沖壓模具類外文文獻(xiàn)翻譯、中英文翻譯、外文翻譯

模具工業(yè)是國民經(jīng)濟(jì)的基礎(chǔ)工業(yè)，是國際上公認(rèn)的關(guān)鍵工業(yè)，工業(yè)發(fā)達(dá)國家稱之為“工業(yè)之母”。模具成型具有效率高，質(zhì)量好，節(jié)省原材料，降低產(chǎn)品成本等優(yōu)點。采用模具制造產(chǎn)品零件已成為當(dāng)今工業(yè)的重要工藝手段。模具在機(jī)械，電子，輕工，紡織，航空，航天等工業(yè)領(lǐng)域里，已成為使用最廣泛的工業(yè)化生產(chǎn)的主要工藝裝備，它承擔(dān)了這些工業(yè)領(lǐng)域中60%--80%產(chǎn)品零件，組件和部件的加工生產(chǎn)。”模具就是產(chǎn)品質(zhì)量”，“模具就是經(jīng)濟(jì)效益”的觀念已被越來越多的人所認(rèn)識和接受。在中國，人們已經(jīng)認(rèn)識到模具在制造業(yè)中的重要基礎(chǔ)地位，認(rèn)識更新?lián)Q代的速度，新產(chǎn)品的開發(fā)能力，進(jìn)而決定企業(yè)的應(yīng)變能力和市場競爭能力。在目前用薄鋼板制造發(fā)動機(jī)罩蓋的傳統(tǒng)還是會持續(xù)相當(dāng)一段時間，所以有必要在鋼板的基礎(chǔ)上通過利用計算機(jī)軟件的功能分析零件的工藝性能（結(jié)構(gòu)合理，受力，是否容易沖出破面、、、），發(fā)現(xiàn)現(xiàn)有零件的不足之處，討論并確定改進(jìn)這些不足之處，進(jìn)而改善模具的設(shè)計，改良沖裁方式；最終實現(xiàn)產(chǎn)品的改良，改善產(chǎn)品的力學(xué)性能，外觀，使用效果，和造價等等。沖壓加工是通過模具來實現(xiàn)的，從模具角度來看，模具生產(chǎn)技術(shù)水平的高低，已成為衡量一個國家產(chǎn)品制造水平高低的重要標(biāo)志，因為模具在很大程度上決定著產(chǎn)品的質(zhì)量、效益和新產(chǎn)品的開發(fā)能力。“模具是工業(yè)生產(chǎn)的基礎(chǔ)工藝裝備”也已經(jīng)取得了共識。據(jù)統(tǒng)計，在電子、汽車、電機(jī)、電器、儀器、儀表、家電和通信等產(chǎn)品中，60%?80%的零部件都要依靠模具成形。用模具生產(chǎn)制件所具備的高精度、高復(fù)雜程度、高一致性、高生產(chǎn)率和低消耗，是其他加工制造方法所不能比擬的。同時，沖壓加工也創(chuàng)造了巨大的價值增值，模具是“效益放大器”，用模具生產(chǎn)的最終產(chǎn)品的價值，往往是模具自身價值的幾十倍、上百倍。目前全世界模具年產(chǎn)值約為600億美元，日、美等工業(yè)發(fā)達(dá)國家的模具工業(yè)產(chǎn)值已超過機(jī)床工業(yè)，從1997年開始，我國模具工業(yè)產(chǎn)值也超過了機(jī)床工業(yè)產(chǎn)值。其中沖壓模具在所有模具（鍛造模、壓鑄模、注塑模等）中，無論從數(shù)量、重量或者是從價值上都位居榜首。由此可見，板料沖壓加工及其模具制造技術(shù)對國民經(jīng)濟(jì)的發(fā)展已經(jīng)并將繼續(xù)作出重大的貢獻(xiàn)。隨著我國經(jīng)濟(jì)的發(fā)展，對這種生產(chǎn)技術(shù)的發(fā)展及專業(yè)技術(shù)人才的需求將與日俱增。因此，加強(qiáng)對板料沖壓加工及其模具制造技術(shù)的研究，具有重要的意義?，F(xiàn)狀和發(fā)展趨勢：經(jīng)過了100多年的發(fā)展，目前小型汽車發(fā)動機(jī)的罩殼的設(shè)計技術(shù)已經(jīng)相當(dāng)成熟的了，但是隨著各式各樣的小型發(fā)動機(jī)的開發(fā)，發(fā)動機(jī)的前后罩也做了很大的改進(jìn)。現(xiàn)在，對小型汽車發(fā)動機(jī)的罩殼的改進(jìn)主要表現(xiàn)在對其構(gòu)造材料的改進(jìn)；例如用樹脂基復(fù)合材料替代傳統(tǒng)的薄鋼板，用RTM制造發(fā)動機(jī)水箱、隔熱罩、發(fā)動機(jī)罩等等，由于用復(fù)合材料來取代原有金屬的發(fā)動機(jī)殼體類零件，重量會有所減輕，且成本也將大大降低，對制造商而言，這個改進(jìn)創(chuàng)造了很大了利潤空間，所以這方面的技術(shù)進(jìn)步還會持續(xù)相當(dāng)長一段時間。就目前而言，我國沖壓模具還存在許多問題，其中模具生產(chǎn)周期、質(zhì)量和數(shù)量仍舊是關(guān)鍵。與國際水平相比，一般來說，我國沖壓模具生產(chǎn)周期要比國外先進(jìn)水平長、壽命約相差一倍、精度差距也較大。數(shù)量的不足主要反映在大型、精密、復(fù)雜、長壽命模具上。存在這些問題的主要原因是：1）行業(yè)結(jié)構(gòu)（如企業(yè)組織結(jié)構(gòu)、產(chǎn)品結(jié)構(gòu)、技術(shù)結(jié)構(gòu)和進(jìn)出口結(jié)構(gòu)等）不合理：2）企業(yè)綜合素質(zhì)欠佳、設(shè)計制造水平較低、開發(fā)能力弱、管理較落后；3）模具人才嚴(yán)重不足；4）資金投入不夠；5）專業(yè)化、標(biāo)準(zhǔn)化、商品化程度低，協(xié)作差：6）模具材料及相關(guān)技術(shù)落后；7）模具生產(chǎn)企業(yè)的效率和效益較低，等等。柳州天隆機(jī)械有限公司所用的沖壓模具還比較落后，利用沖壓模具沖出的零件質(zhì)量也不是很高，經(jīng)常有起皺，尺寸和形狀精度不高，壽命短等缺陷。同時，在排樣時的不合理更造成原材料的浪費。這些因素?zé)o不影響著公司產(chǎn)品質(zhì)量和效益的提高。歸及以上原因主要是由于模具設(shè)計得不夠合理，考慮得不夠周全等所造成的。其次不合理的工藝設(shè)計也是造成零件質(zhì)量不高的原因。工藝設(shè)計是聯(lián)接產(chǎn)品設(shè)計與制造的橋梁和紐帶，合理的成形工藝設(shè)計是模具設(shè)計與制造的基礎(chǔ)，也是決定零件能否順利成形的關(guān)鍵，它將直接關(guān)系到產(chǎn)品的質(zhì)量、成本、生產(chǎn)效率以及模具的使用壽命等方面。在現(xiàn)在這個科技突飛猛進(jìn)的時代里，模具設(shè)計技術(shù)同樣也是在快速的發(fā)展著。模具技術(shù)未來發(fā)展趨勢主要是朝信息化、高速化生產(chǎn)與高精度化發(fā)展。而如今的市場經(jīng)濟(jì)，競爭又十分激烈，要想在市場中站得住腳，那么就必須不斷的提高自己設(shè)計模具的水平，使自己設(shè)計出來的沖壓模具更合理，沖出來的零件質(zhì)量，尺寸和形狀精度，壽命以及資源利用率都能得到大幅度的提高，進(jìn)而才能提高公司的效益和競爭力。1.2選題背景近年來沖壓成形工藝與理論的研究成果近年來，沖壓成形工藝有很多新的進(jìn)展，特別是精密沖裁、精密成形、精密剪切、復(fù)合材料成形、超塑性成形、軟模成形以及電磁成形等新工藝日新月異，沖壓件的精度日趨精確，生產(chǎn)率也有極大提高，正在把沖壓加工提高到高品質(zhì)的、新的發(fā)展水平。由于引入了CAE，沖壓成形已從原來的對應(yīng)力應(yīng)變進(jìn)行有限元等分析而逐步發(fā)展到采用計算機(jī)進(jìn)行工藝過程的模擬與分析，以實現(xiàn)沖壓過程的優(yōu)化設(shè)計。在沖壓毛坯設(shè)計方面也開展了計算機(jī)輔助設(shè)計，可以對排樣或拉深毛坯進(jìn)行優(yōu)化設(shè)計。止匕外，對沖壓成形性能和成形極限的研究，沖壓件成形難度的判定以及成形預(yù)報等技術(shù)的發(fā)展，均標(biāo)志著沖壓成形以從原來的經(jīng)驗、實驗分析階段開始走上由沖壓理論指導(dǎo)的科學(xué)階段，使沖壓成形走向計算機(jī)輔助工程化和智能化的發(fā)展道路。方案：作為沖壓件要大略了解它的沖壓性能的好或者差，用個人的經(jīng)驗或者視覺的判斷就可以了，但是在要求量化的條件下，最好莫過于用機(jī)械相關(guān)的板料分析軟件；我使用DYNAFORM來對沖壓件分析。從分析的圖象的顏色可以判斷沖壓條件是否惡劣，給出的列表數(shù)據(jù)可以清楚得知道，拉伸的情況。依據(jù)它給出的信息，我們可以對沖壓件作出相應(yīng)的改進(jìn)。最后重點放在模具的設(shè)計上來。大體步驟：.用CAE軟件（DYNAFORM）分析，并討論現(xiàn)有零件的工藝性（沖壓性能）.改進(jìn)零件的部分外形，和加強(qiáng)筋分布。.用FASTBLANK展料，并排樣，選出最佳排樣方案。.進(jìn)行相關(guān)運(yùn)算，得出相關(guān)數(shù)據(jù)。描繪出大體輪廓。.利用上面所得數(shù)據(jù)，使用UG畫出模具3維圖（數(shù)模）。.利用上述數(shù)模討論具體零件工藝和相關(guān)方案。.利用AUTOCAD或CAXA繪制模具相關(guān)部件2維圖。.寫課題說明書。沖壓工藝過程的優(yōu)劣，決定了沖壓件制造技術(shù)的合理性、沖壓件的質(zhì)量和產(chǎn)品成本。因此必須對沖壓件進(jìn)行詳盡的工藝分析，分析沖壓件的結(jié)構(gòu)、性能及加工難易程度，確定科學(xué)的、合理的工序方案。并在保證產(chǎn)品的設(shè)計要求、滿足使用條件的情況下盡量減少工序，采用適宜的材料，盡量節(jié)約用料，選擇先進(jìn)且合理的加工技術(shù)，力求生產(chǎn)工藝過程簡單易行，以降低生產(chǎn)成本，提高經(jīng)濟(jì)效益。模具CAE技術(shù)就是在設(shè)計制造模具之前，在計算機(jī)上模擬出沖壓件在模具中成形的真實過程，向用戶告知模具結(jié)構(gòu)設(shè)計、工藝條件狀況是否合理，并最終為用戶提供出最佳的模具設(shè)計工藝方案，可靠性達(dá)到80%以上。從而縮短模具設(shè)計與制造周期2/5（對于復(fù)雜模具而言），并提高模具質(zhì)量和產(chǎn)品合格率，進(jìn)而可大幅度降低制造成本，增強(qiáng)產(chǎn)品的市場競爭力。國內(nèi)模具與國外模具的差距當(dāng)前，我國工業(yè)生產(chǎn)的特點是產(chǎn)品品種多、更新快和市場競爭激烈。在這種情況下，用戶對模具制造的要求是“交貨期短”、“精度高”、“質(zhì)量好”、“價格低”。而供需兩旺是近幾年來我國模具市場的總體表現(xiàn)，2004年仍舊是這個格局。由于汽車、機(jī)電等工業(yè)的發(fā)展增幅回落，再加上原材料漲價，能源緊張，電力供應(yīng)不足，資金周轉(zhuǎn)不暢和運(yùn)費增加，所以2004年模具市場在供需兩旺的情況下，發(fā)展增幅也有所回落。2005年相比，預(yù)計要回落5個百分點以上。在歐美，CAD/CAE/CAM已成為模具企業(yè)普遍采用的技術(shù)。在CAD方面，目前3D設(shè)計也達(dá)到了70%?89%。澳大利亞3D設(shè)計已達(dá)到60%,而我國只是剛剛起步。CAE技術(shù)在歐美應(yīng)用逐漸成熟。在沖模設(shè)計中應(yīng)用CAE軟件，模擬金屬變形過程，分析應(yīng)力應(yīng)變的分布，預(yù)測破裂、起皺和回彈等缺陷，我國只有少部分企業(yè)開始CAE技術(shù)的應(yīng)用。DL圖（沖壓工藝過程圖）設(shè)計的過程中，在沖壓工藝分析、沖壓方向的確定和工序劃分方面我國與國外水平接近。但在工藝補(bǔ)充面的設(shè)計和產(chǎn)品數(shù)模的工藝處理方面還存在著較大的差距，如過拉延部分的設(shè)計，回彈值的處理等方面國外具有豐富的經(jīng)驗，特別是在高精度轎車零件的工藝設(shè)計方面與國外相比仍存在著很大的差距。高速切削是以高切削速度、高進(jìn)給速度和高加工質(zhì)量為主要特征的加工技術(shù)。在國外已是比較成熟的技術(shù)，型面加工精度W0.05mm,不需要研合間隙。修邊模刃口間隙由機(jī)加工保證；鉗裝不需要研配間隙，加工后可直接裝配合模。而國內(nèi)的模具鉗工工作量仍較大。國內(nèi)的加工機(jī)床性能基本與國外設(shè)備相當(dāng)，但在NC技術(shù)參數(shù)方面，走刀路徑、方式及技術(shù)的設(shè)計方面仍存在著差距。另外在模具制造周期、質(zhì)量方面和標(biāo)準(zhǔn)化程度方面也存在著較大的差距。第二章沖壓工藝過程設(shè)計沖壓工藝過程的優(yōu)劣，決定了沖壓件制造技術(shù)的合理性、沖壓件的質(zhì)量和產(chǎn)品成本。因此必須對沖壓件進(jìn)行詳盡的工藝分析，分析沖壓件的結(jié)構(gòu)、性能及加工難易程度，確定科學(xué)的、合理的工序方案。并在保證產(chǎn)品的設(shè)計要求、滿足使用條件的情況下盡量減少工序，采用適宜的材料，盡量節(jié)約用料，選擇先進(jìn)且合理的加工技術(shù)，力求生產(chǎn)工藝過程簡單易行，以降低生產(chǎn)成本，提高經(jīng)濟(jì)效益。模具CAE技術(shù)就是在設(shè)計制造模具之前，在計算機(jī)上模擬出沖壓件在模具中成形的真實過程，向用戶告知模具結(jié)構(gòu)設(shè)計、工藝條件狀況是否合理，并最終為用戶提供出最佳的模具設(shè)計工藝方案，可靠性達(dá)到80%以上。從而縮短模具設(shè)計與制造周期2/5(對于復(fù)雜模具而言)，并提高模具質(zhì)量和產(chǎn)品合格率，進(jìn)而可大幅度降低制造成本，增強(qiáng)產(chǎn)品的市場競爭力。隨著現(xiàn)代生產(chǎn)制造的需要，新產(chǎn)品開發(fā)設(shè)計、制造的質(zhì)量和周期已成為企業(yè)在市場經(jīng)濟(jì)中能夠生存發(fā)展的重要決定性因素之一。計算機(jī)輔助設(shè)計(CAD)及制造(CAM)技術(shù)的推廣應(yīng)用，不僅將產(chǎn)品開發(fā)的設(shè)計者們從繁重的手工制圖方式中解脫出來，同時，對加工制造業(yè)而言應(yīng)該是一次巨大的革命性飛躍。然而，在并行工程CE(ConcurrentEngineering)的概念提出和應(yīng)用前，產(chǎn)品的CAD/CAM/CAE/CAPP由于分屬不同部門的工作內(nèi)容，產(chǎn)品的設(shè)計、制造、分析是在自上而下的串行設(shè)計中完成的，很顯然，針對并行設(shè)計，前者在整個設(shè)計過程中受到不能及時更新的約束，很難做到產(chǎn)品開發(fā)制造集成同步實現(xiàn)，增加了開發(fā)周期和生產(chǎn)成本。公司完成的“國家863/CIMS主題”重大應(yīng)用項目并行工程，通過在新產(chǎn)品開發(fā)CAD/CAM/CAE過程中的實施，體現(xiàn)了良好的應(yīng)用前景。其中，PRO/E三維設(shè)計系統(tǒng)在產(chǎn)品開發(fā)過程中沖壓模具的并行全相關(guān)參數(shù)化設(shè)計已得到很好的應(yīng)用。近年來，隨著計算機(jī)綜合應(yīng)用技術(shù)的迅速發(fā)展，計算機(jī)集成制造系統(tǒng)(CIMS)、并行工程(CE)、虛擬生產(chǎn)(VM)等一系列新技術(shù)將機(jī)械工程制造業(yè)帶進(jìn)了一個嶄新的生產(chǎn)過程模式。有關(guān)資料統(tǒng)計表明，我國在863/CIMS應(yīng)用推廣過程中，相關(guān)企業(yè)均獲得了明顯的經(jīng)濟(jì)和社會效益，在提高生產(chǎn)效率，降低成本、縮短產(chǎn)品周期、提高質(zhì)量方面的成績尤為突出?！安⑿泄こ獭本推湟饬x而言是一個復(fù)雜的系統(tǒng)過程，它解決如何有效的將產(chǎn)品開發(fā)設(shè)計、工藝準(zhǔn)備過程、制造、過程管理、經(jīng)營銷售等過程合理的組織，實現(xiàn)獲得最佳的產(chǎn)品周期和成本。幾年來，公司并行工程項目的啟動和實施，在不同部門的協(xié)同應(yīng)用實施仍處于不斷探索驗證的階段，其中，沖壓模具并行設(shè)計已經(jīng)基本形成了較為完善的過程框架，對于模具設(shè)計制造過程，并行設(shè)計的根本實現(xiàn)必須由核心CAD/CAM/CAE軟件的支持，作為并行工程的設(shè)計系統(tǒng)平臺，公司引進(jìn)了美國PTC公司的PRO/ENGINEER作為CAD/CAM軟件平臺，而沖壓成形數(shù)值模擬分析則引進(jìn)了專業(yè)CAE分析系統(tǒng)DYNAFORM,在模具展開設(shè)計前和過程中，對于模具結(jié)構(gòu)設(shè)計意圖的關(guān)鍵要素利用PRO/E建模并通過標(biāo)準(zhǔn)數(shù)據(jù)格式提交給DYNAFORM進(jìn)行計算分析，預(yù)測可行性干預(yù)改進(jìn)模具結(jié)構(gòu)相關(guān)參數(shù)。另外，在模具的制造上可以實現(xiàn)在PRO/E內(nèi)部的CAD/CAM無縫轉(zhuǎn)接，從而不僅可以完全體現(xiàn)模具設(shè)計意圖、避免工程圖紙的信息損失，還能夠大大縮短制造周期。PRO/ENGINEER在設(shè)計過程中可以利用參數(shù)設(shè)置、關(guān)系(Relations)、參考(Reference)管理實現(xiàn)全相關(guān)(Dependency)參數(shù)化設(shè)計，換言之，在模具設(shè)計的過程中，設(shè)計產(chǎn)品的任何變化都將傳遞到模具所有相關(guān)的結(jié)構(gòu)件上并按照結(jié)構(gòu)設(shè)計意圖自動更新。這大大提高了模具設(shè)計的效率，支持設(shè)計的反復(fù)性，高效率的進(jìn)行設(shè)計更新。PRo/ENGINEER提供了一套方法和各種工具構(gòu)成了一個相對完善的Top-DownDesign的環(huán)境，Top一DownDesign是指在結(jié)構(gòu)設(shè)計中的一種組織方式，其實，不單純在PRo/E環(huán)境下，以往在手工及二維設(shè)計過程中也體現(xiàn)了它的宗旨。Top-DownDesign的主題思想是以圍繞核心設(shè)計意圖進(jìn)行關(guān)聯(lián)式展開設(shè)計。模具并行設(shè)計的實現(xiàn)一般按以下6個步驟來完成：(1)模具設(shè)計者參與提取產(chǎn)品設(shè)計過程中確定產(chǎn)品或原型產(chǎn)品的模型要素，接受或自行完成已經(jīng)具備最終產(chǎn)品全部特點的建模。(2)對產(chǎn)品進(jìn)行工藝分析，以Top-DownDe—sign方式規(guī)劃確定模具重要結(jié)構(gòu)件的層級骨架(Skeletions)組織設(shè)計過程。(3)在Pro/E系統(tǒng)中圍繞產(chǎn)品沖壓加工建立核心組件模型，并根據(jù)工藝需要確定結(jié)構(gòu)參數(shù)，轉(zhuǎn)換數(shù)據(jù)格式提交沖壓CAE分析軟件DYN刪進(jìn)行可靠性分析計算。(4)在Pro/E系統(tǒng)中進(jìn)行模具設(shè)計。由于準(zhǔn)備隨時接受來自設(shè)計部門的變更及分析結(jié)果的干預(yù)進(jìn)行設(shè)計更新，需要利用建模結(jié)構(gòu)、順序、參照控制、特征間關(guān)系、元件間關(guān)系、組件間關(guān)系有效的保證整個模型的可靠性，如當(dāng)產(chǎn)品局部變更時，相應(yīng)凸凹模、定位元件、固定板、上下模板結(jié)構(gòu)特征等必須保證成功的再生(Regenerate)。(5)模具結(jié)構(gòu)設(shè)計完成后，輸出二維工程圖。基于工程圖與三維建模的全相關(guān)性，無論在設(shè)計過程中還是在今后都可確保模具局部結(jié)構(gòu)變化后工程圖自動及時準(zhǔn)確的更新。(6)同時提交模具的CAM部門進(jìn)行工藝分析及編程。Pro/E系統(tǒng)CAD/CAM的無縫連接，使得NC程序同樣可以得到更新.沖模在裝配前應(yīng)根據(jù)沖模的結(jié)構(gòu)特點和技術(shù)要求，確定合理的裝配順序和裝配方法。沖模裝配之后，必須在生產(chǎn)條件下進(jìn)行試沖，沖出的工件按沖壓零件產(chǎn)品圖或試樣進(jìn)行檢查驗收。如果發(fā)現(xiàn)不合格者，必須對沖模進(jìn)行適當(dāng)?shù)恼{(diào)整和修理，然后再試沖，直到生產(chǎn)合格的沖件為止。在沖模工作一段時間后，可采用超前維修。沖模的受力只局限于刃口的附近在使用一段時間以后，刃口處會不可避免地出現(xiàn)不均勻磨損和磨損溝痕，如果提前維修，可避免因凸、凹模間隙不均勻而產(chǎn)生附加彎矩和防止磨損溝痕產(chǎn)生裂紋，以提高模具壽命。實踐證明，并行參數(shù)化設(shè)計技術(shù)在工藝準(zhǔn)備過程中的應(yīng)用，大幅度降低了產(chǎn)品周期，增強(qiáng)了設(shè)計的可靠性，同時為企業(yè)取得了巨大的經(jīng)濟(jì)效益和社會效益?？梢灶A(yù)見，計算機(jī)立用技術(shù)將在生產(chǎn)過程中發(fā)揮更力H重要的作用，并已漸漸成為現(xiàn)代制造業(yè)的一個重要特征。Moldindustryisthefoundationofthenationaleconomy;itisrecognizedasthekeyindustryintheworld;anditisalsoregardedas"themotheroftheindustry"inthedevelopedcountries.Moldinghasmanyadvantages,suchashighefficiency,goodquality,economizingonrawmaterials,reducingthecostoftheproduction.Manufacturingthecomponentsoftheproductionsbymoldingnowhasbecomeanimportanttechnologicalmethodintheindustry.Inthemachinery,electronics,lightindustry,textile,aviation,aerospaceandotherindustrialareas,moldinghasbecomethemostwidelyusedmaintechnicalequipmentoftheindustrializedproduction,whichundertakestheprocessingandproductiontaskof60%-80%oftheproductcomponents,elementsandpartsintheseindustrialfields.Theconceptsthat"Moldistheproductquality"and"Moldistheeconomic-effect"havebeenrealizedandreceivedbymoreandmorepeople.InChina,peoplehaverecognizedtheimportantfoundationofthemoldinginthemanufacturingindustryandtheyhaverealizedthatthemanagementofthecrisisandthemarketcompetivenessoftheenterprisesdependonthespeedofreplacement,newproductdevelopmentcapabilities.Currentlythetraditionofmanufacturingtheenginehoodbythethinsteelplateswillstillbelastquitesometime,soitisnecessarytoanalysisthetechnologicalproperties,suchasthereasonablestructure,theforce,whetheritiseasytobreakoutthesurface,onthebasisofthesteelplatebycomputersoftware,tofindtheshortcomingsofthereadycomponents,discussanddeterminetheimprovementofthesedeficienciesandthusimprovethemolddesignandthestampingmethod,andtorealizeeventuallytheproductimprovementonthemechanicalproperties,appearance,theresultsoftheusageandthecostandsoon.Stampingprocessingisachievedbythemold.Fromthepointofmold,thelevelofmoldproductiontechnologyhasbecometheimportantsymbolofmeasuringthatofthecountry'smanufacturing,becauseonalargeextentthemolddeterminesthecapabilityofproductquality,effectivenessandnewproductdevelopment.Peoplehaveknownthat"moldindustryisthebasisprocessesandequipmentoftheindustrialproduction".Accordingtothestatistics,intheproductsofelectronics,automobile,electricalmachinery,electricalappliances,instruments,meters,homeappliancesandcommunications,60%?80%ofthepartsareshapedbythemolds.Thecharacteristicsofhigh-precision,high-complexity,high-consistency,high-productivityandlow-consumption,whichareacquiredbythemoldproduction,areincomparablewiththeothermanufacturingmethods.Inaddiction,thestampingprocesscancreategreataddedvalue.Themoldis"theamplifierofthevalue";thevalueofthefinalproductionmadebythemoldisoftenhigherthanthatoftheownmolddozens,orevenhundreds.Nowadays,thevalueoftheglobalmoldannualoutputtingisabout60billionU.S.dollars,andtheoutputvalueofthemoldindustryhassurpassedthatofthemachinetoolindustryinJapan,theUnitedStatesandtheotherindustrializedcountries.Since1997,China'soutputvalueofthemoldindustryhasalsoexceededthatofthemachinetoolindustry.Amongallthemolds(forgingmold,diecastingmold,injectionmold,etc.),nomatterthequantity,weightorthevalueofthestampingdieisonthetopone.Thus,sheetmetalstampingandprocessingandthemoldproductiontechnologyhavemadeandwillcontinuemakeagreatcontributiontothedevelopmentofthenationaleconomy.WiththedevelopmentofChina,seconomy,theneedstothetechnologydevelopmentandthetechnicalprofessionalswillberising.Therefore,itissignificantlyimportanttostrengththeresearchofsheetmetalstampingandprocessingandthemoldproductiontechnology.CurrentSituationandDevelopmentTrends:Afterthe100years,development,ithasalreadybeenmaturethatthedesigntechnologyoftheengineofthehoodofthesmall-sizevehicle.However,withtheexploitationoftheallkindsofsmallsizedengine,alotofimprovementshavebeendoneonthefrontandtherearhoodoftheengines.Inthecurrentperiod,theimprovementsofthehoodofthesmall-sizeautomobile,senginearemainlymanifestedintheimprovementoftheconstructionmaterials,forexample,replacethetraditionalthinsteelplatewiththeresin-basedcompositematerialsandmakewiththeenginewatertank,theheatshieldandtheenginecover,etc.byRTM.Aswithcompositematerialsreplacetheoriginalmetalshelltypeofengineparts,theweightwillbereduced,andthecostwillbegreatlyreduced;formanufacturers,thiscreatesagreatdealofprofit,sothetechnicalprogressisalsowillcontinueforalongperiodoftime.Asfarasitgoes,therearestillmanyproblemsintheChina,sstampingdie,andamongtheseproblems,themoldproductioncycle,qualityandquantityarestillthekeys.Comparedtotheinternationalstandards,ingeneral,theproductivecycleofChina,sstampingdieislonger,thelifespanisshortertwiceandthereisawidegapoftheaccuracy.Thelackofquantityismainlyreflectedonthelarge-scale,sophisticated,complex,long-lifemold.Themainreasonsoftheseproblemsarethefollowing:1)theirrationalindustrystructure(suchasenterpriseorganizationalstructure,productstructure,technicalstructureandimportandexportstructure,etc.)2)theweaknessofthecomprehensivecharacteroftheenterprise,thelevelofdesignandproduction,theabilityofdevelopmentandthemanagement;3)theseriousshortageofthequalifiedpersonnel;4)theshortageofthecapital;5)thelowlevelofthespecialization,standardizationandcommercializationandthebadcollaboration:6)theoutmodedmoldmaterialsandrelatedskill;7)thelowefficiencyandbenefitsofthemoldmanufacturingenterprises,etc..ThestampingdiesusedbyTianLongMachineryCompanyLtd.,Liuzhoustillrelativelyfallbehind,sothecomponentsmadebythestampingdiesarewiththeshortcomingsthattheyareoflowquality,lowaccuracyofthesizeandshapeandshortlifespan,andtheyoftenwrinkle.Additionally,theirrationalnestingmayleadtothewasteofrawmaterials.Thereasonsabovearemainlyduetotheunreasonablemolddesignandtheincompleteconsideration.Whafsmore,theunreasonableprocessdesignisthereasonofthelowqualityofthecomponents.Processdesignisthebridgeandlinkbetweentheproductiondesignandmanufacture.Reasonableformingprocessdesignisthebasisofmolddesignandmanufacture,anditisalsothekeythatwhetherthecomponentcanformsmoothly;itisrelateddirectlytothequality,cost,efficiencyoftheproduction,andthemold,slifespanandsoon.Inthepresentera,thetechnologydevelopingrapidly,thetechnologyofmolddesignisalsointhefastdeveloping.Thetendencyofthemoldtechnologyinthefutureisthedevelopmenttowardstheinformationtechnology,high-speedproductionandprecisionofthedevelopment.Nowadays,competitionisveryintenseinthemarketeconomy.Inordertoprevailinthemarket,thelevelofthedesignmustbecontinuallyimprovedsothatthestampingdiesaremorereasonableandthequality,size,shapeaccuracy,lifespanandresourceutilizationofthecomponentsarecanbegreatlyenhanced,whichcanimprovethecompany'sefficiencyandcompetitiveness.1.2BackgroundofthetopicTheResearchResultsoftheofMetalFormingTechnologyandResearchResultsinRecentYearsInrecentyears,stampingformingprocesstherearemanynewadvances,especiallyinprecisionstamping,precisionmolding,precisioncutting,compositematerials,forming,superplasticforming,soft-castingandtheelectromagneticformingofnewtechnologywitheachpassingday,increasingtheaccuracyofprecisionstampingpartsproductivityisalsogreatlyimproved,istoimprovethestampingprocesstohigh-quality,newlevelofdevelopment.SinceCAEisintroduced,thestampingprocesshasdevelopedtocomputersimulationandanalysisprocessfrommakingfiniteelementanalysisbythepairsofstressandstraininordertoachieveoptimaldesign.What,smore,thecomputer-aideddesignhasalsobeenlaunchedinthestampingblankdesigntodrawontheblanklayouttooptimizethedesign.Theresearchontheperformanceofthemetalstampingandformingandthelimitsofforming,aswellasthedeterminationonthedifficultyofthestampingsformingandthedevelopingonthetechniquesofformingforecasting,showsthatthestampingandformingbeginstoenterthescientificstageguidedbythestampingtheoryfromthestageofanalyzingtheoriginalexperienceandexperiments;theseallhelpthetechnologyofstampingandforminggotothedevelopmentofstampingandintelligentcomputer-aidedengineering.Program:Asastampingpress,itsroughperformance,goodorbad,canbethejudgedbypersonalexperienceorvision,butundertheconditionsofrequiringthequantization,peoplewouldbetterusethesheetmetalanalysissoftwareassociatedwiththemechanism;andIuseDYNAFORMtoanalysisthestampingparts.Thecoloroftheimagesintheanalysiscandeterminethattheconditionsofthepressing,andwecanknowclearlythestretchingsituationbythelistofdata.Basedoninformationgiven,wecanimprovecorrespondinglythestampings.Finallyweshouldfocusonthemolddesignup.Generalsteps:AnalyzingbyusingCAEsoftware(DYNAFORM),anddiscussingthemanufacturabilityoftheexistingparts(stampingperformance)Improvingsomepartsshape,andstrengtheningthetendonsdistributionExhibitionofmaterialsbyFASTBLANK,stocklayout,andselectingthebestlayoutprogramMakingcalculations,gettingtheassociateddataanddepictingthegeneraloutlineDrawthethree-dimensionalmoldchart(DAC)bytheuseofthedataaboveandUG6.DiscussingthespecificpartstechnologyandrelatedprogramsaccordingtothemodelDrawingthetwo-dimensionalmapofthedieoftherelatedcomponentsbyAUTOCADorCAXA.Writingthetopicstatement.Theprosandconsoftheprocessofstampingprocessdeterminetherationalityofthestampingpartsmanufacturingtechnology,thestampingpartsqualityandthecostoftheproduction.Thereforethestampingpartsmustbemadeathoroughprocessanalysisandbyanalyzingthestructure,performanceandthedifficultylevelofthestampingpartstochoosethescientificandrationalprocessesprogram.Andtoensuretheproductdesignrequirements,minimizetheprocess,wecouldadopttheappropriatematerials,savethematerials,selecttheadvancedandreasonableprocessingtechnology,andstrivetothesimpleproductionprocesstoreducetheproductioncostsandimprovetheeconomicefficiency.MoldCAEtechnologyistheonewhichsimulatestherealprocessofthestampingdieformingonthecomputerbeforethedesignandmanufactureofmolds,informstheuserthatwhetherthediestructuredesignandtheprocessconditionsarereasonableandultimatelyprovidesuserswiththebestmolddesignprocessprogram.Thereliabilityofthistechnologyismorethan80%.Byusingthetechnologythedesignandmanufacturingcyclecanbereducedby2/5(forcomplexmoldcase)andimprovethemoldqualityandproductqualificationratewhichcansignificantlyreducethemanufacturingcostandenhancetheproductmarketcompetition.GapbetweentheDomesticandForeignMoldAtpresent,thecharacteristicsofChina'sindustrialproductionareproductionvariety,quickupdates,andthefiercemarketcompetition.Inthiscase,therequirementsoftheusersformoldmanufacturingare"theshortdeliverytime","highprecision","goodquality",and"lowprices".ThatthesupplyanddemandarebothboomingisthegeneraldisplayofChina'smoldmarketinrecentyears,andin2004thispatternremains.Asthegrowthrateoftheautomotive,mechanicalandelectricalindustriesdrops,thepriceoftherawmaterialrises,theenergyandtheelectricityisintheshortage,thecapitalisnotenoughtogoroundandthetransportationexpenseisontherise,in2004thegrowthrateofthemoldmarketfallsback,althoughthesupplyanddemandconditionisflourishing.Theconditionin2005isexpectedtobedown5percentagepointscomparedto2004.InEuropeandtheUnitedStates,CAD/CAE/CAMhavebecomeawidelyusedtechnologyinthemoldenterprise.Presentlythematurelevelofthe3DdesignofCADhasreached70%~89%,andAustralian3Ddesign60%,whileChinaisonlyjustonthebeginning.TheApplicationofCAEtechnologyinEuropeandtheUnitedStateshasbeenmature.InChina,onlyfewenterprisesputCAEtechnologywhichcansimulateofmetaldeformationprocess,analyzethedistributionofstressandstraintopredictrupture,forecastthedefectssuchascracking,wrinklingandspringbackintheuseduringthestampingdiedesign.IntheDLChart(stampingprocessdiagram)designprocess,thestampingprocessanalysis,thechoosingofthedirectionofstampingandthedivisionoftheprocessesareclosetothoseofforeigncountries.However,thereisawidegaponthedesignoftheadditionalsurfaceinprocessandproductprocessing,forexample,theforeigntechnologyhastherichexperienceonthedesignofthedrawingoffpartandthedigital-analogprocess,especiallythereisawidedisparitybetweenthehomeandthedomesticontheprocessofthehigh-precisioncarcomponents.Thehigh-speedcuttingisaprocessingskillbyusingthehighcuttingspeed,highfeedrateandhighprocessingquality.Inforeigncountries,ithasbeenarelativelymaturetechnology,thecontourmachiningprecision<0.05mm,whichdoesnotneedtostudyco-gap.Machiningprocessingmakessurethetrimmingdiecuttingedgeclearance;pliersinstallationdonotneedthespottingtime,sothatitcanbedirectlyloadedwithmoldafterprocessing.However,inChina,moldfitter,sworkloadisstilllarge.Althoughtheperformanceofthedomesticmachineisquiteequaltothatoftheequipmentabroad,onthesectorofthetechnologicaldataofNC,thegapisstillexistedonthefeedingpath,methodandthedesign.Inaddition,thedisparityisshowedonthemoldmanufacturingcycle,thequalityandthelevelofstandardization.ChapterIIStampingProcessProjectTheprosandconsoftheprocessofstamping,determinestherationalityofthestampingpartsmanufacturingtechnology,stampingpartsqualityandthecostofproduction,sostampingpartsmustbeanalyzedthoroughly,whichincludestheanalysisonthestructure,performanceandthedifficultylevelofthestampingparts,todeterminethescientificandrationalprocessesprogram.Andtoensuretheproductdesignrequirements,minimizetheprocess,wecouldadopttheappropriatematerials,savethematerials,selecttheadvancedandreasonableprocessingtechnology,andstrivetothesimpleproductionprocesstoreducetheproductioncostsandimprovetheeconomicefficiency.MoldCAEtechnologyistheonewhichsimulatestherealprocessofthestampingdieformingonthecomputerbeforethedesignandmanufactureofmolds,informstheuserthatwhetherthediestructuredesignandtheprocessconditionsarereasonableandultimatelyprovidesuserswiththebestmolddesignprocessprogram.Thereliabilityofthistechnologyismorethan80%.Byusingthetechnologythedesignandmanufacturingcyclecanbereducedby2/5(forcomplexmoldcase)andimprovethemoldqualityandproductqualificationratewhichcansignificantlyreducethemanufacturingcostandenhancetheproductmarketcompetition.Withtheneedsofthemodernmanufacturing,theinvitationanddesignofthenewproduction,thequalityandthecyclehavebecomethekeythatwhetherthebusinesscansurviveanddevelopinthemarketeconomy.Bythehelpofthepromotionandapplicationofcomputer-aideddesign(CAD)andmanufacturingtechnology(CAM),notonlythedesignerswillbefreefromtheheavyandcomplicatedhanddrawingmethod,butalsoitisarevolutionaryhugeleaptothemanufacture.ButbeforetheintroductionandtheapplicationoftheconceptofCE(ConcurrentEngineering),theCAD/CAM/CAE/CAPPoftheproductionbelongtodifferentdepartments,andtheproductdesign,manufactureandanalysisarecompletedintheserialdesignfromtheheadtothefeet.Obviously,fortheconcurrentdesign,theformercannotbeupdatedonthetimethroughoutthedesignprocesssothatitisdifficulttoachievethesynchronousimplementationoftheproduction,sinvitation,fabricationandintegrationandextendthedevelopmentcycleandtheproductioncosts.The"National863/CIMStheme",majorapplicationconcurrentengineeringprojects,completedbythecompanyreflectsapromisingapplicationprospectsbytheimplementationoftheprojectsinthenewproductinvitationthroughCAD/CAM/CAE.And,theparallelfull-stampingdieparametersdesignmadebythePRO/E3Ddesignsystemintheproductdevelopmentprocesshasbeeninaverygoodapplication.Inrecentyears,withtherapiddevelopmentofthecomputercomprehensivetechnology,ComputerIntegratedManufacturingSystem(CIMS),ConcurrentEngineering(CE),VirtualManufacturing(VM)andaseriesoftheothernewtechnologiesbringthemechanicalengineeringindustryintoanewproductionprocessmode.SomestatisticsshowthattherelatedbusinesseshavereceivedsignificanteconomicandsocialbenefitswhenChinaappliesandpopularizes863/CIMS;theenterpriseshavemadeagreatimprovementonrisingproductionefficiency,reducingthecosts,shorteningproductcyclesandenhancingthequality.Intermsofitsmeaning,"ConcurrentEngineering"isacomplexsystematicprocess,whichaddressestheproblemsthathowtodevelopanddesigneffectivelyaproductandtoorganizerationallytheprocesspreparation,manufacturing,processmanagement,businessandsalesprocesstoachievethebestproductcycleandthelowestcost.Duringtheseyears,thelaunchandimplementationoftheparallelprojectinthecompanyarestillintheexplorationwiththecollaborationindifferentdepartments.However,thestampingdieconcurrentdesignhasbeenbasicallyformedintoarelativelycompleteprocessframework;inthemolddesignandmanufacturingprocess,thefundamentalrealizationofthedesignmustberealizedonthesupportofthecoreCAD/CAM/CAEsoftware,andthecompanyintroducedthePRO/ENGINEERoftheU.S.PTC'sastheCAD/CAMsoftwareplatformwhichistheplatformoftheconcurrentengineeringdesignsystem.Beforeandintheprocessofthedesignprocess,thekeyofthediestructuredesignistomoldbyPRO/EandformingthenumericalsimulationistheintroductionofProfessionalCAEanalysissystemDYNAFORM,inthemoldbeforeandbegin,fortheofthekeyelementsofintenttousemodel,tocalculateandanalyzestandarddatawhichisputforwardtoDYNAFORMandtopredictthefeasibilityofinterventions,whichcanimprovediestructureparameters.What,smore,themanufactureofmoldscanachievetheseamlessswitchingoftheCAD/CAMinthePR0/E,whichcannotonlyfullyreflectthemolddesignintentionandavoidthelossofinformationintheengineeringdrawings,butalsocansignificantlyshortenthemanufacturingcycle.PRO/ENGINEERcanusethedesignprocessparametersettings,relations,referencemanagementtorealizethetotaldependencyparametricdesign,inotherwords,inthemolddesignprocess,anychangeoftheproductioninthedesignwillbereflectedtoalloftherelevantstructuralpartsandthedesignwillbeupdatedautomaticallyinaccordancewithstructuraldesign.Itgreatlyimprovestheefficiencyofdiedesign,supportstherepeatabilityofthedesign,andupdatesthedesignwiththehighefficiency.PRo/ENGINEERprovidesasetofmethodsandmakesuparelativelycompletetheenvironmentofTop-DownDesign,whichreferstoanorganizationalapproachinthestructuraldesign,withtheotherkindsoftools.Actually,inthepast,thehandandtwo-dimensionaldesignprocessreflecttheitspurposes,aswellasundertheenvironmentofPRo/E.AroundthecorethemeofthedesignTop-DownDesigncommencescorrelationdesign.Thereal