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- 1 -毕 业 实 习 报 告 长春旭阳富奥江森汽车座椅骨架有限责任公司一、企业简介长春旭阳富奥江森汽车座椅骨架有限责任公司是由长春旭阳工业（集团）股份有限公司与长春富奥江森自控汽车饰件系统有限公司经过友好协商，本着平等互利共同发展的原则，双方共同出资于 2004 年 12 月 15 日在长春市经济技术开发区工商分局注册成立的企业。公司注册资本 5000 万元人民币，长春旭阳工业（集团）股份有限公司以其座椅分公司厂房、设备等实物净资产 3000 万元出资，占注册资本的 60%；长春富奥江森自控汽车饰件系统有限公司以设备、技术及部分材料 2000 万元出资，占注册资本的 40%。公司主要经营范围是：设计、生产、销售汽车座椅骨架、仪表板骨架、冲压件等机械产品，并提供售后服务以及公司董事会随时决定的其它产品。公司主要生产设备：CNC 钢丝弯曲机、粉末静电喷涂线、冲压生产线、焊接机器人生产线、座椅装配线、高频焊管生产线、阴极电泳线、电镀自动生产线。公司包括六个分厂，分别是：冲压分厂、材料分厂、焊装分厂、机加分厂、工具分厂及涂装分厂。我已经在该公司上班，经公司安排我在未来的六个月里分别在公司的六个分厂进行实习，我在学校安排的实习时间里分别在冲压分厂、材料分厂与工具分厂进行生产实习工作。二、实习内容生产实习是我们材料成型专业知识结构中不可缺少的组成部分，并作为一个独立的项目列入专业教学计划中。其目的在于通过实习使学生获得基本生产的感性知识，理论联系实际，扩大知识面；同时生产实习又是锻炼和培养学生业务能力及素质的重要渠道，也是学生接触社会、了解企业状况的一个重要途径，逐步实现由学校学习到社会工作的转变。通过生产实习可以培养我们初步担任技术工作的能力、初步了解企业管理的基本方法和技能；体验企业工作的内容和方法。这些实践知识，对我们今后的学习乃至以后的工作，都是十分有必要的。实习内容：1. 了解实习企业概况，设备及生产和管理情况。- 2 -2. 收集课题相关资料，重点掌握复合模、连续模设计、制造、装配及维修等方面知识。三、实习过程3.1 入厂前培训在实习过程中，我主要在冲压分厂、材料分厂、工具分厂进行了实习。3.1.1 冲压分厂简介长春旭阳富奥江森汽车座椅骨架有限责任公司的冲压分厂可以说是该单位的支柱，公司大部分产品都是在这个车间生产的。车间工作人员情况：在职冲压工人 200 余名、机修、天车、辅助工人若干名。车间设备情况：两台 500 吨液压压力机、六台 250 吨曲柄压力机、两台 250 吨液压压力机、100 吨、60 吨曲柄压力机若干。车间生产产品：由于冲压分厂是该企业的支柱分厂，加工产品众多。只举出几件产品如开迪、红旗、奥迪、宝莱、捷达等汽车的座椅座盆。3.1.2 材料分厂简介长春旭阳富奥江森汽车座椅骨架有限责任公司的材料分厂主要是该单位原材料与半成品的分厂。该分厂是这个企业中较小的一个分厂。车间工作人员情况：在职工人 38 人，机修、天车、电工共 8 人。车间设备情况：高频焊管机、平板机、剪板机、曲柄压力机及弯管机。主要产品有：马自达 6 左右横梁，捷达左右管框，一汽红旗座椅管框，及冲压用的板材与焊管。3.1.3 工具分厂简介长春旭阳富奥江森汽车座椅骨架有限责任公司的工具分厂是主要进行该厂模具维修及小型模具制造的工作单元。该分厂是这个企业的一个必不可少的单元，因为该企业的主要产品是冲压件，模具损坏是不可避免的。该分厂每天的工作量都很大，只要该企业任何一个分厂的模具出问题，工具分厂都要指派专业技术人员前往现场研究模具维修方案，为保证工厂能顺利的生产，工具分厂的作用是显而易见的。车间工作人员情况：模具钳工 10 人，车床、铣床、刨床、磨床操作工人共 15人，镗床、电火花机床、线切割机床、数控铣床操作工人共 9 人。车间设备情况：车床、铣床、刨床、磨床、镗床、电火花机床、线切割机床、数控铣床。- 3 -3.1.4 长春旭阳富奥江森汽车座椅骨架有限责任公司安全通则1)在工作中和上班前四个小时内不准饮酒。2)不准把小孩带进车间。3)作业前必须按规定穿戴好劳动保护用具。4)工作前要检查工具、设备、安全措施是否完好，发现缺陷要及时汇报和处理。5)不是自己操作的设备不准随意开动，各种开关、阀门、警告牌等不准乱动。6)工作中不准唱歌、闲谈、打闹，以及做与工作无关的事情。7)非电气人员不准装拆电气设备和线路。8)变电间、配电间、油库、漆库、空压站等要害部位，非本岗人员未经许可不准入内，9)不准跨越运转着的设备和各种输送带、输送链，并严禁对运转中的设备进行加油、擦拭、清扫等工作。10) 凡标有“禁止烟火”的场所，不得吸烟或未经许可进行明火作业。11) 各处消防器材要经常保持良好状态，不得乱动乱用。12) 各种安全防护装置信号标志等要经常保持齐全有效，不准任意拆除。13) 保持工作场所整洁和道路畅通及零件按规定堆放。14) 一旦发生重大或恶性未遂事故时要保护现场，做好受伤人员的救护工作和防止事故扩大工作，并及时上报安全部门及领导。15) 一旦发生触电身亡事故时，要迅速使受害者脱离电源，并就地立即抢救（人工呼吸） ，同时通知医疗部门及领导。3.2 进厂实习3.1.1 冲压分厂实习在冲压车间实习的几天里我深刻体会到冲压的危险性，为此，我学习了在设计冲压模具时要注意的安全要求。设计冲压模具时除了应考虑到保证冲压件的质量外，还必须考虑到其安全性。为防止操作者的手不进入上下模具空间，在冲压模具上可以设计机械化上下料装置或采用复合模具、连续模具等。为防止人体某一部分夹入模具之间，模具导柱末端外露不得大于 8mm，尽量减少模具辅助部件冲压危险区，在危险部位开设放手的安全糟，或设置防护栏棚等。为了防止冲压模具破碎伤人，模具应具有足够的强度，除工作部分外，不得有尖角；定位件应压入配合；紧固件应有防松措施；冲压模具的负荷中心尽量与压力机中心重合；模具上使用的弹簧应为压缩弹簧，并加设必要- 4 -的护罩等。在冲压分厂，除了对安全有了一个深刻的认识外，在与现场工程师交流学习中我还对自己以前不太熟悉的一些冲压模具知识有了一个深层次的认识。1)首先，冲压模具都能完成哪些工作呢？剪断加工(切断铁板完全分离) ，穿切(冲切)，呈封闭曲线的完全分离，外形切割(外切割)、侧面切割，呈开放型曲线的完全分离，打眼儿(穿孔)，打洞，切断(剪切)，完全分离，切开(冲口)，部分性分离。弯曲(弯曲)，除弯成 V 字型的 V 弯曲之外，还有 L 字弯曲、台阶状的 Z 字弯曲、N 字弯曲、帽型弯曲等。 ，弯成筒型的卷边加工(蝶板弯曲)、圆型弯曲，扭转弯曲，拧弯，加工成有底的容器状。冲绞产品：干电池套(碱性电池、锂电池(锰钢电池罐的小型化处理)、电容器盒、洗碗池、汽车的引擎罩、V 型皮带轮罩、易拉罐的拉手和盖子之间的接合等。冲压模具还能进行许多种加工、这里只介绍上述加工的几种应用及组合。半穿孔、凸出、打通、切弯、压瘪、打钢印、修边、细冲切等。2)其次就是对冲压模具结构及各部分作用有了更深层次的了解。冲压模具的构造大体上可分为刀具部、保持部和辅助部。 刀具部(打孔机、冲模)直接作用于材料的部分保持部(打孔机盘、冲模盘、外套、挡板等)作用是固定刀具辅助部(脱模器、量计、衬垫、压力等)为是刀具发挥作用的辅助部分打孔机盘+打孔机+导销3.2.2 材料分厂实习材料车间是供应原材料与半成品的车间，设备有限，我只对本车间的高频焊管机的生产工艺流程进行了初步的了解。高频焊管机的生产工艺流程纵剪 开卷 矫平 剪切对焊 高频焊接 TBS 成型 铣边 螺旋活套 去内外毛刺 超声波探伤 焊缝热处理 空冷水冷 平端 切断 矫直 定径 水压试验 全管体探伤 综合检验 印标 - 5 - 发运 入库 打包3.2.3 工具分厂实习在工具分厂实习的几天里，我学到了不少知识，对一些冲裁模具常见维修问题做了如下总结：1) 冲头易断原因分析处理方法薄弱冲模切入刃口部分过长重新计算其长度使切入刃口部分合理下模刃口被废料堵死清除堵死的废料冲头太过松动重新固定冲头冲头刃口钝化/材质硬度高研磨刃口/更换冲头材质打板导向不良,冲头单边受力修配打板间隙冲头刃口太短,与打板干涉增长刃口长度卸料力不均,卸料倾斜调整卸料力上下模间隙变位调整间隙薄弱冲模设计不合理修改结构,增加強度2) 毛边毛刺原因分析处理方法刃口不锋利或崩缺研磨刃口冲头拉伤或崩缺研磨冲头冲头与刃口间隙不当调整间隙送料不到位或定位不良调整送料及定位压毛边压出毛刺修整压毛边镶件两种切料不吻合产生毛刺设计切料量加 R 角3) 冲孔跳料及堵料原因分析处理方法刃口间隙过大调整刃口间隙冲头过短加高冲头长度冲头或模板未去磁将冲头模板退磁- 6 -落料孔未做锥度加大落料孔斜度刃口钝化,毛边大钻大落料孔,只留直身位刃口直身位太長缩短直身位落料孔有倒角加大落料孔去除倒角由于实习时间有限，只总结出这几点，但这也是我得到的前所未有的收获。四、实习心得为期三周的实习结束了，在这期间我总共在三个车间进行生产实习，在工厂技术人员的带领下看到了很多也学到了很多。让我对原先在课本上许多不很明白的东西在实践观察中有了新的领悟和认识。在这个科技时代中，高技术产品种类繁多，生产工艺、生产流程也各不相同，但不管何种产品，从原料加工到制成产品都是遵循一定的生产原理，通过一些主要设备及工艺流程来完成的。因此，在生产实习过程中，首先要了解其生产原理，弄清生产的工艺流程和主要设备的构造及操作。其次，在专业人员指导下，通过实习过程见习产品的设计、生产及开发等环节，初步培养我们的知识运用能力。我概括起来有以下几方面：1、了解了当代，模具工业的发展概况，生产程序及产品供求情况。2、了解了模具产品生产方法和技术路线的选择，工艺条件的确定以及流程的编制原则。3、了解了模具产品的质量标准、技术规格和使用要求。4、在企业员工的指导下，见习生产流程，锻炼自己的实践能力及知识运用能力。5、社会工作能力得到了相应的提高,在实习过程中，我们不仅从企业职工身上学到了知识和技能，更使我们学会了企业中科学的管理方式和他们的敬业精神。感到了生活的充实和学习的快乐，以及获得知识的满足。真正的接触了社会，使我们消除了走向社会的恐惧心理，使我们对未来充满了信心，以良好的心态去面对社会。同时，也使我们体验到了工作的艰辛，了解了当前社会大学生所面临的严峻问题，促使自己努力学习更多的知识，为自己今后的工作奠定良好的基础。本次实习是我第一次亲身感受了所学知识与实际的应用，理论与实际的相结合，让我们大开眼界，也算是对以前所学知识的一个初审吧！在短短的三个星期中，也让我初步的认识了这个社会，对于以后做人所应把握的方向也有所启发！- 7 -参考文献1 王孝培.冲压手册 ，北京：机械工业出版社，20002 冲模设计手册编写组.冲模设计手册，北京：机械工业出版社，20003 肖景容.姜奎华.冲压工艺学,北京：机械工业出版社，20054 史铁梁.模具设计手册，北京： 机械工业出版社，20065 成虹.冲压工艺与模具设计，北京：机械工业出版社，20036 李天佑.冲模手册，北京：机械工业出版社，20007 赵世友.冲压工实用手册，北京：辽宁科技技术出版社，20068 陈炎嗣.冲压模具设计与制造技术，北京：北京出版社，19919 张辽远.现代加工技术，北京：机械工业出版社，200210齐国光.陈良浩.机械制造学，北京：石油大学出版社，1996 年11朱伟成.汽车零件精密锻造技术，北京：北京理工大学出版社，199912王新华.汽车冲压技术，北京：北京理工大学出版社，199913李天佑.冲模图册，北京：机械工业出版社，198814郑大中.模具结构图册，北京：机械工业出版社，199215周开华.简明精冲手册，北京：国防工业出版社，199916第一汽车制造厂工装设计室.汽车覆盖件冲模，北京：机械工业出版社， 197917王孝培.冲压设计资料，北京：机械工业出版社，198318粱炳文.实用板金冲压工艺图集：第 1 集，北京：机械工业出版社， 199919李硕本.冲压工艺等，北京：机械工业出版社，198220李寿章.板金成型原理与工艺，西安：西北工业大学出版社，198221William F.Hosford,Robert M.Caddell.”Netal formingMechanics and.metallurgy”,PrenticeHall,Inc.WEnglewood Cliffs.N.J.17632,1983毕业实习报告学学 院：院： 机械工程学院 专业年级：专业年级： 材料成型及控制工程 03 姓姓 名：名： 梁恒 班级学号：班级学号： 1-32 指导教师：指导教师： 伦凤艳 二七二七 年年 三三 月月 十十 九九 日日 毕业设计（论文）译文英文题目：英文题目：A LOW COST KNOWLEDGE BASE SYSTEM FRAMEWORK FOR PROGRESSIVE DIE DESIGN 汉语题目：汉语题目： 一种级进模设计的低成本知识库系统框架 学学 院：院： 机械工程学院 专业年级：专业年级： 材料成型及控制工程 姓姓 名：名： 梁 恒 班级学号：班级学号： 1-32 指导教师：指导教师： 伦凤艳 二六二六 年年 六六 月月 十一十一 日日毕业设计（论文）开题报告题目名称：题目名称： 膜片弹簧的冲压工艺及模具设计 学学 院：院： 机械工程学院 专业年级：专业年级： 材料成型及控制工程 03 姓姓 名：名： 梁 恒 班级学号：班级学号： 1-32 指导教师：指导教师： 伦凤艳 二二 七七 年年 四四 月月 十六十六 日日- 1 -膜片弹簧的冲压工艺及模具设计1、本课题的项目背景及研究意义近些年，中国汽车产业飞速发展，以 2006 年为例，据南方都市报 2007 年 3 月6 日报道 2006 年我国汽车行业盈利增长超 200 亿! 2006 年我国汽车产业再度呈现较快发展态势。汽车产销双双突破 700 万辆，分别达到 727.97 万辆和 721.6 万辆，同比增长 27.32%和 25.13%。产销与上年相比增速明显加快。全国汽车行业规模以上企业累计完成工业增加值 3791.02 亿元，同比增长 34.52%，增幅高于全国工业增加值增速水平(16.60%)17.92 个百分点，增长额为 972.91 亿元；累计完成工业总产值15556.16 亿元，同比增长 29.20%，增长额为 3516.17 亿元；累计完成工业销售产值15215.16 亿元，同比增长 2.47%，增长额为 3279.24 亿元。 （4）以上数据可以说明中国汽车业迎来了前所未有的春天，汽车行业的发展也带动了汽车零部件制造业的飞速发展，面临发展就面临竞争，很多汽车零部件企业已经有了很强的危机意识，怎么才能让自己企业的产品在严峻的市场上站住脚已经成为了现在汽车零部件企业领导人迫切要考虑的问题。据统计，在轿车的 2000 余件零件中，冲压件占 40%以上。包括车身覆盖件、车身结构件和中小型冲压件。可见，冲压件在汽车零件中位置的重要性，汽车冲压件的质量取决于什么呢？毫无疑问，是冲压模具。我的毕业设计题目是：膜片弹簧的冲压工艺及模具设计。膜片弹簧是汽车上离合器的一个重要零部件，可以说离合器的质量取决于膜片弹簧的质量。离合器的主要功能是切断和实现对传动系的动力传递。主要作用：1)汽车起步时将发动机与传动系平顺地接合，确保汽车平稳起步；2)在换挡时将发动机与传动系分离，减少变速器中换挡齿轮之间的冲击；3)限制传动系所承受的最大转矩，防止传动系各零件因过载而损坏；4)有效地降低传动系中的振动和噪声。可以看出离合器是汽车一个十分重要了部件。所以离合器的质量至关重要，以膜片弹簧为主要零件的膜片弹簧离合器以其以下优点得到广泛应用：1)膜片弹簧具有较理想的非线性特性；2)结构简单，轴向尺寸小，零件数目少，质量小；3)高速旋转时，压紧力降低很少，性能较稳定；4)压力分布均匀，摩擦片磨损均匀；5)易于实现良好的通风散热，使用寿命长；- 2 -6)平衡性好；7)有利于大批量生产，降低制造成本。 膜片弹簧的作用显而易见，又因为它的自身结构，其生产方法主要是冲压，所以膜片弹簧的冲压工艺及模具设计就显得至关重要。2、本课题研究的理论依据、主要内容及研究方法2.1、理论依据 我的设计题目是膜片弹簧的冲压工艺及模具设计，通过冲裁工艺即可完成该膜片弹簧的生产。依据所学的理论知识，以及自己在工厂实习中学到的知识，冲裁模具设计过程如下：方案设计：在工艺分析的基础上，综合考虑产品的产量和精度要求。所用材料的性能，工厂的技术力量，设备情况及模具制造情况，确定该工件的工艺过程和每道工序的冲模结构形式。详细设计：在方案设计的基础上，进一步设计模具各部分零件的具体结构尺寸。在设计过程中运用到的理论知识如下：1)分析零件的结构形状，尺寸精度，材料、生产批量等是否符合冲压工艺要求，从而确定冲压的可能性和经济性。 材料：零件材料是否具有良好的冲压性能。 结构形状：冲裁件内，外形要尽量避免尖锐清角。 尺寸精度：未注公差按 IT14 级。2)确定冲裁工艺方案及模具结构形式，包括工序性质，工序顺序，工序数目，工序组合及模具结构形式。3)冲压模具的设计计算。（1） 排样设计计算条料宽度计算步距画出排样图（2） 冲压力计算冲压力是指在冲裁时，压力机应具有的最小压力。冲压力是选择冲床吨位，进行模具强度、刚度校核依据。（3） 压力中心计算- 3 -对称形状的单个冲裁件，冲模的压力中心就是冲裁件的几何中心。 （4） 模具刃口尺寸计算（5） 确定各主要零件的外形尺寸（6） 计算模具的闭合高度模具的闭合高度 H 模具应介于压力机的最大装模高度 Hmax 与最小装模高度Hmin 之间，否则就不能保证正常的安装与工作。其关系为： Hmin+10mm=H 模具Hmax，则该压机不能用，若 H 模具Hmax，则可以再加垫板。4)绘制冲模总装图利用自己所学的二维、三维绘图软件进行绘制。5)绘制非标准零件图利用自己所学的二维、三维绘图软件进行绘制，注意标注公差，写明技术要求。（3）2.2、课题研究的主要内容1)确定合理的冲压工艺方案。2)冲压模具结构形式正确。3)所设计的零件具有良好的加工工艺性。4)对关键零部件的强度、刚度进行校核计算。5)所确定的方案及设计结构在满足使用功能的前提下，所设计的冲压模具要便于制造，并具有良好的技术经济指标。2.3、研究方法1)对现有文献分析，查阅现有国内外有关模具设计的文献资料，深刻理解现有冲裁模具的结构及冲压工艺性，设计过程中充分借鉴现有的优良设计结构及工艺，在此基础上进行设计。2)重视理论分析，认真学习与冲裁模具设计、冲压工艺相关的理论，对基本的现有的冲裁模具结构及冲压工艺有十分的了解。掌握基本的模具设计理论模具设计和模具制造。3)在前期充分论证的基础上对其进行详细设计，主要对该零件冲压工艺及冲压模具结构进行论证。4)设计时充分使用指导教师以及身边其他技术人员的人力资源，不盲目设计。- 4 -5)理论与实际相结合，力求设计满足经济行和工艺性要求，使设计真正满足工程化的要求。3、研究条件和可能存在的问题本人大学期间曾经对三维造型软件 UG、PRO/E、CATIA 进行学习，对 UG 的应用较熟练，为本次毕业设计中三维造型部分打下了基础。另外，由于在长春旭阳富奥江森汽车座椅骨架有限责任公司这个特殊的环境里做毕业设计，可以充分与工产的工程师进行交流，能得到大量实际设计经验。由于本课题直接与实际相关，设计的经济性、可靠性、实用性都要做系统的考虑，与平时做的课程设计有本质的区别。膜片弹簧结构如图 3.1 所示，外形简单，只是圆形，但零件中间有 18 个均布的通槽而且每相邻两处通槽间隙很小，一次成型零件质量与模具强度都很难保证。 （4，5）如图 3.1我初步拟定的冲压工艺方案是：成型这个零件的冲压工序分三序，第一序落料冲孔复合模，成型出中心圆孔及圆周的 18 个均布的椭圆形小孔。如图 3.2- 5 -图 3.2第二序以中间的圆孔及前一序冲出的椭圆孔定位，间隔冲出 18 个通槽中的 9 个如图 3.3：图 3.3图 3.3- 6 -第三序冲出其余的 9 个通槽，以前一序冲出的一个通槽前段的椭圆于中间的孔定位完成冲压，如图 3.4：图 3.44、预期成果本课题最终将完成任务书上所要求的全部内容，以及所设计冲裁模具的三维数字化模型。 5、进度安排 序号设计阶段设计内容时间安排1开题阶段收集并整理设计所需的相关资料，撰写开题报告3.193.252方案论证阶段系统方案设计及方案论证3.264.1- 7 -3详细设计阶段模具总体结构设计，零部件设计，绘制图纸4.2 6.34改进设计阶段工艺审查，改进设计6.3 6.125答辩阶段撰写毕业论文，准备答辩。6.136.30- 8 -参考文献1 冲模设计手册编写组.冲模设计手册，北京：机械工业出版社，2000，195-2002 史铁梁.模具设计手册，北京： 机械工业出版社，2006，256-2803 成虹.冲压工艺与模具设计，北京：机械工业出版社，2003，134-1404 William F.Hosford,Robert M.Caddell.”Netal formingMechanics and.metallurgy”,PrenticeHall,Inc.WEnglewood Cliffs.N.J.17632,1983，109-110毕业设计论文外 文 翻 译沈阳航空航天大学毕业设计（论文）2Die history1 Die position in industrial productionMold is a high-volume products with the shape tool, is the main process of industrial production equipment. With mold components, with high efficiency, good quality, low cost, saving energy and raw materials and a series of advantages, with the mold workpieces possess high accuracy, high complexity, high consistency, high productivity and low consumption , other manufacturing methods can not match. Have already become an important means of industrial production and technological development. The basis of the modern industrial economy. The development of modern industrial and technological level depends largely on the level of industrial development die, so die industry to national economic and social development will play an increasing role. March 1989 the State Council promulgated on the current industrial policy decision points in the mold as the machinery industry transformation sequence of the first, production and capital construction of the second sequence (after the large-scale power generation equipment and the corresponding power transmission equipment), establish tooling industry in an important position in the national economy. Since 1997, they have to mold and its processing technology and equipment included in the current national focus on encouraging the development of industries, products and technologies catalog and to encourage foreign investment industry directory. Approved by the State Council, from 1997 to 2000, more than 80 professional mold factory owned 70% VAT refund of preferential policies to support mold industry. All these have fully demonstrated the development of the State Council and state departments tooling industry attention and support. Mold around the world about the current annual output of 60 billion U.S. dollars, Japan, the United States and other industrialized countries die of industrial output value of more than machine tool industry, 沈阳航空航天大学毕业设计（论文）3beginning in 1997, Chinas industrial output value has exceeded the mold machine tool industry output. According to statistics, home appliances, toys and other light industries, nearly 90% of the parts are integrated with production of chopsticks; in aircraft, automobiles, agricultural machinery and radio industries, the proportion exceeded 60%. Such as aircraft manufacturing, the use of a certain type of fighter dies more than 30,000 units, of which the host 8000 sets, 2000 sets of engines, auxiliary 20 000 sets. From the output of view, since the 80s, the United States, Japan and other industrialized countries die industry output value has exceeded the machine tool industry, and there are still rising. Production technology, according to the International Association predicts that in 2000, the product best pieces of rough 75%, 50% will be finished mold completed; metals, plastics, ceramics, rubber, building materials and other industrial products, most of the mold will be completed in more than 50% metal plates, more than 80% of all plastic products, especially through the mold into.沈阳航空航天大学毕业设计（论文）4 2 The historical development of mold The emergence of mold can be traced back thousands of years ago, pottery and bronze foundry, but the large-scale use is with the rise of modern industry and developed. The 19th century, with the arms industry (guns shell), watch industry, radio industry, dies are widely used. After World War II, with the rapid development of world economy, it became a mass production of household appliances, automobiles, electronic equipment, cameras, watches and other parts the best way. From a global perspective, when the United States in the forefront of stamping technology - many die of advanced technologies, such as simple mold, high efficiency, mold, die and stamping the high life automation, mostly originated in the United States; and Switzerland, fine blanking, cold in Germany extrusion technology, plastic processing of the Soviet Union are at the world advanced. 50s, mold industry focus is based on subscriber demand, production can meet the product requirements of the mold. Multi-die design rule of thumb, reference has been drawing and perceptual knowledge, on the design of mold parts of a lack of real understanding of function. From 1955 to 1965, is the pressure processing of exploration and development of the times - the main components of the mold and the stress state of the function of a mathematical sub-bridge, and to continue to apply to on-site practical knowledge to make stamping technology in all aspects of a leap in development. The result is summarized mold design principles, and makes the pressure machine, stamping materials, processing methods, plum with a structure, mold materials, mold manufacturing method, the field of automation devices, a new look to the practical direction of advance, so that pressing processing apparatus capable of producing quality products from the first stage. Into the 70s to high speed, launch technology, precision, security, development of the second stage. Continue to emerge in this process a variety of high efficiency, business life, high-precision multi-functional automatic school to help with. Represented by the number of working places as much as other progressive die and dozens of multi-station 沈阳航空航天大学毕业设计（论文）5transfer station module. On this basis, has developed both a continuous pressing station there are more slide forming station of the press - bending machine. In the meantime, the Japanese stand to the worlds largest - the mold into the micron-level precision, die life, alloy tool steel mold has reached tens of millions of times, carbide steel mold to each of hundreds of millions of times p minutes for stamping the number of small presses usually 200 to 300, up to 1200 times to 1500 times. In the meantime, in order to meet product updates quickly, with the short duration (such as cars modified, refurbished toys, etc.) need a variety of economic-type mold, such as zinc alloy die down, polyurethane rubber mold, die steel skin, also has been very great development. From the mid-70s so far can be said that computer-aided design, supporting the continuous development of manufacturing technology of the times. With the precision and complexity of mold rising, accelerating the production cycle, the mold industry, the quality of equipment and personnel are required to improve. Rely on common processing equipment, their experience and skills can not meet the needs of mold. Since the 90s, mechanical and electronic technologies in close connection with the development of NC machine tools, such as CNC wire cutting machine, CNC EDM, CNC milling, CNC coordinate grinding machine and so on. The use of computer automatic programming, control CNC machine tools to improve the efficiency in the use and scope. In recent years, has developed a computer to time-sharing by the way a group of direct management and control of CNC machine tools NNC system. With the development of computer technology, computers have gradually into the mold in all areas, including design, manufacturing and management. International Association for the Study of production forecasts to 2000, as a means of links between design and manufacturing drawings will lose its primary role. Automatic Design of die most fundamental point is to establish the mold standard and design standards. To get rid of the people of the past, and practical experience to judge the composition of the design center, we must take past experiences and ways of thinking, for series, numerical value, the number of type-based, as the design criteria to the computer store. Components are dry because of mold constitutes a million other differences, to come up with a can adapt to 沈阳航空航天大学毕业设计（论文）6various parts of the design software almost impossible. But some products do not change the shape of parts, mold structure has certain rules, can be summed up for the automatic design of software. If a Japanese companys CDM system for progressive die design and manufacturing, including the importation of parts of the figure, rough start, strip layout, determine the size and standard templates, assembly drawing and parts, the output NC program (for CNC machining Center and line cutting program), etc., used in 20% of the time by hand, reduce their working hours to 35 hours; from Japan in the early 80s will be three-dimensional cad / cam system for automotive panel die. Currently, the physical parts scanning input, map lines and data input, geometric form, display, graphics, annotations and the data is automatically programmed, resulting in effective control machine tool control system of post-processing documents have reached a high level; computer Simulation (CAE) technology has made some achievements. At high levels, CAD / CAM / CAE integration, that data is integrated, can transmit information directly with each other. Achieve network. Present. Only a few foreign manufacturers can do it.沈阳航空航天大学毕业设计（论文）73 Chinas mold industry and its development trend Die & Mould Industry Status Due to historical reasons for the formation of closed, big and complete enterprise features, most enterprises in China are equipped with mold workshop, in factory matching status since the late 70s have a mold the concept of industrialization and specialization of production. Production efficiency is not high, poor economic returns. Mold production industry is small and scattered, cross-industry, capital-intensive, professional, commercial and technical management level are relatively low. According to incomplete statistics, there are now specialized in manufacturing mold, the product supporting mold factory workshop (factory) near 17 000, about 600 000 employees, annual output value reached 20 billion yuan mold. However, the existing capacity of the mold and die industry can only meet the demand of 60%, still can not meet the needs of national economic development. At present, the domestic needs of large, sophisticated, complex and long life of the mold also rely mainly on imports. According to customs statistics, in 1997 630 million U.S. dollars worth of imports mold, not including the import of mold together with the equipment; in 1997 only 78 million U.S. dollars export mold. At present the technological level of China Die & Mould Industry and manufacturing capacity, Chinas national economy in the weak links and bottlenecks constraining sustainable economic development. 3.1 Research on the Structure of industrial products mold In accordance with the division of China Mould Industry Association, China mold is divided into 10 basic categories, which, stamping die and plastic molding two categories accounted for the main part. Calculated by output, present, China accounts for about 50% die stamping, plastic molding die about 20%, Wire Drawing Die (Tool) about 10% of the worlds advanced industrial countries and regions, the proportion of plastic forming die die general of the total output value 40%.沈阳航空航天大学毕业设计（论文）8 Most of our stamping die mold for the simple, single-process mode and meet the molds, precision die, precision multi-position progressive die is also one of the few, die less than 100 million times the average life of the mold reached 100 million times the maximum life of more than accuracy 3 5um, more than 50 progressive station, and the international life of the die 600 million times the highest average life of the die 50 million times compared to the mid 80s at the international advanced level. Chinas plastic molding mold design, production technology started relatively late, the overall level of low. Currently a single cavity, a simple mold cavity 70%, and still dominant. A sophisticated multi-cavity mold plastic injection mold, plastic injection mold has been able to multi-color preliminary design and manufacturing. Mould is about 80 million times the average life span is about, the main difference is the large deformation of mold components, excess burr side of a large, poor surface quality, erosion and corrosion serious mold cavity, the mold cavity exhaust poor and vulnerable such as, injection mold 5um accuracy has reached below the highest life expectancy has exceeded 20 million times, the number has more than 100 chamber cavity, reaching the mid 80s to early 90s the international advanced level. 3.2 mold Present Status of Technology Technical level of Chinas mold industry currently uneven, with wide disparities. Generally speaking, with the developed industrial countries, Hong Kong and Taiwan advanced level, there is a large gap. The use of CAD / CAM / CAE / CAPP and other technical design and manufacture molds, both wide application, or technical level, there is a big gap between both. In the application of CAD technology design molds, only about 10% of the mold used in the design of CAD, aside from drawing board still has a long way to go; in the application of CAE design and analysis of mold calculation, it was just started, most of the game is still in trial stages and animation; in the application of CAM technology manufacturing molds, first, the lack of advanced manufacturing equipment, and second, the existing process equipment (including the last 10 years the introduction of advanced equipment) or 沈阳航空航天大学毕业设计（论文）9computer standard (IBM PC and compatibles, HP workstations, etc.) different, or because of differences in bytes, processing speed differences, differences in resistance to electromagnetic interference, networking is low, only about 5% of the mold manufacturing equipment of recent work in this task; in the application process planning CAPP technology, basically a blank state, based on the need for a lot of standardization work; in the mold common technology, such as mold rapid prototyping technology, polishing, electroforming technologies, surface treatment technology aspects of CAD / CAM technology in China has just started. Computer-aided technology, software development, is still at low level, the accumulation of knowledge and experience required. Most of our mold factory, mold processing equipment shop old, long in the length of civilian service, accuracy, low efficiency, still use the ordinary forging, turning, milling, planing, drilling, grinding and processing equipment, mold, heat treatment is still in use salt bath, box-type furnace, operating with the experience of workers, poorly equipped, high energy consumption. Renewal of equipment is slow, technological innovation, technological progress is not much intensity. Although in recent years introduced many advanced mold processing equipment, but are too scattered, or not complete, only about 25% utilization, equipment, some of the advanced functions are not given full play. Lack of technology of high-quality mold design, manufacturing technology and skilled workers, especially the lack of knowledge and breadth, knowledge structure, high levels of compound talents. Chinas mold industry and technical personnel, only 8% of employees 12%, and the technical personnel and skilled workers and lower the overall skill level. Before 1980, practitioners of technical personnel and skilled workers, the aging of knowledge, knowledge structure can not meet the current needs; and staff employed after 80 years, expertise, experience lack of hands-on ability, not ease, do not want to learn technology. In recent years, the brain drain caused by personnel not only decrease the quantity and quality levels, and personnel structure of the emergence of new faults, lean, make mold design, manufacturing difficult to raise the technical level.沈阳航空航天大学毕业设计（论文）10 3.3 mold industry supporting materials, standard parts of present condition Over the past 10 years, especially the Eighth Five-Year, the State organization of the ministries have repeatedly Material Research Institute, universities and steel enterprises, research and development of special series of die steel, molds and other mold-specific carbide special tools, auxiliary materials, and some promotion. However, due to the quality is not stable enough, the lack of the necessary test conditions and test data, specifications and varieties less, large molds and special mold steel and specifications are required for the gap. In the steel supply, settlement amount and sporadic users of mass-produced steel supply and demand contradiction, yet to be effectively addressed. In addition, in recent years have foreign steel mold set up sales outlets in China, but poor channels, technical services support the weak and prices are high, foreign exchange settlement system and other factors, promote the use of much current. Mold supporting materials and special techniques in recent years despite the popularization and application, but failed to mature production technology, most still also in the exploratory stage tests, such as die coating technology, surface treatment technology mold, mold guide lubrication technology Die sensing technology and lubrication technology, mold to stress technology, mold and other anti-fatigue and anti-corrosion technology productivity has not yet fully formed, towards commercialization. Some key, important technologies also lack the protection of intellectual property. Chinas mold standard parts production, the formation of the early 80s only small-scale production, standardization and standard mold parts using the coverage of about 20%, from the market can be assigned to, is just about 30 varieties, and limited to small and medium size. Standard punch, hot runner components and other supplies just the beginning, mold and parts production and supply channels for poor, poor accuracy and quality.沈阳航空航天大学毕业设计（论文）11 3.4 Die & Mould Industry Structure in Industrial Organization Chinas mold industry is relatively backward and still could not be called an independent industry. Mold manufacturer in China currently can be divided into four categories: professional mold factory, professional production outside for mold; products factory mold factory or workshop, in order to supply the product works as the main tasks needed to die; die-funded enterprises branch, the organizational model and professional mold factory is similar to small but the main; township mold business, and professional mold factory is similar. Of which the largest number of first-class, mold production accounts for about 70% of total output. Chinas mold industry, decentralized management system. There are 19 major industry sectors manufacture and use of mold, there is no unified management of the department. Only by China Die & Mould Industry Association, overall planning, focus on research, cross-sectoral, inter-departmental management difficulties are many. Mold is suitable for small and medium enterprises organize production, and our technical transformation investment tilted to large and medium enterprises, small and medium enterprise investment mold can not be guaranteed. Including product factory mold shop, factory, including, after the transformation can not quickly recover its investment, or debt-laden, affecting development. Although most products factory mold shop, factory technical force is strong, good equipment conditions, the production of mold levels higher, but equipment utilization rate. Price has long been Chinas mold inconsistent with their value, resulting in mold industry own little economic benefit, social benefit big phenomenon. Dry as dry mold mold standard parts, standard parts dry as dry mold with pieces of production. Dry with parts manufactured products than with the mold of the class of anomalies exist.沈阳航空航天大学毕业设计（论文）12沈阳航空航天大学毕业设计（论文）13 4 Die trend 4.1 mold CAD / CAE / CAM being integrated, three-dimensional, intelligent and network direction (1) mold software features integrated Die software features of integrated software modules required relatively complete, while the function module using the same data model, in order to achieve Syndicated news management and sharing of information to support the mold design, manufacture, assembly, inspection, testing and production management of the entire process to achieve optimal benefits. Series such as the UK Delcams software will include a surface / solid geometric modeling, engineering drawing complex geometry, advanced rendering industrial design, plastic mold design expert system, complex physical CAM, artistic design and sculpture automatic programming system, reverse engineering and complex systems physical line measurement systems. A higher degree of integration of the software includes: Pro / ENGINEER, UG and CATIA, etc. Shanghai Jiaotong University, China with finite element analysis of metal plastic forming systems and Die CAD / CAM systems; Beijing Beihang Haier Software Ltd. CAXA Series software; Jilin Gold Grid Engineering Research Center of the stamping die mold CAD / CAE / CAM systems . (2) mold design, analysis and manufacture of three-dimensional Two-dimensional mold of traditional structural design can no longer meet modern technical requirements of production and integration. Mold design, analysis, manufacturing three-dimensional technology, paperless software required to mold a new generation of three-dimensional, intuitive sense to design the mold, using three-dimensional digital model can be easily used in the product structure of CAE analysis, tooling manufacturability evaluation and CNC machining, forming process simulation and 沈阳航空航天大学毕业设计（论文）14information management and sharing. Such as Pro / ENGINEER, UG and CATIA software such as with parametric, feature-based, all relevant characteristics, so that mold concurrent engineering possible. In addition, Cimatran company Moldexpert, Delcams Ps-mold and Hitachi Shipbuilding of Space-E/mold are professional injection mold 3D design software, interactive 3D cavity, core design, mold base design configuration and typical structure . Australian company Moldflow realistic three-dimensional flow simulation software MoldflowAdvisers been widely praised by users and applications. China Huazhong University of Science have developed similar software HSC3D4.5F and Zhengzhou University, Z-mold software. For manufacturing, knowledge-based intelligent software function is a measure of die important sign of advanced and practical one. Such as injection molding experts Cimatrons software can automatically generate parting direction based parting line and parting surface, generate products corresponding to the core and cavity, implementation of all relevant parts mold, and for automatically generated BOM Form NC drilling process, and can intelligently process parameter setting, calibration and other processing results. (3) mold software applications, networking trend With the mold in the enterprise competition, cooperation, production and management, globalization, internationalization, and the rapid development of computer hardware and software technology, the Internet has made in the mold industry, virtual design, agile manufacturing technology both necessary and possible. The United States in its 21st Century Manufacturing Enterprise Strategy that the auto industry by 2006 to achieve agile manufacturing / virtual engineering solutions to automotive development cycle shortened from 40 months to 4 months. 4.2 mold testing, processing equipment to the precise, efficient, and multi-direction (1) mold testing equipment more sophisticated, efficient沈阳航空航天大学毕业设计（论文）15 Sophisticated, complex, large-scale mold development, testing equipment have become increasingly demanding. Precision Mould precision now reached 2 3m, more domestic manufacturers have to use Italy, the United States, Japan and other countries in the high-precision coordinate measuring machine, and with digital scanning. Such as Dongfeng Motor Mould Factory not only has the capacity 3250mm 3250mm Italian coordinate measuring machine, also has a digital photography optical scanner, the first in the domestic use of digital photography, optical scanning as a means of spatial three-dimensional access to information, enabling the establishment from the measurement of physical model output of engineering drawings the whole process of mold making, reverse engineering a successful technology development and applications. This equipment include: second-generation British Renishaw high-speed scanners (CYCLON SERIES2) can be realized and contact laser probe complementary probe, laser scanner accuracy of 0.05mm, scanning probe contact accuracy of 0.02 mm. Another German company GOM ATOS portable scanners, Japan Rolands PIX-30, PIX-4 desktop scanner and the United Kingdom Taylor Hopsons TALYSCAN150 multi-sensor, respectively Three-dimensional scanner with high speed, low-cost and functional composite and so on. (2) CNC EDM Japan Sodick linear motor servo drive using the companys AQ325L, AQ550LLS-WEDM have driven fast response, transmission and high positioning accuracy, the advantages of small thermal deformation. Switzerland Chanmier company NCEDM with P-E3 adaptive control, PCE energy control and automatic programming expert systems. Others also used the powder mixed EDM machining technology, micro-finishing pulse power and fuzzy control (FC) technologies. (3) high-speed milling machine (HSM) Milling is an important means of cavity mold. The low-temperature high-speed milling with the workpiece, cutting force is small, smooth processing, processing quality, processing efficiency (for the general milling process 5 to 10 times) and can process hard 沈阳航空航天大学毕业设计（论文）16materials (60HRC) and many other advantages. Thus in the mold processing more and more attention. Ruishikelang company UCP710-type five-axis machining center, machine tool positioning accuracy up to 8m, home-made closed-loop vector control spindle with a maximum speed 42000r/min. Italy RAMBAUDIs high-speed milling, the processing range of up to 2500mm 5000mm 1800mm, speed up 20500r/min, cutting feed speed of 20m/min. HSM generally used large, medium-sized mold, such as motor cover mold, die casting mold, large plastic surface machining, the surface precision up to 0.01mm.4. 3 rapid economic modeling techniques Shorten the product development cycle is an effective means of market competition to win one. Compared with the traditional mold process, fast economic modeling technology is a short molding cycle, the characteristics of low cost, precision, and life can meet the production needs, overall economic efficiency is more significant in the mold manufacturing technology, specifically the following main technology. (1) rapid prototyping and manufacturing (RPM). It consists of three-dimensional laser lithography (SLA); laminated profile manufacturing (LOM); laser powder sintering prototyping (SLS); Fused Deposition Molding (FDM) and three-dimensional printing forming technology (3D-P) and so on. (2) the surface forming tooling. It refers to the use of spray, chemical corrosion, electroforming and new method for the formation of the cavity surface and a fine pattern technology. (3) Casting forming tooling. There are bismuth tin alloy tooling, zinc alloy tooling, resin composite forming technology and silicon rubber mold molding technology. (4) cold extrusion mold technology and ultra-molded shapes. (5) multi-point forming technology. (6) KEVRON steel blanking blanking tooling. (7) mold blank rapid manufacturing technology. Mainly dry sand Mold Casting, Vacuum Mold Casting, Resin Sand Mold Casting Lost Wax Casting, and other 沈阳航空航天大学毕业设计（论文）17technologies. (8) Other aspects of technology. Such as the use of nitrogen gas spring pressure side, discharge, quick die technology, stamping unit technology, and cutting edge technology and solid surfacing edge inserts die casting technology.4.4 mold materials and surface treatment technology developed rapidly Industry to the level of mold, material application is the key. Due to improper selection and use of materials, causing premature die failure, which accounts for more than 45% failure die. In the mold material, commonly used cold work tool steel with CrWMn, Cr12, Cr12MoV and W6Mo5Cr4V2, flame hardened steel (such as Japan, AUX2, SX105V (7CrSiMnMoV), etc.; used a new type of hot work die steel American H13, Sweden QRO80M, QRO90SUPREME, etc.; used a pre-hardened plastic mold steel (such as the U.S. P20), age-hardening steel (such as the U.S. P21, Japan NAK55, etc.), heat treatment hardened steel (such as the United States, D2, Japan, PD613, PD555, Sweden wins the White 136, etc.), powder die steel (such as Japan KAD18 and KAS440), etc.; panel drawing die used HT300, QT60-2, Mo-Cr, Mo-V cast iron, large-scale mold with HT250. more regular use of Precision Die Hard Steel Results YG20 and other alloys and carbide. in the mold surface treatment, the main trends are: the infiltration of a single element to the multi-element penetration, complex permeability (such as TD method) development; by the general diffusion to the CVD, PVD, PCVD, ion penetration , the direction of ion implantation, etc.; can use the coating are: TiC, TiN, TiCN, TiAlN, CrN, Cr7C3, W2C, etc., while heat from the air treatment means to the development of vacuum heat treatment. In addition, the current strengthening of the laser, glow plasma Nitriding and electroplating (plating) enhanced anti-corrosion technologies are also more and more attention.沈阳航空航天大学毕业设计（论文）18 4.5 mold industry new techniques, new ideas and new models have been gradually recognized In the forming process, the main function of composite stamping die, superplastic forming, plastic precision molding technology, plastic mold gas-assisted injection technology and hot runner technology, high-pressure injection molding technology. On the other hand, with the continuous development of advanced manufacturing technology and raise the level of mold industry as a whole, in the mold industry, there are some new design, production, management ideas and models. Concrete are: to adapt to the characteristics of mold-piece production flexible manufacturing technologies; to create the best management and effective teamwork, lean production; to enhance rapid response capabilities of Concurrent Engineering, Virtual Manufacturing and global agile manufacturing, manufacturing of new production networks philosophy; extensive use of standard parts common parts of the division of work mode of production; meet the environmental requirements of sustainable development and green design and manufacturing.沈阳航空航天大学毕业设计（论文）19 Summary The 21st century, in the new situation of economic globalization, with capital, technology and labor market re-integration of equipment manufacturing in China after joining the WTO will become the worlds equipment manufacturing base. In the modern manufacturing industry, no matter which industry, engineering equipment, are increasingly used to provide the products from the mold industry. In order to meet the users high-precision mold manufacturing, short delivery time, the urgent demand low-cost, mold industry is extensive application of modern advanced manufacturing technology to speed up the mold industry, technological progress, to meet the basic sectors of the mold process equipment urgent needs.沈阳航空航天大学毕业设计（论文）2模具的发展模具的发展1 模具在工业生产中的地位模具在工业生产中的地位模具是大批量生产同形产品的工具，是工业生产的主要工艺装备。采用模具生产零部件，具有生产效率高、质量好、成本低、节约能源和原材料等一系列优点，用模具生产制件所具备的高精度、高复杂程度、高一致性、高生产率和低消耗，是其他加工制造方法所不能比拟的。已成为当代工业生产的重要手段和工艺发展方向。现代经济的基础工业。现代工业品的发展和技术水平的提高，很大程度上取决于模具工业的发展水平，因此模具工业对国民经济和社会发展将起越来越大的作用。1989 年 3 月国务院颁布的关于当前产业政策要点的决定中，把模具列为机械工业技术改造序列的第一位、生产和基本建设序列的第二位(仅次于大型发电设备及相应的输变电设备)，确立模具工业在国民经济中的重要地位。1997 年以来，又相继把模具及其加工技术和设备列入了当前国家重点鼓励发展的产业、产品和技术目录和鼓励外商投资产业目录 。经国务院批准，从 1997 年到 2000年，对 80 多家国有专业模具厂实行增值税返还 70%的优惠政策，以扶植模具工业的发展。所有这些，都充分体现了国务院和国家有关部门对发展模具工业的重视和支持。目前全世界模具年产值约为 600 亿美元，日、美等工业发达国家的模具工业产值已超过机床工业，从 1997 年开始，我国模具工业产值也超过了机床工业产值。据统计，在家电、玩具等轻工行业，近 90的零件是综筷具生产的；在飞机、汽车、农机和无线电行业，这个比例也超过 60。例如飞机制造业，某型战斗机模具使用量超过三万套，其中主机八千套、发动机二千套、辅机二万套。从产值看，80 年代以来，美、日等工业发达国家模具行业的产值已超过机床行业，并又有继续增长的趋势。据国际生产技术协会预测，到 2000 年，产品尽件粗加工的 75%、精加工的 50将由模具完成；金属、塑料、陶瓷、橡胶、建材等工业制品大部分将由模具完成，50以上的金属板材、80以上的塑料都特通过模具转化成制品。沈阳航空航天大学毕业设计（论文）32 模具的历史发展模具的历史发展模具的出现可以追溯到几千年前的陶器和青铜器铸造，但其大规模使用却是随着现代工业的掘起而发展起来的。19 世纪，随着军火工业(枪炮的弹壳)、钟表工业、无线电工业的发展，冲模得到广泛使用。二次大战后，随着世界经济的飞速发展，它又成了大量生产家用电器、汽车、电子仪器、照相机、钟表等零件的最佳方式。从世界范围看，当时美国的冲压技术走在前列许多模具先进技术，如简易模具、高效率模具、高寿命模具和冲压自动化技术，大多起源于美国；而瑞士的精冲、德国的冷挤压技术，苏联对塑性加工的研究也处于世界先进行列。50 年代，模具行业工作重点是根据订户的要求，制作能满足产品要求的模具。模具设计多凭经验，参考已有图纸和感性认识，对所设计模具零件的机能缺乏真切了解。从 1955 年到 1965 年，是压力加工的探索和开发时代对模具主要零部件的机能和受力状态进行了数学分桥，并把这些知识不断应用于现场实际，使得冲压技术在各方面有飞跃的发展。其结果是归纳出模具设计原则，并使得压力机械、冲压材料、加工方法、梅具结构、模具材料、模具制造方法、自动化装置等领域面貌一新，并向实用化的方向推进，从而使冲压加工从仪能生产优良产品的第一阶段。进入 70 年代向高速化、启动化、精密化、安全化发展的第二阶段。在这个过程中不断涌现各种高效率、商寿命、高精度助多功能自动校具。其代表是多达别多个工位的级进模和十几个工位的多工位传递模。在此基础上又发展出既有连续冲压工位又有多滑块成形工位的压力机弯曲机。在此期间，日本站到了世界最前列其模具加工精度进入了微米级，模具寿命，合金工具钢制造的模具达到了几千万次，硬质合金钢制造的模具达到了几亿次 p 每分钟冲压次数，小型压力机通常为 200 至300 次，最高为 1200 次至 1500 次。在此期间，为了适应产品更新快、用期短(如汽车改型、玩具翻新等)的需要，各种经济型模具，如锌落合金模具、聚氨酯橡胶模具、钢皮冲模等也得到了很大发展。从 70 年代中期至今可以说是计算机辅助设计、辅助制造技术不断发展的时代。随着模具加工精度与复杂性不断提高，生产周期不断加快，模具业对设备和人员素质的要求也不断提高。依靠普通加工设备，凭经验和手艺越来越不能满足模具生产的需要。90 年代以来，机械技术和电子技术紧密结合，发展了 NC 机床，如数控线沈阳航空航天大学毕业设计（论文）4切割机床、数控电火花机床、数控铣床、数控坐标磨床等。而采用电子计算机自动编程、控制的 CNC 机床提高了数控机床的使用效率和范围。近年来又发展出由一台计算机以分时的方式直接管理和控制一群数控机床的 NNC 系统。随着计算机技术的发展，计算机也逐步进入模具生产的各个领域，包括设计、制造、管理等。国际生产研究协会预测，到 2000 年，作为设计和制造之间联系手段的图纸将失去其主要作用。模具自动设计的最根本点是必须确立模具零件标准及设计标准。要摆脱过去以人的思考判断和实际经验为中心所组成的设计方法，就必须把过去的经验和思考方法，进行系列化、数值化、数式化，作为设计准则储存到计算机中。因为模具构成元件也干差万别，要搞出一个能适应各种零件的设计软件几乎不可能。但是有些产品的零件形状变化不大，模具结构有一定的规律，放可总结归纳，为自动设计提供软件。如日本某公司的 CDM 系统用于级进模设计与制造，其中包括零件图形输入、毛坯展开、条料排样、确定模板尺寸和标准、绘制装配图和零件图、输出 NC 程序(为数控加工中心和线切割编程)等，所用时间由手工的 20%、工时减少到 35 小时；从 80 年代初日本就将三维的 CADCAM 系统用于汽车覆盖件模具。目前，在实体件的扫描输入，图线和数据输入，几何造形、显示、绘图、标注以及对数据的自动编程，产生效控机床控制系统的后置处理文件等方面已达到较高水平；计算机仿真(CAE)技术也取得了一定成果。在高层次上，CADCAMCAE 集成的，即数据是统一的，可以互相直接传输信息实现网络化。目前国外仅有少数厂家能够做到。沈阳航空航天大学毕业设计（论文）53 我国模具工业现状及发展趋势我国模具工业现状及发展趋势由于历史原因形成的封闭式、 “大而全”的企业特征，我国大部分企业均设有模具车间，处于本厂的配套地位，自 70 年代末才有了模具工业化和生产专业化这个概念。生产效率不高，经济效益较差。模具行业的生产小而散乱，跨行业、投资密集，专业化、商品化和技术管理水平都比较低。据不完全统计，全国现有模具专业生产厂、产品厂配套的模具车间（分厂）近17000 家，约 60 万从业人员，年模具总产值达 200 亿元人民币。但是，我国模具工业现有能力只能满足需求量的 60左右，还不能适应国民经济发展的需要。目前，国内需要的大型、精密、复杂和长寿命的模具还主要依靠进口。据海关统计，1997年进口模具价值 6.3 亿美元，这还不包括随设备一起进口的模具；1997 年出口模具仅为 7800 万美元。目前我国模具工业的技术水平和制造能力，是我国国民经济建设中的薄弱环节和制约经济持续发展的瓶颈。3.1 模具工业产品结构的现状模具工业产品结构的现状 按照中国模具工业协会的划分，我国模具基本分为 10 大类，其中，冲压模和塑料成型模两大类占主要部分。按产值计算，目前我国冲压模占 50左右，塑料成形模约占 20，拉丝模（工具）约占 10，而世界上发达工业国家和地区的塑料成形模比例一般占全部模具产值的 40以上。 我国冲压模大多为简单模、单工序模和符合模等，精冲模，精密多工位级进模还为数不多，模具平均寿命不足 100 万次，模具最高寿命达到 1 亿次以上，精度达到 35um，有 50 个以上的级进工位，与国际上最高模具寿命 6 亿次，平均模具寿命 5000 万次相比，处于 80 年代中期国际先进水平。 我国的塑料成形模具设计，制作技术起步较晚，整体水平还较低。目前单型腔，简单型腔的模具达 70以上，仍占主导地位。一模多腔精密复杂的塑料注射模，多色塑料注射模已经能初步设计和制造。模具平均寿命约为 80 万次左右，主要差距是模具零件变形大、溢边毛刺大、表面质量差、模具型腔冲蚀和腐蚀严重、模具排气不畅和型腔易损等，注射模精度已达到 5um 以下，最高寿命已突破 2000 万次，型腔数量已超过 100 腔，达到了 80 年代中期至 90 年代初期的国际先进水平。沈阳航空航天大学毕业设计（论文）63.2 模具工业技术结构现状模具工业技术结构现状 我国模具工业目前技术水平参差不齐，悬殊较大。从总体上来讲，与发达工业国家及港台地区先进水平相比，还有较大的差距。 在采用 CAD/CAM/CAE/CAPP 等技术设计与制造模具方面，无论是应用的广泛性，还是技术水平上都存在很大的差距。在应用 CAD 技术设计模具方面，仅有约10%的模具在设计中采用了 CAD，距抛开绘图板还有漫长的一段路要走；在应用CAE 进行模具方案设计和分析计算方面，也才刚刚起步，大多还处于试用和动画游戏阶段；在应用 CAM 技术制造模具方面，一是缺乏先进适用的制造装备，二是现有的工艺设备（包括近 10 多年来引进的先进设备）或因计算机制式（IBM 微机及其兼容机、HP 工作站等）不同，或因字节差异、运算速度差异、抗电磁干扰能力差异等，联网率较低，只有 5%左右的模具制造设备近年来才开展这项工作；在应用CAPP 技术进行工艺规划方面，基本上处于空白状态，需要进行大量的标准化基础工作；在模具共性工艺技术，如模具快速成型技术、抛光技术、电铸成型技术、表面处理技术等方面的 CAD/CAM 技术应用在我国才刚起步。计算机辅助技术的软件开发，尚处于较低水平，需要知识和经验的积累。我国大部分模具厂、车间的模具加工设备陈旧，在役期长、精度差、效率低，至今仍在使用普通的锻、车、铣、刨、钻、磨设备加工模具，热处理加工仍在使用盐浴、箱式炉，操作凭工人的经验，设备简陋，能耗高。设备更新速度缓慢，技术改造，技术进步力度不大。虽然近年来也引进了不少先进的模具加工设备，但过于分散，或不配套，利用率一般仅有 25%左右，设备的一些先进功能也未能得到充分发挥。缺乏技术素质较高的模具设计、制造工艺技术人员和技术工人，尤其缺乏知识面宽、知识结构层次高的复合型人才。中国模具行业中的技术人员，只占从业人员的 8%12%左右，且技术人员和技术工人的总体技术水平也较低。1980 年以前从业的技术人员和技术工人知识老化，知识结构不能适应现在的需要；而 80 年代以后从业的人员，专业知识、经验匮乏，动手能力差，不安心，不愿学技术。近年来人才外流不仅造成人才数量与素质水平下降，而且人才结构也出现了新的断层，青黄