The hottest new mold research based on Rapid Proto

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The research and development of new molds based on rapid prototyping (RP) and virtual manufacturing (VM)

time is constantly advancing the development of the times. "Automation" is no longer the most popular word in engineering development. Instead, "humanization" is becoming increasingly important. In order to realize the ultimate goal of humanized design of products, the intermediate molding stage can not be ignored

although the traditional cad/cam system has realized rapid modeling, achieved efficient design and manufacturing to a certain extent, and is widely used in aerospace, shipbuilding, locomotives and other industrial products and life products, with the development of the complexity of market demand and the freedom of the product itself, when these systems can no longer meet people's individual needs, they show the lack of humanization. Rapid prototyping (RP), which has been gradually developed since the end of last century, has greatly improved the shortcomings of the original traditional system in human-computer communication. In the rapid prototyping system, users can directly design and establish the physical model of their envisaged products through the participation of local or even remote rapid prototyping instruments. Such an interface, in the process of product research and development modeling, users can also participate in it, express their ideas and purposes, so as to truly realize humanized design

Dr. Heinemann, the director of Audi in Germany, once mentioned such a legend in his speech to express Audi's product development concept

it can be seen that the three elements of quality, time and cost play a decisive role in the final successful product. Then from these three aspects, let's make a comparison between traditional cad/cam system and modern RP system

(1) time. For example, when the traditional design has problems in the mold making stage, it can only go back to the design stage for improvement. In RP system, during virtual modeling, the product designer can discuss with the technical engineer through the sub virtual model, and there is no need to stay in the whole design process because of a simple draft angle problem. Production efficiency is naturally improved

(2) quality. In the process of virtual modeling, RP system can not only simulate the geometric shape of the product, but also the dynamic characteristics of the product, such as coherence, strength, hardness and so on, and then simulate the whole processing environment. In such repeated tests, the quality of the product is of course relatively high. And the precision of the mold is higher than that of the traditional mold on the basis of moving the experimental machine to the pre made one

(3) cost. Because the traditional product development and planning are based on a lot of paper-based document information, such as engineering drawings, material costs, purchase order and so on. The RP system is based on the electronic model for completing these preliminary work without leaving any impurities in the tube. Although the material price of later manufacturing solid models is relatively expensive, from the perspective of long-term return on investment, efficiency and quality promote the market, win customers, and save other costs such as delay in advertising and transportation, so on the whole, the cost is saved

therefore, based on the above characteristics and advantages of rapid prototyping system, it has been widely used and has a very good market prospect. A series of RP instruments designed and developed by the famous strata sys company in the United States have been highly praised by the market. Innovative companies such as Eaton and caterpillar have won a large number of customers by combining RP technology with computers and networks

however, RP system still has some shortcomings. At present, RP systems mainly include LOM (Laminated Object Manufacturing) layered solid manufacturing method, SL (stereo lithography) stereolithography molding method, FDM (fused deposition modeling) melting deposition molding method, SLS (selective laser sintering) selective laser sintering method and mm (model maker) modeling method. No matter which kind, they all have their own defects to a certain extent, such as difficulty in building parts with particularly complex structures, limited optional molding materials, insufficient environmental protection in the molding process, and so on. Then, if the model is completely virtual on the original basis, that is, the whole modeling process is completed digitally, then all the problems existing in the above solid modeling process will be solved. This is virtual manufacturing system (VM)

the so-called virtual manufacturing is actually the mapping of the actual manufacturing process on the computer. That is, using computer simulation and virtual reality technology, with the support of high-performance computers and high-speed networks, and with the cooperation of groups on computers, to manage and control the product manufacturing process, such as product design, process planning, processing and manufacturing, performance analysis, quality inspection, and so on, so as to enhance the decision-making and control ability at all levels of the manufacturing process. It is based on information technology, simulation technology and virtual reality technology. With the help of virtual environment, it can obtain all kinds of information. Before the construction of product design or manufacturing system is realized, people can experience the assembly performance of products or the state of assembly system in the future, so as to further approach humanized design. The key and advantages of virtual manufacturing are briefly illustrated with a chart below

it can be seen that virtual manufacturing technology has achieved its characteristics of high efficiency, environmental protection and high quality in theoretical system, open architecture, shape simulation, assembly simulation, man-machine cooperation, motion and dynamics simulation, machining simulation and so on. Therefore, it is widely used in major and small industries, such as coal mining, medical treatment and so on. Especially in the automobile manufacturing process, such as the world's first-line automobile manufacturers, General Motors (GM), Ford (Ford), Chrysler (Daimler Chrysler). Based on its application to virtual manufacturing technology, its R & D work cycle changes from 7.1.3. When the product has one of the following conditions, type inspection should be carried out; The monthly period is shortened to 18 months, which is about% lower, and the cost is also reduced by 50%. Taking the car shape panel as an example, its part information generally includes overall information, geometric information, technical requirements information, and implicit process information. The simulation system developed by combining virtual manufacturing system with computer can meet the requirements of design and manufacturing. This simulation system is described in a divergent way

in these four main processes, according to product demand, market demand, and more importantly, customer demand, the rational application of virtual manufacturing technology combined with networking technology can realize various information integrated management, correct evaluation of product research and development, green manufacturing, energy conservation, and shortening the R & D life cycle, so as to realize the so-called humanized product research and development

in general, rapid prototyping technology and virtual manufacturing technology still have some deficiencies and immaturity, but this just shows that they have a broad space for development. Social development, technological progress, product innovation, people's personalized pursuit of life, and so on, all of which require the humanized characteristics of modern product design. The further improvement of rapid prototyping technology and virtual manufacturing technology will surely realize the real humanized design


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