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First, the modular method of mold
Shortening the design cycle and improving design quality is one of the keys to shortening the entire mold development cycle. Modular design is the use of product components in the structural and functional similarity, and to achieve product standardization and composition. A lot of practice shows that modular design can effectively reduce product design time and improve design quality. Therefore, this paper explores the use of modular design methods in mold design.
Modular design of the implementation of the mold:
1, establish a module library
The establishment of the module library has three steps: module division, construction feature model and user-defined feature generation. Standard parts are a special case of a module and exist in the module library. The definition of standard parts requires only the last two steps. Module division is the first step in modular design. The rationality of module division directly affects the function, performance and cost of the modular system. The module division of each type of product must go through technical research and repeated argumentation to obtain the division results. For molds, functional modules and structural modules are mutually inclusive. The structural module may have a large structural change in a local area, and thus it may contain a functional module; and the local structure of the functional module may be relatively fixed, and thus it may include a structural module. After the module design is completed, the required module's feature model is manually constructed in the Pro/E Part/Assembly space, using the user-defined features of Pro/E to define the two variable parameters of the module: Resizing and assembly relationships form User-Defined Features (UDFs). After the user-defined signature file (file with gph as suffix) is generated and then stored by name of the grouping technology, the establishment of the module library is completed.
2. Development of module library management system
The system uses two inferences, structure selection reasoning and automatic module modeling to determine the module. The first inference gives the approximate structure of the module, and the second inference ultimately determines all the parameters of the module. The "plasticity" objective of the module is achieved through this approach. In the structure selection inference, the system accepts the module name, function parameter and structure parameter input by the user, performs reasoning, and obtains the name of the applicable module in the module library.
If you are not satisfied with the result, the user can specify the module name. The module obtained in this step is still indefinite, and it lacks definitions of dimensional parameters, precision, material characteristics, and assembly relationships. In automatic modeling inference, the system uses input size parameters, precision features, material features and assembly relationship definitions to drive user-defined feature models, and dynamically and automatically models and automates module feature models. The automatic modeling function was developed using Pro/TOOLKIT, a secondary development tool of C language and Pro/E. The mold design can be quickly completed by calling the module. After the application of this system, the mold design cycle is significantly shortened. Due to the careful consideration of the quality of the module in the design of the module, a fundamental guarantee of the quality of the mould is provided. The module library stores independent UDFs files, so the system has scalability.
Second, the defects in the mold manufacturing process and preventive measures
1, forging processing
High-carbon, high-alloy steels, such as Cr12MoV, W18Cr4V, etc., are widely used to make molds. However, these kinds of steels have the defects of segregation of components, uneven coarseness of carbides, and non-uniform microstructure. The use of high-carbon, high-alloy steel manufacturing molds, must use a reasonable forging process to form the module blank, so that on the one hand the steel can reach the size and specification of the module blank, on the one hand can improve the organization and performance of the steel. In addition, high-carbon, high-alloy die steels have poor thermal conductivity, the heating speed cannot be too fast, and the heating should be uniform. In the forging temperature range, a reasonable forging ratio should be used.
2, cutting processing
The cutting process of the die should strictly ensure the fillet radius at the size transition, and the arc and the straight line should be smooth. If the cutting quality of the mold is poor, it may cause mold damage in the following three aspects: 1) Due to improper cutting, the sharp corners or fillet radius will be too small, which will cause the mold to have serious stress concentration during work. . 2) After the cutting process, the surface is too rough, there may be defects such as knife marks, cracks, and cuts. These are stress concentration points, cracks, fatigue cracks, or the origin of thermal fatigue cracks. 3) The cutting process fails to completely and evenly remove the decarburized layer formed when the mold hair is damaged during rolling or forging. This may cause a non-uniform hardened layer during the heat treatment of the mold, resulting in a decrease in wear resistance.
3, grinding processing
The mold is generally ground after the fire and tempering to reduce the surface roughness. The overheating of the mold surface due to excessive grinding speed, excessively fine grain size of the grinding wheel, or poor cooling conditions may cause local microstructure changes, softening of the surface, reduced hardness, or high residual tensile stress. Such phenomena will reduce the service life of the mold. Selecting appropriate grinding process parameters to reduce local heat generation, grinding and stress removal under possible conditions can effectively prevent grinding cracks. There are many measures to prevent grinding overheating and grinding cracks, such as: using coarse-grained grinding wheel with strong cutting force or grinding wheel with poor adhesion, reducing the grinding feed rate of the mold; selecting suitable coolant; grinding processing After 250-300 °C tempering to eliminate grinding stress.
4, EDM
When the die is processed by the EDM process, the current density in the discharge area is large, and a large amount of heat is generated. The temperature of the die processed area is as high as about 10000 DEG C. Due to the high temperature, the metallographic structure of the heat-affected zone is bound to change. Melting occurs due to high temperatures, then quenches, quickly solidifies, and forms a resolidified layer. It can be seen under the microscope that the solidified layer is bright white and there are many microscopic cracks inside. In order to prolong the service life of the die, the following measures can be adopted: Adjusting EDM parameters EDM or mechanical grinding is used to grind the surface after EDM, and the white bright layer in the abnormal layer is removed, especially the micro-cracks are removed. A low-temperature tempering is arranged after EDM to stabilize the anomalous layer and prevent microcracks from spreading.
According to the method described in the text, the development cycle can be shortened and the defects of the mold manufacturing can be effectively prevented, the quality of the mold manufacturing can be improved, and the production cost can be reduced.
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