The development progress of the mould plays a very key role in the progress of the whole project and is an important part of the production preparation of the OEMs. Next, from the release of body data to the final acceptance of the mold, we will talk about the mold development process and schedule control.
1. Released the number of body craft
The body design department releases the product digital model, and the engineering development department carries out process pre-analysis and price prediction (as bidding comparison data) according to the product digital model, and uses the body process digital model to conduct bidding and corresponding process analysis of molds.The bidding process is not discussed in detail here. The following is a brief talk about mold development and management from the calibration (that is, to determine the mold factory).
2. Feasibility analysis of the manufacturing process of body parts (mold developers and engineering development departments)
After receiving the digital model of the body process, the mold developer will analyze the feasibility of the process for each part.In principle, the mould factory is required to perform CAE analysis (i.e. part formability simulation analysis) on all newly developed parts.
The role of CAE analysis:
Through CAE analysis, we can more intuitively observe the forming process of parts sheet material;
Shorten the cycle of mold design and analysis;
Predict the possibility of mold;
Adopt the optimization design, the maximum limit reduces the mold and steel consumption, reduces the manufacturing production cost;
Identify potential risks of molds and parts prior to manufacturing;
Ensure mold design rationality, reduce the design cost;
Through the analysis of the potential problems of the parts, the mold factory can timely put forward reasonable suggestions for design changes, and promote the development work more efficiently.
According to the CAE analysis results of the mold factory, the development department can make full use of the experience of field production and debugging to check whether the process parameters are reasonable and whether the drawing supplement is reasonable. In view of the risk of wrinkling or cracking of the parts, the development department can timely propose solutions.
3. Design and countersign of DL diagram
Mold DL drawing design can be carried out after CAE analysis, and can be carried out simultaneously in most cases.
DL diagram design is Design Layout, stamping process analysis and design, also known as the mold process flow chart, including: parts sheet size, stamping direction and Angle, stamping process arrangement, feeding direction, waste knife distribution and cutting edge direction, waste elimination direction, CH hole, left and right parts identification, each process labeling, etc.
At the same time, the DL drawing should also reflect the stamping equipment of the relevant process, the height of the die, the material of the die, the working stroke of the blank holder or the sheet, the positioning mode of the sheet, the pressure analysis of the completion process, etc.
DL design is completed, in principle, in the mold factory should complete the internal audit, internal audit after the completion of the problem is corrected can be provided to the same development department, and sign, DL figure sign is critical, as a direct result of the late mold design, and also have great influence to later mold development cycle, if the DL figure later change, the development cycle and cost will be caused great waste, the rationality of the main engineering development department audit parts process, the correctness of the machine parameters, process the rationality of the supplement, material utilization, combined with the press censorship feeding convenience, etc.
4. Design and countersign mold structure drawing
Mold structure drawing countersign order: drawing mold drawing countersign -- plastic flanging mold countersign -- trimming and punching mold countersign.
Because the casting and processing cycle of the mold is a hard time and cannot be compressed, so in order to ensure the progress of the project, the design link of the mold structure drawing is very important. The time of the design link of the mold should be advanced as far as possible to strive for the manufacturing time of the subsequent mold.
The first sampling of the mold is generally semi-manual sample, only the forming can be required, the rest of the trimming and punching can be completed by line cutting, so the drawing die and plastic flanging type mold design should be carried out first, and then the trimming and punching type mold design.
The mould factory shall design the mould structure drawing according to the DL drawing. After the design is completed, it shall also pass the internal review first. After the problems are corrected, it can be reviewed and countersigned by the development department of the main engine factory.
OEMD should focus on:
Mold functionStructural stability and strength
Mold production safety
Compliance of mold parameters with mass production press
Convenience of commissioning and production
Consistency of the material and technical agreement requirements of the main parts of the mold
For the problems found in the review, the mold factory should be asked to rectify as far as possible.Part of the problem may be far less influence on product function, but may affect the work convenient, may also reduce the production efficiency, in order to catch time and schedule, mold factory cooperate changes may not be too, at this time, need the same developers (engineer) drive and determination, because in the design phase changes no matter how late than fast (molding) after the change, the need to mold factory designers the perspective-taking, more standing in the point of view of the production department.
Some of the controversial issues require objective discussion by multiple parties to find the best solution.In the process of mold drawing review, engineering development and technical personnel are required to stand firm and have excellent technical and on-site debugging experience, which can reduce many problems in the later stage.
5. Issuance of casting digital model and review and rectification of foam solid model (styrofoam)
After the mold structure drawing design review, the foam type can be made.In the foam solid stage, the project team needs to release casting data to ensure the castability of the solid model. The foam solid model is a kind of material formed by polystyrene foamed at high temperature. NC processing is carried out according to the mold structure drawing, and the appropriate mold processing allowance (8-10 days) and the shrinkage rate of the foam are considered.
The production cycle of Styrofoam is usually about one week. After the production is completed, it needs to be reviewed on site. First, it needs to ensure the consistency with the mold structure drawing.The second is to check whether the problems in the review of the mold structure drawing are corrected in place, or the problems not found in the review of the design drawing. The review of styrofoam is an indispensable process in the process of mold making, because it is the last pass of the mold structure change. Once it enters the casting stage, the mold structure is difficult to change.
6. Mold casting
After the rectification of Styrofoam production is completed, it can be shipped to the foundry for casting. The specific process will not be discussed in detail here. The casting cycle of the mold is 15-20 days.Among them, the defects such as sand inclusion in the casting can only be seen after processing.
7. NC digital model release and NC processing of its molds
NC processing can be carried out after the mold casting is completed, but the premise is that the NC data has been released. The mold factory can carry out NC programming according to the NC data of the product, and then carry out the NC processing of the mold. The NC processing of the mold can be roughly divided into:Long Xi - assemblage - semi-finishing - finishing, etc., in the process of NC machining, can be found if there is a sand casting or defects such as cracks, NC processing after the completion of the need to mold heat treatment to achieve the required hardness, mold NC processing cycle is 20 to 25 days commonly, in the case of project development time nervous, how to reasonable arrangement of NC machining time is very important, project developers, can be used to schedule control to the scene and supervise mold factory prepare the reasonable processing plan.Try not to let the CNC machining machine idle, to ensure the progress.
8. Mold fitter, debugging and sampling process
Die fitter stage includes: mold base and, clamping, testing, sampling, etc., after mold NC machining for subsequent fitter still left a certain margin, bench debugging main check up and down mould research and rate, oriented research and rate, to ensure the stamping out qualified stampings, through die locksmith debugging, can identify the quality of the mould, but also can determine the size of the cutting, etc.
9. Pre-acceptance of molds
Mold factory in plan time to complete all on their own and make grinders mould debugging qualified, can apply to the same development for pre-acceptance, mold factory need to provide the mould self-check report and the qualified rate of stamping parts, such as development department after received the mold factory pre-acceptance application, organize personnel to mold factory pre-acceptance, mainly from the static, dynamic stamping mould quality three aspects for acceptance of the mould, dynamic and static test in accordance with the standards, stamping parts surface quality, shape, dimensional accuracy and stiffness test is divided into three aspects.
In principle, the problems found in the pre-acceptance process are required to be packaged and shipped after the mold factory's rectification is completed. However, if some problems do not affect the production quality and the rectification is easy, the mold factory is allowed to send fitter personnel to the production area for continuous rectification under the condition of tight progress.
10. Production place debugging and acceptance of mold quantity
Because of difference of machine tool, mold profile and rate difference, such as to ensure the product quality mold upon the acceptance of prestressing, moved to the amount of origin need to debug, after the first round of the general drawing mould research and time for 1 to 2 months, and the whole mould debugging cycle for six months or longer time, mould quantity origin debugging process always revolve around the following aspects:
The stamping parts need to be clamped on the welding fixture to verify the coordination of die, clamp, fixture and welding fixture;
Ensure the precision of the stamping parts, the stamping parts are placed on the gage for inspection, and the qualified rate is generally more than 90%;
The mould factory shall be responsible for rectifying the problems found on the fixture of the stamping parts or the problems or defects reported in the welding debugging process;
Conformance inspection of mold dynamic and static inspection items;
The continuous production reliability of the die in the mass production press, that is, the continuous production scrap rate is required to be less than 2%
The mold debugging and rectification cycle is relatively long. After the above rectification is completed and the production runs in a stable manner for 3 months, the engineering development department can organize mold users, security personnel, quality inspectors and other personnel to carry out the final acceptance of the mold and sign the final acceptance report.
After the final acceptance of the mold, the development of the mold is considered to be completed in stages.However, as long as the mold is not scrapped and the life cycle of the mold continues, the work of the engineering development department will never end, but will be transferred to the production system and process department for use, management and maintenance.Mold in good use and maintenance, can prolong the service life, reduce the reject rate, improve production efficiency, bring considerable economic benefits for the company.
