On mold design and manufacturing under the concept

Mold design and manufacturing under the concept of green manufacturing

mold industry is the basis of manufacturing industrial production, and its production technology level is high and low It has become an important symbol to measure the level of manufacturing. In the past, the traditional mold design process generally only needed to consider the basic attributes of the mold product, such as the function, quality, cost and life of the mold, and little or no consideration was given to its environmental attributes. Generally speaking, according to conventional thinking, a small mold product becomes a pile of waste "garbage" after it is used, and the recycling rate is low. This is also the most fundamental reason for the difficulty of mold opening in the mold industry. Because once the mold is opened, the mold material is difficult to reuse, resulting in high cost. At the same time, the most important thing is that this will cause a serious waste of resources and energy, and the toxic and harmful substances contained in mold materials will seriously pollute the ecological environment and harm human health. Luo Baihui, a mold expert, believes that the realization of green design and manufacturing of molds will greatly accelerate the rapid development of the mold industry, which is also an inevitable trend of mold development, so as to truly achieve the goals of high quality, low cost, high efficiency and low pollution of mold design and manufacturing. Green technology will have a far-reaching impact on the future living environment of mankind

green manufacturing mainly includes the following aspects: first, manufacturing problems, including the whole process of product life cycle; The second is environmental impact; the third is resource optimization. Green manufacturing is the intersection and organic integration of these three parts. It is a modern manufacturing mode that comprehensively considers environmental impact and resource efficiency. Its goal is to make products in the whole product life cycle from design, manufacturing, packaging, transportation, use to scrap disposal. It has the least negative impact on the environment and the highest efficiency of resource use. Green mold not only has little impact on the environment when used It should also promote the whole process from manufacturing to scrapping, and the construction of Yangpu Petrochemical free trade park will cause the least damage to the environment in its life cycle

1 mold design

1.1 traditional design and green design

traditional mold design only considers that qualified molds can be designed and manufactured. Not too much consideration will be given to whether the material has an impact on the environment. Whether the produced mold can be reprocessed and reused after use. In the green design of the mold, the impact on the environment is considered from beginning to end, and the recycling of the mold is also considered

1.2 selection of materials

the green degree of mold materials has a very important impact on the green performance of the final product. The material selection of green design must be based on green materials Abandon the chemical methods used in the past for surface treatment of materials Instead, physical methods are used to achieve the purpose of corrosion prevention or easy demoulding. Select high-quality mirror mold steel to process the mold cavity; Use stainless steel materials to process anti-corrosion molds to replace electroplating; Or replace chromium plating with nickel phosphorus plating, which is less harmful to the environment

the basic properties that green materials should have are: ① low pollution, low energy consumption and low cost; ② easy processing and no or less pollution in the processing process; ③ degradable and reusable

1.3 design standardization

mold standardization is the premise of organizing mold professional production. The specialized production of mold is the key to improve mold quality, shorten mold manufacturing cycle and reduce cost. (1) Adopt and purchase standard mold bases and other standard parts. Mold bases and standard parts are produced by specialized manufacturers and enterprises through social division of labor, so that limited resources can be optimized. The die is usually discarded, but the punch and die can't be used again But the mold base is still basically intact Therefore, the use of standard mold base is conducive to the reuse of mold base. There are many kinds of mold bases for stamping and injection molds, and these mold bases are basically made of standard upper and lower mold bases. Guide post. It is composed of guide sleeve and other components. At the same time The standardization of mold base can greatly reduce the equipment used in the production of mold base, so as to save resources. It is also conducive to management

(2) standardization and standardization of each structural unit of the mold. This can speed up the design speed, shorten the design cycle and facilitate the processing management

1.4 removable design

during the use of the mold, some parts and components suffer great wear due to excessive friction and impact. At this time. The mold can still be used only by replacing these parts. In addition. Sometimes as long as the working parts are replaced, the production of a new product can be realized. Non disassembly not only causes a lot of waste of repeatable parts and materials. And because the waste is not easy to dispose It will also seriously pollute the environment. Therefore, in the early stage of design, we should consider the problem of disassembly: ① choose the general structure as much as possible for replacement. ② On the premise of meeting the strength requirements. Try to use removable connection. Such as threaded connection, no welding, riveting, etc

1.5cad, CAPP, cam, CAE application

CAD, CAPP/CAM is a major measure for mold design to move towards total automation. Using CAD/CAPP/CAM technology, less or no drawings can be processed and managed, resources can be saved, and the cycle of mold design and manufacturing can be shortened. It can improve the success rate of mold development and mold quality. Nowadays, CAE technology has been widely used. First, CAD technology can be applied to design the general structure of the product Mark its basic size, and then use CAE technology to analyze the structure, feasibility and process of the product. Now CAD three-dimensional software (such as Pro/E, Solidworks, UG, etc.) basically integrates CAE technology, which can simulate the flow of materials and analyze their strength, stiffness, impact resistance experimental simulation, etc. The use of CAD/CAE provides a basic platform for the realization of concurrent engineering, so it improves the efficiency of mold design and shortens the whole design cycle. Green product analysis is realized

1.6 design of manufacturing environment

the noise and pollution of mechanical production workshops, especially stamping workshops, are very serious. It poses a great threat to the health of the staff and interferes with the surrounding peace. Therefore, the noise generated should be controlled during the mold design. Even eliminate. Generally, there are several methods to eliminate machine noise: using V-belt instead of gear transmission; Replace rigid clutch with friction clutch; Do a good job in the dynamic balance of the rotating body such as the flywheel: cover the main parts of the press that produce noise with a sound proof cover: use a non impact mold base with a shock absorber, etc

1.7 packaging scheme design

the design of packaging scheme mainly includes three aspects: the selection of packaging materials, the improvement of packaging structure, and the recycling of packaging materials and their wastes. The use of packaging materials and waste have a great impact on the environment In particular, some materials that are difficult to recycle or degrade can only be incinerated or buried. Therefore, the packaging of products should be as simple as possible and use green packaging materials (non-toxic, pollution-free, recyclable and degradable materials), which can not only reduce the waste of resources, but also reduce the pollution to the environment

1.8 design of recycling treatment

mold recycling treatment is to consider the possibility of recycling after the mold is used and the method and cost of recycling treatment at the mold design stage. The main contents of recyclable design include recyclable materials and signs, recycling treatment methods, recyclable technical and economic evaluation and recyclable structural design. The main measures are as follows; ① Use mold materials that have little impact on the environment, such as non-toxic and harmless materials, renewable materials, easily recyclable materials, etc; ② Use reusable materials; ③ Renovate and reprocess the used mold parts. 2. Mold manufacturing

adopts advanced mold manufacturing technology. In the manufacturing process, selecting the manufacturing process with the lowest production waste and energy consumption is an important part of realizing green manufacturing

2.1 flexible manufacturing technology (FMS)

an automatic manufacturing system composed of several numerical control equipment, material handling and storage devices and computer control systems, which can be quickly adjusted according to the changes of manufacturing tasks and production varieties. It includes multiple flexible manufacturing cells. It can be quickly adjusted according to the changes of manufacturing tasks or production environment, so as to be suitable for multi variety, medium and small batch production. It can manufacture any kind of parts in a variety of parts by simply changing the software

2.2 highspeedmaclliiing (HSM)

mold manufacturing is an important field of high-speed machining applications. Mold cavity processing has been monopolized by EDM in the past, but its processing efficiency is low. However, the cutting force of high-speed machining is small, and the die steel that can be milled and hardened by 60HRC has a very small machined surface roughness value; For molds with shallow cavities and large radius, high-speed milling can completely replace EDM: for molds with deep cavities and small curvature, high-speed milling can be used as rough machining and semi precision machining, while EDM is only used as finish machining. This can greatly improve the production efficiency and shorten the cycle. The cutting speed of steel can reach 600-800m. Nearly 300 experimental standards/min are integrated in this module

2.3 virtualmanufacturing

virtual manufacturing refers to all links in the manufacturing process. Including product design, processing, assembly, and even the production organization management and scheduling of enterprises Supported by software technology and with the help of high-performance hardware, a workable virtual manufacturing environment is formed. Generate digital products on the computer local/wide area network Realize product design, performance analysis, process decision-making, manufacturing assembly and quality inspection. Characteristics of Virtual Manufacturing: ① product performance can be predicted without manufacturing physical prototype, saving manufacturing costs Shorten the product development cycle; ② In product development, problems can be found as early as possible to achieve timely feedback and correction; ③ Product development in the form of software simulation; ④ The whole manufacturing activity has a high degree of parallelism

applying virtual manufacturing technology to the mold industry can reduce the development cycle. Product design, mold design, mold manufacturing process, mold assembly and debugging, and mold trial are all carried out on the computer, which improves the production efficiency and product quality, reduces the production cost, and fills the gap between mold CAD, cam and production management

2.4 reverse engineering technology (the team used ultradurreveneng, re)

reverse engineering is to scan the existing physical model, collect the coordinate data information of its surface, and generate the wireframe model of the model surface according to the collected data After that, the concave convex die conversion, scaling, rotation, translation and other processing can be carried out on the model as required, and then the processing program of the die can be automatically generated. The machining program that automatically generates molds can be applied to a wide range of CNC systems. This can greatly reduce human labor and waste, improve the success rate of mold manufacturing, and play a positive role in promoting the green manufacturing of molds

2.5 rapid prototyping technology

it is the general term of group technology developed in recent years, which can rapidly produce samples or parts directly according to CAD models. It integrates modern scientific and technological achievements such as CAD technology, numerical control technology, laser technology and material technology. Is advanced