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1、模具设计技术发展与应用现状模具设计技术发展与应用现状李志李志李志 Manager of Mold/Die Development TeamManager of Mold/Die Development TeamManager of Mold/Die Development Team模具制造业发展现状和趋势模具制造业发展现状和趋势模具制造业发展现状和趋势模具制造业发展现状和趋势模具工业是支柱产业：汽车，电子，机械，家电，通讯模具生产向精密，高质量，短交货期方向发展模具工业东移，从日本，美国，欧洲向东南亚尤其中国转移数字化设计和制造技术是提高产品质量，缩短交货周期，提高竞争性重要保证主要内容主要内
2、容主要内容主要内容模具设计技术发展与应用现状1. 模具制造业发展现状和趋势2. 模具CAD/CAM 系统成功应用要素3. 模具的数字化设计及制造主要内容主要内容主要内容主要内容3. 模具的数字化设计及制造3.1 注塑模设计及制造过程的关键技术 塑料产品成型性 - CAE 塑料产品结构性 - CAA 模具设计和制造 导向技术 3.2 级进模设计及制造过程的关键技术 冲压模具数字化设计过程 级进模设计和制造 导向技术3.3 汽车覆盖件模设计及制造过程的关键技术 汽车覆盖件数字化设计过程 汽车覆盖件产品成型性 - CAE 汽车覆盖件冲压工艺设计 汽车覆盖件结构设计4. 结论注塑模级进模汽车覆盖件模T
3、echnology ProgressionTechnology ProgressionDrawing Based Feature Based Process Based Knowledge BasedUserGroup DepartmentEnterpriseData Mgmt Process Mgmt Collaboration Knowledge8874 959902Digital DrawingsSolidsFeaturesVisualizationMaster ModelDigital ModelsAuto threadsAero threadsConsumer ProductsMac
4、hineryDigitalProcessesProcess WizardsOptimizationRule based modelingWAVEPredictive EngineeringPervasive knowledgeKBE languageKnowledge checkersExpert applicationsAutomationKnowledge Management File-based data managementVaultingApplicationEncapsulationProduct Structure ManagementConfiguration Managem
5、entChange mgmtSecurityCAx IntegrationsERP/MRP IntegrationsVariant ManagementVisualizationMulti-SiteRDV模具模具CAD/CAM CAD/CAM 系统成功应用要素系统成功应用要素通用CAD/CAM SystemHuge assemblyFeature basedFreeform surfaceKnowledge based模具过程导向AutomationAssociationFlexibilityEasy to use用户部门TrainingStandardizationCustomization
6、Designer experienceTotal Product EngineeringTotal Product EngineeringKnowledge Driven AutomationKnowledge Driven AutomationKnowledge AutomationKnowledge Automationunique capability blends the power of unique capability blends the power of KBE with utility of high-end mechanical KBE with utility of h
7、igh-end mechanical CADCADProcess WizardsProcess Wizards Process Wizards, Advisors, Checkers, Process Wizards, Advisors, Checkers, Process Wizards, Advisors, Checkers, Quality & Validation ToolsQuality & Validation ToolsQuality & Validation ToolsInjection Mold Design/Manufacturing ProcessInjection Mo
8、ld Design/Manufacturing Process注塑模设计过程及相关技术注塑模设计过程及相关技术产品设计（面向制造设计）模具设计和制造过程导向复杂分模设计修改产品成型性 产品结构性产品成型性产品成型性 CAECAE注塑充模流动、保压模拟注塑冷却模拟注塑应力分析和翘曲模拟CAE CAE 产品产品产品产品MoldflowHUST flow产品结构性 分模线及死角Moldability CheckFind parting linesFind cavity & core facesSimulating cavity & core splitFind undercutsFind verti
9、cal and small draft facesFind crossover faces which to be splitFind openings which to be shut off产品结构性型腔面定义Color parting regionFind all cavity/core regionRegion faces can be re-assigned by usersProduct Design AdvisorProduct Design AdvisorValidate Part surfaces for:Positive & Negative FacesVertical F
10、acesUndercut areasDraft anglesAutomatic parting line generationCombine region/parting line definitionBenefitsBenefitsValidation for ManufacturabilitySimplify Parting by use of color assignment in downstream modulesHandle very complex parting easilyFind and color cavity/core regionsFace draft analysi
11、sSplit facesProvide Model/Face & Sharp corner informationVolume / sheet boundary informationExamines plastic part geometry for manufacturability产品结构性厚度分析Identification of thick areas that could form defects in the casting process产品结构性厚度分析产品结构性厚度分析Show minimum thickness area and valueImproved efficie
12、ncy is achieved through streamlined workflows created byThe understanding of specific detailed processesGuiding users through these processesLinking complex operations into automated sequencesProcess Wizards - Embedded Industry KnowledgeProcess Wizards - Embedded Industry KnowledgePrepackaged vertic
13、al solutions that provide expert guidance through industry-leading standard practices模具设计和制造模具设计和制造 导向技术导向技术 integrated design environmentProject guidance and Automatic assembly buildFamily mold supportMold Coordinate System set upShrinkageWorkpieceLayout Mold ToolsAutomated Parting functionalityMol
14、d Base CatalogsStandard Parts CatalogsEjector pin post processing Sliders and liftersSub-insert designGate designRunner designCooling designElectrode designMoldTrimPocketingBOM Automated draftingCasting Process AssistantView ManagerWhats the value of Mold Wizard? Whats the value of Mold Wizard? prod
15、uctivity gains in Mold Design of 2-to-1 to 10-to-1 through:process automationadvanced tools for parting libraries for molds and standard components. Time to market:Start mold design while part is still being altered through: associativity between Part and mold design.Swap modelInconsistent design pr
16、ocesses are solved by: providing a standardized, but still fully customizable design process.0MonthsConceptEngineering Field TIMEWhy?Why?Its all about productivity! Create it faster Change it fasterINNOVATION SPEED COST QUALITYINNOVATION SPEED COST QUALITY Do it right the first time.Focused solution
17、s provide extraordinary gains in specific product development areasTIMEMonths注塑模具设计和制造 复杂分模Parting linesParting surfacePatch upParting example3300 faces part4 days to create core/cavity manually4 hours finish association core/cavity 注塑注塑模具设计和制造模具设计和制造 Patch PatchAutomatically internal holeComplicate
18、d hole patchTrim Region PatchCreate a bounding box for selected facesTrim the bounding box with reference facesCreate sheet body patch by boundary edgesTrim Region PatchModel version Comparison and SwapRegardless translation format (IGES, Step,)Show new, removed, changed and remained facesAutomatic
19、update of Core & CavityBenefitsEasy to detect changes between different model versionsNo redundant work due to translation format of 3D models Enables quick mold updates Automatic Update of all downstream functionsProductProduct Change management Change managementUpdate to a new model version in no
20、timeProductProduct Change management Change managementAVI demo comparison- Other MCAD systems- Other EDS products注塑注塑模具设计和制造模具设计和制造 互换技术互换技术 Mold Mold DesignDesignCatiaCatiaParasolidParasolidSolid WorksSolid WorksOthers Others Pro-EngineerPro-EngineerSolid EdgeSolid EdgeI- I-deasdeas Replace dumb or
21、iginal product modelReplace dumb original product model Keep fully associative after swapping Keep fully associative after swapping Users can manually match edge/face Users can manually match edge/face After swap obsolete parting line and surfaces will be After swap obsolete parting line and surface
22、s will be automatically deleted (also patch surfaces)automatically deleted (also patch surfaces)Change Management: Associative SwapBenefitsNo redundant work due to translation format of 3D models Enables quick mold updates Automatic and Associative Update of all downstream functionsEasily create cus
23、tom libraries by creating a data fileno need to create models Automatically generate BOM and pocketsOne method used by several modulesOne interchangeable model for several catalogsOpen structure for customization of standard parts and moldbaseAdd/remove plates and components while associativity rema
24、insIndividual positioning for each mold componentBenefits:Create custom libraries without knowledge of UnigraphicsMold CustomizationMold CustomizationStandardStandard Libraries LibrariesMold Bases:Metric: DME, Hasco, Futaba, Universal, Rabourdin, STRACK, LKM, MisumiInch: DME, Hasco, Omni, Universal,
25、 DME interchangeable, Hasco interchangeableStandard parts:Metric: DME, Hasco, Futaba, Rabourdin, STRACKInch: DME, Hasco, Omni, Yates Hydraulic cylindersInterchangeable Standard PartsUse only one model and bitmap to cover different catalogsNew Bitmaps to clearly display parameters and Standard PartsE
26、asier to expand data baseEasily create custom libraries by creating a data fileno need to create models Automatically generate BOM and pocketsBenefits:Mirror Assembly WizardMirror Assembly WizardView managementView managementTree structure to manage Mold Assembly display1.Blank/Unblank2.Show selecte
27、d3.Freeze sub-assembly (for improved performance)4.Close/Open component (for improved performance) 5.Change component colorProgressive Die DesignSheet Metal StampingsProgressive Die Design/Manufacturing ProcessProgressive Die Design/Manufacturing ProcessSheet metal partsAutomatic CAM IntegrationDraw
28、ing & BOMProgressive Die Structure DesignProgressive Die Process DesignProgressive Die Process Planning冲压工艺性分析冲压工艺性分析冲压工艺性分析冲压工艺性分析冲压工艺设计与计算冲压工艺设计与计算冲压工艺设计与计算冲压工艺设计与计算条料排样条料排样条料排样条料排样模具总体结构设计模具总体结构设计模具总体结构设计模具总体结构设计模具零件详细设计（二维工程图）模具零件详细设计（二维工程图）模具零件详细设计（二维工程图）模具零件详细设计（二维工程图）模具零件制造模具零件制造模具零件制造模具零件制造装
29、配调试装配调试装配调试装配调试Challenges of Progressive Die Challenges of Progressive Die ManufacturersManufacturersTime to marketTime to market Progressive die design is on the product critical Progressive die design is on the product critical pathpathChanging product designsChanging product designs Product desig
30、n changes are made throughout Product design changes are made throughout the progressive die design process the progressive die design processProduct design dataProduct design dataDesigns originate in any CAD systemDesigns originate in any CAD systemHuman resourcesHuman resources Experienced die des
31、igners are expensive Experienced die designers are expensiveImprove the design process and make it effective Design wizardPre-processBlank layoutStrip layoutDie base designInsert design(Punch &die)Detailing(Drawings)CAM integrationProgressive Die Design Process / Contents Progressive Die Design Proc
32、ess / Contents Process PlanningFeature RecognitionFeature BuilderFeature SolidDumb SolidSheet Metal PartDie base designInsert group design Standard partRelief designDie Structure DesignPreprocess Map form featuresBlank layoutScrap/Overlap/Overcut designStrip layoutStrip simulationForce Center Calcul
33、ationOther FunctionsPocketingBOMDraftingView ManagementDesign ToolsKey TechnologyKnowledge Based DesignKnowledge Based Design Build in progressive die design Build in progressive die design Best PracticesBest Practices and and Know-howKnow-how Design Rules and Parameters are available in a design sy
34、stemEffectively capture, share and leverage sheet metal stamping knowledgeLess experienced designers can quickly achieve higher levels of proficiency The design process of Progressive dies is strongly experience dependentAn example of knowledge for process design Key Technology-continueDesign Associ
35、ation It happens often to change the design, A CAD system should have the ability to maintain the consistent. Sheet Metal Part Design Company Automotive Consumer product Electronics Sheet Metal Part Manufacturing CompanyRe-create Sheet Metal Part ModelProgressive Die DesignDie ManufacturingSheet Met
36、al Part Production Sheet Metal Part Sample & Final PartOrderRequirementQualityDelivery Time 3D Part or 2D DrawingChange requestChange requestWizard FocusWizard Focus ! !Change requestChange requestChange requestKey Technology-continueProductExterior boundary ChangeAdd/remove featureHole dimension ch
37、angeBlank LayoutAdjust blank layout: width, pitch, etc.Pre-ProcessUpdate BlankDefine new processScrap DesignAdjust scraps: remove, add scrapsStrip LayoutProcess DefinitionPitchBlank OrientationScrap DesignSheet Metal PartRemove AllInsert GroupDelete unused inserts, add new inserts Update process of
38、design association Key Technology-continue Structure Design AutomationStructure Design Automation There are more than 200-1000 parts designed in one progressive die. Automatically capture design knowledge Automatically capture design knowledge embedded in the process designembedded in the process de
39、signPre-store various kinds of pre-configured Pre-store various kinds of pre-configured die base libraries die base libraries Provide die base design tools to increase Provide die base design tools to increase design flexibility: add/remove die plate, design flexibility: add/remove die plate, guide
40、bush/post; split die plates; edit size guide bush/post; split die plates; edit size of any component, of any component, Use standard insert groups to speed up Use standard insert groups to speed up design procedure design procedure Provide all most important suppliers Provide all most important supp
41、liers catalogscatalogs ofof standard partsstandard partsAutomatically make pocketsAutomatically make pocketsKey Technology-continueProcess Design AutomationProcess Design AutomationAutomatically captures the sheet metal part Automatically captures the sheet metal part information, such as, unit, thi
42、ckness and information, such as, unit, thickness and sheet metal featuressheet metal featuresSupports various stamping processesSupports various stamping processesAutomatic strip layoutAutomatic strip layoutAutomatic operation simulationAutomatic operation simulationAutomatic process force and force
43、 Automatic process force and force center calculationcenter calculationAdvanced layout allows users to design Advanced layout allows users to design their own processes freelytheir own processes freely Strip Layout and SimulationStrip Layout and Simulation Automatic strip layoutAutomatic strip layou
44、tAutomatic operation simulationAutomatic operation simulationAutomatic process force and force center Automatic process force and force center calculationcalculationAdvanced layout allows users to design their Advanced layout allows users to design their own processes freelyown processes freelyCompu
45、ter Product Computer Product Structure DesignStructure DesignStructure DesignStructure DesignAutomotive Stamping DieAutomotive Stamping DieAutomotive Stamping Die Process Automotive Stamping Die Process ProductProcessingLayoutFormabilityPressDie DesignCAMDie Development Process - ChallengesDie Devel
46、opment Process - ChallengesChallengesIntegration with product designRapid response to product design changesCapturing die development knowledgeGlobal standardization of development processDiscovering problems prior to physical tryoutReducing die lead time (critical path)Reducing cost per dieAutomoti
47、veAutomotive Stamping Die Process Die ToolsStamping Die Process Die Tools TASKSTOOLSAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessProductProcessingLayoutFormabilityPressDie DesignCAMDie Operation Line-upAutomotive Stamping Die ProcessAutomotive Stamping Die Process3D Representation o
48、f manufacturing processAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessProcessing Items shown in GreenBenefits Processing model can be saved permanently in the part file. Parametric approach for easy update due to engineering changesVisual display of the state of the sheet metal at eac
49、h stage of manufactureLineup: collects the entire sequence of operations to manufacture a partOperation: collects the tasks performed in a given dieTipping sequence: assists in orienting the product part in press positionTip: orients the product part in the pressAutomotive Stamping Die ProcessAutomo
50、tive Stamping Die ProcessForm Task: describes areas of the product that are formed to final shapeArea Fill: allows holes, cutouts, trims of the product part to be filledCarryover: allows the sheet metal shape from the previous operation to be copied into this operation Automotive Stamping Die Proces
51、sAutomotive Stamping Die ProcessTrim Task: defines trimming and piercing tasks to be performed on the product partFlange Task: models the shape of the sheet metal after flanging has been performed Automotive Stamping Die ProcessAutomotive Stamping Die ProcessTASKSProductProcessingLayoutFormabilityPr
52、essDie DesignCAMAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessAutomotive Stamping Die Process - ToolbarsAutomotive Stamping Die Process - ToolbarsLayout Items shown in GreenBenefits Addendum and binder are defined parametrically using a section-based approachAutomatically creates an
53、accurate trim line to save the user many manual stepsSophisticated math provides smooth transitions from one section to another Geometric Engine of Addendum SurfaceAccurate Trim LineCreate complex surface in one stepSmooth transition of shapeCalculations consider formabilityBinder WrapCreate a devel
54、opable surface representing the shape of the sheet metal after the binder closesDie SectionCreate one or more sections to define the addendumRepresented as a series of parameters that can be edited individually by the userShape is optimized to conform to the constraints imposed AddendumCreate the ad
55、dendum surface based on one or more die section featuresDie Output CurvesCreate accurate trim line saving the user many manual stepsTASKSTOOLSProductProcessingLayoutFormabilityPressDie DesignCAMAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessFEA Process FlowchartFEA Process Flowchart S
56、tamping Design Stamping Design Methodology Methodology with the help of with the help of Advanced FEA Advanced FEA Process Modeling Process ModelingDeck Lid Outer SimulationDeck Lid Outer SimulationBlank - AKDQ Steel 0.040” GageBinder WrapDeck Lid Outer SimulationDeck Lid Outer SimulationThinning Co
57、ntourSplit RegionMetal Flow Was Required Eliminate Split ConditionMetal Flow Prediction: 80 mmMetal Flow Measurement: 70 mm13% ErrorDeck Lid Outer SimulationDeck Lid Outer SimulationAnimation Please Click HereAnimation Please Click HereLoose Metal ConditionLoose Metal ConditionDeck Lid Outer Simulat
58、ionDeck Lid Outer SimulationSpringback ContourOf Trimmed PanelMaximum Springback LocationPrediction: 3.7 mmMeasurement: 4.5 mm18% ErrorDeck Lid Outer SimulationDeck Lid Outer SimulationConclusions:Metal Flow, splitting, loose material condition and springback were predicted using FEMDie design must
59、be modified to improve formability / using draw beads to eliminate springback and loose materialTASKSTOOLSProductProcessingLayoutFormabilityPressDie DesignCAMAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessPress Model component Reads press model to size Die Operation Line-up Automotive
60、 Stamping Die ProcessAutomotive Stamping Die ProcessTASKSTOOLSProductProcessingLayoutFormabilityPressDie DesignCAMAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessAutomotive Stamping Die Process - ToolbarsAutomotive Stamping Die Process - ToolbarsDie Design Items shown in GreenBenefits
61、Dies modeled 100% as solidsImproves visualization and analysis which results in reduced physical try-out2D drawings eliminatedAutomates creation of casting patternsNew dies created by automated “morphing” of previous diesDramatically reduces cost and lead timeCaptures & leverages best practices Draw
62、 Die PunchUpper BinderLower BinderUpper PadFlange PostTrim PostSteel InsertScrap Cutter BaseTrim Steel & Scrap cutterFlange SteelDie DesignDie DesignAutomotive Stamping Die ProcessAutomotive Stamping Die ProcessAutomotive Stamping Die Process - ToolsAutomotive Stamping Die Process - Tools总结总结总结总结所有模具设计可以采用3D 数字化技术完成数字化技术使得虚拟设计(Virtual Design)成为现实, 可以完成设计,检测,视觉效果过程导向技术可以加速模具设计, 提高设计质量Thank you !Thank you !Questions?Questions?
