模具设计与制造外文翻译

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1 英文原文

Mould Design and Manufacturing

CAD and CAM are widely applied in mould design and mould making.CAD allows you to draw a model on screen ,then view it from every angle using 3-D animating and ,finally ,to test it by introducing various parameters into the digital simulation models (pressure ,temperature ,impact ,etc .)

CAM ,on the other hand ,allows you to control the manufacturing quality .The advantages of these computer technologies are legion ;shorter design times (modifications can be made at the speed of the computer ).lower cost ,faster manufacturing ,etc .This new approach also allows shorter production runs ,and to make last-minute changes to the mould for a particular part. Finally ,also ,these new processes can be use to make complex parts .

Computer-Aided Design (CAD) of Mould

Traditionally, the creation of drawings of mould tools has been a time-consuming task that is not part of the creative process. Drawings are an organizational necessity rather than a desired part of the process .

Computer-Aided Design (CAD) means using the computer and peripheral devices to simplify and enhance the design process .CAD systems offer an efficient means of design ,and can be use to create inspection equipment .CAD data also can play a critical role in selecting process sequence .

A CAD system consists of three basic components ;hardware ,software,

User ,The hardware components of a typical CAD system include a processor ,a system display, a keyboard, a digitizer, and a plotter. The software component of a CAD system consists of the programs which allow it to perform design and drafting functions. The user is the tool designer who uses the hardware and software to perform the design process.

Based on he 3-D data of the product, the core and cavity have to be designed first.

Ussrally the designer begins with a preliminary part design ,which means the work around the core and cavity could change .Modern CAD systems can support this with calculating a spot line for a defined draft direction ,splitting the part in the core and cavity side and generating the run-off or shut-off true faces .After the calculation of the optimal draft of the part, the position and direction of the cavity, slides and inserts have to be defined .Then, in the conceptual stage, the positions and the geometry of the mould –such as slides, ejection system, etc. –are roughly defined. With this information, the size and thickness of the plates can be defined and the corresponding standard mould that comes nearest to the requirements is chosen and changed accordingly –by adjusting the constraints and paramenter so that any number of plates with any size can be use in the mould. Detailing the functional components and adding the standard any size can be used in the mould. Detailing the functional compontnts and adding the standard components complete the mould. This all happens in 3D .Moreover ,the mould system provide functions for the checking, modifying and detailing of the part .Already in this early stage ,drawings and bill of materials can be created automatically.

Through the use of 3D and the intelligence of the mould system, typical 2D mistakes –such as a collision between cooling and components/cavities or the wrong position of a hole –can be eliminated at the beginning. At any stage a bill of materials and drawings can be created-allowing the material to be ordered on time and always having an actual document to discuss with the customer or a bid for a mould base manufacturer .

The use of a special 3D mould design system can shorten development cycles, improve mould quality ,enhance teamwork and free the designer from tedious routine work .The development cycles can be shortened only when organization and personnel measures are taken. The part design, mould design, electric design and mould manufacturing departments have to consistently work together in a tight relationship .

Computer-Aided Manufacturing (CAM ) of Mould

One way to reduce the cost of manufacturing and reduce lead-time is by setting

up a manufacturing system that uses equipment and personnel to their fullest potential .the foundation for this type of manufacturing system as the use of CAD data to help in madding key process decisions that ultimately improve machining precision and reduce non-productive time .This is called as computer-aided manufacturing (CAM).The objective of CAM is to produce, if possible ,sections of a mould without intermediate steps by initiating machining operations from the computer workstation .

With a good CAM system, automation does not just occur within individual features. Atuomation of machining processes also occurs between all of the features make up a part, resulting in tool-path optimization. As you create features, the CAM system constructs a process plan for you .Operations are ordered based on a system analysis to reduce tool changes and the number of tools used .

On the CAM side the trend is toward newer technologies and processes such as micro milling to support the manufacturing of high-precision injection moulds with complex 3D structures and high surface qualities. CAM software will continue to add to the depth and breadth of the machining intelligence inherent in the software until the CNC programming process becomes completely automatic. This is especially true for advanced multifunction machine tools becomes completely automatic This is especially true for advanced multifunction machine tools that require a more flexible combination of machining operations .CAM software will continue to automate more and more of manufacturing redundant work that can be handled faster and more accratrly by computers, while retaining the control that machinists need.

With the emphasis in the mould making industry today on producing moulds in the most efficient manner while still maintaining quality, mold makers need to keep up with the latest software technologies-packages that will allow them to program and cut complex moulds quickly so that mould production time can be reduced .In a nutshell, the industry is moving toward improving the quality of data exchange between CAD and CAM as well as CAM to the CNC ,and CAM software is becoming more “intelligent” as it relates to machining processes-resulting in reduction in both cycle time and overall machining time .Five-axis machining also is emerging as a “must-have” on the shop floor-especially when dealing with deep

cavities. And with the introduction of electronic date processing (EDP) into the mould making industry, new opportunities have arisen in mould-making to shorten production time, improve cost efficiencies and achieve higher quality.

The Science of mold Making

The traditional method of making large automotive sheet metal dies by model building and tracing has been replaced by CAD/CAM terminals that convert mathematical descriptions of body panel shapes into cutter paths.Teledyne Specialty Equipment’s Efficient Die and Mold facility is one of the companies on the leading edge of this transformation.

Only a few years ago, the huge steel dies requited for stamping sheet metal auto body panels were built by starting with a detailed blueprint and an accurate full-scale master model of the part. The model was the source from which the tooling was designed and produced.

The dies, machined from castings, were prepared from patterns made by the die manutacturers or something supplied by the car maker. Secondary scale models called” tracing aids” were made from the master model for use on duplicating machines with tracers. These machines traced the contour of the scale model with a stylus, and the information derived guided a milling cutter that carved away unwanted metal to duplicate the shape of the model in the steel casting.

All that is changing. Now, companies such as Teledyne Specialty Equipment’s Efficient Die and Mold operation in Independence, OH, work from CAD data supplied by customers to generate cutter paths for milling machines, which then automatically cut the sheet metal dies and SMC compression molds.

Although the process is used to make both surfaces of the tool, the draw die still requires a tryout and “benching” process. Also, the CAD data typically encompasses just the orimary surface of the tool, and some machined surfaces, such as the hosts and wear pads, are typically part of the math surface.

William Nordby, vice president and business manager of dies and molds at Teledyne, says that “although no one has taken CAD/CAM to the point of building

the entire tool, it will eventually go in that direction because the “big thrdd” want to compress cycle times and are trying to cut the amount of time that it takes to build the tooling. Tryout, because of the lack of development on the design end, is still a very time-consuming art, and very much a trial-and-error process.”

No More Models and Tracing Aids

The results to this new technology are impressive. For example, tolerances are tighter and hand finishing of the primary die surface with grinders has all but been eliminated. The big difference, says Gary Kral, Teledyne’s director of engineering, is that the dimensional control has radically improved. Conventional methods of making plaster molds just couldn’t hold tolerances because of day-to-day temperature and humidity variations.”

For SMC molds the process is so accurate , and because there is no spring back like there is when stamping sheet metal, tryouts are not always required.SMC molds are approved by customers on a regulate basis without ever running a part .Such approvals are possible because of Teledyne’s ability to check the tool surface based on mathematical analysis and guarantee that it is made exactly to the original design data. Because manual trials and processes have been eliminated, Teledyne has been able to consider foreign markets.” The ability to get a tool approved based on the mathe gives us the opportunity to compete in places we wouldn’t have otherwise,” says Nordby. According to Jim Church, systems manager at Teledyne, the company used to have lots of pattern makers ,and still has one model maker.” But 99.9 percent of the company’s work now is from CAD data. Instead of model makers, engineers work in front of computer monitors.”

He says that improvements in tool quality and reduction in manufacturing time are significant. Capabilities of the process were demonstrated by producing two identical tools. One was cut using conventional patterns and tracing mills, and the other tool was machined using computer generated cutting paths. Although machining time was 14 percent greater with the CAM-generated path, polishing hours were cut by 33 percent. In all ,manufacturing time decreased 16.5 percent and tool quality increased 12 percent.

Teledyne’s CAD/CAM system uses state-of-the-art software that allows engineers to design dies and molds, develop CNC milling cutter paths and incorporate design changes easily. The system supports full-color, shaded three-dimensional modeling on its monitors to enhance its design and analysis capabilities. The CAD/CAM system also provides finite element analysis that can be used to improve the quality of castings , and to analyze the thermal properties of molds. Inputs virtually from any customer database can be used either directly or through translation.

CMM Is Critical

Teledyne’s coordinate measuring machine(CMM),says’ Church,”is what has made a difference in terms of being able to move from the traditional manual processes of mold and die making to the automated system that Teledyne uses today.”The CMM precisely locates any point in a volume of space measuring 128 in, by 80 in, by 54 in, to an accuracy of 0.0007 in. It can measure parts, dies and molds weighing up to 40 tons. For maximum accuracy,the machine is housed in an environmentally isolated room where temperature is maintained within 2 deg.F of optimum. To isolate the CMM from vibration, it is mounted on a 100-ton concrete block supported on art cushions.

According to Nordby, the CMM is used not only as a quality tool, but also as a process checking tool. “ As a tool goes through the shop, it is checked several times to validate the previous operation that was performed.” For example, after the initial surface of a mold is machined and before any finish work is done, it is run through the CMM for a complete data check to determine how close the surface is to the required geometry.

The mold is checked with a very dense pattern based on flow lines of the part. Each mold is checked twice, once before benching and again after benching. Measurements taken from both halves of the mold are used to calculate theoretical stock thickness at full closure of the mold to verify its accuracy with the CAD design data.

Sheet Metal Dies Are Different

“Sheet metal is a different ballgame,” says Nordby, “because you have the issue of material springback and the way the metal forms in the die. What happens in the sheet metal is that you do the same kinds of things for the male punch as you would with SMC molds and you ensure that it is 100 percent to math data. But due to machined surface tolerance variations, the female half becomes the working side of the tool. And there is still a lot of development required after the tool goes into the press. The math generated surfaces apply primarily to the part surface of the tool.”EMS Tracks the Manufacturing Process

Teledyne’s business operations also are computerized and carried over a network consisting of a V AX server and PC terminals. IMS (Effective Management Systems) software tracks orders, jobs in progress, location of arts, purchasing, receiving, and is now being upgraded to include accounting functions.

Overall capabilities of the EMS system include bill-of-material planning and control, inventory management, standard costing, material history, master production scheduling, material requirements planning, customer order processing, booking and sales history, accounts receivable, labor history, shop floor control, scheduling, estimating, standard routings, capacity requirements planning, job costing, purchasing and receiving, requisitions, purchasing and receiving, requisitions, purchasing history and accounts payable.

According to Frank Zugaro, Teledyne’s scheduling manager, the EMS software was chosen because of its capabilities in scheduling time and resources in a job shop environment. All information about a job is entered into inventory management to generate a structured bill of material. Then routes are attached to it and work orders are generated.

The system provides daily updates of data by operator hour as well as a material log by shop order and word order. Since the database is interactive, tracking of materials received and their flow through the build procedure can be documented and cost data sent to accounting and purchasing.

Gary Kral, Teledyne’s director of engineering, says that EMS is really a tracking device, and one of the systems greatest benefits is that it provides a documented

record of everything involving a job and eliminates problems that could arise from verbal instructions and promises. Kral says that as the system is used more, they are finding that it pays to document more things to make it part of the permanent record. It helps keep them focused.

2 中文翻译

模具设计与制造

CAD和CAM广泛用于模具的设计和制造中。CAD允许你在屏幕上画出模型，然后采用三维动画从各个角度进行观察，最后通过在数字仿真模型上引入个类参数（压力、温度、冲力等）进行测试。而CAM，从另一方面来说，能够控制制造质量。这些计算机技术的优点是很多的：设计时间短（可用计算机的速度进行修改）、费用低、制造快，等等。这种新的方法还允许进行小批量生产，可以在最后一分钟对某个特定零件的模具进行改动。最后这些新工艺还可以用来制造复杂的零件。

模具的计算机辅助设计

一直以来模具的制图是一项费时的工作，它不属于创造性工艺过程的一部分。制图不是工艺过程所要求的部分，但对工艺组织来说是必要的。

计算机辅助设计（CAD是采用计算机急其他外围装置来简化和提高设计过程。CAD系统提供了一高效的设计方法，并且当它和坐标测量机器和其他检验设备结合使用时可用来创立检验程序。在选择工艺顺序时CAD数据将发挥关键的作用。

一个CAD 系统由3 个基本的部件组成：硬件、软件、用户。一个典型的CAD 系统的硬件部分包括一个处理器、一个系统显示器、一个键盘、一个数字转换器和一个绘图仪。而CAD系统的软件部分由允许其完成设计和画图功能的程序组成。用户是模具的设计者，他采用硬件和软件来完成设计过程。

在产品的三维数据的基础上，应首先对模芯和型腔进行设计。通常设计人员先进行零件的预设计，这意味着可以改变围绕模芯和型腔所进行的工作。现代CAD系统可以支持该设计，先针对确定好的画图方向计算出一条分模线，将零件分成模芯和型腔两侧，并生成出流表面和截流表面。在计算出零件的最佳设计草案后，再确定型腔、滑道和嵌件的位置和方向。然后在初步设计阶段，粗略地定

出模具部分的位置和几何形状-例如滑动装置、喷出系统等。有了这些信息，便可确定板的大小和厚度，并从产品标准目录中选取相应的标准模具。如果没有一个标准的模具能满足需要，则选择和要求最接近的标准模具并做相应修改通过调整限制和参数使得任意数量的任意尺寸的板子都能设计中。对功能部分进行细化，并加入标准部件完成整个模具的设计。这一切均在三维空间中进行。此外，模具系统还提供了对零件进行检查、修改和细化的功能。早在这个阶段，就可以自动生成图纸和材料清单了。

通过运用模具设计系统的三维设计及功能，可以在开始阶段就消除二维设计中的典型错误例如冷却系统和部件/型腔间的碰撞或孔的位置错误。在任何阶段都能生成材料和图纸清单-从而能准时订购材料，并且总是具备实际的文件可用来与客户进行探讨，或者对模具制造商来说是能给出报价。

一个特定的三维模具设计系统的使用能缩短研发周期，提高模具质量，增进团队合作，使设计人员从沉闷的工作解脱出来。但经济上的成功主要取决于工作流程的组织。只有采取了适当的组织方法和人员评估策略才能缩短研发周期。零件设计、模具设计、电气设计以及模具制造部门必须紧密合作，协同工作。

模具的计算机辅助制造

减少制造费用和研发周期的一个方法是建立能够充分发挥设备和人员潜力的制造系统。这类制造系统的基础是采用CAD数据来帮助对主要工艺做出决策，使得最终能够提高机器精度并减少不直接从事生产的时间。这就被称为计算机辅助设计（CAM）。CAM的目的是，如果可能的话，通过从计算机工作站启动机器运作，从而直接生产出模具断面而不需要经过中间步骤。

对于一个好CAM系统，自动化不仅仅体现在某个地方的细节上。加工工艺的自动化还体现在组成一个零件的各个侧面之间，最终导致方法路径的最优化。当你要生产多种特征是，CAM系统会为你构建一个工艺规划，它会在系统分析的基础上指定操作步骤以减少工具的变动以及所采用的工具的数据。

在CAM 方面，发展趋势是新技术和新工艺，例如微研磨，以支持带复杂三维结构和高表面质量的高精度注塑模具的制造。CAM软件将继续在软件本身固有的智能化加工的深度和广度上发展，直到计算机数值（CNC）编程工艺变成完全自动化。对于要求加工操作步骤能更灵活地组合在一起的先进的多功能加工工具来说

尤其如此。CAM软件在保持机械师所需要的控制同时，将继续使多余的制造工艺渐渐自动化，使其通过计算机更快更精确地进行操作。在强调模具制造业的维持质量的同时还要以最高效率的方式制造模具的今天。模具制造商们需要紧跟最新的软件技术包，以便使他们能够快速地规划并制造出复杂的模具，从而减少模具生产时间。简单的说，模具制造业正朝着提高CAD和CAM之间以及CAM和CNC 之间数据交换的质量方向发展，并且CAM软件在涉及加工工艺方面变得更为智能化-从而减少了生产周期和总的加工时间。同时五轴加工已作为“必须有的”加工方式出现在车间工场-尤其是在涉及型腔较深的场合。随着电子数据处理（EDP）被引入模具制造业，模具制造出现了新的发展机会，从而可以缩短生产时间、提高成本效率并获得更好的质量。

模具制造科学

传统的通过制造模具加工大型板材的方法已经被可以把实体的形状信息转换为切削路径的CAD/CAM所取代了。这个专门的高效的灵活的公司就是这种转换技术前言的一部分。

在几年以前，大型的需要自动送料的巨大金属模具在详细的蓝图上和一个准确的全面的模形上开始建造，这个模形是工具被设计和生产的起源。

模具是由浇铸转化来的，它由模形制造演化而来，而且由模具制造商和汽车生产商赞助。第二种类型的模型叫做路线辅助追踪，他由替代追踪的模型发展而来，这些机器用探头扫描机器的轮廓，所获得的信息控制加工机切去不需要的金属以便复制模型。

现在所有这些都被改变了，现在像TSEED这类大公司独立运作，用客户提供的CAD数据产生加工机的加工路线，用于自动加工板材模和SMC复合材料。虽然这个工艺只被应用于加工工件的俩个表面，但模具还需要一个实验过程，而且，CAD数据只包含工件原始表面的数据和像垫圈这类的机加工过的表面和一些数学模型的部分。

威廉是在泰勒德尼的模具制造工业的代主官，他说“虽然没人把CAD/CAM 用于制造所有工件，但他终将向这个方向发展，因为三巨头要压缩循环时间而且试图减少制造工具的时间。因为缺少向设计结果的发展，试验仍然是一向非常费时间的工作，也是一个不断改进的过程。