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In recent years, China's mold industry has made great progress. In 2005, the value of production and sales of molds was 61 billion yuan, and in 2010 it was about 112 billion yuan, which averaged 20 to 25 per year. The technical level of the mold has also been significantly improved. The performance of some domestic high-quality molds has approached the advanced level of similar foreign products. Most of these high-quality molds are plastic molds and stamping molds. Stamping die machining is inseparable from WEDM. According to statistics, there are about 80 WEDM in China for stamping die processing.
The status quo of China's advanced level stamping die marks the advanced level of stamping die is high-precision, long-life, multi-position progressive die, it has a complex structure, manufacturing is difficult, high precision, long life, high production efficiency and low consumption of material The characteristics of energy are one of the key mold types developed in China.
Representative motor core lamination automatic carbide multi-position progressive die, accuracy of 2m, step accuracy of 3m, double-rotation precision 1, tile precision 1m, surface roughness Ra 0.1 ~ 0.4m, Lifespan is 100 million times; automatic core lamination of motor cores, such as Auberge of USA, Kuroda of Japan, and Porsche of France, accuracy is 1m, step accuracy is 2m, and die life is 200 million times. Although the accuracy is close to the advanced level in foreign countries, there is a certain gap in life.
High-level air conditioner fin multi-position progressive die, accuracy of 2m, convex, concave die face nearly a thousand, punching gap of more than 300 in 0.01mm, one out of the fins up to 36 columns , Mold life of more than 200 million times; Japan's high-precision machine, the United States OAK, Italy's GBS company's 36-72 series of fins progressive die, accuracy of 2m, step accuracy of 3m, life more than 500 million times. Similarly, the accuracy is close to the advanced level in foreign countries, but there is a big gap in die life.
High-precision forming color tube electron gun parts (G5) 25 station carbide grade progressive die, precision of 2m, the mold is used in high-speed punching machine, punching 0.245mm thick non-magnetic stainless steel, after various processes, products Accuracy of 5m, mold life of more than 30 million times; Japan's Toshiba, Japan Hitachi and other companies manufacturing color tube electron gun parts progressive die, accuracy of 2m, step accuracy of 3m, die life of more than 50 million times. There is also a gap in die life.
High-performance integrated circuit frame 32 station progressive die, precision of 2m, high-speed punch speed of 350 ~ 500 beats / min, life of more than 30 million times; Japanese Yamada, the United States Aoboge and other companies manufacturing 100 The integrated circuit frame molds above the feet have an accuracy of 2m, a step accuracy of 3m, and a die life of 100 million times.
There is also a 50-station progressive mold for mobile phone connectors, such as independent innovation, accuracy of 2m, step accuracy of 3m, die life of 200 million times; digital camera spring sheet 18 station progressive die, connector 46 station progressive die, etc. Both have reached a higher level.
According to Luo Baihui, a mold specialist, the manufacturing level (accuracy, surface roughness, etc.) of representative precision, complex, high-efficiency, and long-life stamping dies in China has approached or reached advanced levels in foreign countries. Holes and other key parts basically rely on precision WEDM processing, indicating that China's sophisticated, complex, efficient, long-life stamping die technical progress and WEDM technology progress is closely related.
China's WEDM is divided into two categories: low-speed wire-cut WEDM (LSWEDM) and high-speed wire-WEDM (HSWEDM). Precision, high-efficiency, complex, long-life stamping die is generally processed by LSWEDM.
LSWEDM status at home and abroad and its application in the stamping mold In general, the technical content of LSWEDM is a high-tech product in the machine tool industry. However, from the perspective of domestic and international development, its own technical level can be roughly divided into: top level, high level Three levels of mid-range.
â—† Top machine This LSWEDM represents the highest level of the current, but basically is the product of Switzerland and Japan. The maximum cutting speed of this machine is 400-500mm2/min, the maximum processing accuracy is up to 1m, the surface roughness Ra is 0.05m, the processing surface has no degenerating layer, has a 0.02mm filament cutting function, complete functions, and a high degree of automation . For example: AGIECUTVERTEX series machine tools of Archie AG in Switzerland, the contour accuracy Tkm (Tkm = [maximum-minimum]/2) of the machined workpiece is 1m, Ra is 0.05m, and the processing surface has no deteriorating layer; ROBOFIL 2050TW of Charmilles, Switzerland, 6050TW double wire cutting machine, the highest processing accuracy of 1m, Ra is 0.05m, with a perfect surface quality; there are related machine tools such as Mitsubishi, Makino, and Sodick produced in Japan.
The biggest feature of this type of machine tool is that it not only has high machining accuracy, but also has no deteriorating layer on the surface. It can directly complete the precision machining of the mold. The life of the processed mold has reached the level of mechanical grinding.
â—† high-end machine (standard machine)
Such machines generally have automatic threading function, no resistance electrolysis power supply, and some also have filament (0.03mm) cutting function, the maximum cutting speed 400 ~ 500mm2/min, processing accuracy is generally 3m (accuracy definition is not the same) Ra is 0.2-0.3m. This type of machine tool is also basically manufactured by Swiss and Japanese companies. For example: AGI ECUTEXCELLENCE series of Swiss Archie, its processing accuracy (Tkm) 1.5m, Ra is 0.1m, has a higher level; Another example: AGIECUTPROGRESS series machine of Archie AG of Switzerland, the first cutting processing, its cutting speed is In the case of 350-500mm2/min, Ra can reach 0.8m, which is of great practical value, and it is the best in high-end machines. Machines with high-end machines also include Swiss Miller, Mitsubishi, Sodick, and Makino.
Such machine tools are also widely used for precision stamping die machining, but some still require grinding, grinding and machining.
â—† Mid-range machine (entry machine)
In order to meet the needs of the Chinese market, Swiss-Japanese and Japanese-owned (joint venture) companies in China also produce some mid-range machine tools. Such as: the relevant model machine tool produced by Japan Sodick Special (Suzhou); the relevant model machine tool in the Dalian Mitsubishi FA series; the machine tool of the Swiss Charmilles ROBOFIL 380, 390 and the XENON machine produced by Beijing Agie Charmilles. These machines are generally 60-80 thousand yuan/set (mid-range specifications). Taiwanese and Taiwanese companies producing on the mainland are also generally producing mid-range LSWEDMs.
Mid-range machine tools generally have no resistance, anti-electrolytic power supply, cutting speed of 300 ~ 400mm2 / min, processing accuracy of up to 5m, Ra is 0.4 ~ 0.5m.
It should be pointed out that according to the machine tool data provided by foreign countries, the evaluation methods of the machining accuracy of the companies are not the same. The materials, shapes, and sizes of the processed workpieces used to evaluate the machining accuracy are also different. Therefore, the top machine, the high-end machine, and the mid-range machine The statement is for reference only.
Due to the combination of LSWEDM's precision machining technology and the processing surface integrity technology, LSWEDM processing technology has reached a new level, and has promoted the advancement of precision, complex, long-life stamping die processing technology, making LSWEDM inaccurate in precision stamping die processing. The role of substitution. With the rapid development of the mold industry, the market of LSWEDM is also expanding. In 2003, the annual output of LSWEDM was only 800 units. By the end of 2004, it had reached 1800 units. In 2005, it reached 2,400 units. In 2006, the preliminary statistics were about 3,500 units. 25 to 3 billion RMB. It is expected that there will be more room for development in the future.
HSWEDM's technological progress HSWEDM is also used for stamping die processing, but generally in the middle and low-grade mold. Due to its practicality and economy, there is a large market in China. The current annual output is about 3.5 to 4 million units/year, and the output value is about 1.4 billion RMB. Mold manufacturing companies are basically equipped with such machine tools, some as many as 15 to 20, but this type of machine tool processing accuracy is low (size accuracy 0.015mm), the surface quality is poor, but the recent HSWEDM technology level has been compared Great progress.
According to the principles of LSWEDM's multiple cutting to realize precise machining, the research on HSWEDM's multiple cutting technology began and a breakthrough was made. For example, a number of companies in Shanghai, Suzhou New Sparks, and other companies have developed and produced new cutting HSWEDM products several times to improve the machining accuracy and surface quality. Achieving multi-cutting processing technology, the main problems to be solved are: control of the change of the electrode wire space shape during processing. For this purpose, a highly wear-resistant guide device, a constant tension control mechanism, and wire feed speed program control adjustment are used. Measures, which are the basic conditions for achieving multiple cuttings; a new type of pulse power with narrow pulse width and high peak current is an important guarantee for improving the level of multiple cutting processes; another example: using short-range reciprocating walking, changing the tracking control method, and performing the system Process testing develops multiple cutting software, etc.; improving the machine's movement accuracy is more important for multiple cutting HSWEDM.
Multiple cuts increase the level of HSWEDM's processing technology. For example: Suzhou New Spark Company's multiple cutting HSWEDM, after three cutting surface roughness Ra1.2m, the average processing speed 50mm2/min, the workpiece surface gloss, no cutting stripe. The maximum cutting speed of the machine tool is 190mm2/min, and the best surface roughness is Ra0.8m. In Shanghai, a large number of HSWEDM TP series are cut several times, Ra1.0m after three cuttings, and the machining accuracy (dimension difference) is 6.0m. The example of the Octagonal Workpiece (below) illustrates the application of multiple cutting techniques on HSWEDM, which greatly improves the level of HSWEDM processing technology.
Prospects of WEDM Mold Processing Technology With the continuous development of multi-position progressive dies, single-row progressive die technology has evolved to double-row multi-row progressive die technology; moreover, the function of multi-position progressive die has become increasingly complex. Take the motor core automatic lamination multi-position progressive die as an example, there are core large-scale automatic laminations, iron core double-row twisted slot laminations, multi-row straight laminations, large lamination laminations, double-turn laminations Wait. Therefore, the mold structure is more and more complex, the manufacturing difficulty is getting more and more difficult, and the requirements for precision machining are getting higher and higher. In order to meet the needs of mold development, we have promoted the development of WEDM to a higher level and represented the high-level development direction of WEDM. Should belong to LSWEDM. In the processing of LSWEDM, in order to reduce human intervention and ensure that the desired process indicators are achieved, automation and informatization are the development direction of LSWEDM.
In the top machine, high-end machine perfect expert system and electrode wire automatic exchange (multi-station automatic threading, double wire cutting automatic wire replacement), and further automatic workpiece exchange (AWC), in order to automatically complete the entire process, Reduce human intervention to achieve the intended processing goals.
The AGIEVISON CNC system in Ache, Switzerland cooperates with robots or handling devices and network functions to form an intelligent manufacturing system. For example, the American Archie EVOLUTION3LSWEDM of the United States's Chelar Tool & Die Co., Ltd. is equipped with an SD10 robot and PROWNSHARPECMM measuring machine capable of mounting 10 workpiece trays. The automatic unattended operation is achieved. The annual operating time of the machine tool has reached 6800 hours.
Swiss Miller's Millennium Edition CNC system is based on the WINDOWSNT operating system. It controls the built-in QCRW robot on the ROBOFIL 240CC/440CC and has a tray that can handle up to 100kg of workpieces. In addition, the CNC system has a standard configuration for accessing a local area network (LAN). An RJ-45 interface and an Ethernet card are also installed on the machine.
In terms of automation and informatization, there are also Japanese Sodick CNC systems and Japan Mitsubishi's 64-bit CNC systems. With these fully functional systems and standardized mechanical interfaces, robots via 3R systems or EROWA systems can be easily used. Realize the automatic exchange of workpieces (pallets).
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