With the solid model made by rapid prototyping, combined with precision casting, metal spraying, electroplating and electrode grinding, the mold can be quickly manufactured. The manufacturing cycle is generally 1/5 to 1/10 of the traditional CNC cutting method, but the cost is only It is 1/3 to 1/5. A variety of processes have been developed based on mold materials, production costs, RP prototype materials, production batches, and mold accuracy requirements. 1) Using a rapid prototyping part as a master mold to make a silicone rubber mold. When the number of parts manufactured is small (in batches of 20 to 50 pieces), the RP prototype is generally used as a master mold, and silicone is cast by a room temperature vulcanized silicone rubber. Rubber mold. Due to the good flexibility and elasticity of silicone rubber, for parts with complicated structure, fine pattern, no draft angle (even with a certain degree of draft angle) and parts with deep grooves, the parts can be directly taken out after casting. . The process can produce various plastic parts and paraffin models in small batches quickly, easily and inexpensively, and is widely used in aerospace, sporting goods, toys and decorative equipment. The production cycle is about 1 week. The cost is 1/15-1/20 of the steel mold. The following picture shows the rapid mold making case of the telescope shell developed by Yunnan Optical Instrument Factory. Through the production of the RP model and the transformation of ABS plastic samples using silicone rubber molds, Yunnan Optical Instrument Factory quickly realized the development of new products, including RP prototypes, with a production cycle of 6 days. 2) Metal spraying (Metal Spraying) molding method When the required life of the mold is less than 3,000 pieces, the RP prototype is generally used as the master mold, and the low melting point molten metal (such as zinc aluminum alloy) is fully atomized and then fixed. The speed is sprayed onto the surface of the master mold to form the surface of the mold cavity, and the backing composite material is filled to prepare a zinc-aluminum alloy soft mold. The process method is simple, the cycle is short, and the surface of the cavity and its fine pattern are simultaneously formed at one time. The production cycle is 1 to 2 weeks, and the cost is 1/3 to 1/5 of the numerically processed steel mold. 3) Using a rapid-formed part as a master mold to make a steel mold. When the mold requires a life of more than 3,000 pieces, the RP prototype can be used as a master mold to reproduce an integral grinding wheel composed of a mixture of epoxy resin and silicon carbide (3D). Grinding wheel), grinding the whole graphite electrode on the graphite electrode forming machine, or depositing copper on the surface of the RP prototype by electroforming by about 2~3mm thick, removing the RP prototype to obtain the electrode shell, filling the backing The material is made into an integral copper electrode. The steel mold is manufactured by electric discharge machining using the above integral graphite electrode or integral copper electrode. The mold manufacturing process avoids CNC machining, saves CNC programming and processing time, and has high complex accuracy. The mold making cycle is 3 to 4 weeks, and the cost is 1/2-1/3 of the numerically processed steel mold. The following picture shows the case of rapid tooling for engine connecting rods developed by Yituo Group. Through the production of the connecting rod RP model, the graphite electrode of the connecting rod is fabricated by the graphite electrode integral forming technology, and the connecting rod steel mold is manufactured by electric discharge machining. The production cycle is 3 weeks.
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