模具结构制作分析

0SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIAL第一次成功FirstTrialRightThisdocumentandtheinformationcontainedareSagemMobilesR&D(Ningbo)propertyandshallnotbecopiedordisclosedtoanythirdpartywithoutpriorwrittenauthorization1SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMouldDesign-MouldMakingOverview2SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMouldMakingMonthsProductdesign•Modelling•Mechanicsdesign•RawmaterialforproductPrototypepiece•Machining•Sintering•SLTMouldmanufacturing•Moulddesign•PartsmachiningandassemblyWeeksFOT(Firstoutoftool)•Testdrive•Processparameters•Trimmingmeasurements•VisualqualityFAI•(Firstarticleinspection)Production•Correctrawmaterial•Correctshrinkage•CorrectvalueforinjectionmouldingMonths/YearsV&A•FOT•FAI•CmkDays3SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMouldMakingProductdesignMoulddesignGrindingHeattreatmentEDMsinkEDMwireMouldmanufacturingHSMsteelElectrmillNCelectrodeElectrdesignMilling,insertsDrawingsAssemblyT1DesignstartFrozenfileNCsteelPredesignofmould/PartitionT2PurchasingdefineT4ManufacturingstartT5IntermediatereviewofscheduleT3MouldmeetingMilling,softpartsV&AT6FOTFAICmkApprovalSamplingSamplingTrim4SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMoldDesigningBeforestartofmolddesigningMoldbaseselectionCavityandcoredesignRunnersystemselectionGatingVentingCoolingEjectionMoldmaterialselectionMolddesigningMoldManufacturing,Sampling,FAIProductdesignreviewMolddesignverificationDesignreview5SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMoldMakingLeadtimeofnewmoldistypically8-10weeksMolddesigningtimeis~2-3weeksMolddesigningcontributes5-15%totalmoldcostProductchangesduringthedesignphasecanbeimplementedwithminimumcostsandarethereforepreferred0%10%20%30%40%50%60%70%80%90%100%MoldcostAssemblyGrindingSurfacetreatingMillingEDMElectrodemfg.NCprogr.ElectrodedesignMolddesignMaterials6SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMoldDesigningMolddesigningconsistofsimultaneous“what-if”decisionswhicheffecttoeachotherFinaldesignisoftencompromiseofseveraldesignconsiderationsandchoicesAnyofthedesignalternativescannotbeignoredwhileaimingthebestpossibledesignPoordesignwhichisnotsuitableforproductionoftenleadtohigherproductioncosts,whichinturnwastesvaluableresourcesSuccessfuldesigningisusuallyacombinationofpreviousdesignsandnewtechnology7SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALBeforeStartofMoldDesigning8SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALIntroductionTherearemanyrulesformolddesigningRulesandstandardpracticesarebasedonlogicandpreviousexperienceRulesmayvarybetweencompaniesandcontinentsbutbasicprinciplesarestillthesameMolddesignermustbeopenfornewideasandmethodsandreadytogobacktodrawingboardinanystageofdesigningprocessifneeded9SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALBeforeStartofMoldDesigningBeforeamolddesignisstarted,therearesomebasicfactsthatmustbeconsidered,gatheredandagreed:Productdetails&drawingsExpectedproductionquantitiesMoldingmachinespecificationsInjectionpoint(gating)ShrinkagePartingline10SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALProductDetails&DrawingsAretolerancesspecifiedandreasonable?•Aretolerancessameasknown/expectedwhenquoted?Whatdraftangles?•Draftanglesshouldbemorethan1°toavoidproblemsinejectionofthepart(PC+ABS)•Draftangleslessthan1°shouldbecarefullyconsidered•Draftangleismaterialandsurfaceroughnessdependent•Toolowdraftangleincreasestheriskofvisualeffects(scratch)WhatisthefunctionofproductWhataresurfacerequirements11SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALExpectedProductionQuantity1000,10,000or1,000,000pcs?Moldsusedinmoldingpartsformobilephonesarebuiltwith2,4or8cavities•A-cover,2-cavity•Window,4-cavity•Releasekey,8-cavityNumberofcavitiesdependalsoon:•theavailableproductiontime•machineshotsize•shapeandsizeofthepartandmoldcostsMoldswithmorecavitiesaremoreexpensivetobuildthansinglecavitymoldsbutadvantageishigherproductivityinsametimeperiod12SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMoldingMachineSpecificationsTiebarortiebarlessmoldingmachine?Tiebarclearanceandplatensize•Willmoldfitontheplatens?•Aremoldmountingholesstandardsizeandistheholelayoutknown?LocatingringsizeClampingforce•Cavityfillingpressurewilltrytoopenthemoldatpartingline13SagemMobilesResearchandDevelopment(Ningbo)Co.,Ltd.萨基姆移动电话研发(宁波)有限公司CONFIDENTIALMoldingMachineSpecificationsF=600xprojectedarea(cm2)Projectedarea=projectedareaofallcavities+projectedareaofrunners•SeparatingforceFisequalwithproductofpressureptimesprojectedareaA•Asaruleofthumb,clampingforceneededcanbecalculatedas:CoreCavityFFExample:600x(100cm2)=60000kg=60tons3.9x(15.5in2)=61.3TonsWit