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1、Heat Treatment of Die and Mould Oriented Concurrent DesignLI Xiong,ZHANG Hong-bing,RUAN Xueyu,LUO Zhonghua,ZHANG YanAbstract: Many disadvantages exist in the traditional die design method which belongs to serial pattern. It is well known that heat treatment is highly important to the dies. A new ide
2、a of concurrent design for heat treatment process of die and mould was developed in order to overcome the existent shortcomings of heat treatment process. Heat treatment CAD/CAE was integrated with concurrent circumstance and the relevant model was built. These investigations can remarkably improve
3、efficiency, reduce cost and ensure quality of R and D for products.Key words:die design; heat treatment; mouldTraditional die and mould design,mainly by experience or semiexperience，is isolated from manufacturing process.Before the design is finalized，the scheme of die and mould is usually modified
4、time and again，thus some disadvantages come into being,such as long development period,high cost and uncertain practical effect.Due to strong desires for precision,service life,development period and cost,modern die and mould should be designed and manufactured perfectly.Therefore more and more adva
5、nced technologies and innovations have been applied,for example,concurrent engineering,agile manufacturing virtual manufacturing,collaborative design,etc.Heat treatment of die and mould is as important as design,manufacture and assembly because it has a vital effect on manufacture，assembly and servi
6、ce lifeDesign and manufacture of die and mould have progressed rapidly，but heat treatment lagged seriously behind themAs die and mould industry develops，heat treatment must ensure die and mould there are good state of manufacture，assembly and wearresistant properties by request. Impertinent heat tre
7、atment can influence die and mould manufacturing such as overhard andsoft and assemblyTraditionally the heat treatment process was made out according to the methods and properties brought forward by designerThis could make the designers of die and mould and heat treatment diverge from each other，for
8、 the designers of die and mould could not fully realize heat treatment process and materials properties，and contrarily the designers rarely understood the service environment and designing thought. These divergences will impact the progress of die and mould to a great extent. Accordingly，if the proc
9、ess design of heat treatment is considered in the early designing stage，the aims of shortening development period，reducing cost and stabilizing quality will be achieved and the sublimation of development pattern from serial to concurrent will be realizedConcurrent engineering takes computer integrat
10、ion system as a carrier,at the very start subsequent each stage and factors have been considered such as manufacturing，heat treating，properties and so forth in order to avoid the errorThe concurrent pattern has dismissed the defect of serial pattern,which bring about a revolution against serial patt
11、ernIn the present workthe heat treatment was integrated into the concurrent circumstance of the die and mould development，and the systemic and profound research was performed1 Heat Treatment Under Concurrent CircumstanceThe concurrent pattern differs ultimately from the serial pattern(see Fig1).With
12、 regard to serial pattern，the designers mostly consider the structure and function of die and mould，yet hardly consider the consequent process，so that the former mistakes are easily spread backwardsMeanwhile，the design department rarely communicates with the assembling，cost accounting and sales depa
13、rtmentsThese problems certainly will influence the development progress of die and mould and the market foregroundWhereas in the concurrent pattern，the relations among departments are close，the related departments all take part in the development progress of die and mould and have close intercommuni
14、on with purchasersThis is propitious to elimination of the conflicts between departments，increase the efficiency and reduce the costHeat treatment process in the concurrent circumstance is made out not after blueprint and workpiece taken but during die and mould designingIn this way，it is favorable
15、to optimizing the heat treatment process and making full use of the potential of the materials2 Integration of Heat Treatment CADCAE for Die and MouldIt can be seen from Fig2 that the process design and simulation of heat treatment are the core of integration frameAfter information input via product
16、 design module and heat treatment process generated via heat treatment CAD and heat treatment CAE module will automatically divide the mesh for parts drawing，simulation temperature field microstructure analysis after heattreatment and the defect of possible emerging (such as overheat,over burning)，a
17、nd then the heat treatment process is judged if the optimization is made according to the result reappeared by stereoscopic vision technologyMoreover tool and clamping apparatus CAD and CAM are integrated into this systemThe concurrent engineering based integration frame can share information with o
18、ther branchThat makes for optimizing the heat treatment process and ensuring the process sound2.1 3-D model and stereoscopic vision technology for heat treatmentThe problems about materials，structure and size for die and mould can be discovered as soon as possible by 3-D model for heat treatment bas
19、ed on the shape of die and mouldModeling heating condition and phase transformation condition for die and mould during heat treatment are workable，because it has been broken through for the calculation of phase transformation thermodynamics，phase transformation kinetics，phase stress,thermal stress，h
20、eat transfer，hydrokinetics etcFor example，3-D heatconducting algorithm models for local heating complicated impression and asymmetric die and mould，and M ARC software models for microstructure transformation was usedComputer can present the informations of temperature，microstructure and stress at ar
21、bitrary time and display the entire transformation procedure in the form of 3-D by coupling temperature field,microstructure field and stress fieldIf the property can be coupled,various partial properties can be predicted by computer2.2 Heat treatment process designDue to the special requests for st
22、rength，hardness，surface roughness and distortion during heat treatment for die and mould，the parameters including quenching medium type，quenching temperature and tempering temperature and time，must be properly selected，and whether using surface quenching or chemical heat treatment the parameters mus
23、t be rightly determinedIt is difficult to determine the parameters by computer fullySince computer technology develops quickly in recent decades,the difficulty with largescale calculation has been overcomeBy simulating and weighing the property，the cost and the required period after heat treatmentit
24、 is not difficult to optimize the heat treatment process2.3 Data base for heat treatmentA heat treatment database is described in Fig3The database is the foundation of making out heat treatment processGenerally，heat treatment database is divided into materials database and process databaseIt is an i
25、nexorable trend to predict the property by materials and processAlthough it is difficult to establish a property database，it is necessary to establish the database by a series of testsThe materials database includes steel grades,chemical compositions，properties and home and abroad grades parallel ta
26、blesThe process database includes heat treatment criterions，classes，heat preservation time and cooling velocityBased on the database，heat treatment process can be created by inferring from rules2.4 Tool and equipment for heat treatmentAfter heat treatment process is determined，tool and equipment CAD
27、CAE system transfers the information about design and manufacture to the numerical control deviceThrough rapid tooling prototype，the reliability of tool and the clamping apparatus can be judgedThe whole procedure is transferred by network，in which there is no manmade interference3 Key Technique3.1 C
28、oupling of temperature，microstructure，stress and propertyHeat treatment procedure is a procedure of temperature-microstructurestress interactionThe three factors can all influence the property (see Fig4)During heating and cooling，hot stress and transformation will come into being when microstructure
29、 changes.Transformation temperature-microstructure and temperaturemicrostructureand stress-property interact on each otherResearch on the interaction of the four factors has been greatly developed,but the universal mathematic model has not been builtMany models fit the test nicely，but they cannot be
30、 put into practiceDifficulties with most of models are solved in analytic solution，and numerical method is employed so that the inaccuracy of calculation existsEven so，comparing experience method with qualitative analysis，heat treatment simulation by computer makes great progress3.2 Establishment an
31、d integration of modelsThe development procedure for die and mould involves design,manufacture，heat treatment，assembly，maintenance and so onThey should have own database and mode1They are in series with each other by the entityrelation modelThrough establishing and employing dynamic inference mechan
32、ism ，the aim of optimizing design can be achievedThe relation between product model and other models was builtThe product model will change in case the cell model changesIn fact，it belongs to the relation of data with die and mouldAfter heat treatment model is integrated into the system，it is no mor
33、e an isolated unit but a member which is close to other models in the systemAfter searching，calculating and reasoning from the heat treatment database,procedure for heat treatment，which is restricted by geometric model,manufacture model for die and mould and by cost and property，is obtainedIf the re
34、striction is disobeyed， the system will send out the interpretative warningAll design cells are connected by communication network3.3 Management and harmony among membersThe complexity of die and mould requires closely cooperating among item groupsBecause each member is short of global consideration
35、 for die and mould development，they need to be managed and harmonizedFirstly,each item group should define its own control condition and resource requested,and learn of the request of up-and-down working procedure in order to avoid conflictSecondly，development plan should be made out and monitor mec
36、hanism should be establishedThe obstruction can be duly excluded in case the development is hinderedAgile management and harmony redound to communicating information， increasing efficiency，and reducing redundancyMeanwhile it is beneficial for exciting creativity，clearing conflict and making the best
37、 of resource4 Conclusions(1) Heat treatment CADCAE has been integrated into concurrent design for die and mould and heat treatment is graphed,which can increase efficiency，easily discover problems and clear conflicts(2) Die and mould development is performed on the same platformWhen the heat treatme
38、nt process is made out，designers can obtain correlative information and transfer self-information to other design departments on the platform(3) Making out correct development schedule and adjusting it in time can enormously shorten the development period and reduce costReferences：1 ZHOU Xiong-hui，P
39、ENG Ying-hongThe Theory and Technique of Modern Die and Mould Design and ManufactureMShanghai：Shanghai Jiaotong University Press 2000(in Chinese)2 Kang M，Park& Computer Integrated Mold ManufacturingJInt J Computer Integrated Manufacturing，1995，5：229-2393 Yau H T，Meno C HConcurrent Process Planning f
40、or Finishing Milling and Dimensional Inspection of Sculptured Surface in Die and Mould ManufacturingJInt J Product Research，1993，31(11)：270927254 LI Xiang，ZHOU Xiong-hui，RUAN Xue-yuApplication of Injection Mold Collaborative Manufacturing System JJournaI of Shanghai Jiaotong University，2000，35(4)：13
41、91-13945 Kuzman K，Nardin B，Kovae M ,et a1The Integration of Rapid Prototyping and CAE in Mould Manufacturing JJ Materials Processing Technology，2001，111：2792856 LI Xiong，ZHANG Hongbing，RUAN Xue-yu，et a1Heat Treatment Process Design Oriented Based on Concurrent EngineeringJJournal of Iron and Steel R
42、esearch，2002，14(4)：2629文献出处：LI Xiong,ZHANG Hong-bing,RUAN Xueyu,LUO Zhonghua,ZHANG Yan. Heat Treatment of Die and Mould Oriented Concurrent DesignJ. Journal of Iron and Steel Research，2006,13(1):40-43，74模具热处理及其导向平行设计李雄，张鸿冰，阮雪榆，罗中华，张艳摘要：在一系列方式中，传统模具设计方法存在许多缺点。众所周知,热处理对模具起着非常重要的作用。为了克服模具热处理工艺存在的缺点，一种新
43、的模具热处理工艺并行设计方法已经被开发出来了。热处理CAD/CAE技术是集成了并行环境和有关模型而建立的。这些调查研究可以显著提高效率，降低成本，并保证产品质量达到R和D级。关键词：模具设计；热处理；模具传统模具设计主要是依照自身实践经验或依照部分实践经验，而不是制造工艺。在设计完成之前，模具方案通常要被一次又一次的改进，于是有些缺点便出现，例如开发时期长，成本高和实际效果不明显。由于对精确性、使用寿命、开发期和费用的严格要求，先进的模具要求设计和制造得十分完善。因此越来越先进的技术和创新方法被应用其中，例如并行工程、敏捷制造业、虚拟制造业、协同合作设计等。模具的热处理与模具设计，制造和装配同
44、样重要。因为它对模具的制造装配和使用寿命又及其重要的影响。模具设计与制造发展十分迅速，但是热处理发展却严重滞后它们。随着模具工业的发展，热处理必须保证模具有良好的制造装配和磨损耐热性能。不切实际的热处理将导致模具材料过硬或过软，同时影响模具装配性能。传统的热处理工艺是按照设计师提出的方法和特性制作出来的。这样会使模具设计师和热处理工艺师意见产生分歧，而模具设计师却不能充分地了解热处理工艺和材料的性能，相反热处理工艺师却很少了解模具的使用环境和设计思路。这些分歧将在很大程度上影响模具的发展。因此，如果把热处理工艺设计放在设计阶段之前，则缩短开发周期，减少花费和保证质量等目标将会被考虑，而且从串行
45、到并行的发展模式也将会实现。并行工程是以计算机集成系统作为载体，在开始以后，每个阶段和因素都被看作如制造、热处理、性能等等，以避免出现错误。并行模式已经摒除了串行模式的缺陷，由此带来了一场对串行模式的革命。在当前的工作中，热处理被集成到了模具开发的并行环境中，同时也正在进行这种系统性和深入性的研究。并行模式与串行模式存在根本的不同（见图1）。对于串行模式，设计者大多考虑的是模具的结构与功能，但很难考虑相关的工艺，以致前者的错误很容易蔓延到后面。与此同时，设计本门很少与装配，预算会计和销售部门沟通。这些问题当然会影响模具的开发进度和市场前景。然而在并行模式中，不但以上部门关系联系密切，所有参加模
46、具开发的部门都与买家有密切的交流。这有助于协调各部门消除矛盾，提高工作效率，同时降低成本。(a)(b)(a)串行模式 （b）并行模式并行环境下的热处理工艺不是在方案和工件确定以后，而是在模具设计的时候制定出来的。这样的话，将有利于优化热处理工艺，充分利用材料。从图2中可以看出，热处理工艺的设计与模拟是一体化模式的核心。在信息输入产品模块中后，经热处理工艺过程产生的热处理CAD和热处理CAE模块将对于零件图，热处理以后模拟温度场的微观结构分析和可能出现的缺陷（例如过热，烧伤）自动划分网络，如果优化是根据立体视觉技术的结果重新出现，则这项热处理工艺已经被审核。而且工具与夹具的CAD和CAE也集成于
47、这种系统中。以并行工程为基础的集成模式可以与其它类似模式共享信息。这样使热处理工艺得到优化，并确保改工艺准确。在形成模具的基础上，材料，结构和尺寸的问题能通过热处理三维模型尽快发现出来。在热处理过程中，模具加热条件和相变条件是切合实际的，因为通过计算相变热力、相变动力、相应力、热应力、传热速度、流体动力等已经取得重要突破。例如，能进行局部复杂表面和不对称模具的三维热传导模型计算，和能进行微观结构转变的MARC软件模型。计算机能够在任何时间提交温度，微观结构和应力的信息，并通过连接温度场微观结构领域和力场来显示三维形式的全部改变过程。如果再加上这种特性，则各部分性能都能通过计算机预见。由于对强度
48、和硬度，表面粗糙度和模具热处理变形的特殊要求，淬火介质的种类、淬火温度、回火温度和时间等参数特性必须经过适当的选择，以及是否使用表面淬火或化学热处理，这种特性必须准确的制定下来。自从计算机技术在最近几十年迅速的发展，难以进行大型计算已经成为过去。通过模拟和仔细考虑热处理特性，热处理后的成本和所须时间，这些都并不难优化热处理工艺。热处理数据库在图3中描述。数据库是制定热处理工艺的基础。一般来说，热处理数据库分为材料数据库和工艺数据库。通过材料和工艺来预测特性已成为一种必然的趋势。尽管很难建立一个特性数据库，但通过一系列的测试来建立数据库是必要的。材料数据库包括材料牌号、化学成分、性能和国内外同级别目录表。工艺数据库包括热处理标准、种类、保温时间和冷却温度。基于数据库，热处理工艺可以通过推理规则创造出来。在热处理工艺确定以后，工