1.3　Process Method and Equipment of Mould　模具制造方法及设备

1.3.1　Manufacturing Method of Mould　模具的制造方法

Mould manufacturing refers to the production of moulds.It comprises of two procedures.First， material used to make mould parts （normally metals） is processed with certain manufacturing equipment and technology and is changed in shape， size， relative position， and quality to become the mould parts in accordance to the requirements.Second， these parts are matched， positioned， connected， fixed， and assembled into moulds.　模具制造是指模具的生产，它包括两个步骤。首先，在一定的制造装备和制造工艺条件下，直接对模具零件材料（一般为金属材料）进行加工，以改变其形状、尺寸、相对位置和性质，使之成为符合要求的模具零件。其次，再将这些零件经配合、定位、连接与固定、装配成为模具。

Major methods used to process mould materials （metallic or non-metallic） into moulds include the conventional mechanical processing， special processing， and plastic processing， casting and welding.　将模具材料（金属或非金属）加工成模具的方法，主要有常规机械加工、特种加工以及塑性加工、铸造和焊接加工方法等。

（1）Conventional Mechanical Processing　常规机械加工

Conventional mechanical processing （i.e.， the traditional cutting and grinding） is an indispensable， important processing method in mould manufacturing.Even moulds are manufactured with other processing methods， some work is still done with cutting or grinding， such as the mould base processing， mould blank processing， moulded surface processing and hole machining.　常规机械加工（即传统的切削与磨削加工）是模具制造中不可缺少的一种重要的加工方法。即使是用其他加工方法制造模具，也需要采用切削或磨削加工来完成某些工作。例如模架加工、模坯加工、模具型面加工以及孔类加工等。

The obvious advantages of the conventional mechanical processing are its high machining accuracy， high production efficiency， and adaptability workpieces of different shapes and sizes can be manufactured with the same machine and tools.However， it also has several disadvantages.It is slow to process workpieces of a complicated shape； it is difficult to process hard materials； its material utilization is not high； it requires a skilled operator.In spite of all these， the conventional mechanical processing method is still the principal processing method in mould manufacturing.　常规机械加工的明显特点是加工精度高、生产效率高，而且用相同的机床和工具可以加工出各种形状和尺寸的工件。但是，用常规机械加工方法加工复杂的形状时，其加工速度很慢，硬的材料也难以加工；材料的利用率不高；而且还要求有熟练的操作工人。尽管如此，在模具制造过程中常规机械加工仍然是主要的加工手段。

（2）Special Processing　特种加工

Special processing， also known as electric processing， is unconventional machining， which is different from the conventional machining method.Broadly speaking， it refers to any processing method that does not use tools harder than the workpiece or exert obvious mechanical forces during the machining process， but directly uses electrical energy， chemical energy， sound energy， light energy to remove redundant parts on the workpiece in order to meet requirements for shape， size and surface roughness.It includes the electric spark forming processing， wire cut electrical discharge machining （WEDM）， electrolytic machining， electrochemical polishing， electrolytic grinding， electroforming， chemical etching， ultrasonic machining， laser processing， etc.　特种加工是有别于常规机械加工方法的非传统加工方法，也称电加工。从广义上来说，特种加工是指那些不需要用比工件更硬的工具，也不需要在加工过程中施加明显的机械力，而是直接利用电能、化学能、声能、光能等来除去工件上的多余部分，以达到一定的形状、尺寸和表面粗糙度要求的加工方法，其中包括电火花成形加工、电火花线切割加工、电解加工、电化学抛光、电解磨削、电铸、化学蚀刻、超声波加工、激光加工等。

Special processing relative to the conventional mechanical processing， has the following features.　特种加工相对于常规机械加工，有如下特点。

①The processing situation has nothing to do with the hardness of workpiece， can be achieved conquering the unyielding with the yielding.

②Tool and the workpiece is generally not contact， don’t have to exert obvious mechanical force during the machining process.

③Processing all kinds of complicated shape parts.

④Easy to implement process automation.

Because of the special processing has the characteristic of these precious， so special processing get more and more widely used in mould manufacturing， and become an important method of mould processing.

①加工情况与工件的硬度无关，可以实现以柔克刚。

②工具与工件一般不接触，加工过程不必施加明显的机械力。

③可加工各种复杂形状的零件。

④易于实现加工过程自动化。

正因为特种加工有上述这些可贵的特点，所以特种加工在模具制造中得到越来越广泛的应用，并成为模具加工中的一种重要方法。

（3）Plastic Processing　塑性加工

Plastic processing mainly refers to cold extrusion moulding， in which the quenched forming mould （the original male mould） is forced by pressure into the blank made of steel or other soft material without previously undergoing hardening treatment， leaving a duplicate shape of the original male mould on the blank， and producing the mould needed.　塑性加工主要是冷挤压制模法，即将淬火过的成形模（原阳模）强有力地压入未进行硬化处理的模坯（钢或其他软质材料）内，使原阳模的形状复印在被压的模坯上，制成所需要的模具。

Cold extrusion moulding method has several advantages.Moulds obtained through this method do not need moulded surface finishing， so it saves time and material.It can be used to make moulds with different moulded surfaces in precision and so a master mould can be used to make many identical moulds.One disadvantage of this method is that an original male forming mould is required in advance， and the mould produced through pressure tends to deform during quenching.　冷挤压制模法有几个优点。冷挤压制模法所成形的模具完全不需要将型面进行精加工，它制模速度快、省料，可以制成各种复杂型面的模具，且形状精确，利于用一套原模制作多副相同模具。这种制模法一定要事先制作一个成形的原阳模，而且压制后的模具在淬火时易引起变形。

（4）Casting　铸造

Moulds the demand for whose precision and service life is not high can be produced quickly through simple and convenient casting process.　对于一些精度和使用寿命要求不高的模具，人们往往会用简单方便的铸造法快速制成。

①Iron casting.Moulds that are large and irregular such as the car shell are normally produced through casting.The advantages of producing moulds through casting include： it is easy to produce moulds of complicated shapes； there is no limit for the size of the mould； the cost is low； the process is well lubricated and so there is little conglutination during the process.Chief shortcomings of the method are that the producing moulds have poor wear resistance and poor precision.　铸铁。像加工汽车外壳等大件且不规则形状的模具，一般都用铸造方法制成。铸铁模在制造上的优点是，可以很容易铸出复杂的形状，尺寸不受限制，便于进行机械加工，而且价格低，润滑性好，胶着少。它的缺点是耐磨性差，精度差。

②Zinc-base alloy.Zinc-base alloy is a typical material used to make simple mould through casting.It has the following advantages： low melting point， good castability and relatively high precision， and good strength， abrasion resistance and lubricity the same as mild steel.The technology of casting moulds with low-melting-point zinc-base alloys is known as the method of rapid moulds manufacturing.With this technology moulds can be made at a fast speed and in complicated shapes.However， the mould material used in this technology is soft and has a poor heat resistance， so the mould life is short.Therefore， this technology is mainly adopted in trial production or in small batch production.　锌基合金。锌基合金是一种用铸造法制造简易模具的典型材料，其熔点低，可铸性好，所以铸造精度相对较高，而且还具有软钢那样的强度、耐磨性和润滑性。用低熔点材料锌基合金铸造模具，也称快速制模法，其制模速度快，容易制成形状复杂的模具，但模具的材质较软，耐热性差，所以模具寿命短，多用于试制和小批量生产的场合。

In order to improve the quality and service life of rapid moulds manufacturing through this method， beryllium copper alloy， which has a better thermal conductivity and durability， is used to replace zinc-base alloy.This material is mainly used for the production of subtle complex moulds in large batches.　为了提高快速制模的质量和使用寿命，也有用导热性和耐久性较好的铍铜合金代替锌基合金的，主要用于生产批量较大而又细微的复杂模具。

③Synthetic resin.Synthetic resin can also be used in casting moulds.The materials used include phenolic resin， polyester resin， epoxy resin， etc.The advantages of casting moulds with synthetic resin are：the mould can be produced at a high speed；the mould is light and is free from rusting；the mould is easy to replicate and repair.But synthetic resin has a poor abrasion resistance and a large thermal deformation； besides， it does not have a high intensity and it goes fatigue and ageing easily.　合成树脂。铸造法制模也有用合成树脂的，主要有酚醛树脂、聚酯树脂、环氧树脂等。合成树脂模的优点是容易快速制模，轻而无锈，复制和维修都比较简单。但耐磨性差，遇热变形大，且强度不高、易疲劳老化。

（5）Welding　焊接

The modules separately processed and prepared can be welded together to form the mould needed.Compared with the overall processing methods， such a mould manufacturing method （using welding） is simple， rapid， material efficient， and can be used to produce mould of unrestricted sizes.However， it is difficult to guarantee high accuracy in welding， and it is likely to leave heat strain and internal stress inside the mould so that moulds produced in this way have a poor ability to withstand impact.Welding is mainly used to produce large moulds which do not demand for high accuracy， or to repair moulds.　焊接法制模是将分散加工好的模块焊接在一起，形成所需的模具。这种制模方法与整体加工相比，加工简单、快速、省料、尺寸大小不受限制。但精度难以保证，易残留热应变及内部应力，承受冲击的能力差。主要用于精度要求不高的大型模具的制造，或是用于模具的修复。

1.3.2　Conventional Machining Method and Equipment of Mould　模具的常规机械加工及其设备

（1）Turning Processing and Lathe　车削加工及车床

Turning processing refers to the workpiece rotates as the background movement， cutting tool moves as the feedding movement of the cutting method.This method is mainly used for processing of rotary surface： the outer circle and inner circle， end face， cone， thread， rotary forming surface， rotary groove and drill hole， counterboring， reaming， knurling， etc.　车削加工是指工件旋转做主运动、刀具移动做进给运动的切削加工方法。主要用来加工各种回转表面：外圆、内圆、端面、锥面、螺纹、回转成形面、回转沟槽以及钻孔、扩孔、铰孔、滚花等。

Turning processing can be conducted on horizontal lathes， vertical lathes， turret lathes， copying lathes， automatic lathes， CNC lathes and a variety of special purpose lathes.　车削加工可以在卧式车床、立式车床、转塔车床、仿形车床、自动车床、数控车床以及各种专用车床上进行。

1—Change gear box　挂轮架；2—Operating handle　操作手柄；3—Spindle box　主轴箱；4—Saddle（Big carriage）　床鞍（大拖板）；5—Cross-slide　中拖板；6—Square tool post　方刀架；7—Rotary plate　转盘；8—Small slide　小拖板；9—Tailstock　尾座；10—Lathe bed　床身；11—Right base　右床脚；12—Feed rod　光杆；13—Lead screw　丝杆；14—Apron　溜板箱；15—Left base　左床脚；16—Feeding box　进给箱

1—Base　底座；2—Table　工作台；3—Vertical column　立柱；4—Vertical tool post　垂直刀架；5，9—Beam　横梁；6—Feeding box of vertical tool post　垂直刀架进给箱；7—Ram head　侧刀架；8—Ram head feeding box　侧刀架进给箱

（2）Milling Processing and Milling Machine　铣削加工及铣床

Milling processing refers to the machining method in which the milling cutter rotates as the principal motion while the workpiece moves as the feeding movement.Milling can be used to machine planes （including the horizontal， vertical and inclined plane according to the machining position）， grooves （including rectangular grooves， key grooves， V-type grooves， dovetail grooves， T-type grooves， circular grooves， spiral grooves） and forming surfaces， etc.， and can also be used for hole processing （including drill hole， counterboring， reaming， milling holes） and dividing.　铣削加工是指铣刀旋转做主运动、工件移动做进给运动的切削加工方法。铣削可加工平面（按加工时所处的位置又分为水平面、垂直面和斜面）、沟槽（包括直角槽、键槽、V形槽、燕尾槽、T形槽、圆弧槽、螺旋槽）和成形面等，还可进行孔加工（包括钻孔、扩孔、铰孔、铣孔）和分度工作。

Milling can be conducted on horizontal milling machines， vertical milling machines， plano-milling machines， tool milling machines and various special milling machines.　铣削加工可以在卧式铣床、立式铣床、龙门铣床、工具铣床以及各种专用铣床上进行。

1—Column　床身；2—Cantilever　悬臂；3—Milling cutter mandrel　铣刀心轴；4—Pylon　挂架；5—Table　工作台；6—Saddle　床鞍；7—Knee　升降台；8—Base　底座

（3）Boring Processing and Boring Machine　镗削加工及镗床

The boring processing refers to the cutting machining method in which the boring cutter rotates as the background motion， the workpiece or boring cutter moves as the feeding movement.　镗刀旋转做主运动、工件或镗刀做进给运动的切削加工方法称为镗削加工。

1—Spindle box　主轴箱；2—Vertical column　立柱；3—Rotary table　圆工作台；4—Slide　滑座；5—Base　底座

1—Bed　床身；2，8—Lie milling head　卧铣头；3，6—Vertical milling head　立铣头；4—Vertical column　立柱；5—Beam　横梁；7—Controller　控制器；9—Table　工作台

1—Table　工作台；2—Workpiece　工件；3—Profiling　靠模；4—Milling cutter　铣刀；5—Vertical column　立柱；6—Spindle box　主轴箱；7—Spindle　主轴；8—Bed　床身

Boring processing is mainly conducted on boring-milling machine， boring machine， is one of the commonly used methods for machining holes.　镗削加工主要在镗铣床、镗床上进行，是加工孔常用的方法之一。

1—Spindle box　主轴箱；2—Former vertical column　前立柱；3—Boring spidle　镗轴；4—Facing head　平旋盘；5—Table　工作台；6—Upper slide　上滑座；7—Under slide　下滑座；8—Bed　床身；9—Back bearing　后支承；10—Back vertical column　后立柱

1—Bed　床身；2—Saddle　床鞍；3—Table　工作台；4—Vertical column　立柱；5—Spindle box　主轴箱

1—Beam　横梁；2—Spindle box　主轴箱；3—Vertical column　立柱；4—Table　工作台；5—Bed　床身

1—Cross slide　横向滑座；2—Longitudinal slide　纵向滑座；3—Rotary table　回转工作台；4—Vertical column　立柱；5—Spindle box　主轴箱；6—Bed　床身

1—Spindle box　主轴箱；2—Spindle　主轴；3—Table　工作台；4—Bed　床身

Kong kim boring machine is named with diamond boring tool， it is a kind of high speed precision boring machine.　金刚镗床因采用金刚石镗刀而得名，它是一种高速精密镗床。

（4）Drilling Processing and Drill Machine　钻削加工及钻床

Drilling processing refers to the machining method which machines hole with a drill or reamer， counter bit on the workpiece.　用钻头或铰刀、锪钻在工件上加工孔的加工方法称为钻削加工。

Drilling can be conducted on the bench drilling machines， vertical drilling machines， radial drilling machines， also can be conducted on lathes， milling machines， boring-milling machines， and other machine tools.　钻削可以在台式钻床、立式钻床、摇臂钻床上进行，也可以在车床、铣床、镗铣床等机床上进行。

1—Gearbox　变速箱；2—Feed box　进给箱；3—Spindle　主轴；4—Table　工作台；5—Base　底座；6—Vertical column　立柱

1—Base　底座；2—Vertical column　立柱；3—Rocker　摇臂；4—Screw rod　丝杆；5，6—Motor　电动机；7—Spindle box　主轴箱；8—Spindle　主轴

（5）Planing Processing and Planer　刨削加工及刨床

Planing processing refers to a machining method which makes plane tool do the level straight line reciprocating movement relative to the workpiece.Planing can process plane （according to the process’s position is divided into horizontal， vertical， inclined plane）， groove （including rectangular slot， V groove， dovetail slot and T slot） and linear shaping face， etc.　刨削加工是指用刨刀对工件做水平相对直线往复运动的切削加工方法。刨削可以加工平面（按加工时所处的位置又分为水平面、垂直面、斜面）、沟槽（包括直角槽、V形槽、燕尾槽、T形槽）和直线型成形面等。

1—Beam　横梁；2—Table　工作台；3—Ram　滑枕；4—Regulating handle of the ram position　滑枕位置调节手柄；5—Clapper box　摆动刀架；6—Handlebar for locking　紧定手把；7—Control handle　操纵手柄；8—Handlebar for rapid movement of table　工作台快移手把；9—Regulating handle of feed rate　进给量调节手柄；10—Velocity adjustment handle　速度调节手柄；11—Stroke handle　行程手柄；12—Bed　床身；13—Base　底座；14—Reversing handle for feed mov-ement　进给运动换向手柄；15—Handle for table movement direction　工作台移动方向手柄

1—Bed　床身；2—Table　工作台；3—Beam　横梁；4—Vertical clapper box　立刀架；5—Upper beam　上横梁；6—Vertical column　立柱；7—Feed box　进给箱；8—Gearbox　变速箱；9—Side clapper box　侧刀架

Planing can be conducted on shaping machine and double housing planer.Shaping machine is suitable for small and medium-sized workpieces.Double housing planer is suitable for processing large workpieces or multiple small and medium-sized workpieces at the same time.　刨削可以在牛头刨床和龙门刨床上进行。牛头刨床适宜加工中小型工件；龙门刨床适宜加工大型工件或同时加工多个中小型工件。

（6）Grinding and Grinding Machine　磨削加工及磨床

Grinding refers to the machining method use abrasive wheel or coated abrasive as a cutting tool， machining workpiece surface with high line speed.It has the characteristics of high machining accuracy， high hardness materials can be processed.Grinding can process excircle，inner circle， cone， plane， forming surface， thread， tooth profile and other surfaces， also can grinding all kinds of cutting tools.　磨削加工是指用砂轮或涂附磨具作为切削工具、以较高的线速度对工件表面进行加工的方法。它具有加工精度高、可加工高硬度材料的特点。磨削可加工外圆、内圆、锥面、平面、成形面、螺纹、齿形等多种表面，还可刃磨各种刀具。

1—Bed　床身；2—Workhead　头架；3—Abrasive wheel　砂轮；4—Inner circle abrasive tool　内圆磨具；5—Support frame　支架；6—Wheel supporting frame　砂轮架；7—Tailstock　尾架；8—Table　工作台；9，11—Hand wheel　手轮；10—Travel stop dog　行程挡块

1—Bed　床身；2—Table 工作台；3—Workhead　头架；4—Grinding carriage　砂轮架；5—Carriage　滑鞍

1—Hand wheel（for moving table）　（工作台移动）手轮；2—Wheelhead　磨头；3—Slide plate　拖板；4—Hand whell（for moving wheelhead）　（磨头移动）　手轮；5—Grinding wheel dresser　砂轮修正器；6—Column　立柱；7—Travel stop dog　行程挡块；8—Table（Saddle）　工作台；9—Hand wheel（for moving wheelhead）　（磨头移动）手轮；10—Bed　床身

1—Grinding carriage　砂轮架；2—Carriage　滑鞍；3—Vertical column　立柱；4—Table　工作台；5—Bed　床身；6—Saddle　床鞍

1，2—Grinding wheel frame column　立柱；3—Bed　床身；4—Table　工作台；5—Saddle　床鞍

Grinding is mostly conducted on the grinding machine.　磨削加工大多在磨床上进行。

（7）Numerical Control （NC） Machine　数控机床

With the rapid development of science and technology， profound changes have taken place in mechanical manufacturing technology.Key components of modern mechanical products are usually sophisticated and are processed in small batches and frequent remodel.Obviously such components cannot be machined on special purpose machine tools or combined machines， whereas the processing accuracy and production efficiency may be greatly limited if the processing is manually operated with the aid of contour machines and profiling machines， or with the aid of drawing lines or sample plates.Complicated curves and surfaces， in particular， cannot be processed in the ordinary machine tools.　随着科学技术的飞速发展，机械制造技术发生了深刻的变化。现代机械产品的一些关键零部件，往往都精密复杂，加工批量小，改型频繁，显然不能在专用机床或组合机床上加工。而借助靠模和仿形机床，或者借助划线和样板用手工操作的方法来加工，加工精度和生产效率受到很大程度的限制。特别对空间的复杂曲线曲面，在普通机床上根本无法实现。

1—Base　底座；2—Photoelectric tape reader　光电读带器；3—Tool control board　机床操纵台；4—Operation panel of numerical control system　数控系统操作面板；5—Guide rail　导轨；6—Tool post　刀架；7—Protective door　防护门；8—Tailstock　尾座

1—Bed　床身；2—Lower table　下工作台；3—Upper table　上工作台；4—Headstock　头架；5—Abrasion wheel spindle　砂轮主轴；6—Tailstock　尾座；7—Control panel　控制箱；8—Detection box　检测箱；9—Operation desk　操作台

1—Base　底座；2—Electrical cabinet　电气柜；3—Oil tank　油箱；4，13，14—Position control device　位控装置；5—Gearbox　变速箱；6—Spindle box　主轴箱；7—Shield　防护罩；8，9—Travel stop dog　行程挡块；10—Operation panel of numerical control system　数控系统操作面板；11—Carriage　滑鞍；12—Saddle　床鞍；15—Bed　床身；16—Table　工作台

In order to solve the above problems， a new type of machine has come into being， that is the numerical control machine.It effectively solves the above contradictions and has provided automated processing means for single piece and small-batch production and especially for moulds parts with complicated surfaces.　为了解决上述问题，一种新型的数字程序控制机床，即数控机床应运而生，它极其有效地解决了上述矛盾，为单件、小批量生产，特别是像模具这样的复杂型面零件提供了自动化加工手段。

1—Outer cover　外罩；2—Workpiece　工件；3—Cooling liquid supply tubes　冷却液管；4—Vertical column　立柱；5—Milling head　铣削头；6—Control panel　控制面板；7—Cutting tool　刀具；8—Table　工作台；9—Reference point　参考点

1—Base　底座；2—Table　工作台；3—Drill　钻头；4—Tool changer chuck　刀库夹头；5—Multiple-step tool changer　多工位刀库；6—Vertical column　立柱；7—Turret　转塔；8—Control panel　控制面板

（8）Combined Machine　组合机床

Combined machines are highly efficient， automatic special machine tools which adopt serialized， standardized general parts combined with a small number of special parts.Just like common special machine tools， they have the characteristics of simple structure， high efficiency， and high precision.They can be readjusted and recombined to adapt to the change of workpiece，and render multicut， multiaspect and multistation processes at the same time.They are especially fit for processing one part or several similar parts in one or more processes in mass production.Combined machine tools can complete processes such as drilling， expanding， reaming， boring and tapping， rolling， and turning， milling， grinding， and are mostly suitable for processing box-type parts.　组合机床是以系列化、标准化的通用部件为基础，配以少量的专用部件组成的高效自动化专用机床。它既具有一般专用机床结构简单、生产效率高、易保证精度的特点，又能适应工件的变化，重新调整和重新组合，对工件采用多刀、多面及多工位加工，特别适用于大批、大量生产中对一种或几种类似零件的一道或几道工序进行加工。组合机床可以完成钻、扩、铰、镗孔和攻螺纹、滚压以及车、铣、磨削等工序，最适合箱体类零件的加工。

1—Position control device　位控装置；2—Manipulator　机械手；3—Numerical control cabinet　数控柜；4—Tool changer　刀库；5—Spindle box　主轴箱；6—Operation panel of numerical control system　数控系统操作面板；7—Vertical column　立柱；8—Table　工作台；9—Saddle　床鞍；10—Bed　床身

1—Saddle　床鞍；2—Cutting tool　刀具；3—Tool changer　刀库；4—Numerical control cabinet　数控柜

1—Side base　侧底座；2—Base of column 立柱底座；3—Vertical column　立柱；4—Spindle box　主轴箱；5—Power control box　动力箱；6—Sliding table　滑台；7—Middle base　中间底座；8—Fixture　夹具

1.3.3　Special Processing and Equipment of Mould　模具特种加工及其设备

（1）EDM and WEDM Processing　电火花和线切割加工

Electric spark machining is also called electro-discharge machining（EDM for short），electroerosion machining，is a kind of the method of using the heat energy produced by pulse discharge for processing.Its process is： continually produce pulsed spark discharge between the tool and workpiece， the discharge when local， transient high temperature keep the metal melting， gasification and removal in materials.Visible to the spark in discharge process， so called electro-discharge machining.　电火花加工又称放电加工（简称EDM）、电蚀加工，是一种利用脉冲放电产生的热能进行加工的方法。其加工过程为：使工具和工件之间不断产生脉冲性的火花放电，靠放电时局部、瞬时产生的高温把金属熔解、气化而蚀除材料。放电过程可见到火花，故称之为电火花加工。

Wire cut EDM（WEDM for short）， is a new form of technology developed in the late 1950s in former Soviet Union on the basis of electro-discharge machining.The technology uses spark discharges from the linear electrodes （molybdenum wire or copper wire）to cut the workpiece， so it is called WEDM， sometimes referred to as “wire cut”.　电火花线切割加工（简称WEDM）是在电火花加工的基础上，20世纪50年代末在前苏联发展起来的一种新的工艺形式，是用线状电极（钼丝或铜丝）靠火花放电对工件进行切割，故称为电火花线切割，有时简称线切割。

1—Workpiece　工件；2—Pulse power supply　脉冲电源；3—Feed control apparatus　进给调节装置；4—Tool　工具；5—Working solution　工作液；6—Filter　过滤器；7—Pump of working solution　工作液泵

1—Hydraulic pump and oil tank　液压泵油箱；2—Bed　床身；3—Working solution case　工作液箱；4—Vertical column　立柱；5—Spindle　主轴；6—Pulse power supply　脉冲电源；7—Control panel　控制板

1—Insulating base　绝缘底板；2—Workpiece　工件；3—Pulse power supply　脉冲电源；4—Molybdenum wire　钼丝；5—Guide pulley　导向轮；6—Support　支架；7—Wire spool　储丝筒

（2）Electrochemical Machining　电化学加工

Electrochemical Machining （ECM） is divided into four categories.

①Electrolytic machining： the workpiece （as anode） is dissolved and the metal material on it is removed； the workpiece materials reduce， including electrolytic machining and electrolytic polishing.

1—Pulse power supply　脉冲电源；2—Workpiece　工件；3—Working solution case　工作液箱；4—Pure water　纯水；5—Pump　泵；6—Drum for putting new wire　新丝放丝筒；7—Table　工作台；8—X-axis motor　X轴电动机；9—Numerical control device　数控装置；10—Y-axis motor　Y轴电动机；11—Drum for waste wire　废丝卷筒

②Plating， coating： the metal materials are deposited on the workpiece （as cathode） surface； workpiece materials increase， including electroplating， local plating， electroforming and composite electroplating.

③Electrolytic grinding， electrochemical honing， electrolytic milling： the workpiece as the anode is dissolved and a lot of materials on it are removed， the cathode with the grind and mill mechanical action removes material on anode further that the anode is activated and forms electrochemical mechanical compound technology.

④Other composite process， such as electrolytic-EDM compound technology， electrolysis-EDM-machinery compound technology.

电化学加工（简称ECM）分四类。

①工件（作为阳极）溶解去除金属材料的电解加工——工件材料减少，包括电解加工和电解抛光。

②工件（作为阴极）表层沉积金属的电镀、涂覆——工件材料增加，包括电镀、局部涂镀、电铸和复合电镀。

③工件作为阳极溶解去除大量材料，具有磨、研等机械作用的阴极对阳极的进一步去除材料使阳极活化而形成的电化学机械复合工艺，有电解磨削、电解珩磨、电解研磨。

④其他复合工艺，如电解电火花复合工艺、电解电火花机械复合工艺。

1—Power supply　电源；2—Cathode　阴极；3—Anode　阳极；4—Pump　泵；5—Electrolyte　电解液

（3）Laser Machining and Ultrasonic Machining　激光加工和超声波加工

Laser technique is developed in the early 1960s.Laser processing can be used for punching， cutting， fine-tuning of electronic devices， welding， heat treatment， laser storage， laser guidance and other fields.Laser processing is characterized by high speed and small deformation and can be used to process various materials.It has displayed increasing superiority in the production practice and has drawn increasing attention.　激光技术是20世纪60年代初发展起来的一门新兴科学。激光加工可以用于打孔、切割、电子器件的微调、焊接、热处理以及激光存储、激光制导等各个领域。由于激光加工速度快、变形小，可以加工各种材料，在生产实践中愈来愈显示它的优越性，愈来愈受人们的重视。

1—Plating bath　电镀槽；2—Anode　阳极；3—Power supply　电源；4—Electroforming tier　电铸层；5—Master mould　原模；6—Stirrer　搅拌器；7—Electroforming fluid　电铸液；8—Filter　过滤器；9—Pump　泵；10—Heater　加热器

1—Workpiece　工件；2—Air inlet　进气口；3—Pressure gauge　压力表；4—Collecting lens　聚光透镜；5—Laser beam　激光束；6—Nozzle　喷嘴

The operation principle of laser machining is that， with the extremely high energy focused by laser， the temperature at the processing spot on the workpiece can reach thousands of， or even ten thousand degrees， causing the material to melt and evaporate.When the molten material is blasted away by the thermal shock wave， corresponding processing is thus realized.　激光加工工作原理就是利用聚焦的激光能量密度极高，被照射工件加工区域温度达数千度，甚至上万度的高温将材料瞬时熔化、蒸发，并在热冲击波作用下，将熔融材料爆破式喷射去除，达到相应的加工目的。

1—Charge sensor　电荷传感器；2—Welding nozzle　焊接喷嘴；3—Protective gas　保护气体；4—Collecting lens　聚光透镜；5—Half-reflecting mirror　半反射镜；6—Laser beam　激光束；7—Coaxial optical sensor　同轴光学传感器；8—Side optical sensor　侧面光学传感器；9—Acoustic sensor　声学传感器；10—Weld pool　焊接熔池

1—Tool　工具；2—Workpiece　工件；3—Abrasive suspension liquid　磨料悬浮液；4，5—Amplitude transformer　变幅杆；6—Transducer　换能器；7—Ultrasonic generator　超声波发生器

1—Support　支架；2—Counterweight　平衡物；3—Table　工作台；4—Tool　工具；5—Amplitude transformer　变幅杆；6—Transducer　换能器；7—Guideb rail　导轨；8—Scaleplate　标尺

Ultrasonic machining（USM）particularly suitable for hard brittle materials of conductor and non-conductor effective processing， is a useful complement to special processing technology， the main processes are： punching， cutting， cleaning， welding， flaw detection， etc.　超声波加工（USM）特别适合对导体、非导体的脆硬材料进行有效加工，是对特种加工工艺的有益补充，目前主要的工艺有：打孔、切割、清洗、焊接、探伤等。

1.3.4　New Technique and New Process of Mould　模具新技术、新工艺

（1）Rapid Prototyping Technology　快速成型技术

The basic principle of rapid prototype （RP）， also called rapid master mould forming， increase-material manufacturing， laminated manufacturing or layered manufacturing， is to make limited two-dimensional discrete refined delamination on the complex three-dimensional entity or shell. RP technology mainly depends on the development of numerical control technology， and nearly all RP devices are equipped with numerical control systems.Presently the comparatively mature RP techniques include： stereolithography（SL）， selective laser sintering（SLS）， laminated object manufacturing（LOM）， fuseddeposition modeling（FDM）， three-dimensional printing（3D-P）， and solid ground curing（SGC）.Other RP methods are still in further study.　快速成型（RP）又叫快速原模成型、增材制造、叠层制造或分层制造，其基本思想都是基于将复杂的三维实体或壳体，作有限的二维离散细化分层。快速成型技术主要依托数控技术的发展，几乎所有的快速成型设备都配数控系统。目前比较成熟的工艺方法：光敏树脂液相固化（SL）、选择性粉末激光烧结（SLS）、薄片分层叠加成型（LOM），熔丝堆积成型（FDM），三维打印法（3D-P）和固基光敏液相法（SGC）。其他方法还在进一步研究中。

1—Laser device　激光器；2—Scraper　刮刀；3—Elevated working platform　可升降工作台；4—Flume　液槽

1—Laser device　激光器；2—Roller for paving powder　铺粉滚筒；3—Watch window　观察窗口；4—Plane sintering　平面烧结；5—Raw material powder　原料粉末；6—Generate workpiece　生成工件；7—Piston suppling powder　供粉活塞；8—Piston taking shape　成型活塞

The process principle of stereolithography apparatus （SLA） is based on the liquid photosensitive resin polymerization.That is， photopolymerization takes place quickly when liquid photosensitive resins are treated with ultraviolet rays of certain wavelengths and power.Their molecular weight increases sharply， so that the materials turn from liquid to solid and get solidification.　光敏树脂液相固化成型设备（SLA）的工艺原理是基于液态光敏树脂光聚合原理工作的，即液态光敏树脂材料在一定波长和功率的紫外线照射下迅速发生光聚合反应，分子量剧增，材料从液态转化成固态，达到固化。

Selective laser sintering forming（SLS） is the use of metal and nonmetal powder material under the laser irradiation， sintering， hot melt forming layer upon layer into a three-dimensional entity under computer control.　选择性粉末激光烧结成型（SLS）是利用金属、非金属的粉末状材料在激光照射下，烧结热熔成型，在计算机控制下层层堆积成三维实体。

Laminated object manufacturing （LOM）combines laser cutting with bonding technique.Sheets （paper or plastic film） covered with hot-melt adhesives are cut with laser according to the CAD layered model， and are then hot-pressed with a hot pressing roller so that the bottom layer of the sheets adheres to the forming workpiece.The sheets pile up to form the mould.　薄片分层叠加成型（LOM）是利用激光切割与黏合工艺相结合，用激光将涂有热熔胶的纸质、塑料薄膜等片材按照CAD分层模型轨迹切割成型，然后通过热压辊热压，使其与下层已成型的工件层粘接，从而堆积成型。

1—Computer　计算机；2，6—Guide roller　导向辊；3—Mechanism of storaging and sending raw material　存储及送料机构；4—Table　工作台；5—Raw material　原材料；7—Mechanism for hot-sticking-press　热粘压机构；8—Laser cutting system　激光切割系统

1—Forming workpiece　成型工件；2，3—Heating shower nozzle　加热喷头；4—Filament material　料丝

Fused deposition modeling （FDM） makes use of the hot-melting and cohesiveness features of the thermoplastic material， and modeling takes place when the material deposits under computer control.Filamentous material is fed through a wire feed mechanism into a tiny heating spray nozzle where it is heated and melted.The nozzle， while moving within a plane along the contour and filling path of the part under the control of the computer， squeezes out the molten material which combines with the previous layer of material and solidifies.After completion of one layer of deposition， the working station drops by the distance of just one layer， and the melt-spray process continues.A three-dimensional model forms when layers of material is so added to one another.　熔丝堆积成型（FDM）工艺是利用热塑性材料的热熔性、粘接性，在计算机控制下层层堆积成型的。丝状材料通过送丝机构将其送进一个微细加热喷嘴的喷头，并被加热熔化，在计算机的控制下，喷头在平面内沿着零件截面轮廓和填充轨迹移动，同时将熔融材料挤出，并与前一层熔结固化在一起。一个片层沉积完成后，工作台下降一个层厚的距离，继续熔喷沉积下一层，如此层层叠加形成立体模型。

1—Paving powder　铺粉；2—Monolayer printing　单层印刷；3—Declining piston　下降活塞；4—Circulation repetition　循环重复；5—Intermediate stage　中间阶段；6—Printing the end layer　印刷最后一层；7—Finished product of part　零件成品

The process principle of three-dimensional printing （3D-P）： under the control of the computer， the nozzle sprays adhesives according to information about the section of the model onto the material paved with a layer of power which then combines and forms a section on the material.After completion of a layer， the work table drops by the distance of just one layer of the material， and the processes of paving powder and spraying adhesives continue.The procedure goes on until the three-dimensional physical product is produced.The product thus obtained normally needs to be further solidified or sintered in a furnace in order to improve the adhesive strength.　三维打印法（3D-P）的工艺原理是：喷头在计算机的控制下，按照截面轮廓的信息，在铺好的一层粉末材料上，有选择地喷射粘接剂，使部分粉末粘接，形成截面层。一层完成后，工作台下降一个厚度，铺粉，喷粘接剂，再进行下一层的粘接，如此循环，直至形成三维实体产品。粘接得到的制件需要置于加热炉中做进一步的固化或烧结，以提高粘接强度。

1—Machined face　加工面；2—Inflicting equably photosensitive liquid material　均匀施加光敏液材料；3—Mask UV-light （ultraviolet light） exposure　掩膜紫外光曝光；4—Remove no-solidify raw-material　清除未固化原料；5—Fill wax　填蜡；6—Rubdown　磨平；7—Drip moulding　成型件；8—Wax　蜡；9—Workpiece　零件

Solid ground curing process principle（SGC）.Forming process of a layer is done by 5 steps： added substance； mask UV-light exposure； remove no-solidify excess liquid material； fill wax to the interspace； rubdown.Ion-imaging-technology is adopted for mask， so the same film can be repeated use.Due to the complexity of process， SGC forming machine is one of the most huge forming machine of all.　固基光敏液相法（SGC）的工艺原理。一层的成形过程由5步来完成：添料；掩膜紫外光曝光；清除未固化的多余液体料；向空隙处填充蜡料；磨平。掩膜的制造采用了离子成像技术，因此同一底片可以重复使用。由于过程复杂，SGC成型机是所有成形机中最庞大的一种。

（2）CAD/CAM for Mould　模具CAD/CAM

With the development of industrial production and science and technology， the increase of market demand， as well as the products renewal speed up， products are developing towards complex， precision， more varieties， high quality and short delivery cycle， which requires the mould production has a shorter cycle， lower cost and higher quality.Rely on experience and manual skills of traditional mould design and manufacturing way far cannot satisfy the requirements， and application of computer in mould computer aided design（CAD）and computer aided manufacturing（CAM）is an effective way to solve this contradiction.　随着工业生产和科学技术的发展，市场需求的增加，以及产品更新换代速度的加快，产品生产正向复杂、精密、多品种、高质量和交货周期短的方向发展，这就要求模具生产具有更短的周期、更低的成本和更高的质量。依赖经验和手工技能的传统模具设计与制造方式远远不能满足这种要求，而应用计算机进行模具的计算机辅助设计（CAD）和计算机辅助制造（CAM）是解决这一矛盾的有效途径。

1—Printer　打印机；2—Server　服务器；3—CAD/CAM workstation　CAD/CAM工作站；4—DNC software workstation　传输软件工作站；5—Multiport board　多接口板；6—CNC machine center　数控加工中心；7—Milling machine　铣床；8—Electric discharge machine　电加工机床；9—Wire cutting machine　线切割机床

1—Factory　工厂；2—Workshop　车间；3—Manufacturing machine　加工设备

（3）Surface Engineering Technology for Mould　模具表面工程技术

Mould material is the basis of die and mould industry.The continuous development of mould forming technology has put increasingly high demand for mould materials.And the specialization and industrialization of mould manufacturing and processing require that the cost of mould material and processing be reduced as much as possible.For years， thanks to the constant efforts of the engineering， technical and scientific research personnel， a series of new mould materials have been researched and developed， and the original heat treatment process of the die steel was improved and optimized.However， in many cases， it is still difficult to meet the requirements for die of high performance and low costs.Surface engineering technology is a comparatively active and quickly developing branch in the fields of materials science and engineering.Their application in the field of mould processing and manufacturing has to a great extent made up the deficiency in mould materials.　模具材料是模具工业的基础。模具成形加工技术的不断发展，对模具材料提出的要求越来越高。而模具制造加工的专业化与产业化又要求尽量地降低模具材料及其加工的费用。尽管多年来，由于工程技术人员和科研人员的不断努力，研制开发了系列新型模具材料，并对原有模具钢的热处理工艺进行了改进与优化，但在许多场合，仍难以满足模具的高性能、低成本的要求。表面工程技术是当前材料学科与工程领域中表现较为活跃、发展较为迅速的分支。表面工程技术在模具加工与制造领域中的应用，在很大程度上弥补了模具材料的不足。

There are extensive applications of the surface engineering technologies to mould processing and manufacturing.These do not just include the traditional surface quenching technology （such as induction hardening， flame hardening， etc.）， thermal expansion-infiltration technology （such as carburizing， nitriding， carbonitriding， metallic infiltration， etc.）， surface welding technology and hard chromium plating technology， but also include technologies that have been developed rapidly in the recent 20 years such as the laser surface strengthening technology， physical vapor deposition （PVD）， chemical vapor deposition （CVD）， ion implantation technology and thermal spraying technology， brush plating technology and chemical plating technology， etc.Moreover， the traditional surface engineering technologies are being developed and perfected.For instance， the thermal expansion-infiltration technology is developing from the infiltration of a single element to that of multiple elements.The emergence and perfection of the metallic infiltration with molten salt method provides a cheap and high quality process of mould surface strengthening.The traditional electroplating technology has developed to the composite plating process，not only the highly hard cermet can be coated by electroplating， self-lubricating coating is also possible to be electroplated， which， when plated on the surface of the mould cavity， can greatly improve the performance of demoulding on the mould.　可应用于模具加工与制造的表面工程技术非常广泛，不仅包括传统的表面淬火技术（如感应淬火、火焰淬火等）、热扩渗技术（如渗碳、渗氮、碳氮共渗、渗金属等）、堆焊技术和电镀硬铬技术外，还有近20年来迅速发展起来的激光表面强化技术、物理气相沉积技术（PVD）、化学气相沉积技术（CVD）、离子注入技术、热喷涂技术、电刷镀技术和化学镀技术等。而且，传统的表面工程技术也在不断完善与发展之中。如热扩渗技术正由渗单一元素向多元共渗的方向发展，而熔盐渗金属法的出现与完善，为模具表面强化提供了廉价而优质的工艺途径。又如，传统的电镀技术已发展到复合电镀工艺，不仅可以完成高硬度的金属陶瓷涂层的电镀，而且可以电镀自润滑涂层，将其镀于模具内腔表面，可大大改善模具的脱模性能。

1—Base material　基材；2—Coating　涂层；3—Spray stream tube　喷涂流束；4—Burning material　燃烧材料；5—Burning gas　燃烧气体；6—Wire rod or bar　线材或棒材；7—Oxygen　氧气；8—Fuel gas　燃料气；9—Pulverization gas　雾化气

1—Compressed air for pulverization　雾化用压缩空气；2—Wire rod　线材；3—Electric arc area　电弧区；4—Liquation particle　熔融粒子；5—Coating　涂层；6—Base material　基材

1—Vacuum pump　真空泵；2—Cooling water　冷却水；3—Sample　试样；4—Pressure gauge　压力表；5—Air inflow（Ar or N2）　进气（氩气或氮气）；6—Feeding device　送料装置；7—Control box　控制箱

1—Spark plug　火花塞；2—Powder　粉末；3—Nitrogen　氮气；4—Acetylene　乙炔；5—Oxygen　氧气；6—Base material　基材

1—Powder and current-carrying N2 gas　粉末和载流N2气；2，3—Compressed air　压缩空气；4—Aerosphere　大气层；5—Dia-mond squirt flow（1372m/s）　钻石喷射流（1372m/s）；6—Pulv-erization squirt flow　雾化喷射流；7—Base material　基材；8—Coating　涂层；9—Diamond flow　钻石流；10—Liquation powder particle　熔融粉末颗粒；11—Maximum temperature 5000℉ of liquation flow　熔流最高温度5000℉

1，7—Heater　加热器；2—ZaSc light harvesting lens　ZaSc集光透镜；3—Speculum　反射镜；4—Laser beam　激光束；5—CO2 laser gene-rator　CO2激光发生器；6—Window　窗口；8—Matrix　基体；9—Ceramic　陶瓷