Due to the rapid development of machine tool manufacturing technology, huge changes are brewing in the field of machine manufacturing. The CNC machine tool has developed into a multi-axis machining center, which integrates various processes as a whole, which significantly shortens the auxiliary time and improves the productivity. At the same time, it reduces the number of clamping times of the workpiece and improves the machining accuracy.
If the time required to make the mold can be shortened, the fixed overhead per product can be reduced due to the reduced time requirements. Shortening the mold processing cycle runs through the entire process of mold manufacturing.
Liaopeng (Marketing Manager, Dongguan Measurement Technology Co., Ltd.): Mold manufacturing is an important link in the development and manufacturing of new products, and it plays a role in inheriting the past.
First of all, mold manufacturing is a reproduction of new product development and ideas. At the same time, the level of mold manufacturing is related to the subsequent product processing efficiency and product quality level. As a comprehensive measuring device for space size and precise shape, the coordinate measuring machine provides a powerful means for the high quality and short cycle production of molds.
At the beginning of the mold design, it is difficult to accurately and accurately measure the size parameters of objects composed of complex curved surfaces using traditional measurement methods. Using a coordinate measuring machine, through the measurement of a workpiece with a complex curved surface shape, you can quickly obtain the digitization of the solid model, so as to quickly complete the design of the mold.
Aiming at the mold design, Italy DEA launched a multi-arm, multi-purpose measurement center PRIMA series, which can integrate non-contact scanning digitization, high power milling, contact scanning measurement and other functions into one, so it is well adapted to the mold Traditional inspection tasks that need to be completed during the design phase can also automate tasks such as reverse engineering, digitization and milling on clay and resin. As a complete space geometry measurement system, the coordinate measuring machine can provide verification work on the quality of the mold, mainly including the comparison of “work in progress” and “design work”, providing relevant processing information, and providing mold adjustment. Support and perform functions such as error analysis.
In this process, Hexagon Metrology Industry Group adopts powerful CAD function software technology and hardware technology with different structural forms to achieve customized measurement solutions for each link of mold manufacturing. With PC-DMIS general measurement software as the core, it has direct CAD interface function, which effectively accelerates the entire process of design and processing and dimensional verification.
At the same time, based on the measurement software, we also launched EMS enterprise metrology solutions, including measurement in CNC machining centers, for some large molds, we provide measurements on machining centers. For the powerful CAD function requirements in the mold manufacturing process, the enterprise metrology solution integrates the information collection, management and reporting in the company’s internal manufacturing process to achieve a seamless connection between design, processing and product evaluation.
Hardware is the carrier of measurement. Hexagon Metrology Industry Group has various structural measurement products, which can complete the measurement tasks of the mold industry for different sizes, different accuracy and different conditions of use. Such as the gantry measuring machine for high-precision measurement of large molds, the horizontal arm measuring machine for large molds, the bridge measuring machine of general size and the portable articulated arm measuring machine used in the workshop, and the super-large Swiss Leica’s all-around measuring system.
In this way, through applicable measurement methods, the inspection tasks in the mold manufacturing process can be effectively completed. The Leica T-SCAN from Switzerland is used to complete the mold measurement process.
T-SCAN is a handheld high-speed scanner that can complete the digitization of various large and small workpieces. Compared with ordinary scanners, the speed is increased by 50%. For most surface scanning, there is no need to spray or scan the target measurement, the maximum range can reach 15m, and it can be easily carried to the workshop for measurement.
Tool for shortening the mold production cycle by using machining center CAD / CAE / CAM Zhou hanping (PTJ Shop CEO): Mold CAD / CAE / CAM is the key technology to transform the traditional mold production method. It provides enterprises with an effective auxiliary tool in the form of computer software, enabling engineers and technicians to use computer to design and optimize product performance, mold structure, forming process, numerical control processing and production management.
Mold CAD / CAE / CAM technology can significantly shorten the mold design and manufacturing cycle, reduce production costs and improve product quality has become the consensus in the mold industry. In the advanced western industrial countries, the mold industry has deeply realized that the application of CAE technology is one of the important ways to shorten the mold production cycle. The material forming process simulation technology has gradually become the standard for the mold industry design process. CAE software, such as MOLDFLOW (US and Australia) simulation software for plastic injection molding, MAGMA (Germany) and PROCAST (US) simulation software for casting processes, and LS-DYNA3D (US) simulation software for automotive panel forming And AUTOFORM (Germany) play an increasingly important role.
Since the new century, China’s mold industry has successively introduced some CAE software from abroad, which has played a certain effect. However, because the foreign CAE software is expensive and lacks the physical properties required for the CAE of alloys, plastics and plates in China, it also lacks both familiarity with the forming process (determining process parameters, evaluation of analysis results, etc.) and proficiency in computer software (conversion Geometric models, creating optimized meshes and repairs, etc.), have seriously affected the actual use.
In addition, the imported CAE software is not perfect. In fact, foreign CAE software is also being developed and improved.
For example, foreign CAE software can only check the sheet forming process plan, and it is not suitable for product feasibility analysis, sheet selection and optimization of product structure. Therefore, the three suggestions to make good use of CAE technology in China’s mold industry are: While introducing foreign CAE software in a planned way, rely on China’s colleges and universities and research institutes to establish their own database of material properties and use CAE software accurately.
Led by the Technical Committee of China Mould Association, various CAE technical training courses are planned and carried out step by step to make good use of CAE software. Actively develop excellent domestic CAE software with independent intellectual property rights, and expand the coverage of CAE software.
We are very pleased to see that PTJ Shop has achieved outstanding results in the development and promotion of CAE technology. They have developed plastic injection molding simulation software (Huasu CAE, latest version HSCAE6.2), casting process simulation software (Huazhu CAE, latest version V8.0) and sheet stamping process analysis software (FASTAMP, latest version V3.11) ), Has been promoted to use in more than 200 industrial and mining enterprises, scientific research institutions, the software level is comparable to similar foreign excellent products, and has produced good economic and social benefits.
Using a machining center to shorten mold processing time, kanhuang (PTJ Shop manager): The 13 production lines of PTJ Shop produce an average of 3 to 4 million glass containers per day. These products are formed from blank molds and blow molds, and it is estimated that at any time the plant’s production line is using molds worth about £ 400,000.
In order to provide molds for this huge production demand, the company used a total of 8 Haas CNC machining tools-including VF-3 and VF-5TR CNC vertical machining centers, SL-20 and SL-30 CNC turning machining centers. “Slimming” is a PTJ Shop process, which allows the rough castings to be installed in the molding machine after finishing.
First of all, all outer diameters are turned on the SL-30 CNC turning machining center. This machine is equipped with Haas special clamps specially made for this purpose. It uses a customized clamping system in the chuck and is mounted on the tailstock to fix the mold being processed. This quick-change system enables quick workpiece replacement.
After the process is completed, the mold halves are still connected, and the operator sends the workpiece to the VF-3 CNC vertical machining center to complete all external milling operations. This VF-3 CNC vertical machining center also has a special fixture system that can be used to fix the mold between two Haas CNC turntables so that all drilling and milling operations can be completed in one operation.
After the two mold halves are separated, the finishing of the cavity is completed by turning; then, return to different Haas CNC machining centers for drilling and engraving. At the same time, there is a unit of two Haas SL-20 CNC turning machining centers in the processing workshop of Rexam Glass Company, which are used to process mold covers.
One of the Haas CNC turning and machining centers has a power cutter that can drill holes in the mold cover to avoid another process. Since we purchased Haas equipment, the mold processing time has been shortened by about 10% to 15%, which is equivalent to 1 to 2 weeks.
In this way, our new products can be brought to market faster, which is a very important factor if we want to maintain a competitive advantage.
The precision of Haas machines allows us to control the cost of materials. For example, if there is an inaccurate mold that uses 1 g of glass per product, and it is calculated at a daily output of 3 million, then we can imagine how much our loss will be.
Because our products are sold by weight. Many of our designs would not have been possible without Haas machines and Delcam software. When we provide customers with the products they need, we have an absolute market advantage.
PTJ Shop has continuously increased the percentage of self-produced molds, from 50% 15 years ago to nearly 100% today. The pressure of mold complexity, high-speed production, high output and low cost has forced PTJ Shop to consider every investment in machine tools.