近年來，模具行業結構調整步伐加快，大型、精密、復雜、長壽命模具發展速度明顯高于行業的總體發展速度。模具的質量和壽命相互關聯，影響模具壽命的主要因素有模具的材質和坯料處理、相關的熱處理、大連模具加工精度(du)(du)（輪廓精度(du)(du)和(he)位置精度(du)(du)等）、模(mo)具(ju)(ju)的(de)(de)表面質量（包括表面粗糙度(du)(du)、硬度(du)(du)和(he)表面層金相組(zu)織結構）等，其中最(zui)關鍵的(de)(de)影響(xiang)因素是(shi)(shi)模(mo)具(ju)(ju)的(de)(de)精度(du)(du)，特(te)別(bie)是(shi)(shi)模(mo)具(ju)(ju)的(de)(de)裝配精度(du)(du)。因此(ci)，要(yao)(yao)制作高精度(du)(du)模(mo)具(ju)(ju)，特(te)別(bie)是(shi)(shi)多腔(qiang)精密(mi)模(mo)，最(zui)重要(yao)(yao)的(de)(de)就是(shi)(shi)采用優質的(de)(de)工(gong)藝方(fang)案(an)，以(yi)提高零件的(de)(de)加(jia)工(gong)精度(du)(du)和(he)加(jia)工(gong)效率，能適應(ying)市(shi)場需(xu)求。

加工現狀及改善目標

已加工完成的1出8腔試驗模如圖2所示，各工序加工機床生產過程工時數據記錄見表1。此加工工藝方案模具加工總(zong)工(gong)(gong)時(shi)(shi)達到1304小時(shi)(shi)，由此推(tui)算(suan)1出128腔模具加工(gong)(gong)總(zong)工(gong)(gong)時(shi)(shi)需要(yao)20864小時(shi)(shi)，以45天(tian)為一(yi)套模具加工(gong)(gong)周(zhou)期(qi)，共需要(yao)208臺加工(gong)(gong)設備，設備需求量過大(da)，加工(gong)(gong)方案低效，無法滿(man)足客戶實際訂(ding)單(dan)周(zhou)期(qi)需求。

從成本(ben)、周期、資源綜合(he)考慮，必須進行(xing)加工提(ti)效(xiao)，才能滿足模(mo)具交付周期。目標是各工序平均(jun)提(ti)效(xiao)30%，加工合(he)格(ge)率(lv)達到95%

（1）CNC粗銑工(gong)(gong)(gong)序(xu)優(you)化(hua)　CAM程序(xu)策略(lve)(lve)優(you)化(hua)使用(yong)的PowerMILL軟件(jian)(jian)(jian)(jian)是(shi)(shi)由(you)英國Delcam公司開發的專業的CAM編程軟件(jian)(jian)(jian)(jian)，該軟件(jian)(jian)(jian)(jian)安全性能高且(qie)粗、精加(jia)工(gong)(gong)(gong)策略(lve)(lve)多(duo)，運用(yong)靈(ling)活。利用(yong)軟件(jian)(jian)(jian)(jian)特性，加(jia)工(gong)(gong)(gong)方(fang)法由(you)原來的“偏置粗銑策略(lve)(lve)”優(you)化(hua)為“預鉆孔＋等(deng)(deng)高策略(lve)(lve)”后，切(qie)削刀路軌(gui)跡化(hua)繁為簡(jian)，效率(lv)提(ti)升較明顯，可(ke)(ke)提(ti)效32%。，設計專用(yong)工(gong)(gong)(gong)裝(zhuang)(zhuang)夾具可(ke)(ke)有效降(jiang)低停(ting)機等(deng)(deng)待浪費，提(ti)高機床稼動(dong)率(lv)。根據零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)特性，設計排位6個(ge)槽可(ke)(ke)裝(zhuang)(zhuang)夾6個(ge)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)的工(gong)(gong)(gong)裝(zhuang)(zhuang)，其重(zhong)量剛好(hao)適(shi)合手工(gong)(gong)(gong)安全搬運，裝(zhuang)(zhuang)夾后單(dan)個(ge)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)不需(xu)要再分中和校表找正，一次裝(zhuang)(zhuang)夾可(ke)(ke)加(jia)工(gong)(gong)(gong)6個(ge)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)的正、反(fan)兩側共(gong)4面的特征(zheng)，優(you)化(hua)之前現(xian)(xian)場(chang)(chang)的低效操作(zuo)，實現(xian)(xian)了快速裝(zhuang)(zhuang)夾、批量加(jia)工(gong)(gong)(gong)，大幅縮短了現(xian)(xian)場(chang)(chang)操作(zuo)導致的停(ting)機等(deng)(deng)待時(shi)(shi)間(jian)(jian)。原加(jia)工(gong)(gong)(gong)方(fang)案是(shi)(shi)單(dan)件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)(gong)，每件(jian)(jian)(jian)(jian)需(xu)要4次裝(zhuang)(zhuang)夾，6件(jian)(jian)(jian)(jian)共(gong)需(xu)24次裝(zhuang)(zhuang)夾，6件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)(gong)總(zong)工(gong)(gong)(gong)時(shi)(shi)達12.6h。新加(jia)工(gong)(gong)(gong)方(fang)案使用(yong)專用(yong)工(gong)(gong)(gong)裝(zhuang)(zhuang)夾具，6件(jian)(jian)(jian)(jian)共(gong)需(xu)4次裝(zhuang)(zhuang)夾，單(dan)件(jian)(jian)(jian)(jian)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)的切(qie)削時(shi)(shi)間(jian)(jian)是(shi)(shi)1.3h（不含刀具切(qie)換時(shi)(shi)間(jian)(jian)），以每個(ge)工(gong)(gong)(gong)位裝(zhuang)(zhuang)夾時(shi)(shi)間(jian)(jian)是(shi)(shi)0.2h計算(suan)，加(jia)工(gong)(gong)(gong)總(zong)工(gong)(gong)(gong)時(shi)(shi)為8.6h，可(ke)(ke)提(ti)效46%。

（2）TUR工序　原加工方案(an)單件(jian)加工尾部預留(liu)15mm藝(yi)腳，新加工方案(an)采用長圓坯料，一次裝夾車(che)削8個(ge)零件(jian)，批(pi)量加工優化后可提案(an)35％。

1）采用組(zu)合備料，一次裝夾(jia)完成加工(gong)(gong)分件，減少去(qu)除工(gong)(gong)藝腳線割工(gong)(gong)時0.5h/件。

2）密封圈槽(cao)和擋水片槽(cao)車削工序加(jia)工完成，減少熱處理(li)后磨床精(jing)加(jia)工工時(shi)0.3h/件。

3）車(che)削余量(liang)由原來(lai)的0.3mm調整為0.15mm，減少熱處理后車(che)床半精(jing)工工時0.5h/件(jian)。

4）材料成(cheng)本縮減25％，原出(chu)8件(jian)需要340mm，新工藝出(chu)8件(jian)只需260mm。

（3）GRI工序設計工裝　原加工方(fang)案單件加工尾部(bu)預留藝腳(jiao)，新加工方(fang)案使用專(zhuan)用工裝夾具，無需每件都(dou)校表找正，優化后可實現快速切換加工，提(ti)效30%，見(jian)表7。

1）使用專用工(gong)裝夾具(ju)，實現(xian)批量快速切換(huan)加(jia)工(gong)，減少零件(jian)裝夾校正(zheng)時(shi)間0.3h/件(jian)。

2）密封圈槽、擋(dang)水片槽采用車削直(zhi)接加工(gong)完成，減(jian)少精磨時間0.3h/件(jian)。