What is a mold? Mold design and application? Thank you, God help ah!

Mold mújù (mold; mould; die; tooling; matrix; pattern) industrial production used for injection molding, blow molding, extrusion, die casting or forging molding, smelting, stamping, stretching and other methods to get the desired product of the various molds and tools. Introduction In short, a mold is a tool used to form items, this tool has a variety of components, different molds are composed of different parts. It mainly realizes the processing of the shape of the article through the change of the physical state of the molded material. China yuyao mold industry cluster has more than 1300 mold enterprise [Edit this paragraph] simple classification according to the molding of different materials, mold can be divided into metal mold and non-metallic mold. Metal molds are divided into: casting molds (non-ferrous metal die casting, steel casting), and forging molds, etc.; non-metallic molds are also divided into: plastic molds and inorganic non-metallic molds. According to the different materials of the mold itself, the mold can be divided into: sand mold, metal mold, vacuum mold, paraffin mold and so on. Among them, with the rapid development of polymer plastics, plastic molds and people's lives are closely related. Plastic molds can be generally divided into: injection molding molds, extrusion molds, gas-assisted molding molds and so on. Large-scale production of non-sheet metal steel parts - cold heading, die forging, metal molds, etc. Sheet metal out of the material - hot rolled, cold rolled, hot rolled, cold rolled Sheet metal processing - deep drawing, up type, bending, punching, and Non-ferrous metals - die-casting, powder metallurgy Plastic parts - injection molding, blow molding (plastic bottles), extrusion (pipe fittings) Other categories of molds: Alloy molds Sheet metal molds Plastic molds Stamping molds Casting molds Extrusion molds Die casting molds Automotive molds Rolling wire molds Other Mould Mould material The most important factor of mould material is thermal strength and thermal stability, commonly used mould material: Working temperature Forming material Mould material <30℃ Zinc alloy Cr12, Cr12MoV, GCr15, T8, T10 300～500℃ Aluminum alloy, copper alloy 5CrMnMo, 3Cr2W8, 9CrSi, W18Cr4V, 5CrNiMo, W6Mo5Cr4V2, M2 500～800℃ Aluminum alloy, copper alloy, steel titanium GH130, GH33, GH37 800～1000℃ Titanium alloy, steel, stainless steel, nickel alloy K3, K5, K17, K19, GH99, IN100, ЖC-6NX88, MAR-M200, TRW-NASA, WA ＞1000℃ Nickel alloy copper-based alloy mold [Edit paragraph] mold production process mold is a model, according to the model to make products, but the mold is how to produce it, may be in addition to the mold professionals most of the answer is not out. Molds have been irreplaceable in our lives, most of our daily necessities are inseparable from the mold, such as computers, telephones, fax machines, keyboards, cups and so on these plastic products needless to say, in addition to automobiles and motorcycles like the engine cover is also made with the mold, the light of an automobile a variety of molds have to be used to more than 20,000. So the role of modern life mold is irreplaceable. As long as the mass production can not be separated from the mold, at least in the last 50 years can not be separated. So how is the mold made? The following is a brief introduction to the modern mold production process. (1) ESI (Earlier Supplier Evolvement Supplier Early Involvement): This stage is mainly between the customer and the supplier of product design and mold development and other aspects of the technical discussions, the main purpose is to allow suppliers to clearly understand the product designer's design intent and accuracy requirements, but also to allow product designers to better understand the mold production capabilities, product process performance, so that the mold production process. The main purpose is to let the supplier clearly understand the product designer's design intention and accuracy requirements, and also to let the product designer better understand the mold production capacity, product process performance, so as to make more reasonable design. (2) Quotation (Quotation): including the price of the mold, the life of the mold, the mold delivery period. (3) Order (Purchase Order): customer orders, deposits issued and the acceptance of supplier orders. (4) mold production planning and scheduling arrangements (Production Planning and Schedule Arrangement): this stage needs to be for the specific date of delivery of the mold to the customer to make a reply. (5) mold design (Design): the possible use of design software Pro/Engineer, UG, Solidworks, AutoCAD, CATIA, etc. (6) Procurement of materials (7) mold processing (Machining): the processes involved are roughly the car, gong (milling), heat treatment, grinding, computerized gongs (CNC), electric discharge (EDM), Line cutting (WEDM), coordinate grinding (JIG GRINGING), laser engraving, polishing and so on. (8) mold assembly (Assembly) (9) mold trial (Trial Run) (10) sample evaluation report (SER) (11) sample evaluation report approval (SER Approval) [Edit this paragraph] the basic design principle of the mold Because the different molding molds have been applied to many areas, coupled with the professional mold manufacturing technology in these years there have been changes in the development of certain, so the In this section, the general design rules for vacuum suction molding molds are summarized. Vacuum forming mold design includes the batch size, molding equipment, precision conditions, geometric shape design, dimensional stability and surface quality and so on. 1, the batch size of the experimental, mold production hours, can be manufactured using wood or resin. However, if the experimental mold is to obtain product data on shrinkage, dimensional stability and cycle time, etc., should use a single-cavity mold to experiment, and can ensure that it can be used in production conditions. Molds are generally made of gypsum, copper, aluminum or aluminum-steel alloys, rarely used aluminum-resin. 2, geometric shape design, design, often take into account the dimensional stability and surface quality. For example, product design and dimensional stability requires the use of negative molds, but the surface requires high gloss products require the use of positive molds, so that the plastic parts ordering party will be a comprehensive consideration of these two points, so that the products can be produced under the best conditions. Experience has proved that does not meet the actual processing conditions of the design is often a failure. 3, dimensional stability, in the molding process, the surface of the plastic part in contact with the mold than leaving the mold part of the dimensional stability is better. If later due to the need for material stiffness requires a change in material thickness, may lead to the conversion of male mold to female mold. The dimensional tolerance of the molded part should not be less than 10% of the shrinkage. 4, the surface of the plastic part, in terms of the scope of the molding material can be wrapped, the surface structure of the plastic part can meet should be molded in contact with the mold. If possible, the clean surface of the part should not be in contact with the mold surface. As in the case of bathtubs and washtubs made with negative molds. 5. Trimming. If a mechanical horizontal saw is used to saw off the clamping edge of the molded part, there should be at least a 6 to 8 mm allowance in the height direction. Other trimming work, such as grinding, laser cutting or jetting, must also allow an allowance. The gap between the cutting line of the knife edge mold is minimal, and the distribution width of the punching mold trimming is also very small, these are to be noted. 6, contraction and deformation, plastic is easy to shrink (such as PE), some plastic parts are easy to deformation, no matter how to prevent, plastic parts in the cooling stage will be deformed. Under these conditions, it is necessary to change the shape of the mold to adapt to the geometric deviation of the plastic part. For example: although the wall of the part is kept straight, but the center of the reference has been deviated from 10mm; you can raise the base of the mold to adjust the amount of shrinkage of such deformation. 7, shrinkage, in the manufacture of plastic molding mold must take into account the following shrinkage factors. ① Shrinkage of molded products. If the shrinkage of the plastic is not clearly known, it must be obtained by taking samples or by testing with similarly shaped molds. Note: Only the shrinkage rate can be obtained by this method, not the deformation size. ② Shrinkage caused by the unfavorable influence of the intermediate medium, such as ceramics and silicone rubber. ③ Shrinkage of the material used in the mold, e.g., shrinkage when casting aluminum. [Edit this paragraph] mold how to repair According to incomplete statistics, the annual consumption value of the mold in the machining industry is five times the total value of all kinds of machine tools, it can be seen, machinery, metallurgy, light industry, electronics and other industries in the mold market is so huge. Another example: in the metallurgical industry, only the annual consumption of hot rolls in more than three hundred thousand tons, the value of hot rolls accounted for more than 5% of the cost of steel production. Mold consumption, not only directly increase production costs, but also due to the frequent replacement of molds and cause a large number of production lines frequently shut down into greater economic losses. The failure of the mold in fact are due to its surface layer of local material wear and scrapping, and mold processing cycle is very long, the processing cost is very high (especially precision and complex molds or large mold manufacturing and processing costs up to hundreds of thousands of dollars or even millions of dollars). Therefore, the mold really bear the role of wear and tear of specific parts of the surface strengthening, in order to greatly extend and improve the service life of the mold, is undoubtedly an important economic significance of the method. In addition, most of the mold only because of the surface of a very thin layer of material is worn out after the failure of the scrap, therefore, only the mold and key metal parts surface wear local area repair, and in the process of repairing the surface of the mold really actually bear the wear of the surface coated with a layer of high-hardness wear-resistant metal layer, can be "turned into treasure", not only to make the Mold repair, the service life of the repaired mold will also be a substantial increase over the original mold, the economic benefits are huge (for example: repair a power plant motor large shaft, including a variety of preparation time with a micro-beam cold welding machine only a few days, but can create millions of yuan of economic benefits). Mold repair machine is to repair mold surface wear, processing defects of high-tech equipment. The principle of the mold repair machine is the use of high-frequency electric spark discharge principle, heatless surfacing of the workpiece to repair surface defects and wear of metal molds, the main feature is the heat-affected area is small, the mold will not be deformed after the repair, not annealed, no stress concentration, no cracks, to ensure that the mold is intact; you can also use its reinforcing function of the surface of mold workpiece reinforcement treatment to achieve the mold's abrasion resistance, Heat resistance, corrosion resistance, etc. Mold repair machine to strengthen the mold long life, good economic efficiency. Can be applied to a variety of iron-based alloys (carbon steel, alloy steel, cast iron), nickel-based alloys and other metal materials such as molds and workpiece surface strengthening and repair and greatly improve the service life. Application scope: machinery, automobile, light industry, home appliances, petroleum, chemical industry, electric power and other industrial equipment manufacturing sector and the use of the sector, the key wear parts of the aircraft engine, hot extrusion molds, temperature extrusion film tooling, hot forging touch, rolling steel rolling guide, rolls, automotive engine camshafts and other parts and molds Mold - Machinery Manufacturing Mold design and production requirements are: precise size, surface finish; reasonable structure, high production efficiency, Easy to automate; easy to manufacture, high life expectancy, low cost; design in line with the needs of the process, economic and reasonable. Mold structure design and parameter selection should consider the rigidity, guidance, unloading mechanism, positioning methods, gap size and other factors. The wearing parts on the mold should be easy to replace. For plastic molds and die-casting molds, also need to consider a reasonable pouring system, molten plastic or metal flow state, into the cavity position and direction. In order to improve productivity, reduce runner casting loss, can use multi-cavity mold, in a mold can be completed at the same time more than one of the same or different products. In mass production should be used in high efficiency, high precision, high life expectancy mold. Stamping mold should be used for multi-station progressive die, can use carbide insert progressive die to improve life. In the small batch production and new product trial production, should be used in simple structure, fast manufacturing, low cost of simple molds, such as combination of punching die, sheet punching die, polyurethane rubber mold, low melting point alloy mold, zinc alloy mold, superplastic alloy mold and so on. Molds have begun to use computer-aided design (CAD), that is, through the computer as the center of a set of systems for optimal design of the mold. This is the development direction of mold design. Mold manufacturing according to the structural characteristics, divided into the plane of the blanking die and cavity mold with space. Punching die using convex die and concave die size precision fit, some even no clearance fit. Other forging dies such as cold extrusion die, die casting die, powder metallurgy mold, plastic mold, rubber mold, etc. belong to the cavity mold, used to form three-dimensional shape of the workpiece. Cavity mold in the length, width and height of the three directions have size requirements, complex shape, manufacturing difficulties. Mold production is generally a single piece, small batch production, manufacturing requirements are strict, accurate, and more use of precision processing equipment and measuring devices. Plane blanking die can be processed by wire cutting for initial molding, and then form grinding, coordinate grinding and other methods to further improve the accuracy. Forming grinding can be used for optical projection curve grinder, or with the reduction of imitation, repair wheel mechanism of the surface grinder, but also in the precision surface grinder with special forming grinding tool grinding. Coordinate grinding machine can be used for precision positioning of the mold to ensure precision hole diameter and hole distance. Computer numerical control (CNC) continuous trajectory coordinate grinding machines can also be used to grind convex and concave molds of any curved shape. Cavity molds are mostly machined with CNC machining centers, EDM and electrolytic machining. The addition of a three-way translating head device in EDM can improve the quality of cavity machining. Electrolytic machining to increase the inflatable electrolysis can improve productivity. Computer numerical control multi-axis milling machine processing, coordinate grinding and machining center machine tools, is an important equipment for cavity mold processing. The surface grinding and polishing of the cavity is generally used in electric or wind-powered tools, with a variety of grinding, polishing wheels and grinding paste powder, but also ultrasonic grinding, extrusion honing, chemical polishing and other methods. Coordinate measuring machine and optical projection comparator is commonly used in mold manufacturing precision measuring equipment.