Abstract : This paper mainly discusses the design of automotive panels, according to the characteristics of MFC manufacturing, it is necessary to standardize and digitize some typical mold structures in the design process of automotive panel molds to improve the production efficiency of automotive panels. That is, the MFC modeling based car cover mold design.
1. Car cover mould
1.1. Development of the mold industry
In recent years, the development of molds has been paid more and more attention by people. It has gathered various high-tech, can directly form, weld and assemble materials into parts, components or products with its precision, precision and flow. Line, ultra-miniature, energy-saving, environmental protection, as well as product performance, appearance, etc., are beyond the reach of traditional methods. Mold is an important part of modern manufacturing technology, it is a national or enterprise manufacturing level and production capacity mark.
1.2. The significance of the design of automobile cover mould
The automobile cover mould is one of the important components in the automobile mould. The quality of its production and manufacture directly affects the subsequent production of the automobile, and it is also an important guarantee for the individualization and upgrading of the automobile. Therefore, how to effectively improve the production efficiency of automotive panel molds has become a very meaningful work.
In the entire manufacturing process of automotive molds, the design process of the mold is not only a time-consuming task, but also an important basis for actual processing in the future. According to Dowlatshahi's data:
1. The 70% manufacturing cost of General Motors' truck transmissions depends on the design stage.
2. Ford Motor Company's experience: Of the four manufacturing factors of design, raw materials, labor, and corporate general management expenses, 70% of production savings come from design innovation.
3. Product design generally accounts for 5% to 15% of product cost, but he determines 75% of total manufacturing cost and 80% of product quality and performance. [1]
It can be seen that the role of design work is particularly important. However, in practice, a lot of time is spent on the design of the mold structure, and the time spent on the design of the profile is correspondingly compressed, and this is exactly what we need. On the contrary, how to effectively shorten the time in structural design, so that staff can spend more time on the design of the car model is particularly important.
3. Current status and general process of automotive panel mold design
3.1. Current status of automotive panel mold design
In the design, it often happens that the design work of the designer and the work of the manufacturing, assembly, and assembly personnel conflict with each other, causing additional work such as rework and refurbishment, which not only increases the cost of production, but also seriously Delaying the construction period and delaying the timing of products being put on the market lead to serious consequences of losing market competitiveness.
The most direct impact of this should be the conflict between the designer's design and the MFC styling. It is often the case that the designer's design MFC styling cannot be realized, resulting in continuous rework and negotiation modification.
3.2. MFC design
MFC is lost foam casting (also called solid casting, Taiwan called Bao Lilong casting). This process is commonly used in foreign automotive mold castings. The production model is based on plastic (polystyrene plastic), and the FMC model produced is economical. , saving cost, casting molding surface processing allowance is small, high precision.
Due to the casting of the physical model of the process, the molding process is simplified, and there is no need for mold repairing, boxing, core dropping, etc. during casting, so that the casting blank has no burr, no parting surface, cavity mesh, and smooth hole. This process is suitable for single-piece and complex phantoms and is the best choice for automotive mold making.
3.3. General process of car cover mould design
The general design process for automotive cover moulds is as follows:
1. According to the needs of the manufacturer, the mold concept design analysis.
2, mold work analysis, process analysis, draw process drawings.
3, according to the process drawings, the CAD/CAM design of the mold structure (multiple foreign direct 3D design, domestic multi-purpose 2D design).
4. CAD/CAM is converted to NC code, ready for CNC plus work.
5, MFC modeling, if there is an inappropriate place, go to CAD / CAM design coordination.
6, casting, profile processing.
It is worth noting here that in the whole design process, CAD/CAM modeling is the key part of the design, which plays a role in linking up and down. The important thing of MFC is that it determines whether the designer's ideas can be turned into reality. In the actual design, the weight ratio of these two parts is the largest, and the MFC model has high requirements for the workers. It is necessary not only to understand the designer's design intention, but also to express the parts in terms of entities, especially in the design. Domestically, mainly based on 2D design, it is particularly difficult, and it will take more time than the same work abroad.
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