模具设计外文翻译

外文资料翻译

系别. 专业. 班级. 姓名. 学号. 指导教师.

2011年4 月

一、China’s mold industry

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, commercial 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.

1、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. 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, 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、mold Present Status of Technology

Technical level of China's mold industry currently uneven, 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 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. 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, 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. 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 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, 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, 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.

3、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. Dry with parts manufactured products than with the mold" of the class of anomalies exist.

二、Basic terminology

1、Impression

The injection mould is an assenbly of parts containing within an inpression into which plastic material is injected and cooled. It is the impression which gives the moulding its form. The impression may, therefore, be defined as thatpart of the mould which imparts shape to the moulding.

The impression is formed by two mould mimbers:

(i)The cavity, which is the female portion of the mould, gices the moulding its

external form.

(ii)The core, which is the male portion of the mould , forms the internal shape of the moulding.

2、Cavity an core plates

The basic mould in this case consists of two plates. Into one plate is sunk the cavity which shapes the outside form of the moulding and os therefore known as the cavity plate. Similarly, the core which projects form the core plate forms the inside shape of the moulding os closed, the two plates come together forming a space between the cavity and core which is the impression.

3、Sprue bush

During the injection process plastic material is delivered to the mozzle of the machie as a melt;it is then tramsferred to the impression though a passage. The material in this passage is termed the sprue, and the bush is called a sprue bush.

4、Runner and gate systems

The material may bedirectly injected into the impression though the sprue bush or for moulds containing several impressions it may pass from the sprue bush hole through a runner

and gate system therefore entering the impression.

5、Register ring

If the material is to pass without hidrance into the mould the mozzle and sprue must be correctly aligned. To endure that this is so the mould must be central to the machine and this can be achieved by including a regicter ring.

6、Guide pillars and bushes

To mould an even-walled article it is necessary to ensure that the cavity and core are keptin alignmemt. This is done by incorporating guide pillars on one mould plate which then enter corresponding guide bushes in the other mould plate as the mouls closes.

7、Fixed half and moving half

The various mould parts fall naturally into two sections or halves. Hence, that half attached to the stationary platen of the machine (indicated by the chain dotted line)is termed the fixed half, The other half of the mould attached to the moving platen of the machine is known simply as the moving half. Now it has to be situsted. Generally the core is situated in the moving half and the overriding reason why this is so, is as follows:

The moulding as it cools, will shrink on to the core and remain with it as the mould opens. This will occur irrespective of whether the core is in the fixed half or the moving half. However, this shrinkage on to the core means that some form of ejector system is almostly certainly necessary. Motivation for this ejector system iseasily provided if the core is in the moving half. Moreover, in the case of our single-impression basic mould, where a direct sprue feed to the underside of the moulding is desired the cavity must be in the fixed half and the core in the moving half.

8、Methods of incorporating cavity and core

We have now seen that in general the core is incorporsted in the moving half and the cavity in the fixed half. However, there are various methods by which the cavity and core can be incorporated in their respective halves of the mould. These represent two basic alternatives (i) the integer method where the cavity and core can be machined form steel plates which become part of the structural build-up of the mould, or (ii) the cavity and core can be machined form small blocks of steel, termed inderts, and subsequently bolstered. The choice between these alternatives constitutes an important decision on the part of the mould designer. The final result, nevertheless, will be the contains the core is termed the core plate and the plate or assembly which contains the cavity is termed the cavity plate.

9、Cavity Fabrication

When a decision for making a mold is made, the cost is predicated on producing a

specified quantity of parts without additional tooling expenditure. Sometimes, the anticipatesare quantities are exceeded; other times, they all short of requirements, and costly repairs becomenecesary in order to supply the needs.

In the making of cavities by machining, grinding, or electric discharge machining, there is constant drive to improve the rate of metal removal. Cutting tools as well as machine tools are developed for heavier and faster cuts; grinding wheels are tailor-made for special steels to allow deeper cuts per pass; and EDM machines are revamped to burn the metal at an accelerated pace.It is fully appreciated that faster mental-removal rate leads to more economical manufacture,but at the same time it mast be recognized that the newer cavity fabrication is associated with generation of more heat and indirectly with higher stresses that if not relieved can cause premature gailure.

Suppliers of tool steel caution the user against fabricating stresses and strongly advise a stress-relieving operation. When a steel is to be heat-treated and a preheat cycle ia part of the heat-treating specification, then the metal-removal stresses will be eliminated.

A great number of cavities are made of prehardened steel, and therefore would not be heat-treated.For those cavities,a stress-relieving operation should be carried out immediately after fabricaton.the stress-relieving temperature as a rule is about 100oF below the tempring heat and is held for 30 min. for each inch of steel thickness. It is best to check the stress-relieving heat and time with the maker of the steel.

The information about fabrication stress has always been emphasized by the steelmakers,but for some reason it has not been given the attention it deserves. Since a tool drawing should cover all the requirements of a tool element, it would be the appropriate place for a note such as the following:

Note: For heat-treated steel:“Note: Use preheat and harden to RC ____.”

Note: For prehardened steel:“Note: Stress relieve@___oF for____hours

per____ inch of thickness.”

Every effort should be made to eliminate the invisible source of problems, namely，fabricating stresses.Mold cavities can be produced by a variety of processes. The process to be used is Determined.First of all by the lowest cost at which the cavity can be produced for the desired end result. Other factors include precision of repairability. Frequently, a combination of processes is employed in order to meet all the specified requirements. The most common processes are discussed in the following sections.

Specifically, investment casting may be considered for applications where the number of cavities is greater than six and tolerances of dimensions are in the range of ±0.005. It is

particularly adaptable to complex shapes and unusual configurations as well as for surface that are highly decorative and difficult to obtain by conventional processes. These decorative surface may have a wood grain, leather grain, or textured surface suitable for handle grips,etc.

A lmost any alloy of steel or beryllium copper alloys can be cast to size and heat-treated metal hardness that is within the range of the alloy being cast. Acomparative cost evaluation will in many cases favor the investment process. The investment cast tooling when produced by qualified people can be of the same quality as those machined from bar stock., i.e.,they can be free of porosity, proper hardness, uniform with respect to each other, and where (and-where)the time element is a factor-can be produced in days instead of weeks. In this process, cavities have been made that weigh as much as 750 lb.

The investment caqsting method calls for a model of a low-melt material such as wax, plastic, or frozen mercury. The model is a reproduction of the desired cavity block and, when cast, is ready for mounting in the base. It incorporates shrinkage allowances as well as a gating system for metal pouring. The complete model is sipped in a slurry of fine refractory material and then encased in the investment material, which may be plaster of paris or mixtures of ceramic materials with high refractory properties. With the encased investment fully set up, the model is removed from the mold by heating in can over to liquefy the meltable material and cause it to run out. The molten material is reclaimed for further use. The mold or investment casing is fully dried out during the heating. After these steps, the investment is preheated to 1000°to 2000oF in preparation for the pouring of the metal. The preheat temperature is governed by the type of metal. When pouring is completed and solidification of the metal has taken place, the investment material is broken away to free the casting for removal of the gates and cleaning.

The making of the model for cavity and core blocks of meltable material is an intermediate step. These model blocks are cast in molds that are the staring point for the process. The starting-point mold consists of the part cavity or core where the parting line width as well as block portin for mounting, etc., are built around the part cavity and core, and thus form the shape needed as the complete block.

The investment-casting process was developed commercially to a high dehree of precision and quality during World War II for the manufacture of aviation gasturbine blades were made of alloys, which were difficult or impossible to be foged. Subsequently, refinements have been developed in the investment-casting process that are especially valuable to the moldmaking field. Most these improvements are in the area of investment materials for the pyrpose of maintaining closer tolerances on the castings. Some mold shops have equipped

themselves with the ability to produce investment castings alongside their regular fabrication facilities.

三、Feed System

It is necessary to paovide a flow-way in the injection mould to connect the nozzle of the injection machine to each impression. This flow-way is termed the feed system. Normally the feed system comprises a sprue, runner and gate. These terms apply equally to the flow-way itself, and to the molded material which is removed from the flow-way itself in the process of extracting the molding.

1、Sprue

A spure is a channel though which to transfer molten plastic injected from the nozzle of the injector the mold. It is a part of spure bush, which is a separate part from th mold.

2、Runner

A runner is a channel that guides molten plastic into the cavity of a mold.

3、Gate

A gate is an entrance through which molten plastic enters the cavity. The gate has the following functions:restricts the flow and the direction of molten plastic;simplifies cutting of a runner and moldings to simplify finishing of parts;quickly cools and solidifies to avoid backflow after molten plastic has filled up in the cavity.

4、Cold slug well

The purpose of the cold slug well, shown oppwsite the sprue, is theoretically to receive the material that has chilled at the front of the nozzle during the cooling and ejection phase. Perhaps of greater importance is the fact that it provides positive means whereby the sprue can be pulled from the sprue bush for ejection purposes.

The sprue, the runner, and the gate will be discarded after a part is complete. However, the runner and the gate are important items that affect the quality or the cost of parts.

四、Parting Surface

The parting surfaces of a mould are those portion of both mould plates, adjacent to the impressions, which butt together to form a seal and prevent the loss of plastic material from the impression. The parting surface is 1、classified flat and non-flat

The mature of the parting surface depends entirely on the shape of the component. A further consideration os that the parting surface must be chosen so that the molding can be removed from the mould. Many molding are required which have a parting line which lies on

a non-planar or curved surface.

When the parting surface os not flat, there is the quertion of unbalanced forces to consider in certain instances. The plastic material when under pressure within the impression, will exert a force which will tend to open the mould in the lateral direction. If this happens some flashing may occur on the angled face. The movement between the two mould halves will be resisted by the guide pillars, but even so, because of the large forced involved, it is desirable to balance the mould by reversing the step so that the parting surface continues across the mould as a mirror image of the section which includes the impression. It is often convenient to spercify an even number of impressions when considering this type of mould, as impressions positioned on opposite sides of the mould?s centre-line serve to balance the mould.

五、Mould cooling

One fundamental principle of injection molding os that hot material enters the mouls, where it cools rapidly to a temperature at which it solidified sufficiently to retain the shape of the impression. The temperature of the mould os therefore important as it governs a portion of the overall molding cycle. While the melt flows more freely in a hot mould, a greater cooling period is required before the solidified molding can be ejected. Alternatively, while the melt solidifies quickly in a cold mould it may not reach the extremities of the impression. A compromise between the two extremes must therefore be accepted to obtain the optimum molding cycle.

The operating temperature for a particular mould will depend on a number of factors which include the following:type and grade of material to be molded;length of flow within the impression;wall section of the molding;length of the feed system, etc. It is often found advantageous to use a slightly higher temperature than is required just to fill the impression, as this tends to impreove the surface finish of the molding by minimizing weld lines, flow marks and other blemishes.

To maintain the required temperature differential between the mould and plastic material, water or other fluid is circulated through holes or channels within the mould. These holes or channels are termed flow-ways or water-ways and the complete system of flow ways is termed the circuit.

During the impression filling stage the hottert material will be in the vicinity of the entry point, i. e. the gate, the coolest material will be at the point farthest from the entry. The temperature of the coolant fluid, however, increases as it passes though the mould. Therefore

to achieve an even cooling rate over the molding surface it is necessary to locate the incoming coolant fluid adjacent to…hot?molding surfaces and to locate the channels containing…heated?coolant fluid adjacent to …cool?molding surfaces. However, as will be seen from the following discussion, it is not always practicable to adopt the idealized appreach and the designer must use a fair amount of common sense when laying out coolant circuits if unnercessarily expensive moulds are to be avoided.

Units for the circulation of water and other fluids are commercially available. These units are simply connected to the mould via flexible hoses, with these units the mould?s temperature can be maintained within close limits. Close temperature control is not possible using the alternative system in which the mould is connected to a cold water supply.

It is the mould designer?s responsibility to provide an adequate circulating system within the mould. In general, the simplest systems are those in which holes are bored longitudinally through the mould plates. However, this is not necessarily the most dfficient method for a particular mould.

When using drillings for the circulation of the coolant, however, these must not be positioned too close to the impression say closer than 16mm as this is likely to cause a marked temperature66variation across the impression, with resultant molding problems.

The layout of a circuit is often complicated by the fact that flow ways must not be drilled too close to any other hole in the same mould plate. It will be recalled that the mould plate has a large number of holes or recessers, to accommodate ejector pins, guide pillars, guide bushes, sprue bush, inserts, etc. How close it is safe to position in a flow way adjacent to another hole depends to a large extent on the depth of the flow way driolling required. When drilling deep flow ways there is a tendency for the drill to wander off its prescribed course. A rule which is often applied is that for drillings up to 150mm deep the flow way should not be closer than 3 mm to any other hole. For deeper flow ways this allowance is increased to 5 mm.

To obtain the best possible position for a circuit it is good practice to lay the circuit in at the earliest opportunity in the design. The other mould itens such as ejector pins, guide bushes, etc. , can then be positioned accordingly.

六、Designs CAD/CAM

Although CAD/CAM manufactures and suppliers are addressing the challenges mold disigners face when using software, these designers are still grappling with a number of issues. Kevin Crystal, senior quality engineer with The Protomold Co. (Maple Plain, MN)-a rapid injection molding company-reports that the greatest challenges he faces are with file

translation and creating drafted surfaces. IGES, STIP, etc. are imperfect tools as implemented by various CAD packages, ??he explains, Some pack ages create horrible models, some are so-so, and some are pretty reliable , but none that I know of are perfect. Also, draft cause subtle changes in faces, and if you don?t understand what is happening one of two things will happen:your CAD package if it?s good will till you itcan?t create the draft, or your CAD package woll create geometry that has internal faces, hairline cracks or other defects. ??Adequate training is a problem that Jack Mason, general manager Unity Mold LLC-a provider of precision molds used for molding ezotic materials such as stainless stiil and ceramic, and fixtures associated with the various secondary processes-faces. He also finds retraining as a result of equipment/software evolution a challenge.

Excellent techn ical support tops the trio?s list of what to look for in a supplier. Accu-Mold?s Holby also wants up-to-date information and his phone calls returned in a timely manner. Mason of Unity Molds also wants his response time quick-and qualified.

Although not specifically a CAD/CAM challenge, offshore cimpetition is probably the number challenge faced by moldmakers today-especially offshore suppliers. As a result, domistic moldmakers need to capitalizi on values other than lower cost molds they bring to their customers-such as quick turnaround, mold quality and product/process consulting. Today?s CAD/CAM software supports moldmakers? efforts in each of these areas.

Also, as the workforce continues to age and retire, the experience level represented by that workforce diminishes. CAD/CAM systems are beginning to incorporate knowledge-based technology that can be used to capture employees? expertise so that it can be referenced and reapplied. Though curredtly the level of information captured is still fairly simple, it represents a valuable asset for most manufacturers.

In the past, mold, tool and die work often required selecting a CAM system that did a very good job of machining cavities and cores-but was unable to machine the various aspects of mold bases, like slots, channels, coolant lines, ejector and alignment pins. The moldmaker would have to fumble around trying to machine these aspects CAM system. More and more CAM systems are developong broad functionality to be able to handle moldmaking?s broad machining requirements.

Due to time pressures, many shops just don?t have the time to explore all the tools that the software they own already provides. In many cases, software tools that could dramatically affect tumaround time go unused becaude the user simply doe sn?t have the time to learn them.

Often these unused tools complement what a shop already does, making the process much more efficient. An example is automated feedrate optimization-a feature that may already be

in your software. This technology benefits the user in many ways. For instance, it can save on wear and tear on the equipmint, provide a better surface finish, and optimize the feedrati to maximizethe utilization of the machine tool. Ultimately, the real value can be measured in dollars by reducing the time it take to machine the mold.

HSM combines high feedrates with high spindle speeds, specific tools and specific tool motion-delivering faster turnaround and a superior finish. Feedrate optimization lets users run that same job at the most efficient varying feedrates, saving even more time tool wear and money.

To make sure you are maximizing your software investmint, rely on your local reseller who sold you the software. They are there to help you make the most of the software you purchased. A good reseller can quickly give you guidance and point you in the right direction.

To be successful in this highly competitive environmint, moldmakers need to invest in establishing the most efficient and effective processes, and remove bottlenecks form their operations before they look into which software to use. Image courtesy of Cimatron.

The second major challenge is getting to a point when cores, cavities and electrodes can be machined. Companies can only machine so fast and the design of these components in 3-D is where time can be cut in the overall process.

All existing toolpath generators drive tools into corners where the tool?s engage-ment with the material-and consequently the machining load-rises dramatically. To compensate for this, programmers are forced to use smaller stepovers, shallower depths-of-cut, slower spindle speeds and slower feedrates in some combination. This, of course, results in extended ma-chining time, and therefore higher costs.

First, enrure systems can handle translated geometry. The reuse of imported data is a critical part of the process. Systems have to be able to reuse data that may not be created to the same level of tolerance as in theirsystem-allowing for small mathematical errors without causing modeling or manufacturing systems to struggle. The ability for the system to repair geometry with topological problems is an important tool to improve productivity in the process.

Steer your CAD/CAM investmints toward open solutions. CAD/CAM systems that are based on a common geometric modeling engene can share geomitry with 100 percent compatibility and no data translation.

Another area of advancement that is tightly connected to CAD/CAM that is increasingly critical for moldmakers is in the area of tools that support collaboration. . The majority of mold design and manufacture is undertaken by sub-contractors-often in locations remote from

the product OEM. Support for the interaction between the OEM, the mold designer, the moldmakers, and cost control. often this has been poorly supported, with basic means of data transfer and only crude means to review issues, designs and models on a real time basis. This is changing.

The CAD/CAM software plays an important role in this scenario. Moldmakers will need to increasingly CAD/CAM packages not only able to keep up with the technological adcancemints of connected sectots (e. g. . , machine tools), but also able to promote themselves as adopters of new technologies. Taking advantage of leading dege technology is vital.

Again, specialization is crucial. The moldmaking process is a very specific one, but at the some time is a large puzzle made of many pieces:data import, analysis, 3-D design, 2-D plot views, two-to five-axis milling, wire EDM, plunge EDM and data export. We believe that the challenge can be tackled-and won-via choosing a CAD/CAM supplier with a proven experience in the entire process, including developing leading-edge technologies as well as providing excellent customer support. In this regard, an efficient technical support to the customers is of paramount importance to establish a virtuous circle: only a deep knowledge of the daily needs of the users can drive the research and development in the right direction.

Thus, when selecting a CAD/CAM vendor, make sure you find one who takes the time to understand the unique challenges your shop faces and is willing to work closely with you to find the right processes for your shop. Your vendor should keep in close contact with you to ensure the latest equipment-as well as machining techniques-is readily acailable. Making the right CAD/CAM investment is crucial to overcoming design challenges to provede your customers with the shortest leadtimes.

一、我国模具工业现状

由于历史原因形成的封闭式、“大而全”的企业特征，我国大部分企业均设有模具车间，处于本厂的配套地位，自70年代末才有了模具工业化和生产专业化这个概念。生产效率不高，经济效益较差。模具行业的生产小而散乱，跨行业、投资密集，专业化、商品化和技术管理水平都比较低。

据不完全统计，全国现有模具专业生产厂、产品厂配套的模具车间（分厂）近17000家，约60万从业人员，年模具总产值达200亿元人民币。但是，我国模具工业现有能力只能满足需求量的60％左右，还不能适应国民经济发展的需要。目前，国内需要的大型、精密、复杂和长寿命的模具还主要依靠进口。据海关统计，1997年进口模具价值6.3亿美元，这还不包括随设备一起进口的模具；

1997年出口模具仅为7800万美元。目前我国模具工业的技术水平和制造能力，是我国国民经济建设中的薄弱环节和制约经济持续发展的瓶颈。

1、模具工业产业结构的现状

按照中国模具工业协会的划分，我国模具基本分为10大类，其中，冲压模和塑料成型模两大类占主要部分。按产值计算，目前我国冲压模占50％左右，塑料成形模约占20％，拉丝模（工具）约占10％，而世界上发达工业国家和地区的塑料成形模比例一般占全部模具产值的40％以上。

我国冲压模大多为简单模、单工序模和符合模等，精冲模，精密多工位级进模还为数不多，模具平均寿命不足100万次，模具最高寿命达到1亿次以上，精度达到3～5um，有50个以上的级进工位，与国际上最高模具寿命6亿次，平均模具寿命5000万次相比，处于80年代中期国际先进水平。

我国的塑料成形模具设计，制作技术起步较晚，整体水平还较低。目前单型腔，简单型腔的模具达70％以上，仍占主导地位。一模多腔精密复杂的塑料注射模，多色塑料注射模已经能初步设计和制造。模具平均寿命约为80万次左右，主要差距是模具零件变形大、溢边毛刺大、表面质量差、模具型腔冲蚀和腐蚀严重、模具排气不畅和型腔易损等，注射模精度已达到5um以下，最高寿命已突破2000万次，型腔数量已超过100腔，达到了80年代中期至90年代初期的国际先进水平。

2、模具工业技术结构现状

我国模具工业目前技术水平参差不齐，悬殊较大。从总体上来讲，与发达工业国家及港台地区先进水平相比，还有较大的差距。

在采用CAD/CAM/CAE/CAPP等技术设计与制造模具方面，无论是应用的广泛性，还是技术水平上都存在很大的差距。在应用CAD技术设计模具方面，仅有约10%的模具在设计中采用了CAD，距抛开绘图板还有漫长的一段路要走；在应用CAE进行模具方案设计和分析计算方面，也才刚刚起步，大多还处于试用和动画游戏阶段；在应用CAM技术制造模具方面，一是缺乏先进适用的制造装备，二是现有的工艺设备（包括近10多年来引进的先进设备）或因计算机制式（IBM微机及其兼容机、HP工作站等）不同，或因字节差异、运算速度差异、抗电磁干扰能力差异等，联网率较低，只有5%左右的模具制造设备近年来才开展这项工

作；在应用CAPP技术进行工艺规划方面，基本上处于空白状态，需要进行大量的标准化基础工作；在模具共性工艺技术，如模具快速成型技术、抛光技术、电铸成型技术、表面处理技术等方面的CAD/CAM技术应用在我国才刚起步。计算机辅助技术的软件开发，尚处于较低水平，需要知识和经验的积累。我国大部分模具厂、车间的模具加工设备陈旧，在役期长、精度差、效率低，至今仍在使用普通的锻、车、铣、刨、钻、磨设备加工模具，热处理加工仍在使用盐浴、箱式炉，操作凭工人的经验，设备简陋，能耗高。设备更新速度缓慢，技术改造，技术进步力度不大。虽然近年来也引进了不少先进的模具加工设备，但过于分散，或不配套，利用率一般仅有25%左右，设备的一些先进功能也未能得到充分发挥。

缺乏技术素质较高的模具设计、制造工艺技术人员和技术工人，尤其缺乏知识面宽、知识结构层次高的复合型人才。中国模具行业中的技术人员，只占从业人员的8%~12%左右，且技术人员和技术工人的总体技术水平也较低。1980年以前从业的技术人员和技术工人知识老化，知识结构不能适应现在的需要；而80年代以后从业的人员，专业知识、经验匮乏，动手能力差，不安心，不愿学技术。近年来人才外流不仅造成人才数量与素质水平下降，而且人才结构也出现了新的断层，青黄不接，使得模具设计、制造的技术水平难以提高。

3、模具工业配套材料，标准件结构现状

近10多年来，特别是“八五”以来，国家有关部委已多次组织有关材料研究所、大专院校和钢铁企业，研究和开发模具专用系列钢种、模具专用硬质合金及其他模具加工的专用工具、辅助材料等，并有所推广。但因材料的质量不够稳定，缺乏必要的试验条件和试验数据，规格品种较少，大型模具和特种模具所需的钢材及规格还有缺口。在钢材供应上，解决用户的零星用量与钢厂的批量生产的供需矛盾，尚未得到有效的解决。另外，国外模具钢材近年来相继在国内建立了销售网点，但因渠道不畅、技术服务支撑薄弱及价格偏高、外汇结算制度等因素的影响，目前推广应用不多。

模具加工的辅助材料和专用技术近年来虽有所推广应用，但未形成成熟的生产技术，大多仍还处于试验摸索阶段，如模具表面涂层技术、模具表面热处理技术、模具导向副润滑技术、模具型腔传感技术及润滑技术、模具去应力技术、模

具抗疲劳及防腐技术等尚未完全形成生产力，走向商品化。一些关键、重要的技术也还缺少知识产权的保护。

我国的模具标准件生产，80年代初才形成小规模生产，模具标准化程度及标准件的使用覆盖面约占20%，从市场上能配到的也只有约30个品种，且仅限于中小规格。标准凸凹模、热流道元件等刚刚开始供应，模架及零件生产供应渠道不畅，精度和质量也较差。

4、模具工业产业组织结构现状

我国的模具工业相对较落后，至今仍不能称其为一个独立的行业。我国目前的模具生产企业可划分为四大类：专业模具厂，专业生产外供模具；产品厂的模具分厂或车间，以供给本产品厂所需的模具为主要任务；三资企业的模具分厂，其组织模式与专业模具厂相类似，以小而专为主；乡镇模具企业，与专业模具厂相类似。其中以第一类数量最多，模具产量约占总产量的70%以上。我国的模具行业管理体制分散。目前有19个大行业部门制造和使用模具，没有统一管理的部门。仅靠中国模具工业协会统筹规划，集中攻关，跨行业，跨部门管理困难很多。

模具适宜于中小型企业组织生产，而我国技术改造投资向大中型企业倾斜时，中小型模具企业的投资得不到保证。包括产品厂的模具车间、分厂在内，技术改造后不能很快收回其投资，甚至负债累累，影响发展。

虽然大多数产品厂的模具车间、分厂技术力量强，设备条件较好，生产的模具水平也较高，但设备利用率低。

我国模具价格长期以来同其价值不协调，造成模具行业“自身经济效益小，社会效益大”的现象。“干模具的不如干模具标准件的，干标准件的不如干模具带件生产的。干带件生产的不如用模具加工产品的”之类不正常现象存在。

二、模具基本术语

1、成型腔（又称型腔）

注塑模具是由几部分组合在一起形成成型腔，塑料熔体注入成形腔，并在成形腔内冷却成型。是成形腔形成了塑件的形状。因此，成型腔被定义为模具的成型部件。

成形腔由两部分组成：

（i）型腔，即模具的凹模部分，形成塑件的外部形状。

（ii）型芯，即模具的凸模部分，形成塑件的内部形状。

2、型腔和型芯

最简单的模具包括凉快模板。一块模板下陷成形腔，用于形成塑件的外部形状，这块木板被称为型腔板。同理，型芯板上凸起的型芯加工塑件的内部形状。这两块板拼合起来，在型腔和型芯之间形成的空间就是成型腔。

3、浇口套

注塑过程中，塑料以熔融状态从注塑机喷嘴射出，然后流过一通路进入模具成形腔。熔体流过的通路称作主流道，其套称作浇口套。

4、分流道和浇口系统

塑料熔体可能经过浇口套直接进入模具一个或几个型腔，或者熔体从浇口套流出，经过分流道和浇口再进入型腔。

5、定位圈

如果想让熔体没有任何阻碍地进入模具，注塑机的喷嘴和模具主流道必须位于同一轴线上。为确保正确安装，模具必须安装在注塑机的中心部位，（我们可以）通过使用定位圈达到这一目的。

6、导柱和导套

若加工具有均匀壁厚的塑件，必须确保型腔和型芯在同一轴线，这可以依靠导柱和导套实现。导柱安装在一块模板上，合模是进入安装在另一块模板上对应的导套里。

7、固定部分和移动部分

各种模具结构（虽然不同，但均匀）可以划分为两个部分或部件。因此，固定在注塑机固定板的部分称为定模部分，同理，固定在注塑机移动板的部分称为动模部分。这样模具被安装在注塑机上。通常型芯安装在动模部分，其原理如下：塑件冷却后开模，由于熔体的收缩作用使塑件紧紧地包在行星上，这与型芯是安装在定模部分还是动模部分无关。然而塑件包紧在型芯上意味着必需使用某种形式的推出系统。如果型芯安装在动模部分，推出系统运动的动力很容易获得，此外，但型腔模具中，熔体直接进入模具内部，型腔必须固定在定模部分，型芯

必然安装在动模部分。

8、型腔和型芯的安装方法

现在，我们已经知道型芯通常安装在动模部分，型腔安装于定模部分。然而，型腔和型芯在模具内的安装方式有多种。这里介绍两种方式供选择：（i）整体式，型腔和型芯均由一块钢板制成，形成模具结构的一部分；（ii）型腔和型芯由小块钢板或钢块坯料加工，称为镶件，镶装在支撑板上。选择哪种（型腔和型芯的）安装形式在模具设计中十分重要。不过，不论选择哪种方式，最终结果是相同的。不论哪种设计，包含型芯的模板或组合件被称为型芯板，包含型腔的模板或组合件被称为型腔板。

9、型腔制造

当决定制造一个模型时，没有额外工具制造费用，成本通过生产具体量零件来进行预测。有时，超过了预计的数量；有时，他们供不应求，为了满足需要，昂贵的修理成为必须的。

通过机械的，磨的，或者电子发射机械地来制造腔，有一个固定的动力来提高金属迁移速率，切割工具正如金属工具已经被发展成为更重要的和更快的切割；为了每次能得到更深的切割口，磨制的轮子用特殊的刚来定做；为了在加快的等速下燃烧金属EDM机器已经被提高（改进）。已经完全的意识到更快的金属迁移速率导致更多的电子产生，但是同时它已经被意识到更新的腔制造与产生较多的热量有关。如果没有减轻能引起早期的失败，还直接与更高的压力有关。

金属钢谨慎的供应者反对制造压力和坚强地劝告压力-救助的操作，当钢将被热处理时，钢是热处理和预先加热周期的部分热处理规格，然后金属出去压力将被消减。

多数的腔是用变硬的钢制成的。因此，不必进行热处理。对于那些腔在立即制定之后，一个缓解压力的操作将被实施。对于每英寸钢厚环节压力温度作为一个规则大约是100°F，低于调好的热量，大约持续30min，对于钢的制造者，最好检查缓解压力的热量。

钢的制造者已经强调了关于制造压力的信息，但是对于一些原因还没有得到应有的关注。因为一个工具成型应该包括一个工具元素的所有需要，对于符号应该有合适的位置，例如下面：