High-speed machining is the development trend of automotive mold manufacturing
High-speed machining technology is an advanced manufacturing technology in the 21st century, with strong vitality and broad application prospects. A series of problems that have been plagued by conventional machining of automotive molds can be solved by high-speed machining technology. In recent years, high-speed machining technology in the industrialized countries of the United States, Germany, Japan, etc. has been widely used in most mold companies, and about 85% of the mold EDM process has been replaced by high-speed machining. High-speed machining technology combines high efficiency, high quality and low consumption, and has become the mainstream in the international mold manufacturing process.
Through the practical application of high-speed machining technology in the automotive mold manufacturing industry at home and abroad, high-speed machining technology has the following advantages:
First, high-speed cutting processing improves processing speed
High-speed machining performs high-speed machining of automotive molds at a cutting speed of about 10 times higher than conventional cutting. Since the excitation frequency of the high-speed machine tool spindle far exceeds the natural frequency range of the “machine tool-tool-workpiece†system, the automotive mold processing process is smooth and without impact.
Second, high-speed cutting processing production efficiency
Machining the mold with a high-speed machining center or a high-speed milling machine can complete the roughing and finishing of the profile and the machining of other parts of the automobile mold in one-time clamping of the workpiece, the so-called "One Pass Machining". The application of high-speed machining technology has greatly improved the development speed of automotive molds.
Third, high-speed machining can obtain high-quality processed surface
Thanks to the extremely small step and depth of cut, high-speed machining results in a high surface quality and even eliminates the need for a trimmer.
Fourth, simplify the processing
Conventional milling can only be carried out before quenching, and the deformation caused by quenching must be manually finished or electroformed to form. Now it can be done by high-speed machining without surface hardening caused by electrical machining. In addition, due to the reduced amount of cutting, high-speed machining can use smaller diameter tools to machine smaller fillet radii and mold details, saving some machining or manual finishing, thus shortening the production cycle.
Fifth, high-speed cutting processing makes the car mold repair process more convenient
In the process of using the automobile mold, it is often necessary to repair it several times to prolong the service life. If high-speed machining is used, the work can be completed faster, the machining effect of the milling machine can be obtained, and the original NC program can be used without reprogramming. And can be accurate.
Sixth, high-speed machining can process rigid automotive molds with complex shapes
According to the high-speed cutting mechanism, the cutting force is greatly reduced during high-speed cutting, and the cutting process becomes easier. The high-speed cutting process has great advantages in cutting high-strength and high-hardness materials, and can be processed with complex profiles and high hardness. Car molds.
The significance of research on high-speed cutting technology of automobile mold
High-speed machining technology has been widely used in the automotive mold manufacturing industry at home and abroad, and has achieved great benefits, but the mechanism and related theory of high-speed machining is still not perfect, and the high-speed cutting database for automotive molds has not yet been established. Domestic and foreign companies choose high-speed cutting tool parameters and high-speed machining parameters. The traditional "trial cutting" method and "experience" method are still used. When processing a new type of material, it is often necessary to use a variety of tools for repeated cutting tests. Research and analysis of tool wear, damage and its causes, to find a set of the best tool materials and processing parameters, so repeated many times, blindness, and a lot of manpower, financial resources and resources. For high-speed machining of special materials such as alloy cast iron, high-strength alloy steel, super alloy (such as titanium alloy), how to choose the right cutting tool according to material characteristics, how to design reasonable cutting parameters, is still researching and developing. in.
Regarding the establishment and use of high-speed cutting databases, there have been few relevant literature reports at home and abroad. This is mainly because the high-speed cutting technology started late, and the practical high-speed cutting data currently available for production is still very scarce.
China's research on high-speed cutting technology for automotive molds started late. In recent years, many mold companies have purchased a large number of high-speed processing equipment and cutting tools from the United States, Germany, France, Japan and other countries, and in the practice of exploring the process technology of automotive mold high-speed cutting, and achieved some successful experience. However, on the one hand, the introduction of equipment does not mean the introduction of technology. High-speed cutting, especially for high-speed cutting of large-scale automotive panel molds, has no successful experience for reference. How to make the imported equipment play its due role as soon as possible is a major issue facing enterprise managers and engineering technicians; On the other hand, technicians use and learn while working, explore and accumulate certain high-speed machining examples, process parameters and work experience. How to save these valuable experiences and lessons for other technical personnel to learn from, avoid more Detours are also a problem.
Auto mold companies must not only establish a high-speed machining and cutting database, but also a "characteristic" cutting database for the processing characteristics of automotive panel molds. The established cutting database can not only store high-speed cutting parameters, but also store excellent high-speed cutting. Processing examples and decision-making knowledge, so this is a database that can “automatically grow knowledgeâ€; on the basis of data and experience, it is also necessary to effectively manage high-speed machining CNC programming tasks. Establishing such a database for the unique situation of the mold company has gone far beyond the scope of general cutting database, but the establishment and application of this "characteristic" database will certainly improve the quality and efficiency of high-speed processing of automotive molds, and bring considerable benefits to enterprises. Economic benefits.
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