What is mold? Mold design and application? Thank god, help me.

Mold mú jú (mold; Mould; Death; Tooling; Matrix; Various molds and tools used in industrial production, through injection molding, blow molding, extrusion, die casting or forging, melting, stamping and stretching to obtain the required products. In short, molds are tools used to shape objects. This tool is composed of various parts, and different molds are composed of different parts. It mainly realizes the processing of the shape of the article by changing the physical state of the molding material. There are more than 300 mold enterprises in Yuyao, China/KLOC-0 [edit this paragraph]. According to different materials, molds can be divided into metal molds and non-metal molds. Metal molds are divided into: casting molds (non-ferrous metal die casting, steel castings) and forging molds; Non-metallic molds are 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 are closely related to people's lives. Generally, plastic molds can be divided into injection molds, extrusion molds and gas-assisted molding molds. Large-scale production of non-sheet metal steel parts-cold heading, die forging, metal die and other sheet metal discharging-hot rolling, cold rolling, hot coil, cold coil sheet metal processing-drawing, bulging, bending, punching, blanking non-ferrous metals-die casting, powder metallurgy plastic parts-injection molding, blow molding (plastic bottles), extrusion (pipe fittings) molds Other categories: alloy molds, sheet metal molds, plastic molds. The most important factors of mold materials are thermal strength and thermal stability. Common mold materials: working temperature molding materials: zinc alloy Cr 12, Cr 12MoV, GCr 15, T8, t10 aluminum alloy, copper alloy 5CrMnMo, 3Cr2W8, 9CrSi and w65438+. W6Mo5Cr4V2, M2 500 ~ 800℃ aluminum alloy, copper alloy, steel titanium GH 130, GH33, GH37 800 ~ 1000℃ titanium alloy, steel, stainless steel, nickel alloy K3, K5 k 17 and K/Kloc. TRW- NASA, WA >1000℃ molds play an irreplaceable role in our lives, and most of our daily necessities are inseparable from molds, such as computers. Needless to say, telephones, fax machines, keyboards, cups and other plastic products. In addition, the covers of automobile and motorcycle engines are also made of molds, and a single automobile needs more than 20,000 molds. Therefore, the role of modern life mold is irreplaceable. As long as it is mass-produced, it is inseparable, at least in the last 50 years. So how is the mold made? The following is a brief introduction to the modern mold production process. 1) ESI (early participation in early supplier evolution): This stage is mainly a technical discussion between customers and suppliers on product design and mold development. The main purpose is to let suppliers clearly understand the design intent and precision requirements of product designers, and at the same time let product designers better understand the mold production capacity and product process performance, so as to make more reasonable designs. 2) Quotation: including mold price, mold life and mold delivery date. 3) Purchase orders: the issuance of customer orders and deposits and the acceptance of supplier orders. 4) Mold production plan and schedule: At this stage, the specific delivery date of the customer's mold needs to be replied. 5) Mold design: The design software that may be used includes Pro/Engineer, UG, Solidworks, AutoCAD, CATIA, etc. 6) Purchasing materials 7) Mold processing: The processes involved include turning, gong (milling), heat treatment, grinding, computer gong (CNC), electric spark (EDM) and WEDM. 8) Mold assembly 9) Mold trial operation)/KOOC-0/0) Sample evaluation report (SER)/KOOC-0//KOOC-0/) Sample evaluation report approval [Edit this paragraph] Basic design principles of molds Because different molding molds have been used in many fields, the manufacturing technology of professional molds has also reached a certain level in recent years. The design of vacuum suction molding molds includes batch and molding equipment. 1, the size of the batch experiment, the die output is small, and it can be made of wood or resin. However, if the experimental mold is used to obtain the data of shrinkage, dimensional stability, cycle time and so on, the single cavity mold should be used for the experiment, which can be used under production conditions. Moulds are generally made of gypsum, copper, aluminum or aluminum-steel alloy, and aluminum-resin is rarely used. 2, geometric design, design, often have to consider the dimensional stability and surface quality. For example, product design and dimensional stability require female die, but products with high surface gloss need a male mold. In this way, plastic parts orderers will comprehensively consider these two points, so that products can be produced under the best conditions. Experience has proved that designs that do not meet the actual processing conditions often fail. 3. Dimensional stability. In the molding process, the dimensional stability of the surface of plastic parts in contact with the mold is better than that of parts leaving the mold. If the material thickness is required to be changed due to the need of material stiffness in the future, it may lead to the conversion of male die into female die. The dimensional tolerance of plastic parts should not be less than 10% of shrinkage. 4, plastic surface, in terms of the range of molding materials can cover, can meet the surface structure of plastic parts should be formed in contact with the mold. If possible, the smooth cleaning of plastic parts should not be in contact with the mold surface. Just like the bathtub and washbasin made in the female model. 5. When decorating, if the clamping edge of plastic parts is cut off with a mechanical cross saw, there should be at least 6 ~ 8 mm allowance in the height direction. Other dressing work, such as grinding, laser cutting or jet cutting, must also leave allowance. It should be noted that the cutting line gap of the knife-edge die is the smallest, and the distribution width of the blanking die is also very small when trimming. 6. Shrinkage and deformation. Plastic is easy to shrink (such as PE), and some plastic parts are easy to deform. No matter how to prevent it, plastic parts will be deformed during the cooling stage. In this case, it is necessary to change the shape of the molding die to adapt to the geometric deviation of plastic parts. For example, although the wall of a plastic part remains straight, its reference center has deviated from10 mm; The die holder can be raised to adjust the shrinkage of this deformation. 7. Shrinkage: The following shrinkage factors must be considered when manufacturing the plastic suction mold. ① Shrinkage rate of molded products. If the shrinkage rate of plastic cannot be clearly known, it must be obtained by sampling or testing with a mold of similar shape. Note: this method can only get the shrinkage, but not the deformation. (2) Shrinkage caused by the adverse effects of intermediate media, such as ceramics and silicone rubber. (3) Shrinkage rate of materials used in molds, such as shrinkage rate when casting aluminum. [Edit this paragraph] According to incomplete statistics, the annual consumption value of molds in the mechanical processing industry is five times the total value of various machine tools. Obviously, the mold market in machinery, metallurgy, light industry, electronics and other industries is so huge. Another example is the metallurgical industry, where the consumption of hot-rolled rolls alone is more than 300,000 tons per year, and the value of hot-rolled rolls accounts for more than 5% of the steel production cost. The large consumption of molds not only directly increases the production cost, but also causes a large number of production lines to stop production frequently due to frequent mold replacement, which becomes a greater economic loss. The failure of the mold is actually due to the wear of local surface materials, and the processing cycle of the mold is very long, and the processing cost is extremely high (especially the manufacturing and processing cost of precision and complex molds or large molds is as high as hundreds of thousands or even millions of yuan). Therefore, it is undoubtedly a method with important economic significance to strengthen the surface of the specific parts in the mold that really bear the wear effect, thus greatly prolonging and improving the service life of the mold. In addition, most of the dies are invalid and scrapped only because there is a thin layer of material worn on the surface. Therefore, it is only necessary to repair the worn local areas and key metal parts of the mold, and in the process of repair, a metal layer with high hardness and high wear resistance is coated on the surface of the mold that actually bears wear, so that the mold can be turned into treasure, which not only makes the mold repaired, but also greatly prolongs the service life of the repaired mold compared with the original mold, and has great economic benefits (for example, repairing the motor shaft of the power plant, including the mold repairing machine, is a high-tech equipment for repairing the surface wear and processing defects of the mold. The principle of mold repairing machine is to repair the surface defects and wear of metal mold by using the principle of high-frequency electric spark discharge. Its main feature is that the heat affected zone is small, and the repaired mold will not deform, anneal, concentrate stress or crack, thus ensuring the integrity of the mold. It can also be used to strengthen the surface of the die workpiece and realize the wear resistance, heat resistance and corrosion resistance of the die. The mould repairing machine has long service life and good economic benefits. It can be used to strengthen and repair the surfaces of iron-based alloys (carbon steel, alloy steel, cast iron), nickel-based alloys and other metal materials, greatly improving the service life. Scope of application: manufacturing and using departments of machinery, automobile, light industry, household appliances, petroleum, chemical industry, electric power and other industrial equipment, key wear-resistant parts of aero-engines, hot extrusion dies, warm extrusion films, hot forging dies, rolling guide rails for steel rolling, rollers, camshafts of automobile engines and other parts and dies-the design and manufacturing requirements of mechanical manufacturing dies are: accurate dimensions, smooth surface; Reasonable structure, high production efficiency and easy automation; Easy manufacture, long service life and low cost; The design meets the technological requirements and is economical and reasonable. Stiffness, orientation, unloading mechanism, positioning mode, gap size and other factors must be considered in die structure design and parameter selection. The wearing parts on the mold should be easily replaced. For plastic molds and die-casting molds, it is also necessary to consider the reasonable gating system, the flow state of molten plastic or metal, and the position and direction of entering the cavity. In order to improve productivity and reduce the pouring loss of runner, multi-cavity mold can be used to complete multiple identical or different products in one mold at the same time. High-efficiency, high-precision and long-life molds should be used in mass production. The stamping die should adopt multi-station progressive die and cemented carbide insert progressive die to improve the service life. In small batch production and trial production of new products, simple molds with simple structure, fast manufacturing speed and low cost should be adopted, such as combined molds, sheet molds, polyurethane rubber molds, low melting point alloy molds, zinc alloy molds, superplastic alloy molds, etc. Mold has begun to adopt computer-aided design (CAD), that is, through a computer-centered system to optimize mold design. This is the development direction of mold design. According to the structural characteristics, die manufacturing can be divided into flat blanking die and concave die with space. Stamping die uses the size of punch and die to fit accurately, and some even fit without gap. Other forging dies, such as cold extrusion dies, die casting dies, powder metallurgy dies, plastic dies, rubber dies, etc. All of them belong to cavity molds, which are used to shape three-dimensional workpieces. The female die has three dimensional requirements: length, width and height, and its shape is complex and it is difficult to manufacture. Mold production is generally a single piece and small batch, and the manufacturing requirements are strict and accurate, and the processing equipment and measuring devices used are also relatively precise. The plane blanking die can be initially formed by wire cutting, and then the precision can be further improved by form grinding and coordinate grinding. Form grinding can use optical projection curve grinder, or surface grinder with grinding wheel mechanism of copying and dressing, or special form grinding tool on precision surface grinder. Coordinate grinder can be used for accurate positioning of molds to ensure accurate aperture and hole spacing. Computer numerical control (CNC) continuous trajectory coordinate grinder can also be used to grind any curved punch and die. Cavity molds are mostly used in CNC machining centers, EDM and electrochemical machining. Adding three-way translation head device in EDM can improve the machining quality of cavity. Adding gas-filled electrolysis to electrochemical machining can improve production efficiency. Computer numerical control multi-axis milling machine, coordinate grinder and machining center machine tool are important equipment for cavity mold processing. Generally, electric or pneumatic tools are used to grind and polish the surface of the cavity, and various grinding wheels, polishing wheels and paste powder can also be used for ultrasonic grinding, extrusion honing and chemical polishing. Coordinate measuring machine and optical projection comparator are commonly used precision measuring equipment in mold manufacturing.