In recent years, our country mould industry had great progress. 2005 output value of 61 billion yuan mold, an estimated 2006 in 72 billion, at an average annual rate of 20% ~ 25%. Mould technology level also have improved significantly and some domestic high quality mould performance has been close to the advanced level of the same products abroad, and these high quality mould for plastic mould and most punch mould. The punch mould processing without edm WEDM (WEDM). According to statistics, China has about 80% of WEDM used to punch mould processing.
The level of our country's advanced punch mould the status quo :Progressive metal stamping marks the advanced level is high precision, long life, multi-position into modules, it has the structure complex, manufacturing is difficult, high precision, long service life, high efficiency and low energy consumption characteristics of material, is China's focus on the development of precision mould one of varieties.
Representative motor iron core automatic laminated hard alloy multi-position into the mold, the accuracy of 2 μ m, step up to 3 μ m from the precision and accuracy of 1 μ m double back, the accuracy of 1 μ m patchwork, surface roughness Ra0.1 ~ 0.4 u m, life of 100 million; Mr Bloomberg, the United States, Japan, France treasure the black field while motor iron core double row automatic laminated module, and precision
For 1 μ m, step 2 μ m from the precision, die life, 200 million times. Although precision is already close to international advanced level, but life has certain disparity.
High levels of air conditioner fin multi-position into the mold, the accuracy of 2 μ m, convex, concave die working in the nearly and the cutting clearance for 0.01 mm of more than 300 place, a rushed out of the fin number of 36 columns, die life of 200 million or more; Japan high precision machine, the United States, OAK, Italy produced GBS 36 ~ 72 columns fin of progressive die, the accuracy of 2 μ m, step 3 μ m from the precision, life of 500 million or more. Also, precision is already close to international advanced level, but die life gap.
Reflect the CPT electron gun parts difficult forming (G5) 25 location of progressive die hard alloy and precision of 2 μ m, mould in high speed punch on the application and rushed the 0.245 mm thick without magnetic stainless steel, by the procedure, products of accuracy ± 5 μ m, mould life of 30 million or more; Japan's Toshiba, Japan's Hitachi etc companies manufacture of CPT electron gun parts of progressive die, the accuracy of 2 μ m, step 3 μ m from the precision, die life of 50 million or more. The same die life have difference.
High performance integrated circuit 32 location framework of progressive die, the accuracy of 2 μ m, at high speed punch up velocity 350 ~ 500 / cent, life for 30 million times more; Japan, the United States Mr Bloomberg, yamada companies such as the article 100 feet above manufacture of integrated circuit frame mode, the accuracy of 2 μ m, step 3 μ m from the precision, die life, 100 million times.
And as the independent innovation of mobile phone connector 50 location of progressive die, the accuracy of 2 μ m, step 3 μ m from the precision, die life, 200 million times; Digital camera the spring of 18 location of progressive die, connectors and location of progressive die and so on all reached higher level.
As can be seen, the representative of China's sophisticated, complex, high efficiency, long life of punch mould manufacturing level (accuracy, the surface roughness, etc) has come close to or reached international advanced level, and these type of the die holes, positioning hole and key parts basically rely on WEDM precision processing, our state's precision, complex, high efficiency, long life stamping die technology progress and WEDM technology progress closely related.
China's low speed WEDM divided into go silk WEDM (LSWEDM) and walking at high speed wire WEDM (HSWEDM) two kinds. Precise, efficient, complex, the long life stamping dies by processing general LSWEDM.
LSWEDM situation at home and abroad and its application in stamping die
Overall, the technical content of the machine tool LSWEDM industry of high-tech products, but from the domestic and foreign development situation, the level of technology itself can be divided into: top, top grade, intermediate 3 administrative levels.
Top machine
This LSWEDM represents the current highest level, but basically all is Switzerland and Japanese products. This kind of machine tool of the biggest cutting speed for 400 ~ 500 was the/min, processing precision can reach the highest degree is obtai μ m, the surface roughness Ra for 0.05 u m, processing surface have no metamorphic layer, have φ 0.02 mm thread cutting function, the function is all ready, a high degree of automation. For example: Switzerland of archie AGIE CUT VERTEX series machine tool, the machining precision of outline Tkm (Tkm = ± [maximum, the minimum] / 2)
Is +-1 m, Ra for 0.05 m, processing surface have no metamorphic layer; Switzerland of ROBOFIL2050TW, 6050 summer mill TW double wire cutting machine, the highest processing precision degree is obtai μ m, Ra for 0.05 u m, has a perfect processing surface quality; And such as Japan, makino carries out production, mitsubishi ShaDiKe related machine tools.
This kind of machine tool biggest characteristic is not only high machining accuracy and surface have no metamorphic layer, can be done directly mould precision processing, the processing of the die life, has reached the level of mechanical grinding.
High-grade machine (standard machine)
This kind of machine tools generally has to be automatic wear silk function, no resistance the electrolytic power, and some also have filaments (phi 0.03 mm) cutting function, the biggest cutting speed is 400 ~ 500 was the/min, processing precision in general ± 3 m (precision definition not the same), Ra for 0.2 ~ 0.3 u m, this kind of machine tools and basically by Switzerland and the Japanese company production. For example: Swiss archie series of AGIE CUT EXCELLENCE, the machining accuracy (Tkm) + /-1.5 m, Ra for 0.1 m, has the high level; And as: Switzerland of archie AGIE CUT PROGRESS series machine tool, the first time cutting processing, the cutting speed for 350 ~ 500 was the/min, Ra can reach 0.8 m, with a great practical value, this in high-end machine is outstanding person. With the level of high-grade machine machine tools and Switzerland mill, Japan mitsubishi, summer ShaDiKe, makino carries out production related machine tools.
This kind of machine tool also widely used in precision stamping mould processing, but some still need to research, grinding with processing.
Intermediate machine (entry machine)
Switzerland, Japan in China's owned (joint venture) enterprise in order to adapt to the needs of the Chinese market, but also some intermediate production machine tools. Such as: Japan ShaDiKe special (suzhou) production about model machine tools; Dalian mitsubishi FA series about type of machine tools; Switzerland ROBOFIL380, 390 summer mill machines and Beijing archie summer
Mill production of XENON machine tools. These machine tools in 60 ~ 800000 yuan commonly/Taiwan (intermediate specification). Taiwan and Taiwan in the mainland of the production enterprise general also in production
File level of LSWEDM.
Intermediate machine with no resistance, and generally the electrolytic power supply, cutting speed for 300 ~ 400 was the/min, processing precision can reach ± 5 μ m, Ra for 0.4 ~ 0.5 u m.
It should be pointed out, according to foreign provide the machine tool material, the company the machining accuracy of evaluation method is endless and same, used to evaluate the machining accuracy of processing the workpiece material, shape, size is also different, accordingly, about top machine, high-grade machine, intermediate machine expression is only for reference.
Because precision processing technology and processing LSWEDM surface integrity technology union, make LSWEDM processing technology on a new level, and promote the precision, complex, the long life stamping mould processing technology progress, make LSWEDM in precision stamping dies in processing has irreplaceable function. With the rapid development of die and mould industry is, LSWEDM
The market is being expanded in 2003, annual output 800 sets of domestic LSWEDM only, to 2004 already reach 1800, 2005 to 2400 units in 2006, preliminary statistics, about 3500 units, the value of about 25 to 3 billion RMB. Expected to come and the larger development space.
HSWEDM progress of technology
HSWEDM punch mould processing also for use, but general with medium and low grade mould give priority to. Because of its practicability and economy, so in the large market, at present the annual production is up to 3.5 ~ 40000 Taiwan/years or so, the value of about 1.4 billion yuan. Mould manufacturing enterprise basically are all armed with this kind of machine tools, some as many as 15 to 20 sets, but this kind of machine tool processing precision low (size accuracy of 0.015 mm), processing surface quality is bad, but recent HSWEDM technology standards have great progress.
According to many realize precision processing cutting LSWEDM principle, and began to carry on the multiple HSWEDM cutting technology research, and to improve. Such as Shanghai a lot, suzhou new spark and so on some enterprise development and production of many new products HSWEDM cutting, improve the machining accuracy, improved the surface quality. Realize cutting processing technology many times, the main problem is: in process of wire electrode space form of change control, for this reason, the high wear resistance of the orientation device, the constant tension control mechanism and the silk speed program control regulation go step, this is to realize the basic condition of cutting many times; The narrow pulse width, peak value of the current new pulse power is to improve the level of the cutting process many times guarantee; And as: the short-range reciprocating go silk, change the tracking control method and system process test development such as cutting software many times; Improve the precision machine tool for many times the movement cutting HSWEDM is more important.
Many times the cutting improve HSWEDM processing technology level. For example: the suzhou new spark company many times of HSWEDM cutting, in three times after cutting surface roughness Ra than 1.2 u m, average processing speed was/min 50 frequency, processing the surface gloss, without cutting stripe. The machine's maximum cutting speed was the 190 / min, best surface roughness Ra0.8 μ m; Shanghai a series of cutting HSWEDM TP many times, in three times after cutting Ra than 1.0 u m, processing precision (the difference in size) than 6.0 u m. In the company of the eight party workpiece machining, for example (table 1) and how many times the cutting technology in the application of HSWEDM, make HSWEDM processing technology a greater level ascension.
Project process indicators
The first cut the second cut the third cutting
Pulse parameters P P33.1 P3.1 P0.0.0
Compensation quantity f (mm) 0.14 0.10 0.09
Cutting speed v (was/min) 66 45 55
The surface roughness Ra (μ m) 3.45 1.40 0.80
Processing precision (mm) 0.05
WEDM mould processing technology outlook
As multi-position into the development of the mould, the single row of progressive die technology to double the column of progressive die technology development; And multi-position into the function of the model is more and more complicated. On motor iron core automatic laminated multi-position into the mold, for example, have large size to be automatic laminated core, the double row twist slot laminated, multi straight slot laminated, slalom laminated, double rotary laminated, etc. Therefore, the mould structure and more and more complex, manufacturing, precision processing increasingly difficult to demand more and more, in order to meet the needs of the development of the mould, promote the WEDM to a higher level of development, and representatives of the trend of WEDM high-level LSWEDM should belong to. In the process of LSWEDM, in order to reduce human intervention, ensure the expected process indicators, automation, informatization is the development direction of LSWEDM.
In the top machine, high-grade machine perfect expert system and electrode wire automatic exchange (to wear silk, progressive double wire cutting automatically change the silk), and on the basis of further realize the automatic exchange (AWC), for automatic completion of all processing process, reduce human intervention, in order to reach the predetermined processing target.
Switzerland's o AGIE VISON CNC system and robots or loading and unloading equipment and network combined with the function, composition intelligent manufacturing system. The United States, for example, Chelar work of the Swiss company die archie EVOLUTION 3 LSWEDM, with can install 10 workpiece tray SD10 type manipulators and PROWN&SHARPE CMM measuring machine, realize the automatic unattended operation, machine tool operation hours in up to 6800 h.
The Swiss company millennium edition of the summer mill CNC system is based on WINDOWS NT operating system in ROBOFIL240CC / 440 CC on built-in control QCRW type manipulator, have can weigh up to 100 kg workpiece loading and unloading the tray. In addition, CNC system has access to a local area network (LAN) standard configuration, and on board with a RJ-45 interface and Ethernet card.
In the automation, information, and Japan ShaDiKe CNC system, Japan mitsubishi company 64 CNC system, etc, with the function complete system, match with standardized mechanical interface, through the 3 R system or EROWA system robots, can be realized workpiece (pallet) automatic exchange.
