轿车覆盖件用大型淬硬钢模具高品质加工技术基础及应用

As the maximum of car output production country, processing capacity of automobile mold for our country is still far adapting for need retrofitting and updating of car. The mold manufacturing processing of high-end cars key covering can not reach the design requirements. Therefore, This project focus on the technology difficulties in process of large panel hardened steel molds of high-end cars. Firstly, to improve manchined quality of mold, this research starts from the high hardness and efficient hard milling technology of blending surface, dynamic characteristics of multi-axis CNC machining process system，improvement of annular cutter precision CNC machining process, the development of dedicated new tool and comprehensive optimization technology of high-precision processing of typical characteristics shaped surface of the large cover mold and so on. Secondly, through the developing high-precision processing optimization method of large complex curved surface hardening mould based on machine tool technology system dynamic performance, carry on advanced tool design, new type circular tool precision NC programming and process technology optimization facing shape-performance-application unification of high hardness form surface machining. Finally, The research will form integrated optimization technique of high quality processing technology of high hardness large factor surface mould with hardness joining together, and form the new process, new method, new tool design and process optimization software with proprietary intellectual property right, which will provide theoretical guidance for high quality processing of high-grade car for our country with large covering mould and provide practical technical support for automobile covering mould processing industry.

作为汽车产量第一大国，我国的汽车模具加工能力还远远不能适应汽车改型换代的需要，中高档轿车关键覆盖件的模具制造加工还达不到设计要求。因此，本项目针对中高档轿车用大型覆盖件淬硬钢模具高品质加工技术的难点，从高硬度拼接曲面高效硬铣削技术、多轴联动数控加工工艺系统动力学特性、环形铣刀精密数控加工工艺优化、专用新型刀具的开发及大型覆盖件模具典型特征形面高效精密加工工艺综合优化技术等方面着手，通过开发基于机床-刀具工艺系统动态性能的大型复杂曲面淬硬模具加工工艺优化方法、进行面向高硬度形面加工用形-性-用统一的先进刀具设计和新型环形刀具精密数控加工编程及工艺技术优化，形成具有硬度拼接的高硬度大型复杂型面模具的高品质加工工艺综合优化技术，形成具有自主知识产权的新工艺新方法、新型刀具设计及工艺优化软件，为我国中高档轿车用大型覆盖件模具的高品质加工提供理论指导及为汽车覆盖件模具加工行业提供实用技术支持。

作为汽车产销量的第一大国，目前我国的汽车模具加工制造能力还远远不能适应汽车改型换代的需要，中高档轿车关键覆盖件的模具制造加工还达不到设计要求。本项目针对中高档轿车关键覆盖件模具切削加工过程的关键技术问题，从高硬度拼接曲面高效硬铣削技术、多轴联动数控加工工艺系统动力学特性、环形铣刀精密数控加工工艺优化、专用新型高效刀具开发及大型覆盖件模具典型特征形面高效精密加工工艺综合优化技术等5个方面进行了深入系统研究，建立了具有硬度拼接特征的大型淬硬钢模具干式铣削条件下的极限切屑厚度预测模型，为铣削过程的优化控制及加工型面误差控制提供了技术方法；建立了主轴-刀柄-刀具结合面接触刚度解析模型及加工系统综合刚度场模型，确定了自由曲面铣削颤振多维稳定域和工艺优化界定条件，提出了加工误差控制的过程集成优化工艺方法；建立了环形刀几何参数、曲面几何参数、残留高度与行距之间的数学模型，提出了铣削平坦凹曲面最小曲率半径的判定原则；搭建了基于SERCOS报文传输命令通道及服务通道的开放式数控系统来实现相关插补策略，为数字化加工过程的智能控制提供了基础；提出了高硬材料切削用刀具一体化设计与几何建模方法，形成了刀具“形-性-用”一体化设计制造理论与工艺方法，搭建了整硬球刀类刀具的设计制造系统的软硬件平台，研制了椭球头、旋转抛物面型球头和“8”字型等不同形状的非圆球头铣刀，为高硬度型面模具高效率和高品质加工提供了基本工具，形成具有硬度拼接特征的高硬度大型复杂型面模具的高品质加工工艺综合优化技术。共发表学术论文83篇，开发专用新型高效刀具7种15把，获得授权发明专利23项、软件著作权2项，制定相关工艺规范2项，培养博士生13人、硕士生31人。本项目成果为我国中高档轿车用大型覆盖件模具的高品质加工提供了理论指导及为汽车覆盖件模具加工行业的技术提升提供支持。