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Processing Technology In Mold Manufacturing

2022-06-15 Hits: 15 views

Mold manufacturing technology has developed rapidly and has become an important part of modern manufacturing technology. Modern die and mold manufacturing technology is developing in the direction of accelerating informatization, improving manufacturing flexibility, agile manufacturing and system integration. If you are looking for Mold manufacturer, we are your best choice. Here are some mold manufacturing processes


  1. EDM


(1) Basic principles


EDM (electrical discharge machining) is a special machining method that uses the electric erosion generated by the pulse discharge between the two poles immersed in the working fluid to remove the conductive materials. It is also called electric discharge machining or electric erosion machining. It is called electrical discharge machining in English, or EDM for short.


(2) Basic equipment: EDM machine tool.


(3) Main features


Capable of machining materials and workpieces with complex shapes that are difficult to be cut by ordinary machining methods; No cutting force during machining; No burrs, knife marks, grooves and other defects; Tool electrode material need not be harder than workpiece material; Direct use of electric energy processing, easy to realize automation; After machining, there is a metamorphic layer on the surface, which must be further removed in some applications; It is troublesome to purify the working fluid and deal with the smoke pollution generated in the processing.


(4) Scope of use


Machining molds and parts with complex shaped holes and cavities; Processing all kinds of hard and brittle materials such as cemented carbide and quenched steel; Processing deep and fine holes, special-shaped holes, deep grooves, narrow seams and cutting thin sheets; Processing various forming tools, templates, thread ring gauges and other tools and measuring tools.


  1. WEDM


(1) Basic principles


Using the continuously moving fine metal wire (called electrode wire) as electrode, the workpiece is etched and cut by pulse spark discharge. In English, it is called wire cut electrical discharge machining, or WEDM for short, or wire cut.


(2) Basic equipment: WEDM machine tool.


(3) Main features


Besides the basic characteristics of EDM, WEDM has some other characteristics:


① Any two-dimensional curved surface with a straight line as its generatrix can be machined without manufacturing complex tool electrodes;


② Can cut about 0.05mm narrow seam;


③ All the surplus materials are not processed into scraps during processing, which improves the utilization rate of energy and materials;


④ In the low-speed WEDM with electrode wires that are not recycled, because the electrode wires are constantly updated, it is beneficial to improve the machining accuracy and reduce the surface roughness;


⑤ The cutting efficiency that WEDM can achieve is generally 20-60mm2/ min, up to 300mm2 / min; The machining accuracy is generally ± 0.01 to ± 0.02 mm, up to ± 0.004 mm; The surface roughness is generally ra2.5 to 1.25 microns, up to Ra0.63 microns; The cutting thickness is generally 40-60mm, and the maximum thickness can reach 600mm.


(4) Scope of use


Mainly used for processing: various workpieces with complex and precise shapes, such as punch, die, punch and die, fixed plate, discharge plate, etc; Forming tools, templates, metal electrodes for EDM forming; Various micro holes, slots, arbitrary curves, etc. With the outstanding advantages of small machining allowance, high machining precision, short production cycle and low manufacturing cost, it has been widely used in production. At present, the domestic and foreign WEDM machines account for more than 60% of the total number of EDM machines.


  1. electro chemical machining


(1) Basic principles


Based on the principle of anodic dissolution in the electrolysis process and with the help of the formed cathode, a process method is called electrochemical machining, which processes the workpiece according to a certain shape and size.


(2) Scope of use


ECM has obvious advantages in machining difficult materials, complex shape or thin-walled parts. ECM has been widely used, such as rifling, blade, integral impeller, mold, special-shaped hole and special-shaped parts, chamfering and deburring. And in the processing of many parts, ECM technology has played an important or even irreplaceable role.


  • Advantages
  • Wide processing range. ECM can process almost all conductive materials, and is not limited by mechanical and physical properties such as strength, hardness and toughness of the materials. The metallographic structure of the processed materials basically does not change. It is commonly used to process hard to machine materials such as cemented carbide, high temperature alloy, quenched steel and stainless steel.


(4) Limitations


The machining accuracy and stability are not high; The processing cost is higher, and the smaller the batch, the higher the additional cost of a single piece.


  1. laser processing


(1) Basic principles


Laser processing is to use the energy of light to reach a very high energy density at the focus after being focused by the lens, so that the material can be melted or vaporized in a very small time and be etched to realize processing.


(2) Main features


Laser processing technology has the advantages of less material waste, obvious cost effect in large-scale production, and strong adaptability to processing objects. In Europe, laser technology is basically used for welding high-end automobile shell and base, aircraft wing, spacecraft fuselage and other special materials.


(3) Scope of use


Laser processing is the most commonly used application of laser system. The main technologies include: laser welding, laser cutting, surface modification, laser marking, laser drilling, micromachining and photochemical deposition, stereolithography, laser etching, etc.

  1. electron beam processing


(1) Basic principles


Electron beam processing (EBM) is the processing of materials using the thermal or ionization effects of high-energy convergent electron beams.


(2) Main features


High energy density, strong penetrability, wide range of primary penetration, large weld width ratio, fast welding speed, small heat affected zone and small working deformation.


(3) Scope of use


The range of materials processed by electron beam is wide, and the processing area can be very small; The machining precision can reach the nanometer level, realizing molecular or atomic machining; High productivity; The pollution produced by processing is small, but the cost of processing equipment is high; It can process micro holes, narrow slots, etc. it can also be used for welding and fine lithography. Vacuum electron beam welding technology is the main application of electron beam machining in automobile manufacturing.


  1. ion beam machining


(1) Basic principles


Ion beam machining is realized by accelerating and focusing the ion flow generated by the ion source to the surface of the workpiece in a vacuum state.


(2) Main features


Because the ion current density and ion energy can be accurately controlled, the machining effect can be accurately controlled to achieve ultra precision machining at the nano level, even at the molecular and atomic levels. In ion beam processing, the pollution is small, the processing stress and deformation are very small, and the adaptability to the processed materials is strong, but the processing cost is high.


(3) Scope of use


7.Ion beam processing can be divided into etching and coating according to its purpose.


1) Etching process


Ion etching is used to process grooves on gyroscope air bearings and dynamic pressure motors. It has high resolution, good accuracy and repeatability. Another aspect of ion beam etching applications is to etch high-precision graphics, such as electronic components such as integrated circuits, optoelectronic devices and optical integrated devices. Ion beam etching can also be used to thin materials and make specimens for transmission electron microscopy.


2) Ion beam coating processing


There are two forms of ion beam coating: sputtering deposition and ion plating. A wide range of materials can be plated by ion plating. Metal or non-metal films can be plated on both metal and non-metal surfaces. Various alloys, compounds, or some synthetic materials, semiconductor materials, and high melting point materials can also be plated.


Ion beam coating technology can be used to prepare lubricating film, heat-resistant film, wear-resistant film, decorative film and electrical film.

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