1、模具设计技术发展与应用现状 李志 Manager of Mold/Die Development Team,模具制造业发展现状和趋势,模具工业是支柱产业：汽车，电子，机械，家电，通讯 模具生产向精密，高质量，短交货期方向发展 模具工业东移，从日本，美国，欧洲向东南亚尤其中国转移,数字化设计和制造技术是提高产品质量， 缩短交货周期，提高竞争性重要保证,主要内容,模具设计技术发展与应用现状1. 模具制造业发展现状和趋势 2. 模具CAD/CAM 系统成功应用要素 3. 模具的数字化设计及制造,主要内容,3. 模具的数字化设计及制造 3.1 注塑模设计及制造过程的关键技术塑料产品成型性 - CAE塑
2、料产品结构性 - CAA模具设计和制造 导向技术 3.2 级进模设计及制造过程的关键技术冲压模具数字化设计过程级进模设计和制造 导向技术 3.3 汽车覆盖件模设计及制造过程的关键技术汽车覆盖件数字化设计过程汽车覆盖件产品成型性 - CAE汽车覆盖件冲压工艺设计汽车覆盖件结构设计 4. 结论,Technology Progression,Drawing Based Feature Based Process Based Knowledge Based,User Group Department Enterprise,Data Mgmt Process Mgmt Collaboration Kno
3、wledge,88,74,95,99,02,Digital Drawings,Solids Features Visualization Master Model,Digital Models,Auto threads Aero threads Consumer Products Machinery,Digital Processes,Process Wizards Optimization Rule based modeling WAVE,Predictive Engineering,Pervasive knowledge KBE language Knowledge checkers Ex
4、pert applications Automation,Knowledge Management,File-based datamanagement,Vaulting Application Encapsulation,Product Structure Management ConfigurationManagement Change mgmt Security,CAx Integrations ERP/MRP Integrations Variant Management,Visualization Multi-Site RDV,模具CAD/CAM 系统成功应用要素,通用CAD/CAM
5、System Huge assembly Feature based Freeform surface Knowledge based,模具过程导向 Automation Association Flexibility Easy to use,用户部门 Training Standardization Customization Designer experience,Total Product Engineering,Knowledge Driven Automation Knowledge Automation unique capability blends the power of K
6、BE with utility of high-end mechanical CAD Process Wizards Process Wizards, Advisors, Checkers, Quality & Validation Tools,Injection Mold Design/Manufacturing Process,注塑模设计过程及相关技术,产品设计 （面向制造设计）,模具设计和制造过程导向 复杂分模 设计修改,产品成型性 产品结构性,产品成型性 CAE,注塑充模流动、保压模拟 注塑冷却模拟 注塑应力分析和翘曲模拟,CAE 产品,Moldflow HUST flow,产品结构性
7、 分模线及死角,Moldability Check Find parting lines Find cavity & core faces Simulating cavity & core split Find undercuts Find vertical and small draft faces Find crossover faces which to be split Find openings which to be shut off,产品结构性 型腔面定义,Color parting region Find all cavity/core region Region faces
8、can be re-assigned by users,Product Design Advisor,Validate Part surfaces for: Positive & Negative Faces Vertical Faces Undercut areas Draft angles Automatic parting line generation Combine region/parting line definition,Benefits Validation for Manufacturability Simplify Parting by use of color assi
9、gnment in downstream modules Handle very complex parting easily,Find and color cavity/core regions Face draft analysis Split faces Provide Model/Face & Sharp corner information Volume / sheet boundary information,Examines plastic part geometry for manufacturability,产品结构性 厚度分析,Identification of thick
10、 areas that could form defects in the casting process,产品结构性 厚度分析,Show minimum thickness area and value,Improved efficiency is achieved through streamlined workflows created by The understanding of specific detailed processes Guiding users through these processes Linking complex operations into autom
11、ated sequences,Process Wizards - Embedded Industry Knowledge,Prepackaged vertical solutions that provide expert guidance through industry-leading standard practices,模具设计和制造 导向技术,integrated design environment,Project guidance and Automatic assembly build Family mold support Mold Coordinate System set
12、 up Shrinkage Workpiece Layout Mold Tools Automated Parting functionality Mold Base Catalogs Standard Parts Catalogs Ejector pin post processing Sliders and lifters,Sub-insert design Gate design Runner design Cooling design Electrode design MoldTrim Pocketing BOM Automated drafting Casting Process A
13、ssistant View Manager,Whats the value of Mold Wizard?,productivity gains in Mold Design of 2-to-1 to 10-to-1 through: process automation advanced tools for parting libraries for molds and standard components. Time to market: Start mold design while part is still being altered through: associativity
14、between Part and mold design. Swap model Inconsistent design processes are solved by: providing a standardized, but still fully customizable design process.,0,Why?,Its all about productivity!,Create it faster,Change it faster,INNOVATION SPEED COST QUALITY,Do it right the first time.,Focused solution
15、s provide extraordinary gains in specific product development areas,注塑模具设计和制造 复杂分模,Parting lines Parting surface Patch up,Parting example,3300 faces part 4 days to create core/cavity manually4 hours finish association core/cavity,注塑模具设计和制造 Patch,Automatically internal hole Complicated hole patch,Tri
16、m Region Patch,Create a bounding box for selected faces Trim the bounding box with reference faces Create sheet body patch by boundary edges,Trim Region Patch,Model version Comparison and Swap Regardless translation format (IGES, Step,) Show new, removed, changed and remained faces Automatic update
17、of Core & CavityBenefits Easy to detect changes between different model versions No redundant work due to translation format of 3D models Enables quick mold updates Automatic Update of all downstream functions,Product Change management,Update to a new model version in no time,Product Change manageme
18、nt,AVI demo comparison,- Other MCAD systems,- Other EDS products,注塑模具设计和制造 互换技术,Dumb Solid,Solid Works,Others ,Pro-Engineer,Solid Edge,I-deas,Replace dumb original product modelKeep fully associative after swappingUsers can manually match edge/face After swap obsolete parting line and surfaces will
19、be automatically deleted (also patch surfaces),Change Management: Associative Swap,Benefits No redundant work due to translation format of 3D models Enables quick mold updates Automatic and Associative Update of all downstream functions,Easily create custom libraries by creating a data file no need
20、to create models Automatically generate BOM and pockets One method used by several modules,One interchangeable model for several catalogs Open structure for customization of standard parts and moldbase Add/remove plates and components while associativity remains Individual positioning for each mold
21、component,Benefits:,Create custom libraries without knowledge of Unigraphics,Mold Customization,Standard Libraries,Mold Bases: Metric: DME, Hasco, Futaba, Universal, Rabourdin, STRACK, LKM, Misumi Inch: DME, Hasco, Omni, Universal, DME interchangeable, Hasco interchangeable Standard parts: Metric: D
22、ME, Hasco, Futaba, Rabourdin, STRACK Inch: DME, Hasco, Omni, Yates Hydraulic cylinders,Interchangeable Standard Parts,Use only one model and bitmap to cover different catalogs New Bitmaps to clearly display parameters and Standard Parts Easier to expand data base,Easily create custom libraries by cr
23、eating a data file no need to create models Automatically generate BOM and pockets,Benefits:,Mirror Assembly Wizard,Automatic tool path generation,CAM Automation,Automatic hole recognition through face information added by Mold Wizard Automatic detection of any combination of faces Automatic selecti
24、on of templates and processes Produce all the necessary tool paths automatically to manufacture the holes,Map to CAM processes,Interface Spreadsheet,Mold Wizard attributes on geometry,View management,Tree structure to manage Mold Assembly displayBlank/Unblank Show selected Freeze sub-assembly (for i
25、mproved performance) Close/Open component (for improved performance) Change component color,Progressive Die Design,Sheet Metal Stampings,Progressive Die Design/Manufacturing Process,Sheet metal parts,Automatic CAM Integration,Drawing & BOM,Progressive Die Structure Design,Progressive Die Process Des
26、ign,Progressive Die Process Planning,冲压工艺性分析 冲压工艺设计与计算 条料排样 模具总体结构设计 模具零件详细设计（二维工程图） 模具零件制造 装配调试,Challenges of Progressive Die Manufacturers,Time to market Progressive die design is on the product critical path,Changing product designsProduct design changes are made throughout the progressive die de
27、sign process,Product design data Designs originate in any CAD system,Human resourcesExperienced die designers are expensive,Improve the design process and make it effective,Design wizard,Pre-process Blank layout Strip layout,Die base design Insert design(Punch &die),Detailing(Drawings) CAM integrati
28、on,Progressive Die Design Process / Contents,Process Planning,Feature Recognition Feature Builder,Feature Solid,Dumb Solid,Sheet Metal Part,Die base design Insert group design Standard part Relief design,Die Structure Design,Preprocess Map form features Blank layout Scrap/Overlap/Overcut design Stri
29、p layout Strip simulation Force Center Calculation,Other Functions,Pocketing BOM Drafting View Management Design Tools,Key Technology,Knowledge Based Design,Build in progressive die design Best Practices and Know-how Design Rules and Parameters are available in a design system Effectively capture, s
30、hare and leverage sheet metal stamping knowledge Less experienced designers can quickly achieve higher levels of proficiency,The design process of Progressive dies is strongly experience dependent,An example of knowledge for process design,Key Technology-continue,Design Association,It happens often
31、to change the design, A CAD system should have the ability to maintain the consistent.,Key Technology-continue,Product Exterior boundary Change Add/remove feature Hole dimension change,Blank Layout Adjust blank layout: width, pitch, etc.,Pre-Process Update Blank Define new process,Scrap Design Adjus
32、t scraps: remove, add scraps,Strip Layout Process Definition Pitch Blank Orientation Scrap Design Sheet Metal Part Remove All,Insert Group Delete unused inserts, add new inserts,Update process of design association,Key Technology-continue,Structure Design Automation,There are more than 200-1000 part
33、s designed in one progressive die.,Automatically capture design knowledge embedded in the process design Pre-store various kinds of pre-configured die base libraries Provide die base design tools to increase design flexibility: add/remove die plate, guide bush/post; split die plates; edit size of an
34、y component, Use standard insert groups to speed up design procedure Provide all most important suppliers catalogs of standard parts Automatically make pockets,Key Technology-continue,Process Design Automation,Automatically captures the sheet metal part information, such as, unit, thickness and shee
35、t metal features Supports various stamping processes Automatic strip layout Automatic operation simulation Automatic process force and force center calculation Advanced layout allows users to design their own processes freely,Strip Layout and Simulation,Automatic strip layout Automatic operation sim
36、ulation Automatic process force and force center calculation Advanced layout allows users to design their own processes freely,Computer Product,Computer Product,Structure Design,Structure Design,Automotive Stamping Die,Automotive Stamping Die Process,Typical Process Flow Outline,CAM,*Focus on items
37、in blue boxes,Die Development Process,Die Development Process - Challenges,Spring-back compensation,Formability analysis,Add binder and addendum,Die face Machining,Pattern Design,Pattern Machining,Die Structure Design,Die Structure Templates,Challenges Integration with product design Rapid response
38、to product design changes Capturing die development knowledge Global standardization of development process Discovering problems prior to physical tryout Reducing die lead time (critical path) Reducing cost per die,Automotive Stamping Die Process Die Tools,DFM Advisor Software to verify that the pro
39、duct adheres to Design For Manufacturing criteria Die Engineering A collection of tools that defines and creates geometry to illustrate your manufacturing process in a 3-D format Die Design Process specific design tools that automate the generation of die component solids,PROCESSING,Organize Data Id
40、entify Die Operations Create Die Tips, Position Parts Create Part Developments Perform Trim Angle Checks Create Die Operation Lineup (DOL),TASKS,DFM Advisor Die Engineering Tools Modeling, Drafting, Assemblies Master Model Concept WAVE Linked Sheet Bodies,TOOLS,Automotive Stamping Die Process,Die Op
41、eration Line-up,Automotive Stamping Die Process,3D Representation of manufacturing process,Automotive Stamping Die Process,Die Engineering Tools,Process Assistant Lineup Operation Tipping Form Task Area Fill Binder Wrap Die Section Addendum Output Die Curves Binder Ring Carryover Trim Task Pierce Ta
42、sk Flange Task Tipping Sequence Trim Angle Check Punch Progression Die Face,Processing,Items shown in Green,Benefits Processing model can be saved permanently in the part file. Parametric approach for easy update due to engineering changes Visual display of the state of the sheet metal at each stage
43、 of manufacture,Lineup: collects the entire sequence of operations to manufacture a part,Operation: collects the tasks performed in a given die,Tipping sequence: assists in orienting the product part in press position,Tip: orients the product part in the press,Automotive Stamping Die Process,Form Ta
44、sk: describes areas of the product that are formed to final shape,Area Fill: allows holes, cutouts, trims of the product part to be filled,Carryover: allows the sheet metal shape from the previous operation to be copied into this operation,Automotive Stamping Die Process,Trim Task: defines trimming
45、and piercing tasks to be performed on the product part,Flange Task: models the shape of the sheet metal after flanging has been performed,Automotive Stamping Die Process,Develop Binder Wrap Build Addendum Create Die Tooling File,TASKS,Die Engineering Tools Modeling, Freeform Features, Solid Modeling
46、, Analysis Master Model Concept Sheet Metal Features,Automotive Stamping Die Process,Automotive Stamping Die Process - Toolbars,Die Engineering Tools,BENEFITS,Process Assistant Lineup Operation Tipping Form Task Area Fill Binder Wrap Die Section Addendum Output Die Curves Binder Ring Carryover Trim
47、Task Pierce Task Flange Task Tipping Sequence Trim Angle Check Punch Progression Die Face,Layout,Items shown in Green,Benefits Addendum and binder are defined parametrically using a section-based approach Automatically creates an accurate trim line to save the user many manual steps Sophisticated ma
48、th provides smooth transitions from one section to another,The Die Engineering Tools Module provides the operators to create all the additional geometry required to manufacture the part.,Geometric Engine of Addendum Surface,Accurate Trim Line,Create complex surface in one step,Smooth transition of s
49、hape,Calculations consider formability,Binder Wrap,Create a developable surface representing the shape of the sheet metal after the binder closes,Die Section,Create one or more sections to define the addendum Represented as a series of parameters that can be edited individually by the user Shape is optimized to conform to the constraints imposed,Addendum,Create the addendum surface based on one or more die section features,
