With the rapid development of the national economy and the substantial improvement of people's living standards, people's demand for automobiles is increasing, and the market competition for automobile molds is becoming more and more fierce. “Good qualityâ€, “high precisionâ€, “low price†and “short delivery time†are the basic requirements for modern automobile molds. However, the automobile mold is a large mold, which is bulky, complicated in structure, high in dimensional accuracy and surface roughness, and is difficult to manufacture. Moreover, the thin-walled structure in which the base is hollowed out in order to reduce the weight of the mold and the inlaid structure used for the maintenance of the intermediate profile are more difficult to design and manufacture. In general, a car cover part requires three or more passes to complete, that is, at least three or more pairs of molds are required to produce a car cover part. If the car cover parts are not designed with the actual manufacturing in mind, the designed molds may not be processed at all during the manufacturing process, or the manufactured molds cannot produce the expected products, resulting in the scrapping of the molds. To extend the product development cycle, this economic loss is unimaginable. However, the mold is unpredictable during the design phase and will be difficult during the manufacturing process. Virtual manufacturing technology is a software technology, which is a higher stage of CAD/CAE/CAM/CAPP and simulation technology. It can realize the whole process of mold from design to manufacturing to inspection on the computer. According to the simulation process of virtual model, The design of the mold is modified on the computer according to the "real" processing condition, thereby avoiding problems that may occur in the mold manufacturing process, thereby achieving the purpose of shortening the development cycle of the mold, reducing the development cost, and improving the production efficiency, thus being an automobile mold. Develop one of the most promising, practical and effective technologies.
Virtual manufacturing (VM)
Virtual Manufacturing (Virtual Manufacturing), also called pseudo-real manufacturing, is a new idea first proposed by the United States in the late 1980s. It is the use of information technology, simulation technology, computer technology, etc. for people, things, information and The manufacturing process is fully simulated to identify problems that may arise during manufacturing. Precautions are taken before the actual production of the product, so that the product can be successfully manufactured in one time, so as to reduce costs, shorten the product development cycle, and enhance the competitiveness of the enterprise. In virtual manufacturing, the product is simulated and simulated on the computer from the initial shape design, production process modeling, simulation processing, model assembly to inspection. The actual production of the product is not required to verify the mold design. Reasonable, thus reducing the troubles caused by the pre-design to the post-processing manufacturing, and avoiding the occurrence of mold scrapping, thereby achieving the goal of improving the yield of product development, shortening the product development cycle, and reducing the manufacturing cost of the enterprise.
Virtual manufacturing has been trying to give it a unified definition since its inception, but virtual manufacturing involves a wide range of knowledge. Different researchers, different starting points and different focuses, so the understanding is very different, resulting in virtual manufacturing still There is no exact definition. In different definitions, we can understand virtual manufacturing as a technical synthesis of the virtual design technology of the product, the virtual manufacturing technology of the product, and the key technologies of the virtual manufacturing system.
Product Virtual Design Technology (VDT)
The virtual design technology of the product (VirtualD eSignTechnology) is designed for the principle, structure and performance of the digital product model. The product is designed on the computer, simulates various manufacturing schemes, analyzes the structural performance and assemblability of the product to obtain the product design. Evaluate and predict performance results to optimize product design and process design, and reduce problems that may arise during manufacturing to reduce costs and shorten production cycles.
Product Virtual Manufacturing Technology (VMT)
Virtual Manufacturing Technology (VirtualM anufacturingTechnology) uses computer simulation technology to select the processing method, process sequence, tooling and process parameters of the parts according to the existing resources, environment, production capacity, etc., and build a virtual model on the computer. Simulation analysis of processing processability, assembly processability, fit between mating parts, connectivity between connectors, and mobility between moving members are performed. Through the analysis, the defects in the processing and the problems occurring in the assembly can be found in advance, and the manufacturing process can be modified accordingly until the entire manufacturing process is completely reasonable to achieve the optimization purpose. The virtual manufacturing technology of the product mainly includes material thermal processing technology simulation, assembly process simulation, sheet metal forming simulation, machining process simulation, mold manufacturing simulation, product trial simulation and so on.
Virtual Manufacturing System (VMS)
Virtual Manufacturing System (Virtual Manufacturing System) introduces simulation technology into the numerical control model to provide a virtual environment that simulates the actual production process. The machine control model is used for simulation, which enables the enterprise to optimize the manufacturing process based on the control behavior of the shop. Control, the goal is to optimize the process in actual production, and the better configuration of the manufacturing system. With the advent of the network era, the virtual manufacturing technology has been rapidly developed, and the research field is becoming wider and wider, except for the virtual manufacturing domain itself. Manufacturing theory system, design information and 3D visualization of production process, system global optimal decision theory and technology in virtual environment, open architecture of virtual manufacturing system, assembly simulation of virtual product, virtual environment and virtual manufacturing process In addition to human-machine collaborative work, experts at this stage are investing a lot of time to research virtual manufacturing technology integration systems and related software development. Washington State University has developed a virtual environment VEDAM system for design and manufacturing on PTC's Pro/enginee: CAD/CAM system, including processing equipment modeling environment, virtual design environment, virtual manufacturing environment and virtual assembly environment. The National University of Singapore, Lee and Noh, etc., developed a virtual manufacturing prototype system as a test bed for engineering and production activities using the Internet, expert system development tools, HTML/VRML and database systems. Driven by the huge demand for applications, foreign software companies have also launched a number of software that supports virtual manufacturing such as Deneb, Multigen, dVISE, World-ToolKit, and EA1. Virtual manufacturing technology is a multi-disciplinary and multi-technology integration. Its related technical support includes simulation technology, modeling technology, computer graphics, visualization technology, multimedia technology, virtual reality technology, etc., and these technologies are well integrated and applied. The focus of current research.
Application of virtual manufacturing in automobile cover mould
The development of automotive panel molds is subject to many aspects such as reliability, aesthetics, economy, manufacturability and maintainability. In the traditional car cover mold development process, after the mold design and manufacturing is completed, it is necessary to undergo repeated debugging and modification to obtain satisfactory automotive parts. During the debugging process, some forming defects, such as cracking, wrinkling, rebound, and warping, are mainly due to the experience of the mold pliers, through the cycle of trial, repair, re-test, and mold repair. solve. This method not only reduces the production efficiency, but also produces molds that often fail to meet the expected requirements and lengthen the mold development cycle. Virtual manufacturing technology can greatly shorten this cycle. Because in a virtual reality environment, designing and manufacturing a car does not require the construction of a solid model, engineers can take advantage of the visual advantages of a virtual “natural†environment to integrate structural analysis, virtual design, component assembly, and performance optimization of automotive molds into computer virtualization. Performed in the manufacturing system, based on the overall layout of the exterior of the automotive body parts and the interaction between the components, interactive modeling of mold geometry, technical performance, production and manufacturing. And simulation analysis, thus avoiding repeated mold repair, ensuring the accuracy requirements of the mold; and because the generated simulation model can be directly manipulated and modified, the data can be reused, thus greatly shortening the cycle of mold development Cs-i21 virtual manufacturing technology It has a very good advantage compared to technologies such as rapid prototyping, reverse design, reverse engineering, and knowledge-based engineering. Because virtual manufacturing technology has a unique virtual design manufacturing environment, the entire development process of the mold can be carried out completely in a virtual “real†environment, and the physical manufacturing is started after the requirements of expected performance and quality are met. The mold meets the user's needs in one time, greatly reducing the scrap rate of the mold and reducing the development cost of the enterprise.
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