CN103801654A - Method used for manufacturing die foam full model - Google Patents
Method used for manufacturing die foam full model Download PDFInfo
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- CN103801654A CN103801654A CN201210436982.XA CN201210436982A CN103801654A CN 103801654 A CN103801654 A CN 103801654A CN 201210436982 A CN201210436982 A CN 201210436982A CN 103801654 A CN103801654 A CN 103801654A
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Abstract
The invention provides a method used for manufacturing a die foam full model. The method comprises the steps that a digital die three dimensional model is designed; expansion processing is carried out on the die three dimensional model, wherein an expansion coefficient formula is that expansion coefficient=1/(1-the shrinkage rate of a casting material); a foam blank is prepared, wherein the size of the foam blank is larger than the size of the preprocessed die three dimensional model; and based on the preprocessed die three dimensional model, a numerical control machining device is used to machine the foam blank to prepare the die foam full model. According to the method, the numerical control machining device is used to machine the die foam full model, which can greatly reduce the dependence on production workers of the foam full model, and can improve the machining speed of the die foam full model; high and consistent accuracy can be ensured; and the whole die manufacturing process can be speeded up.
Description
Technical field
The present invention relates to technology of die manufacturing field, particularly relate to a kind of method of mfg. moulding die foam real type.
Background technology
Manufacturing and designing of mould is a very complicated process, and it relates to all aspects in manufacture field.And mfg. moulding die foam real type is important step and the aspect of Mould Machining.For example, conventionally, by mould foam real type is embedded in sand, then water molten iron, foam melts, and molten iron is just full of the space originally being occupied by foam real type, casts out thus die blank.And then described blank is processed and obtained final mould or mold component.
In the prior art, the manufacturing process flow of mould foam real type is: first carry out two-dimentional layout design; Then made by hand according to two-dimentional drawing by workman.In the case, the crudy of foam real type and manufacturing speed depend on workman's skills involved in the labour completely.And a masterful technique workman needs cultivation and contact for many years, this has seriously restricted mould production capacity.
For this reason, wish a kind of new technique and reduce the dependence to experienced operator.
Summary of the invention
The object of the present invention is to provide a kind of new mould foam real type manufacturing process to reduce the dependence to experienced operator.
For achieving the above object, the invention provides a kind of method of mfg. moulding die foam real type, described method comprises the steps: modelling step (1): design digitized mould threedimensional model; Pre-treatment step (2), described pre-treatment step comprises expansion step (21): described mould threedimensional model is carried out to expansion process, and wherein, the coefficient of expansion meets following formula: the coefficient of expansion=1/ (shrinkage factor of 1-founding materials); Blanking step (3): prepare foam blank, wherein the size of foam blank is greater than the size of the mould threedimensional model after pre-treatment step (2) is processed; And digital control processing step (4): based on pretreated described mould threedimensional model, with numerical control processing apparatus, foam blank is processed to make described mould foam real type.
The size that the size of foam blank is greater than mould threedimensional model refers to that the peripheral profile of foam blank can contain mould threedimensional model, in other words, foam blank is processed to the full mold that can make mould threedimensional model.
Pass through said method, carry out processing mold foam real type with numerical control processing apparatus, can greatly alleviate the dependence of foam real type being made to workman, and can improve the process velocity of mould foam real type, and can guarantee higher and more consistent precision, thereby be conducive to accelerate whole die manufacture.
Furthermore, technique scheme this by the effective combination of the three-dimensional process technology of Three Dimensional Solid Design and mould full mold, solved the problem existing in the application of mould Three Dimensional Solid Design, be conducive to improve mould mould full mold working (machining) efficiency and shorten die manufacturing cycle.
Preferably, described pre-treatment step (2) further comprises that surplus applies step (22): for the mould threedimensional model through expansion process, need the position of processing to apply allowance after casting.The implication that applies allowance refers to reserved allowance.For example, if wish to have for platform the allowance of 5mm, need to increase in position of platform the size of 5mm, increase the material of 5mm.
Preferably, described method further comprises decomposition step (5): described threedimensional model is carried out to layering and/or piecemeal, described mould threedimensional model is resolved into at least two submodels; Described blanking step (3) comprises sub-blank blanking step (31): for each submodel is prepared the sub-blank of foam; Described digital control processing step (4) comprises sub-member numerical control procedure of processing (41): based on each described submodel, process respectively the sub-blank of corresponding foam to obtain the sub-member of mould foam real type with numerical control processing apparatus, wherein, described method further comprises amalgamation step (6): described in amalgamation, the sub-member of mould foam real type is to obtain described mould foam real type.
Preferably, in described decomposition step, make within the size of described submodel is in the range of work of numerical control processing apparatus, and/or make the size of described submodel be less than or equal to the size of working standard foam block.Described working standard foam block can be commercially available standard foam piece, for example, is of a size of the foam block of 6000mmx 1200mm x 600mm or is of a size of the foam block of 5000mm x 1000mm x 500mm.Described working standard foam block can also be the conventional foam block obtaining after commercially available standard foam piece is cut apart.For example be of a size of the conventional foam block of 1200mm x 1200mm x 600mm, or be of a size of the conventional foam block of 1000mmx 500mm x 500mm.
Preferably, the thickness of described submodel is not less than 100 millimeters, is more preferably not less than 200 millimeters.Thereby, make the sub-member making there is good rigidity.
Preferably, the thickness of described submodel is not more than the thickness of working standard foam block.Thereby, in the time of blanking without being pasted together stacked working standard foam block.
Preferably, make the thickness of submodel as much as possible equal the thickness of working standard foam block.Thereby can reduce processing capacity.
Preferably, described sub-member numerical control procedure of processing (41) comprises the steps: programming step (411): foam real type submodel is carried out to NC Machining Program; Simulation process (412): the program weaving is carried out to simulating, verifying; Programming procedure of processing (413): after simulating, verifying passes through, with the program after weaving, the sub-blank of foam is processed, to prepare the sub-member of foam real type.By simulating, verifying, can pinpoint the problems in actual first being processed, and deal with problems.
Preferably, after casting, need the position of processing to comprise bottom surface, insert, barricade, guide plate, spigot surface and/or spring platform.
Preferably, described method further comprises detecting step (7): detect and process with numerical control processing apparatus the described mould foam real type making, if the described mould foam real type making is undesirable, it is carried out to hand finish.Thereby determine whether whether the described mould foam real type making meets the requirements, need to repair or no need to again making.By checking procedure, can guarantee that the mould foam real type making meets the requirements.
Accompanying drawing explanation
Fig. 1 is the schematic diagram of the mould threedimensional model of the first embodiment;
Fig. 2 is the schematic diagram of the first embodiment mould threedimensional model after expanding;
Fig. 3 is the explanation schematic diagram that the first embodiment mould threedimensional model after expanding is applied to allowance;
Fig. 4 is the explanation schematic diagram that the first embodiment mould threedimensional model after applying allowance shown in Fig. 3 is carried out to blanking;
Fig. 5 is the schematic diagram of the submodel after pretreated the first embodiment mould threedimensional model is cut apart;
Fig. 6 is the explanation schematic diagram that the first embodiment mould threedimensional model after cutting apart is carried out to the first method of blanking;
Fig. 7 is the explanation schematic diagram that the first embodiment mould threedimensional model after cutting apart is carried out to the second method of blanking;
Fig. 8 is the schematic diagram of the second embodiment mould threedimensional model after expanding and after applying allowance;
Fig. 9 is the explanation schematic diagram that carries out blanking after the mould threedimensional model shown in Fig. 8 is cut apart;
Figure 10 is the flow chart of an exemplary method.
The specific embodiment
For making object of the invention process, technical scheme and advantage clearer, below in conjunction with the accompanying drawing in the embodiment of the present invention, the technical scheme in the embodiment of the present invention is further described in more detail.In the accompanying drawings, same or similar label represents same or similar element or has the element of identical or similar functions from start to finish.Described embodiment is the present invention's part embodiment, rather than whole embodiment.Be exemplary below by the embodiment being described with reference to the drawings, be intended to for explaining the present invention, and can not be interpreted as limitation of the present invention.Based on the embodiment in the present invention, those of ordinary skills are not making the every other embodiment obtaining under creative work prerequisite, all belong to the scope of protection of the invention and below in conjunction with accompanying drawing, embodiments of the invention are elaborated.
In description of the invention; it will be appreciated that; term " orientation or the position relationship of the indication such as " center ", " longitudinally ", " laterally ", 'fornt', 'back', " left side ", " right side ", " vertically ", " level ", " top ", " end " " interior ", " outward " they are based on orientation shown in the drawings or position relationship; be only the present invention for convenience of description and simplified characterization; rather than indicate or imply that the device of indication or element must have specific orientation, construct and operation with specific orientation, therefore can not be interpreted as limiting the scope of the invention.
The method of mfg. moulding die foam real type comprises the steps: modelling step 1 according to an embodiment of the invention: design digitized mould threedimensional model; Pre-treatment step 2, described pre-treatment step comprises expansion step 21: described mould threedimensional model is carried out to expansion process, and wherein, the coefficient of expansion meets following formula: the coefficient of expansion=1/ (shrinkage factor of 1-founding materials); Blanking step 3: prepare foam blank, wherein the size of foam blank is greater than the size of the mould threedimensional model after pre-treatment step 2 is processed; And digital control processing step 4: based on pretreated described mould threedimensional model, with numerical control processing apparatus, foam blank is processed to make described mould foam real type.
Pass through said method, carry out processing mold foam real type with numerical control processing apparatus, can greatly alleviate the dependence of foam real type being made to workman, and can improve the process velocity of mould foam real type, and can guarantee higher and more consistent precision, thereby be conducive to accelerate whole die manufacture.
In the first embodiment, needing the mould of manufacturing is a cone.The diameter of the bottom surface of described cone is d0, is highly h0.For this mould builds mould threedimensional model.Fig. 1 is the schematic diagram of the mould threedimensional model of the first embodiment, and the diameter of the bottom surface of the cone shown in Fig. 1 (the mould threedimensional model building with digital form) is d0, is highly h0.That is to say, mould threedimensional model has identical size with mould.But mould threedimensional model also can have larger size with respect to mould, for example size of mould threedimensional model also can equal die size/(shrinkage factor of 1-founding materials).The advantage of this kind of mode is to omit expansion step, but also exists and easily forget the shortcoming of indivedual sizes divided by shrinkage factor.。
Fig. 2 is the schematic diagram of the first embodiment mould threedimensional model after expanding.The diameter of the bottom surface of the first embodiment mould threedimensional model after expanding is d1, is highly h1.Coefficient of expansion p equals 1/, and (shrinkage factor of 1-founding materials q).That is to say d1=d*p=d*1/(1-q), h1=h*1/(1-q).
In literary composition, " contraction " of indication is casting alloy from settable liquid and is cooled to the volume that produces room temperature process and the reduction of size.Comprise liquid contraction, solidification shrinkage, Solid State Contraction three phases.Liquid contraction is the reduction in bulk that molten metal occurs due to the reduction of temperature.Solidification shrinkage is the reduction in bulk that molten metal solidifies (liquid state changes into the solid-state) stage.Liquid contraction and solidification shrinkage show as the reduction of alloy volume, are commonly referred to " body contraction ".The Solid State Contraction reduction in bulk that to be metal occur due to the reduction of temperature under solid-state, although Solid State Contraction also causes the reduction of volume, represents by the dimension reduction amount of foundry goods, conventionally therefore be called " linear shrinkage ".
The kind of alloy is different with composition, and its shrinkage factor is also different, and in iron-carbon alloy, the shrinkage factor of casting pig is little, and the shrinkage factor of cast steel is large.Following table is the linear shrinkage ratio of conventional casting alloy.
In addition, the pouring temperature of metal has impact to shrinkage factor, and pouring temperature is higher, and liquid contraction is larger; The structure of foundry goods and mold material also have impact to shrinking, and cavity shape is more complicated, the deformability of mold material is poorer, and larger to the obstruction of shrinking, shrinkage factor is less.
Fig. 3 is the explanation schematic diagram that the first embodiment mould threedimensional model after expanding is applied to allowance.The implication that applies allowance refers to reserved allowance.For example, if wish to have for platform the allowance of 5mm, need to increase in position of platform the size of 5mm, increase the material of 5mm.After casting, need the position of processing for example can comprise bottom surface, insert, barricade, guide plate, spigot surface and/or spring platform etc.In examples shown, only need the reserved allowance in bottom surface.Divide and represent the allowance that applies with black part in the drawings.Apply after described allowance, the height of mould threedimensional model is increased to h2 from h1.Mould threedimensional model now represents with label S.
Fig. 4 is the explanation schematic diagram that the first embodiment mould threedimensional model after applying allowance shown in Fig. 3 is carried out to blanking.Foam blank is provided, and wherein the size of foam blank T is greater than the size of the mould threedimensional model S after expanding and applying allowance processing.Foam official written reply T can form by polylith foams are gentle.Also can be to be formed by the cutting of monolithic foams.
Fig. 5 is the schematic diagram of the submodel after pretreated the first embodiment mould threedimensional model is cut apart or decomposed.Be about to highly for the mould threedimensional model S of h2 is cut apart or resolve into three submodel S1, S2, S3.The height of three submodel S1, S2, S3 is respectively hs1, hs2 and hs3.In figure, be only illustrated in short transverse and cut apart, as required, also can on width and length direction, cut apart, or in two or three directions, cut apart simultaneously.For example a model is halved in three directions of length simultaneously, and obtained eight submodels.
Height hs1, hs2 and the hs3 of three submodel S1, S2 shown in Fig. 5, S3 can have multiple combination mode.For example, suppose that h2 is 1.2 meters, hs1, hs2 and hs3 can be respectively 0.5m, 0.5 meter and 0.2 meter; 0.4 meter, 0.4 meter and 0.4 meter; Or 0.5 meter, 0.4 meter and 0.3 meter.
Advantageously, in described decomposition step, make within the size of described submodel is in the range of work of numerical control processing apparatus, and/or make the size of described submodel be less than or equal to the size of working standard foam block.Described working standard foam block can be commercially available standard foam piece, for example, is of a size of the foam block of 6000mm x 1200mm x 600mm or is of a size of the foam block of 5000mm x 1000mm x 500mm.Described working standard foam block can also be the conventional foam block obtaining after commercially available standard foam piece is cut apart.For example be of a size of the conventional foam block of 1200mm x 1200mm x 600mm, or be of a size of the conventional foam block of 1000mm x 500mm x 500mm.
Advantageously, the thickness of described submodel is not less than 100 millimeters.Thereby, make the sub-member making there is good rigidity.And the thickness of described submodel can be set to be not more than the thickness of working standard foam block.Thereby, in the time of blanking without being pasted together stacked working standard foam block.More advantageously, make the thickness of submodel as much as possible equal the thickness of working standard foam block.Thereby can reduce processing capacity.
Fig. 6 is the explanation schematic diagram that the first embodiment mould threedimensional model after cutting apart is carried out to the first method of blanking.Fig. 7 is the explanation schematic diagram that the first embodiment mould threedimensional model after cutting apart is carried out to the second method of blanking.In Fig. 6, be that three submodel S1, S2, S3 prepare respectively sub-blank T1, T2 and T3, wherein, sub-blank T1, T2 and T 3 are rectangle (can be also other suitable shapes), and size is different.And in Fig. 7, be that to divide other to prepare sub-blank be identical blank Ta for three submodel S1, S2, S3.
After blanking, in digital control processing step, process corresponding foam blank to obtain mould foam real type member; Or in digital control processing step, process the sub-blank of corresponding foam to obtain the sub-member of mould foam real type.
Described sub-member numerical control procedure of processing comprises the steps: programming step: foam real type submodel is carried out to NC Machining Program; Simulation process: the program weaving is carried out to simulating, verifying; Programming procedure of processing: after simulating, verifying passes through, with the program after weaving, the sub-blank of foam is processed, to prepare the sub-member of foam real type.By simulating, verifying, can pinpoint the problems in actual first being processed, and deal with problems.
Described method further comprises amalgamation step: described in amalgamation, the sub-member of mould foam real type is to obtain described mould foam real type.Described method can further include detecting step: detect the described mould foam real type making, if the described mould foam real type making is undesirable, it is carried out to hand finish.Thereby determine whether whether the described mould foam real type making meets the requirements, need to repair or no need to again making.By checking procedure, can guarantee that the mould foam real type making meets the requirements.
Fig. 8 is the schematic diagram of the second embodiment mould threedimensional model after expanding and after applying allowance.Fig. 9 is the explanation schematic diagram that carries out blanking after the mould threedimensional model shown in Fig. 8 is cut apart.The second embodiment is a cone, has columniform recess in bottom.And described cylindrical recess also needs reserved allowance.In the embodiment shown in fig. 9, be that the sub-blank of three sub-model preparations is identical.
Figure 10 is the flow chart of an exemplary method.Method shown in Figure 10 comprises the steps: successively
Modelling step 1: design digitized mould threedimensional model;
Decomposition step 6: described threedimensional model is carried out to layering and/or piecemeal, described mould threedimensional model is resolved into at least two submodels, in described decomposition step, make within the size of described submodel is in the range of work of numerical control processing apparatus, and/or make the size of described submodel be less than or equal to the size of working standard foam block;
Blanking step 3: for each submodel is prepared the sub-blank of foam, wherein the size of the sub-blank of foam is greater than the size of the three-dimensional submodel of mould after decomposition step (2) is processed;
Digital control processing step 4: based on the three-dimensional submodel of pretreated described mould, with numerical control processing apparatus, the sub-blank of foam is processed to make the sub-member of described mould foam real type;
Amalgamation step 6: described in amalgamation, the sub-member of mould foam real type is to obtain described mould foam real type; And
Detecting step 7: detect the described mould foam real type making, if the described mould foam real type making is undesirable, it is carried out to hand finish.
Technical scheme of the present invention this by the effective combination of the three-dimensional process technology of Three Dimensional Solid Design and mould full mold, solved the problem existing in the application of mould Three Dimensional Solid Design, be conducive to improve mould mould full mold working (machining) efficiency and shorten die manufacturing cycle.
Finally it is to be noted: above embodiment only, in order to technical scheme of the present invention to be described, is not intended to limit.Although the present invention is had been described in detail with reference to previous embodiment, those of ordinary skill in the art is to be understood that: its technical scheme that still can record aforementioned each embodiment is modified, or part technical characterictic is wherein equal to replacement; And these modifications or replacement do not make the essence of appropriate technical solution depart from the spirit and scope of various embodiments of the present invention technical scheme.
Claims (10)
1. a method for mfg. moulding die foam real type, is characterized in that, comprises the steps:
Modelling step (1): design digitized mould threedimensional model;
Pre-treatment step (2), described pre-treatment step comprises expansion step (21): described mould threedimensional model is carried out to expansion process, and wherein, the coefficient of expansion meets following formula:
The coefficient of expansion=1/ (shrinkage factor of 1-founding materials);
Blanking step (3): prepare foam blank, wherein the size of foam blank is greater than the size of the mould threedimensional model after pre-treatment step (2) is processed; And
Digital control processing step (4): based on pretreated described mould threedimensional model, with numerical control processing apparatus, foam blank is processed to make described mould foam real type.
2. the method for mfg. moulding die foam real type as claimed in claim 1, it is characterized in that, described pre-treatment step (2) further comprises that surplus applies step (22): for the mould threedimensional model through expansion process, need the position of processing to apply allowance after casting.
3. the method for mfg. moulding die foam real type as claimed in claim 1 or 2, it is characterized in that, described method further comprises decomposition step (5): described threedimensional model is carried out to layering and/or piecemeal, described mould threedimensional model is resolved into at least two submodels;
Described blanking step (3) comprises sub-blank blanking step (31): for each submodel is prepared the sub-blank of foam;
Digital control processing step (4) comprises sub-member numerical control procedure of processing (41): based on each described submodel, process respectively the sub-blank of corresponding foam to obtain the sub-member of mould foam real type with numerical control processing apparatus,
Wherein, described method further comprises amalgamation step (6): described in amalgamation, the sub-member of mould foam real type is to obtain described mould foam real type.
4. the method for mfg. moulding die foam real type as claimed in claim 3, it is characterized in that, in described decomposition step, make within the size of described submodel is in the range of work of numerical control processing apparatus, and/or make the size of described submodel be less than or equal to the size of working standard foam block.
5. the method for mfg. moulding die foam real type as claimed in claim 3, is characterized in that, the thickness of described submodel is not less than 100 millimeters.
6. the method for mfg. moulding die foam real type as claimed in claim 3, is characterized in that, the thickness of described submodel is not more than the thickness of working standard foam block.
7. the method for mfg. moulding die foam real type as claimed in claim 5, is characterized in that, makes the thickness of submodel as much as possible equal the thickness of working standard foam block.
8. the method for mfg. moulding die foam real type as claimed in claim 3, is characterized in that, described sub-member numerical control procedure of processing (41) comprises the steps:
Programming step (411): foam real type submodel is carried out to NC Machining Program;
Simulation process (412): the program weaving is carried out to simulating, verifying;
Programming procedure of processing (413): after simulating, verifying passes through, with the program after weaving, the sub-blank of foam is processed, to prepare the sub-member of foam real type.
9. the method for mfg. moulding die foam real type as claimed in claim 2, is characterized in that, needs the position of processing to comprise bottom surface, insert, barricade, guide plate, spigot surface and/or spring platform after casting.
10. the method for mfg. moulding die foam real type as claimed in any one of claims 1-9 wherein, it is characterized in that, described method further comprises detecting step (7): detect the described mould foam real type making, if the described mould foam real type making is undesirable, it is carried out to hand finish.
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Application publication date: 20140521 |