精密模具--钟表匠的工具中英文翻译、外文文献翻译

附录 A：外文翻译精密模具-钟表匠的工具作者: 罗勃特 尼尔里最近， IMI 拜访了瑞士 Lausen 的 Ronda (朗达)SA, 参观了该公司最新的金属注射模(MIM) 和陶瓷的注射模(CIM) 铸造零件的设备。这台设备看起来和普通的设备没什么两样。 但普通又好像并不适合来形容这台注射模具设备, 除非你认为重量只有 0.0025g，大小只有 0.003mm 的模具很普通。而且,由于 Ronda 通过自动化的手段提高了成本的同时也提高了质量，使用这种模具的挑战性正在增加。 结果，二天时间的三个微小零件的偏移模具在无人看管的情况下奇迹般地实现了偏移。精密的如一只瑞士的手表我们经常能听到用“像瑞士手表一样”的语句来形容某件事做的极端地细致和精密。 那么至少可以看出，这句话已经远远地超过了它本身的意义了。而Ronda 也毫无疑问地成为了制造精微细小模具的专家了，虽然更高精密的零件也只是刚开始 。瑞士手表-准确地说是手表内部零件的机心确保了准时的功能。并且 Ronda 是第一个被业内人士公认瑞士用品牌手表的独立制造商。而且在去年它就已经走过了 50 年的风雨历程。Ronda 只做石英一类手表机心-并用 CIM/ MIM 技术在手表框内作记号- 该品牌已占据了大部分市场。 Ronda 品牌常和如 Anne Klein ， Bulova ， Breitling ， Gucci ，Swiss Army， Esprit ，Raymond Weil ， Junghans 以及其他许多熟悉又受人尊敬的商标的知名手表放在一起。此外 Ronda 的生产和制造中心在 Lausen ，而且在瑞士南部有一个装配中心还有一个在泰国的曼谷。总计有超过 1,000 位职员，其中有 600 名在泰国, 他们在去年生产和装配了超过二千万块的手表机心, 使 Ronda 成为全球市场上的第五大手表制造商。制造二千万块的机心需要生产和组合的零配件至少超过十亿个,他们大部 份是用金属捺印或以机器制造而成。 然而尽管它已占领了大部分市场， Ronda 仍有不小的竞争压力而且正不断努力减低成本。 一块手表机心以 Ronda 的要求至少要生产和装配超过 30 个零配件的组合和含有一个集成电路和一个电池，而又仅仅以低于 SFr 2(美金 $1.40)的价格 在全球市场上卖。 这样注射模具已经成为 Ronda 的竞争策略的一个主要部分。Ronda 开始在 1987 年做它自己的注射模具, 这么做部分是迫于成本压力, 但是也是利用塑料设计的可能性。 这样就可以以许多形式来节约成本。因为塑料零配件不需要二次加工如钻孔和再加工，因此可以节约大量的时间。 同时, 多功能的塑料零配件能代替若干的金属零配件和节约他们的装配时间。 而且可以灵活地设计。微型自动润滑电磁马达的注射成形就是我们看到的一个最好的例子。 事实上如果金属零件在承担额外操作时是不可能不润滑的。 但是由于磁铁很小，用塑料同样来制造这个零件也很困难。然而，Ronda 的工程师们对他们单独带有真空输送系统的立式注射机进行改装，先前该系统只能制造小的金属零配件，而现在这一部分也同样适用于错模。使注射工具自然化大部分的 Rondas 的生产空间是一排排的金属加工机器，而且冲压机正在忙碌地冲压,打磨, 或加工齿轮和轴，其他的机器则用于制造手表机心。五十年的在机器工具方面和模具方面所获得的技术已经可以很娴熟地制造一个小的只能用放大镜才能看到齿牙的齿轮的模具，并且采用一模多腔注射Ronda 做它所有的铸模设计都是在内部进行的,他们直接地把电脑辅助设计（CAD）/ 电脑辅助制造（CAM）设计出来的文件传送到 CNC 工作机上进行加工。他们也曾经有一段时间尝试在外面购买一些工具，但最终也只是失败告终; 因为某个程序一变，一个铸模就需要超过 100 个的更改，而且它几乎要一年的时间才能完全的发挥它的真正功能。所以现在所有的生产工具都是内部的。虽然工具是非常小，但是机器零件之间由于配合很精密，所以互相之间的协调度很高。 模具加工中心装备了可以制造和使用电极，高速切削，火花冲蚀和可以切割和 0.03mm 细线一样精细的线切割机的现代化机器。Ronda 的模塑部门是非常简单: 只有八台注射机，而且最大的夹具有 45 吨。时间最久的二个是 Arburgs 的; 接下来的二个来自 Netstal; 而且最新的四个是 Battenfelds 的。 所有的机器是在生产中三次或者五次轮换,有时一星期有六天的轮换。 正如你所会期待的,每部机器特定地被买来生产小的零配件的, 而且全部都做。虽然如此，Ronda 的工程师表示当他们获得装备了可由公司的提供的 Mikromelt 技术的 Battenfeld 机器的时候，他们的精密制造水平会更上一层。Mikromelt 由一根小(14 毫米) 直径螺杆组成，它特地为小容积的铸件设计的。 依照 Ronda 标准, 螺杆在一个 1%毫米的增量中的转动是可以控制的,这是非常均等和比较重要的，只允许非常细微的冲程而且当填充容积非常小时材料的测量也一样要求很精密。 要达到如何小呢? 一个用 POM 固化的玻璃球已经足够做所有我们看到的用一模八腔模具所做的齿轮了，而且其中的 20%被留在浇道系统里， 且零件重量只有 0.0026 g。浇道的容积是零件的好几倍是不可避免的，但它不能和原料相混合所以需要再研磨加工，对铸造的零件只需要二次的再研磨; 每一次都要 100%的研磨。 但这样的结果并没有造成财产的损失因为再研磨后的浇道可以卖到外面用于其他方面。让事物做得完美。 。 。Ronda 几乎从没有发现一部标准的生产机器以符合它的需要。为了生产需要，公司内部开发了机械设计和制造技术。许多用于金属的冲锻加工, 打磨， 嵌入,焊接, 和润滑的生产和装配的机器都由内部制造, 如同大部份用于装配的机器一样。 同样地,工程师用注射模具制造微小零部件的方法也是内部的。对于现在在立式注射机上用于注入成形的输送微型磁铁存在的挑战,Ronda 的工程师先是调整了真空管运输技术使之可移除用于手表机心装配件上的小金属嵌件。 这种方法有足够可靠性来允许在无监视员的模塑错模的过程完全自动化。 这个在磁铁内部的成形零件, 直径为 1.2mm 厚为 0.4mm。收集和清除这些几乎没有质量或重量的模具零配件可是每天的挑战, 多功能清除器其实很普通并且被清除后的零部件能很容易飘浮在周围的气流中，因为它们的重力不足以在清除之后使他们落下， 正因为有了这种为金属零配件发明的解决方案, Ronda 应用这一个实际知识到微小塑料零配件上。为了更好地进行质量管理，他们建造真空系统来把这些零件进行控制并把它们分类到各自的包装袋里。MIM/ CIM 是一个主要的保证如果能提供注射模塑技术和钟表客户商,陶瓷和金属的模具制造手表将是 一个很有前景的行业，而且 Ronda 能提供包装和机心，一切就像组装一样方便。Ronda 的优良模具的成功是引进 MIM/CIM 技术，其中的关键是部分因为有了 MIM的 14%和 CIM 的 22%的费用减缩，同时在有泉华烤箱和电子显微镜的光导模具上投资了很大的成本。该技术能够很好地进行模具质量控制。相对在标准的注射机上做的模具，Ronda 用重达 35 吨的 BattenfeldPlus350 注塑机来注塑 CIM/ MIM 零部件，对于今天的注射机制造水平来讲是一个有趣的现象，Plus 系列虽然它有完整的微处理器控制,但是它是Battenfelds 生产线上最低等级的,设计的价格也相对低廉。然而,光导模具设施是主要的投资。 虽然用于烧结和接触反应的黏结机构花费高达 1,600 到 1,700 瑞士法朗。 但由于它能变换黏结剂，所以在接触反应的过程中允许较高的容量控制,可从固体直接转换到气体而并不需要转化成中间的液体状态。 Ronda 必须在气体储存罐和在车间内再建一个符合严格的瑞士环境的要求的车间。 虽然炉气表面看是被排出去了，但是它可能被排放在车间内。 所以这里有许多的安全装置和连锁装置。黏结机构和烧结过程的管理是通过安装了特别的微软软件的奔腾计算机来控制的。 温度对制品的质量具有显著性影响的决定因素。 Ronda 从材料供应商收到完整的过程规范后再做大量的测试以保证正确结果。CIM 的加工时间超过50 个小时比只需要大约 10 小时的 MIM 加工时间要长的多了，其中最主要的原因就是一个是被动冷却和一个是主动冷却。 尽管生产周期很长和高成本的材料, 这些制造出来的零配件却有真正的成本优势同竞争方法作比较。就拿钛的例子来作个比较,钛是一个非常流行制造手表壳的材料， CIM 和MIM 有一个成本上的优势。 不能用于注射成型的金属必须得用机器加工，而且每块手表壳所花费的时间比可用于批量生产的 CIM/MIM 技术要多得多。 拿大部分金属和塑料作比较的话, 那么金属模具能有更好的设计灵活性。比如 CIM 的材料就可以提供多种颜色, 以适应市场上手表作为时尚饰品的需要。用 MIM 制造的一般金属制品在电子显微镜的观察下总是比铸模金属零件更好。 没有空隙或潜伏的破裂/ 疲劳线。 为了能够铸造非常精密的 MIM 和 CIM 零配件并除去繁琐的轮磨加工，那可是在金属块上磨制以获得手表石英完美的曲率的可靠方法。附录 B：外文原文Precision Moulding The Watchmakers ToolBy: Robert NeilleyRecently, IMI visited Ronda SA in Lausen, Switzerland, to see how the company set up its new production facility for metal injection moulded (MIM) and ceramic injection moulded (CIM) parts. We also looked at the existing injection moulding facility Ronda uses for its normal production. Normal may not be the best word to describe Rondas injection moulding, unless you think that moulding parts weighing as little as .0025g, with tolerances as small as 3micron (.003 mm) is normal.Moreover, the challenge of doing that kind of moulding is multiplied by Rondas drive to contain costs and simultaneously raise quality through automation. As a result, two of the days three shifts moulding these micro parts are unattended ghost shifts.Precise as a Swiss WatchEach of us has heard-and likely said-the words like a Swiss watch to mean something extremely detailed and precise that operates perfectly. Well, at least in this plant, those words are more than a figure of speech. Ronda really had no choice but to become a specialist in producing microscopically small yet highly precise parts from its beginning. It does indeed make Swiss watches-the watch movements, to be exact-that is, the inner part of the watch that performs all the timekeeping functions. Ronda was the first officially recognized independent manufacturer of Swiss watch movements and marked 50 years in business last year.Ronda makes only analog quartz watch movements-the CIM/MIM technology marks an expansion into watch casings-and specializes in the higher end of the market. Ronda movements are found inside such watches as Anne Klein, Bulova, Breitling, Gucci, Swiss Army, Esprit, Raymond Weil, Junghans, and many other familiar, well-respected brands. Besides the production/engineering center at Lausen,- 44 -Ronda has an assembly operation in southern Switzerland and another in Bangkok, Thailand. In all, more than 1,000 employees, 600 of them in Thailand, produced and assembled more than 20 million watch movements last year, making Ronda the number five producer on the world market.Making 20 million movements requires the production and assembly of more than a billion individual parts, most of them stamped or machined from metal. Yet even with its concentration on the high end of the market, Ronda is under competitive pressure and constantly seeking to cut costs. A watch movement at the low end of Rondas range, which requires production and assembly of more than 30 parts and contains an integrated circuit and a battery, sells on the world market for less than SFr 2 (US$ 1.40). Injection moulding has become a key part of Rondas competitive strategy.Ronda began doing its own injection moulding in 1987, partly in response to the cost pressure, but also to take advantage of plastics design possibilities. Cost savings come in many forms. The plastics parts need no secondary operations like machining or hole drilling, thus saving assembly time. Also, the multifunctional plastic parts can eliminate a number of metal parts and their assembly times. And there is the design flexibility.One excellent example we saw is the encapsulation moulding of a tiny magnet to form a self-lubricating rotor. It was virtually impossible to do this in metal without lubrication, which entails additional assembly operations. Nor was it easy to make the part in plastic because of the minuscule size of the magnet. However, Rondas engineers modified their single vertical moulding machine with a vacuum feeding system previously developed for small metal parts, and now this part also runs on ghost shifts.Making Injection Tools Came NaturallyThe majority of Rondas production space is rows of metalworking machines and stamping presses busily cutting, grinding, or turning the metal gears, spindles, and other parts used in the watch movements. Fifty years of skill acquired in machining the tools and dies used to make tiny metal parts was excellent training for creating a multicavity injection tool for moulding a gear wheel with teeth too small to be seen without a magnifying glass.Ronda does all its mould design in-house, transferring the CAD/ CAM files directly to the CNC machine tools. They tried buying tools outside a few times butwith poor results; one mould needed more than 100 changes, and it was almost a year before it would function properly. Now all tool production is done inside. Though the tools are relatively small, the amount of machining time is high because of the precision. The mouldmaking shop is equipped with current generation machines for making and using electrodes, high-speed cutting, spark erosion, and wire EDM using cutting filaments as fine as .03 mm.Rondas moulding department is very compact: there are eight injection machines and the largest clamp is 45 tons. The oldest two are Arburgs; the next two are from Netstal; and the most recent four are Battenfelds. All machines are in production three shifts, five and sometimes six days a week. As you would expect, each machine was bought specifically to produce small parts, and all do. Nonetheless, Ronda engineers say they were able to reach new levels of precision when they acquired the Battenfeld machines equipped with the companys optional Mikromelt technology.Mikromelt consists of a small (14 mm) diameter screw specially designed to feed very small volumes. Equal or greater importance, according to Ronda, is that screw movement is controllable in increments of one one-hundredth of a millimeter, to allow very precise strokes and metering of material even when the shot volume is very small. How small? One pellet of glass-bead-reinforced POM is enough to make all the gear wheels coming from the eight-cavity mould we were watching-with 20 percent of the pellet left in the runner system. Part weight: .0026g. The runners, which inevitably are a large multiple of the part volume, are reground but never mixed with virgin material. Regrind is used only twice to mould parts; 100 percent each time. This results in no loss in properties and the regrind is then sold outside for use in other applications.To Have Things Done Right. . .Ronda has almost never found a standard production machine that meets its needs. Of necessity then, the company developed machine design and fabrication skills in-house. Many of the production and assembly machines for metal stamping, grinding, inserting, welding, and lubricating have been made in-house, as have most of the machines used for assembly. Likewise, engineers created solutions for handling micro-sized injection moulded parts.Presented with the challenge of feeding tiny magnets for encapsulation moulding in the vertical machine, Ronda engineers adapted vacuum-tube transporttechnology previously developed to move small metal inserts used in watch movement assembly. The solution is reliable enough to allow complete automation of the process on the unattended moulding shifts. The finished part, with the magnet inside, is .40 mm thick and has a diameter of 1.20 mm.Collecting and moving moulded parts that have almost no mass or weight-also true of many metal parts at Ronda-is a daily challenge. Multiple ejectors are the norm and the ejected parts could easily float away on ambient air currents since the force of gravity is not enough to make them fall after ejection. Having invented solutions for metal parts, Ronda applied this know-how to handling small plastic parts. They built vacuum systems that collect and sort the parts into separate bags by cavity for quality control purposes.MIM/CIM is a Major CommitmentGiven its injection moulding skills and contacts with its watchmaker clients, moulding ceramic and metal watch cases is a logical business expansion, and Ronda can supply the casing and the movement as an assembly. The keys to entering MIM/ CIM successfully, according to Ronda, are excellent moulds, in part due to the high shrink rates-MIM 14 percent, CIM 22 percent-and a major investment in postmoulding technology including debinding and sintering ovens and electron microscopes for quality control.By contrast, the moulding is done on standard injection machines. The fact that Ronda is moulding CIM/MIM parts on its 35-ton Battenfeld Plus 350 makes an interesting comment on the performance levels of todays injection machines. The Plus Series, though it has full micro-processor controls, is the low end of Battenfelds line, designed to sell at relatively low prices.The postmoulding facility is a major investment, however. Ovens for sintering and catalytic debinding that operate at 1,600 to 1,700 are costly. The catalytic process allows superior tolerance control because it converts the binder, in this case POM, directly from its solid state to gas without an intermediate liquid form. Ronda had to add an outside gas storage area and rebuild an existing space at one end of its plant to meet stringent Swiss environmental requirements. Though the oven exhaust is vented externally, it could be vented in the room. There are numerous safety devices and interlocks.Management of the debinding and sintering processes is computer control