The advantage of the three-dimensional solid design is that it can intuitively reflect the real state of the design. Through the digital analysis methods such as motion simulation and interference check, the problems that were previously found in manufacturing can be avoided at the design stage. The standard parts library can provide parameterized and serialized parts that can be directly assembled for the die structure design; the stamping equipment library and typical structural library provide a reference model for the structural design; and the basic structural library makes the die design more flexible and intelligent. The organic combination of resource bank and knowledge engineering forms the knowledge base of the mold structure design and becomes the basis of the three-dimensional solid design. With the combination of 3D-DL diagram technology and solid foam processing technology, it can achieve true 3D solid design. And as an opportunity to promote the entire mold life cycle technology. The integration of CAE/CAD/CAM for mold manufacturing has made mold production more and more dependent on high-tech means, minimizing the intensity of manual labor, improving mold manufacturing accuracy, and shortening the mold production cycle.
Resource Bank, Knowledge Engineering and Knowledge Resource Bank
The resource library includes: standard parts library, stamping equipment library, typical structure library and infrastructure library. It provides a wealth of resources for physical design:
â—† Standard parts library
The high degree of integration of modern mold design requires that the part model has unity in all aspects of design and manufacturing. For a large number of standard parts determined by parameters, it is desirable to select only the part specification parameters when quoting in the standard parts library. You can get the correct standard parts. It does not need to be re-modeled, which is to realize the parameterization drive.
CATIA software has unique advantages in managing standard parts. The Catalog Editor is a tool for classifying, managing, and using standard parts.
The overall establishment process of the three-dimensional parametric standard part library is as follows:
1) Summarize a common shape model as a basic element for building a database and establish parameterized features.
2) Join the specification table to the parameter profile. Enables feature parameters to follow a defined series of changes.
3) Use the Catalog Editor module to classify and manage the series of signature files.
According to the type of mold standard parts, the standard parts can be divided into: installation and connection, guidance, lifting, limit, turn-over device, positioning, pressure-returning device, in-out material device, side-flush device, punching, elastic element, Pneumatic components 12 standard parts.
Combined with the functions of standard parts and features of use, they can be divided into the following three categories:
Ordinary standard parts
Multi-standard, into a series is its main feature. The use of the Catalog for the management of standard parts makes the search and application more convenient and faster. The catalog will be a large number of series of standard parts, according to type, divided into multiple groups, each group and then gradually refined. Make the huge library of standard parts clear and organized. Use the Catalog Browser to select the specifications. Once inserted into the mold assembly, it can be quickly positioned once, making it very convenient.
2. User Component (standard parts with Boolean operations)
The User Component is another standard component insertion method that is different from the Catalog Browser. It can use the user-defined features to automatically perform Boolean operations with specified features while inserting standard components.
Many standard parts of the installation station, with its specifications change. The standard part is made with an automatic Boolean operation function so that it can be inserted into the assembly with the User Component command and the corresponding casting part is also generated.
3. Power Copy and UDF (Local Standard Structure)
Power Copy and User Defined Features (UDF) is a feature definition tool of CATIA V5. Through it, designers can customize features that are often used in structural design. A three-dimensional solid model can be generated by calling the corresponding feature file and setting the corresponding conditions and adjustment parameters.
The standard structures made with Powercopy are mainly used in castings, such as booms and platens. Like ordinary standard parts, they also change in a series. The difference is that they are "long" on the main structure of the mold. Need to specify some positioning elements and parameters when inserting, and directly added to the entity in the form of Boolean operations. This feature modification and deletion are very convenient.
UDF-defined user features are encapsulated into a feature that is displayed in the structure tree, reducing the feature footprint. Moreover, UFD features can be recognized as processing features. This feature provides great convenience for the subsequent NC programming process.
Power Copy and User Defined Features (UDF) can simplify and standardize structural modeling. Improved modeling efficiency and accuracy, reducing duplication of effort.
â—† Stamping equipment library
The establishment of the stamping equipment library changed the status of the stamping equipment in the mold design. The designer directly designs the structure of the stamping equipment, and has intuitive feedback on the size and balance of the mold. When designing the pressure plate troughs and supporting rods, the pressure model can be directly used for spatial arrangement. In addition, these stamping devices can also be added to the motion simulation analysis of the mold to make the motion analysis more realistic.
â—† Infrastructure Library
The basic structure library is a knowledge-based intelligent design resource library in the CATIA V5 environment, and is an organic combination of the knowledge engineering and the general structure of the mold. First of all, we must establish the solid model of the mold based on the original information; then combine the design experience and rules to establish the design knowledge set of the mold structure; Finally, through a variety of knowledge inference methods to achieve automatic design of the mold structure. Taking the establishment of a single-action drawing die base structure as an example, a drawing model base frame model and a drive parameter can be defined according to the characteristics of the mold structure. The more universal this model is, the better the representation is. When establishing, we must also fully consider the relationship with the rules of knowledge. Then the drawing die structural design specification is formed in CATIA, and the connection relationship between the driving parameters and the rules is established. Finally, join the IF-THEN form of inference structure. In the design process of the drawing die, the designer only needs to control several basic characteristic parameters. The system will automatically provide a reasonable structure scheme based on the structural rules input into the computer in advance; the establishment of the knowledge-based infrastructure library Formed the basic template of the mold structure. Ensure the accumulation and reuse of knowledge.
â—† Summary of Knowledge Resource Library
The standard parts library provides a large number of parameterized, serialized parts that can be directly assembled for the design; the stamping equipment library and the typical structural library provide a practical reference model for the structural design; and the basic structural library makes the mold design more intelligent. The organic combination of resource bank and knowledge project forms a knowledge resource library for mold structure design and becomes a solid foundation for 3D solid design.
3D Solid Design Based on Design Ideas
The physical design process of the mold is the process of design thinking. It is totally different from ordinary solid modeling in the way of thinking. Simple physical modeling is often performed with reference to physical objects or reference drawings. The cartographer can directly measure the feature size according to the actual object or drawing, and draw the features one at a time. There is no problem with design changes, nor is there a build process. The real mold structure entity design focuses on design rather than solid modeling. Design is a process of creation. Every dimension and every structure of a mold needs to be determined by the designer himself. And the design is an iterative process. Each design needs repeated argumentation and repeated changes to achieve more reasonable results.
The design process of the mold includes four processes: mold design concept, mold design, mold structure review, proofreading, and plotting. Throughout the physical design process, there are always two issues surrounding:
1) How to effectively use the existing knowledge resources in the design and unify the designer's design thinking.
2) Whether the modification information of the product digital model can be transmitted in time, and whether the modification of the mold structure is convenient.
The above two points will directly affect the quality and efficiency of mold design. To this end, we propose: Based on the design ideas of the associated modeling concept, based on the following four parts.
â—† Standardization of structure
The mold structure standardization idea is the basis of the entire modeling concept. Try to adopt a standardized structure, so that the mold design process becomes a standard structure of the product process. The various components are parameterized, standardized, and serialized. Then add them together by Boolean operations. Finally form a complete design. However, due to the characteristics of the single-piece and small-lot products of the mold product, only the application of the standard structure can be considered in the design, and the possibility of fully realizing the portfolio integration of the standard structure is very small.
In the mold design conception stage, the typical structure library provides designers with a large number of typical structures that can be referenced. These structures rely on the accumulation of previous design resources. Although they are designed for specific molds, they provide ideas and references for future designs.
â—† Infrastructure based on knowledge repository
At the beginning of the mold design, the designer began to sketch the overall structure of the mold. At this time, various mold structures change in the mind of the designer. These thoughts are often flashed and cannot be intuitively reflected. The knowledge-based infrastructure library can be flexibly changed according to the designer's ideas and in accordance with the input of good structural specifications. Designers can intuitively see the changes in the mold structure during these parameter adjustments. These functions are very effective for the initial design of the mold. First, according to the characteristics of the mold structure, select the appropriate basic framework template, the designer only needs to control a few basic characteristic parameters, the system will automatically provide a reasonable structure scheme based on the structural rules and verification rules that are input into the computer in advance. . In addition, although the mold design has the characteristics of one-piece small batch production, each mold is different. However, in the same project, customers often have the same technical requirements for the same type of mold, and many molds have similar structures. We will parameterize and regularize these similar structures according to the customer's technical requirements and form an infrastructure library for the project. Not only meet the customer's technical requirements, but also improve the design efficiency.
â—† Association-based design
CATIA's associated functions make cross-references between parts more reliable. When part B references some feature element (for example, a face or a line) on another part A, if the associated function is turned on and part A changes, the part referenced in part B is also updated. This association function guarantees the synchronization of the referenced elements. Make references more reliable. There is also an advanced correlation function - Publication. Using the association established by the Publication, it only recognizes the Publication element, and does not emphasize which part object, this publication is more flexible and the application is more extensive.
The traditional mold design process is a linear process, that is, after the DL diagram is designed, the mold structure is designed. With the relevance design of the Publication, it is possible to use the preliminary DL draft for the preliminary design of the mold structure during the drafting phase of the DL diagram. After the formal drawing of the DL diagram is completed, the temporary surface is updated to the formal DL diagram surface, and the structural perfection work is continued. Using this design flow, the two design phases can be parallelized, without having to compress the DL diagram and the structure design time, but it can effectively shorten the entire mold design cycle.
In the mold structure design, we publish the most important basic elements (drawings, axes, parameters, etc.) that affect the mold structure. The entire mold structure is used as a reference trunk to extend the design. If the mold structure needs to be adjusted, it is only necessary to modify these basic elements, and it is possible to achieve the purpose of pulling the whole body. The use of this associative design method clarifies the design ideas and provides a good solution to the rapid modification of the mold.
In addition, during the mold design process, repeated modifications of the product's digital model often lead to repeated design work. With associative design, structural designers simply do not have to deal with changes in the small-to-medium range of products, and CATIA's affiliate updates are automatically performed. Only when the number of products changes greatly, designers need to intervene.
â—† Flexible use of various standard parts
In the process of structural refinement, the POWER COPY type standard parts provide the standard structure of the casting body. The User Component standard that can automatically Boolean operation, because the installation station and standard parts are in a PART part, the installation station will move along with the parts movement, change is very convenient. Ordinary standard parts are simple to operate and easy to use.
The above content covers the entire process from the conception to the refinement of the mold design. In each design stage, there are corresponding resources and knowledge as support. Taking structural standardization as the leading ideology, using parametric, intelligent knowledge bases, and reasonable Boolean calculation methods, the organic combination of design thinking and knowledge resources is realized, and the design thinking is quickly embodied. The flexible use of these resources, whether it is the design of the early design, or the late structural changes have provided a good operating environment, truly improve the quality and efficiency of mold design.
Digital analysis
The use of cross-section inspection, interference inspection, relative motion interference inspection, motion simulation and other analytical means to truly reflect the actual working conditions of the mold to ensure the reliability of the design.
â—† Section inspection
The CATIA Spatial Analysis Module provides a variety of cross-section inspection modes. Can be used to check the mold structure, audit mold design is reasonable and so on. In addition, it helps the designer to understand the internal structure of the mold and check the strength of the mold structure.
â—† Interference checking
The CATIA spatial analysis module provides various analysis modes such as interference check, contact check, and minimum distance check. It can effectively analyze the spatial relationship between two or more parts in an assembly, and calculate the specific values ​​to generate a spatial analysis report.
â—† Motion Simulation
The CATIA-DMU electronic prototype motion simulation module enables the designer to verify the movement of the mechanism through simulation. Based on the constraint relationship between parts, 2D and 3D motion pairs are established and a motion mechanism is established for simulation. In addition, speed, acceleration, interference, clearance, etc. can be analyzed.
The above is a valuable experience that has been summarized in the long-term automotive mold design. Its fundamental purpose is to integrate various resources and knowledge to serve the design. We use various concepts and processes to standardize and improve design efficiency, and comprehensively use various testing and management tools to improve design quality. Create a high-efficiency, high-quality solid design platform. At present, this technology has been widely used by FAW Mold and has completed a number of domestic and foreign projects. The successful development of three-dimensional physical design technology for automotive molds has optimized the mold structure, improved the knowledge utilization ratio, shortened the mold production cycle, and improved the product quality and performance/price ratio.
Resource Bank, Knowledge Engineering and Knowledge Resource Bank
The resource library includes: standard parts library, stamping equipment library, typical structure library and infrastructure library. It provides a wealth of resources for physical design:
â—† Standard parts library
The high degree of integration of modern mold design requires that the part model has unity in all aspects of design and manufacturing. For a large number of standard parts determined by parameters, it is desirable to select only the part specification parameters when quoting in the standard parts library. You can get the correct standard parts. It does not need to be re-modeled, which is to realize the parameterization drive.
CATIA software has unique advantages in managing standard parts. The Catalog Editor is a tool for classifying, managing, and using standard parts.
The overall establishment process of the three-dimensional parametric standard part library is as follows:
1) Summarize a common shape model as a basic element for building a database and establish parameterized features.
2) Join the specification table to the parameter profile. Enables feature parameters to follow a defined series of changes.
3) Use the Catalog Editor module to classify and manage the series of signature files.
According to the type of mold standard parts, the standard parts can be divided into: installation and connection, guidance, lifting, limit, turn-over device, positioning, pressure-returning device, in-out material device, side-flush device, punching, elastic element, Pneumatic components 12 standard parts.
Combined with the functions of standard parts and features of use, they can be divided into the following three categories:
Ordinary standard parts
Multi-standard, into a series is its main feature. The use of the Catalog for the management of standard parts makes the search and application more convenient and faster. The catalog will be a large number of series of standard parts, according to type, divided into multiple groups, each group and then gradually refined. Make the huge library of standard parts clear and organized. Use the Catalog Browser to select the specifications. Once inserted into the mold assembly, it can be quickly positioned once, making it very convenient.
2. User Component (standard parts with Boolean operations)
The User Component is another standard component insertion method that is different from the Catalog Browser. It can use the user-defined features to automatically perform Boolean operations with specified features while inserting standard components.
Many standard parts of the installation station, with its specifications change. The standard part is made with an automatic Boolean operation function so that it can be inserted into the assembly with the User Component command and the corresponding casting part is also generated.
3. Power Copy and UDF (Local Standard Structure)
Power Copy and User Defined Features (UDF) is a feature definition tool of CATIA V5. Through it, designers can customize features that are often used in structural design. A three-dimensional solid model can be generated by calling the corresponding feature file and setting the corresponding conditions and adjustment parameters.
The standard structures made with Powercopy are mainly used in castings, such as booms and platens. Like ordinary standard parts, they also change in a series. The difference is that they are "long" on the main structure of the mold. Need to specify some positioning elements and parameters when inserting, and directly added to the entity in the form of Boolean operations. This feature modification and deletion are very convenient.
UDF-defined user features are encapsulated into a feature that is displayed in the structure tree, reducing the feature footprint. Moreover, UFD features can be recognized as processing features. This feature provides great convenience for the subsequent NC programming process.
Power Copy and User Defined Features (UDF) can simplify and standardize structural modeling. Improved modeling efficiency and accuracy, reducing duplication of effort.
â—† Stamping equipment library
The establishment of the stamping equipment library changed the status of the stamping equipment in the mold design. The designer directly designs the structure of the stamping equipment, and has intuitive feedback on the size and balance of the mold. When designing the pressure plate troughs and supporting rods, the pressure model can be directly used for spatial arrangement. In addition, these stamping devices can also be added to the motion simulation analysis of the mold to make the motion analysis more realistic.
â—† Infrastructure Library
The basic structure library is a knowledge-based intelligent design resource library in the CATIA V5 environment, and is an organic combination of the knowledge engineering and the general structure of the mold. First of all, we must establish the solid model of the mold based on the original information; then combine the design experience and rules to establish the design knowledge set of the mold structure; Finally, through a variety of knowledge inference methods to achieve automatic design of the mold structure. Taking the establishment of a single-action drawing die base structure as an example, a drawing model base frame model and a drive parameter can be defined according to the characteristics of the mold structure. The more universal this model is, the better the representation is. When establishing, we must also fully consider the relationship with the rules of knowledge. Then the drawing die structural design specification is formed in CATIA, and the connection relationship between the driving parameters and the rules is established. Finally, join the IF-THEN form of inference structure. In the design process of the drawing die, the designer only needs to control several basic characteristic parameters. The system will automatically provide a reasonable structure scheme based on the structural rules input into the computer in advance; the establishment of the knowledge-based infrastructure library Formed the basic template of the mold structure. Ensure the accumulation and reuse of knowledge.
â—† Summary of Knowledge Resource Library
The standard parts library provides a large number of parameterized, serialized parts that can be directly assembled for the design; the stamping equipment library and the typical structural library provide a practical reference model for the structural design; and the basic structural library makes the mold design more intelligent. The organic combination of resource bank and knowledge project forms a knowledge resource library for mold structure design and becomes a solid foundation for 3D solid design.
3D Solid Design Based on Design Ideas
The physical design process of the mold is the process of design thinking. It is totally different from ordinary solid modeling in the way of thinking. Simple physical modeling is often performed with reference to physical objects or reference drawings. The cartographer can directly measure the feature size according to the actual object or drawing, and draw the features one at a time. There is no problem with design changes, nor is there a build process. The real mold structure entity design focuses on design rather than solid modeling. Design is a process of creation. Every dimension and every structure of a mold needs to be determined by the designer himself. And the design is an iterative process. Each design needs repeated argumentation and repeated changes to achieve more reasonable results.
The design process of the mold includes four processes: mold design concept, mold design, mold structure review, proofreading, and plotting. Throughout the physical design process, there are always two issues surrounding:
1) How to effectively use the existing knowledge resources in the design and unify the designer's design thinking.
2) Whether the modification information of the product digital model can be transmitted in time, and whether the modification of the mold structure is convenient.
The above two points will directly affect the quality and efficiency of mold design. To this end, we propose: Based on the design ideas of the associated modeling concept, based on the following four parts.
â—† Standardization of structure
The mold structure standardization idea is the basis of the entire modeling concept. Try to adopt a standardized structure, so that the mold design process becomes a standard structure of the product process. The various components are parameterized, standardized, and serialized. Then add them together by Boolean operations. Finally form a complete design. However, due to the characteristics of the single-piece and small-lot products of the mold product, only the application of the standard structure can be considered in the design, and the possibility of fully realizing the portfolio integration of the standard structure is very small.
In the mold design conception stage, the typical structure library provides designers with a large number of typical structures that can be referenced. These structures rely on the accumulation of previous design resources. Although they are designed for specific molds, they provide ideas and references for future designs.
â—† Infrastructure based on knowledge repository
At the beginning of the mold design, the designer began to sketch the overall structure of the mold. At this time, various mold structures change in the mind of the designer. These thoughts are often flashed and cannot be intuitively reflected. The knowledge-based infrastructure library can be flexibly changed according to the designer's ideas and in accordance with the input of good structural specifications. Designers can intuitively see the changes in the mold structure during these parameter adjustments. These functions are very effective for the initial design of the mold. First, according to the characteristics of the mold structure, select the appropriate basic framework template, the designer only needs to control a few basic characteristic parameters, the system will automatically provide a reasonable structure scheme based on the structural rules and verification rules that are input into the computer in advance. . In addition, although the mold design has the characteristics of one-piece small batch production, each mold is different. However, in the same project, customers often have the same technical requirements for the same type of mold, and many molds have similar structures. We will parameterize and regularize these similar structures according to the customer's technical requirements and form an infrastructure library for the project. Not only meet the customer's technical requirements, but also improve the design efficiency.
â—† Association-based design
CATIA's associated functions make cross-references between parts more reliable. When part B references some feature element (for example, a face or a line) on another part A, if the associated function is turned on and part A changes, the part referenced in part B is also updated. This association function guarantees the synchronization of the referenced elements. Make references more reliable. There is also an advanced correlation function - Publication. Using the association established by the Publication, it only recognizes the Publication element, and does not emphasize which part object, this publication is more flexible and the application is more extensive.
The traditional mold design process is a linear process, that is, after the DL diagram is designed, the mold structure is designed. With the relevance design of the Publication, it is possible to use the preliminary DL draft for the preliminary design of the mold structure during the drafting phase of the DL diagram. After the formal drawing of the DL diagram is completed, the temporary surface is updated to the formal DL diagram surface, and the structural perfection work is continued. Using this design flow, the two design phases can be parallelized, without having to compress the DL diagram and the structure design time, but it can effectively shorten the entire mold design cycle.
In the mold structure design, we publish the most important basic elements (drawings, axes, parameters, etc.) that affect the mold structure. The entire mold structure is used as a reference trunk to extend the design. If the mold structure needs to be adjusted, it is only necessary to modify these basic elements, and it is possible to achieve the purpose of pulling the whole body. The use of this associative design method clarifies the design ideas and provides a good solution to the rapid modification of the mold.
In addition, during the mold design process, repeated modifications of the product's digital model often lead to repeated design work. With associative design, structural designers simply do not have to deal with changes in the small-to-medium range of products, and CATIA's affiliate updates are automatically performed. Only when the number of products changes greatly, designers need to intervene.
â—† Flexible use of various standard parts
In the process of structural refinement, the POWER COPY type standard parts provide the standard structure of the casting body. The User Component standard that can automatically Boolean operation, because the installation station and standard parts are in a PART part, the installation station will move along with the parts movement, change is very convenient. Ordinary standard parts are simple to operate and easy to use.
The above content covers the entire process from the conception to the refinement of the mold design. In each design stage, there are corresponding resources and knowledge as support. Taking structural standardization as the leading ideology, using parametric, intelligent knowledge bases, and reasonable Boolean calculation methods, the organic combination of design thinking and knowledge resources is realized, and the design thinking is quickly embodied. The flexible use of these resources, whether it is the design of the early design, or the late structural changes have provided a good operating environment, truly improve the quality and efficiency of mold design.
Digital analysis
The use of cross-section inspection, interference inspection, relative motion interference inspection, motion simulation and other analytical means to truly reflect the actual working conditions of the mold to ensure the reliability of the design.
â—† Section inspection
The CATIA Spatial Analysis Module provides a variety of cross-section inspection modes. Can be used to check the mold structure, audit mold design is reasonable and so on. In addition, it helps the designer to understand the internal structure of the mold and check the strength of the mold structure.
â—† Interference checking
The CATIA spatial analysis module provides various analysis modes such as interference check, contact check, and minimum distance check. It can effectively analyze the spatial relationship between two or more parts in an assembly, and calculate the specific values ​​to generate a spatial analysis report.
â—† Motion Simulation
The CATIA-DMU electronic prototype motion simulation module enables the designer to verify the movement of the mechanism through simulation. Based on the constraint relationship between parts, 2D and 3D motion pairs are established and a motion mechanism is established for simulation. In addition, speed, acceleration, interference, clearance, etc. can be analyzed.
The above is a valuable experience that has been summarized in the long-term automotive mold design. Its fundamental purpose is to integrate various resources and knowledge to serve the design. We use various concepts and processes to standardize and improve design efficiency, and comprehensively use various testing and management tools to improve design quality. Create a high-efficiency, high-quality solid design platform. At present, this technology has been widely used by FAW Mold and has completed a number of domestic and foreign projects. The successful development of three-dimensional physical design technology for automotive molds has optimized the mold structure, improved the knowledge utilization ratio, shortened the mold production cycle, and improved the product quality and performance/price ratio.
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