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English
Mold production process refers to the entire manufacturing process from raw materials to finished molds, which is a concentrated embodiment of precision mechanical manufacturing technology. Modern mold manufacturing mainly includes the following key process flows:
1、 Mold design and process planning
This is the starting point of the production process, which mainly includes:
Digital design: using CAD software for mold 3D structure design, determining parting surface, cavity layout, cooling system, ejection mechanism, etc
Process analysis: Conduct mold flow analysis and structural analysis through CAE software, predict and solve potential problems
Process specification formulation: Prepare detailed processing process cards, determine the processing sequence, process methods, and technical requirements for each part
2、 Material preparation and rough machining
Material selection: Choose suitable mold steel based on mold type (injection mold, die-casting mold, stamping mold) and working conditions, such as P20, 718, H13, S136, etc
Material pretreatment: forging and annealing treatment are carried out to improve the internal structure of the material and eliminate internal stress
Rough machining of raw materials: traditional mechanical processing methods such as milling and planing are used to remove most of the excess, preparing for subsequent precision machining
3、 Precision machining and heat treatment
This is the core process of mold manufacturing:
Numerical Control Machining (CNC)
Precision milling of complex surfaces using three-axis and five axis machining centers
The processing accuracy can reach ± 0.005-0.02mm, and the surface roughness Ra is 0.8-1.6 μ m
Complete the processing of main molded parts such as cavities, cores, and sliders
Special processing technology
Electric discharge machining (EDM): used for machining deep grooves, corner cleaning, complex irregular holes, and hard materials that are difficult for CNC to complete
Forming machine is used for processing complex cavities
Wire cutting is used for machining precision contours and through holes
Slow wire cutting: Processing accuracy can reach ± 0.002mm, surface roughness Ra 0.4 μ m, used for high-precision inserts, punches, etc
Heat treatment and surface treatment
Overall heat treatment: quenching+tempering to improve the overall hardness and wear resistance of the mold
Vacuum heat treatment: reduce oxidation and decarburization, maintain surface smoothness
Surface strengthening treatment: nitriding, PVD/CVD coating (TiN, TiCN, DLC, etc.), significantly improving surface hardness, wear resistance, and corrosion resistance
4、 Precision machining and polishing
Coordinate grinding machine processing: Processing precision hole systems to ensure hole position accuracy and aperture accuracy
Precision surface grinding: ensuring the flatness and perpendicularity of the mold parting surface and mating surface
Mold polishing: manual or mechanical polishing (ultrasonic polishing, magnetic polishing)
Polishing the surface of the cavity to a mirror finish (Ra 0.025-0.1 μ m) or the desired texture (etching treatment)
The polishing quality directly affects the appearance and demolding performance of the product
5、 Standard component assembly and debugging
Standard component installation: Install standard accessories such as guide post guide sleeve, top pin, slider component, cooling joint, etc
Mold assembly: Assemble all parts into a complete mold according to the assembly drawing
Trial molding and debugging
Conduct trial production on the corresponding molding equipment
Adjust process parameters (temperature, pressure, time)
Check the size and appearance of the product, and solve problems such as burrs, shrinkage marks, and insufficient filling
Optimize the cooling system effect and demolding performance
6、 Testing and Quality Control
Throughout the entire production process:
Process inspection: Use calipers, micrometers, height gauges, etc. for size inspection after each process
Precision measurement: using a coordinate measuring machine (CMM) to detect complex surfaces and positional accuracy
3D scanning comparison: laser scanning of actual molds, comparative analysis with the original 3D model
Hardness testing: Ensure that the hardness after heat treatment meets the design requirements
7、 Application of Modern Advanced Manufacturing Technology
High speed milling (HSM): The spindle speed can reach 20000-40000rpm, achieving high-precision and high-efficiency machining
Composite processing technology: turning milling composite center, completing multiple processes with one clamping
Additive Manufacturing (3D Printing)
Metal 3D printing manufacturing of conformal cooling water channels significantly improves cooling efficiency
Printing complex structured mold inserts to reduce assembly components
Intelligent Manufacturing: IoT based Machine Tool Networking, Production Process Monitoring, Digital Factory Management System
8、 Maintenance and upkeep
Maintenance during the production process: regular cleaning, lubrication, and inspection of vulnerable parts condition
Storage management: Molds that are not used for a long time need to be coated with anti rust oil and stored in a dry environment
Repair and refurbishment: repair worn parts, replace damaged parts, and extend the service life of molds
The mold production process is a complex process that is technology intensive and involves multiple collaborative processes. Modern mold manufacturing is developing towards high precision, high efficiency, long lifespan, and intelligence, with digital technology running through the entire process of design, processing, and testing. Successful mold production not only requires advanced equipment, but also experienced technicians and strict quality control systems to produce precision molds that meet the needs of high-quality and high-efficiency production.
