Mold making refers to the processing of forming and blanking tools, as well as cutting and die-cutting molds. Normally, a mold consists of two parts: an upper mold and a lower mold. Place the steel plate between the upper and lower molds, and the material is formed under the action of the press. When the press is opened, the workpiece determined by the shape of the mold will be obtained or the corresponding waste will be removed. From electronic connectors to automotive instrument panels, workpieces can be molded using molds. Progressive mold refers to a set of molds that can automatically move processed workpieces from one workstation to another and obtain molded parts at the last workstation. The mold processing technology includes cutting molds, stamping molds, composite molds, extrusion molds, four slide molds, progressive molds, stamping molds, die-cutting molds, etc.
1. Metal stamping dies: continuous die, single die, composite die, stretching die
2. Plastic molding molds: injection molds, extrusion molds, vacuum forming molds
3. Die casting molds
4. Forging molds
5. Powder metallurgy molds
6. Rubber mold
Cutting: front mold material, rear mold material, insert material, row material, inclined top material;
Frame opening: front mold frame, rear mold frame;
Thickening: Thickening the front mold cavity, rear mold cavity, and parting line;
Copper gong: front mold copper gong, rear mold copper gong, parting line clear angle copper gong;
Wire cutting: inlay parting line, copper male, inclined top pillow position;
Computer gong: fine gong parting line, fine gong rear mold core;
Electric spark: front mold coarse, copper male, male mold wire clear angle, rear mold bone position, pillow position;
Drilling, pinholes, and top pins;
UGNX, Pro/NC, CATIA, MasterCAM, SurfCAM, TopSolid CAM, SPACE-E, CAMWORKS, WorkNC, TEBIS, HyperMILL, Powermill, GibbsCAM, FEATURECAM, and more
(1) A set of molds generally consists of a concave mold, a convex mold, and a mold frame, and some may also be multiple assembled modules. So the combination of upper and lower molds, the combination of inserts and cavities, and the assembly between modules all require high machining accuracy. The dimensional accuracy of precision molds often reaches the micrometer level.
(2) Some products, such as car covers, airplane parts, toys, and household appliances, have complex shapes and surfaces composed of multiple curved surfaces. Therefore, the mold cavity surface is very complex. Some surfaces must be processed using mathematical calculation methods.
(3) The production of small batch molds is not mass production, and in many cases only one batch is produced.
(4) In multi process mold processing, various processes such as milling, boring, drilling, reaming, and threading are always used.
(5) The use of repetitive production molds has a lifespan. When the use of a mold exceeds its lifespan, a new mold needs to be replaced, so the production of molds often has repeatability.
(6) In the production of imitation machining molds, sometimes there are neither drawings nor data, and imitation machining needs to be carried out based on the actual object. This requires high imitation accuracy and no deformation.
(7) The mold material is excellent and has high hardness. The main material of the mold is often made of high-quality alloy steel, especially for molds with long service life, which are often made of martensitic steel such as Crl2 and CrWMn. This type of steel has strict requirements from rough forging, processing to heat treatment. Therefore, the formulation of processing technology cannot be ignored, and heat treatment deformation is also a serious issue that needs to be taken seriously in processing.
Based on the above characteristics, the selection of machine tools should meet the processing requirements as much as possible. The numerical control system should have strong functions, high machine tool accuracy, good rigidity, good thermal stability, and the ability to imitate.
Arrangement of processing technology flow
1. Bottom processing, guaranteed processing quantity;
2. Alignment of casting blank benchmark, inspection of 2D and 3D surface allowance;
3. Rough machining of 2D and 3D surfaces, non installation and non working surface machining (including safety platform surfaces, buffer installation surfaces, pressure plate surfaces, and side reference surfaces);
4. Before semi precision machining, find the correct side reference surface to ensure accuracy;
5. Semi precision machining of 2D and 3D surfaces, precision machining of various installation work surfaces (including limit block installation surface and contact surface, insert block installation surface and back surface, punch installation surface, waste cutter installation surface and back surface, spring installation surface and contact surface, various stroke limit work surfaces, wedge installation surface and back surface), semi precision machining of various guide surfaces and guide holes, leaving a margin for precision machining process reference holes and height reference surfaces, and recording data;
6. Check and recheck the machining accuracy;
7. The fitter inlaying process;
8. Before precision machining, align the process reference hole reference surface and check the allowance of the embedded block;
9. 2D and 3D precision machining surfaces, side punch surfaces and hole positions, precision machining process reference holes and height references, precision machining guide surfaces and guide holes;
10. Check and recheck the machining accuracy.
1. The process planning should be concise and expressed in detail, and the processing content should be expressed numerically as much as possible;
2. At the key and difficult points of processing, special emphasis should be placed on the craftsmanship;
3. Need to combine processing areas and express the process clearly;
4. When the inlay needs to be processed separately, pay attention to the process requirements for processing accuracy;
5. After combined processing, the embedded parts that need to be processed separately shall meet the benchmark requirements for process installation and separate processing during combined processing;
6. In mold processing, springs are the most easily damaged, so it is necessary to choose mold springs with long fatigue life. Mold springs made in Europe and America have a long fatigue life, and famous brands include
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