Design of automobile cover mold for MFC modeling1

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Design of automobile cover mold for MFC modeling1 [Copy link]

1. Automobile Covering Parts Mold
1.1. Development of Mold Industry
In recent years, the development of molds has been paid more and more attention by people. It embodies various high-tech technologies and can quickly and accurately directly shape, weld and assemble materials into parts, components or products. Its efficiency, precision, streamline, ultra-miniaturization, energy saving, environmental protection, as well as product performance and appearance are all beyond the reach of traditional process methods. Molds are important equipment of modern manufacturing technology. They are a symbol of the manufacturing level and production capacity of a country or enterprise.
1.2. The importance of automobile covering parts mold design
Automobile covering parts mold is one of the important components of automobile molds. The quality of its production and manufacturing directly affects the subsequent production of automobiles. It is also an important guarantee for automobile personalization and upgrading. Therefore, how to effectively improve the production efficiency of automobile covering parts molds has become a very meaningful task.
In the entire manufacturing process of automobile molds, the design process of molds is not only a time-consuming task, but also an important basis for actual processing in the future. According to Dowlatshahi's data:
1. 70% of the manufacturing cost of General Motors' truck transmission parts depends on the design stage.
2. Ford Motor Company’s experience: Among the four major manufacturing factors of design, raw materials, labor and general management expenses of the enterprise, 70% of production savings come from design innovation.
3. Product design generally accounts for about 5% to 15% of product cost, but it determines 75% of total manufacturing cost and 80% of product quality and performance. [1]
It can be seen that the role of design work is particularly important. However, in actual work, a lot of time is often spent on mold structure design, and the time spent on surface design is correspondingly compressed, which is exactly the opposite of what we need. Therefore, how to effectively shorten the time for structural design so that staff can spend more time on automobile surface design is particularly important.
3. The current situation and general process of automobile cover mold design
3.1. The current situation of automobile cover mold design
In the design process, the design work of designers and the work of process, manufacturing and assembly personnel often conflict with each other, resulting in additional work such as rework and renovation, which not only increases the cost of product production, but also delays the construction period and the timing of product launch in the market in serious cases, leading to the serious consequence of losing market competitiveness.
The most direct impact should be the conflict between the designer's design and the MFC modeling. It often happens that the designer's design of the MFC modeling cannot be realized, resulting in constant rework and negotiation between the two parties.
3.2. MFC modeling design
MFC is lost foam casting (also known as solid casting, Taiwan called Bao Lilong casting). This process is widely used in foreign automobile mold castings. The model is made of plastic (polystyrene plastic) instead of wood. The FMC model produced is economical and applicable, saving costs, with less machining allowance on the casting surface and high precision. Because the solid model casting of this process simplifies the modeling process, there is no need to perform mold repair, box matching, core dropping and other processes during casting, so the casting blank has no burrs, no parting surface, cavity mesh block, and smooth holes. This process is suitable for single-piece and complex molds and is the best choice for automobile mold manufacturing.
3.3. General process of automobile cover mold design The
general design process of automobile cover mold is as follows:
1. Conduct mold concept design analysis according to the needs of the manufacturer.
2. Analyze the working condition of the mold, analyze the process, and draw the process drawings.
3. Perform structural CAD/CAM design of the mold according to the process drawings (foreign countries often directly conduct 3D design, while domestic countries often use 2D design).
4. Convert CAD/CAM to NC code to prepare for CNC processing.
5. MFC modeling, if there are any inappropriate places, transfer to CAD/CAM design coordination.
6. Casting and surface processing.
It is worth noting here that in the entire design process, CAD/CAM modeling is the key link of the design, which plays a connecting role. The importance of MFC lies in that it determines whether the designer's ideas can be turned into reality. Therefore, in actual design, the time proportion of these two parts is the largest, and MFC modeling has high requirements for workers. Not only must they be able to understand the designer's design intentions, but they must also express each part with entities. Especially in the current situation where 2D design is still the main method in China, it is particularly difficult and will inevitably take more time than the same work abroad.