德语
Stamping is mainly used in the production of large-scale parts forming. Therefore, stamping molds have become an indispensable equipment in the stamping production process and are technology-intensive products. In the past decade, especially in the past 10 years after 2005, the number of automobile mold manufacturing enterprises has increased a lot, and the industry's fixed assets have been rapidly invested.
The design and manufacturing of molds are directly related to the quality of stamping parts, the production efficiency of stamping parts and the production cost of stamping parts.
In other words, the design level of molds and the level of manufacturing technology are also regarded as a very important measure, that is, the level of product manufacturing in this country. Therefore, to a very large extent, it plays a decisive role in the quality, efficiency of the product, and the development and development capabilities of new products.
If there is a problem with the mold during stamping production, it will directly affect the product production efficiency and production cost. Therefore, the design of stamping molds is very important. Good or bad design directly affects production, costs, and even benefits.
In modern industrial production, molds are one of the important process equipment. Molds occupy an important position in all walks of life, especially in the stamping process and the molding process of plastic forming.
Overall, stamping molds account for 50% of all industries in my country, which shows its importance. Since my country's reform and opening up, with the rapid development of my country's economy, the demand for molds in my country's market has also continued to grow, and the mold industry has also developed rapidly.
To ensure the service life of the mold, we must reasonably select mold materials and correctly implement the heat treatment process.
The choice of the correct steel type and the heat treatment process should correspond to the different uses of the mold. In addition, it should also be based on its working state, stress conditions, performance of the material to be processed, production batch and productivity, and the performance of the requirements of the above description should be focused on.
According to the role of the mold in the composition structure, the structural composition of the mold is mainly process parts, and the structural zero process parts are directly involved in the process process until it is completed. It also comes in direct contact with the blank. Process parts mainly include positioning parts, working parts, unloading parts and pressing parts.
However, structural parts are completely different from process parts. They do not directly participate in the process process, nor have direct contact with the blank. They only have a guaranteed effect on the completion of the process process, or improve the function of the mold.
Structural parts mainly include fastening parts, guide parts, standard parts and some other parts. However, it should be noted that not all stamping molds must contain these six parts.
The first thing to consider when designing the structure of a stamping mold is safety. Accidents must not be caused by errors in the structural design of the stamping mold.
Even the actual operator of stamping molds is absolutely not allowed to put himself in a dangerous situation. During the design process of stamping mold structure, the design operator's sense of security must be guaranteed. During processing, the mold should also have a certain bearing strength.
The future development of stamping mold technology should be based on the requirements of "fast delivery", "high precision", "high quality" and "low price" of mold products. How can this be achieved? To meet this series of standards, we must develop these items in a timely manner:
Vigorously promote the CAD/CAM/CAE technology of molds. The CAD/CAM/CAE technology of molds can be called the future development trend of mold design.
With the continuous development and progress of microcomputer software, the basic maturity has been achieved to popularize mold CAD/CAM/CAE technology. Various mold industries and enterprises will also increase the development of CAD/CAM technology training and its technical services; and expand the application of CAE technology to a larger extent.
Speed up milling. The milling and processing industry, which has developed rapidly abroad in recent years, has greatly improved the processing efficiency. Not only can it also make the surface finish reach an extremely high level. In addition, the processing of high-hardness modules also has the advantages of low temperature rise and small thermal deformation.
The rapid development of milling processing technology has also added fresh momentum to the manufacturing of cavity molds in the automotive industry and large and medium-sized home appliance industries. Judging from the current development level, it has developed towards a higher direction of agility, intelligence and integration.
Scan and digitize the mold. High-speed scanning machines and mold scanning systems provide many functions required from scanning models or real objects to processing desired models, greatly shortening the mold development and manufacturing cycle. Some fast scanning systems can be quickly installed on existing CNC milling machines and machining centers to achieve rapid data acquisition, automatic generation of machining programs of various CNC systems, and CAD data in different formats, and used for "reverse engineering" in the mold manufacturing industry.
The mold scanning system has been successfully applied in industries such as automobiles, motorcycles, and home appliances. I believe it will play a greater role during the 10th Five-Year Plan period.
Electric spark milling. EDM milling processing technology is also called EDM processing technology. This is a new technology that replaces the traditional molded electrode processing cavity. It is a simple tubular electrode with high-speed rotation for three-dimensional or two-dimensional contour processing, so there is no longer the need to manufacture complex molded electrodes. This is obviously a major development in the field of EDM forming processing.
Machine tools using this technology have been used abroad in mold processing. This technology is expected to develop.
Improve the standardization of stamping molds. The standardization of stamping molds in my country is still in the stage of continuous improvement. Although the current coverage rate of stamping mold standard parts in my country has reached about 30%, it is still a big gap compared with other countries, especially developed countries. At present, the coverage rate of stamping molds in developed countries abroad can generally reach about 80%.
Select high-quality materials and advanced surface treatment technology. It is very necessary to use high-quality materials and apply the corresponding advanced surface treatment technology to improve the life of stamping molds, such as choosing high-quality steel materials. The key to exerting the performance of steel materials of stamping molds is whether the heat treatment and surface treatment of stamping molds can be made more.
The future development trend of stamping mold heat treatment is to use vacuum heat treatment technology. Not only should we develop surface treatment technology for stamping molds, but we should also develop advanced technologies such as vapor deposition (TiN, TiC, etc.) and ion spraying with advanced processes.
The grinding and polishing of stamping molds is automated and intelligent. The quality of the surface of the stamping mold can be said to have a great impact on the service life of the stamping mold and the quality of the appearance of the stamping parts.
Research and invent automated and intelligent grinding and polishing methods to replace the current manual methods, thereby improving the surface quality of stamping molds. This is also an important development direction for stamping molds in the future.
Develop a system for automated mold processing. The development of automated processing of stamping molds can be said to be the long-term development goal of my country's mold industry.
The automatic processing system of stamping molds mainly uses a reasonable combination of multiple machine tools to work; it is equipped with accompanying positioning fixtures or positioning plates; the CNC library of stamping mold tools and tools is also quite complete; the CNC flexible synchronization system is also very complete; and a quite complete monitoring and control system is also set up for quality.
Domestic automobile stamping manufacturing companies actively absorb the advanced experience of internationally renowned automobile mold companies (such as Toyota, GM, Ford, etc.). They began to use three-dimensional software for design at the beginning of their establishment. On the one hand, it facilitates intuitive interference inspection during design, and on the other hand, it can conduct some motion analysis.
High-end automotive stamping mold manufacturing requires parametric design of molds from the design aspect, and actively and effectively combines software template technology to achieve secondary development, forming fixed and standardized design parameters and design templates for the enterprise, achieving full parameter correlation and full parameter drive.
That is, changes in mold components or part parameters can quickly drive changes in CAE results, changes in mold processes, optimization of mold structures, etc.
Currently, more than 70% of the large-scale CNC equipment required for the manufacturing of large-scale automobile panel molds, especially large-scale gantry five-axis linkage equipment, needs to be imported.
In order to innovate and develop high-quality high-end molds for large-scale covering parts, we must develop the development capabilities of CNC processing equipment and testing equipment, focusing on the research and development of 4-5 meter moving beam type super-heavy gantry machining centers, large-scale three-axis, five-axis linkage CNC gantry machining centers.
And special emphasis is placed on the research and development of key core components of CNC machine tools, such as high-speed precision electric spindles, tool magazine manipulators, CNC rotary tables, high-speed protection devices, CNC power tool holders and double-swing angle milling heads. At the same time, we must also focus on the research and development of CNC machine tool CNC systems.
In view of the continued high requirements for automobile lightweighting, safety, and impact resistance, the demand for high-strength automobile structural steel plate parts is increasingly evident.
As the strength of high-strength automotive structural steel plates increases, their stamping formability decreases, especially when the strength exceeds 1000MPa. Especially for some parts with complex shapes, conventional cold stamping processes are almost impossible to form.
On the one hand, ultra-high-strength automotive steel plates have high strength at room temperature, so their plastic deformation range is very narrow, requiring large stamping forces, and they are prone to cracking during stamping. On the other hand, the rebound of parts after stamping increases, resulting in poor dimensional and shape stability of parts. For this reason, to develop high-end automotive mold manufacturing technology, it is necessary to solve the stamping and hot forming of high-strength steel plate parts.
Hot stamping forming technology for automobile parts is a new technology specially used to form high-strength steel plate stamping parts. It can form stamping parts with a strength of up to 1500MPa, and there is almost no rebound when formed at high temperatures. It has the advantages of high forming accuracy and good forming performance.
At present, major automobile manufacturers in Europe, the United States, Japan and other countries have successfully applied high-strength steel plate hot forming technology to the production of automobile components, effectively improving market competitiveness. It is very suitable for the technological innovation of automobile parts such as door anti-collision bars, bumper reinforcement beams, A, B, C pillars, door frame reinforcement beams, etc.
The core of hot stamping technology for automotive parts includes the uniformity of the continuous heating furnace and gas protection measures, mold technology with a cooling system that allows the sheet to be evenly cooled and formed at a set cooling rate, and an effective temperature control system.
The design of the cooling system must not only quickly cool the parts to ensure the strength of the parts; it must also quickly take away the residual heat of the mold after each hot stamping through the cooling system to ensure that the initial conditions of the mold are the same before each stamping, thereby stabilizing stamping quality and product quality.
In addition, the development of high-strength steel plate hot forming CAE technology is also necessary for the development of high-end automotive mold manufacturing.
Auto parts hot stamping technology
In order to continuously improve production efficiency and improve the level of automation, and to meet the needs of parts stamping technology and economy, multi-station progressive dies are often actively developed for small and medium-sized automobile parts.
The multi-station progressive die can complete multiple stamping processes for parts, including punching, bending, drawing and forming, etc., and combines partial separation with continuous forming.
The mold must have a high-precision guide and accurate distance system, and be equipped with automatic feeding, automatic part ejection, safety detection and other devices. However, the mold structure is complex and there are many inserts. The mold manufacturing accuracy requirements are very high, and the manufacturing and assembly are very difficult. It is an important representative of technology-intensive automotive molds and an important issue for high-end automotive molds.
Source: Xiaowanzi Mechanical Design, Forging and Stamping
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