外文翻譯 無繩電話聽筒注塑模具設計

1、本科畢業(yè)設計外文翻譯 學 院： 機械與控制工程學院 課題名稱：無繩電話機聽筒注塑模具設計 專業(yè)(方向)： 機械設計制造及其自動化 （模具設計與制造） 班 級： 機械11-2班 學 生： 陸自遠 指導教師： 劉 羽 日 期： 2015年3月11日 現(xiàn)代模具制造和高速加工摘要：在現(xiàn)代工業(yè)生產(chǎn)中，模具作為重要的工藝裝備。通過高速加工制造模具已經(jīng)越來越普遍，分別用于許多的場合。所以我們對模具的了解和認識必須是多層次多方位的。關鍵詞：模具；高速加工目前模具制造的發(fā)展現(xiàn)狀和趨勢 模具作為重要的工藝裝備，在消費品、電器電子、汽車、飛機制造等工業(yè)部門中，占有舉足輕重的地 位。工業(yè)產(chǎn)品零件粗加工的 75%，精加

2、工的 50%及塑料零件的 90%將由模具完成。目前中國模具市場需求 已達 500 億元之規(guī)模。汽車模具、特別是覆蓋件模具年增長速度將超過 20 %；建材模具也迅速發(fā)展， 各種異型材模具、墻面和地面模具成為模具的新增長點，今后幾年塑料門窗和塑料排水管增長將超過 30 %；家電模具年增長速度將超過 10 %；IT 業(yè)年均增長速度超過20% ，對模具的需求占模具市場的20%。2004 年中國機床工具工業(yè)產(chǎn)值將繼續(xù)增長。我國模具制造市場潛力巨大。根據(jù)資料統(tǒng)計，近年來，我國模具的年總產(chǎn)值達到30億美元，進口超過10億美元，出口超過1億美元。增長從1995年的25%增加到2005年的50%。國外專家預言：

3、亞洲在全球模具制造中占據(jù)的份額，將從1995年的25%增加至2005年的50%。 一、中國模具工業(yè)發(fā)展迅速，形成了華東和華南兩大基地，并且逐漸擴大到其他省份。(山東,安徽,四川) 1996年2002年，模具制造業(yè)產(chǎn)值年平均增長14%，2003年增長25%。2003年我國模具產(chǎn)值為450億人 民幣?？偖a(chǎn)量位居世界第3，出口模具 3.368億美元，比上年增長33.5%。但是，我國技術含量低的模具已供過于求，精密、復雜的高檔模具很大部分依靠進口。每年進口模具超過10億美元。出口超過1億美元精密模具精度要求在23m,大型模具需要滿足8000kN 合模力注塑機的要求;小型模具需滿足直徑1mm 塑料管的要

4、求。目前，采用高速切削生產(chǎn)模具已經(jīng)成為模具制造的大趨勢，在國外一些模具生產(chǎn)廠家，高速機床大面積取代電火花機床，高速切削大大提高了模具生產(chǎn)效率。機床企業(yè)瞄準模具生產(chǎn)企業(yè)，有的加工中心生產(chǎn)廠機床的60%以上賣給模具加工企業(yè)。高速切削逐漸取代電火花精加工模具在國外的模具制造企業(yè)已經(jīng)普遍采用，高速切削生產(chǎn)模具已經(jīng)成為逐漸模具制造的大趨勢，大大提高了模具生產(chǎn)效率和質(zhì)量。 采用高速切削替代電火花生產(chǎn)模具，可以明顯提高效率、提高模具精度、使用壽命長。 2高速加工在模具制造中的應用 21 高速切削的優(yōu)點1）刀具的高轉(zhuǎn)速和機床的高進給以及高加速度，大大提高金屬切除率； 2）高速切削減小切削力； 3）高速切削熱大

5、部分由切屑帶走，工件發(fā)熱少； 4）高速切削減少振動，提高加工質(zhì)量； 22 高速加工應用于模具加工的效益 1） 快速粗加工和半精加工，提高加工效率； 2） 高速高精度精加工硬切削代替光整加工，表明質(zhì)量高，形狀精度提高，EDM 加工提高效率50%， 減少手工修磨； 3） 硬切削加工最后成型表面，提高表面質(zhì)量、形狀精度，(不僅是表面粗糙度低， 而且表面光亮度高)，用于復雜表面的加工更具優(yōu)勢；4）避免EDM加工產(chǎn)生的表面損傷，提高模具壽命20%；5） 結合CAD/CAM技術快速加工電極，特別是形狀復雜、薄壁類電極。 3采用高速切削加工模具需要解決的問題在國內(nèi)，由于資金、技術等方面的原因，應用高速切削生

6、產(chǎn)模具還處于初期階段。 還存在機床、刀具、 工藝以及其他方面的一些問題需要逐步解決。缺點是加工成本高，對刀具的使用有較高的要求，不能使用過大的刀具，要有復雜的計算機編程技術做支持，設備運行成本高。二、加工模具的高速加工機床，模具精加工和硬切削加工需要數(shù)控高速機床,模板、模架加工需要精密、高效數(shù)控機床等。許多機床企業(yè)瞄準模具生產(chǎn)，有的加工中心生產(chǎn)廠機床的60%以上賣給模具企業(yè)。模具行業(yè)今后幾年年均50億元的固定資產(chǎn)投入，其中80%是購買模具加工設備，也就是說每年有40億元人民幣要購買金切機床。目前我國數(shù)控機床的平均利用率大約20%，高速機床的利用率35%。模具企業(yè)也有相當?shù)膯挝毁徺I高速機床，從6

7、00040000rmp 的都有。1高速機床的技術參數(shù)要求 加工中心主軸大功率、高轉(zhuǎn)速，滿足粗精加工；精加工模具要用小直徑刀具，機床一般要達到15000 20000rmp。通常主軸轉(zhuǎn)速在10000rpm以下的機床可以進行粗加工和半精加工，達不到精加工的精度；無法達到400m/min以上的切削速度。 2 五軸機床的應用增加趨勢 1）加工路線靈活，表面形狀復雜； 2）加工范圍大，適合多種類型模具加工；3）切削條件好，減少刀具磨損，提高刀具壽命；3 購買 CAD/CAM 軟件和高速機床配套。據(jù)統(tǒng)計，每年有幾十億美元用于進口機床，大部分電加工機床和高速機床需要進口。 三、高速切削模具的刀具技術高速切削加

8、工還需配備適宜高速切削的刀具。高速加工刀具材料的進展促使了高速加工的發(fā)展。硬質(zhì)合金涂層刀具、聚晶增強陶瓷刀具使得兼顧高硬度的刀刃部和高韌性的基體成為可能。聚晶立方氮化硼 (PCBN)刀片,其硬度可 35004500HV。聚晶金剛石(PCD)其硬度可 600010000HV。近年來德國 SCS、日本三菱(神鋼)及住友、瑞士山特維克、美國肯納飛碩等國外著名刀具公司都先后推出了各自的高速切削刀具，不僅有高速切削普通結構鋼的刀具,還有能直接高速切削淬硬鋼的陶瓷刀具等超硬刀具,尤其是涂層刀具異軍突起,在淬硬鋼的半精加工和精加工中發(fā)揮著巨大作用。新刀具材料和刀具技術的出現(xiàn)已經(jīng)使高速加工上的瓶頸問題不再會出

9、現(xiàn)在刀具上。 但是，進口刀具的昂貴價格也阻礙高速切削模具的重要因素。 一般來說,刀具以及刀夾的加速度達到3g以上，刀具的徑向跳動要小于0.015mm，而刀的長度不能大于4倍的刀具直徑。根據(jù) SANDVIK 公司的實際統(tǒng)計，在使用碳氮化鈦(TICN)涂層的整體硬質(zhì)合金立銑刀(58HRC)進行高速銑削時,粗加工刀具線速度約為100m/min,而精加工和超精加工時,其線速度超過了280m/min。這樣對刀具的材料(包括硬度、韌性、紅硬性(高溫狀態(tài)下保持切削性能)、刀具的形狀(包括排屑 性能、表面精度、動平衡性等)以及刀具壽命都有很高的要求。根據(jù)國內(nèi)模具高速精加工的經(jīng)驗，采用小直徑球頭銑刀進行模具精加

10、工時，線速度超過了400800m/min。選擇足夠高速度的機床硬切削模具精加工。 Delcam 采用0.8mm直徑的刀具加工窄槽，轉(zhuǎn)速40000rpm，0.1mm深度，進給速度 30m/min。. 1 選擇刀具參數(shù)，如負前角刀具等。刀具要求比普通加工要求抗沖擊韌性更高，還要求抗熱沖擊能力強； 2 采取多種方法提高刀具壽命，降低刀具成本。 3 采用高速刀柄，目前應用最多的是HSK刀柄，熱壓裝夾刀具。注意刀具裝夾后的整體動平衡； 4 當前的刀具企業(yè)在解決高速切削刀具技術方面已經(jīng)做了很多工作，面向加工的刀具服務會幫助解決很多問題，刀具生產(chǎn)廠家成為主體，參考刀具生產(chǎn)廠家提供的技術參數(shù)。 四、提高高速切

11、削模具效率的工藝技術 1 刀具直徑和長度的選擇 2HSM 和 EDM 的選擇 3干切削和潤滑冷卻 4 進給選擇：通常進給量 銑刀直徑10%，進給寬度 銑刀直徑 40%。 根據(jù)材料情況合理選擇加工工藝參數(shù) 國外高速銑削加工零件材料質(zhì)量較，材料質(zhì)量標準相同,加工性能比較穩(wěn)定；而國外公司生產(chǎn)的刀具也 是以他們的材料標準做試驗；推薦的加工參數(shù)一般比較適合他們的標準，如果使用他們的刀具，與國內(nèi)的零件材質(zhì)有一定的區(qū)別,在高速銑削時,這種差別表現(xiàn)得較為明顯，有些參數(shù)可以直接應用，但有些效果就比較差。而國內(nèi)企業(yè)一般選用零件材質(zhì)有一定的標準,所使用的零件材料，特別是能用高速加工的零件材質(zhì)，一般會局限在某些零件材

12、料范圍內(nèi),這對我們應用高速加工技術也提供了有利的條件，會在較少的加工材料 范圍內(nèi)應用。這里要強調(diào)的是，一定要在這些材料上選取優(yōu)化出一套適合本企業(yè)的加工工藝參數(shù)，并且納 入企業(yè)標準。選用國產(chǎn)刀具,很少有推薦高速銑削的技術參數(shù)的,有必要做試驗,取得比較滿意的參數(shù),最好選 用固定的刀具生產(chǎn)廠家,減少試驗的次數(shù),形成加工技術標準,這樣可以提高設備有效利用率,降低生產(chǎn)成本,可 以取得較好的經(jīng)濟效益。 五、高速切削的加工刀具路徑和編程 1） 平面進給路徑選擇 2） 輪廓加工路徑選擇 3） 保持切削載荷平穩(wěn) 4） 保持相對平穩(wěn)的進給量和進給速度 5） 在平面切削中保持園拐角 6） 合理選擇精加工余量HSC精

13、加工對CAM的編程要求：1）盡量避免拐角的銑削運動；2）盡量避免工件外的進刀與退刀運動，直接從輪廓進入下一個深度?；蛘卟捎寐菪€或斜向進給切入； 3）恒定每刃進給，提高質(zhì)量，延長刀具壽命；4）輪廓加工保持在水平面上等。高速切削 CAM 軟件： Delcam 公司幾年前就開始了高速切削加工編程技術的研究，開發(fā)了高速切削自動編程軟件模塊；最近， MasterCAM 公司也開發(fā)了高速切削自動編程軟件模塊；國內(nèi)北航海爾也在開發(fā)高速切削自動編程軟件模塊； 六、 高速機床數(shù)控系統(tǒng)的特點 1） 高速數(shù)據(jù)處理 2） 拐角預測處理 3） NURBS 非有理樣條插補曲線加工 七、 高速切削模具的安全問題 1） 刀

14、具磨損和破壞的監(jiān)測； 2） 刀片連接的強度； 3） 和普通機床加工不同，安全防護和開機前對機床和刀具的嚴格檢查非常重要。 八、 目前我國在采用高速加工模具技術中存在的問題 1機床 1） 國產(chǎn)高速機床整體性能尚有差距，功能部件性能還不能滿足要求。包括電主軸的功率和轉(zhuǎn)速，進口機床價格高； 2） 機床的高速下動態(tài)特性研究還不夠，因而影響整機的性能； 3） 五軸機床還不夠成熟，進口機床價格太高； 4） 配套技術和設備還不完全。 2 刀具： 1） 國產(chǎn)刀具還不能夠適應高速切削的應用，特別是高速硬切削光整加工。進口刀具價格高。刀具技 術是影響高速切削加工模具的一個重要因素。 2） 配套技術還不夠，包括刀柄

15、、成套在線動平衡等。 3 高速模具加工工藝技術及實驗 1） 由于高速加工模具的歷史比較短，缺乏應用經(jīng)驗積累； 2） 對高速切削工藝研究比較少，投入不夠，立項比較困難； 3） 缺少高速切削數(shù)據(jù)庫或手冊，目前還是空白； 4） 模具生產(chǎn)廠家對高速切削的認識不夠，缺乏長期效益的分析對比； 4 缺乏高速切削自動編程軟件； 5 缺乏五軸聯(lián)動高速切削自動編程 CAM 軟件。 Modern mold manufacturing and high speed machining外文原文：Abstract: In the modern industrial production, mold is an impor

16、tant process equipment. Through high-speed processing and manufacturing mold has been more and more common, respectively used in many occasions. So our understanding and understanding to the mold must be multi-layer compositeKey words: The mould; High speed machiningTreating and the modern mould mak

17、e high speed One, summarizes 1 the present situation that the mould makes at present and trend The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. The mould is im

18、portant handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. Industrial product part rough process 75%, the finish machining 50% and plastic part 90% will be completed from the mould. Th

19、e Chinese mould market demand already reaches scale of 500 hundred million yuan at present. The automobile mould , the annual growth rate covering piece of mould especially will exceed 20 %; Also prompt building material mould development , various heterotype material the mould , wall surface and fl

20、oor mould become new mould growth point , plastic doors and windows and plastic drain-pipe increase to exceeding 30 by in the upcoming several years %; The home appliance mould annual growth rate will exceed 10 %; The IT industry year increases % speed equally exceeding 20 , the need to the mould ac

21、counts for 20 of mould marketplace %.2004 annual Chinese machine tools implements industry output value will continue to increase. Our country mould fabrication market potential is enormous. The basis data counts , in recent years, our country mould year gross output value reaches 3 billion U. S. do

22、llar , entrance exceeds 1 billion U. S. dollar, exceed 100 million U. S. dollar outlet. Increase by from 25% to increase to 2005 50% of 1995. The expert foretells that abroad: Asia portion being occupied by in mould fabrication in the whole world, will from 25% to increase to 2005 50% of 1995. Chine

23、se mould industry has been expanding by leaps and bounds , has formed east China and two big South China bases, and has expanded gradually arriving at other province. In 2002 (Shandong , Anhui , Sichuan) in 1996 , mould manufacturing industry output value annual average growth 14% , grows by 25% in

24、2003. In 2003 our country mould output value is 45 billion RMB. The gross product place occupies the world the 3rd, exports a mould increases 33.5% compared to last year 336,800,000 U. S. dollar. But, contents low our country technology moulds already pile up in excess of requirement , very most sup

25、port of accurate , complicated top grade mould imports. Every year the entrance mould exceeds 1 billion U. S. dollar. Exceed 100 million U. S. dollar outlet. Precise mould accuracy requires that 3 mu ms , large-scale moulds require that 8000 satisfied kN agree well with model force injection machine

26、 request in 2 ; The minitype mould needs the request satisfying the diameter 1 mm silent stock tube. At present, adopt quick-cutting to produce a mould already becoming the general trend that the mould makes, a few moulds have produced a ma nufacturer in abroad , high-speed machine tool large area h

27、as substituted the electric spark machine tool , quick-cutting has improved the mould efficacy greatly. Machine tool enterprise aims at mould manufacturing enterprises , some treating centres 60% all above of the machine tool producing a factory sells treating enterprise to a mould. The mould fabric

28、ation enterprise substituting the electric spark finish machining mould gradually in abroad has adopt quick-cutting already commonly , quick-cutting has produced a mould already becoming the general trend that the mould makes gradually , has improved the mould efficacy and mass greatly. Adopt quick-

29、cutting to replace electric spark producing a mould , can get on the stick obviously , improves mould accuracy , life time growing. 2 high speed processes application in making in the mould 2.1 quick-cutting merit: 1) cutter high rotation rate and the machine tool height enter be given to and high a

30、cceleration , improve metal excision rate greatly; quick-cutting diminutions cut a force; 3) quick-cutting heat major part generate heat from the cuttings entrainment , workpiece being short; 4) quick-cutting cut down vibration , improve treating mass; 2.2 high speed treating apply to the beneficial

31、 result that the mould processes 1) fleetness rough process and half finish machining, improve treating efficiency; 2) high speed high-accuracy finish machining replace only entire the height processing , indicating mass , form accuracy rise , 50%, cuts down repair a mill by hand than EDM processes

32、a potentiation; 3) cuts the surface processing final molding stiffly , improve surface mass , form accuracy, the treating (not only being that surface harshness is low, and the surface radiance is high) , being used for complicated surface has more advantage; 4) the surface loss that EDM treating pr

33、oduces , improve mould life-span 20%; 5) processes an electrode rapidly combining with the CAD/CAM technology , especially, the form is complicated , thin-wall is similar to an electrode. 3 adopt quick-cutting to process a mould needing the problem solving In in the homeland, since the aspect cause

34、such as fund , technology , the quick-cutting applying produce a mould be in the initial stage stage. Return the machine tool , cutter , handicraft back to existence as well as some problem of aspect needs to proceed orderly other solve. The shortcoming is that finished cost is high, correct cutter

35、sigmatism have comparatively high demand, can not have used big cutters , need to have the complicated computer programming technology to be used for support , equipment running cost height. Two, the high speed processing a moulds processes a machine tool Mould finish machining and hard cutting trea

36、ting require that the numerical control high-speed machine tool , form board , model put up the precision processing need , high-effect numerical control machine tool etc.The mould aiming at produces a lot of machine tool enterprise some treating centres 60% all above of the machine tool producing a

37、 factory sells enterprise to a mould. The fixed assets having 5 billion yuan without exception in the upcoming several years throws into mould industry , 80% is the machine tool buying a mould process equipment , just saying every year having 4 billion yuan of RMB to buy Jinqie among them. At presen

38、t average our country numerical control machine tool utilization ratio approximately 20%, the high-speed machine tool utilization ratio 3 5%. Also, mould enterprise has the unit suitable to buy a high-speed machine tool , complies with 6000 40000 rmps to have. 1 high-speed machine tool technology pa

39、rameter demands Process centre chief axis high-power , high rotation rate , satisfied rude finish machining; The finish machining mould wants to need to reach 15000 20000 rmp like the cutter , the machine tool with minor diameter. Generally, the chief axis rotation rate machine tool under 10000 rpm

40、can carry out rough process and half finish machining , cannot reach the finish machining accuracy; Have no way to reach 400 the above m/min cutting speed. 2 five scrolls of machine tools application increases a trend 1) treating route is nimble , the surface form is complicated; 2) treating range i

41、s big , the various type mould suitable processes; 3) cuts life-span of condition easy to cut down cutter wear , to raise a cutter,; 3 the softwares buying CAD/CAM and high-speed machine tools assort On the grounds of the machine tool , major part counting , having several billions U. S. dollar to b

42、e used to enter port every year, the electromachining machine tool and the high-speed machine tool need to import. Three, quick-cutting mould cutter technology Quick-cutting processes the cutter needing allocating proper quick-cutting. Progressing processing cutter materials in high speed has urged

43、development of high speed treating. The cutter , knife edge headquarter and high tenacity base gathering crystal strengthening the ceramics cutter being able to be used giving consideration to high hardness experience and observe carbide alloy coating becoming possibility. Gather the crystal cube ni

44、triding boron (PCBN) bit, whose hardness may amount to 3500 4500 HV. Gather crystal miamond (PCD) its hardness but amount to 6000 10000 HV. Germany SCS , Japan Mitsubishi (magical steel) and Sumitomo , Switzerland Shanteweike , USA Kenna are in recent years swiftly large wait for the famous abroad c

45、utter company to successively have debuted the respective quick-cutting cutter, not only cutter having average structural steel of quick-cutting, the ceramics cutter still having direct quick-cutting of energy quenching hard steel is waiting for an effect to surpass the hard cutter, especially the c

46、oating cutter appears all of a sudden , bringing into play in quenching half finish machining and finish machining of hard steel. New cutter material and cutter technology appearing already make the bottleneck pr oblem that high speed has processed no longer be able to appear on the cutter. But, exp

47、ensive entrance cutter price also blocks quick-cutting mould key factor. Above to come to saying the cutter and the cutter holder acceleration reach 3 gs the sort, the cutter circular runout needs to be smaller than 0.015 mm, but the knife length is unable greater than 4 times cutters diameter. The

48、reality according to SANDVIK company has counted , the carbide alloy has stood on in the entirety using carbon nitriding titanium (TICN) coating when milling cutters (58 HRC) carry out high speed bright metal chopping , rough process cutter linear speed has been 100 m/min about , whose linear speed

49、has exceeded but 280 m/min when finish machining and microstoning. Such demands to cutter material (include the hardness , tenacity , red hardness keep the form (include row of crumbs function , surface accuracy , dynamic balance sex etc. (cutting the function) , the cutter under high temperature st

50、ate) as well as cutter life-span all has very highly. Experience according to in the homeland mould high speed finish machining, linear speed has exceeded 400 800 m/min when adopt the young diameter ball head milling cutter to carry out mould finish machining. The machine tool choosing sufficient hi

51、gh-speeds cuts mould finish machining stiffly. Delcam adopt 0.8 mm diameter cutter to process the narrow slot , rotation rate 40000 rpm , 0.1 mm depth, feed speed 30 m/min. 1 chooses the cutter parameter , the cutter waits if shouldering an anterior angle. The cutter requires that the ability proces

52、sing request shock resistance tenacity more highly , requiring that heat resistance pounds than average is strong; 2 adopts various method improving cutter life-span , reduces cutter cost. 3 adopt the high speed hilt , HSK hilt , heat pressing applying the most being at present to pretend to grip a

53、cutter. Pay attention to a cutter pretend to grip overall in the day afer tomorrow dynamic balance; 4current cutter enterprise has already done many jobs in the field of the technology resolving the quick-cutting cutter , serving facing the cutter processing may help to solve much problem , the cutt

54、er has produced a manufacturer becoming the main body , the reference cutter has produced the technology parameter that the manufacturer provides. Four, improve quick-cutting mould efficiency technology 1 cutter diameter and the length choice 2 HSM and the EDM choice 3 does cutting and the lubricati

55、ng cooling 4 feeds choice: Move forward generally giving amounts identical , the treating function comparison is stable; But, the cutter that the company produces abroad is also that the standard makes an experiment with their material; The treating being recommended by is suitable to their standard

56、 comparatively like the parameter , material quality has the certain difference with domestic part , this difference shows comparatively obviously , some parameters can apply directly, but some effect dispatches right away comparatively during the period of high speed bright metal chops if using the

57、ir cutter. But select and use part material quality in the homeland like enterprise having the certain standard, what be put into use part material, can use the part material quality that high speed processes especially , the general meeting is limited in some part material range inner, that this ap

58、plies the high speed processing technology to us has also provided advantageous condition , has been able to apply to less treating material within range. Being needing to emphasize that here, must choose the treating technological parameter optimizing out a set of capital suitable enterprise on the

59、se material , is brought into company standard and. The technology selecting and using the domestic cutter , seldom having the bright metal recommending high speed to chop parametric , is necessary making an experiment, get the comparatively satisfied parameter , produce a manufacturer had better to select and use the fixed cutter , cut down