手机面板注塑模具设计【一模两腔】【说明书+CAD】
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长春理工大学光电信息学院毕业设计（论文）题目申报表 院 别 机 电 工 程 分 院 教 研 室 指导教师 职称 职称 2013年 月 日题目名称手机面板注塑模设计题目类别设计类题目性质结合实际专业机 械设 计参加本题目学生人数1人论文类虚拟题目题目来源、教师准备情况、主要培养学生哪些能力1本题目来源于指导教师的命题。2指导教师对此课题有理论基础及实际经验，在师生共同努力下定能顺利、按期完成该课题设计。3本课题主要培养学生对已有知识的运用能力、查找资料和阅读能力、英译汉的能力、工程机械的设计、制造能力。题 目 内 容 及 要 求一、内容：对模具行业的发展状况、现代注塑模具设计制造技术、注塑模具的设计方法及过程进行了阐述。采用计算机辅助设计（CAD）可以大大提高设计的精确性；计算机辅助工程（CAE），可以提高塑料模具的设计制造水平及塑件质量；利用计算机辅助加工（CAM）可以把设计师的意图准确的反映在产品上。二、要求：论文内容包括:1 合理选择模具结构，正确确定模具成型零件的结构形状、尺寸及其技术要求。使所涉及的模具制造工艺性良好，造价便宜。2充分利用塑料成型优良的特点，尽量减少后加工。3涉及的模具应当高效、优质、安全可靠的生产，且模具使用寿命长实践环节安排实习长春第一机床长实验 金工实习基地计算机应用 计算机绘图中、外文参考资料： 1我国塑料模具行业发展日趋大型化精度越来越高 J.工具技术， 2008，（06）9-9.锐. 2孙安垣 我国塑料模具行业发展日趋大型化 J.工程塑料应用， 2008，（04）.3陈勇，韦玉屏塑料模具材料的种类及应用 J.装备制造技术， 2007，（09）96-97.4杨俊秋. 塑料模具新型材料的种类与发展动向 J.模具技术， 2007，（03）59-62.5塑料模具业持续高速发展 J.现代制造， 2007，（08）67-67.6塑料模具模具业未来的佼佼者 J.现代制造， 2006，（4）.7刘保臣，李雪娜，申长雨热流道注射模具设计 J.工程塑料应用， 2007，（02）58-60.8孙锡红.我国塑料模具发展现状及发展建议 J.电加工与模具， 2010，（S1）31-33.9周永泰.我国塑料模具现状与发展趋势 J.塑料， 2000，（06）23-27.10塑料模具发展迅速，高档模具成为主流市场展望“2008国际橡塑展” J.模具制造，2008，（03）.11申开智.塑料成型模具.第二版 M . 北京：中国轻工业出版社， 200612杨占尧.注射模具典型结构图例 M . 北京：化学工业出版社， 2005教研室主任审 批 签 字分 院 院 长审 批 签 字注：题目类别和题目性质请用符号填在相应栏内。长春理工大学光电信息学院学生毕业设计（论文）登记表分院机电工程分院专业机械设计制造及其自动化班级学生姓名指导教师设计（论文）起止日期教研室主任题目名称（包括主要技术参数）及要求一、1. 题目名称：手机面板注塑模具设计二、2. 要求：论文内容包括:1 合理选择模具结构，正确确定模具成型零件的结构形状、尺寸及其技术要求。使所涉及的模具制造工艺性良好，造价便宜。2充分利用塑料成型优良的特点，尽量减少后加工。3涉及的模具应当高效、优质、安全可靠的生产，且模具使用寿命长论文开题报告（设计方案论证）应包括以下几方面的内容：1、 本课题研究的意义；2、调研（社会调查）情况总结；3、查阅文献资料情况（列出主要文献清单）；4、拟采取的研究路线；5、进度安排。（1）.本课题研究的意义：对模具行业的发展状况、现代注塑模具设计制造技术、注塑模具的设计方法及过程进行了阐述。采用计算机辅助设计（CAD）可以大大提高设计的精确性；计算机辅助工程（CAE），可以提高塑料模具的设计制造水平及塑件质量；利用计算机辅助加工（CAM）可以把设计师的意图准确的反映在产品上。（2）调研情况总结：综合了成型工艺分析，模具结构设计，最后到模具零件的加工方法，模具总的装配等一系列模具生产的所有过程。能很好的学习致用的效果。在设计该模具的同时总结了以往模具设计的一般方法、步骤，模具设计中常用的公式、数据、模具结构及零部件。把以前学过的基础课程融汇到综合应用本次设计当中来，所谓学以致用。在设计中除使用传统方法外，同时引用了CAD、UG等软件，使用Office软件，力求达到减小劳动强度，提高工作效率的目的。（3）.参考文献：1我国塑料模具行业发展日趋大型化精度越来越高 J.工具技术，2008，（06）9-9.锐.2孙安垣 我国塑料模具行业发展日趋大型化 J.工程塑料应用，2008，（04）.3陈勇，韦玉屏塑料模具材料的种类及应用 J.装备制造技术，2007，（09）96-97.4杨俊秋. 塑料模具新型材料的种类与发展动向J.模具技术，2007，（03）59-62.5塑料模具业持续高速发展 J.现代制造，2007，（08）67-67.6塑料模具模具业未来的佼佼者 J.现代制造，2006，（4）.7刘保臣，李雪娜，申长雨热流道注射模具设计 J.工程塑料应用，2007，（02）58-60.8孙锡红.我国塑料模具发展现状及发展建议 J.电加工与模具，2010，（S1）31-33.9周永泰.我国塑料模具现状与发展趋势 J.塑料， 2000，（06）23-27.10塑料模具发展迅速，高档模具成为主流市场展望“2008国际橡塑展” J.模具制造，2008，（03）.11申开智.塑料成型模具.第二版 M .北京：中国轻工业出版社， 200612杨占尧.注射模具典型结构图例 M .北京：化学工业出版社， 2005（4）.拟采取的研究路线：指导老师下达任务充分理解本课题要解决的问题查阅文件和素材（图书馆、上网）翻译英文资料（吉林省图书馆，长春市图书馆，达新校区图书馆）到长春精诚机械参观撰写论文（吉林省图书馆，长春市图书馆，达新校区图书馆）CAD绘图指导教师审查修改、完善、定稿准备答辩。5进度安排： 2月 28日 3月 15日 查阅文件，书籍材料。 3月 16日 3月 29日 翻译英文材料。 3月 30日 4月 26日 写课题论文，写初稿。 4月 27日 5月 17日 完善论文，定稿。 5月 18日 6月 7日 绘制设计草图、打印。 6月 8日 6月 17日 整理，熟悉文件,准备答辩 指导教师审阅意见： 年 月 日 记事：指导教师审阅意见：年 月 日长春理工大学光电信息学院毕业设计（论文）登记表分院机电工程分院专业机械设计制造及其自动化班级学生姓名指导教师设计（论文）起止日期2013年3月26月21教研室主任题目名称（包括主要技术参数）及要求一、1. 题目名称：手机面板注塑模具设计二、2. 要求：论文内容包括:1 合理选择模具结构，正确确定模具成型零件的结构形状、尺寸及其技术要求。使所涉及的模具制造工艺性良好，造价便宜。2充分利用塑料成型优良的特点，尽量减少后加工。3涉及的模具应当高效、优质、安全可靠的生产，且模具使用寿命长 论文开题报告（设计方案论证）应该包括以下几方面内容： 1、本课题研究的意义；2、调研（社会调查）情况总结；3、查阅文献资料情况（列出主要文献清单）； 4、拟采取的研究路线；5、进度安排。（1）.本课题研究的意义：对模具行业的发展状况、现代注塑模具设计制造技术、注塑模具的设计方法及过程进行了阐述。采用计算机辅助设计（CAD）可以大大提高设计的精确性；计算机辅助工程（CAE），可以提高塑料模具的设计制造水平及塑件质量；利用计算机辅助加工（CAM）可以把设计师的意图准确的反映在产品上。（2）.调研情况总结：综合了成型工艺分析，模具结构设计，最后到模具零件的加工方法，模具总的装配等一系列模具生产的所有过程。能很好的学习致用的效果。在设计该模具的同时总结了以往模具设计的一般方法、步骤，模具设计中常用的公式、数据、模具结构及零部件。把以前学过的基础课程融汇到综合应用本次设计当中来，所谓学以致用。在设计中除使用传统方法外，同时引用了CAD、UG等软件，使用Office软件，力求达到减小劳动强度，提高工作效率的目的（3）.参考文献：1我国塑料模具行业发展日趋大型化精度越来越高 J.工具技术，2008，（06）9-9.锐.2孙安垣 我国塑料模具行业发展日趋大型化 J.工程塑料应用，2008，（04）.3陈勇，韦玉屏塑料模具材料的种类及应用 J.装备制造技术，2007，（09）96-97.4杨俊秋. 塑料模具新型材料的种类与发展动向J.模具技术，2007，（03）59-62.5塑料模具业持续高速发展 J.现代制造，2007，（08）67-67.6塑料模具模具业未来的佼佼者 J.现代制造，2006，（4）.7刘保臣，李雪娜，申长雨热流道注射模具设计J.工程塑料应用，2007，（02）58-60.8孙锡红.我国塑料模具发展现状及发展建议 J.电加工与模具，2010，（S1）31-33.9周永泰.我国塑料模具现状与发展趋势 J.塑料， 2000，（06）23-27.10塑料模具发展迅速，高档模具成为主流市场展望“2008国际橡塑展” J.模具制造，2008，（03）.11申开智.塑料成型模具.第二版 M .北京：中国轻工业出版社， 200612杨占尧.注射模具典型结构图例 M .北京：化学工业出版社， 20054拟采取的研究路线,： 指导老师下达任务充分理解本课题要解决的问题查阅文件和素材（图书馆、上网）翻译英文资料（吉林省图书馆，长春市图书馆，达新校区图书馆）到长春精诚机械参观撰写论文（吉林省图书馆，长春市图书馆，达新校区图书馆）CAD绘图指导教师审查修改、完善、定稿准备答辩。5进度安排：3月2 日3月15日 查阅文件，书籍材料。3月16日3月29日 翻译英文材料。3月30日4月26日 写课题论文，写初稿。4月27日5月17日 完善论文，定稿。5月18日6月7 日 绘制设计草图、打印。6月8 日6月21日 整理，熟悉文件。指导教师审阅意见：年 月 日 记事：指导教师审阅意见：年 月 日3指导教师审阅意见：年 月 日记事: 指导教师审阅意见：年 月 日毕业设计（论文） 外文翻译塑料成型（一）塑料注射成型许多不同的加工过程习惯于把塑料颗粒、粉末和液体转化成最终产品。塑料材料用模具成型，并且适合用多种方式成型。在大多数情况下，热塑性材料可以用许多方法成型，但热固性塑料需要用其他方法成型。对于热塑性材料有这种事实的认识，它常常被加热成为另一种柔软状态，然后在冷却以前成型。对于热固性塑料，换句话说，在它加工以前还没有形成聚合物，在化学反应加工过程中发生变化，如通过加热、催化剂或压力处理。记住这个概念在学习塑料加工过程和聚合物的形成是很重要的。塑料注射成型越来越广泛地运用于热塑性材料的成型工艺。它也是最古老的一种方式。突然间，塑料注射成型材料占所有成型材料消费的30%。塑料注射成型适合于大批量生产，当原材料被成单一的步骤转换成为塑料物品和单步自动化的复杂几何形状制品。在大多数情况下，对于这样的制品，精加工是不需要的。所生产的各种各样的产品包括：玩具、汽车配件、家用物品和电子消费物品。因为塑料注射模具有很多易变的相互影响，那是一种复杂的虚慎重考虑的加工过程。塑料注射模具设备的成功是不依赖于机器变化到恰当的步骤，只有淘汰了需要注射变化的机器，才会导致适应液压变化、料筒温度变化和材料黏度变化的机器的产生。增加机器重复注射的能力的变化可以帮助减少公差，降低次品等级和增加产品质量。对于任何模具注射设备的操作人员目的是制造产品，成为特等品、用最短的时间、用重复精度和全自动化生产作为周期。模塑人员在生产过程中总是想尽办法降低或消除不合格产品。对于塑料注射模具有高要求的光学制品，或者有高附加值的制品如：家用电器制品，它的利润大大降低。一种塑料注射模具的生产周期或顺序由五个阶段组成：（1）注射或填充模具（2）补料或压缩（3）保压（4）冷却（5）局部注射塑料颗粒被投入料斗并且打开塑料注射料筒，在那里颗粒被旋转螺杆带动进入料筒。螺杆的旋转强迫塑料颗粒在高压下挤压料筒筒壁导致它变成熔体。随着压力的增加，旋转螺杆被迫后退直到有足够的塑料被注射成为储料。塑料螺杆强迫熔融的塑料从料筒流到喷嘴、主流道经浇注系统，最终进入模具型腔。当注射模具型腔容积被充满。当塑料接触冷的模具表面，它被固化以减少表层。当模具保持熔融状态，塑料沿着模芯充满整个模具。，利用率特别高，在注射时型腔被充满95%98%。接着成型过程进入补料阶段。当型腔被充满，熔融塑料便开始冷却。冷却塑料的收缩，就增加了诸如凹痕、孔洞和尺寸不稳定等制品缺陷的发生。为了补偿收缩，增加塑料压入型腔。当型腔被封裹，为防止的熔融状态塑料从型腔内流向出口，把压力应用于熔体。这种压力必须应用直到出口为固态。这种加工可分为两步（补料和保压）或可能包含成为一步（保压或第二阶段）。在补料时，熔体被补料压力收缩补偿压入型腔。在保压时，压力仅仅防止聚合物回流。在保压阶段完成以后，冷却阶段开始。在冷却时，是制品在型腔内保持需具体说明的一个阶段。在冷却持久的阶段主要依靠材料的特性和制品的收缩率。典型的，制品温度必须冷却到材料的注射温度。在冷却制品时，这种机器塑料熔体被冷却到下一个周期。聚合物是以剪切作用为主题的，如同加热圈获得能量一样。当注射开始，到塑料注射终止。聚合物会立刻出现在冷却阶段以前，直到模具打开和制品被注射。当聚合物被编制成有用的文章，它们被称为：塑料、橡胶和纤维。许多聚合物，例如棉花和羊毛来自自然，但是绝大多数商业的产品都是人造的，都来源于此。一系列众所周知的材料包括酚醛塑料，涤纶，尼龙，聚硅氧烷，有机玻璃，纤维素，聚丙乙烯和特氟隆。在1930年以前，商业用的聚合物没有广泛应用。然而它们本应该作为新材料在19世纪下半叶出名，却没有成功。在该期间，它们所以未能发展，部分原因是不了解它们的性质，特别是，聚合物结构曾是许多无结果争论的主题。二十世纪的两次事件使聚合物声名雀起，并且在世界范围内占据了很重要的地位。第一次是成功的商业塑料产品叫做酚醛塑料。它有用的工业价值在1912年表现得近乎疯狂，并且在以后许多年发挥着巨大的价值。今天，酚醛塑料仍然在一系列的人造的产品中占有一席之地。在1912年以前，由塑料制造的材料是有用的，但是那种材料的制造从未提供像发明了酚醛塑料以后，形成新聚合物的动力那样有价值。第二次事件与基础学科的自然聚合物有关，被欧洲的史涛丁格和美国的卡罗瑟夫发现，他们在特达华州的杜邦公司工作。一些重要的研究在20世纪20年代被开展，史涛丁格主要从事基础工作。卡罗瑟夫的成功导致了我们目前巨大塑料工业的发展，引起了对化学聚合物的关注，并且在今天仍然引起了强烈而明显的关注。（二）热力学的性质热力学是工程科学最重要的领域之一。这门科学是用来解释大多数东西是如何做功的，有些东西为什么不按所预期的那样做功，另外一些东西又为什么根本不做功。热力学是工程师在设计汽车发动机、热泵、火箭发动机、发电站燃汽轮机、空气调节器、超导电输电线，太阳能加热系统等所用的科学知识的关键部分。热力学以能的各种概念为中心，能量守恒这一概念是热力学的第一定律。这是热力学以及工程分析的起点，热力学的第二个要领是熵；熵提供一种用以确定某一过程是否可行的手段。产生熵的过程是可行的，消灭熵的过程是不可行的，这个要领是热力学第二定律的基础。他还为一种工程分析奠定了基础，在这种工程分析中，人们可以算出从给定的能源中所能获得的有用功率的最大值，或算出做某种工作所能获得的有用功率的最小值。若要在工程分析中应用热力学，就必须对能和熵这些概念有一个清楚的了解。科学家关心的是利用这些数据，结合能量守恒及熵的产生这些基本概念来分析复杂系统性能。举一个工程师感兴趣的例子一个大型中心发电站。在该发电站，能源是某种形式的石油，有时是天然气；该发电站的作用是把燃料能尽可能地转化成电能，并把电能沿输电线输送出去。简单的说，该发电站的发电方式是：使水沸腾，利用蒸汽转动汽轮机，汽轮机再转动发电机。这类发电站中最简单的只能把大约25%的燃料转化成电能。但该发电站却能把大约40%的燃料转化成电能，这是因为该发电站是经过精心设计的结果，把热力学的基本原理仔细的用于该系统内的数百个零部件。进行这些计算的设计工程师，利用了由物理学家研究出来的有关蒸汽特性的数据；而物理学家则是利用实验测得的数据，结合热力学理论，研究出这种特性的数据的。目前在研究中的一些发电站，如果说的确按热力学分析所预测的那样工作，可以将多达55%的燃料能转化成电能。热始终是自发的从较热的物体流向较冷的物体，这一规律是一种新的物理概念。在能量守恒原理中或其他任何一种自然规律中，没有给我们规定热的方向。如果能量能自发的从冰块流向周围的水中，这可能和能量的守恒完全一致，但这一过程决不发生。这一概念是热力学第二定律的实质。很明显，冷冻机是一种物理系统，用于厨房的电冰箱、冷场库和空调装置，它不仅必须遵从第一定律（能量守恒）也必须遵从第二定律。为了弄清冷冻机为什么没有违背第二定律，必须对这一定律加以说明，热力学第二定律实质上是说：热不会自发地从较冷的物体流向较热的物体。换句话说，热之所以能从较冷的物体流向较热的物体，是外界力量做功的结果，现在我们弄清了某一日常的自然过程。如水和冰之间的热流动和冷冻机热从里面向外面流动之间的区别。在水、冰系统中，能量的交换是自发产生的，因而热的流动是水流向冰。水放出了能量从而变冷，而冰吸收热量从而融化。另一方面，在冷冻机中，能量交换不是自发产生的，而需要改变热的流动方向，并通过进一步加热较暖的周围环境而使冷冻机内部变冷，就必须依靠外力做功。21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。22高速加工在模具制造中的应用 221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； 222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。23 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。（三）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。31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。32五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；33 购买CAD/CAM软件和高速机床配套据统计，每年有几十亿美元用于进口机床，大部分电加工机床和高速机床需要进口。（四）高速切削模具的刀具技术 高速切削加工还需配备适宜高速切削的刀具。高速加工刀具材料的进展促使了高速加工的发展。硬质合金涂层刀具、聚晶增强陶瓷刀具使得兼顾高硬度的刀刃部和高韧性的基体成为可能。聚晶立方氮化硼(PCBN)刀片,其硬度可达35004500HV。聚晶金刚石(PCD)其硬度可达600010000HV。近年来德国SCS、日本三菱(神钢)及住友、瑞士山特维克、美国肯纳飞硕等国外著名刀具公司都先后推出了各自的高速切削刀具，不仅有高速切削普通结构钢的刀具,还有能直接高速切削淬硬钢的陶瓷刀具等超硬刀具,尤其是涂层刀具异军突起,在淬硬钢的半精加工和精加工中发挥着巨大作用。新刀具材料和刀具技术的出现已经使高速加工上的瓶颈问题不再会出现在刀具上。 但是，进口刀具的昂贵价格也阻碍高速切削模具的重要因素。 一般来说,刀具以及刀夹的加速度达到3g以上，刀具的径向跳动要小于0.015mm，而刀的长度不能大于4倍的刀具直径。根据SANDVIK公司的实际统计，在使用碳氮化钛(TICN)涂层的整体硬质合金立铣刀(58HRC)进行高速铣削时,粗加工刀具线速度约为100m/min,而精加工和超精加工时,其线速度超过了 280m/min。这样对刀具的材料(包括硬度、韧性、红硬性(高温状态下保持切削性能)、刀具的形状(包括排屑性能、表面精度、动平衡性等)以及刀具寿命都有很高的要求。根据国内模具高速精加工的经验，采用小直径球头铣刀进行模具精加工时，线速度超过了400800m/min。选择足够高速度的机床硬切削模具精加工。Delcam 采用0.8mm直径的刀具加工窄槽，转速40000rpm，0.1mm深度，进给速度30m/min。. 1 选择刀具参数，如负前角刀具等。刀具要求比普通加工要求抗冲击韧性更高，还要求抗热冲击能力强； 2 采取多种方法提高刀具寿命，降低刀具成本。 3 采用高速刀柄，目前应用最多的是HSK刀柄，热压装夹刀具。注意刀具装夹后的整体动平衡；4 当前的刀具企业在解决高速切削刀具技术方面已经做了很多工作，面向加工的刀具服务会帮助解决很多问题，刀具生产厂家成为主体，参考刀具生产厂家提供的技术参数。（五）提高高速切削模具效率的工艺技术1 刀具直径和长度的选择2 HSM和EDM的选择 3 干切削和润滑冷却 4 进给选择：通常进给量 铣刀直径10%，进给宽度 铣刀直径40%。 根据材料情况合理选择加工工艺参数国外高速铣削加工零件材料质量较，材料质量标准相同,加工性能比较稳定；而国外公司生产的刀具也是以他们的材料标准做试验；推荐的加工参数一般比较适合他们的标准，如果使用他们的刀具，与国内的零件材质有一定的区别,在高速铣削时,这种差别表现得较为明显，有些参数可以直接应用，但有些效果就比较差。而国内企业一般选用零件材质有一定的标准,所使用的零件材料，特别是能用高速加工的零件材质，一般会局限在某些零件材料范围内,这对我们应用高速加工技术也提供了有利的条件，会在较少的加工材料范围内应用。这里要强调的是，一定要在这些材料上选取优化出一套适合本企业的加工工艺参数，并且纳入企业标准。选用国产刀具,很少有推荐高速铣削的技术参数的,有必要做试验,取得比较满意的参数,最好选用固定的刀具生产厂家,减少试验的次数,形成加工技术标准,这样可以提高设备有效利用率,降低生产成本,可以取得较好的经济效益。（六）高速切削的加工刀具路径和编程 1） 平面进给路径选择 2） 轮廓加工路径选择 3） 保持切削载荷平稳 4） 保持相对平稳的进给量和进给速度 5） 在平面切削中保持园拐角 6） 合理选择精加工余量HSC精加工对CAM的编程要求：1）尽量避免拐角的铣削运动；2）尽量避免工件外的进刀与退刀运动，直接从轮廓进入下一个深度。或者采用螺旋线或斜向进给切入；3）恒定每刃进给，提高质量，延长刀具寿命；4）轮廓加工保持在水平面上等。高速切削CAM软件：Delcam 公司几年前就开始了高速切削加工编程技术的研究，开发了高速切削自动编程软件模块；最近，MasterCAM 公司也开发了高速切削自动编程软件模块；国内北航海尔也在开发高速切削自动编程软件模块；六、 高速机床数控系统的特点 1） 高速数据处理 2） 拐角预测处理3） NURBS非有理样条插补曲线加工七、 高速切削模具的安全问题 1） 刀具磨损和破坏的监测； 2） 刀片连接的强度； 3） 和普通机床加工不同，安全防护和开机前对机床和刀具的严格检查非常重要。八、 目前我国在采用高速加工模具技术中存在的问题 81 机 床 1） 国产高速机床整体性能尚有差距，功能部件性能还不能满足要求。包括电主轴的功率和转速，进口机床价格高； 2） 机床的高速下动态特性研究还不够，因而影响整机的性能； 3） 五轴机床还不够成熟，进口机床价格太高； 4） 配套技术和设备还不完全。 82 刀 具： 1） 国产刀具还不能够适应高速切削的应用，特别是高速硬切削光整加工。进口刀具价格高。刀具技术是影响高速切削加工模具的一个重要因素。 2） 配套技术还不够，包括刀柄、成套在线动平衡等。 83 高速模具加工工艺技术及实验 1） 由于高速加工模具的历史比较短，缺乏应用经验积累； 2） 对高速切削工艺研究比较少，投入不够，立项比较困难； 3） 缺少高速切削数据库或手册，目前还是空白； 4） 模具生产厂家对高速切削的认识不够，缺乏长期效益的分析对比；Injection Molding Many different processes are used to transform plastic granules, powders, and liquids into product. The plastic material is in moldable form, and is adaptable to various forming methods. In most cases thermosetting materials require other methods of forming. This is recognized by the fact that thermoplastics are usually heated to a soft state and then reshaped before cooling. Theromosets, on the other hand have not yet been polymerized before processing, and the chemical reaction takes place during the process, usually through heat, a catalyst, or pressure. It is important to remember this concept while studying the plastics manufacturing processes and polymers used. Injection molding is by far the most widely used process of forming thermoplastic materials. It is also one of the oldest. Currently injection molding accounts for 30% of all plastics resin consumption. Since raw material can be converted by a single procedure, injection molding is suitable for mass production of plastics articles and automated one-step production of complex geometries. In most cases, finishing is not necessary. Typical products include toys, automotive parts, household articles, and consumer electronics goods.Since injection molding has a number of interdependent variables, it is a process of considerable complexity. The success of the injection molding operation is dependent not only in the proper setup of the machine hydraulics, barrel temperature variations, and changes in material viscosity. Increasing shot-to-shot repeatability of machine variables helps produce parts with tighter tolerance, lowers the level of rejects, and increases product quality (i.e., appearance and serviceability).The principal objective of any molding operation is the manufacture of products: to a specific quality level, in the shortest time, and using repeatable and fully automatic cycle. Molders strive to reduce or eliminate rejected parts in molding production. For injection molding of high precision optical parts, or parts with a high added value such as appliance cases, the payoff of reduced rejects is high.A typical injection molding cycle or sequence consists of five phases;1. Injection or mold filling2. Packing or compression3. Holding 4. Cooling5. Part ejectionPlastic granules are fed into the hopper and through an in the injection cylinder where they are carried forward by the rotating screw. The rotation of the screw forces the granules under high pressure against the heated walls of the cylinder causing them to melt. As the pressure building up, the rotating screw is forced backward until enough plastic has accumulated to make the shot. The injection ram (or screw) forces molten plastic from the barrel, through the nozzle, sprue and runner system, and finally into the mold cavities. During injection, the mold cavity is filled volumetrically. When the plastic contacts the cold mold surfaces, it solidifies (freezes) rapidly to produce the skin layer. Since the core remains in the molten state, plastic follows through the core to complete mold filling. Typically, the cavity is filled to 95%98% during injection. Then the molding process is switched over to the packing phase.Even as the cavity is filled, the molten plastic begins to cool. Since the cooling plastic contracts or shrinks, it gives rise to defects such as sink marks, voids, and dimensional instabilities. To compensate for shrinkage, addition plastic is forced into the cavity. Once the cavity is packed, pressure applied to the melt prevents molten plastic inside the cavity from back flowing out through the gate. The pressure must be applied until the gate solidifies. The process can be divided into two steps (packing and holding) or may be encompassed in one step(holding or second stage). During packing, melt forced into the cavity by the packing pressure compensates for shrinkage. With holding, the pressure merely prevents back flow of the polymer malt.After the holding stage is completed, the cooling phase starts. During, the part is held in the mold for specified period. The duration of the cooling phase depends primarily on the material properties and the part thickness. Typically, the part temperature must cool below the materials ejection temperature. While cooling the part, the machine plasticates melt for the next cycle.The polymer is subjected to shearing action as well as the condition of the energy from the heater bands. Once the short is made, plastication ceases. This should occur immediately before the end of the cooling phase. Then the mold opens and the part is ejected. When polymers are fabricated into useful articles they are referred to as plastics, rubbers, and fibers. Some polymers, for example, cotton and wool, occur naturally, but the great majority of commercial products are synthetic in origin. A list of the names of the better known materials would include Bakelite, Dacron, Nylon, Celanese, Orlon, and Styron.Previous to 1930 the use of synthetic polymers was not widespread. However, they should not be classified as new materials for many of them were known in the latter half of the nineteenth century. The failure to develop them during this period was due, in part, to a lack of understanding of their properties, in particular, the problem of the structure of polymers was the subject of much fruitless controversy.Two events of the twentieth century catapulted polymers into a position of worldwide importance. The first of these was the successful commercial production of the plastic now known as Bakelite. Its industrial usefulness was demonstrated in1912 and in the next succeeding years. Today Bakelite is high on the list of important synthetic products. Before 1912 materials made from cellulose were available, but their manufacture never provided the incentive for new work in the polymer field such as occurred after the advent of Bakelite. The second event was concerned with fundamental studies of the nature polymers by Staudinger in Europe and by Carohers, who worked with the Du Pont company in Delaware. A greater part of the studies were made during the 1920s. Staudingers work was primarily fundamental. Carothers achievements led to the development of our present huge plastics industry by causing an awakening of interest in polymer chemistry, an interest which is still strongly apparent today. The Nature of ThermodynamicsThermodynamics is one of the most important areas of engineering science used to explain how most things work, why some things do not the way that they were intended, and why others things just cannot possibly work at all. It is a key part of the science engineers use to design automotive engines, heat pumps, rocket motors, power stations, gas turbines, air conditioners, super-conducting transmission lines, solar heating systems, etc. Thermodynamics centers about the notions of energy, the idea that energy is conserved is the first low of thermodynamics. It is starting point for the science of thermodynamics is entropy; entropy provides a means for determining if a process is possible.This idea is the basis for the second low of thermodynamics. It also provides the basis for an engineering analysis in which one calculates the maximum amount of useful that can be obtained from a given energy source, or the minimum amount of power input required to do a certain task.A clear understanding of the ideas of entropy is essential for one who needs to use thermodynamics in engineering analysis. Scientists are interested in using thermodynamics to predict and relate the properties of matter; engineers are interested in using this data, together with the basic ideas of energy conservation and entropy production, to analyze the behavior of complex technological systems.There is an example of the sort of system of interest to engineers, a large central power stations. In this particular plant the energy source is petroleum in one of several forms, or sometimes natural gas, and the plant is to convert as much of this energy as possible to electric energy and to send this energy down the transmission line.Simply expressed, the plant does this by boiling water and using the steam to turn a turbine which turns an electric generator.The simplest such power plants are able to convert only about 25 percent of the fuel energy to electric energy. But this particular plant converts approximately 40 percent; it has been ingeniously designed through careful application of the basic principles of thermodynamics to the hundreds of components in the system.The design engineers who made these calculations used data on the properties of steam developed by physical chemists who in turn used experimental measurements in concert with thermodynamics theory to develop the property data.Plants presently being studied could convert as much as 55 percent of the fuel energy to electric energy, if they indeed perform as predicted by thermodynamics analysis. The rule that the spontaneous flow of heat is always from hotter to cooler objects is a new physical idea. There is noting in the energy conservation principle or in any other law of nature that specifies for us the direction of heat flow. If energy were to flow spontaneously from a block of ice to a surrounding volume of water, this could occur in complete accord with energy conservation. But such a process never happens. This idea is the substance of the second law of thermodynamics.Clear, a refrigerator, which is a physical system used in kitchen refrigerators, freezers, and air-conditioning units must obey not only the first law (energy conservation) but the second law as well.To see why the second law is not violated by a refrigerator, we must be careful in our statement of law. The second law of thermodynamics says, in effect, that heat never flows spontaneously from a cooler to a hotter object.Or, alternatively, heat can flow from a cooler to a hotter object only as a result of work done by an external agency. We now see the distinction between an everyday spontaneous process, such as the flow of heat from the inside to the outside of a refrigerator.In the water-ice system, the exchange of energy takes place spontaneously and the flow of heat always proceeds from the water to the ice. The water gives up energy and becomes cooler while the ice receives energy and melts.In a refrigerator, on the other hand, the exchange of energy is not spontaneous. Work provided by an external agency is necessary to reverse the natural flow of heat and cool the interior at the expense of further heating the warmer surroundings. 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
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