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I. Production Processes
1. Cutting Processing
When milling the tooth profile, high - speed milling technology may be adopted. This technology can improve processing efficiency while ensuring processing precision. To ensure the milling precision, milling cutters with high rigidity and high precision may be used, and an on - line measurement system is used to monitor the processing dimensions of the tooth profile in real - time during the processing so that adjustments can be made in a timely manner. The control of the allowance after rough processing is also crucial. An excessive or insufficient allowance will affect the quality and efficiency of subsequent finishing. Modern CNC lathes are usually equipped with advanced allowance analysis software, which can accurately calculate the processing allowance required for each part.
2. Grinding Process
In the grinding process, ultra - precision grinding technology may be adopted, which can make the surface roughness of the mold reach the nanometer level. At the same time, in order to ensure the uniformity of grinding, the worktable of the grinding machine may be driven by a high - precision linear motor to ensure the accurate movement trajectory of the mold during the grinding process. To avoid grinding burns and other defects, an advanced cooling and lubrication system will be adopted. This system can accurately deliver the coolant to the grinding area, take away the grinding heat, and also play a lubricating role to improve the grinding quality. In the precision grinding stage, special grinding pastes and grinding tools may be used. For example, diamond grinding paste and high - precision grinding discs are adopted, and the surface finish is further improved by accurately controlling the grinding pressure and grinding time.
3. Electrical Discharge Machining (EDM) During electrical discharge machining, high - precision electrodes will be used. The production of electrodes usually adopts precision machining methods such as wire - cutting machining. Moreover, the electrical discharge machining machine may be equipped with an advanced discharge control system, which can accurately control the discharge energy and discharge frequency to ensure that the complex shapes processed have high - dimensional accuracy and good surface quality. To improve the efficiency and quality of electrical discharge machining, powder - mixed electrical discharge machining technology may also be adopted. That is, conductive powders of a certain particle size are mixed into the working fluid, which can improve the discharge state and make the processed surface more uniform and smooth.
II. Materials
Mold Steel In addition to common mold steels such as Cr12MoV and D2, some high - end high - finish twelve - tooth molds may adopt powder - metallurgy mold steels, such as ASP - 23, ASP - 30, etc. These powder - metallurgy steels have a finer and more uniform grain structure, and their hardness, toughness, and wear resistance are better than those of traditional mold steels. When quenching and tempering the mold steel, advanced heat - treatment processes such as vacuum quenching will be adopted. Vacuum quenching can reduce the oxidation and decarburization of the steel during the heating process, ensuring that the properties of the steel are fully utilized. At the same time, the tempering temperature and time will be accurately controlled during the tempering process to obtain an ideal combination of hardness and toughness.
III. Production Flow and Cycle
1. Design Stage In the mold design process, in addition to considering basic parameters such as size, shape, and tooth profile, finite element analysis (FEA) will also be carried out. Through finite element analysis, the stress distribution of the mold during the working process can be simulated, the structural design of the mold can be optimized, and the situation of stress concentration leading to mold damage during the use process can be avoided. This analysis process may increase the design cycle by 1 - 3 days, but it can greatly improve the reliability of the mold.
2. Processing Stage In the blank preparation process, for some molds with special requirements, flaw detection may be carried out on the steel blanks to ensure that there are no internal defects in the blanks. This detection process may take 1 - 2 days. In the rough processing process, in order to improve processing efficiency and quality, a compound processing machine tool may be adopted. This kind of machine tool can complete various processing procedures such as turning and milling on a single device, reducing the turnover time of the mold between different devices. In the finishing stage, for parts with high - precision requirements, multiple ultra - precision processing procedures may be added. For example, ion - beam polishing and other treatments may be carried out after grinding. This may extend the finishing time by 3 - 5 days, but it can significantly improve the surface quality of the mold.
3. Inspection and Debugging Stage In the inspection process, in addition to using conventional inspection equipment such as coordinate measuring machines, an optical scanner may also be used to perform three - dimensional scanning on the surface of the mold to obtain detailed data of the mold surface and compare it with the design model, so as to more accurately discover dimensional deviations and surface defects. This scanning process may take 1 - 2 days. When debugging and correcting according to the inspection results, advanced technologies such as laser repair may be adopted to repair local defects of the mold to ensure the repair quality and precision of the mold.
IV. Application Scenarios
1. Stamping Industry When stamping some high - strength alloy sheets, the advantages of the high - finish twelve - tooth mold are more obvious. For example, when stamping titanium alloy sheets in the aerospace field, the high - finish of the mold can reduce the friction between the sheet and the mold, prevent the surface of the sheet from being scratched, and ensure that the quality of the stamped aerospace components meets high - standard requirements. For the stamping of some ultra - thin metal sheets, the high - finish mold can better control the deformation of the sheets and improve the flatness and dimensional accuracy of the stamped products.
2. Injection Molding Industry (if applicable) When injecting some high - performance plastics, such as polyether - ether - ketone (PEEK), etc., the high - finish mold can ensure the smoothness and dimensional accuracy of the surface of plastic parts. Since high - performance plastics such as PEEK have high processing temperatures and viscosities, the high - finish mold can reduce the flow resistance of plastics in the mold and improve the quality and efficiency of injection molding. In the micro - injection molding field, the high - finish twelve - tooth mold can be used to produce micro - plastic gears and other parts. These micro - parts have extremely high requirements for the precision and surface quality of the mold, and the high - finish mold can meet this demand.
V. Precautions
1. During Use When stamping or injecting high - viscosity materials, in addition to controlling pressure and temperature, attention should also be paid to the material discharge and exhaust problems of the mold. For stamping molds, it is necessary to ensure that waste materials can be discharged smoothly to prevent waste materials from piling up and affecting the normal operation of the mold; for injection molds, the exhaust grooves should be reasonably designed to avoid bubbles and other defects during the injection molding process. During high - speed stamping or injection molding, vibration monitoring of the mold should be carried out to prevent the decrease or damage of the mold precision due to excessive mold vibration. Equipment such as acceleration sensors can be used to monitor the vibration of the mold in real - time.
2. During Storage When storing the mold for a long time, in addition to applying anti - rust oil, vacuum packaging and other methods can also be used to protect the mold to prevent moisture and corrosive substances in the air from damaging the mold. For molds with special coatings, contact between the coating and other hard objects should be avoided during storage to prevent damage to the coating.
3. Maintenance During the maintenance process of the mold, in addition to regularly inspecting and repairing worn or damaged parts, surface strengthening treatment can also be carried out on the mold. For example, ion - implantation and other technologies can be used to treat the surface of the mold to improve the hardness and wear resistance of the mold surface and extend the service life of the mold. According to the usage of the mold, a life prediction model of the mold should be established. By analyzing factors such as the usage frequency, processing materials, and working pressure of the mold, the remaining service life of the mold can be predicted, and preparations for mold replacement or major repair can be made in advance.
I. Production Processes
1. Cutting Processing
When milling the tooth profile, high - speed milling technology may be adopted. This technology can improve processing efficiency while ensuring processing precision. To ensure the milling precision, milling cutters with high rigidity and high precision may be used, and an on - line measurement system is used to monitor the processing dimensions of the tooth profile in real - time during the processing so that adjustments can be made in a timely manner. The control of the allowance after rough processing is also crucial. An excessive or insufficient allowance will affect the quality and efficiency of subsequent finishing. Modern CNC lathes are usually equipped with advanced allowance analysis software, which can accurately calculate the processing allowance required for each part.
2. Grinding Process
In the grinding process, ultra - precision grinding technology may be adopted, which can make the surface roughness of the mold reach the nanometer level. At the same time, in order to ensure the uniformity of grinding, the worktable of the grinding machine may be driven by a high - precision linear motor to ensure the accurate movement trajectory of the mold during the grinding process. To avoid grinding burns and other defects, an advanced cooling and lubrication system will be adopted. This system can accurately deliver the coolant to the grinding area, take away the grinding heat, and also play a lubricating role to improve the grinding quality. In the precision grinding stage, special grinding pastes and grinding tools may be used. For example, diamond grinding paste and high - precision grinding discs are adopted, and the surface finish is further improved by accurately controlling the grinding pressure and grinding time.
3. Electrical Discharge Machining (EDM) During electrical discharge machining, high - precision electrodes will be used. The production of electrodes usually adopts precision machining methods such as wire - cutting machining. Moreover, the electrical discharge machining machine may be equipped with an advanced discharge control system, which can accurately control the discharge energy and discharge frequency to ensure that the complex shapes processed have high - dimensional accuracy and good surface quality. To improve the efficiency and quality of electrical discharge machining, powder - mixed electrical discharge machining technology may also be adopted. That is, conductive powders of a certain particle size are mixed into the working fluid, which can improve the discharge state and make the processed surface more uniform and smooth.
II. Materials
Mold Steel In addition to common mold steels such as Cr12MoV and D2, some high - end high - finish twelve - tooth molds may adopt powder - metallurgy mold steels, such as ASP - 23, ASP - 30, etc. These powder - metallurgy steels have a finer and more uniform grain structure, and their hardness, toughness, and wear resistance are better than those of traditional mold steels. When quenching and tempering the mold steel, advanced heat - treatment processes such as vacuum quenching will be adopted. Vacuum quenching can reduce the oxidation and decarburization of the steel during the heating process, ensuring that the properties of the steel are fully utilized. At the same time, the tempering temperature and time will be accurately controlled during the tempering process to obtain an ideal combination of hardness and toughness.
III. Production Flow and Cycle
1. Design Stage In the mold design process, in addition to considering basic parameters such as size, shape, and tooth profile, finite element analysis (FEA) will also be carried out. Through finite element analysis, the stress distribution of the mold during the working process can be simulated, the structural design of the mold can be optimized, and the situation of stress concentration leading to mold damage during the use process can be avoided. This analysis process may increase the design cycle by 1 - 3 days, but it can greatly improve the reliability of the mold.
2. Processing Stage In the blank preparation process, for some molds with special requirements, flaw detection may be carried out on the steel blanks to ensure that there are no internal defects in the blanks. This detection process may take 1 - 2 days. In the rough processing process, in order to improve processing efficiency and quality, a compound processing machine tool may be adopted. This kind of machine tool can complete various processing procedures such as turning and milling on a single device, reducing the turnover time of the mold between different devices. In the finishing stage, for parts with high - precision requirements, multiple ultra - precision processing procedures may be added. For example, ion - beam polishing and other treatments may be carried out after grinding. This may extend the finishing time by 3 - 5 days, but it can significantly improve the surface quality of the mold.
3. Inspection and Debugging Stage In the inspection process, in addition to using conventional inspection equipment such as coordinate measuring machines, an optical scanner may also be used to perform three - dimensional scanning on the surface of the mold to obtain detailed data of the mold surface and compare it with the design model, so as to more accurately discover dimensional deviations and surface defects. This scanning process may take 1 - 2 days. When debugging and correcting according to the inspection results, advanced technologies such as laser repair may be adopted to repair local defects of the mold to ensure the repair quality and precision of the mold.
IV. Application Scenarios
1. Stamping Industry When stamping some high - strength alloy sheets, the advantages of the high - finish twelve - tooth mold are more obvious. For example, when stamping titanium alloy sheets in the aerospace field, the high - finish of the mold can reduce the friction between the sheet and the mold, prevent the surface of the sheet from being scratched, and ensure that the quality of the stamped aerospace components meets high - standard requirements. For the stamping of some ultra - thin metal sheets, the high - finish mold can better control the deformation of the sheets and improve the flatness and dimensional accuracy of the stamped products.
2. Injection Molding Industry (if applicable) When injecting some high - performance plastics, such as polyether - ether - ketone (PEEK), etc., the high - finish mold can ensure the smoothness and dimensional accuracy of the surface of plastic parts. Since high - performance plastics such as PEEK have high processing temperatures and viscosities, the high - finish mold can reduce the flow resistance of plastics in the mold and improve the quality and efficiency of injection molding. In the micro - injection molding field, the high - finish twelve - tooth mold can be used to produce micro - plastic gears and other parts. These micro - parts have extremely high requirements for the precision and surface quality of the mold, and the high - finish mold can meet this demand.
V. Precautions
1. During Use When stamping or injecting high - viscosity materials, in addition to controlling pressure and temperature, attention should also be paid to the material discharge and exhaust problems of the mold. For stamping molds, it is necessary to ensure that waste materials can be discharged smoothly to prevent waste materials from piling up and affecting the normal operation of the mold; for injection molds, the exhaust grooves should be reasonably designed to avoid bubbles and other defects during the injection molding process. During high - speed stamping or injection molding, vibration monitoring of the mold should be carried out to prevent the decrease or damage of the mold precision due to excessive mold vibration. Equipment such as acceleration sensors can be used to monitor the vibration of the mold in real - time.
2. During Storage When storing the mold for a long time, in addition to applying anti - rust oil, vacuum packaging and other methods can also be used to protect the mold to prevent moisture and corrosive substances in the air from damaging the mold. For molds with special coatings, contact between the coating and other hard objects should be avoided during storage to prevent damage to the coating.
3. Maintenance During the maintenance process of the mold, in addition to regularly inspecting and repairing worn or damaged parts, surface strengthening treatment can also be carried out on the mold. For example, ion - implantation and other technologies can be used to treat the surface of the mold to improve the hardness and wear resistance of the mold surface and extend the service life of the mold. According to the usage of the mold, a life prediction model of the mold should be established. By analyzing factors such as the usage frequency, processing materials, and working pressure of the mold, the remaining service life of the mold can be predicted, and preparations for mold replacement or major repair can be made in advance.
