Fine manufacturing of high-end automotive molds

Dai Zengliang, Chief, Programming Technology Division, Mould Center, Great Wall Motor Co., Ltd.

At present, automobile companies are developing towards higher low-carbon environmental protection and safety based on traditional manufacturing. The requirements for the mold are not only the surface quality and dimensional accuracy, but also the formation of the part is safe and stable. At the same time, the dangerous zone and safety zone of the forming curve should be analyzed. Therefore, we can't simply use the traditional manufacturing process to improve the qualified performance of the parts, but to achieve the qualification and stability of the molds and parts with a more refined manufacturing process.

With the development of molds, the technology of domestic automobile equipment has been relying on the extensive workmanship mode of the fitter and the fitter as the core. It is gradually replaced by the intensive modern production management mode based on technology and design-centered. . The advancement of the mold manufacturing process technology, debugging problems are advanced to the processing of digital design, and even the stamping process design stage, has become a widely used mode. The traditional concept of mold production is also being replaced by the concept of high-tech management (see Figure 1).

figure 1

The traditional manufacturing process shifts to the forefront of technology development, making the production process more convenient. From drawing to subsequent analysis, analysis and compensation of springback, analysis of outer impact line, drift line, and sharp edge. In addition, based on the CAE analysis, the method of CAE analysis is modified according to the result of the debugging, and the problem in the field is reproduced in the computer; the correction scheme is provided to guide the on-site debugging; the strain difference cloud map of the CAE analysis and the actual part can be made, Workpiece mesh strain analysis.

Processing digital-analog design technology (see Figure 2), based on material thinning and mold surface compensation of dynamic elastic deformation of the mold, the material is uneven during the drawing process, and the surface of the mold convex and concave model in which the NC machining is fully in place is uniform. When the material is thick, the gap between the profile and the sheet is uneven, which affects the coloring rate of the part. After obtaining the required forming force by sheet metal stamping CAE analysis, the forming force is directly applied to the lower mold, and the analysis result is that the lower mold is concave. Therefore, before the NC machining, we consider the relevant factors that affect the mold clamping rate, compensate the machining die surface, reduce the manual training and improve the mold clamping rate.

In addition, the virtual mold clamping technology (see Figure 3), using fast data acquisition means, data collection and analysis of key parts of the mold, and data virtual mold clamping, intuitive analysis of the actual mold clamping gap, no mold clamping Before we collected the data, we dealt with some problems in time, thus reducing the commissioning time of the hydraulic machine .

figure 2

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