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本科畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告
題目名稱
遙控器面板注塑模具設(shè)計(jì)
學(xué)生姓名
專業(yè)班級(jí)
學(xué)號(hào)
一、 選題的目的和意義：
模具是工業(yè)生產(chǎn)中使用極為廣泛的基礎(chǔ)工藝裝備。在汽車(chē)、電機(jī)、儀表、電子、通信、家電和輕工業(yè)等行業(yè)中，60%～80%的零件都要依據(jù)模具成形，并且隨著近年來(lái)這些行業(yè)的迅速發(fā)展，對(duì)模具的要求越來(lái)越迫切，精度要求越來(lái)越高結(jié)構(gòu)要求也越來(lái)越復(fù)雜。模具已廣泛應(yīng)用于電機(jī)電器產(chǎn)品、電子和計(jì)算機(jī)產(chǎn)品、儀表、家用電器、汽車(chē)、軍械、通用機(jī)械等產(chǎn)品的生產(chǎn)中。
本課題要求設(shè)計(jì)遙控器面蓋的注塑模具，注塑成型是現(xiàn)代塑料工業(yè)中的一種重要的加工方法 注塑模具由于其專用性和獨(dú)一性，在設(shè)計(jì)時(shí)主要考慮到工廠現(xiàn)有的設(shè)備情況、產(chǎn)品的生產(chǎn)批量及模具的壽命。這遙控器面蓋為批量生產(chǎn)，但由于該塑料制件尺寸比較小，模具的結(jié)構(gòu)相對(duì)比較簡(jiǎn)單，模具制造成本比較底，在生產(chǎn)時(shí)主要考慮到模具壽命盡量要高，所以對(duì)模具材料提出了較高的要求。遙控面蓋是一個(gè)外形件，尺寸精度要求不高，但對(duì)外層的表面粗糙度要求比較高，因此在設(shè)計(jì)時(shí)在能順利成型出塑料制品的情況下，對(duì)模具型腔的表面拋光工藝要求比較高。
從總體結(jié)構(gòu)上來(lái)看，該制件是一個(gè)尺寸較小，壁厚較薄，整體結(jié)構(gòu)比較簡(jiǎn)單的塑料件。由于壁厚較薄，脫模時(shí)如果受力不均則易會(huì)產(chǎn)生變形從而出現(xiàn)制品缺陷，因此對(duì)脫模機(jī)構(gòu)及冷卻系統(tǒng)的設(shè)計(jì)要求較高。
按照現(xiàn)今注塑模具設(shè)計(jì)的總體趨勢(shì)，注塑模具的設(shè)計(jì)已很少使用手工繪圖或完全由二維軟件來(lái)進(jìn)行設(shè)計(jì)，且模具標(biāo)準(zhǔn)件已在注塑模具設(shè)計(jì)中大量采用。
因此本課題將采取使用模具二維軟件CAD和三維軟件Pro/E綜合使用來(lái)進(jìn)行模具的結(jié)構(gòu)設(shè)計(jì)，且在模具設(shè)計(jì)的過(guò)程中綜合考慮模具制造工藝及注塑成型工藝。
二、 國(guó)內(nèi)外研究綜述：
塑料工業(yè)是當(dāng)今世界上增長(zhǎng)最快的工業(yè)門(mén)類之一，而注塑模具是其中發(fā)展較快的種類，因此，研究注塑模具對(duì)了解塑料產(chǎn)品的生產(chǎn)過(guò)程和提高產(chǎn)品質(zhì)量有很大意義。工業(yè)發(fā)展水平的不斷提高，工業(yè)產(chǎn)品更新速度加快，對(duì)模具的要求越來(lái)越高，盡管改革開(kāi)放以來(lái)，模具工業(yè)有了較大發(fā)展，但無(wú)論是數(shù)量還是質(zhì)量仍滿足不了國(guó)內(nèi)市場(chǎng)的需要， 目前滿足率只能達(dá)到70%左右。造成產(chǎn)需矛盾突出的原因，一是專業(yè)化、標(biāo)準(zhǔn)化程度低，除少量標(biāo)準(zhǔn)件外購(gòu)?fù)?，大部分工作量均需模具廠去完成。加工企業(yè)管理的體制上的約束，造成 模具制造周期長(zhǎng)，不能適應(yīng)市場(chǎng)要求。二是設(shè)計(jì)和工藝技術(shù)落后，如模具CAD/CAM技術(shù)采用不普遍，加工設(shè)備數(shù)控化率低等，亦造成模具生產(chǎn)效率不高、周期長(zhǎng)?？傊峭狭藱C(jī)電、 輕工等行業(yè)發(fā)展的后腿。
模具按國(guó)家標(biāo)準(zhǔn)分為十大類，其中沖壓模、塑料模占模具用量的主要部分。按產(chǎn)值統(tǒng)計(jì)，我國(guó)目前沖壓占50%-60%，塑料模占25-30。國(guó)外先進(jìn)國(guó)家對(duì)發(fā)展塑料模很重視，塑料 模比例一般占30%-40%。國(guó)內(nèi)模具中，大型、精密、復(fù)雜、長(zhǎng)壽命模具比較低，約占20%左右，國(guó)外為50%以上。我國(guó)模具生產(chǎn)企業(yè)結(jié)構(gòu)不合理，主要生產(chǎn)模具能力集中在各主機(jī)廠的 模具分廠(或車(chē)間)內(nèi)，模具商品化率低，模具自產(chǎn)自用比例高達(dá)70%以上。國(guó)外，70%以上 是商品化的。
注塑成型是現(xiàn)代塑料工業(yè)中的一種重要的加工方法 ,模具是現(xiàn)代化工業(yè)生產(chǎn)的重要工藝裝備，被稱為“工業(yè)之母”。而塑料模具又是在整個(gè)模具工業(yè)中的一枝獨(dú)秀，發(fā)展極為迅速。世界上注塑模的產(chǎn)量約占塑料成型模具總產(chǎn)量的 50 %以上 ,尤其是家電盒型注塑產(chǎn)品需求量不斷增加，注塑成型能一次成型形狀復(fù)雜、尺寸精確的制品 ,適合高效率、大批量的生產(chǎn)方式 ,以發(fā)展成為熱塑性塑料和部分熱固性塑料最主要的成型加工方法 ，注塑模具的設(shè)計(jì)與制造主要依賴于設(shè)計(jì)者的經(jīng)驗(yàn)和技師的制造技藝 ,一般需要經(jīng)過(guò)反復(fù)調(diào)試和修模才能正式投入生產(chǎn) ,這種傳統(tǒng)的生產(chǎn)方式不僅使產(chǎn)品的生產(chǎn)周期延長(zhǎng) ,生產(chǎn)成本增加 ,而且難以保證產(chǎn)品的質(zhì)量，要解決這些問(wèn)題 ,必須以科學(xué)分析的方法 ,研究各個(gè)成型過(guò)程的關(guān)鍵技術(shù)，塑料注塑成型是一個(gè)復(fù)雜的加工與物理過(guò)程 ,為實(shí)現(xiàn)注塑產(chǎn)品的更新?lián)Q代 ,提高企業(yè)的競(jìng)爭(zhēng)能力 ,必須進(jìn)行注塑模具設(shè)計(jì)與制造及成型過(guò)程分析的 CAD/ CAM/ CAE集成技術(shù)的研究國(guó)外注塑模 CAD/ CAM/ CAE 技術(shù)研究的成果有關(guān)統(tǒng)計(jì)數(shù)據(jù)表明:采用注塑模 CAD/ CAE/CAM 技術(shù)能使設(shè)計(jì)時(shí)間縮短 50 %,制造時(shí)間縮短 30 %,成本下降 10 %,塑料節(jié)省 7 % 注塑模計(jì)算機(jī)模擬技術(shù)正朝著與 CAD/ CAE無(wú)縫整體集成化方向發(fā)展 ,注塑 CAD 所構(gòu)造的幾何模型為實(shí)現(xiàn)注塑模 CAE技術(shù)提供了基本的幾何拓?fù)湫畔⒑吞卣餍畔?,注塑模 CAE的目標(biāo)是通過(guò)對(duì)塑料材料性能的研究和注射成型工藝過(guò)程的模擬和分析 ,為塑料制品的設(shè)計(jì)、材料選擇、模具設(shè)計(jì)、注射成型工藝的制定及注射成型工藝過(guò)程的控制提供科學(xué)依據(jù) 。 現(xiàn)時(shí)國(guó)際上占主流地位的注射模CAD軟件有Pro/E、I-DEAS、UG、SolidWorks等；結(jié)構(gòu)分析軟件有MSC、Analysis等；注射過(guò)程數(shù)值分析軟件有MoldFlow等；數(shù)控加工軟件有MasterCAM、Cimatron等.現(xiàn)代模具生產(chǎn)中采用集特種加工設(shè)備為一體的數(shù)控加工中心加工型腔零件，減少工序間的銜接環(huán)節(jié)，減少多次裝夾定位造成的誤差，減少經(jīng)手人員的數(shù)量，質(zhì)量和周期由計(jì)算機(jī)數(shù)據(jù)處理人員控制，盡可能避免人為失誤，使得生產(chǎn)周期和成本估算的精確性大大提高，生產(chǎn)質(zhì)量也得到保證。目前注塑模設(shè)計(jì)方法比較多，但是最常用的設(shè)計(jì)步驟如下：
（1）了解設(shè)計(jì)任務(wù)
（2）塑件的結(jié)構(gòu)工藝性分析
（3）分型面及澆注系統(tǒng)的設(shè)計(jì)
（4）模具設(shè)計(jì)方案論證
（5）主要零部件的設(shè)計(jì)計(jì)算
（6）成型設(shè)備的校核計(jì)算
（7）繪制模具裝配圖
（8）繪制零件圖
（9）編寫(xiě)設(shè)計(jì)計(jì)算說(shuō)明書(shū)
三、 畢業(yè)設(shè)計(jì)（論文）所用的主要技術(shù)與方法：
1.基本設(shè)計(jì)思路
塑件注塑成型工藝分析：做出零件的三維造型，對(duì)塑件進(jìn)行結(jié)構(gòu)工藝性分析，分析塑件塑料的成型工藝性及確定注塑成型工藝參數(shù)。
注射機(jī)型號(hào)的選擇：初選注射機(jī)并確定注射成型的工藝參數(shù)，注射機(jī)相關(guān)計(jì)算的校核和成型設(shè)備。
模具結(jié)構(gòu)設(shè)計(jì)方案論證：分型面的選擇、澆注系統(tǒng)的設(shè)計(jì)方案選擇、成型部分及其零件設(shè)計(jì)、排溢系統(tǒng)設(shè)計(jì)、脫模機(jī)構(gòu)的設(shè)計(jì)、冷卻系統(tǒng)的設(shè)計(jì)，模體與支撐連接零件的結(jié)構(gòu)。
遙控器面蓋模具相關(guān)結(jié)構(gòu)設(shè)計(jì)的計(jì)算，主要包括澆注系統(tǒng)的計(jì)算、成型零件的結(jié)構(gòu)設(shè)計(jì)和計(jì)算、脫模方面的計(jì)算以及冷卻系統(tǒng)的相關(guān)設(shè)計(jì)計(jì)算，模架的確定和標(biāo)準(zhǔn)件的選用和成型設(shè)備的校核計(jì)算。
2.擬采用的途徑（研究手段）
主要采用模具CAD/CAM/CAE等軟件來(lái)進(jìn)行模具的設(shè)計(jì)，在模具設(shè)計(jì)過(guò)程中要綜合考慮到模具制造工藝以及注塑成型工藝，主要包括：
（1）根據(jù)遙控面蓋技術(shù)要求進(jìn)行相關(guān)的計(jì)算、分型面的設(shè)計(jì)、確定型腔和型芯、模具結(jié)構(gòu)的詳細(xì)設(shè)計(jì)、塑料充填過(guò)程分析等幾個(gè)方面。
（2）利用PRO/E或者UG確定分型面，生成上下模腔和模芯，進(jìn)行側(cè)抽芯機(jī)構(gòu)的設(shè)計(jì)，再進(jìn)行流道、澆口以及冷卻水管的布置。
（3）利用PRO/E的EMX4.1來(lái)自動(dòng)生成模板、標(biāo)準(zhǔn)模架及模具標(biāo)準(zhǔn)零件，并將PRO/E生成總裝圖轉(zhuǎn)換.dwg擴(kuò)展名的圖，再用Autocad編輯出正確清晰的2D總裝圖。
四、 主要參考文獻(xiàn)與資料獲得情況：
[1] 武良臣,呂寶占 《互換性與技術(shù)測(cè)量》 北京郵電出版社 2009
[2] 莫亞林，侯守明《工程圖學(xué)》中國(guó)電力出版社2007
[3]彭建生，《模具設(shè)計(jì)與加工速查手冊(cè)》機(jī)械工業(yè)出版社2005
[4] 《塑料模設(shè)計(jì)手冊(cè)》編寫(xiě)組．塑料模設(shè)計(jì)手冊(cè)．第二版．北京：機(jī)械工業(yè)出版社，1994
[5] 彭建生，秦曉剛《模具技術(shù)問(wèn)答》機(jī)械工業(yè)出版社2000
[6] 鄂大辛 ，《成型工藝與模具設(shè)計(jì)》北京理工大學(xué)出版社2007
[7] 馬金駿，塑料模具設(shè)計(jì)．北京：中國(guó)科學(xué)出版社，1985
五、 畢業(yè)設(shè)計(jì)（論文）進(jìn)度安排（按周說(shuō)明）
第一周，收集資料
第二周，進(jìn)行部分?jǐn)?shù)據(jù)計(jì)算并撰寫(xiě)論文大綱
第三周，撰寫(xiě)畢業(yè)設(shè)計(jì)論文
第四周，運(yùn)用AutoCAD設(shè)計(jì)部分零件圖與裝配圖
六、 指導(dǎo)教師審批意見(jiàn)：
指導(dǎo)教師： （簽名）
年 月 日
5
附錄：
外文資料與中文翻譯
外文資料：
Modern mold making
Ⅰ.the stamping die development history and status of technology
?
In 1953, the Changchun First Automobile Works in China for the first time established a die shop, the car plant in 1958 began manufacturing automotive panel die. 60 years of the 20th century began producing fine blanking dies. Come a long road of development, China has formed about 300 billion (not including Hong Kong, Macao and Taiwan statistics.) Production capacity of various types of stamping dies. Formed, such as Ningbo and Zhejiang HUANGYAN region "Die village"; Guangdong Corporation and some large rapid rise of township enterprises, K el o n, M id e a, K on ka and other groups have established their own mold manufacturing center; joint ventures and wholly foreign-owned the mold companies now have thousands. With the pace with international standards continues to accelerate, increasing market competition, production and design of the mold has been growing recognition that product quality, cost, and new product development capacities. Mold manufacturing technology to measure a country's manufacturing sector has become an important indicator of the level, and largely determine the survival space. At present, China stamping die, whether in quantity or in quality, technology and other capabilities have made significant progress, but with national needs and the world advanced level, the gap is still great. In the international competition situation, I had the mold industry has rapidly developed, many specialized research centers continue to die set up, mold steel of the structure and made significant achievements, but there is still a big gap. First, imports of high-tech mold most of the large precision molds, mold and exports most of the lower middle and low-tech die, so high-tech high-grade die stamping die market, the overall satisfaction rate is lower than satisfaction rate, which mold development has lagged behind the production of stamping parts, and low-technology market to meet the rate of middle and low die stamping die is higher than the overall market to meet the rate; second is due to the price of the mold is much lower than international market prices, has some competition force, so its prospects in the international market; third in recent years, Hong Kong-and Taiwan-owned, foreign-funded enterprises in China developed rapidly in a large number of these enterprises stamping dies produced for own use no precise statistics, it is not included in the figures being.
Ⅱ. Modern mold manufacturing technology development
?The development of modern technology should die mold products to meet the "short delivery time", "high precision", "good quality", "low price" request for service. Urgent need to develop to meet this requirement as a number of
?(1) to comprehensively promote universal DBD / DBM / DBE technology
?Die DBD / DBM / DBE technology is the development direction of mold design and manufacturing. With the computer software development and progress, universal DBD / DBM / DBE technology, conditions are ripe, the businesses will increase DBD / DBM technical training and technical service efforts; further expand the scope of DBE technology. The development of computers and networks are making DBD / DBM / DBE technology trans-regional, cross-enterprise, campus-wide in the industry as possible to promote and achieve re-integration of technical resources to enable virtual manufacturing possible.
?(2) High-speed milling
The development of foreign high-speed milling process in recent years, significantly improve the processing efficiency, and to get a high surface finish. In addition, the module can also be processed with high hardness, but also with low temperature rise, thermal deformation and so on. High-speed milling technology, automotive, home appliance manufacturing industry in the large cavity mold injected new vitality. It currently has more agile, intelligent, integrated direction.
(3) die scanning and digitizing system
High-speed scanner provides scanning system and mold from the model or in kind to the processing of the scanned model of the desired number of features required, greatly reducing the manufacturing cycle in the development of mold. Some quick scan system can be quickly installed in existing CNC milling machine and machining center, for fast data acquisition, automatic generation of a variety of CNC machining process, the DBD data in different formats, for mold manufacturing "reverse engineering . "
?(4) the degree of standardization to improve die
Degree of standardization of the mold is increasing, estimates that the current use of standard mold coverage has reached about 30%. Developed countries is generally about 80%.
?(5) high-quality materials and advanced surface treatment technology
Application of high quality steel and the corresponding surface treatment technology to improve the life of the mold it is very necessary. Mold heat treatment and surface treatment can fully mold steel material properties play a key part. Direction of development of mold heat treatment is the use of vacuum heat treatment. In addition to the mold surface should improve the development of advanced technologies such as laser surface treatment.
?
?(6) Mold Polishing
?Automation, intelligent mold surface quality of mold life, the appearance of quality parts and so have a greater impact of automation and intelligence of the grinding and polishing methods replace the existing manual in order to improve the quality of the mold surface is important trends.
??(7) die development of automatic processing system
???This is our long-term development goals mold industry. Automatic mold machine processing system should be more than the rational combination; with accompanying plate positioning fixture or positioning; a complete equipment, tool CNC database; a complete CNC flexible synchronization system; a quality monitoring and control system. Of course, as the user to choose the right equipment, if the selection properly, not only can not make money but make the machine work into the bitter situation.
??Ⅲ. Modern mold manufacturing technology trends
?????Die technology is mainly towards the future development trend of information technology, high-speed high-precision production and development. Therefore, the design technology, the development focus is to promote DBD / DBE / DBM technology, and continue to improve efficiency, especially in sheet metal forming process of the computer simulation analysis. Die DBD, DBE technology should be declared human, integration, intelligence and network direction, and improve the mold DBD, DBM system-specific level. To improve the DBD, DBE, DBM technology, establish a complete database and development of the mold expert systems and improve software usability is very important.
? ?From the processing technology, the development focused on high-speed processing and precision machining. At present, the development of highly processed high-speed milling, high speed polishing and high-speed electronic processing and rapid tooling technologies. At present, the development of precision machining parts precision mold and the surface roughness of less 1μm Pa ≤ 0.1μm variety of precision machining.
Ⅳ,.the modern mold manufacturing
1.CAD/CAE/CAM computer-aided design, simulation, manufacturing integration
CAD / CAE / CAM integration, integration technology is the most advanced modern mold making the most reasonable mode of production. Use of computer-aided design, support engineering and manufacturing systems, according to the respective mold parts designed to prepare the NC machining of parts from design to manufacturing process is an inevitable process, which is from CAD / CAE / CAM system carried out, The processing line cable input directly from the processing machine, can be used in the preparation of procedures of processing the system analog functions, will be part tool, tool holder, fixture, platform and tool speed, path, etc. are displayed, to check the program prepared correctness. In short the CAD / CAE / CAM system development and simulation of processing can not fully understand the problems identified, resulting in processing prior to prepare the complete set of processing change work, which for the efficient and accurate processing of the mold has a very important part .
2. Advanced equipment in the modern mold making role
The inevitable trend of modern mold making, machining is possible to replace the manual process, especially now that CNC lathes, multi-axis machine tools, CNC mold engraving machine, EDM machine, CNC precision grinding machines, coordinate measuring machines, scanners and other modern equipment widely used in factories, but most of these devices are basically the application of the procedures used CAD / CAE / CAM system to produce, the operator of work procedures in accordance with the provisions of work piece clamping, with a cutting tool and operation of the machine will be able to automatically complete the processing tasks, and created the ideal mold parts or complete the processing operation for the next part.
3. Die materials and surface treatment technology
Due to improper selection and use of materials, resulting in premature failure of the mold, which accounts for more than 45% die failure. Price structure throughout the mold, the materials, the proportion of small, generally 20% to 30%, therefore, the choice of high quality steel and application of surface treatment technology to improve the life of the mold it is very necessary. For tool steel, the ESR technique to be used, such as the use of powder metallurgy high speed steel powders manufactured. Variety of different specifications tool steel, refined products, products of, try to shorten the delivery time is also an important trend.
Mold heat treatment of the main trends: the infiltration of a single element to the multi-element penetration, complex permeability (such as TD method) development; by the general spread of the CVD, PVD, PCVD, ion penetration, ion implantation and other direction; addition, the current laser enhanced glow plasma technology and electroplating (plating) and other anti-corrosion technology to strengthen more and more attention.
V, reverse engineering
Reverse engineering is the first of the parts (the processing of the product) to scan the CAD data generated in multiple formats, and then in the other CAD / CAE / CAM software in the modified design, the technology is the most popular modern mold manufacturing mold manufacturing technology. mold manufacturing company dedicated to development and production of the scanning system, it can be successfully applied to reverse engineering, mold manufacturing, it can not only improve the performance of CNC machine tools, expanding the function of CNC machine tools, CNC machine tools but also improve efficiency., Renscan200, Cyclone high-speed scanner has been Qingdao H a I e r, Jinan Q I n g q i, national mold center and other units started.
Ⅵ. Summary and Outlook
With the development and progress of computer software, CAD / CAE / CAM technology is getting more mature, and its application in the modern mold will become more widespread. Can be expected in the near future, mold manufacturing to separate from the machine manufacturing industry, and independent national economy to become an indispensable pillar industries, while also further promote the integration of the mold manufacturing technology, intelligence, beneficiary , efficient direction.
中文翻譯：
現(xiàn)代模具制造
一、 沖壓模具發(fā)展歷史和技術(shù)水平狀況
1953年，長(zhǎng)春第一汽車(chē)制造廠在中國(guó)首次建立了沖模車(chē)間，該汽車(chē)廠于1958年開(kāi)始制造汽車(chē)覆蓋件模具。我國(guó)于20世紀(jì)60年代開(kāi)始生產(chǎn)精沖模具。走過(guò)漫長(zhǎng)的發(fā)展道路，目前我國(guó)已形成約300多億元（未包括港、澳、臺(tái)的統(tǒng)計(jì)數(shù)字。）各類沖壓模具的生產(chǎn)能力。形成了如浙江寧波和黃巖地區(qū)的“模具之鄉(xiāng)”；廣東一些大集團(tuán)公司和鄉(xiāng)鎮(zhèn)企業(yè)迅速崛起，科龍、美的、康佳等集團(tuán)紛紛建立了自己的模具制造中心；中外合資和外商獨(dú)資的模具企業(yè)現(xiàn)已有幾千家。隨著與國(guó)際接軌的腳步不斷加快，市場(chǎng)競(jìng)爭(zhēng)的日益加劇，模具的生產(chǎn)和設(shè)計(jì)已經(jīng)越來(lái)越認(rèn)識(shí)到產(chǎn)品質(zhì)量、成本和新產(chǎn)品的開(kāi)發(fā)能力的重要性。模具制造技術(shù)現(xiàn)已成為衡量一個(gè)國(guó)家制造業(yè)水平高低的重要標(biāo)志，并在很大程度上決定企業(yè)的生存空間。目前我國(guó)沖壓模具無(wú)論在數(shù)量上，還是在質(zhì)量、技術(shù)和能力等方面都已有了很大發(fā)展，但與國(guó)民經(jīng)濟(jì)需求和世界先進(jìn)水平相比，差距仍很大。在國(guó)際競(jìng)爭(zhēng)的局勢(shì)下，我過(guò)的模具工業(yè)得到飛速的發(fā)展，很多的專門(mén)模具研究中心不斷的建立起來(lái)，模具結(jié)構(gòu)和鋼材的研究取得了顯著的成就，但還是存在很大的差距。 一是進(jìn)口模具大部分是技術(shù)含量高的大型精密模具，而出口模具大部分是技術(shù)含量較低的中低檔模具，因此技術(shù)含量高的中高檔模具市場(chǎng)滿足率低于沖壓模具總體滿足率，這些模具的發(fā)展已滯后于沖壓件生產(chǎn)，而技術(shù)含量低的中低檔模具市場(chǎng)滿足率要高于沖壓模具市場(chǎng)總體滿足率； 二是由于我國(guó)的模具價(jià)格要比國(guó)際市場(chǎng)價(jià)格低許多，具有一定的競(jìng)爭(zhēng)力，因此其在國(guó)際市場(chǎng)的前景看好； 三是近年來(lái)港資、臺(tái)資、外資企業(yè)在我國(guó)發(fā)展迅速，這些企業(yè)中大量的自產(chǎn)自用的沖壓模具無(wú)確切的統(tǒng)計(jì)資料，因此未能計(jì)入上述數(shù)字之中。
二．現(xiàn)代模具制造技術(shù)的發(fā)展方向
現(xiàn)代模具技術(shù)的發(fā)展應(yīng)該為適應(yīng)模具產(chǎn)品“交貨期短”、“精度高”、“質(zhì)量好”、“價(jià)格低”的要求服務(wù)。達(dá)到這一要求急需發(fā)展如下幾項(xiàng)
(1)全面推廣普及DBD/DBM/DBE技術(shù)
模具DBD/DBM/DBE技術(shù)是模具設(shè)計(jì)制造的發(fā)展方向。隨著微機(jī)軟件的發(fā)展和進(jìn)步，普及DBD/DBM/DBE技術(shù)的條件已基本成熟，各企業(yè)將加大DBD/DBM技術(shù)培訓(xùn)和技術(shù)服務(wù)的力度；進(jìn)一步擴(kuò)大DBE技術(shù)的應(yīng)用范圍。計(jì)算機(jī)和網(wǎng)絡(luò)的發(fā)展正使DBD/DBM/DBE技術(shù)跨地區(qū)、跨企業(yè)、跨院所地在整個(gè)行業(yè)中推廣成為可能，實(shí)現(xiàn)技術(shù)資源的重新整合，使虛擬制造成為可能。
(2)高速銑削加工
國(guó)外近年來(lái)發(fā)展的高速銑削加工，大幅度提高了加工效率，并可獲得極高的表面光潔度。另外，還可加工高硬度模塊，還具有溫升低、熱變形小等優(yōu)點(diǎn)。高速銑削加工技術(shù)的發(fā)展，對(duì)汽車(chē)、家電行業(yè)中大型型腔模具制造注入了新的活力。目前它已向更高的敏捷化、智能化、集成化方向發(fā)展。
(3)模具掃描及數(shù)字化系統(tǒng)
高速掃描機(jī)和模具掃描系統(tǒng)提供了從模型或?qū)嵨飹呙璧郊庸こ銎谕哪Ｐ退璧闹T多功能，大大縮短了模具的在研制制造周期。有些快速掃描系統(tǒng)，可快速安裝在已有的數(shù)控銑床及加工中心上，實(shí)現(xiàn)快速數(shù)據(jù)采集、自動(dòng)生成各種不同數(shù)控系統(tǒng)的加工程序、不同格式的DBD數(shù)據(jù)，用于模具制造業(yè)的“逆向工程”。
(4)提高模具標(biāo)準(zhǔn)化程度
我國(guó)模具標(biāo)準(zhǔn)化程度正在不斷提高，估計(jì)目前我國(guó)模具標(biāo)準(zhǔn)件使用覆蓋率已達(dá)到30%左右。國(guó)外發(fā)達(dá)國(guó)家一般為80%左右。
(5)優(yōu)質(zhì)材料及先進(jìn)表面處理技術(shù)
選用優(yōu)質(zhì)鋼材和應(yīng)用相應(yīng)的表面處理技術(shù)來(lái)提高模具的壽命就顯得十分必要。模具熱處理和表面處理是否能充分發(fā)揮模具鋼材料性能的關(guān)鍵環(huán)節(jié)。模具熱處理的發(fā)展方向是采用真空熱處理。模具表面處理除完善應(yīng)發(fā)展工藝先進(jìn)的激光表面處理等技術(shù)。
(6)模具研磨拋光
將自動(dòng)化、智能化模具表面的質(zhì)量對(duì)模具使用壽命、制件外觀質(zhì)量等方面均有較大的影響，研究自動(dòng)化、智能化的研磨與拋光方法替代現(xiàn)有手工操作，以提高模具表面質(zhì)量是重要的發(fā)展趨勢(shì)。
( 7)模具自動(dòng)加工系統(tǒng)的發(fā)展
這是我國(guó)模具工業(yè)長(zhǎng)遠(yuǎn)發(fā)展的目標(biāo)。模具自動(dòng)加工系統(tǒng)應(yīng)有多臺(tái)機(jī)床合理組合；配有隨行定位夾具或定位盤(pán)；有完整的機(jī)具、刀具數(shù)控庫(kù)；有完整的數(shù)控柔性同步系統(tǒng)；有質(zhì)量監(jiān)測(cè)控制系統(tǒng)。作為用戶當(dāng)然要選合適的設(shè)備，如果選型不當(dāng)，不但不能賺錢(qián)反而令陷入為機(jī)器打工的苦澀局面。
三．現(xiàn)代模具制造技術(shù)的發(fā)展趨勢(shì)
模具技術(shù)未來(lái)發(fā)展趨勢(shì)主要是朝信息化、高速化生產(chǎn)與高精度化發(fā)展。因此從設(shè)計(jì)技術(shù)來(lái)說(shuō)，發(fā)展重點(diǎn)在于大力推廣DBD/DBE/DBM技術(shù)的應(yīng)用，并持續(xù)提高效率，特別是板材成型過(guò)程的計(jì)算機(jī)模擬分析技術(shù)。模具DBD、DBE技術(shù)應(yīng)向宣人化、集成化、智能化和網(wǎng)絡(luò)化方向發(fā)展，并提高模具DBD、DBM系統(tǒng)專用化程度。為了提高DBD、DBE、DBM技術(shù)的應(yīng)用水平，建立完整的模具資料庫(kù)及開(kāi)發(fā)專家系統(tǒng)和提高軟件的實(shí)用性十分重要。
從加工技術(shù)來(lái)說(shuō)，發(fā)展重點(diǎn)在于高速加工和高精度加工。高度加工目前主要是發(fā)展高速銑削、高速研拋和高速電 加工及快速制模技術(shù)。高精度加工目前主要是發(fā)展模具零件精度1μm以下和表面粗糙度Pa≤0.1μm的各種精密加工。
四、現(xiàn)代模具的制造
1.CAD/CAE/CAM計(jì)算機(jī)輔助設(shè)計(jì)、模擬、制造一體化
CAD/CAE/CAM一體化集成技術(shù)是現(xiàn)代模具制造中最先進(jìn)最合理的生產(chǎn)方式。使用計(jì)算機(jī)輔助設(shè)計(jì)、輔助工程與制造系統(tǒng)，按設(shè)計(jì)好的模具零件分別編制該零件的數(shù)控加工程序是從設(shè)計(jì)到制造的一個(gè)必然過(guò)程，該過(guò)程都是從CAD/CAE/CAM系統(tǒng)內(nèi)進(jìn)行的，其加工程序直接由聯(lián)機(jī)電纜輸入加工機(jī)臺(tái)，在編制程序時(shí)可利用系統(tǒng)中的加工模擬功能，將零件刀具、刀柄、夾具，平臺(tái)及刀具移動(dòng)速度、路徑等顯示出來(lái)，以檢查程序編制的正確性?？傊贑AD/CAE/CAM系統(tǒng)內(nèi)編制和模擬加工程序可以充分了解發(fā)現(xiàn)的問(wèn)題，從而在加工之前，將整套加工程序作好完善修改工作，這對(duì)于高效、準(zhǔn)確的加工模具零件有著相當(dāng)重要的意義。
2.先進(jìn)設(shè)備在現(xiàn)代模具制造中的作用
現(xiàn)代模具制造的必然趨勢(shì),就是機(jī)械加工盡可能地取代人工加工，尤其現(xiàn)在數(shù)控車(chē)床、多軸聯(lián)動(dòng)機(jī)床、數(shù)控模具雕刻機(jī)、電火花加工機(jī)床、數(shù)控精密磨床、三坐標(biāo)測(cè)量機(jī)、掃描儀等現(xiàn)代設(shè)備在工廠中的廣泛使用，而且這些設(shè)備大部分所用的程序基本上都是應(yīng)用CAD/CAE/CAM系統(tǒng)產(chǎn)生的，操作人員工作按照規(guī)定的程序裝夾工件,配備刀具和操作，機(jī)臺(tái)就能自動(dòng)地完成加工任務(wù),并將理想的模具零件制造出來(lái)或?yàn)橄乱患庸すば蛲瓿梢?guī)定的部分。
3.模具材料及表面處理技術(shù)
因選材和用材不當(dāng)，致使模具過(guò)早失效，大約占失效模具的45%以上。在整個(gè)模具價(jià)格構(gòu)成中，材料所占比重不大,一般在20%～30%,因此，選用優(yōu)質(zhì)鋼材和應(yīng)用表面處理技術(shù)來(lái)提高模具的壽命就顯得十分必要。對(duì)于模具鋼來(lái)說(shuō),要采用電渣重熔工藝，如采用粉末冶金工藝制造的粉末高速鋼等。模具鋼品種規(guī)格多樣化、產(chǎn)品精細(xì)化、制品化，盡量縮短供貨時(shí)間亦是重要發(fā)展趨勢(shì)。
模具熱處理的主要趨勢(shì)是：由滲入單一元素向多元素共滲、復(fù)合滲（如TD法）發(fā)展；由一般擴(kuò)散向CVD、PVD、PCVD、離子滲入、離子注入等方向發(fā)展；另外，目前對(duì)激光強(qiáng)化、輝光離子氮化技術(shù)及電鍍（刷鍍）防腐強(qiáng)化等技術(shù)也日益受到重視。
五、逆向工程
逆向工程即先對(duì)制件（所加工的產(chǎn)品）進(jìn)行掃描生成多種格式的CAD數(shù)據(jù)，再在另外的CAD/CAE/CAM軟件中進(jìn)行改型設(shè)計(jì)，該技術(shù)是現(xiàn)代模具制造中最流行的模具制造技術(shù)。英國(guó)雷尼紹公司專門(mén)為模具制造開(kāi)發(fā)生產(chǎn)的掃描系統(tǒng)，就可以成功地應(yīng)用于模具制造的逆向工程中，它不僅可以改善數(shù)控機(jī)床的性能，擴(kuò)大數(shù)控機(jī)床的功能，而且還能提高數(shù)控機(jī)床的效率。雷尼紹公司的R e t r o s c an、Renscan200、Cyclone 高速掃描機(jī)已被青島海爾、濟(jì)南輕騎、國(guó)家模具中心等單位開(kāi)始使用。
六、總結(jié)與展望
隨著計(jì)算機(jī)軟件的發(fā)展和進(jìn)步，CAD/CAE/CAM技術(shù)也日臻成熟，其現(xiàn)代模具中的應(yīng)用將越來(lái)越廣泛?？梢灶A(yù)料不久的將來(lái)，模具制造業(yè)將從機(jī)械制造業(yè)中分離出來(lái)，而獨(dú)立成為國(guó)民經(jīng)濟(jì)中不可缺少的支柱產(chǎn)業(yè)，與此同時(shí)，也進(jìn)一步促進(jìn)了模具制造技術(shù)向集成化、智能化、益人化、高效化方向發(fā)展。
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