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2011 届毕业设计（论文）课题任务书院(系)：机械工程系 专业：材料成型与控制工程 指导教师厉春元学生姓名阳章立课题名称雕刻机进气门外壳正反拉伸复合模设计内容及任务这次设计的任务是设计制造隔板的一副模具，并绘出模具装配图、模具零件图以及编写设计说明书。首先我们需要知道模具在加工中的作用和设计的基本要求。模具的作用是将压力机的作用力通过模具传递给金属板料，在其内部产生使之变形的内力，使板料毛坯发生变形，从而获得满足一定性能要求的及符合所需尺寸及形状的制品。在生产实际中。模具的作用在于保证冲件的质量、提高生产率和降低成本等。为此除了采用行之有效的工艺手段、进行正确的模具设计及选择合理的模具结构之外，还必须满足以下几个要求：制造精度高 操作性能良好 使用寿命长 制造周期短 模具成本低。对于雕刻机进气门外壳，它属于带凸缘圆筒型件，从结构上我们可以得知需要落料、正拉深和反拉深三个工序过程。从零件的工艺性分析可以看出此零件对落料是很适合的。但从拉深方面考虑就需要计算出拉深系数，判断能否一次拉深成功，这也是本设计中需要重点分析的地方。再有对模具结构和压力机的选择也是重点。在模具零件的结构设计上，也需要注意很多细小而不可忽视的问题。对于整个设计过程可以按以下的方法来设计计算。取得必要的资料，确定工艺方案，进行必要的工艺计算，模具的总体设计，模具主要零部件的结构设计，绘图，分析一个主要零件的加工工艺路线。1、 取得必要的资料 取得注明具体技术要求的产品零件图。 收集工件加工的工艺工艺过程卡片。 了解工件的生产批量。 确认工件原材料的规格及毛坯情况。 熟悉冲压车间的设备和情况。2、 确定工艺方案 对零件进行工艺性分析。 根据工艺计算，确定工序数目。 计算拉深系数，确定拉深次数。 根据生产批量、尺寸大小、精度要求选择合理的加工方案。3、 进行必要的工艺计算。 设计材料的排样和计算毛坯尺寸。 计算落料力、卸料力、压边力、拉深力和顶件力等。 计算或估算模具各主要零件的厚度。 计算凸、凹模的工作部分尺寸。4、 模具的总体设计在上述分析计算的基础上，进行模具的结构的总体设计，估算出外形尺寸。5、 模具主要零部件的结构设计 工作部分零件的设计。（凸模、凹模、凸凹模等） 定位零件的设计。（挡料销） 卸料零件的设计。（卸料板） 导向零件的设计。（导柱、导套）6、 选定冲压设备 压力机的标称压力必须大于冲压的工艺力。 压力机的装模高度必须符合模具的闭合高度的要求。 压力机的行程要符合要求。7、 绘制模具总图 主视图 俯视图 工件图 排样图 列出明细表 技术要求及说明8、 绘制各非标准件的零件图9、 分析一个主要零件的加工工艺路线。拟达到的要求或技术指标完成本次设计后将会对我大学所学的知识进行巩固，使我所学的各种专业知识在实践中得以应用，在设计过程中也将会对绘图的能力的提高有很大的帮助，还能使我的AUTOCAD和PRO/E的应用能力加强，设计的成果可以供其它同类零件的模具设计参考和借鉴。进度安排起止日期工作内容2010.12.202011.01.02完成毕业设计的选题和开题报告。2011.01.032011.01.20对设计的相关资料进行整理。2011.03.102011.03.21进行设计的初期计算。201103.222011.04.05设计模具的结构。2011.04.052011.05.01绘制装配图和零件图。2011.05.022011.05.15对整个设计进行合理性检查。2011.05.162011.05.25设计说明书的输入以及毕业答辩的准备。2011.06.072011.06.10毕业设计答辩。主要参考资料1、卢吉连著，我国模具应用技术现状与发展，模具技术，2000年， 第六期 90-922、胡石玉 龚光容著，模具制造技术，南京 东南大学出版社，1997年12月 1-53、黄毅宏著，模具知道工艺，北京 机械工业出版社，2000年，1-44、李发致著，模具先进制造技术，北京 机械工业出版社，2003年，1-135、陈良杰著，国外模具技术发展动态，模具工业，2005年，第一期，1-66、高佩福著，实用模具制造技术，第二版，北京 中国轻工业出版社，2000年 7、万战胜著，冲压工艺及模具设计，北京 中国铁道出版社，1995年8、模具实际与制造技术教育丛书编委会编，模具结构设计，机械工业出版社，2004年9、王树勋著，模具实用技术设计综合手册，广州 华南理工大学出版社，1995年10、冯晓曾 王家瑛 何世禹著，模具寿命指南，机械工业出版社，1994年11、周永泰著，改革开放以来我国模具工业发展主要成就，模具工业，2005年，第三期12、郭广兴著，U型弯曲模具磨耗分析及解决，天津汽车，2002年，第一期13、程西智，郝永辉著，中厚板弯曲的最高效工艺设计及最优化模具设计的研究探讨，机电信息，2005年，第十三期14、山东大学材料学院高军张国强吴恩启赵振铎 济南历下高信模具厂董云青张凤文，弯曲件成形工艺及其模具设计，航空制造技术，2002年 第八期15、王德俊著，板料弯曲的新工艺与新模具，机电工程技术 2005年 第34卷 第5期16、史建国, 胡志越, 徐刚著，V、U 形件弯曲时坯料的偏移原因及控制方法，轻工机械2005 年第2 期教研室意见签名：年 月 日院(系)主管领导意见签名：年 月 日湖南工学院毕业设计(论文)开题报告 题目雕刻机进气门外壳盖落料正反拉深复合模学生姓名阳章立班级学号212070319 专业材料成型及控制工程题目：雕刻机进气门外壳盖正反拉伸复合模设计1. 结合课题任务情况，查阅文献资料，撰写15002000字左右的文献综述。模具被称为工业产品之母。所以工业的高速发展也离不开模具工业的不断进步。中国模具巿场规模巨大，随着国内模具工业高速发展，技术也获得了较大的飞跃，但是，仍然面对高档模具以进口为主的尴尬局面。提升技术实力，乃是中国模具工业发展的前途所在。随着冲压金属制品在机械、电子、交通、国防、建筑、农业等各行业的广泛应用，对冷冲压模具的需求日益增加，冲压模在国民经济中的重要性也日益突出。模具作为一种高附加值和技术密集型产品，其技术水平的高低已经成为一个国家制造业水平的重要标志之一。因此我选择了模具设计的课题，即设计一副能够生产所给隔板冲槽、冲孔、落料 的模具，并且结构合理、能保证制品的精度、表面质量。在设计中能熟练使用PRO/E、AUTOCAD等机械、模具相关绘图软件。 现代模具行业是技术、资金密集型的行业。它作为重要的生产装备行业在为各行各业服务的同时，也直接为高新技术产业服务。由于模具生产要采用一系列高新技术，如CAD/CAE/CAM/CAPP等技术、计算机网络技术、激光技术、逆向工程和并行工程、快速成型技术及敏捷制造技术、高速加工及超精加工技术等等，因此，模具工业已成为高新技术产业的一个重要组成部分，有人说，现代模具是高技术背景下的工艺密集型工业。模具技术水平的高低，在很大程度上决定着产品的质量、效益和新产品的开发能力，因此已成为衡量一个国家产品制造水平高低的重要标志。 模具工业是无以伦比的效益放大器。用模具加工产品大大提高了生产效率，而且还具有节约原材料、降低能耗和成本、保持产品高一致性等特点。因此模具被称为效益放大器，在国外，模具被称为金钥匙、进入富裕社会的原动力等等。从另一个角度上看，模具是人性化、时代化、个性化、创造性的产品。更重要的是模具发展了，使用模具的产业其产品的国际竞争力也提高了。据国外统计资料，模具可带动其相关产业的比例大约是1:100，即模具发展1亿元，可带动相关产业100亿元。 模具不是批量生产的产品。它具有单件生产和对特定用户的依赖特性。就模具行业来说，引进国外先进技术，不能采用通常的引进产品许可证和技术转让等方式，而主要是引进已经商品化了的CAD/ CAM /CAE软件和精密加工设备等。模具的CAD/CAE/CAM涉及面广、集多种学科与工程技术于一体，是综合型、技术密集型产品。如塑料模具的CAE技术要利用高分子材料学、流变学、传热学、计算力学、计算机图形学等知识，涉及的领域还包括声波及电磁场、温度场等各类物理场，通过工程分析、来建立塑料成型的数学和物理模型，构造有效的数值计算方法，实现成型过程的动态仿真分析。现代化的模具要实现数字化设计、数字化制造、数字化管理、数字化生产流程。这些模具的数字化代表了现代模具的一个方面，没有模具的数字化，就没有现代模具。模具的CAD/CAE/CAM技术日新月异，重要的工作是后续对人员的培训和对于引进的软件进行二次开发。像我们熟知的CIMATRON公司不但在塑料模具的CAD/ CAM软件上在中国保持其市场占有率并且在扩大，而且在冲压模具、多成份橡胶制鞋模具等领域开拓，也将大显身手；开发FUTABA、LKM、MISUMI标准模架数据库的工作也已提上日程。这是为模具行业服务的具体体现。 1我国模具工业基本状况简介 我国模具工业近年来发展很快，据不完全统计，2003年我国模具生产厂点约有万多家，从业人员约50多万人，2004年模具行业的发展保持良好势头，模具企业总体上订单充足，任务饱满，2004年模具产值530亿元。进口模具18.13亿 美元，出口模具4.91亿美元，分别比2003年增长18%、32.4%和45.9%。进出口之比2004年为3.69:1，进出口相抵后的进净口达13.2亿美元，为净进口量较大的国家。 在万多家生产厂点中，有一半以上是自产自用的。在模具企业中，产值过亿元的模具企业只有20多家，中型企业几十家，其余都是小型企业，多数只有几十名职工，百十万产值，自有资金有限，靠自我发展很困难。 近年来， 模具行业结构调整和体制改革步伐加快，主要表现为：大型、精密、复杂、长寿命中高档模具及模具标准件发展速度快于一般模具产品；塑料模和压铸模比例增大；专业模具厂数量增加，能力提高较快；三资及私营企业发展迅速；国企股份制改造步伐加快等。 2004年模具行业还显现另外两个特点，一是各地政府对模具工业的发展进一步关注。许多地方政府进一步认识到模具工业对发展制造业的重要意义，因此加强了模具工业园区的建设。已有的园区进一步扩大，如宁波余姚、宁海和苏州昆山等模具园区都有所扩大；新的模具工业园区正在加紧建设，如重庆、大连、深圳市等已建立模具园区；另外沈阳、西安、成都、上海、宁波北仑、浙江黄岩等地都在积极筹备建立模具园区，以利带动地区模具及相关产业链乃至制造业的发展，有些高科园内模具企业已占有相当的份量，像天津高新区就有40多家模具企业。是外资及社会投资模具产业增长显著。许多地方加强了吸引外资及合资投入模具工业的工作，特别是在高新技术园区和工业园区，外资、合资模具企业进一步增加，如苏州昆山模具园区，60%以上是外资企业。大连模具园区到日本、韩国招商。而有些地区高科技园内模具企业已占有相当的份量，像天津高新区有40多家模具企业。由于汽车产业发展的拉动，社会投资模具产业有所加强，如五粮液集团投资5亿元建立汽车模具生产厂，比亚迪公司投资2亿元建立了北京汽车模具公司，等等。 从地区分布来说，以珠江三角洲和长江三角洲为中心的东南沿海地区（模具产值已占全国总量的70%左右）发展快于中西部地区，南方的发展快于北方。目前发展最快、模具生产较为集中的省份是广东和浙江。我国模具总量虽然已位居日、美、德之后，但设计制造水平在总体上要比德、美、日、法、意等发达国家落后许多，也要比英国、加拿大、西班牙、葡萄牙、韩国、新加坡等有差距。 2落后和差距主要表现在下列几方面 （1）总量供不应求、产品结构不够合理。其中中低档模具供过于求，中高档模具自配率严重不足，大量进口。国内模具总量中属大型、精密、复杂、长寿命模具的比例不足30%，国外在50%以上。 （2）企业组织结构都不够合理。 我国模具生产厂点中多数是自产自配的工模具车间（分厂），自产自配比例高达60%左右，国外70%以上是商品模具；专业模具厂也大多数是大而全 、小而全的组织形式，国外模具企业是大而专、大而精。2004年中国模协在德国访问时，从德国工、模具行业组织-德国机械制造商联合会（VDMA）工模具协会了解到，德国有模具企业约5000家。2003年德国模具产值达48亿欧元。其中（VDMA）会员模具企业有90家，这90家骨干模具企业的产值就占德国模具产值的90%，可见其规模效益。（3） 工艺装备水平低，且配套性不好，利用率低，技术结构、模具产品水平比国际水平低许多。而模具生产周期却要比国际水平长许多。 产品水平低主要表现在对后续使用模具制造制件的工艺（如冲压工艺）理解上，在模具设计上；在加工中精度、型腔表面粗糙度、寿命及模具的复杂程度上等。现代模具行业是技术密集型、资金密集型的产业，由于模具行业是微利行业，因而总体来看模具行业在科研开发和技术攻关方面投入太少，至使科技进步的步伐跟不上模具市场的需要。虽然国内许多企业已引进了不少国外先进设备，但总的来看装备水平仍比国外企业落后许多，特别是设备数控率和CAD/CAM应用覆盖率要比国外企业低得多。由于体制和资金等方面原因，引进设备不配套、设备与附配件不配套现象十分普遍，设备利用率低，开发能力较差，科研开发及技术攻关方面投入太少。不重视产品开发，在市场经济中常处于被动地位。 （4）技术人才严重不足，经济效益欠佳。随着时代的进步和技术的发展，能掌握和运用新技术的人才如模具结构设计、模具工艺设计异常短缺，高级钳工及企业管理人才也非常紧缺。我国模具企业技术人员比例低，水平也较低，我国每个职工平均每年创造模具产值约合1万美元左右，国外模具工业发达国家大多1520万美元，有的达到 2530万美元。我国模具企业大都微利，缺乏后劲。 （5）与国际水平相比，模具企业的管理落后更甚于技术落后。技术落后易被发现，管理落后易被忽视。国内大多数模具企业还沿用过去作坊式管理模式，真正实现现代化企业管理的还不多。信息化、数字化管理在模具企业应用现在刚刚开始。 （6）专业化、标准化、商品化的程度低，协作差。 由于长期以来受大而全小而全影响，模具专业化生产水平低，专业化分工不细，商品化程度也低。目前国内每年生产的模具，商品模具只占40%左右，其余为自产自用。模具企业之间协作不好，难以完成较大规模的模具成套任务。与国际水平相比要落后许多。模具标准化水平低， 模具标准件使用覆盖率低也对模具质量、成本有较大影响，特别是对模具制造周期有很大影响。 20年来我国模具制造水平有了很大的提高，模具的CAD/ CAM已很普遍，CAE/CAPP也在积极推广。如今我国生产的模具精度已达到微米级，与20年前相比，模具寿命提高了几十倍，模具生产周期缩短了约3/4，模具的标准件使用覆盖率从几乎是零，达到45%左右。 20年来我国模具人才的培养也上了一个很大的台阶。20年前我国大专院校都没有设立模具专业的，而如今，已有六、七十所大专院校设立了模具专业。中国模协在全国建有38个模具人才培训基地。 上述情况正是我们模具行业和模具相关行业要一同努力，使之发展的领域，在这里也希望有越来越多的人加入到模具的行列中。2.选题依据、主要研究内容、研究思路及方案。这次设计的任务是设计制造一副模具，并绘出模具装配图、模具零件图以及编写设计说明书。首先我们需要知道模具在加工中的作用和设计的基本要求。模具的作用是将压力机的作用力通过模具传递给金属板料，在其内部产生使之变形的内力，使板料毛坯发生变形，从而获得满足一定性能要求的及符合所需尺寸及形状的制品。在生产实际中。模具的作用在于保证冲件的质量、提高生产率和降低成本等。为此除了采用行之有效的工艺手段、进行正确的模具设计及选择合理的模具结构之外，还必须满足以下几个要求：制造精度高 操作性能良好 使用寿命长 制造周期短 模具成本低。对于隔板，它属于圆板带槽孔，从结构上我们可以得知需要落料、冲孔槽两个工序过程。从零件的工艺性分析可以看出此零件对落料、冲孔槽是很适合的。再有对模具结构和压力机的选择也是重点。在模具零件的结构设计上，也需要注意很多细小而不可忽视的问题。对于整个设计过程可以按以下的方法来设计计算。取得必要的资料 分析冲压零件的工艺性分析确定工艺方案主要工艺参数计算模具工作部分尺寸计算及强度校核选用模架，确定闭合高度模具的主要零部件结构设计模具的装配、工作原理和安全技术分析一个主要零件的加工工艺路线。3.工作进度及具体安排。2010.12.202011.01.02 完成毕业设计的选题和开题报告。2011.01.032011.01.20 对设计的相关资料进行整理。2011.03.102011.03.21 进行设计的初期计算。2011.03.222011.04.05 设计模具的结构。2011.04.052011.05.01 绘制装配图和零件图。2011.05.022011.05.15 对整个设计进行合理性检查。2011.05.162011.05.25 设计说明书的输入以及毕业答辩的准备。2011.06.072011.06.09 毕业设计答辩。指导教师批阅意见 指导教师(签名)： 年 月 日说明：开题报告作为毕业设计（论文）答辩委员会对学生答辩资格审查的依据材料之一，此报告应在导师指导下，由学生填写，将作为毕业设计（论文）成绩考查的重要依据，经导师审查后签署意见生效。 本科毕业设计（论文）中期报告 填表日期：2011 年 5 月 20 日院（系）机械工程系班级成型0703学生姓名阳章立课题名称：雕刻机进气门外壳盖正反拉伸复合模设计课题主要任务： 根据零件给出的尺寸、材料、精度要求和生产批量设计出加工空气滤清器壳的复合模，保证规定的生产率和高质量的冲压件的同时，力求成本低、模具寿命长，安全可靠。并绘制出模具的总装配图和主要非标准零件的零件图。编写完整详细设计说明书。1、简述开题以来所做的具体工作和取得的进展或成果课题选定以后，我搜集了许多关于此次设计得资料，并进行了整理。在明确了设计路线后，开始进行设计得一些初期工作。首先对加工零件进行了加工工艺和结构工艺的分析，发现此零件很适合进行落料、拉深工序。通过用“形心法”计算出毛坯尺寸，并且求出了拉深系数，得出只需要拉深一次就能成功的结论。同时提出了四种加工此零件的方案，最后确定采用落料、正反拉深复合模。应为这个方案不仅可以提高生产效率而且加工出的零件精度也比较高。接下来对模具的排样做出了合理的布置，使材料利用率达到较高的水平。计算了冲压过程中所需要的各种冲压工艺力，包括落料力、卸料力、压边力、拉深力、顶料力等，并对压力机进行了合理的吨位初选。选择压力机的时候运用了选压力机的通用法则，对其进行了正确的选取。复合模在结构上采用了正装的形式，这样更有利于拉深件的顺利成型。2、下一步的主要研究任务，具体设想与安排在进行了上述的设计工作以后，接下来需要计算出落料、正拉深和反拉深工作部分的尺寸。并确定模具的闭合高度。还需要设计出模具的主要零件的具体结构，包括落料凹模、凸凹模、反拉深凸模、反拉深凹模、凹模固定板等。绘制模具的装配图，并列出模具所需零件的详细清单和技术要求。所有的非标准零件需要绘制出零件图。由于拉深的深度较大，对压力机的电机也需要进行功率校核，并提出了润滑的附加工序。最后需要对模具的一个主要零件导套进行了简单的加工工艺路线的制定。3、存在的具体问题在设计中遇到了一些需要仔细考虑的问题，如下：总工艺力与压力机的选取。主要零件的结构设计。长行程拉深对压力机电机的要求。防止拉深过程中出现裂纹等现象的处理办法。4、指导教师对该生前期研究工作的评价指导教师签名：日 期： 毕业设计（论文）指导教师评阅表院（系）：机械工程系 学生姓名阳章立学 号212070319班 级成型0703专 业材料成型与控制工程指导教师姓 名厉春元课题名称雕刻机进气门外壳盖正反拉伸复合模设计评语：（包括以下方面，学习态度、工作量完成情况；检索和利用文献能力、计算机应用能力；学术水平或设计水平、综合运用知识能力和创新能力；）是否同意参加答辩：是 否指导教师评定成绩分值：指导教师签字： 年 月 日毕业设计（论文）评阅教师评阅表院、系： 机械工程学院 学生姓名阳章立学 号212070319班 级成型0703专 业材料成型与控制工程课题名称雕刻机进气门外壳盖正反拉伸复合模设计评语：（对论文学术评语，包括选题意义；文献利用能力；所用资料可靠性；创新成果及写作规范化和逻辑性）针对课题内容给设计者（作者）提出3个问题，作为答辩时参考。1.2.3.评 分：是否同意参加答辩是 否评阅人签名： 年 月 日 1英文说明英文说明/loecvte/loecvte/loecvte/loecvte/jsviMoldMoldMoldMold highhighhighhigh speedspeedspeedspeed millingmillingmillingmilling processingprocessingprocessingprocessing technologytechnologytechnologytechnologyHnmanHnmanHnmanHnman FoctorsFoctorsFoctorsFoctors RessearchRessearchRessearchRessearch UnitUnitUnitUnit ;Institute;Institute;Institute;Institute ofofofof soundsoundsoundsound andandandand preventionpreventionpreventionprevention vibrationvibrationvibrationvibration Rsearch.Rsearch.Rsearch.Rsearch.UnUnUnUniv iv iv iversityersityersityersity ofofofof SouthamptonSouthamptonSouthamptonSouthampton so17so17so17so17 .IBJ.UK.IBJ.UK.IBJ.UK.IBJ.UKTheTheTheThe abstractabstractabstractabstractIntroduced the high speed milling in the mold processing application aswell as the influence, and brief introduction high speed milling engine bed structure, controlsystem and cutting tool. Has carried on the simple analysis to the high speed processingcraft.KeyKeyKeyKey wordwordwordwordhighhighhighhigh speedspeedspeedspeed milling;milling;milling;milling; mmmmoldoldoldold processingprocessingprocessingprocessingFirst,First,First,First, forewordforewordforewordforewordIn the modern mold production, along with to models artistic and the function mustobtain more and more high, models the internal structure to design more and more complex,the mold contour design day by day is also complex, the free curved surface accounts for theproportion to increase unceasingly, the corresponding mold structure also designs more andmore complex. These all set a higher request to the mold processing technology, not onlyshould guarantee the high manufacture precision and the surface quality, moreover mustpursue the processing surface artistic. Along with is unceasingly thorough to the high speedprocessing engineering research, is processing the engine bed, the numerical control system,the cutting tool system, CAD/ especially Correlation technology and so on CAM softwaredevelops unceasingly under the impetus, high speed processes the technology more andmore many to apply in the mold cavity processing and the manufacture.The numerical control high-speed cutting processing took in the mold manufacture amost important advanced manufacture technology, is the collection is highly effective, highquality, the low consumption in a body advanced manufacture technology. Is opposite in thetraditional machining, its cutting speed, entered to the speed had the very big enhancement,moreover cut the mechanism not to besame. The high-speed cutting caused the machiningto have the leap, its specific power metal excision rate enhanced 30%40%, the cutting2force reduced 30%, the cutting tool working durability enhanced 70%, remained hotly largescale reduces in the work piece cutting, the low step shudder vanished nearly. Along withthe cutting speed enhancement, unit time semifinished materials material removing rateincreased, the cutting time reduced, the processing efficiency enhanced, thus reduced theproduct manufacture cycle, enhanced the product market competitive power. At the sametime, the high speed processing small amount entered quickly causes the cutting force toreduce, the scrap high speed discharged reduced the work piece cutting force and thethermal load distorts, enhances the rigidity to be bad and the thin wall componentsmachining possibility. Because cutting force reducing, the rotational speed enhancementcauses the cutting system the operating frequency to be far away the engine bed the low stepnatural frequency, but the work piece surface roughness is most sensitive to the low stepfrequency, from this reduced the surface roughness. In mold high hard steel stock(HRC45HRC65) in the processing process, uses the high-speed cutting to be possible tosubstitute for the working procedure which the electrical finishing and rubs truncatespolishes, thus has avoided the electrode manufacture and the time-consuming electricalfinishing, large scale reduced fitters polishing with to throw the light quantity. Thin wallmold work piece more and more needs which regarding some markets in, the high speedmilling also may smoothly complete, moreover in the high speed milling CNC processingcenter, a mold attire clamps may complete the multiplex step of processing.The high speed processing technology has had the huge influence to the moldprocessing craft, changed the traditional mold processing to use the annealing millingprocessing heat treatment to rub truncates or the electric spark machining manually polishes, polishes and so on the complex long technical process, even might usethe high-speed cutting processing substitution original complete working procedure. Thehigh speed processing technology besides may apply in the hard mold cavity directprocessing (in particular half precision work and precision work), in EDM aspect and so onelectrode processing, fast type manufacture also obtained the widespread application. Themass productions practice indicated that, the application high-speed cutting technology maysave in the mold following processing 80% handwork to grind the time approximately,saves the processing cost expense nearly 30%, the mold face work precision may reach 1 m,the cutting tool cutting efficiency may enhance one time.Second,Second,Second,Second, highhighhighhigh speedspeedspeedspeed millingmillingmillingmilling processingprocessingprocessingprocessing engineengineengineengine bedbedbedbed3The high-speed cutting technology is one of machining technology main developmentdirections, it along with foundation technology the and so on CNC technology,microelectronic technology, new material and new structure development but steps a higherstair. Because the mold processes particular as well as high speed processing technologyown characteristic, (processed engine bed, numerical control system, cutting tool to themold high speed processing related technology and the craft system and so on) proposedprocessed a higher request compared to the traditional mold.1. 1. 1. 1. HighHighHighHigh stablestablestablestable engineengineengineengine bedbedbedbed strutstrutstrutstrut partpartpartpartThe high-speed cutting engine bed lathe bed and so on supports the part to be supposedto have very well moves, the static rigidity, hot rigidity and best damping characteristic. Themajority of engine beds all use high grade, the high rigidity and Gao Kangzhang the grayiron took the strut part material, some engine bed companies also increase the high dampingcharacteristic in the foundation polymer concrete, by increases its vibration-proof and thethermostability, this not only may guarantee the engine bed precision is stable, also mayprevent when cutting the cutting tool inspires trembles. Uses the enclosed lathe bed design,the overall casting lathe bed, the symmetrical lathe bed structure and has the denselycovered stiffener and so on also enhances the engine bed stable important measure. Someengine bed companies research and development departments in design process, but alsouses the modality analysis and the finite element structure computation and so on, optimizedthe structure, stably causes the engine bed strut part to be reliable.2. 2. 2. 2. EngineEngineEngineEngine bedbedbedbed mainmainmainmain axleaxleaxleaxleThe high speed engine bed main axle performance is the realization high-speed cuttingprocessing important condition. The high-speed cutting engine bed main axle rotationalspeed scope is 10000100000m/Min, the main axle power is bigger than 15kW. Is notbigger than 0.005mm through the main axle compressed air of or axial play between thecooling system control hilt and the main axle. Also requests the main axle to have the fastvertical speed, to assign the performance which the position is fast stops (namely to haveextremely high angle addition and subtraction speed), therefore the high speed main axleoften uses the liquid static pressure bearing type, the air static pressure bearing type, thethermo-compression nitriding silicon (Si3N4) the ceramic bearing magnetism aerosolbearing type isostructuralism form. Lubricates uses technology and so on oil gas lubrication,splash lubrication. The main axle cools uses the main axle interior water cooling generallyor air cooled.43. 3. 3. 3. TheTheTheThe engineengineengineengine bedbedbedbed actuatesactuatesactuatesactuates thethethethe systemsystemsystemsystemIn order to satisfy the mold high speed processing the need, high speed processes theengine bed the actuation system to be supposed to have the following characteristic:(1)(1)(1)(1) highhighhighhigh enteringenteringenteringentering forforforfor speed.speed.speed.speed.The research indicated that, regarding the minor diameter cutting tool, enhances therotational speed and each tooth enters for the quantity is advantageous in reduces the cuttingtool attrition. At present commonly used entering for the speed range is 2030m/Min, likeuses leads greatly the ball bearing guide screw transmission, enters may reach 60m/ for thespeedMin; Uses the straight line electrical machinery then may enable to achieve 120m/ tothe speedMin.(2)(2)(2)(2) highhighhighhigh acceleration.acceleration.acceleration.acceleration.Has the good acceleration characteristic to the three dimensional complex curvedsurface silhouette high speed processing request actuation system, the request provides thedriver which the high rapid advance or progress gives (to enter speed approximately 40m/quicklyMin, the 3D outline processing speed is 10m/Min), can provide 0.4m/S2 to 10m/Thes2 acceleration and reduces the speed.The engine bed manufacturer mostly uses the entire closed loop position servo-controlslightly to lead, the great size, the high grade ball bearing guide screw or leads greatly manyguide screws. Along with the electrical machinery technology development, the advancedstraight line electric motor already was published, and the success applied in the CNCengine bed. The advanced straight line direct motor drive enable the CNC engine bed nolonger to have the mass inertia, in advance, question and so on lag and vibration, sped upthe servo speed of response, increased the servo-control precision and the engine bedprocessing precision.4. 4. 4. 4.NumericalNumericalNumericalNumerical controlcontrolcontrolcontrol systemsystemsystemsystemThe advanced numerical control system is guaranteed the mold complex curved surfacehigh speed processing quality and the efficiency key aspect, the mold high-speed cuttingprocessing to the numerical control system basic request is:A. High speed numerical control return route (Digital control loop), including: 32 or above64 bit parallel processors and 1.5Gb hard disk; Extremely short straight line electricalmachinery sampling time.B. Speed and acceleration feed-forward control (Feed forward control); Digital actuationsystem crawling control (Jerk control).C. Advanced inserts makes up the method (to insert based on the NURBS transect makes5up), by obtains the good surface quality, the precise size and the high geometry precision.D. Pretreatment (Look-ahead) function. The request has the large capacity cushion register,may read in advance and inspects many segments (for example the DMG engine bed to bepossible to reach 500 segments, the Simens system may reach a 10002000 segment), inorder to when is processed the superficial shape (curvature) changes may promptly adoptchanges for measure and so on speed by avoids cutting and so on.E. The error compensatory function, including because the straight line electrical machinery,the main axle and so on gives off heat the hot error which causes to compensate, thequadrantal error compensates, the measurement system error compensates and so on thefunction. In addition, the mold high-speed cutting processing very is also high to the datatransmission speed request.F.The traditional data connection, like the RS232 serial mouth transmission speed is 19.2kb,but many advanced processings centers haveused the ether local area network (Ethernet)to carry on the data transmission, the speed may reach 200kb.5. 5. 5. 5.CoolingCoolingCoolingCooling lubricationlubricationlubricationlubricationThe high speed processing uses the belt coating the hard alloy tools, in high speed, thehigh temperature situation does not need the cutting compound, the cutting efficiency to behigher. This is because: The milling main axle high speed revolves, the cutting compound ifachieved the cutting area, first must overcome the enormous centrifugal force; Even if itovercame the centrifugal force to enter the cutting area, also was possible as a result of thecutting area high temperature but to evaporate immediately, the cooling effect very small didnot even have; At the same time the cutting compound can cause the cutting tool edge of asword the temperature intense change, is easy to cause the crack the production, thereforemust pick the oil used/Gas cooling lubrication dry type cutting way. This way may use thecompressed gas rapidly the cutting which the cutting area produces, thus the massivecuttings hotly will carry off, at the same time might forms extremely thin microscopicprotective film after the atomization lubricating oil in the cutting tool edge of a sword andthe work piece surface, but effectively will lengthen the cutting tool life and enhances thecomponents the surface quality.Third,Third,Third,Third, high-speedhigh-speedhigh-speedhigh-speed cuttingcuttingcuttingcutting processingprocessingprocessingprocessing cuttingcuttingcuttingcutting tooltooltooltoolThe cutting tool is in the high-speed cutting processing one of most active importantfactors, it is affecting the processing efficiency, the production cost and the product6processing precision directly. The cutting tool must withstand load and so on hightemperature, high pressure, friction, impact and vibration in the high speed processingprocess, the high-speed cutting cutting tool should have the good machine capability and thethermostability, namely has the good anti- impact, the wearability and resists heat the wearycharacteristic. The high-speed cutting processing cutting tool technological developmentspeed is very quick, application many like diamonds (PCD), cubic boron nitride (CBN),ceramic cutting tool, coating hard alloy, (carbon) titanium nitrides hard alloy TIC (N) and soon.In the processing cast iron and in the alloy steel cutting tool, the hard alloy is the mostcommonly used cutting tool material. Hard alloy tools resistance to wear good, but thesolidity ratio cube boron nitride and the ceramics are low. In order to enhance degree ofhardness and the superficially attractive fineness, uses the cutting tool coating technology,the coating material for the titanium nitrides (TiN), the aluminium nitride titanium (TiALN)and so on. The coating technology causes the coating by the sole coating development formultilayered, the many kinds of coating material coating, has become one of enhancementhigh-speed cutting ability essential technical. The diameter in the 1040mm scope, also hasthe carbon titanium nitrides coating the hard alloy bit to be able to process the Luo riverdegree of hardness to be smaller than 42 materials, but the titanium nitrides aluminumcoating cutting tool can process the Luo river degree of hardness is 42 even higher materials.When high-speed cutting steel products, the cutting tool material should select the hotrigidity and the fatigue strength high P kind of hard alloy, the coating hard alloy, the cubicboron nitride (CBN) and the CBN compound cutting tool material (WBN) and so on. Thecutting cast iron, should select the fine grain K kind of hard alloy to carry on the roughmachining, selects the compound nitrided silicon ceramics or the crystal combination cubeboron nitride (PCNB) the compound cutting tool carries on the precision work. Whenprecise processing non-ferrous metal or nonmetallic material, should select crystalcombination diamond PCD or the CVD diamond coating cutting tool. When choice cuttingparameter, in view of the circular shear blade and a ball milling cutter, should pay attentionto the effective diameter the concept. The high speed milling cutting tool should press thebalance design manufacture. The cutting tool front angle must be smaller than theconventional cutting tool front angle, the clearance angle is slightly big. The host vice-cutting edge attachment point should the cavetto or the lead angle, increases the vertex angle,prevents the knife point place hot attrition. Should enlarge nearby the knife point the cuttingedge length and the cutting tool material volume, enhances the cutting tool rigidity. Is safe7in the guarantee and satisfies the processing request under the condition, the cutting toolhangs extends as far as possible short, cutter body central toughness is friends with. The hiltmust be sturdier than the cutting tool diameter, connects the handle to assume but actuallythe pyramidal, by increases its rigidity. As far as possible centralthe refrigerant hole in thecutting tool and the cutting tool system.Aball end mill must consider effectively cuts thelength, the cutting edge must be as far as possible short, two spiral grooves balls end millusually uses in the thick mill complex curved surface, four spiral grooves balls end millusually uses in the fine mill complex curved surface.Fourth,Fourth,Fourth,Fourth, moldmoldmoldmold highhighhighhigh speedspeedspeedspeed processingprocessingprocessingprocessing craftcraftcraftcraftThe high speed processing including take removes the remainder as the goal roughmachining, the residual rough machining, as well as take gains the high grade processingsurface and the slight structure as the goal half precision work, the precision work and themirror surface processing and so on.1. 1. 1. 1. RoughRoughRoughRough machiningmachiningmachiningmachiningThe mold rough machining essential target is pursues in the unit time materialremoving rate, and is half precision work preparation work piece geometry outline. In thehigh speed processing rough machining should adopt the craft plan is the high cutting speed,Gao Jin giving rate and the small cutting specifications combination. The contourprocessing way is one processing way which the multitudinous CAM software usesgenerally. Using is spiral contour and so on the Z axis contour two ways which are many,also is in processes the region only time to feed, in does not lift the knife in the situation toproduce continuously the smooth cutting tool way, enters, draws back the knife way to usethe circular arc to cut into, to cut. The spiral contour way characteristic is, has not waited thehigh level between the knife road migration, may avoid frequently lifting the knife, feedingto the components surface quality influence and mechanical device nonessential consuming.Tois steep and the flat site processes separately, the computation suits contour and suits theuse similar 3D bias the region, and may use the spiral way, in very little lifts the cutting toolway which the knife in the situation produces optimizes, obtains the better surface quality.In the high speed processing, certainly must adopt the circular arc to cut into, to cut theconnection way, as well asthe circular arc transition, avoids changing the cutting tool toenter suddenly for the direction, the prohibition use direct under knife connection way,avoids burying the cutting tool the work piece. When processes the mold cavity, shouldavoid the cutting tool vertical insertion work piece under, but should use inclines the knife8way (commonly used angle of bank for 2030), best uses the screw type under knife by toreduce the cutting tool load. When processes the mold core, should under the knife thenlevel cut into the work piece as far as possible first from the work piece. The cutting toolcuts into, cuts when the work piece should use as far as possible inclines the type (or roundarc-type) cuts into, cuts, vertically avoids cutting into, cutting. Uses climbs up the typecutting to be possible to reduce the cutting heat, reduces the cutting tool stress and the workhardening degree, improves the processing quality.2. 2. 2. 2. HalfHalfHalfHalf precisionprecisionprecisionprecision workworkworkworkThe mold half precision work essential target is causes the work piece outline shapesmoothly, surface finish remainder even, this especially is important regarding the tool steelmold, because it will affect time the precision work cutting tool layer of cutting area changeand cutting tool load change, thus influence cutting process stability and precision worksurface quality.The rough machining is based on the volume model, the precision work then is based on theface mold. Before develops CAD/The CAM system to the components geometry descriptionis not continual, after because has not described in front of the rough machining, theprecision work processes the model the average information, therefore the rough machiningsurface surplus processing remainder distribution and the great surplus processingremainder is unknown. Therefore should fifty-fifty the precision work strategy carry on theoptimization after to guarantee half precision work the work piece surface has the evensurplus processing remainder. The optimized process includes: After the rough machiningthe outline computation, the great surplus processing remainder computation, the biggestpermission processing remainder determination, is bigger than the biggest permissionprocessing remainder the profile district (for example transition radius and so on scoopchannel, corner is smaller than rough machining cutting tool radius region) as well as whenhalf precision work the knife heart path computation to the surplus processing remainderand so on.The existing mold high speed processes CAD/The CAM software has the surplus processingremainder analysis function mostly, and can act according to the surplus processingremainder the size and the distribution situation uses the reasonable half precision workstrategy. After like the MasterCAM software provided has tied the shape milling (Pencilmilling) and the surplus milling (Rest milling) and so on the method eliminates the roughmachining the surplus processing remainder big quoin by to guarantee the following9working procedure even processing remainder.3. 3. 3. 3. PrecisionPrecisionPrecisionPrecision workworkworkworkThe mold high speed precision work strategy is decided by the cutting tool and thework piece contact point, but the cutting tool and the work piece contact point but changesalong with the processing surface curved surface slope and the cutting tool effective radiuschange. Regarding by the complex curved surface processing which many curved surfacecombination but becomes, should carry on the continuous treating as far as possible in aworking procedure, but is not carries on the processing separately to each curved surface, byreduces lifts the knife, under the knife number of times. However, because processes thesuperficial slope change, if only defines the processing the side to eat the knife quantity(Step over), possibly creates on the slope different surface the actual step of distancenon-uniformity, thus influence processing quality.In the ordinary circumstances, the precision work curved surface radius of curvatureshould be bigger than the cutting tool radius 1.5 times, by evades the no admittance to thedirection suddenly transformation. In the mold high speed precision work, when each timecuts into, cuts the work piece, enters for the direction change should as far as possible usethe circular arc or the curve switches over, avoids using the straight line to switch over, bymaintains the cutting process the stability.Fifth,Fifth,Fifth,Fifth, concludingconcludingconcludingconcluding remarkremarkremarkremarkThe high-speed cutting technology is one of machining technology main developmentdirections, at present mainly applies in the automobile industry and the mold profession, inthe processing complex curved surface domain, work piece itself or the cutting tool systemrigidity request high processing domain and so on, is the many kinds of advancedprocessings technology integration in particular, its is highly effective high grade, esteemsfor the people. It not only involves to the high speed processing craft, moreover alsoincludes high speed processes the engine bed, the numerical control is systematic, thehigh-speed cutting cutting tool and CAD/CAM technology and so on. The mold high speedprocessing technology generally has applied at present in the developed country moldmanufacturing industry, but still waited for in our countrys application scope and theapplication level the enhancement, because it had the tradition to process the incomparablesuperiority, still will be the next processing technology inevitable development direction./loecvte/loecvte/loecvte/loecvte/jsvi10模具高速铣削加工技术模具高速铣削加工技术模具高速铣削加工技术模具高速铣削加工技术人为因素研究单位,建立健全的防振动研究,南安普敦大学,S017,IJB 英国摘 要介绍了高速铣削在模具加工中的应用以及影响， 并简要的介绍了高速铣削机床的结构、控制系统和刀具。对高速加工的工艺进行了简单的分析。关键词高速铣削；模具加工一、 前言在现代模具生产中，随着对塑件的美观度及功能要求得越来越高，塑件内部结构设计得越来越复杂，模具的外形设计也日趋复杂，自由曲面所占比例不断增加，相应的模具结构也设计得越来越复杂。这些都对模具加工技术提出了更高要求，不仅应保证高的制造精度和表面质量，而且要追求加工表面的美观。随着对高速加工技术研究的不断深入，尤其在加工机床、数控系统、刀具系统、CAD/CAM 软件等相关技术不断发展的推动下，高速加工技术已越来越多地应用于模具型腔的加工与制造中。数控高速切削加工作为模具制造中最为重要的一项先进制造技术，是集高效、优质、低耗于一身的先进制造技术。相对于传统的切削加工，其切削速度、进给速度有了很大的提高，而且切削机理也不相同。高速切削使切削加工发生了本质性的飞跃，其单位功率的金属切除率提高了 30%40%， 切削力降低了 30%， 刀具的切削寿命提高了70%，留于工件的切削热大幅度降低，低阶切削振动几乎消失。随着切削速度的提高，单位时间毛坯材料的去除率增加了，切削时间减少了，加工效率提高了，从而缩短了产品的制造周期，提高了产品的市场竞争力。同时，高速加工的小量快进使切削力减少了，切屑的高速排出减少了工件的切削力和热应力变形，提高了刚性差和薄壁零件切削加工的可能性。由于切削力的降低，转速的提高使切削系统的工作频率远离机床的低阶固有频率， 而工件的表面粗糙度对低阶频率最为敏感， 由此降低了表面粗糙度。在模具的高淬硬钢件(HRC45HRC65)的加工过程中， 采用高速切削可以取代电加工和磨削抛光的工序，从而避免了电极的制造和费时的电加工，大幅度减少了钳工的打磨与抛光量。对于一些市场上越来越需要的薄壁模具工件，高速铣削也可顺利完成，而且在高速铣削 CNC 加工中心上，模具一次装夹可完成多工步加工。高速加工技术对模具加工工艺产生了巨大影响，改变了传统模具加工采用的“退火铣削加工热处理磨削”或“电火花加工手工打磨、抛光”等复杂冗长的工艺流程，甚至可用高速切削加工替代原来的全部工序。高速加工技术除可应用于淬硬11模具型腔的直接加工(尤其是半精加工和精加工)外，在 EDM 电极加工、快速样件制造等方面也得到了广泛应用。大量生产实践表明，应用高速切削技术可节省模具后续加工中约 80%的手工研磨时间，节约加工成本费用近 30%，模具表面加工精度可达 1 m，刀具切削效率可提高 1 倍。二、 高速铣削加工机床高速切削技术是切削加工技术的主要发展方向之一，它随着 CNC 技术、微电子技术、新材料和新结构等基础技术的发展而迈上更高的台阶。由于模具加工的特殊性以及高速加工技术的自身特点， 对模具高速加工的相关技术及工艺系统(加工机床、 数控系统、刀具等)提出了比传统模具加工更高的要求。1. 高稳定性的机床支撑部件高速切削机床的床身等支撑部件应具有很好的动、静刚度，热刚度和最佳的阻尼特性。大部分机床都采用高质量、高刚性和高抗张性的灰铸铁作为支撑部件材料，有的机床公司还在底座中添加高阻尼特性的聚合物混凝土， 以增加其抗振性和热稳定性，这不但可保证机床精度稳定，也可防止切削时刀具振颤。采用封闭式床身设计，整体铸造床身，对称床身结构并配有密布的加强筋等也是提高机床稳定性的重要措施
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