工程塑料手冊(cè)[M]. 上海：上?？茖W(xué)技術(shù)出版社. 2003.
[5] 《塑料模具設(shè)計(jì)手冊(cè)》編寫(xiě)組. 塑料模設(shè)計(jì)手冊(cè)[M]. 第二版. 北京：機(jī)械工業(yè)出版社. 1999.
[6] 唐志玉，李德群，徐佩弦. 塑料模具設(shè)計(jì)師指南[M]. 北京：國(guó)防工業(yè)出版社.1999.
[7] 陳錫棟，周小玉. 實(shí)用模具技術(shù)手冊(cè)[M]. 北京：機(jī)械工業(yè)出版社. 2003.
[8] 詹友剛. ProE/ENGINEER 中文野火版5.0模具設(shè)計(jì)教程[M]. 第二版. 北京：機(jī)械工業(yè)出版社. 2010.
[9] 馮炳虎，韓泰榮，殷振海，蔣文森.模具設(shè)計(jì)與制造簡(jiǎn)明手冊(cè)[M]. 上海：上?？茖W(xué)技術(shù)出版社.1991.
[10] 王衛(wèi)衛(wèi). 材料成型設(shè)備[M]. 北京：機(jī)械工業(yè)出版社. 2010.
四、方案擬定及進(jìn)度安排
一、產(chǎn)品基本要求分析
二、根據(jù)CAD二維圖紙對(duì)設(shè)計(jì)模型進(jìn)行Pro/E三維造型
三、塑件材料選擇
四、成型方法及其工藝的選擇
五、注射機(jī)的選擇
六、模具相關(guān)結(jié)構(gòu)的設(shè)計(jì)
七、成型零件的制造工藝分析設(shè)計(jì)
八、模具材料的選擇
九、模具工作過(guò)程分析
十、繪制相關(guān)圖紙
十一、編寫(xiě)設(shè)計(jì)說(shuō)明書(shū)
十二、自選一個(gè)重要模具零件編制加工工藝路線(xiàn)，進(jìn)行相關(guān)的計(jì)算，并編制加工工藝卡和工序卡。
進(jìn)度安排：
1、3月1日 選取課題及編寫(xiě)開(kāi)題報(bào)告；
2、3月2日 ～ 4月1日 英文論文翻譯；
3、4月2日 ～ 5月4日 查詢(xún)相關(guān)資料，產(chǎn)品基本要求分析。
根據(jù)CAD二維圖紙對(duì)設(shè)計(jì)模型進(jìn)行Pro/E三維造型；
4、5月5日 ～ 5月7日 塑件材料選擇、注射機(jī)的選擇、成型方法及其工藝的選擇；
5、5月7日 ～ 5月20日 模具相關(guān)結(jié)構(gòu)的設(shè)計(jì)；
6、5月21日 ～ 5月23日 成型零件的制造工藝分析設(shè)計(jì)；
7、5月24日 ～ 5月25日 整理設(shè)計(jì)說(shuō)明書(shū)，按照學(xué)院得規(guī)范要求排版打印設(shè)計(jì)說(shuō)明書(shū)；
7、5月26日 ～ 5月29日 準(zhǔn)備答辯；
8、6月1日 ～ 6月10日 上交畢業(yè)設(shè)計(jì)資料，評(píng)閱。
指導(dǎo)教師批閱意見(jiàn)
指導(dǎo)教師(簽名)： 年 月 日
注：可另附A4紙
Die history
1 Die position in industrial production
Mold is a high-volume products with the shape tool, is the main process of industrial production equipment.
采用模具生產(chǎn)零部件，具有生產(chǎn)效率高、質(zhì)量好、成本低、節(jié)約能源和原材料等一系列優(yōu)點(diǎn)，用模具生產(chǎn)制件所具備的高精度、高復(fù)雜程度、高一致性、高生產(chǎn)率和低消耗，是其他加工制造方法所不能比 With mold components, with high efficiency, good quality, low cost, saving energy and raw materials and a series of advantages, with the mold workpieces possess high accuracy, high complexity, high consistency, high productivity and low consumption , other manufacturing methods can not match. 已成為當(dāng)代工業(yè)生產(chǎn)的重要手段和工藝發(fā)展方向。 Have already become an important means of industrial production and technological development. 現(xiàn)代經(jīng)濟(jì)的基礎(chǔ)工The basis of the modern industrial economy. 現(xiàn)代工業(yè)品的發(fā)展和技術(shù)水平的提高，很大程度上取決于模具工業(yè)的發(fā)展水平，因此模具工業(yè)對(duì)國(guó)民經(jīng)濟(jì)和社會(huì)發(fā)展將起越來(lái)越大的作用。
The development of modern industrial and technological level depends largely on the level of industrial development die, so die industry to national economic and social development will play an increasing role. 1989 年 3 月國(guó)務(wù)院頒布的《關(guān)于當(dāng)前產(chǎn)業(yè)政策要點(diǎn)的決定》中，把模具列為機(jī)械工業(yè)技術(shù)改造序列的第一位、生產(chǎn)和基本建設(shè)序列的第二位 ( 僅次于大型發(fā)電設(shè)備及相應(yīng)的輸變電設(shè)備 ) ，確立模具工業(yè)在國(guó)民經(jīng)濟(jì)中的重要地位。 March 1989 the State Council promulgated "on the current industrial policy decision points" in the mold as the machinery industry transformation sequence of the first, production and capital construction of the second sequence (after the large-scale power generation equipment and the corresponding power transmission equipment), establish tooling industry in an important position in the national economy. 1997 年以來(lái)，又相繼把模具及其加工技術(shù)和設(shè)備列入了《當(dāng)前國(guó)家重點(diǎn)鼓勵(lì)發(fā)展的產(chǎn)業(yè)、產(chǎn)品和技術(shù)目錄》和《鼓勵(lì)外商投資產(chǎn)業(yè)目錄》。 Since 1997, they have to mold and its processing technology and equipment included in the "current national focus on encouraging the development of industries, products and technologies catalog" and "to encourage foreign investment industry directory." 經(jīng)國(guó)務(wù)院批準(zhǔn)，從 1997 年到 2000 年，對(duì) 80 多家國(guó)有專(zhuān)業(yè)模具廠(chǎng)實(shí)行增值稅返還 70% 的優(yōu)惠政策，以扶植模具工業(yè)的發(fā)展。 Approved by the State Council, from 1997 to 2000, more than 80 professional mold factory owned 70% VAT refund of preferential policies to support mold industry. 所有這些，都充分體現(xiàn)了國(guó)務(wù)院和國(guó)家有關(guān)部門(mén)對(duì)發(fā)展模具工業(yè)的重視和支持。 All these have fully demonstrated the development of the State Council and state departments tooling industry attention and support. 目前全世界模具年產(chǎn)值約為 600 億美元，日、美等工業(yè)發(fā)達(dá)國(guó)家的模具工業(yè)產(chǎn)值已超過(guò)機(jī)床工業(yè)，從 1997 年開(kāi)始，我國(guó)模具工業(yè)產(chǎn)值也超過(guò)了機(jī)床工業(yè)產(chǎn)值。 Mold around the world about the current annual output of 60 billion U.S. dollars, Japan, the United States and other industrialized countries die of industrial output value of more than machine tool industry, beginning in 1997, China's industrial output value has exceeded the mold machine tool industry output.
2 China's mold industry and its development trend
模具工業(yè)現(xiàn)狀 Die & Mould Industry Status
由于歷史原因形成的封閉式、“ 大 而全” 的 企業(yè)特征，我國(guó)大部分企業(yè)均設(shè)有模具車(chē)間，處于本廠(chǎng)的配套地位，自 70 年代末才有了模具工業(yè)化和生產(chǎn)專(zhuān)業(yè)化這個(gè)概念。 Due to historical reasons for the formation of closed, "big and complete" enterprise features, most enterprises in China are equipped with mold workshop, in factory matching status since the late 70s have a mold the concept of industrialization and specialization of production. 生產(chǎn)效率不高，經(jīng)濟(jì)效益較差。 Production efficiency is not high, poor economic returns. 模具行業(yè)的生產(chǎn)小而散亂，跨行業(yè)、投資密集，專(zhuān)業(yè)化、商品化和技術(shù)管理水平都比較低。 Mold production industry is small and scattered, cross-industry, capital-intensive, professional, commercial and technical management level are relatively low.
據(jù)不完全統(tǒng)計(jì)，全國(guó)現(xiàn)有模具專(zhuān)業(yè)生產(chǎn)廠(chǎng)、產(chǎn)品廠(chǎng)配套的模具車(chē)間（分廠(chǎng)）近17000家，約60萬(wàn)從業(yè)人員，年模具總產(chǎn)值達(dá)200億元人民幣。 According to incomplete statistics, there are now specialized in manufacturing mold, the product supporting mold factory workshop (factory) near 17 000, about 600 000 employees, annual output value reached 20 billion yuan mold. 但是，我國(guó)模具工業(yè)現(xiàn)有能力只能滿(mǎn)足需求量的60％左右，還不能適應(yīng)國(guó)民經(jīng)濟(jì)發(fā)展的需要。 However, the existing capacity of the mold and die industry can only meet the demand of 60%, still can not meet the needs of national economic development. 目前，國(guó)內(nèi)需要的大型、精密、復(fù)雜和長(zhǎng)壽命的模具還主要依靠進(jìn)口。 At present, the domestic needs of large, sophisticated, complex and long life of the mold also rely mainly on imports. 據(jù)海關(guān)統(tǒng)計(jì)，1997年進(jìn)口模具價(jià)值6.3億美元，這還不包括隨設(shè)備一起進(jìn)口的模具；1997年出口模具僅為7800萬(wàn)美元。 According to customs statistics, in 1997 630 million U.S. dollars worth of imports mold, not including the import of mold together with the equipment; in 1997 only 78 million U.S. dollars export mold. 目前我國(guó)模具工業(yè)的技術(shù)水平和制造能力，是我國(guó)國(guó)民經(jīng)濟(jì)建設(shè)中的薄弱環(huán)節(jié)和制約經(jīng)濟(jì)持續(xù)發(fā)展的瓶頸。 At present the technological level of China Die & Mould Industry and manufacturing capacity, China's national economy in the weak links and bottlenecks constraining sustainable economic development.
1、模具工業(yè)產(chǎn)品結(jié)構(gòu)的現(xiàn)狀 2.1 Research on the Structure of industrial products mold
按照中國(guó)模具工業(yè)協(xié)會(huì)的劃分，我國(guó)模具基本分為10大類(lèi)，其中，沖壓模和塑料成型模兩大類(lèi)占主要部分。 In accordance with the division of China Mould Industry Association, China mold is divided into 10 basic categories, which, stamping die and plastic molding two categories accounted for the main part. 按產(chǎn)值計(jì)算，目前我國(guó)沖壓模占50％左右，塑料成形模約占20％，拉絲模（工具）約占10％，而世界上發(fā)達(dá)工業(yè)國(guó)家和地區(qū)的塑料成形模比例一般占全部模具產(chǎn)值的40％以上。 Calculated by output, present, China accounts for about 50% die stamping, plastic molding die about 20%, Wire Drawing Die (Tool) about 10% of the world's advanced industrial countries and regions, the proportion of plastic forming die die general of the total output value 40%.
我國(guó)沖壓模大多為簡(jiǎn)單模、單工序模和符合模等，精沖模，精密多工位級(jí)進(jìn)模還為數(shù)不多，模具平均壽命不足100萬(wàn)次，模具最高壽命達(dá)到1億次以上，精度達(dá)到3～5um，有50個(gè)以上的級(jí)進(jìn)工位，與國(guó)際上最高模具壽命6億次，平均模具壽命5000萬(wàn)次相比，處于80年代中期國(guó)際先進(jìn)水平。 Most of our stamping die mold for the simple, single-process mode and meet the molds, precision die, precision multi-position progressive die is also one of the few, die less than 100 million times the average life of the mold reached 100 million times the maximum life of more than accuracy 3 ~ 5um, more than 50 progressive station, and the international life of the die 600 million times the highest average life of the die 50 million times compared to the mid 80s at the international advanced level.
我國(guó)的塑料成形模具設(shè)計(jì)，制作技術(shù)起步較晚，整體水平還較低。 China's plastic molding mold design, production technology started relatively late, the overall level of low. 目前單型腔，簡(jiǎn)單型腔的模具達(dá)70％以上，仍占主導(dǎo)地位。 Currently a single cavity, a simple mold cavity 70%, and still dominant. 一模多腔精密復(fù)雜的塑料注射模，多色塑料注射模已經(jīng)能初步設(shè)計(jì)和制造。A sophisticated multi-cavity mold plastic injection mold, plastic injection mold has been able to multi-color preliminary design and manufacturing. 模具平均壽命約為80萬(wàn)次左右，主要差距是模具零件變形大、溢邊毛刺大、表面質(zhì)量差、模具型腔沖蝕和腐蝕嚴(yán)重、模具排氣不暢和型腔易損等，注射模精度已達(dá)到5um以下，最高壽命已突破2000萬(wàn)次，型腔數(shù)量已超過(guò)100腔，達(dá)到了80年代中期至90年代初期的國(guó)際先進(jìn)水平。 Mould is about 80 million times the average life span is about, the main difference is the large deformation of mold components, excess burr side of a large, poor surface quality, erosion and corrosion serious mold cavity, the mold cavity exhaust poor and vulnerable such as, injection mold 5um accuracy has reached below the highest life expectancy has exceeded 20 million times, the number has more than 100 chamber cavity, reaching the mid 80s to early 90s the international advanced level.
2、模具工業(yè)技術(shù)結(jié)構(gòu)現(xiàn)狀 2.2 mold Present Status of Technology
我國(guó)模具工業(yè)目前技術(shù)水平參差不齊，懸殊較大。 Technical level of China's mold industry currently uneven, with wide disparities. 從總體上來(lái)講，與發(fā)達(dá)工業(yè)國(guó)家及港臺(tái)地區(qū)先進(jìn)水平相比，還有較大的差距。 Generally speaking, with the developed industrial countries, Hong Kong and Taiwan advanced level, there is a large gap.
在采用CAD/CAM/CAE/CAPP等技術(shù)設(shè)計(jì)與制造模具方面，無(wú)論是應(yīng)用的廣泛性，還是技術(shù)水平上都存在很大的差距。 The use of CAD / CAM / CAE / CAPP and other technical design and manufacture molds, both wide application, or technical level, there is a big gap between both. 在應(yīng)用CAD技術(shù)設(shè)計(jì)模具方面，僅有約10%的模具在設(shè)計(jì)中采用了CAD，距拋開(kāi)繪圖板還有漫長(zhǎng)的一段路要走；在應(yīng)用CAE進(jìn)行模具方案設(shè)計(jì)和分析計(jì)算方面，也才剛剛起步，大多還處于試用和動(dòng)畫(huà)游戲階段；在應(yīng)用CAM技術(shù)制造模具方面，一是缺乏先進(jìn)適用的制造裝備，二是現(xiàn)有的工藝設(shè)備（包括近10多年來(lái)引進(jìn)的先進(jìn)設(shè)備）或因計(jì)算機(jī)制式（IBM微機(jī)及其兼容機(jī)、HP工作站等）不同，或因字節(jié)差異、運(yùn)算速度差異、抗電磁干擾能力差異等，聯(lián)網(wǎng)率較低，只有5%左右的模具制造設(shè)備近年來(lái)才開(kāi)展這項(xiàng)工作；在應(yīng)用CAPP技術(shù)進(jìn)行工藝規(guī)劃方面，基本上處于空白狀態(tài)，需要進(jìn)行大量的標(biāo)準(zhǔn)化基礎(chǔ)工作；在模具共性工藝技術(shù)，如模具快速成型技術(shù)、拋光技術(shù)、電鑄成型技術(shù)、表面處理技術(shù)等方面的CAD/CAM技術(shù)應(yīng)用在我國(guó)才剛起步。 In the application of CAD technology design molds, only about 10% of the mold used in the design of CAD, aside from drawing board still has a long way to go; in the application of CAE design and analysis of mold calculation, it was just started, most of the game is still in trial stages and animation; in the application of CAM technology manufacturing molds, first, the lack of advanced manufacturing equipment, and second, the existing process equipment (including the last 10 years the introduction of advanced equipment) or computer standard (IBM PC and compatibles, HP workstations, etc.) different, or because of differences in bytes, processing speed differences, differences in resistance to electromagnetic interference, networking is low, only about 5% of the mold manufacturing equipment of recent work in this task; in the application process planning CAPP technology, basically a blank state, based on the need for a lot of standardization work; in the mold common technology, such as mold rapid prototyping technology, polishing, electroforming technologies, surface treatment technology aspects of CAD / CAM technology in China has just started. 計(jì)算機(jī)輔助技術(shù)的軟件開(kāi)發(fā)，尚處于較低水平，需要知識(shí)和經(jīng)驗(yàn)的積累。 Computer-aided technology, software development, is still at low level, the accumulation of knowledge and experience required. 我國(guó)大部分模具廠(chǎng)、車(chē)間的模具加工設(shè)備陳舊，在役期長(zhǎng)、精度差、效率低，至今仍在使用普通的鍛、車(chē)、銑、刨、鉆、磨設(shè)備加工模具，熱處理加工仍在使用鹽浴、箱式爐，操作憑工人的經(jīng)驗(yàn)，設(shè)備簡(jiǎn)陋，能耗高。 Most of our mold factory, mold processing equipment shop old, long in the length of civilian service, accuracy, low efficiency, still use the ordinary forging, turning, milling, planing, drilling, grinding and processing equipment, mold, heat treatment is still in use salt bath, box-type furnace, operating with the experience of workers, poorly equipped, high energy consumption. 設(shè)備更新速度緩慢，技術(shù)改造，技術(shù)進(jìn)步力度不大。 Renewal of equipment is slow, technological innovation, technological progress is not much intensity. 雖然近年來(lái)也引進(jìn)了不少先進(jìn)的模具加工設(shè)備，但過(guò)于分散，或不配套，利用率一般僅有25%左右，設(shè)備的一些先進(jìn)功能也未能得到充分發(fā)揮。 Although in recent years introduced many advanced mold processing equipment, but are too scattered, or not complete, only about 25% utilization, equipment, some of the advanced functions are not given full play.
缺乏技術(shù)素質(zhì)較高的模具設(shè)計(jì)、制造工藝技術(shù)人員和技術(shù)工人，尤其缺乏知識(shí)面寬、知識(shí)結(jié)構(gòu)層次高的復(fù)合型人才。 Lack of technology of high-quality mold design, manufacturing technology and skilled workers, especially the lack of knowledge and breadth, knowledge structure, high levels of compound talents. 中國(guó)模具行業(yè)中的技術(shù)人員，只占從業(yè)人員的8%~12%左右，且技術(shù)人員和技術(shù)工人的總體技術(shù)水平也較低。 China's mold industry and technical personnel, only 8% of employees 12%, and the technical personnel and skilled workers and lower the overall skill level. 1980年以前從業(yè)的技術(shù)人員和技術(shù)工人知識(shí)老化，知識(shí)結(jié)構(gòu)不能適應(yīng)現(xiàn)在的需要；而80年代以后從業(yè)的人員，專(zhuān)業(yè)知識(shí)、經(jīng)驗(yàn)匱乏，動(dòng)手能力差，不安心，不愿學(xué)技術(shù)。 Before 1980, practitioners of technical personnel and skilled workers, the aging of knowledge, knowledge structure can not meet the current needs; and staff employed after 80 years, expertise, experience lack of hands-on ability, not ease, do not want to learn technology. 近年來(lái)人才外流不僅造成人才數(shù)量與素質(zhì)水平下降，而且人才結(jié)構(gòu)也出現(xiàn)了新的斷層，青黃不接，使得模具設(shè)計(jì)、制造的技術(shù)水平難以提高。 In recent years, the brain drain caused by personnel not only decrease the quantity and quality levels, and personnel structure of the emergence of new faults, lean, make mold design, manufacturing difficult to raise the technical level.
3、模具工業(yè)配套材料，標(biāo)準(zhǔn)件結(jié)構(gòu)現(xiàn)狀 2.3 mold industry supporting materials, standard parts of present condition
近10多年來(lái)，特別是“八五”以來(lái)，國(guó)家有關(guān)部委已多次組織有關(guān)材料研究所、大專(zhuān)院校和鋼鐵企業(yè)，研究和開(kāi)發(fā)模具專(zhuān)用系列鋼種、模具專(zhuān)用硬質(zhì)合金及其他模具加工的專(zhuān)用工具、輔助材料等，并有所推廣。 Over the past 10 years, especially the "Eighth Five-Year", the State organization of the ministries have repeatedly Material Research Institute, universities and steel enterprises, research and development of special series of die steel, molds and other mold-specific carbide special tools, auxiliary materials, and some promotion. 但因材料的質(zhì)量不夠穩(wěn)定，缺乏必要的試驗(yàn)條件和試驗(yàn)數(shù)據(jù)，規(guī)格品種較少，大型模具和特種模具所需的鋼材及規(guī)格還有缺口。 However, due to the quality is not stable enough, the lack of the necessary test conditions and test data, specifications and varieties less, large molds and special mold steel and specifications are required for the gap. 在鋼材供應(yīng)上，解決用戶(hù)的零星用量與鋼廠(chǎng)的批量生產(chǎn)的供需矛盾，尚未得到有效的解決。 In the steel supply, settlement amount and sporadic users of mass-produced steel supply and demand contradiction, yet to be effectively addressed. 另外，國(guó)外模具鋼材近年來(lái)相繼在國(guó)內(nèi)建立了銷(xiāo)售網(wǎng)點(diǎn)，但因渠道不暢、技術(shù)服務(wù)支撐薄弱及價(jià)格偏高、外匯結(jié)算制度等因素的影響，目前推廣應(yīng)用不多。 In addition, in recent years have foreign steel mold set up sales outlets in China, but poor channels, technical services support the weak and prices are high, foreign exchange settlement system and other factors, promote the use of much current.
模具加工的輔助材料和專(zhuān)用技術(shù)近年來(lái)雖有所推廣應(yīng)用，但未形成成熟的生產(chǎn)技術(shù)，大多仍還處于試驗(yàn)摸索階段，如模具表面涂層技術(shù)、模具表面熱處理技術(shù)、模具導(dǎo)向副潤(rùn)滑技術(shù)、模具型腔傳感技術(shù)及潤(rùn)滑技術(shù)、模具去應(yīng)力技術(shù)、模具抗疲勞及防腐技術(shù)等尚未完全形成生產(chǎn)力，走向商品化。 Mold supporting materials and special techniques in recent years despite the popularization and application, but failed to mature production technology, most still also in the exploratory stage tests, such as die coating technology, surface treatment technology mold, mold guide lubrication technology Die sensing technology and lubrication technology, mold to stress technology, mold and other anti-fatigue and anti-corrosion technology productivity has not yet fully formed, towards commercialization. 一些關(guān)鍵、重要的技術(shù)也還缺少知識(shí)產(chǎn)權(quán)的保護(hù)。 Some key, important technologies also lack the protection of intellectual property.
我國(guó)的模具標(biāo)準(zhǔn)件生產(chǎn)，80年代初才形成小規(guī)模生產(chǎn)，模具標(biāo)準(zhǔn)化程度及標(biāo)準(zhǔn)件的使用覆蓋面約占20%，從市場(chǎng)上能配到的也只有約30個(gè)品種，且僅限于中小規(guī)格。 China's mold standard parts production, the formation of the early 80s only small-scale production, standardization and standard mold parts using the coverage of about 20%, from the market can be assigned to, is just about 30 varieties, and limited to small and medium size. 標(biāo)準(zhǔn)凸凹模、熱流道元件等剛剛開(kāi)始供應(yīng)，模架及零件生產(chǎn)供應(yīng)渠道不暢，精度和質(zhì)量也較差。 Standard punch, hot runner components and other supplies just the beginning, mold and parts production and supply channels for poor, poor accuracy and quality.
模具的發(fā)展趨勢(shì) 3 Die trend
1、模具CAD/CAE/CAM正向集成化、三維化、智能化和網(wǎng)絡(luò)化方向發(fā)展 3.1 mold CAD / CAE / CAM being integrated, three-dimensional, intelligent and network direction
（1）模具軟件功能集成化 (1) mold software features integrated
模具軟件功能的集成化要求軟件的功能模塊比較齊全，同時(shí)各功能模塊采用同一數(shù)據(jù)模型，以實(shí)現(xiàn)信息的綜合管理與共享，從而支持模具設(shè)計(jì)、制造、裝配、檢驗(yàn)、測(cè)試及生產(chǎn)管理的全過(guò)程，達(dá)到實(shí)現(xiàn)最佳效益的目的。 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. 如英國(guó)Delcam公司的系列化軟件就包括了曲面/實(shí)體幾何造型、復(fù)雜形體工程制圖、工業(yè)設(shè)計(jì)高級(jí)渲染、塑料模設(shè)計(jì)專(zhuān)家系統(tǒng)、復(fù)雜形體CAM、藝術(shù)造型及雕刻自動(dòng)編程系統(tǒng)、逆向工程系統(tǒng)及復(fù)雜形體在線(xiàn)測(cè)量系統(tǒng)等。 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. 集成化程度較高的軟件還包括：Pro/ENGINEER、UG和CATIA等。 A higher degree of integration of the software includes: Pro / ENGINEER, UG and CATIA, etc.. 國(guó)內(nèi)有上海交通大學(xué)金屬塑性成型有限元分析系統(tǒng)和沖裁模CAD/CAM系統(tǒng)；北京北航海爾軟件有限公司的CAXA系列軟件；吉林金網(wǎng)格模具工程研究中心的沖壓模CAD/CAE/CAM系統(tǒng)等。 Shanghai Jiaotong 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）模具設(shè)計(jì)、分析及制造的三維化 (2) mold design, analysis and manufacture of three-dimensional
傳統(tǒng)的二維模具結(jié)構(gòu)設(shè)計(jì)已越來(lái)越不適應(yīng)現(xiàn)代化生產(chǎn)和集成化技術(shù)要求。 Two-dimensional mold of traditional structural design can no longer meet modern technical requirements of production and integration. 模具設(shè)計(jì)、分析、制造的三維化、無(wú)紙化要求新一代模具軟件以立體的、直觀(guān)的感覺(jué)來(lái)設(shè)計(jì)模具，所采用的三維數(shù)字化模型能方便地用于產(chǎn)品結(jié)構(gòu)的CAE分析、模具可制造性評(píng)價(jià)和數(shù)控加工、成形過(guò)程模擬及信息的管理與共享。 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. 如Pro/ENGINEER、UG和CATIA等軟件具備參數(shù)化、基于特征、全相關(guān)等特點(diǎn)，從而使模具并行工程成為可能。 Such as Pro / ENGINEER, UG and CATIA software such as with parametric, feature-based, all relevant characteristics, so that mold concurrent engineering possible. 另外，Cimatran公司的Moldexpert，Delcam公司的Ps-mold及日立造船的Space-E/mold均是3D專(zhuān)業(yè)注塑模設(shè)計(jì)軟件，可進(jìn)行交互式3D型腔、型芯設(shè)計(jì)、模架配置及典型結(jié)構(gòu)設(shè)計(jì)。 In addition, Cimatran company Moldexpert, 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 . 澳大利亞Moldflow公司的三維真實(shí)感流動(dòng)模擬軟件MoldflowAdvisers已經(jīng)受到用戶(hù)廣泛的好評(píng)和應(yīng)用。 Australian company Moldflow realistic three-dimensional flow simulation software MoldflowAdvisers been widely praised by users and applications. 國(guó)內(nèi)有華中理工大學(xué)研制的同類(lèi)軟件HSC3D4.5F及鄭州工業(yè)大學(xué)的Z-mold軟件。 China Huazhong University of Science have developed similar software HSC3D4.5F and Zhengzhou University, Z-mold software. 面向制造、基于知識(shí)的智能化功能是衡量模具軟件先進(jìn)性和實(shí)用性的重要標(biāo)志之一。 For manufacturing, knowledge-based intelligent software function is a measure of die important sign of advanced and practical one. 如Cimatron公司的注塑模專(zhuān)家軟件能根據(jù)脫模方向自動(dòng)產(chǎn)生分型線(xiàn)和分型面，生成與制品相對(duì)應(yīng)的型芯和型腔，實(shí)現(xiàn)模架零件的全相關(guān)，自動(dòng)產(chǎn)生材料明細(xì)表和供NC加工的鉆孔表格，并能進(jìn)行智能化加工參數(shù)設(shè)定、加工結(jié)果校驗(yàn)等。 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）模具軟件應(yīng)用的網(wǎng)絡(luò)化趨勢(shì) (3) mold software applications, networking trend
隨著模具在企業(yè)競(jìng)爭(zhēng)、合作、生產(chǎn)和管理等方面的全球化、國(guó)際化，以及計(jì)算機(jī)軟硬件技術(shù)的迅速發(fā)展，網(wǎng)絡(luò)使得在模具行業(yè)應(yīng)用虛擬設(shè)計(jì)、敏捷制造技術(shù)既有必要，也有可能。 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. 美國(guó)在其《21世紀(jì)制造企業(yè)戰(zhàn)略》中指出，到2006年要實(shí)現(xiàn)汽車(chē)工業(yè)敏捷生產(chǎn)/虛擬工程方案，使汽車(chē)開(kāi)發(fā)周期從40個(gè)月縮短到4個(gè)月。 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、模具檢測(cè)、加工設(shè)備向精密、高效和多功能方向發(fā)展 3.2 mold testing, processing equipment to the precise, efficient, and multi-direction
（1）模具檢測(cè)設(shè)備的日益精密、高效 (1) mold testing equipment more sophisticated, efficient
精密、復(fù)雜、大型模具的發(fā)展，對(duì)檢測(cè)設(shè)備的要求越來(lái)越高。 Sophisticated, complex, large-scale mold development, testing equipment have become increasingly demanding. 現(xiàn)在精密模具的精度已達(dá)2～3μm，目前國(guó)內(nèi)廠(chǎng)家使用較多的有意大利、美國(guó)、日本等國(guó)的高精度三坐標(biāo)測(cè)量機(jī)，并具有數(shù)字化掃描功能。 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. 如東風(fēng)汽車(chē)模具廠(chǎng)不僅擁有意大利產(chǎn)3250mm×3250mm三坐標(biāo)測(cè)量機(jī)，還擁有數(shù)碼攝影光學(xué)掃描儀，率先在國(guó)內(nèi)采用數(shù)碼攝影、光學(xué)掃描作為空間三維信息的獲得手段，從而實(shí)現(xiàn)了從測(cè)量實(shí)物→建立數(shù)學(xué)模型→輸出工程圖紙→模具制造全過(guò)程，成功實(shí)現(xiàn)了逆向工程技術(shù)的開(kāi)發(fā)和應(yīng)用。 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. 這方面的設(shè)備還包括：英國(guó)雷尼紹公司第二代高速掃描儀(CYCLON SERIES2)可實(shí)現(xiàn)激光測(cè)頭和接觸式測(cè)頭優(yōu)勢(shì)互補(bǔ)，激光掃描精度為0.05mm，接觸式測(cè)頭掃描精度達(dá)0.02mm。 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. 另外德國(guó)GOM公司的
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