Mold products to achieve the form of green design and green manufacturing technology?

Proposed the specific realization of green technology in the form of green design and green manufacturing technology. On this basis. Compares the difference between the traditional design of the mold and the green design. Explained the realization method of green design and manufacturing of mold. Introduces the advanced manufacturing technology used in today's mold green manufacturing.

In recent years. In order to solve the global environmental pollution problem, a new "green manufacturing" concept is in vogue. Its purpose is to reduce product pollution of the environment, in the design of products throughout the life cycle process focusing on the consideration of product environmental attributes (environmental characteristics), the use of a green technology for all aspects of product design. Green manufacturing mainly includes the following aspects: first, manufacturing issues, including the whole process of the product life cycle; second, the environmental impact of the problem: third, the optimization of resources. Green manufacturing is the cross and organic integration of these three parts, is a comprehensive consideration of environmental impact and resource efficiency of the modern manufacturing model, the goal is to make the product from the design, manufacturing, packaging, transportation, use to end-of-life treatment of the entire product life cycle. Minimal negative impact on the environment. The highest efficiency in the use of resources.

Mold industry is the basis of manufacturing industrialized production, its high level of production technology. Has become an important symbol to measure the level of manufacturing. Previously, the traditional mold design process generally only need to consider the basic attributes of the mold products, such as mold function, quality, cost and life, etc., and little or even no consideration of its environmental attributes. Usually according to conventional thinking, a small mold products in the completion of the use of a pile of discarded "garbage". Recycling rate is low. This is the mold industry in the mold is difficult to open the most fundamental reasons. Because once the mold, mold materials are difficult to reuse, resulting in high cost. At the same time, the most important thing is that this also causes a serious waste of resources, energy, and mold materials contain toxic, harmful substances, will seriously pollute the ecological environment, harmful to human health.

Green mold not only refers to the use of small impact on the environment. It should also be from the manufacturing to the end of the entire life cycle of the environment to minimize the damage.

1 mold design

1.1 traditional design and green design

The traditional mold design only consider the design and manufacture of qualified molds. It does not give much consideration to whether the material has an impact on the environment. Produced after the use of the mold can be reprocessed and reuse. In the green design of the mold from start to finish are considered the impact on the environment, but also consider the recycling of the mold.

1.2 Material selection

The green degree of the mold material has an extremely important impact on the green performance of the final product. Green design material selection must be based on green materials. Abandon the chemical methods used in the past for surface treatment of materials. Replaced by physical methods to achieve the purpose of corrosion or easy to release the mold. Select high-quality mirror mold steel processing mold cavity; stainless steel materials to process corrosion-resistant molds to replace the electroplating; or with little harm to the environment and nickel-phosphorus plating instead of chromium plating.

Green materials should have the basic performance of: ① low pollution, low energy consumption, low cost: ② easy to process and processing pollution-free or less pollution: ③ degradable, reusable.

1.3 design standardization, standardization

Mold standardization is the organization of the premise of the professional production of mold. The specialized production of molds is to improve the quality of molds, shorten the mold manufacturing cycle, the key to reducing costs.

(1) adopt and purchase standard mold frame and other standard parts. Mold frame and standard parts by specialized manufacturers, enterprises through the social division of labor for production, so that the limited resources to optimize the allocation. Moulds are usually scrapped only after the convex and concave mold can no longer be used. But the mold frame is still basically intact. Therefore, the use of standard mold frame to help the reuse of the mold frame. Stamping mold and injection mold mold mold frame have many kinds, and these mold frame is also basically by the standard upper and lower mold seat. Guide pillar. Guide bushings and other components. At the same time. The standardization of the mold frame can make the production of the mold frame used in the equipment is greatly reduced, thus saving resources. Also conducive to management.

(2) the standardization of the mold structure unit, standardization. This can speed up the design, shorten the design cycle, and facilitate processing management.

1.4 Removable design

Mold in the process of use, some of the parts due to excessive friction and impact, wear and tear. At this time. Only need to replace this part of the parts mold can still be used. In addition. Sometimes as long as the replacement of work parts, you can realize the production of a new product. Non-detachable not only cause a large number of repeatable parts and materials waste. And because the waste is not good disposal. Will also seriously pollute the environment. Therefore, in the early stages of design should take into account the problem of disassembly: ① as far as possible to choose a common structure, in order to replace. ② under the premise of meeting the strength requirements. Try to use removable coupling. Such as threaded joints, without welding, riveting, etc..

1.5 CAD, CAPP, CAM, CAE applications

CAD, CAPP / CAM is the mold design towards the overall automation of major measures. The use of CAD / CAPP / CAM technology, can achieve less drawings or no drawings processing and management, saving resources, can shorten the mold design and manufacturing cycle. Can improve the success rate of mold development and mold quality. Today CAE technology has been widely used. First of all, you can apply CAD technology to design the general structure of the product. Mark out its basic size, and then use CAE technology for product structure analysis, feasibility analysis and process analysis. Now the CAD three-dimensional software (such as Pro / E, SolidWorks, UG, etc.) are basically integrated CAE technology, you can simulate the flow of materials and analyze its strength, stiffness, impact resistance experimental simulation. The use of CAD / CAE for the realization of parallel engineering provides the basic platform, so improve the mold design efficiency, shorten the entire design cycle. Realize the green product analysis.

1.6 Manufacturing Environment Design

The noise and pollution in the machinery production workshop, especially the stamping workshop, are very serious. It is a very big threat to the health of the staff, and it also interferes with the peace and quiet of the surrounding area, so it is necessary to control the noise generated during the mold design. Or even eliminated. Usually eliminate machine noise in the following ways: V-belt instead of gear transmission; friction clutch instead of rigid clutch; do a good job of dynamic balancing of the flywheel and other rotating bodies: in the press to produce noise in the main parts of the cover soundproof cover: the use of shock absorbers without impact mold frame and so on.

1.7 Packaging program design

The design of the packaging program mainly includes three aspects: the selection of packaging materials, packaging structure improvement and recycling of packaging materials and their waste. The use of packaging materials and waste has a huge impact on the environment. Especially some materials that are difficult to recycle or degrade, these materials can only be incinerated or buried. Therefore, the product packaging should be as simple as possible and the use of green packaging materials (non-toxic, non-polluting, easy to recycle, easy to degrade materials), which can reduce the waste of resources, but also reduce the pollution of the environment.

1.8 Recycling design

Mold recycling is in the mold design stage to consider the possibility of recycling after the use of mold and recycling methods and costs. The main content of the recycling design includes recyclable materials and symbols, recycling methods, recycling technology and economic assessment and recycling of the structural design. The main measures are as follows; ① use of mold materials that have less impact on the environment, such as non-toxic and harmless materials, renewable materials, easy to recycle materials, etc.; ② use of materials that can be reused; ③ refurbishment and reprocessing of used mold parts and components.

2 mold manufacturing

The use of mold advanced manufacturing technology. In the manufacturing process, the selection of production waste minimization, the lowest energy consumption of the manufacturing process is an important part of the realization of green manufacturing.

2.1 flexible manufacturing technology (FMS)

By a number of CNC equipment, material transportation and storage devices and computer control systems and can be quickly adjusted according to changes in manufacturing tasks and production varieties of automated manufacturing systems. It includes multiple flexible manufacturing units. According to the manufacturing task or production environment changes quickly adjusted to suit the multi-species, small and medium-sized batch production, it is simple to change the method of software to produce a variety of parts in any kind of parts.

2.2 High-speed cutting (HighSpeedMaclliIIing, HSM)

Mold manufacturing is an important area of high-speed processing applications. Mold cavity processing in the past has been monopolized by electrical processing, but its processing efficiency is low. And high-speed machining cutting force is small, can be milling hardened 60HRC mold steel, processing surface roughness value is very small; shallow cavity of the mold with a large radius of the rate of high-speed milling is available to replace the electrical machining: small curvature of the cavity of the depth of the high-speed milling processing as roughing and semi-finishing, electrical machining only as finishing. This can make the production efficiency greatly improved, shortened cycle. Steel cutting speed up to 600-800m/min.

High-speed cutting for mold manufacturing provides a new opportunity for development. It simplifies the processing means, shortens the processing cycle, improves processing efficiency, reduces processing costs, it is currently to a higher degree of agility, intelligence, integration direction, becoming the third generation of mold making technology.

2.3 virtual manufacturing technology (virtualManufacruring)

Virtual manufacturing is the various aspects of the manufacturing process. Including product design, processing, assembly, and even enterprise production organization and management and scheduling for unified modeling. Supported by software technology, with the help of high-performance hardware, the formation of an operational virtual manufacturing environment. In the computer local / wide-area network, to generate digital products. Realize product design, performance analysis, process decision-making, manufacturing assembly and quality inspection.

Virtual manufacturing features: ① no need to manufacture physical prototypes can predict product performance, saving manufacturing costs. Shorten the product development cycle; ② product development can be found early in the problem, to achieve timely feedback and correction; ③ software simulation form of product development; ④ the entire manufacturing activities have a high degree of parallelism.

The application of virtual manufacturing technology in the mold industry, can reduce the development cycle. Product design, mold design, mold manufacturing process, mold assembly debugging, test mold are carried out on the computer, thus improving production efficiency and product quality, and reduce production costs, fill the mold CAD, CAM and production management of the gap between.

2.4 Reverse engineering technology (Reverse Enginee-ng, RE)

Reverse engineering is the existing physical model scanning, the collection of its surface coordinate data information, according to the data collected to generate the model surface wireframe model. Afterwards, the model can be converted to concave and convex molds, scaled, rotated, translated and other processing according to the needs, and then automatically generate the mold processing program. The automatic generation of mold processing program can be applied to a wide range of CNC systems. This can greatly reduce human labor and waste, but also improve the success rate of mold manufacturing, the green manufacturing of mold has played a positive role in promoting.

2.5 rapid prototyping technology

It is the development of recent years, directly based on the CAD model of the rapid production of samples or parts of the group technology in general. It integrates CAD technology, CNC technology, laser technology and materials technology and other modern scientific and technological achievements. Is an important part of advanced manufacturing technology. The application of rapid prototyping technology has been developed from the prototype manufacturing to the mold manufacturing, as long as the mold design out, no matter how complex the structure of the mold, can be manufactured using rapid prototyping technology, which is incomparable to the traditional mold processing. Mold production cycle is greatly shortened. At the same time greatly save the cost of mold production, some of which can be reduced to a fraction of the traditional production methods or even a few tenths. Therefore, in practice, the real realization of the green manufacturing mold.

3 Conclusion

Green design and green manufacturing technology will become the main development direction of the machinery industry in this century. It is also an important way to improve the industrial environment. Currently. Product and process design and material selection system integration, user needs and product use integration, green manufacturing system information integration, green manufacturing process integration and other integration technology research has become an important research content. Green parallel engineering is a new mode of modern green product design and development. It designs products and their whole life cycle process in an integrated and parallel way. Strive to make product developers in the beginning of the design to take into account the entire life cycle of the product from the formation of the concept to the product end-of-life treatment of all factors. Such as quality, cost, user requirements, environmental impact, resource consumption and so on. Mold to achieve green design and manufacturing. Will greatly accelerate the rapid development of the mold industry, but also the inevitable trend of mold development. Thus truly realize the mold design and manufacturing of high quality, low cost, high efficiency, low pollution goals. Green technology will play a far-reaching impact on the future living environment of mankind.

Core keywords: mold