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快速模具制造技术的发展摘要:快速成形与制造（）作为诞生仅十余年的先进制造技术，已成功地实现了快速原型制造，目前正向快速模具制造（）方向迅速发展。主要介绍了快速制模尤其是快速金属模具制造（）技术的现状和发展趋势，分析了模具快速制造的特点和问题，探讨了快速模具制造技术发展面临的关键问题及其应用前景。关键词: 快速成形 RMT技术 快速模具 RT技术 近年来，制造业市场的制造战略重点正在发生从成本与质量到时间与响应的重大转移。快速将多样化的产品推向市场是制造商把握市场先机而求生存的重要保障，快速响应制造已成为国际研究的热点，应运而生的快速成形/快速制模/快速制造技术为企业提高竞争力提供了一种先进的手段，逐渐成为业界的焦点。据有关媒体报道，传统制造业的战略是规模效益第一，二十世纪八十年代提出价格和质量第一，九十年代以来，已发展为市场响应第一。在制造业日趋国际化的状况下，缩短产品开发周期和减少开发新产品投资风险，成为企业赖以生存的关键。 快速成形/快速制模/快速制造技术是基于材料累加成形的一种高新制造技术,被认为是20世纪制造领域的一次革命性突破，可制造注塑模、压铸模、冲压模等各类精密复杂模具，目前已广范应用于汽车、航空航天、船舶、家电、工业设计、医疗、建筑、工艺品制作以及儿童玩具等领域，并且随着这一技术本身的不断发展和完善，其应用范围将不断拓广。在汽车、家电制造业中，模具成形零件占到了制造工时的5070。模具制造是制约我国汽车、家电、轻工等行业发展的瓶颈和关键，随着快速成型软硬件设备与快速成型材料的不断发展和完善，快速原型件的强度和精度得到不断的提高，快速成型技术已经逐渐地深入到快速模具制造领域，基于快速成型方法制造各类简易经济快速模具已成为RP&M应用的热点问题。一、模具快速制造虽然快速成形技术问世时间不长,但由于它对制造业带来的巨大效益使得这一技术的应用日益广泛，特别是给模具的设计与制造带来了一次飞跃。快速原型技术可精确制作模具的型心和型腔，也可直接用于注射过程制作塑料样件，以便发现和纠正出现的错误。由于快速原型制造这一新技术的应用,使模具的设计与制造逐步趋向于数字化、快速化，使模具制造在缩短周期，降低成本的进程中，大大前进了一步。快速制模技术大都是依据快速成型制作的实体模型即样模(母模)采用拷贝方式(如金属喷涂、电镀、复合材料浇注、精铸等)来快速制造模具主要工作零件(凸、凹模或模腔、模芯)的，其制造周期一般为传统的数控切削方法的1/51/10，而成本却仅为其1/31/5。 根据模具材料、生产成本、RP原型的材料、生产批量、模具的精度要求已开发出多种多样的工艺方法。目前的快速制模方法大致有间接制模法和直接制模法，基于RP快速制造模具的方法多为间接制模法。依据材质不同，间接制模法生产出来的模具有软模、桥模和硬模。软模(softtooling)通常指的是硅橡胶模具。用SLA、FDM、LOM或SLS等技术制作的原型，再翻成硅橡胶模具后，向模中灌注双组份的聚氨酯，固化后即得到所需的零件。桥模(bridgetooling)通常指的是可直接进行注塑生产的环氧树脂模具。采用环氧树脂模具与传统注塑模具相比，成本只有传统方法的几分之一，生产周期也大大减少。模具寿命不及钢模，但比硅胶模高，可达10005000件，可满足中小批量生产的需要。硬模(hardtooling)通常指的就是钢质模具，即用间接方式制造金属模具和用快速成形直接加工金属模具。企业间的竞争日益加剧，产品开发周期要求越来越短，为快速制模技术提供了发展机遇和发展空间。随着工业化生产的发展，快速制模技术越来越受到产品开发商和模具界广泛重视，对其研究正方兴未艾，新的技术成果不断涌现，呈现出生机勃勃的发展趋势，有着强大的生命力。二、注塑模快速制造技术金属喷涂制模法1、金属喷涂制模法简介金属喷涂制模法是将快速原型与热喷涂、快速凝固等方法相结合的间接制模法，其工艺是将熔融或半熔融的金属颗粒喷射到通过SLA、SLS或LOM方法制造的原型上，生成金属薄层，然后补强背衬并除去原型后得到模具产品。目前有两种形式，即雾化喷射法（快速凝固工艺RSP）、喷涂法。当模具要求的寿命在3000件以下时，一般采用以RP原型作母模，将低熔点的熔化金属（如锌铝合金）充分雾化后以一定的速度喷射到母模的表面，形成模具型腔表面，充填背衬复合材料，制作锌铝合金软模具。金属喷涂制模法以样模为标准，模具型腔尺寸、几何精度完全取决于样模，型腔表面及其精细花纹一次同时形成，故制模速度快，制造周期短，模具寿命长，成本低，仅为数控法加工钢模的1/3-1/5。模具表面光洁度好，工艺简单，设备要求低，比较适合于注射成型模、压铸模、板料压延模的快速制造。2、金属喷涂制模法工序金属喷涂制模的工序大致可分为五个步骤：（1）模型准备模型可由许多材料制成，包括塑料、石膏、橡胶、木材等。首先建立三维模型，然后对其进行分层切片，并由快速成型机制作出样模。模型准备中最重要的是清理模型表面和涂抹脱模剂。（2）金属喷涂模型脱模剂干燥后，选择最佳的喷涂参数，即可开始在模具上喷涂金属，喷涂时应保证使喷枪连续运动，防止涂层过热变形，涂层厚度一般可控制在23mm。（3）制作模具框架如果模具在工作中要受到内压力或模具必须安装在成型机上工作，模具必须有骨架结构且制成的骨架应带有填料。（4）浇注模具的填充材料应使填充材料具有较高的热导率和较低的凝固收缩率以及较高的抗压强度和耐磨性能。一般选择的填充材料为环氧树脂与铝粉、铝颗粒等金属粉末的混合物。（5）脱模及模具型腔表面抛光处理脱模后要把残留在金属涂层表面的脱模剂清洗干净，然后再根据不同的需要，对模具进行抛光等后期制作。（6）组装试模3、喷涂设备与喷涂材料金属电弧喷涂工作系统一般由喷涂电源、送丝机构、喷枪和压缩气体等系统组成。XDP-5型电弧喷涂设备工作稳定可靠，使用维护方便，能胜任繁重的喷涂工作，其基本参数为： 电源电压：380 V 额定输入容量：12 KVA 额定电流：300 A 压缩空气使用压力：0.6 Mpa 压缩空气消耗量：1.62 m3/min 送丝速度：04.8 m/min用于电弧喷涂制模的材料，在满足低熔点、低收缩率的情况下，应尽可能具有较好的力学性能和较致密的涂层组织。目前市场提供的电弧喷涂用丝材有铝、锌、铜、镍、不锈钢、铝青铜、巴氏合金、复合丝等许多品种。但高熔点金属，如钢、镍、铜等在喷涂时涂层收缩率、热应力、孔隙率都比较大，涂层易开裂、翘曲、剥落，所以目前只有低熔点的锌、铝丝材适合用于模具制造。三、金属喷涂快速制造注塑模技术的应用范例与发展金属喷涂方法制造的模具特别适于生产反应注塑成型工艺中的聚氨酯零部件的生产，广泛用于塑料加工中的反应注塑成型、吹塑成型、结构发泡以及其它一些注塑成型等工艺中，如汽车制造中可以用来生产驾驶盘、汽车仪表盘、座垫、头部靠垫、阻流板、汽车内饰顶蓬等，在轻工业中则可以用来制造聚氨酯鞋底等，金属喷涂快速模具较硅橡胶快速模具的寿命要长，可以应用在注塑机上进行小批量的制品生产。在应用注塑工艺时应考虑到低熔点合金金属喷涂型腔的性能以及模具的寿命极限。为防止模具过早损坏，注射压力不宜过高，但也必须保证制品能够成形的最小注射压力，否则会产生注不满的现象。金属喷涂注塑模具的成功应用范例：1.花盆底座注塑模具如果用传统的电火花加工的方法，其成本约在40005000元之间，制作时间约在一个月左右，而用电弧喷涂快速制模方法来制作，其费用约为1100元左右，工时为60h左右。这也正是电弧喷涂快速模具制造得到广泛重视的原因之一。花盆底座注塑模具制作加工工序：机加工喷涂用底板凹模型腔壳体喷涂前准备喷涂凹模金属壳体环氧树脂和铝粉配置与填充环氧树脂固化喷涂母模表面清理喷涂凸模金属壳体环氧树脂和铝粉配置与填充环氧树脂固化凸、凹模分离与模具表面清理机加工模具零件组装试模。2.滴灌用滴头快速模具国家节水灌溉中心的滴灌用滴头快速模具是通过制作滴头RP模型，采用金属喷涂制模法制造锌铝合金软模具，注射成型1000件滴头产品，用于农业节水灌溉试验。国家节水灌溉中心以RP&M原型作母模来翻制滴灌用滴头模具，发挥了快速成型制造技术的优越性，快速地实现了新产品的试制，含RP原型，制作生产周期为仅为2周。3、爱达荷注塑模具美国爱达荷国家工程与环境试验中心采用快速凝固工艺即RSP技术实现了注塑模具的快速经济制造。该方法采用快速原型技术制作的样件作为母体样板，通过喷涂到母体样板的金属或合金熔滴的沉积制造模具。 工艺过程为：熔融的工具钢或其它合金被压入喷嘴，与高速流动的隋性气体相遇而形成直径约0.05mm的雾状熔滴，喷向并沉积到母体样板上，复制出母样的表面结构形状，借助脱模剂使沉积形成的钢制模具与母样分离，即可快速制出所需模具。最近，西安交通大学机械工程学院先进制造技术研究所成功采用“电弧喷涂和电刷镀一体化模具制造技术” 进行轿车新车型开发中大型冲压模具快速制造，该技术集成了快速原型、电弧喷涂和电刷镀等技术，采用电弧喷涂工艺在模具母模表面快速沉积一层致密的低熔点金属薄壳，从而制作出模具的型腔；在填充适当的背衬材料并脱模后，利用电刷镀技术在模具工作表面刷镀强化涂层，进而完成模具的快速制造。利用该技术与设备，结合快速原型制造技术和高速数控加工技术，可以低成本高效率地进行大型、精密、复杂以及长寿命模具的快速制造。采用电弧喷涂和电刷镀一体化模具制造技术制造覆盖件模具，成本只有传统机械加工钢模具的1/10，制造周期为后者的1/41/5，经济效益十分可观，非常适合于新车型开发中的样车试制和小批量生产。该技术也可以用于注塑模具快速制造。原文：The rapid development of quickly modeling manufacturing techonologyIn recent years, the manufacturing sector of the manufacturing market is undergoing a strategic focus from cost and quality time with the response to a major shift. Rapid diversification of the product into the market to manufacturers grasp market opportunities for the sake of the survival of important support, and rapid response manufacturing has become a hot international research, the right moment rapid prototyping / rapid tooling / Rapid Manufacturing technology enterprises to improve competitiveness to provide an advanced means of gradually become the focus of the industry.According to media reports, the strategy is the traditional manufacturing economies of scale first, and the 20th century to the 1980s prices and quality first, since the 1990s, has been developed as a response to market first. In the manufacturing sector growing international circumstances, shorten product development cycles and reduce investment risks and development of new products, as for the survival of key enterprises.Rapid Prototyping / rapid tooling / manufacturing technology is based on the rapid accumulation of forming a high-tech manufacturing technology, and is regarded as the 20th century created a revolutionary breakthrough in the field, can produce injection mold, die-casting mould, Die, and other sophisticated Die, Fan has been widely used in the automotive, aerospace, shipbuilding, electrical household appliances, industrial design, medical, construction, crafts, as well as childrens toys, and other fields, and with the technology itself to continuously develop and improve, its scope of application will continue Extension.In the automotive, appliance manufacturing industry, forming mold parts manufacturers account for 50 per cent of working hours to 70 per cent. Mould Manufacturing is constraining our automobiles, household appliances, light industry and the development of key bottleneck, with the rapid prototyping software, hardware, and rapid prototyping materials continuous development and improvement, rapid prototyping of the intensity and precision of continuous improvement, rapid prototyping technology has been gradually into the field of rapid tooling, rapid prototyping based on the simple method of manufacturing various types of rapid economic Die RP & M has become a hot issue Applicationfirst, rapid manufacturing mold Although rapid prototyping technology was first time is not long, but because of its manufacturing sector makes the tremendous benefits this technology becomes more widely available, especially to the design and manufacture of molds brought a leap. Rapid prototyping technology can accurately type heart and mold cavity, and can be used directly in the production process of plastic injection sample, in order to identify and correct the mistakes. Because rapid prototyping and manufacturing applications of this new technology, mold design and manufacturing becoming increasingly digital, and rapid, so a reduction in the mould manufacturing cycle, and reduce their costs in the process, a step forward significantly.Rapid Tooling Technology are based on rapid prototyping model that is produced by entities like mode (the mother mode) used copy format (such as metal coating, plating, composite materials casting, casting, etc.) to quickly manufacture key parts Die (convex and concave die or cavities, core), and its general manufacturing cycle for the traditional method of CNC cutting 1 / 5 to 1 / 10, while its costs are only 1 / 3 to 1 / 5According to mold materials, the cost of production, RP prototype materials, production volume, the accuracy of mold has developed a wide range of Process. The current rapid tooling methods generally have an indirect and direct modelling of the system model, based on the RP rapid manufacturing mold for more indirect methods of modelling. Based on different materials, indirect modelling produced by molds are soft mode, and hard-bridge module. Soft mode (softtooling) usually refers to the silicone rubber mold. By SLA, FDM, SLS or LOM technologies such as the production of prototype and then translated into silicon rubber mold, the mold reperfusion bicomponent polyurethane curing after the necessary parts. Bridge mode (bridgetooling) usually refers to the direct production of epoxy resin for injection molds. Using epoxy resin mold compared with the traditional injection mold, cost only a fraction of the traditional methods, production cycle is greatly reduced. Die life than steel form, but high-silica ratio, up to 1000 5000 to meet the needs of small batch production. Die Hard (hard tooling) usually refers to the steel mold, which uses indirect way in manufacturing metal molds and directly processed by rapid prototyping tool.Enterprises increased competition, product development cycle shorter growing demand for rapid tooling technology offers opportunities for development and development space. With the development of industrial production, rapid tooling technology developers and more and more products Die extensive attention, their research is in full swing, new technologies have emerged results, showing a trend of the development of vibrant, it has great vitality. Second, rapid injection mold manufacturing technology - Metalizing molding method 1, Metalizing molding method Profile Metalizing modelling method is rapid prototyping and thermal spraying, such as rapid solidification method with the indirect model of the system, the process is molten or semi-molten metal particles to spray through the SLA, SLS, or LOM prototype manufacturing, Thin metal production, and then back reinforcement lining and remove mold get prototype products. At present, there are two forms, namely, aerosol spray (rapid solidification process RSP), the spraying method. When asked die in the life of the following 3000, the general RP prototype for the mother to die, the molten metal of low melting point (such as the zinc-aluminum alloy) after full atomization of a certain level of the mother-speed jet to the surface, forming Die cavity surface, filling back lining composite materials, the production of zinc-aluminum alloy die. Metalizing molding die for the kind of a standard mold cavity size, geometric accuracy depends entirely on-die, cavity surface and a fine pattern forming at the same time, the molding speed, short manufacturing cycle, mold, long life, low cost , the only stop in NC machining of 1/3-1/5. Die good surface finish, the process is simple, low equipment requirements, more suitable for the injection molding die, die-casting mould, sheet metal rolling mode of rapid manufacturing. 2, metal spraying process modelling method Metalizing molding processes can be broadly divided into five steps: (1) model preparation Model can be made of many materials, including plastic, plaster, rubber, and timber. First a three-dimensional model, and then Slicing them by the rapid prototyping mechanism-like mode. Model preparation is the most important clean-up of the surface and apply release agent. (2) metal spraying model Release Agent drying, select the best spray parameters can begin spraying metal mold, spray gun should be to ensure that continuous campaigns to prevent overheating deformation coating, coating thickness could be controlled in the 2 to 3 mm. (3) Production Die Frame If die in work or be subject to pressure in the mold must be installed on the machine, mold must have a skeleton structure of the skeleton and should be made with fillers. (4) casting mold filling material Materials should be filled with high thermal conductivity and lower solidification shrinkage rates and higher compressive strength and wear resistance. General choice of filling material for epoxy resin and aluminum, aluminum and other metal particle powder mixture. (5) Stripping and the mold cavity surface polishing treatment Stripping after the metal should remain in the release agent on the surface clean, and then in accordance with their different needs, such as polishing die for post-production. (6) test module assembly 3, spraying equipment and spraying materials Metal arc spraying systems generally work by spraying power supply, wire feeder, Lance and compressed gases such as system. XDP-5 arc spraying equipment stable and reliable work, the use of maintenance convenience, equal to the heavy spraying work, and the basic parameters: Power supply voltage: 380 V Rated input capacity: 12 KVA Current Rating: 300 A The use of compressed air pressure: 0.6 Mpa Compressed air consumption: 1.6 2 m3/min Wire feed rate: 0 4.8 m / min Die arc spraying system for the material to meet the low melting point, low shrinkage rate of circumstances, as far as possible should have better mechanical properties and more dense coating. At present the market with wire arc spray materials are aluminum, zinc, copper, nickel, stainless steel, aluminum bronze, Babbit, composite wire, and many other varieties. But high melting point metal, such as steel, nickel, copper, etc., in the spray coating shrinkage rate, heat stress, greater than the porosity of the coating-cracking, warping, peeling, so only low melting point of zinc, wood Lvsi suitable for mold making. Third, Metalizing rapid manufacturing injection mold technology applications and development paradigm Metalizing mold manufacturing method particularly suitable for the production of reaction injection molding of polyurethane components in the production of plastic widely used in the processing reaction injection molding, blow molding, structural foam, as well as a number of other processes such as injection molding , such as car manufacturers can be used in the production of the steering wheel, car dashboards, upholstery, head Cushion, Baffles boards, automotive interior Roof, in the light can be used to make polyurethane soles, Metalizing Rapid Tooling more rapid silicone rubber mold longer life expectancy, can be used in the injection molding machine for the production of small quantities of products. Injection in the application process should take into account the low melting point metal alloy spraying mold cavity, as well as the performance of the life limit. To prevent damage to die prematurely, the injection pressure should not be too high, it must also be able to ensure that products forming the minimum injection pressure, otherwise they will have a note with the phenomenon. Metalizing injection mold examples of the successful application of: 1. Flowerpots injection mold base If the EDM using traditional methods, and the cost about 5,000 yuan in 4000 to between production for about a month or so, and with rapid tooling arc spraying method to produce, the cost is about 1,100 yuan about working hours 60h around. This is exactly what the arc spraying rapid tooling receive widespread one of the reasons. Flowerpots base injection moulding processes: machining Spray bottom concave shell model cavity preparation spraying spraying metal die epoxy resin and aluminum shell configuration and filled with epoxy curing spraying mother die surface cleaning of metal spraying punch epoxy resin and aluminum shell configuration and filled with epoxy curing convex and concave die separation and surface cleaning mold machining mould parts assembly test mode. 2. Drip emitter using rapid tooling Centre national water-saving irrigation drip emitter rapid tooling is used in the production emitter RP model, using metal spraying system of manufacturing zinc-aluminum alloy soft molds, injection molding 1000 emitter products for agricultural water-saving irrigation test. State water-saving irrigation center to RP & M prototype up for the mother-to-use drip irrigation emitters molds, rapid prototyping play to the advantages of technology, rapid realization of the prototype-a new, including RP prototype, the production cycle for the production of only 2 week. 3, Idaho injection mold United States Idaho National Engineering and Environmental Test Center using rapid solidification process that RSP technology to realize rapid economic injection mold manufacturing. The method uses rapid prototyping technology produced as a kind of model mother, the mother model to spray through the metal or alloy droplet depos