Mould Design & Manufacturing – Ib qho kev piav qhia
1. Pwm yog dab tsi?
Lub pwm yog ib qho kev cai -engineered, siab- cov cuab yeej precision uas muab cov duab, qhov ntev thiab qhov chaw tiav rau cov khoom siv raw (polymer yaj, kua hlau, los yog cov ntawv hlau) nyob rau hauv tshav kub, siab thiab/los yog lub sij hawm. Lub neej expectancy yog li ntawm 50 k txhaj tshuaj (prototype aluminium tool) mus rau> 1 lab txhaj tshuaj (hardened steel ntau lawm cuab yeej).
2. Cov Tsev Neeg Tseem Ceeb & Lawv Daim Ntawv Thov
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| Tsev neeg | Txheej txheem | Khoom siv | Yam Yam |
|---|---|---|---|
| Txhaj pwm | 1-300 MPa yaj siab, 30-400 degree | PE, PP, ABS, PC, PA, PEEK | Cov vaj tse, lub kaus mom, iav, cov khoom siv kho mob pov tseg |
| Tuag-casting tuag | 20-80 MPa hlau siab, 650-720 degree | Al, Mg, Zn alloys | Cav brackets, gearbox case, vaj tse |
| Progressive stamping cuab tam | 50-800 kN xovxwm quab yuam | Fe, Cu, Al strip | Connectors, shields, lead-frames, springs |
3. Txuj kev txhim kho ntws
DFM & Part Optimization- phab ntsa thickness, cov qauv, nyob rau hauv - txiav tsom xam, rooj vag & ejector layout
3-D Pwm Tsim- kab noj hniav / tub ntxhais, kab sib faib, pub, txias, cua, ejection, mechanics
Steel Specification- P20, H13, S136, 8407, Cu- alloy inserts; hardness 28-60 HRC, txheej (TiN, DLC)
CNC & EDM Machining- siab-ceev milling (± 0.005 mm), hlau / sinker EDM rau ntse tav
Polishing / Texturing- daim iav A1, SPI B3, VDI 3400, laser kev ntxhib los mos rau lub npe
Kev sib dhos & Spotting- xiav- kuaj xyuas, qhov tob tob 0.02–0.05 mm, ntsuas cua txias
Pwm sim (T0-T1-T2)- luv-steev, qhov rai kawm, daim ntawv qhia qhov ntev, Cpk kos npe-tawm
Kev tsim tawm tes- dhau- daim npav txheej txheem, kev npaj kho mob, daim ntawv teev npe, cov ntaub ntawv ntxaib digital
4. Cov Ntsiab Cai Tsim Nyog
Uniform phab ntsa & tav– 1–3 mm puag, tav=0.4–0.6 t, qhov siab Tsawg dua los yog sib npaug 3 t → balanced txias, tsis muaj dab dej
Draft & radii- Ntau dua lossis sib npaug rau 1℃ntawm du, Ntau dua lossis sib npaug li 2-3℃ntawm textured; sab hauv R Ntau dua lossis sib npaug ntawm 0.5 hli → yooj yim ejection
Rooj vag tswv yim- muab tso rau hauv tuab, zais vestige, txo qis weld- kab; valve- rooj vag rau cov tshuaj pleev ib ce siab
Ua ntej txias- channel suab 3-4 Ø, conformal rau kub -spots, bubblers rau sib sib zog nqus cores → 20-40% voj voog txiav
Ejection balanced- tus pin / lifter layout symmetrical, quab yuam <0.5 MPa projected cheeb tsam → tsis muaj xim dawb
Sab- ua kom tsawg- strips nyob rau hauv - txiav ntawm lifters; sliders ntxiv nqi & hnav → pom zoo rau txhua tus swb
Steel -kev nyab xeeb & cov ntaub ntawv- tawm 0.1-0.2 hli Tshuag ntawm qhov tseem ceeb dims; txhais A-B-C datums up- pem hauv ntej rau CMM
5. Advanced Manufacturing Technologies
Siab -ceev 5-axis milling- 30 k rpm, 0.1 mm pob-end, Ra 0.2 µm as-milled
Graphite / Cu EDM- 2 µm xov orbit, 0.05 mm rib tip tau
Conformal txias los ntawm LPBF- luam tawm Inconel inserts nrog sab hauv raws raws kab noj hniav curvature → 40-60% voj voog txo, qis warpage
Hauv -situ laser texturing- hloov tshuaj etch, digital repeatability, eco-phooj ywg
Induction-cov ntaub qhwv tawv tawv- 58 ± 2 HRC ntawm lub rooj vag lossis siab -shear aav, lub neej × 3
6. Zoo & Kev Ntsuas
CMM + laser scanning- kab noj hniav rau CAD kev sib piv Tsawg dua los yog sib npaug rau 0.02 hli
Hardness & txheej thickness- handheld ultrasonic, 1 µm raug
Siab & flow test– cua txias circuits 1.5 × P-op, tsis xau Tsawg dua los yog sib npaug rau 1 bar poob / 5 min
Kev ntsuas ntsuas- dimensional Cpk Ntau dua lossis sib npaug rau 1.33, kho kom zoo nkauj tsis zoo Tsawg dua lossis sib npaug li 1%, lub sijhawm voj voog ± 5% tsocai
7. Lub neej-Cycle & Maintenance
Npaj polishing- txhua 100 k txhaj tshuaj rau iav - puv resins; weld- kho tau ntawm H13
Kev faib tawm - kab rov - kov- 0.02 hli max hnav tso cai ua ntej re- grind & re-texture
Kub- khiav kev pabcuam- valve pins, cua sov, thermocouples stocked; swb <30 min
Digital twin update- sau txhua qhov kev hloov pauv engineering rau - tiam tom ntej
8. Sustainability & Kev Tswj Tus Nqi
Rov ua dua cov chips- cais steel / tooj liab alloys, rov qab mus rau zeb
Lub zog- ua haujlwm tau zoo- yoo mov noj, 15% hluav taws xob txiav
Sib koom pwm puag- Tsev neeg cov cuab yeej txo cov hlau yuav los ntawm 25%
ROI ntawm kub- khiav- them rov qab 6-12 lub hlis thaum txias - cov khoom siv khiav> 8% qhov hnyav
