【作者】 蔡东海；

【导师】 宋玉泉；

【作者基本信息】 浙江工业大学 ， 机械电子工程， 2007， 硕士

【摘要】 模具工业作为制造业的重要组成部分，具有生产效率高、产品质量好、节约能源和原材料以及成本低等一系列优点，集中体现了现代先进制造技术实现优质、高效、低耗、清洁生产的思想。然而模具的设计与制造是一个多环节、多反复的复杂过程。模具结构随着产品的不同而变化，模具型面的几何形状复杂，模具的生产方式为单件的或小批量的，大量生产模具的情况极为少见。由于在实际制造和检测前，很难保证产品在成型过程中每一个阶段的性能，所以长期以来模具设计大都是凭经验或使用传统的CAD进行的。要设计和制造出一副适用的模具往往需要经过由设计、制造到试模、修模的多次反复，致使模具制作的周期长、成本高，甚至可能造成模具的报废，难以适应快速增长的市场需要。为了适应现代市场的要求，模具工业正广泛应用现代先进制造技术来加速模具工业的技术进步，满足各行各业对模具这一基础工艺装备的迫切需求。本论文旨在将逆向工程(RE)，CAD／CAM，CAE及快速成形(RP)等先进制造技术集成应用于模具制造中。由于目前的RE、CAD／CAM、CAE及RP系统各自为营，不能很好的实现各系统之间的信息集成，故较难在模具制造中实现多个系统的综合应用。因此本论文着重研究了CAD／CAM系统和RE系统的集成、CAD／CAM系统和CAE系统的集成及CAD／CAM系统和RP系统的集成。通过中间数据转换方式实现不同系统之间的集成，从而建立一个完整的用于模具制造的集成系统。集成系统在模具制造中应用的主要步骤为：工件逆向数据扫描，点云数据处理，工件三维模型生成，工件模具设计，工件在模具中成形过程的数值模拟，根据模拟结果优化模具，优化后的模具分层切片处理，模具快速成形，模具NC工步代码生成，模具数控加工。论文通过汽车连杆为实例验证该集成系统的实用性。在连杆模具设计的时候，根据宋玉泉教授专利“汽车连杆辊压塑性精成形工艺及装置”的思想，设计四道辊压模具。经数值模拟所得，这四道辊压模具能较好的实现汽车连杆的辊压塑性精成形，并用快速成形加工出四道辊压模具的样件。连杆模具设计的集成化方法与连杆模具设计的传统工艺方法比较得出，采用该集成系统进行连杆模具设计开发，能有效的缩短模具开发周期，降低成本，改善连杆的成形精度和使用寿命。更多还原

【Abstract】 As an important part of manufacturing, mould technology has many virtues: highefficiency of production, good quality of product, economy of energy and material, lowcost and so on. It represents the idea of advanced manufacturing technologies. Thedesign and manufacture of the mould is a complex process. The structure of mould ischanged by the different product. The shape of the moulding surface is always complex.The amount of mould production is often small, sometimes just single. It is rare to seevolume-produce of mould. The design of mould is resort to the experience or thetraditional for long. It is difficult to ensure the quality of molding at each process beforeexamination and production. It needs many repeats of the process of design、manufacture、examination and modification during the traditional mould production.Therefor, it has the long cycle、the high cost and even the wrong product. It obviouslycan not fit to the growing market. To fit to the market and the need of other industry,mould technology is getting ahead by using the advanced manufacturing technologies.In this paper, I try to integrate RE、CAD/CAM、CAE and RP into the mouldmanufacturing. Due to RE、CAD/CAM、CAE and RP do things in their own ways, it isdifficult to integrate the information of each system. It is also difficult to compositivelyapply to the mould manufacturing. The point of this paper is the research the integrationof CAD/CAM/RE、CAD/CAM/CAE and CAD/CAM/RP and integrate the differentsystems by the way of data transformation. Then establish a integration system for themould manufacturing. The flow process of the integration system is: scan of the part,treating the points data, making the CAD model of the part, design the moulds of thepart, numerical simulation of molding, mend the moulds by the numerical simulation results, slicing the moulds, rapid prototyping of the moulds, generation the NC code ofthe moulds, machining the moulds. The integration system is validated by the exampleof automotive connecting-rod. According to the patent idea of automotiveconnecting-rod precise plastic rolling process, design four suits of moulds. The result ofthe numerical simulation shows that the four suits of moulds can satisfy the preciseplastic rolling process. Then product the four suits of moulds by rapid prototyping. Bycompare the integration way of mould design of connecting-rod to the traditional way ofmould design of connecting-rod we can see that the integration way can obviouslyshorten the cycle of mould design, reduce the cost of mould design and improve theprecision of the molding and the life of connecting-rod.更多还原