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definition

Mold processing refers to the processing of forming and blank making tools. In addition, it also includes cutting molds and die-cutting molds. Generally, the mold is composed of an upper mold and a lower mold. The steel plate is placed 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 mold shape will be obtained or the corresponding waste will be removed. The workpieces ranging from electronic connectors to automobile dashboard can be molded with molds.

Progressive die refers to a set of dies that can automatically move the processed workpiece from one station to another and obtain the formed parts at the last station. Die processing technology includes: cutting die, blanking die, compound die, extrusion die, four slide rail die, progressive die, stamping die, die cutting die, etc.

Mold type

1. Metal stamping die: continuous die, single die, composite die, drawing die.

2. Plastic molding mold: injection mold, extrusion mold, blister mold.

3. Die casting die.

4. Forging die.

5. Powder metallurgy mold.

6. Rubber mold.

Mold processing flow

Material cutting: front mold material, rear mold material, insert material, row position material, inclined top material;

Mold opening frame: front mold frame and rear mold frame;

Roughening: roughening the front mold cavity, the rear mold cavity and the parting line;

Copper male: front mold copper male, rear mold copper male, parting line angle clearing copper male;

Wire cutting: insert parting line, copper male, oblique top pillow position;

Computer gongs: precision gongs parting line, precision gongs back mold core;

Electric spark: front mold thickness, copper male, male mold line angle clearing, rear mold bone position, pillow position; Drilling, pinhole, thimble; Processing line position and line position pressure pole of die thimble hole and waterway hole; Inclined top, composite thimble, equipped with thimble;

other:

(1) Pump, code mold pit, garbage nail (limit nail); (2) Flight model; (3) Nozzle, support, spring, water supply;

Save the mold, polish, front mold and rear mold bone position;

Fine water structure, pull rod spiral hook, spring

Heat treatment, quenching and surface nitriding of important parts;

Mold software

Ugn, pro/nc, CATIA, Mastercam, surf cam, topsolid cam, space-e, camworks, worknc, tebis, hyperMILL, PowerMILL, gibbscam, featurecam, etc

General characteristics

(1) A pair of dies with high machining accuracy are generally composed of female dies, male dies and die bases, and some of them can be multi piece modules. Therefore, the combination of upper die and lower die, the combination of insert and cavity, and the combination between modules all require high machining accuracy. The dimensional accuracy of precision molds often reaches the micron level.

(2) The shape and surface are complex. Some products, such as automobile panels, aircraft parts, toys, household appliances, etc., have shapes and surfaces composed of various curved surfaces, so the surface of the mold cavity is very complex. Some surfaces must be treated mathematically.

(3) Batch small mold production is not mass production, and in many cases only one pair is produced.

(4) Most processes are in the process of die machining, and various processes such as milling, boring, drilling, reaming, tapping and so on are always used.

(5) The service life of repetitive production mold is long. When the service life of a pair of molds exceeds its service life, new molds must be replaced, so the production of molds is often repeated.

(6) In the production of copying molds, sometimes there are neither drawings nor data, and the copying processing should be carried out according to the real object. This requires high imitation accuracy and no deformation.

(7) Excellent mold materials and high hardness molds are mainly made of high-quality alloy steel, especially long-life molds, which often use ledeburite steels such as Crl2 and CrWMn. This kind of steel has strict requirements from blank forging, processing to heat treatment. Therefore, the preparation of processing technology can not be ignored, and heat treatment deformation is also a serious problem in processing.

According to the above characteristics, it is necessary to try to meet the processing requirements when selecting machine tools. For example, the CNC system has stronger functions, higher precision, better rigidity, better thermal stability, and profiling function.

Processing flow

Processing process arrangement

1. The bottom surface is processed, and the processing volume is guaranteed;

2. Casting blank datum alignment, 2D and 3D contour allowance inspection;

3. 2D and 3D contour rough machining, non installation and non working surface machining (including safety platform surface, bumper installation surface, pressing plate plane, side datum plane);

4. Before semi finishing, align the side datum plane to ensure accuracy;

5. Semi finish machining 2D and 3D profiles, finish machining various installation working surfaces (including limit block installation surface and contact surface, insert installation surface, back side, punch installation surface, waste cutter installation surface, back side, spring installation surface and contact surface, various travel limit working surfaces, wedge installation surface and back side), semi finish machining various guide surfaces and guide holes, leaving allowance for finishing process reference holes and height reference surfaces, and record data;

6. Check and recheck the machining accuracy;

7. Fitter inlay process;

8. Before finishing, align the datum plane of the process datum hole and check the allowance of the insert;

9. Finish machining contour 2D and 3D, side punching contour and hole position, finish machining process datum hole and height datum, finish machining guide surface and guide hole;

10. Check and recheck the machining accuracy.

Matters needing attention

1. The process flow is concise and detailed, and the processing content should be expressed numerically as much as possible;

2. For the key and difficult points of processing, special emphasis should be placed on the process;

3. It needs combination processing and clear process expression;

4. When the insert needs to be processed separately, pay attention to the technical requirements of processing accuracy;

5. For the insert parts that need to be processed separately after combined processing, the benchmark requirements for process installation and separate processing during combined processing;

6. The spring is easy to be damaged in mold processing, so the mold spring with long fatigue life should be selected.