用MasterCAM软件编程加工塑胶模的型腔

现代化模具生产中,随着对塑件功能要求的越来越高,塑件内部结构也设计得的越来越复杂。模具型芯的加工一般都是单件生产,一个复杂型芯的加工,往往需要用到多种现代化的数控加工手段。在生产中,运用Pro/ENGINEER、UG、MasterCAM等先进的CAD/CAM软件先进行产品的三维设计,然后根据产品的特点设计模具结构,确定模具型腔、分模面,生成模具型腔实体图、工程图,最后根据模具型腔的特点,拟定数控加工工艺,输入加工参数,生成刀具路径,生成加工程序并输送到数控机床的控制系统进行加工。这些步骤是现代化模具设计生产的过程和趋势,它使复杂…     

初始条件对粉末连杆锻造致密过程影响的模拟研究

为研究在不同初始条件(初始相对密度、摩擦因子)下对粉末连杆锻造致密过程的影响,运用塑性变形有限元软件DEFORM-3D对粉末连杆锻造过程进行了计算机模拟研究;研究结果表明,不同初始条件对粉末连杆锻造成形致密过程具有重要影响:(1)连杆锻造过程受到的等效应力集中在杆身部位,连杆两头的等效应力相对较小,说明其锻造过程各处所受等效应力不均匀,成形密度也不均匀;(2)初始相对密度较小的预锻坯锻造结束时,连杆大头处的材料不能达到致密,初始相对密度大的预成形坯,终锻致密效果好;(3)摩擦因数越大,连杆表面的材料流动阻力就越大,连杆大小两头就越难达到致密,说明摩擦因子对连杆相对密度分布均匀性有较大影响;通过对粉末连杆锻造致密过程影响的研究,为粉末连杆预锻坯和模具的优化设计及粉末锻造连杆的成形规律提供一定理论依据。     

K403材料应用下的模具切削加工技术探析

通过对模具型腔切削加工的影响因素的分析，引出相应的加工方法，从而进一步论述K403材料的特点与加工性能，最后阐释了模具型腔的发展趋势。     

Cimatron E4.0在四缸电喷排气管模具制造中的应用

一、前言随着计算机技术和数控技术的日益发展,数控CAD/CAMCAD/CAM软件编制出更为合理的?本文将结合当今世界CAM软件Cimatron E 4.0对四缸电喷排气管二、结构分析及其工艺特点四缸电喷排气管模具内部型腔结构较为复杂,1所示。图1 四缸电喷排气管模具下模结构如果采取传统的加工方法,不但工艺复杂,而保证。我们根据四缸电喷排气管的模具零件图,拟订其工艺方案如下:三、加工方案通过以上的分析,我们基于Cimatron E 4.0制定出了其数控加工自动编程过程和加工要点。1. 编制程序的前期准备(1) 在Cimatron E 4.0的菜单下将四缸电喷排气…     

铅笔刨面盖模具型芯的设计与加工

一、前言 在现代的模具设计和生产中,通常先应用Pro/ENGINEER、UG、MasterCAM等先进的CAD/CAM软件进行产品的3D图形设计,然后根据产品的图形特点设计模具结构,确定模具型腔、分型面和抽芯结构,生成模具型腔实体图,最后根据模具型腔实体图,编制加工程序在CNC加工中心上进行数控加工.     

浅谈注射模中的CAM运用

一前言随着国内外CAD/CAM技术及计算机硬件的发展产品造型技术从2D制图线框造型向曲面造型实体造型参数化造型及变量化造型发展同时也为CAM技术提供了基础使计算机能够真正意义上地控制生产制造过程一些构造复杂形状特殊精度很高的零件在CAM技术及数控设备的支持下得以加工尤不能忽视的是产品加工的速度精度质量等方面都较以往有了很大的提高那么如何运用CAD/CAM软件编制出较为合理的程序完成模具的加工任务呢本文将就塑料注射模的一些加工要点作论述二编制程序的前期思想及刀具的选用塑料注射模的加工主要可分为模具型腔型芯及电极…     

PowerMILL在标准化锻模锁扣中的应用

本文从锻造模具锁扣加工中存在的问题入手,分析了锻造模具锁扣存在的设计和加工问题,并且分析了所有锁扣的类型和具体的尺寸,从而总结归纳了锁扣的设计标准和数控精加工锁扣的加工参数标准,提高了锁扣的加工效率,减少了模具的加工时间。     

基于MasterCAM的带岛屿型腔零件的数控加工

带岛屿的型腔零件是模具加工中最常见的,该文介绍了用MasterCAM软件对带岛屿的型腔零件进行数控编程及加工的一般方法。文章针对加工工艺、数控编程、加工程序的模拟仿真以及后置处理等几个方面进行了详细分析与介绍。     

液化气灶旋钮注射模设计与数控仿真加工

随着现代机械工业发展,计算机辅助设计(CAD)和计算机辅助制造(CAM)已显示出巨大的潜力,并广泛应用于产品设计和机械制造中。数控加工技术已广泛应用于模具制造业,其中数控铣削是复杂模具零件的主要加工方法。对于简单的模具零件,通常采用手工编程的方法,但大多数模具的型芯和型腔,往往都具有比较复杂的曲面,要加工这样的曲面,手工编程是难以完成,因此需要借助于CAM软件编制加工程序,如Pro/ENGINEER、NX或MasterCAM等。     

SDRC集成的模具设计制造软件──I-DEAS CAD/GAE/CAM

Ｉ－ＤＥＡＳ软件采用以主模型为主的单一数据库和变量化造型技术,具备概念设计、基础设计和详细设计的功能,为模具的集成制造提供了优良的平台。 模具是面向订单式的生产方式,属于单件生产,制造过程复杂,要求交货时间短。如果利用ＣＡＤ、ＣＡＭ单元技术制造模具,制造精度低、周期长。为了解决上述难题,必须将并行工程技术引人到模具制造过程中。 在实际生产过程中,应用Ｉ－ＤＥＡＳ软件,可以将原来的模具结构设计→模具型腔→工艺准备→数控加工指令编程→数控加工串行工艺路线改为由不同的工程师同时进行设计、工艺准备的并行路…     

大功率柴油机连杆疲劳试验和数值模拟

对某型大功率柴油机连杆进行疲劳强度试验,观察连杆断口的微观形貌,分析连杆断裂的主要影响因素.试验结果表明:连杆杆身的残余压应力通常会使疲劳裂纹萌生在构件次表层,具有高平均应力水平的连杆小头对表层夹杂缺陷更加敏感.运用三维有限元数值计算方法和疲劳寿命预测理论,对连杆疲劳耐久性试验进行数值模拟.连杆疲劳试验与虚拟疲劳寿命预估结果的比较表明,基于材料S-N曲线的疲劳寿命预估方法在一定程度上能对疲劳试验中连杆破坏的薄弱部位和疲劳寿命进行模拟与预测.     

Dynamic simulation and neural network compliance control of an intelligent forging center

Automation of forging processes is important for both safety and efficiency in today's advanced manufacturing operations. This work supports the development of an Intelligent Open Die Forging System which will integrate state-of-the-art modelling techniques, automatic die selection and sequencing, full system dynamic simulation, automatic machine programming and coordination, and sensor-based process control to enable the production of more general and complex workpiece geometries than are achievable using current forging methods. Effective automation of this open die forging system requires the coordination and control of the major system components: press, robot, and furnace. In particular, forces exerted on the robot through its manipulation of the workpiece during forging must be minimized to avoid damage to the manipulator mechanism. In this paper, the application of neural networks for compliance control of the forging robot to minimize these forces is investigated. Effectiveness of the neural network-based compliance control module is evaluated through a full dynamic system simulation, which will later form a central part of the complete Intelligent Forging System. Dynamic simulation of the robot is achieved using an efficient O(N) recursive algorithm, while material flow of the workpiece is modeled with a finite element approach. Simulation and timing results for the complete processing system for a specific open die forging example are presented.     

基于预测模型的一万吨水压机模锻质量控制系统

通过对模锻过程中锻件质量影响因素的分析,提出了一种通过预测锻造比来控制锻件质量的方法;为解决一万吨多向模锻水压机模锻过程人为因素和系统干扰造成的质量波动问题提供了一种新思路,并根据模锻过程工艺特点,设计了基于预测模型的模锻过程质量闭环控制系统;该系统以模锻过程信息系统为基础,以预测模型为核心,通过适合的控制算法进行质量闭环控制实现一万吨多向模锻水压机模锻过程质量控制,以保障模锻过程质量稳定。     

A knowledge base model for complex forging die machining

Recent evolutions on forging process induce more complex shape on forging die. These evolutions, combined with High Speed Machining (HSM) process of forging die lead to important increase in time for machining preparation. In this context, an original approach for generating machining process based on machining knowledge is proposed in this paper. The core of this approach is to decompose a CAD model of complex forging die in geometrical features. Technological data and topological relations are aggregated to a geometrical feature in order to create machining features. Technological data, such as material, surface roughness and form tolerance are defined during forging process and dies design. These data are used to choose cutting tools and machining strategies. Topological relations define relative positions between the surfaces of the die CAD model. After machining features identification cutting tools and machining strategies currently used in HSM of forging die, are associated to them in order to generate machining sequences. A machining process model is proposed to formalize the links between information imbedded in the machining features and the parameters of cutting tools and machining strategies. At last machining sequences are grouped and ordered to generate the complete die machining process. In this paper the identification of geometrical features is detailed. Geometrical features identification is based on machining knowledge formalization which is translated in the generation of maps from STL models. A map based on the contact area between cutting tools and die shape gives basic geometrical features which are connected or not according to the continuity maps. The proposed approach is illustrated by an application on an industrial study case which was accomplished as part of collaboration.     

Radial forging force prediction through MR,ANN, and ANFIS models

The application of finite element method and intelligent systems techniques to predict the applied force during the radial forging process is studied. Radial forging is a unique process used for the precision forging of round and tubular components, with or without an internal profile. More than 800 radial forging machines are currently operating worldwide. Since the maximum forging force per die is constant, determining the die force before the process can prevent die damage and material wastage. Then, the results of the FE simulation are applied for two intelligent forecasting systems in artificial neural network and adaptive neuro-fuzzy inference system. Initial billet temperature, die inlet angle, feed rate, and reduction in cross-section are applied as input parameters, and radial forging force is applied as the output parameter. Finally, the results of these two intelligent systems are compared with the multiple regressions method. A sensitivity analysis is carried out to determine how the radial forging force is influenced by the input parameters.     

基于Halcon的汽车连杆工件WD-2的图像处理方法研究

对某一汽车连杆工件WD-2的图像处理方法进行分析。考虑到需要在背景中有效识别该工件的特征,提出一种新的规则加入到图像滤波方法中。借助Halcon软件实现图像获取、去噪、边缘灰度最大化处理,以及特征提取。在现有文献中,基本是以单个规则对图像进行处理,无法满足对特定目标的特征识别要求。因此,提出一种结合两个规则的滤波方法。设置两组实验,一组采用单个规则方法,另外一组采用加入新规则的方法。将得到的效果图进行Imagetest软件评测以及识别率比较,加入新规则的方法得到了最理想的结果,从而验证了该方法更适用于处理WD-2汽车连杆工件的图像。     

基于机器视觉的发动机连杆质量多参数检测

作为主要传动零部件,汽车发动机连杆质量直接影响发动机的传动性能,最终影响着整车的安全性.针对同时实现汽车发动机连杆几何参数、弯曲、扭曲检测问题,提出基于机器视觉的发动机连杆质量多参数检测.构建汽车发动机连杆质量多参数检测视觉系统,研究基于多阈值分析与同态滤波的图像预处理,去除发动机连杆图像中的阴影、增强图像对比度.基于...     

A knowledge-based approach to design for manufacturability

In the light of growing global competition, organizations around the world today are constantly under pressure to produce high-quality products at an economical price. The integration of design and manufacturing activities into one common engineering effort has been recognized as a key strategy for survival and growth. Design for manufacturability (DFM) is an approach to design that fosters the simultaneous involvement of product design and process design. The implementation of the DFM approach requires the collaboration of both the design and manufacturing functions within an organization. Many reasons can be cited for the inability to implement the DFM approach effectively, including: lack of interdisciplinary expertise of designers; inflexibility in organizational structure, which hinders interaction between design and manufacturing functions; lack of manufacturing cost information at the design phase; and absence of integrated engineering effort intended to maximize functional and manufacturability objectives. The purpose of this research is to show how expert systems methodology could be used to provide manufacturability expertise during the design phase of a product. An object- and rule-based expert system has been developed that has the capability: (1) to make process selection decisions based on a set of design and production parameters to achieve cost-effective manufacture; and (2) to estimate manufacturing cost based on the identified processes. The expertise for primary process selection is developed for casting and forging processes. The specialized processes considered are die casting, investment casting, sand casting, precision forging, open die forging and conventional die forging. The processes considered for secondary process selection are end milling and drilling. The cost estimation expertise is developed for the die casting process, the milling and drilling operations, and the manual assembly operations. The results obtained from the application of the expert system suggest that the use of expert systems methodology is a feasible method for implementing the DFM approach.     

Process selection for the design of aluminum components

This paper describes a method for process selection of aluminum components in the early stages of design. Aluminum has many advantages in a variety of applications in its manufacturability and recyclability. Yet, engineers who are trained to design steel components do not take full advantage of this material. The main reason is that engineers tend to be unaware of the many economical processing methods for aluminum. We have developed a program that combines preliminary screening of processes with normalized cost analysis. Design compatibility analysis (DCA) ranks each process based on its feasibility with the basic geometry, material, and production requirements. For top candidates, the program employs external cost routines for detailed comparisons. The primary processes considered are extrusion, sheet forming, forging, die casting, and sand casting. The program extends its compatibility and cost analysis to secondary operations such as bending and machining. The program should be useful for engineer training and as a preliminary design tool. The program uses HyperCard as a front-end, Prolog for logic-based analysis, and Excel for cost calculations.