language
Product Management
- All
- Product Management
- News
- Introduction
- Enterprise outlets
- FAQ
- Enterprise Video
- Enterprise Atlas
Application of Digital Technology in Stamping Die Design and Manufacturing
Release time:
2018-07-05
Source:
In recent years, with the rapid development of China's aviation manufacturing industry and automobile industry, stamping dies are developing at a growth rate of 20% every year. Stamping die is an indispensable process equipment for stamping production, and it is a technology-intensive product. The quality, production efficiency and production cost of stamping parts are directly related to mold design and manufacturing. For example, in the life of a model, the shortest cycle and the most frequent changes are the body. The key to the development of the body lies in the design and manufacture of the body stamping die, which accounts for about 2/3 of the car development time and is a key factor restricting the rapid launch of new models. In our country, imported molds occupy the domestic high-end molds.
In recent years, with the rapid development of China's aviation manufacturing industry and automobile industry, stamping dies are developing at a growth rate of 20% every year. Stamping die is an indispensable process equipment for stamping production, and it is a technology-intensive product. The quality, production efficiency and production cost of stamping parts are directly related to mold design and manufacturing. For example, in the life of a model, the shortest cycle and the most frequent changes are the body. The key to the development of the body lies in the design and manufacture of the body stamping die, which accounts for about 2/3 of the car development time and is a key factor restricting the rapid launch of new models.
In China, imported molds account for about 50% of the domestic high-end mold market. Compared with the international advanced level, we still have a gap of about 5 to 10 years in terms of high-tech molds represented by large, precise and complex. In the stamping die manufacturing industry, the gap is mainly manifested in the accuracy, life, manufacturing cycle and the use of stability and reliability, mold digital design and manufacturing technology behind is one of the main reasons for the product behind. How to deliver high-quality molds to users within a limited development cycle requires stamping die companies to improve technology and management. Mold digital design and manufacturing and enterprise information management technology (including digital design, processing, analysis and information management in the manufacturing process, that is, mold CAD/CAE/CAM/DNC technology) is internationally recognized as an effective technical means to improve the overall level of the mold industry, which can greatly improve the mold production efficiency and product quality, and enhance the comprehensive level and efficiency of enterprises.
Key Technologies in Digital Design and Manufacturing of Mould
With the rapid development and popularization of digital technology, digital has been applied to the whole process of mold manufacturing. From the analysis of Figure 1, it is known that the digital technology of the die is an important factor restricting the development of the stamping die. The digital technology of the mold is the application of computer technology or computer-aided technology in the mold design and manufacturing process. Summarize the successful experience of domestic and foreign stamping die enterprises in the application of computer-aided technology, according to the stamping die manufacturing process, digital stamping die technology is mainly reflected in four aspects.
Application of Stamping CAE Technology in Synchronous Engineering of Product Design
In the synchronous development, the stamping process runs through the whole process of the new product. From understanding the process of the product, to the analysis of the stamping process of the product, to the development of the mold, the stamping process personnel need to participate in the whole process. Stamping CAE technology is based on the actual physical law of the stamping forming process, with the help of computer to truly reflect the interaction between the mold and the sheet metal and the actual deformation of the whole process.
With the rapid development of nonlinear theory, finite element method and computer hardware, the CAE analysis technology of sheet metal forming process has entered the industrial stage after long-term development, and has formed some general or special software, such as AutoForm/PAM-STAMP. These software provide the following analysis and simulation results: material flow, thickness changes, failure, wrinkling, springback, and residual stress and strain. The use of CAE technology in the product concept design stage can make the mold enterprises to the product of each part of the formability, process of rapid and accurate prediction. In a very short period of time, the shape of the part is evaluated, and an accurate and detailed analysis report is given, including the basis for the modification of the digital model, the modification method and the impact on the subsequent process, as the basis for the structural design department to improve the product or determine the scheme [1].
2 Modular-based rapid design system
For stamping dies, structural design often accounts for a large part of the design workload. With the rapid development of computer technology, CAD/CAE/CAM integration technology has been widely used. Stamping die CAD technology in the domestic application, still stay in relying on the experience of mold designers, in the general CAD software system on the level of interactive drawing and modeling, which can not be found in the design process of defects, extend the design cycle of the mold, to some extent also affected the design quality. Based on UG/PROE and a series of computer digital modeling software, the parametric module design of the mold makes "rapid mold design" possible. The standard parts library and template are the basis for the parametric module design of the mold. Through software, a series of standard parts such as guide posts, guide plates, punches, etc. are put into statistical storage so as to be called during design. At the same time, according to different parts, the corresponding mold structure parameters are made into templates, which are also put into the structure library. After getting the mold design task, digest the task requirements (manufacturer's requirements and stamping requirements) in advance; Secondly, combined with the actual production experience on site, call the mold structure library for preliminary design. The mold surface design was carried out again, and then the standard parts library was called to assemble the standard parts. Finally, a complete set of molds was assembled [2]. Through the parametric module design, the typical structure is templated and the repetitive work is intelligent.
(1) Typical structural templating. Based on the idea of templating, various typical structures of stamping dies are classified and summarized, and the places where parametric control can be realized are extracted, and intelligent templates are generated to be applied in the modeling process of the whole design.
(2) intelligent duplication of work. The repetitive work in the design process is achieved by loading intelligent templates and secondary development tools to shorten the design cycle.
3 Parametric programming to achieve high-speed processing of molds.
With the accelerated pace of mold manufacturing, CNC machining has developed from simple surface processing to comprehensive processing of surface and structural surface, and from medium and low speed processing to high speed processing. The application of high-speed machining technology in the mold manufacturing industry mainly has the following advantages: (1) small depth of cut, high feed;(2) improve the surface quality of the workpiece processing, reduce grinding;(3) improve the accuracy, reduce the workload of the mold test;(4) use small tool processing mold details, reduce tool specifications. Reduce the cost of use;(5) to high-precision, large feed way to complete the finishing of hardened steel, and to achieve a high mold surface quality, can reduce the traditional processing due to finishing and then quenching caused by mold deformation, so as to replace some process.
The application of high-speed machining technology in mold manufacturing mainly involves three aspects: machine tools, cutting tools and numerical control programming. The specific workflow is shown in Figure 2. In order to realize the safe and efficient processing of the mold, it is particularly important to have a safer tool path and a reasonable processing strategy. The used tools and machine tool equipment are made into tool library and machine tool library according to the physical size, and then the technical requirements of different parts are listed into libraries (parts library). The digital parameter values of the three libraries are collated and integrated into the programming software to make CAM processing templates, so that the numerical control programming will be safer and faster.
Application of Digital Assembly Technology in Mold Debugging
Mold assembly methods are generally divided into four types: interchangeable assembly method, grouping assembly method, repair assembly method and adjustment assembly method. At the earliest, after the mold is processed in the machining center, the on-site assembly mostly adopts the grouping assembly method: workers directly refer to the 2D part assembly drawing to classify the parts of the guide post guide plate, and then assemble other parts of the mold base according to the sequence of first installing the guide plate and then installing the guide post. After assembly, finish machining is carried out directly. After finish machining, there is no effective comparison and inspection of the guide post accuracy/guide sliding surface position in single piece state, in this way, after finishing the single piece, the upper and lower die bases are closed, and it is found that the guide deviation of the upper and lower die bases is very large, resulting in the strain of the guide plate of the guide post and the damage of the standard parts.
Now, the measurement results of on-line measurement (OMV) (such as the guide column guide data of the upper mold base and the guide column guide data of the lower mold base) after finishing the mold single piece are recorded and counted in the software, compared, and immediately changed if the deviation is found. Fig. 3 is the measurement error distribution diagram of the upper and lower die seats of the drawing die for the engine hood inner plate of a project after processing. According to such measurement results, the area with large error before mold clamping of the upper and lower mold seats can be rectified to ensure the guide gap and the mold clamping quality.
At present, the mold manufacturing in some European and American countries can directly use the repair assembly method (the method of repairing the reserved repair quantity on the specified parts to achieve the assembly accuracy, called the repair method) to carry out the mold assembly. They carry out mold clamping assembly by measuring data and directly matching grinding guide plates or other parts to ensure guide clearance or assembly quality. This method improves the mold closing progress and wins the cycle for the subsequent mold debugging. Based on the measurement data, the application software for analysis and processing, this way of repairing and assembling method should become the trend of mold development in the future.
Information System of Stamping Die Enterprise
Digital technology in the stamping die manufacturing industry is more and more widely used, it is a set of management, design, analysis, manufacturing, testing and other mold manufacturing throughout the life cycle of the integration of all aspects of the integrated application of technology, to effectively manage all aspects, need to rely on enterprise information construction.
The application of enterprise informatization can be simply summarized into two aspects, namely, technology management informatization and production management informatization. Technology management informatization refers to the application of CAD/CAE/CAM technology based on PDM/CAPP to realize the informatization or digitization of mold design and manufacturing simulation. Production management informatization is represented by ERP/MES system, and technology management informatization is the basis of production management informatization [3].
Through this architecture, the product development model and process are optimized, the unified management and sharing of product data, the accumulation and reuse of design knowledge and processing knowledge are realized, and the production process system with workshop scheduling as the core and real-time collection of progress, quality and material information in the production process is established. Through systematic means, the mold enterprise upstream and downstream business process, technical communication process and mold enterprise internal business management process, in the form of information technology fixed down, so as to fully tap the potential of enterprises, improve the efficiency of the use of enterprise resources and the rapid response ability of enterprises, and ultimately the mold enterprise management personnel from the cumbersome affairs of liberation.
1 Establish a product data organization model centered on the mold structure to maintain product data consistency.
PDM/CAPP is used to manage all kinds of files of all molds, and the BOM structure of all kinds of molds is established in the system. At the same time, all kinds of documents related to mold parts, such as digital model from the main engine factory, design task book, mold 3D model, inspection fixture data, change order, etc., are associated with the product structure. The design engineer can query the required technical data by inputting the part drawing number, part name and other means, or obtain the product data by expanding the product structure layer by layer. During the query process, the design engineer does not need to know the physical location of the document storage, and can find the required product document in a short time.
Using PDM/CAPP system, all the mold design data will be unified management in the structured database, the system will automatically keep the mold data synchronization, to ensure the uniqueness and timeliness of the mold data. Design engineers and other downstream departments can obtain the latest mold data and historical files at any time through the PDM/CAPP system, and can ensure the consistency of the data.
2 Establish a project management platform with project progress collection and control as the core to optimize workshop scheduling management.
The workshop management of mold enterprises is a big problem. Production management is a typical project realized according to a single order. Each mold is independent from order receiving, design to production and debugging, and requires a special project leader to carry out progress collection and control management. Since each project contains dozens or even hundreds of sets of molds, each set of molds takes several months, and more than a dozen design, manufacturing and delivery nodes need to be monitored at the same time. The progress collection and management of mold projects is a complicated and tedious job. The ERP/MES system is adopted to realize the functions of order management (business entry), planning and scheduling, material tracking, production scheduling and so on on a unified platform. Through the integration with the management system (ERP) and control system (MES) of the planning layer, the planning, production and control are closely linked, thus establishing a bridge and link of communication between the planning layer and the control layer. Each node in the mold project plan is regarded as the node of data acquisition and control to realize the optimal scheduling of workshop management.
3 Establish a database-based knowledge management system to share knowledge inheritance
Stamping die industry is a very dependent on the "experience" of the industry, foreign companies have formed their own mold design, process and production parameters database. By setting up an integrated platform of CAD, CAPP and CAM systems that can connect the design, process and manufacturing of the whole mold, a unified data management system is formed to effectively manage the stamping process and structure design library, typical process library and debugging problem records and other information of the enterprise, accumulate mold development experience and realize the accumulation of intellectual assets of the enterprise.
4 Establish electronic processes to achieve traceability of the process.
In the PDM/CAPP system, the electronic approval/issuance process model of related documents is established, all approved electronic documents automatically flow in the process according to the approval voting rules, and the process automatically distributes the approval task to the relevant personnel. Approvers involved in different approval processes can vote in an electronic process, such as approval, disapproval, or abstention, and can enter voting opinions. The system will record the information of the entire approval process, and the approved documents will automatically become officially issued documents, thus realizing the traceability of the process.
Previous Page
Previous Page
RELATED INFORMATION
Customer satisfaction is the only criterion for testing product quality. Listen to the voice of customers, grasp their needs, define quality standards with customer satisfaction, and do everything possible to improve customer satisfaction and loyalty.
Products
Contact Information
no. 489, dongye road, dongjing district ,songjiang industrial zone, Shanghai
Message board