Mold industry supporting materials, standard parts of present condition

Mold industry supporting materials, standard parts of present condition  

  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,Cnc machining  molds and other mold-specific carbide special tools, auxiliary materials, and some promotion.  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.  In the steel supply, settlement amount and sporadic users of mass-produced steel supply and demand contradiction, yet to be effectively addressed.  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. 

  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, Cnc machining 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.  Some key, important technologies also lack the protection of intellectual property.

 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.  Standard punch, hot runner components and other supplies just the beginning, mold and parts production and supply channels for poor, poor accuracy and quality.

  Die & Mould Industry Structure in Industrial Organization

  China's mold industry is relatively backward and still could not be called an independent industry.  Mold manufacturer in China currently can be divided into four categories: professional mold factory, professional production outside for mold; products factory mold factory or workshop, in order to supply the product works as the main tasks needed to die; die-funded enterprises branch, the organizational model and professional mold factory is similar to small but the main; township mold business, and professional mold factory is similar.  Of which the largest number of first-class, mold production accounts for about 70% of total output.  China's mold industry, decentralized management system.  There are 19 major industry sectors manufacture and use of mold, there is no unified management of the department.  Only by China Die & Mould Industry Association, overall planning, focus on research, cross-sectoral, inter-departmental management difficulties are many。

  Mold is suitable for small and medium enterprises organize production, and our technical transformation investment tilted to large and medium enterprises, small and medium enterprise investment mold can not be guaranteed.  Including product factory mold shop, factory, including, after the transformation can not quickly recover its investment, or debt-laden, affecting development.

  Although most products factory mold shop, factory technical force is strong, good equipment conditions, the production of mold levels higher, but equipment utilization rate.  

 Price has long been China's mold inconsistent with their value, resulting in mold industry "own little economic benefit, social benefit big" phenomenon.  "Dry as dry  mold mold standard parts, standard parts dry as dry mold with pieces of production.Cnc machining  Dry with parts manufactured products than with the mold" of the class of anomalies exist.

Sea and ship

sea and ship

Mold Present Status of Technology

Mold Present Status of Technology

 Technical level of China's mold industry currently uneven,Cnc machining  with wide disparities.  Generally speaking, with the developed industrial countries, Hong Kong and Taiwan advanced level, there is a large gap.  

  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.  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 stillin 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.  Computer-aided technology, software development, is still at low level, the accumulation of knowledge and experience required.

  Most of our mold factory, mold processing equipment shop old,Cnc machining   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.

 Renewal of equipment is slow, technological innovation, technological progress is not much intensity.  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.

  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. 

  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.  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.  Cnc machining  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.

Mold industry and its development trend

Mold industry and its development trend  

 Die & Mould Industry Status 

  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.  Production efficiency is not high, poor economic returns.  Mold production industry is small and scattered, cross-industry, capital-intensive, professional, comme cnc milling machinercial and technical management level are relatively low. 

  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.  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.  At present, the domestic needs of large, sophisticated, complex and long life of the mold also rely mainly on imports.  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.  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。

 Research on the Structure of industrial products mold

  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.  cnc milling machine 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%. 

  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。

 China's plastic molding mold design, production technology started relatively late, the overall level of low.  Currently a single cavity, a simple mold cavity 70%, and still dominant. A sophisticated multi-cavity mold plastic injection mold, plastic injection mold has been able to multi-color preliminary design and manufacturing.  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,  cnc milling machine 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.

The historical development of mold

The historical development of mold

 The emergence of mold can be traced back thousands of years ago, pottery and bronze foundry, but the large-scale use is with the rise of modern industry and developed.

  The 19th century, Cnc machining with the arms industry (gun's shell), watch industry, radio industry, dies are widely used.  After World War II, with the rapid development of world economy, it became a mass production of household appliances, automobiles, electronic equipment, cameras, watches and other parts the best way.  

 From a global perspective, when the United States in the forefront of stamping technology - many die of advanced technologies, such as simple mold, high efficiency, mold, die and stamping the high life automation, mostly originated in the United States; and Switzerland, fine blanking, cold in Germany extrusion technology, plastic processing of the Soviet Union are at the world advanced.  50's, mold industry focus is based on subscriber demand, production can meet the product requirements of the mold.Cnc machining  Multi-die design rule of thumb, reference has been drawing and perceptual knowledge, on the design of mold parts of a lack of real understanding of function.  From 1955 to 1965, is the pressure processing of exploration and development of the times - the main components of the mold and the stress state of the function of a mathematical sub-bridge, and to continue to apply to on-site practical knowledge to make stamping technology in all aspects of a leap in development.  The result is summarized mold design principles, and makes the pressure machine, stamping materials, processing methods, plum with a structure, mold materials, mold manufacturing method, the field of automation devices, a new look to the practical direction of advance, so that pressing processing apparatus capable of producing quality products from the first stage。

From the mid-70s so far can be said that computer-aided design, supporting the continuous development of manufacturing technology of the times.  With the precision and complexity of mold rising, accelerating the production cycle, the mold industry, the quality of equipment and personnel are required to improve.  Rely on common processing equipment, their experience and skills can not meet the needs of mold.  Since the 90's, mechanical and electronic technologies in close connection with the development of NC machine tools, such as CNC wire cutting machine, CNC EDM, CNC milling, CNC coordinate grinding machine and so on.  The use of computer automatic programming, control CNC machine tools to improve the efficiency in the use and scope.  In recent years, has developed a computer to time-sharing by the way a group of direct management and control of CNC machine tools NNC system。

  With the development of computer technology, computers have gradually into the mold in all areas, including design, manufacturing and management.  International Association for the Study of production forecasts to 2000, as a means of links between design and manufacturing drawings will lose its primary role.  Automatic Design of die most fundamental point is to establish the mold standard and design standards.  To get rid of the people of the past, and practical experience to judge the composition of the design center, we must take past experiences and ways of thinking, for series, numerical value, the number of type-based, as the design criteria to the computer store.

  Components are dry because of mold constitutes a million other differences, to come up with a can adapt to various parts of the design software almost impossible.  But some products do not change the shape of parts, mold structure has certain rules, can be summed up for the automatic design of software.  If a Japanese company's CDM system for progressive die design and manufacturing, including the importation of parts of the figure, rough start, strip layout, determine the size and standard templates, assembly drawing and parts, the output NC program (for CNC machining Center and line cutting program), etc., used in 20% of the time by hand, Cnc machining reduce their working hours to 35 hours; from Japan in the early 80s will be three-dimensional cad / cam system for automotive panel die.  Currently, the physical parts scanning input, map lines and data input, geometric form, display, graphics, annotations and the data is automatically programmed, resulting in effective control machine tool control system of post-processing documents have reached a high level; computer Simulation (CAE) technology has made some achievements.  At high levels, CAD / CAM / CAE integration, that data is integrated, can transmit information directly with each other.  Achieve network.  Present.  Only a few foreign manufacturers can do it.

Die position in industrial production

Die position in industrial production

 Mold is a high-volume products with the shape tool, is the main process of industrial production equipment. 

 With mold components, Cnc machining 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.  Have already become an important means of industrial production and technological development. The basis of the modern industrial economy. 

 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.  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.  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."  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.  All these have fully demonstrated the development of the State Council and state departments tooling industry attention and support. 

 Mold around the world about the current annual output of 60 billion U.S. dollars, Japan, Cnc machining  the United States and other industrialized countries die of industrial output value of more than machine toolindustry, beginning in 1997, China's industrial output value has exceeded the mold machine tool industry output. 

   According to statistics, home appliances, toys and other light industries, nearly 90% of the parts are integrated with production of chopsticks; in aircraft, automobiles, agricultural machinery and radio industries, the proportion exceeded 60%.  Such as aircraft manufacturing, the use of a certain type of fighter dies more than 30,000 units, of which the host 8000 sets, 2000 sets of engines, auxiliary 20 000 sets.  From the output of view, since the 80's, the United States, Japan and other industrialized countries die industry output value has exceeded the machine tool industry, and there are still rising.  Production technology, according to the International Association predicts that in 2000, the product best pieces of rough 75%, 50% will be finished mold completed; metals, plastics, ceramics, rubber,Cnc machining  building materials and other industrial products, most of the mold will be completed in more than 50% metal plates, more than 80% of all plastic products, especially through the mold into.

Power plant The source of clamping force

  

Power plant The source of clamping force

 In the machining process the work piece by the cutting force, Cnc machining centrifugal force, inertia force, such as the role of, in order to ensure that these external force, the workpiece can remain in the fixture by the positioning of the processing to determine the location of components, and should be no vibration or displacement, fixture structure should be set up reliable work piece clamping device folder will be in prison. First, the composition of clamping devices  

  Many different types of clamping devices, but their structures are composed of two parts.   

 1. Power plant The source of clamping force, one human; second is generated by a power device.The device can generate power as the power unit fixture.Cnc machining  Commonly used in power plant are: pneumatic devices hydraulic devices electrical devices electromagnetic devices gas - liquid interaction devices and vacuum devices. Fixture as a result of manual clamping force from the human so it does not power plants.  

  2. Clamping part  

  Receive and impart into the original clamping force to clamp the task force and part of the implementation of the general composition of the following agencies:  

  1) to accept the original force of bodies. Such as handles nuts and used to connect the institutions such as cylinder piston rod.  

  2) Force the middle of delivery. Such as hinges levers and so on.  

  3) Clamping components. Such as plate such as screws.

Force delivery of them in the middle of the original Cnc machining transmission of force to the process of clamping devices can play such as changes in the direction of force to change the size of forces as well as the role of self-locking and so on.  

Fixture of The Development Trend

Fixture of The Development Trend

 Industrial design is the development of human society and the progress of science and technology of the product, Cnc machining from Maurice's" the arts and Crafts Movement", to the German Bauhaus design revolution and the United States of America wide  dissemination and promotion, industrial design after brewing, exploration, formation, development history of more than 100 years of vicissitudes. Today, industrial design has become an independent subject, and a complete set of research system.

 In 1980 the International Council of societies of industrial design ( ICSID ) to the industry as a clearly defined:" production of industrial products, by training, technical knowledge, experience and visual experience, and indicates the material, structure, morphology, structure, color, surface processing, decoration to the new quality and specification, called industrial design. According to the specific circumstances of the time, industrial designer in the industry products are all side or a few aspects of the work, but also the need for industrial designers of packaging, publicity, display, market development and other issues to resolve pay their own technical knowledge and experience and ability of the visual evaluation, which also belongs to the scope of industrial design".

  Material, structure, technology is the product design material and technical basis, on one hand, technology restrict the design; on the other hand, technology is also promoting design. From the point of view of design aesthetics, technology is not only the material basis but also has its own" function" action, as long as good application properties of the materials, Cnc machining to the corresponding structure and suitable processing technology, can create a practical, aesthetic, economic products, namely in the product technology potential" function".

  Any design are the product of the times, its different features, different features reflect the different historical periods of level of science and technology. Technology is the product of the morphological development of the pilot, new material, new technology products, is bound to bring new structure, new forms and new style. Materials, processing technology, structure, product image organic ground is contacted together, a part of the change, it will cause the whole body changes.

  Now, the machining process and fixture with the development of manufacturing technology also make a spurt of progress. Machining process to the various factories in different circumstances, its processing procedures are very different. Break through the past death mode. Make it with different cases has more reasonable technological process. So that product quality greatly improved. Develop processing technology can be rational, but also to meet the basic requirements: guarantee product quality under the premise, as far as possible to improve labor productivity and reduce the processing cost.

 And to make full use of the existing factory production conditions, as far as possible, using domestic and foreign advanced technology and experience. Should also ensure that the good working conditions. But our country present stage still rely mainly on technology personnel experience to prepare process, often does not require step and cutting amount, man-hour quota is to be determined by experience, very rough, the lack of scientific basis, difficult to carry out reasonable economic accounting    International Journal of production Research Association statistics show that, at present, small batch production of many varieties of workpiece varieties accounted for about 85% of the total number of the kind of workpiece.

  Modern manufacturing requirements of enterprises manufacturing products constantly upgrading, to meet the needs of the market and competition. However, the general enterprises are still accustomed to the traditional special fixture, generally in the medium having a production capacity of the plant, some have thousands or even nearly 10000 sets of special fixture; on the other hand, in the production of many varieties of the company, every 3 to 4 years to update 50 ~ 80% special jig, fixture actual wear only 10 ~ 20% or so. Especially in recent years, CNC machine tools, machining center, group technology, flexible manufacturing system ( FMS ), a new processing technology of machine tool fixture, proposed the following new requirements: 

 1) can rapidly and conveniently and equipment of new products put into production, so as to shorten the production cycle, reduce the production cost;

  2) capable of clamping a group with similar characteristics of the workpiece;

  3) can be applied to precision machining of high precision machine tool fixture;

  4) can be applied to all the modern manufacturing technology of new machine tool fixture;

 5) adopts the hydraulic station for power efficient clamping device, in order to further reduce the labor intensity and improve labor productivity;

 6) improve the standardization degree of machine tool fixture.  The development trend of modern machine tool fixture mainly for standardization, efficiency, precision and flexibility in four aspects.

 Use better fixture, can improve labor productivity, improve processing accuracy, reduce waste, machine tool technology can expand the scope, improve the operation of labor conditions.

 Therefore, the fixture machinery manufacturing is an important process equipment. A good fixture is the processing of qualified products of the first condition, in order to allow the clamp has the better development, fixture industry should strengthen the production, learning and research, collaborative efforts, accelerate the use of high technology to transform and upgrade the level of technology to create the pace of jig, fixture professional technology website, make full use of modern information and network technology, and when in keeping with the innovation and development of fixture technology. Active and foreign fixture manufacturer, for joint venture and cooperation, Cnc machining the introduction of technology, it is the reform and development of our country industry is more effective ways of fixture.

Fixture Design Sense

Fixture Design Sense 

 In the machinery industry, how to guarantee the high precision of workpiece, the costs of processing and other substantive issues, has been engaged in the mechanical industry research questions, precision parts which in the design of fixture when we should consider the problems above, efficient fixture is the workpiece precision guarantee, how to make the fixture more efficient, more economical, the industry is the urgent need to resolve.

  With the development of society, the continuous improvement of technology, various high-tech technology gradually infiltrated into all sectors, how to use these high-tech to serve mankind, how to make full use of the technology in mechanical industry, it also requires machinery industry staff continued efforts, innovation. With the development of science and technology, and social needs of the market, the fixture design in progressive super to the flexible manufacturing system development. precision parts  To date, the fixture is mechanical and electrical products manufacturing in the four indispensable tools, tool itself is already highly standardized, the user only needs to press varieties, specifications selection and procurement.

  While the mold and fixture and related products products, there is a need to make changes, usually belong to the special properties of the tool, mould has become an independent industry; fixture at home and abroad is also gradually form a dependent or independent small industry of machine tool industry.

 Combined clamp not only has the standardization, modularization, modular and other contemporary advanced design ideas, and in line with resource conservation principle, more suitable for green manufacturing environment protection principle. So the next fixture technology is an important direction of development unit. 

 Machine tool fixture is usually refers to the use of clamping workpiece clamping device: for the device with various tools, also known as "tool". The auxiliary tool is sometimes generalized to include in the range of machine tool fixture. According to the application range of machine tool fixture, generally can be divided into general jig, fixture and adjustable fixture.

  Universal jig is on general machine tools are generally accompanied by a common fixture, such as a lathe chuck, milling machine rotary table, dividing head, top seat. They have a standardized, with certain universality, can be used to install certain shape and size within the range of the workpiece without the need for special adjustment. However, in actual production, a universal fixture often can not meet the needs of various parts processing; or because of low productivity and must have the universal fixture for proper improvement; or because the shape of the workpiece, the processing requirements to be different specialized design and manufacture of a special jig, in order to solve the actual production needs. 

 Jig is adapted to a workpiece in a processing requirements and the design and manufacturing expertise, its function mainly has the following several aspects:

 1. ensure that the surface of the workpiece being processed mainly includes processing workpieces need maneuvering time of loading and unloading workpieces need the auxiliary time of two part.

  2. using a dedicated fixture, workpiece installation and

conversion work work can be greatly simplified, no longer need to draw the line and to find it, to shorten the working procedure non-cutting time and save line drawing this process, thereby improving the labor productivity. In production due to the adoption of multiple parallel processing workpiece fixture, enabling the simultaneous processing several parts of the motor will time and processing time of the same motor. The rotary multi-station continuous processing fixture, can be used for machining a workpiece at the same time, other workpiece loading and unloading, thereby enabling the auxiliary time and motor time coincides. In short, with the special fixture using and further improvement, can effectively shorten the process time, production to meet the evolving needs of.

 3. using a dedicated fixture can expand the scope of machine tool technology. For example in lathe boring jig attached, can replace boring work; special fixture can be installed after turning the molding surface, so as to give full play to the role of general machine tools.

4. reduce the labor intensity, and ensuring safety production. According to the demand of production, using pneumatic, hydraulic or other mechanical changes, a higher degree of automation of the special fixture, to reduce the labor intensity of workers, protection of production safety and the stability of product quality and high yield of a great role. Processing large workpieces, such as the lathe bed, the lower surfaces of the screw holes on the bed, precision parts  need to flip several times for processing workpieces, high labor intensity and safety. The use of electric rotary drill furniture, can improve production efficiency, reduce labor intensity, ensure safety in production.

Machining Process Planning Function and Content

Machining Process Planning Function and Content

  Machining process is ready for production work mainly on the basis of. According to its raw material and semifinished product supply, machine tool adjustment,Cnc machining  special process equipment design and manufacturing, production scheduling, allocation of labor force, and the production cost accounting.

  The machining process planning and organization of production, planning and scheduling based on. It can make production schedule and the corresponding scheduling, and can be connected to the scientific process, production is balanced, smooth,Cnc machining   to realize high quality, high yield and low consumption. 

 Machining process card and machining process card, are the two main process documents. Machining process card, is illustrated parts machining process technology files. In a single, small batch production, to machining process card guiding production, process card various projects in the preparation of more detailed.

Machining process card for each process detailed formulation, used to direct workers, used for mass production parts and mass production of the important parts in the.

 Making The Machining Process Planning Principles and Steps

  Under certain production conditions,Cnc machining   with minimal consumption of labor and the lowest cost, according to plans processing parts that meet requirements of the drawings, is to develop the basic principle of machining process.

  Formulation of machining process steps are as follows: 

 The under parts of the production program decision production type;

 The analysis of parts processing technology;

 The choice of blank type and manufacturing method;

 The technological process;

 The process design;

 The process documentation.