The revolution that digital technology and car mould make
Time:
Click:290
source:GERMAN CNC Machining
Design of punch craft, structure and the concentration that production technology is technology of car mould production are reflected, the progress of these technologies basically depends on of CAD/CAM/CAE technology rise. The trade is made in car mould, computer application technology and CNC Machining technology more and more the effect that shows its core skill. Current, car mould industry of home is facing unprecedented tremendous opportunity of survival and overspeed development. This kind of development highlights expression to be in the following respects: A huge sum that is diversity above all invests. Day endowment, stage endowment, Euramerican endowment wait for car pattern company a large number of emerge in large numbers; Civilian battalion, appear on the market, state-operated changes make car pattern company intensifying extend and increase investment, and the investment of each enterprise is as high as a few ten million to go to a few 100 million; It is the crucial treatment equipment that car mould makes next -- center of CNC Machining of large dragon door grows into geometrical progression, an enterprise has 10, 20 stage or such 30 facilities are insufficient already to blame; It is high quality talent again rapid to mould industry assemble; Finally is prosperity of car mould market, a lot of pattern companies appear the auspicious situation that demand exceeds supply. A few elements should rely on investment, equipment, talent and market finally change of manufacturing technology talent becomes productivity. Face current new condition, technology especially the development of crucial technology, have far-reaching sense to the development of car mould industry. The core technology that design of mould of CAE technology car makes is punch engineering technology. Punch engineering technology includes process design, shape model design of face design, Xiu Chong point waits all involving a moment the product shapes partial technology. Accordingly, punch technology level decided the design of the mould makes a standard. At present domestic mould production level is the same as international the biggest difference of advanced level reflects the difference in punch craft level to go up. Before the experience that our punch engineering technology basically relies on a person, as home high quality automobile body produces cycle to shorten, the experience that relies on the past will finish punch craft impossible already. One, the maturity of CAE software and should in order to is finite yuan of CAE technology that imitate analysis software is a delegate in the world application already had history of nearly 30 years. Come nearly 10 years, plasticity is out of shape theory shapes in board makings the application in the technology obtained very great progress, the application in making CAE technology is made in car mould becomes very mature, CAE application Yu Chong presses craft to design, can make time trying a model reduces 50% above. Current, CAE technology already made the tool with foreign large car and mould essential industry. The wide application of CAE, should be attributed to CAE business software develop energetically, among them representative software has: The LS-DYNA3D software of lab of stuff of country of LawrenceLivemore of ● United States; The PAM-STAMP software of company of ● France ESI; The OPTRIS software of company of ● France DYNAMICSOFTWARE; The Dynaform software of company of ETA of ● United States; The Autoform software of company of ● Switzerland Autoform. These software each has his strong point, shape to board makings the analysis is very professional and practical. Current, home's top-ranking car pattern company used CAE software, be in the majority with the application of Autoform software. Limited company of Tianjin car pattern passes effort of 2 years, CAE application rate had been achieved 100% , apparent ground shortened the mould debugs cycle. If say, the sophisticated technology that before a few years the mould makes is CAD, so now is CAE. Can forecast, a few years CAE technology will be in factory of domestic car mould to apply mediumly henceforth, gain ground euqally just like today's CAD technology. 2, software of CAE of tradition of design of auxiliary punch technology can be done only shape sexual analysis, and need professional does many pre-treatment, if bisect analyse result is dissatisfactory, still need to come again from the beginning. Because traditional CAE software is the method of a kind of test and verify only, basically use at the comparison of plan, what cannot be used at craft is auxiliary, create CAE technique thereby long-term dissociate at producing a course beyond. CAE software already developed to be able to be done not only nowadays shape purely analysis, and the whole process that can share punch technology. We say assist punch technology for the computer. The respect is designed in craft, automatic or what CAE had punch way is auxiliary affirmatory, fast generate those who draw the affirmatory, long foul line that extends dimension of face, preform to spread out wait for very practical function, the result that and precision far outclass is gotten by the person's experience or place of other CAD method reachs. Analysing a respect, shape in the light of punch, make rush certainly cut deflection of angle, crest line into parts, pull Yan Chong to attack slippery mark, face to shape the character, force that approach a limit, shape all sorts of analysises such as force get perfecting, the extensive sex that analyses content and practical exceeded original CAE content already. Current, CAE software already became a mould to design the essential one part in flow. It faces final user highly, handlers both neither needs very intimate CAE knowledge, also do not need overmuch debug experience actually to be able to use it conveniently. In the developed country, the imitate accordance of result of CAE software analysis is more than 95% , even if first application, also can achieve 60 ～ the accuracy rate of 80% . Contrast in plan especially, shape abundant spends an analysis, cannot exhibit flange to spread out wait for a respect, the result of CAE is very accurate. Current, the stress that CAE technology develops is spring back analysis and craft parameter is automatic optimize, if solved these two difficult problem, will bring revolutionary progress again. Hypostatic design applies company of pattern of current home car to already applied 2 dimension CAD extensively in structural design, partial enterprise uses three-dimensional and hypostatic design in the design of partial pattern, only few number enterprise can accomplish the hypostatic design of 100% . Should saying hypostatic design replaces 2 dimension CAD is the inevitable trend of development. The advantage with hypostatic the biggest design is a design the process is very intuitionistic, can have detailed and true description to the structure, ensure the rationality of the design, analyse in intensity of mould static state and dynamic interference examination, mould wait for a respect to have clear advantage. Below the condition that designing personnel seasonedly to be in short supply in great quantities currently especially, new the personnel that pursues mould design designs an elementary course from entity, can pass short-term groom, 3, can be in after 4 months of others show next better land to finish mould substance to design. A greener reached same level in the past, the time that wants 1 ～ 2 years at least. One, the influence substance that entity designs whole to production technological process is designed not only make designed a method to produce a change, and make produce whole technological process to also produce tremendous change. 1, change manufacturing entity design to make industry trend turns production without the graph without the graph. The company abandons completely 2D blueprint, figure of OK and economic 2D gives graph time, can reduce about 25 ～ from this the mould structure of 40% designs time. Tell from this meaning, entity designs excel 2D design. Having a graph to turn production is to build the base that realized complete digitlization in manufacturing process over, hypostatic design and digitlization are made is each other is requirement but not be each other for sufficient condition. Hypostatic design is OK and ecbolic turn production without the graph, change production to just can reflect the dominant position of hypostatic design adequately conversely without the graph. Manufacture level and manufacturing efficiency without what the graph changes production to be able to raise car pattern in the round, it is period of time will pass CAD/CAM henceforth two kinds of technologies are interactive, obtain the key of technical new breakthrough. Design of substance of Nextpage2, fact CNC Machining can support bubble directly model CNC Machining, cancel traditional bubble fact model make by hand, can shorten greatly production cycle and raise production precision. 3, the NC course that full numerical control changes treatment substance to design range of construction of direct support mould turns treatment. Although most enterprise uses numerical control machine tool to machine mould construction face, but still did not break away from artificial knowledge graph and hand to move an operation, the time with wasteful institute of spot knowledge plan and the discontinuous sex that operate artificially, cause treatment efficiency to drop greatly, factitious error increases greatly. When machining mould construction face by artificial operation commonly, flour extraction exceeds 40% very hard, and the tectonic face that uses NC program to change treatment pattern, can raise the flour extraction of the machine tool 20% ～ 50% (machine tool of flour extraction = is actual cutting handling time / machine tool total man-hour) . Visible, the latent capacity that increases flour extraction is very big. Anyhow, the result that designs entity is delivered to follow-up working procedure directly, can make the efficiency of each working procedure gets rising. Conversely, if hypostatic design faces a design only, still be design purpose in order to give 2D picture finally, the advantage of hypostatic design will sell at a discount greatly. 2, the biggest question that raises entity to design efficiency substance to design existence is, efficiency of the design when applying at first is not tall. Want to solve this problem, can take the following step: 1, aggrandizement Training Within Industry. The content of Training Within Industry includes the field such as technological process of software application, design and method groom. 2, do well fundamental development. Hypostatic design needs to accumulate, need is developed a series of hypostatic standard component and hypostatic example mould, so that can make the small tool of local construction automatically,wait. 3, change idea. Hypostatic design is not pure the change that is design means, more important is treatment of the foreword after it came true and production digitlization, turn production without the graph namely. Although hypostatic design was design itself to bring a trouble, but it is more easy to make make however. We answer to be jumping-off place in order to improve efficiency, it is very necessary that will hypostatic design is regarded and must importunate thing. The develops mould processing technique development of mould processing technique is the development of CNC Machining technology. CNC Machining by pure model face treatment develops comprehensive CNC Machining; By the mould treatment develops fact CNC Machining; By low speed treatment develops treatment of high speed high accuracy; By develop to turn treatment without graph, little person or nobody with operating the treatment that press a plan artificially. The processing technique that develops mainly currently basically includes: ● fact CNC Machining; High accuracy of ● high speed is machined; ● sets a cast to change with efficient treatment; ● total number accuses to turn treatment; Nobody turn ● little person treatment; An outfit that ● benchwork makes do not deserve to be repaired less. Fact CNC Machining and full numerical control change processing technique had discussed in advanced already article, other technology undertakes summarizing here. One, treatment of high speed high accuracy is current high speed high accuracy is machined already by international advanced company is used generally, home also is gaining ground stage by stage and the trend matures. The purpose that high speed machines, not pure it is to improve treatment efficiency, more important is the high accuracy treatment that realizes small step pitch, low remain through high speed. 1, the current situation that high speed machines is current everybody thinks generally: 6000r/min of machine tool turn up is treatment of accurate high speed, amount to above of 8000 ～ 10000r/min to be high speed treatment. Actually, the cutting tool of tall wear-resisting of the card head that chooses tall stiffness only and cutter hub, high accuracy, maintain rotate speed and photograph of speed taking a knife to suit, just realize true high speed treatment possibly. The treatment of car mould face belongs to the treatment of free curved surface with sophisticated height, can realize high speed treatment, more important is to depend on the dynamic precision that curved surface of numerical control machine tool machines, is not to depend on the static precision that says in trade catalogue of common machine tool. But regretful is, the dynamic precision that complex curved surface machines the machine tool returns the standard with uniform neither one to be able to offer reference. One applies to the mill of high speed numerical control of car mould, the integral performance such as the consecutive working hours that must have tall stiffness, high accuracy, high rotate speed, good dynamic performance, high speed to fall at the same time. And do these function depend on is the special software program that the structure of the machine tool, function that controls a system, place chooses, lathe bed cast still solders armor plate? Is main shaft ram or circle cover a bucket? Be line form slideway or sliding slideway? Whether does main shaft have refrigeration? Is half closed circuit still full closed-loop control? Whether to use grating feet to wait for an element. If introduce by manufacturer only rotate speed of machine tool main shaft tall or it is speed of planar and linear feed tall, be impossible to realize mould face high speed to machine. Current, company of Euramerican partial car pattern used 15000r/min of true rotate speed prep above and actual feed speed to obtain the high speed treatment of 10m/min, and Japanese company still basically stops in accurate high speed to machine level, without giving thought to rotate speed how, actual curved surface machines feed speed to break through 6m/min very hard. From use a circumstance actually to look, if reached true high speed, the maintenance of the price of the charge of cutting tool, machine tool and machine tool charge is at present cost of our home mould is accepted hard. Resemble 30000r/min, 60m/min such high speed machining center, belong to medium or small machine tool, apply to the model that note model only model antrum treatment. The processes speed and precision actually on any account of curved surface of process designing of treatment of high accuracy of Nextpage2, high speed, besides decide by the function of the machine tool beyond, below certain condition, more depend on treatment craft and technology of numerical control process designing. We should take seriously and technology of process designing of research numerical control is mixed to treatment precision the influence of efficiency. For example: Cutting tool is instant the curvature radius of feed speed and cutting tool contrail is direct and relevant, when curved surface change is very big, no matter the F value of set is how old, actual and average rate taking a knife is met very low. And if F value setting is too big, can have appeared to cut with the phenomenon that apply part, reduce badly model face precision. Traditional copy treatment to make sure crest line is clear, use treatment of perpendicular crest line commonly. With this kind of method, process designing is simple but change of effective treatment rate is great, affected treatment efficiency badly. Method of major now process designing is right whole model the face makes 45 ° treatment, the advantage is process designing simple, can make sure major crest line is clear, but treatment efficiency is not tall still. The method of process designing of treatment of high speed high accuracy and the problem that should note are very much, list simply as follows: ● divides a process designing and treatment according to characteristic of curved surface geometry; ● machines direction to choose suitable crest line, big curvature direction takes a knife, reduce the slowdown that bend causes; ● machines linear velocity and feed speed photograph to cooperate, maintain actual cutting as far as possible the amount is fixed; Curved surface of ● big slope is machined, row pitch just keeps equidistant up in curved surface tangent; ● changes row pitch according to the place of curved surface, be like: Convex horn row spacing adds Qing Dynasty of close, sunken round horn to wait fortunately; ● reasonable arrangement processes the order of cent piece, because cutting tool wears away,avoid to cause model the face breaks difference. Anyhow, the NC process designing that high speed high accuracy machines is bothered more than common treatment, the process designing man-hour with only much investment and process designing personnel just finish process designing to work likely, but because this kind of devoted meeting machines the rise and gets twice get one's own back of efficiency and precision. 3, the target that the target high accuracy that high accuracy machines machines reduces clamp to repair to the greastest extent namely. For instance: Clearance of fluctuation model point is machined directly reach the designated position; Direct installation need not debug punching punch-die; Pull the curved surface that extend a pattern very tall smooth compliance, without the trace that receive a knife; Of protruding arris relatively Gao Guangjie is spent and experience of reentrant have nothing to do with is waited a moment. 4, the rough machining that rough machining high speed turns a convention is general through deep cutting, low rotate speed, low feed treatment is finished. Rise as what the machine tool machines speed, the processability of the machine tool can have produced a change. The treatment that numerical control machine tool issues in condition of low rotate speed, low feed is torsional very big, and total power is very low however, play of machine tool efficiency does not come out. Machine efficiency to rise, now the development trend of rough machining is medium speed, medium eat deep, tall feed, multilayer treatment is finished. Although the number of plies of treatment increased, but because machine tool power came true the biggest change, can make machine efficiency to raise 30% above commonly. The technique that rough machining high speed changes, special the characteristic that got used to wide choice unifinication to machine a machine tool, can yet be regarded as is worth one kind to popularize the new technology that draw lessons from. 2, set a cast to change set with efficient treatment piece treatment is machined always in the mould very large proportion is held in the quantity, the sense when reducing this division of labor effectively is very great. Best treatment method is little cutting is mixed without cutting, the stress that develops at present is set namely piece cast is changed and reduce treatment range to the greastest extent through reasonable design. 3, nobody turn little person the order that treatment processes as the mould is changed, the center that the machine tool machines is changed, little person and nobody turn treatment is a kind of inevitable development trend. Nobody change treatment to be able to reduce labour cost and mistake to the greastest extent, can realize the 24 serial production of the hour. In labor protection condition is at present taller and taller, more and more circumstances issue holiday, little person and nobody change processing technique to make a kind of natural choice. Nobody are changed can change from little person, from finish machining, or from pull big the respect that two time between realize the most easily etc begins to execute. Nobody are changed should closely around raise machine tool utilization rate, reduce error rate to develop. 4, an outfit that benchwork makes an outfit that does not deserve to repair a when raise machining level main purpose and main show less to accomplish benchwork to make namely do not deserve to be repaired less. Eliminating benchwork is the ideal that a few pattern companies of foreign put forward and catchword, it represented a mould centrally to make development way of the technology: Adopt CAD technique rise and realize complete digitlization to make with little person nobody turn treatment; Adopt CAM technique rise and implementation is assembled, grind close, push those who grind job of job waiting for clamp is efficient; Adopt CAE technique rise and realize a mould to debug one hair success. Car mould makes a technology rely on the application of the new and high technology such as the computer to already developed a new level. Should take seriously currently and differ, but summary rises outside notting have it is design of punch craft, structure and 3 respects such as production technology, of its place correspondence is CAD/CAM/CAE technology rise. The trade is made in car mould, computer application technology and CNC Machining technology more and more the effect that shows its core skill. CNC Milling