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毕业设计(论文)开题报告题目：加热器底座塑料模具设计 系 别 机电信息系 专 业 机械设计制造及其自动化 班 级 姓 名 学 号 导 师 2012年12月24日1.毕业设计（论文）综述（题目背景、研究意义及国内外相关研究情况）1.1题目背景与研究意义：我国塑料模工业从起步到现在，历经半个多世纪，有了很大发展，模具水平有了较大提高，尤其是塑料模具发展速度将高于其它模具，在模具行业中的比例将逐步提高。本设计题目涉及目标均为工程实际零件，通过对塑件的实体测绘，完成基本参数的采集，然后运用塑料模具设计塑料成型工艺等知识，指导学生利用CAD等软件完成模具结构的设计，并进行相关的计算。本设计旨在锻炼学生在技术应用能力上达到培养目标的基本要求，在塑料成型工艺与塑料模具设计技术方面得到全面提高。1.2 国内外相关研究情况：塑料模具增长迅速，比重不断提高。目前，塑料模具在整个模具行业中所占比重约为30%，在未来模具市场中，塑料模具的发展速度将高于其他模具。模具的精度将越来越高。10年前精密模具的精度一般为5微米，现已达到2-3微米，1微米精度的模具也将上市。多功能复合模具将进一步发展。新型多功能复合模具除了冲压成型零件外，还担负叠压、攻丝、铆接和锁紧等组装任务，对钢材的性能要求越来越高。热流道模具在塑料模具中的比重也将逐渐提高。随着塑料成型工艺的不断改进与发展，气辅模具及适应高压注塑成型等工艺的模具也将随之发展。标准件的应用将日益广泛。模具标准化及模具标准件的应用将极大地影响模具制造周期，还能提高模具的质量和降低模具制造成本。快速经济模具的前景十分广阔。以塑代钢、以塑代木的进程进一步加快，塑料模具的比例将不断增大。由于机械零件的复杂程度和精度的不断提高，对塑料模具的要求也越来越高。模具技术含量将不断提高。2本课题研究的主要内容和拟采用的研究方案、研究方法或措施 2.1主要内容： 2.1.1 本设计是以工程实际零件加热器底座塑料模具设计为对象，用于电热器元件的固定支撑放置，该零件一边有横向侧孔，必须考虑测抽芯机构才能完成，因此需要学生充分运用所学知识进行模具结构设计； 2.1.2 确定模具的设计方案，进行整体设计； 2.1.3 主要部件设计计算及校核； 2.1.4 绘制塑料件零件图与模具装配图； 2.1.5编写设计说明书。 2.2研究方法和步骤： 本设计题目涉及目标均为工程实际零件，通过对塑件的实体测绘，完成基本参数的采集，然后运用注塑模具设计、塑料模具设计、塑料成型工艺等知识，利用AutoCAD和Pro/E或soildworks等软件完成模具结构的设计，并进行相关的校核计算，完成包括选材热处理、制造工艺规程、可行性分析等工作。本设计旨在锻炼我们在专业技术应用能力上达到培养目标的基本要求，在塑料成型工艺与塑料模具设计技术方面得到全面提高。图1.加热器底座零件图2.3拟采用的研究方案：方案一：选用卧式注射机，压块加螺钉固定，浇注系统选用侧浇口；方案二：选用立式注射机，螺钉固定，浇注系统选用点浇口。方案比较：卧式注射机适合于高速化生产，模具装拆及调整容易，采用螺钉加压块固定更加安全，侧浇口形状简单，尺寸容易掌握。综上所述，初步选用方案一。3.本课题研究的重点及难点，前期已开展工作 3.1本课题研究的重点及难点：此制品用于电热器元件的固定支撑放置。制品材料为：ABS（丙烯腈丁二烯苯乙烯共聚物），此材料有良好的耐化学腐蚀、表面硬度、加工性和染色性。制品的壁厚、熔料温度对收缩率影响极小。ABS有较强的抗冲击强度，且在低温下也不迅速下降。ABS有一定的硬度和尺寸稳定性，易于成型加工，经过调色可配成任何颜色。 此制品是批量生产，所以我将设计一套塑料成型模具。在设计模具时需要考虑制品的一些特点。制品的主要特点是该零件一边有横向侧孔，两侧有两个上下通孔，且上下孔形状不规则，注塑时很复杂。塑件的尺寸精度有一定的要求，外型需光洁不得有划伤，总体尺寸大小适中。取塑件的最大截面为分型面，底座上面的左右小孔和主体上左右相同的不规则通孔需要抽芯。开模后，塑件包紧动模型芯的力比较大，采用推管推出，推出力比较平稳，塑件不易发生变形。 3.2前期已开展工作： 3.2.1已简单查阅了资料，对注塑模具设计的流程有了一定的了解； 3.2.2已对塑件结构有了了解，并绘制了CAD图。4.完成本课题的工作方案及进度计划（按周次填写）第1周：查阅和收集资料，初步了解课题； 第2-4周：塑件结构分析与绘制，初步计划了设计方案，完成开题报告；第5-8周：浇注系统等结构的选择和尺寸计算，完成中期报告；第9-12周：绘制装配图及零件图；第13-14周：编写论文；第15周：提交论文并进行终期答辩。参考文献1 曹宏深，赵仲治主编.塑料成型工艺与模具设计.北京：机械工业出版社，19932 李秦蕊主编.塑料模具设计.西安：西北工业大学出版社，19953 洪慎章主编.实用注塑模具结构图集.化学工业出版社，20094 孙玲主编.塑料成型工艺与模具设计.清华大学出版社，20085 孙锡红.我国塑料模具发展现状及发展建议.期刊电加工与模具.20106 我国模具发展趋势.期刊模具制造.20037 蒋继宏，王效岳主编注射模具典型结构100例.中国轻工业出版社.20008 颜智伟主编塑料模具设计与结构设计.北京：国防工业出版社.20069 廖念钊，莫雨松互换性与技术测量M.中国计量出版社.200010 宋满仓主编.注塑模具设计.北京：电子工业出版社.201011 王永平主编.注塑模具设计经验点评.机械工业出版社.300312 张中元编. 塑料成型工艺与模具设计. 北京：航空工业出版社.200513 徐进编. 模具材料应用手册. 北京：机械工业出版社.200814 Mita.T.Yamaguchi.T.Kashiwase.T and Kawase,T. Realization og speed biped using modern control theory.Int. J.Control.1984,40.107-119.15 Eldukhri. E, E.Design and control of a biped walking robot.phD thesis.Department of Electronic and Electrical Engineering Univerity of Salford UK.16 Medrano-Xenda.G A and Eldukhri E.E.Biped robot locomotiong in the sagittal plane,Trans.Trans.Inst.Mcasmt and Control,1997.19.38-49.5.指导教师意见（对课题的深度、广度及工作量的意见） 指导教师： 年 月 日6.所在系审查意见： 系主管领导： 年 月 日毕业设计（论文）中期报告题目： 加热器底座塑料模具设计 系 别 机电信息系 专 业 机械设计制造及其自动化 班 级 姓 名 学 号 导 师 2013年3月20日1. 设计（论文）进展状况 1.1本次设计的塑料件为一长方形半封闭样式的加热器底座，产品特点为：底座必须棱廓分明且外表面光滑，底部有两个空心圆柱，顶部有两个不规则柱孔且对称分布，两侧壁有圆孔，分模时要考虑侧向抽芯，最后要求外表无明显浇口痕迹；座体内部不规则柱体要求与侧壁之间光滑过度，在结构设计时需整体考虑模具的合理性。 图1 加热器底座零件二维图图2 加热器底座零件三维图 1.2在开题的基础上进行了部分零件的计算和设计，已调整了结构方案，修改了零件图的不合理结构，并进一步的完成了模具装配草图的绘制。 1.3通过计算塑料件的体积及查阅相关模具设计手册完成了注塑机的选择。选型为：G54-S-200/400型。相关参数如下： 理论注射量： 200/400cm3 最大注射面积：645cm2 最大模具厚度：406mm 锁模力： 2540KN 最小模具厚度：165mm 定位孔直径： 125mm 模板行程: 260mm 拉杆空间： 290368mm 喷嘴球半径： 18mm 喷嘴孔径： 4mm 1.4确定主流道、分流道的形式和尺寸。其浇口套的尺寸如图3所示。分流道截面形状及尺寸如图4所示。 图3浇口套形式与尺寸 图4 分流道截面形状 1.5确定模腔数量及其排列方式、浇口形式。加热器底座的尺寸不太大，为了降低注射成本，根据所选注塑机的注射量，采用一模两型腔的模具。为了满足较高的外观要求，确定采用侧浇口。其选用的侧浇口结构形式如图5所示。图5 侧浇口结构形式 1.6计算并校核型腔部分的强度和刚度，根据圆形端盖的高度确定型腔板的侧壁厚度，型芯固定板的厚度。并确动模板、顶出板，支块厚度及其模具安装方法。 1.7完成了对模具工作部分尺寸进行设计计算。 1.8完成了模具零件结构设计。比如：导柱、导套、拉料杆、复位杆、顶杆、滑块、推板导柱导套等等。 1.9初步绘制模具装配图如图6所示。图6 模具装配图2. 存在问题及解决措施 2.1未考虑到模具冷却问题。解决措施：在模具内添加了冷却系统。 2.2中间型芯的固定存在问题，未限制周向转动。解决措施：在老师的指导下，查阅了相关手册，在动模固定板和型芯的交界处安装骑缝螺钉，防止其周向转动。3. 后期工作安排12周13周：完善模具结构装配图，并完成所有零件图的绘制工作。14周15周：完成模具零件的选材、工艺规程的编制。16周17周：对所有图纸进行校核，编写设计说明书，所有资料提请指导教师检查。18周：准备答辩； 指导老师签字： 年 月 日注：1. 正文：宋体小四号字，行距22磅；标题：加粗 宋体四号字2. 中期报告由各系集中归档保存，不装订入册。外文翻译Treating and the modern mould make high speed One, summarizes 1 the present situation that the mould makes at present and trend The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. Industrial product part rough process 75%, the finish machining 50% and plastic part 90% will be completed from the mould. The Chinese mould market demand already reaches scale of 500 hundred million yuan at present. The automobile mould , the annual growth rate covering piece of mould especially will exceed 20 %; Also prompt building material mould development , various heterotype material the mould , wall surface and floor mould become new mould growth point , plastic doors and windows and plastic drain-pipe increase to exceeding 30 by in the upcoming several years %; The home appliance mould annual growth rate will exceed 10 %; The IT industry year increases % speed equally exceeding 20 , the need to the mould accounts for 20 of mould marketplace %.2004 annual Chinese machine tools implements industry output value will continue to increase. Our country mould fabrication market potential is enormous. The basis data counts , in recent years, our country mould year gross output value reaches 3 billion U. S. dollar , entrance exceeds 1 billion U. S. dollar, exceed 100 million U. S. dollar outlet. Increase by from 25% to increase to 2005 50% of 1995. The expert foretells that abroad: Asia portion being occupied by in mould fabrication in the whole world, will from 25% to increase to 2005 50% of 1995. Chinese mould industry has been expanding by leaps and bounds , has formed east China and two big South China bases, and has expanded gradually arriving at other province. In 2002 (Shandong , Anhui , Sichuan) in 1996 , mould manufacturing industry output value annual average growth 14% , grows by 25% in 2003. In 2003 our country mould output value is 45 billion RMB. The gross product place occupies the world the 3rd, exports a mould increases 33.5% compared to last year 336,800,000 U. S. dollar. But, contents low our country technology moulds already pile up in excess of requirement , very most support of accurate , complicated top grade mould imports. Every year the entrance mould exceeds 1 billion U. S. dollar. Exceed 100 million U. S. dollar outlet. Precise mould accuracy requires that 3 mu ms , large-scale moulds require that 8000 satisfied kN agree well with model force injection machine request in 2 ; The minitype mould needs the request satisfying the diameter 1 mm silent stock tube. At present, adopt quick-cutting to produce a mould already becoming the general trend that the mould makes, a few moulds have produced a manufacturer in abroad , high-speed machine tool large area has substituted the electric spark machine tool , quick-cutting has improved the mould efficacy greatly. Machine tool enterprise aims at mould manufacturing enterprises , some treating centres 60% all above of the machine tool producing a factory sells treating enterprise to a mould. The mould fabrication enterprise substituting the electric spark finish machining mould gradually in abroad has adopt quick-cutting already commonly , quick-cutting has produced a mould already becoming the general trend that the mould makes gradually , has improved the mould efficacy and mass greatly. Adopt quick-cutting to replace electric spark producing a mould , can get on the stick obviously , improves mould accuracy , life time growing. 2 high speed processes application in making in the mould 2.1 quick-cutting merit: 1) cutter high rotation rate and the machine tool height enter be given to and high acceleration , improve metal excision rate greatly; 2) quick-cutting diminutions cut a force; 3) quick-cutting heat major part generate heat from the cuttings entrainment , workpiece being short; 4) quick-cutting cut down vibration , improve treating mass; 2.2 high speed treating apply to the beneficial result that the mould processes 1) fleetness rough process and half finish machining, improve treating efficiency; 2) high speed high-accuracy finish machining replace only entire the height processing , indicating mass , form accuracy rise , 50%, cuts down repair a mill by hand than EDM processes a potentiation; 3) cuts the surface processing final molding stiffly , improve surface mass , form accuracy, the treating (not only being that surface harshness is low, and the surface radiance is high) , being used for complicated surface has more advantage; 4) the surface loss that EDM treating produces , improve mould life-span 20%; 5) processes an electrode rapidly combining with the CAD/CAM technology , especially, the form is complicated , thin-wall is similar to an electrode. 3 adopt quick-cutting to process a mould needing the problem solving In in the homeland, since the aspect cause such as fund , technology , the quick-cutting applying produce a mould be in the initial stage stage. Return the machine tool , cutter , handicraft back to existence as well as some problem of aspect needs to proceed orderly other solve. The shortcoming is that finished cost is high, correct cutter sigmatism have comparatively high demand, can not have used big cutters , need to have the complicated computer programming technology to be used for support , equipment running cost height. Two, the high speed processing a moulds processes a machine tool Mould finish machining and hard cutting treating require that the numerical control high-speed machine tool , form board , model put up the precision processing need , high-effect numerical control machine tool etc.The mould aiming at produces a lot of machine tool enterprise , some treating centres 60% all above of the machine tool producing a factory sells enterprise to a mould. The fixed assets having 5 billion yuan without exception in the upcoming several years throws into mould industry , 80% is the machine tool buying a mould process equipment , just saying every year having 4 billion yuan of RMB to buy Jinqie among them. At present average our country numerical control machine tool utilization ratio approximately 20%, the high-speed machine tool utilization ratio 3 5%. Also, mould enterprise has the unit suitable to buy a high-speed machine tool , complies with 6000 40000 rmps to have. 1 high-speed machine tool technology parameter demands Process centre chief axis high-power , high rotation rate , satisfied rude finish machining; The finish machining mould wants to need to reach 15000 20000 rmp like the cutter , the machine tool with minor diameter. Generally, the chief axis rotation rate machine tool under 10000 rpm can carry out rough process and half finish machining , cannot reach the finish machining accuracy; Have no way to reach 400 the above m/min cutting speed. 2 five scrolls of machine tools application increases a trend 1) treating route is nimble , the surface form is complicated; 2) treating range is big , the various type mould suitable processes; 3) cuts life-span of condition easy to cut down cutter wear , to raise a cutter,; 3 the softwares buying CAD/CAM and high-speed machine tools assort On the grounds of the machine tool , major part counting , having several billions U. S. dollar to be used to enter port every year, the electromachining machine tool and the high-speed machine tool need to import. Three, quick-cutting mould cutter technology Quick-cutting processes the cutter needing allocating proper quick-cutting. Progressing processing cutter materials in high speed has urged development of high speed treating. The cutter , knife edge headquarter and high tenacity base gathering crystal strengthening the ceramics cutter being able to be used giving consideration to high hardness experience and observe carbide alloy coating becoming possibility. Gather the crystal cube nitriding boron (PCBN) bit, whose hardness may amount to 3500 4500 HV. Gather crystal miamond (PCD) its hardness but amount to 6000 10000 HV. Germany SCS , Japan Mitsubishi (magical steel) and Sumitomo , Switzerland Shanteweike , USA Kenna are in recent years swiftly large wait for the famous abroad cutter company to successively have debuted the respective quick-cutting cutter, not only cutter having average structural steel of quick-cutting, the ceramics cutter still having direct quick-cutting of energy quenching hard steel is waiting for an effect to surpass the hard cutter, especially the coating cutter appears all of a sudden , bringing into play in quenching half finish machining and finish machining of hard steel. New cutter material and cutter technology appearing already make the bottleneck problem that high speed has processed no longer be able to appear on the cutter. But, expensive entrance cutter price also blocks quick-cutting mould key factor. Above to come to saying the cutter and the cutter holder acceleration reach 3 gs the sort, the cutter circular runout needs to be smaller than 0.015 mm, but the knife length is unable greater than 4 times cutters diameter. The reality according to SANDVIK company has counted , the carbide alloy has stood on in the entirety using carbon nitriding titanium (TICN) coating when milling cutters (58 HRC) carry out high speed bright metal chopping , rough process cutter linear speed has been 100 m/min about , whose linear speed has exceeded but 280 m/min when finish machining and microstoning. Such demands to cutter material (include the hardness , tenacity , red hardness keep the form (include row of crumbs function , surface accuracy , dynamic balance sex etc. (cutting the function) , the cutter under high temperature state) as well as cutter life-span all has very highly. Experience according to in the homeland mould high speed finish machining, linear speed has exceeded 400 800 m/min when adopt the young diameter ball head milling cutter to carry out mould finish machining. The machine tool choosing sufficient high-speeds cuts mould finish machining stiffly. Delcam adopt 0.8 mm diameter cutter to process the narrow slot , rotation rate 40000 rpm , 0.1 mm depth, feed speed 30 m/min. 1 chooses the cutter parameter , the cutter waits if shouldering an anterior angle. The cutter requires that the ability processing request shock resistance tenacity more highly , requiring that heat resistance pounds than average is strong; 2 adopts various method improving cutter life-span , reduces cutter cost. 3 adopt the high speed hilt , HSK hilt , heat pressing applying the most being at present to pretend to grip a cutter. Pay attention to a cutter pretend to grip overall in the day afer tomorrow dynamic balance; 4current cutter enterprise has already done many jobs in the field of the technology resolving the quick-cutting cutter , serving facing the cutter processing may help to solve much problem , the cutter has produced a manufacturer becoming the main body , the reference cutter has produced the technology parameter that the manufacturer provides. Four, improve quick-cutting mould efficiency technology 1 cutter diameter and the length choice 2 HSM and the EDM choice 3 does cutting and the lubricating cooling 4 feeds choice: Move forward generally giving amounts milling cutter diameters 10% , move forward giving a width milling cutter diameter 40%. According to material, condition chooses the parameter processing handicraft rationally High speed bright metal cuts the mass processing part material abroad fairly good, material quality level is identical , the treating function comparison is stable; But, the cutter that the company produces abroad is also that the standard makes an experiment with their material; The treating being recommended by is suitable to their standard comparatively like the parameter , material quality has the certain difference with domestic part , this difference shows comparatively obviously , some parameters can apply directly, but some effect dispatches right away comparatively during the period of high speed bright metal chops if using their cutter. But select and use part material quality in the homeland like enterprise having the certain standard, what be put into use part material, can use the part material quality that high speed processes especially , the general meeting is limited in some part material range inner, that this applies the high speed processing technology to us has also provided advantageous condition , has been able to apply to less treating material within range. Being needing to emphasize that here, must choose the treating technological parameter optimizing out a set of capital suitable enterprise on these material , is brought into company standard and. The technology selecting and using the domestic cutter , seldom having the bright metal recommending high speed to chop parametric , is necessary making an experiment, get the comparatively satisfied parameter , produce a manufacturer had better to select and use the fixed cutter , cut down the number of times testing that , the standard forming a processing technology, such can improve effective utilization ratio of equipment , lowers production costs , can get the fairly good economic effect. Five, quick-cutting route processing a cutter and programming 1) flat surface feeds the route choice 2) 2) outlines process the route choice 3) Keep cutting loading stable 4) keeps relatively stable moving forward giving amounts and feed speed 5) keeps the garden corner in flat surface cutting 6) chooses the finish machining margin rationally Programming demand of HSC finish machining to CAM: 1) the bright metal avoiding a corner to the full cuts motion; 2) tries ones best to avoid external feed of workpiece and enter next depth return knife motion , direct from the outline. Or adopt a helical line or being sure enter slanting to moving forward; 3) constant each edge feed , improve the quality, prolongs cutter life-span; 4) outline treating are kept waiting in level surface. Quick-cutting CAM software: Several years ago will have started quick-cutting processing programming technology research, the Delcam company , has developed the quick-cutting automation programming software module; Lately, the MasterCAM company has also developed the quick-cutting automation programming software module; You also are in in the homeland north navigation developing the quick-cutting automation programming software module; Six, high-speed machine tool numerical control system characteristic 1) high speed data is processed 2) corner forecasts are handled 3) NURBS are not justified appearance strip runin curve treating Seven, safe quick-cutting mould problem 1） Monitoring wearing a cutter away and destroying; 2） Intensity that the bit links; 3） Strict with the machine tool and the cutter examination is very important and before the average machine tool processing diversity , safety protects and starts up. Eight, there exists problem in our country at present in adopt high speed to process the mould technology 1 machine tool: 1) domestic high-speed machine tool overall function still has the gap , the function component function to be able to not satisfy a request. Power and rotation rate including the electricity chief axis, entrance machine tool price is high; 2）Under the machine tool high speed, the dynamic behaviour studies the function being not enough to affect a complete machine as a result,; 3）The five scroll of machine tool is not enough mature , entrance machine tool price is very high; 4) supporting technology and equipment are fairly incomplete 2 cutters: 1) domestic cutter is not able to adapt to the quick-cutting application , high speed cuts only entire treating especially stiffly. Entrance cutter price is high. The cutter technology is to affect quick-cutting processing a key factor of mould. 2) supporting technologies are not enough to include hilt , online dynamic balance in complete set etc. 3 high speed moulds process the technology and the experiment 1) Be short of the accumulation applying experience since high speed processes the mould history comparatively shortly,; 2）The comparison studying comparison stops throwing into lack, sets up a project to quick-cutting handicraft is difficult; 3) Be short of the quick-cutting data base or the handbook , is still blank space at present; 4) moulds produce the manufacturer cognition lack to quick-cutting , the analysis contrast being short of long range beneficial result; 4 Be short of the quick-cutting automation programming software; 5 Be short of a five scroll of gear quick-cutting automation programming CAM software.Concluding remark The mould marketplace has the intense need, but technology to be unable to keep abreast with to high speed treating. Starting is late , the basis is relatively poor , overall engineering level not being taller than , develops slowlyRequire that one by one, aspect coordinated growth , the product mimic inkstone throwing into combining with enlarging, each comprehensive utilization aspect strengths drive quick-cutting application in making in the mould. Our hope , effort passing every aspect, before the market demand push go down , pass technological progress, look like automobile , machine tool , home appliance , before long, not only our country being going to become a mould producing Great Power, and be going to become a mould producing the powerful country.References 1, Jin Diecheng , Song Fangzhi. The modern mould makes the technology , Beijing: Mechanical industry press, 2001. 2, Xu Hefeng, The digitization mould makes the technology , Beijing: Chemical industry press, 2001. 3,Zhao Bo ,High speed processes the forward position technology that the mould processes. Mould technology , 2000 , (2) 4,Zhang Haiou,The fleetness mould makes the technology current situation and their developing trend. Mould technology , 2000 , (6) 5,Guo Dongming,Wang Xiaoming,Be geared to the needs of the particular kind processing technology that the fleetness creates. Chinese mechanical engineering , 2000 , (11)高速加工和现代模具制造 一、概述 1目前模具制造的发展现状和趋势 模具作为重要的工艺装备，在消费品、电器电子、汽车、飞机制造等工业部门中，占有举足轻重的地位。工业产品零件粗加工的75%，精加工的50%及塑料零件的90%将由模具完成。目前中国模具市场需求已达 500 亿元之规模。汽车模具、特别是覆盖件模具年增长速度将超过 20 %；建材模具也迅速发展，各种异型材模具、墙面和地面模具成为模具的新增长点，今后几年塑料门窗和塑料排水管增长将超过 30 %；家电模具年增长速度将超过 10 %；IT 业年均增长速度超过 20 % ，对模具的需求占模具市场的 20 %。2004 年中国机床工具工业产值将继续增长。我国模具制造市场潜力巨大。根据资料统计，近年来，我国模具的年总产值达到30亿美元，进口超过10亿美元，出口超过1亿美元。增长从1995年的25% 增加到2005年的50%。国外专家预言：亚洲在全球模具制造中占据的份额，将从1995年的25%增加至2005年的50%。 中国模具工业发展迅速，形成了华东和华南两大基地，并且逐渐扩大到其他省份。(山东,安徽,四川) 1996年2002年，模具制造业产值年平均增长14%，2003年增长25%。2003年我国模具产值为450亿人民币。总产量位居世界第3，出口模具3.368亿美元，比上年增长 33.5%。但是，我国技术含量低的模具已供过于求，精密、复杂的高档模具很大部分依靠进口。每年进口模具超过10亿美元。出口超过1亿美元精密模具精度要求在 23 m,大型模具需要满足8000kN合模力注塑机的要求;小型模具需满足直径1mm塑料管的要求。目前，采用高速切削生产模具已经成为模具制造的大趋势，在国外一些模具生产厂家，高速机床大面积取代电火花机床，高速切削大大提高了模具生产效率。机床企业瞄准模具生产企业，有的加工中心生产厂机床的60%以上卖给模具加工企业。高速切削逐渐取代电火花精加工模具在国外的模具制造企业已经普遍采用，高速切削生产模具已经成为逐渐模具制造的大趋势，大大提高了模具生产效率和质量。采用高速切削替代电火花生产模具，可以明显提高效率、提高模具精度、使用寿命长。 2高速加工在模具制造中的应用 21高速切削的优点： 1） 刀具的高转速和机床的高进给以及高加速度，大大提高金属切除率； 2） 高速切削减小切削力； 3） 高速切削热大部分由切屑带走，工件发热少； 4） 高速切削减少振动，提高加工质量； 22高速加工应用于模具加工的效益 1） 快速粗加工和半精加工，提高加工效率； 2） 高速高精度精加工硬切削代替光整加工，表明质量高，形状精度提高，比EDM加工提高效率50%，减少手工修磨； 3） 硬切削加工最后成型表面，提高表面质量、形状精度，(不仅是表面粗糙度低，而且表面光亮度高)，用于复杂表面的加工更具优势； 4） 避免EDM加工产生的表面损伤，提高模具寿命20%； 5） 结合CAD/CAM技术快速加工电极，特别是形状复杂、薄壁类电极。 3 采用高速切削加工模具需要解决的问题 在国内，由于资金、技术等方面的原因，应用高速切削生产模具还处于初期阶段。 还存在机床、刀具、工艺以及其他方面的一些问题需要逐步解决。 缺点是加工成本高，对刀具的使用有较高的要求，不能使用过大的刀具，要有复杂的计算机编程技术做支持，设备运行成本高。 二、加工模具的高速加工机床 模具精加工和硬切削加工需要数控高速机床,模板、模架加工需要精密、高效数控机床等。许多机床企业瞄准模具生产，有的加工中心生产厂机床的60%以上卖给模具企业。模具行业今后几年年均有50亿元的固定资产投入，其中80%是购买模具加工设备，也就是说每年有40亿元人民币要购买金切机床。目前我国数控机床的平均利用率大约20%，高速机床的利用率35%。模具企业也有相当的单位购买高速机床，从600040000rmp的都有。 1高速机床的技术参数要求 加工中心主轴大功率、高转速，满足粗精加工；精加工模具要用小直径刀具，机床一般要达到1500020000rmp。通常主轴转速在10000rpm以下的机床可以进行粗加工和半精加工，达不到精加工的精度；无法达到400m/min以上的切削速度。 2 五轴机床的应用增加趋势 1）加工路线灵活，表面形状复杂； 2）加工范围大，适合多种类型模具加工； 3）切削条件好，减少刀具磨损，提高刀具寿命； 3 购买CAD/CAM软件