摘要消失模铸造工艺生产汽车变速箱体已在全国十多家企业获得应用，但复杂变速箱发泡模具的设计与制造问题是困扰很多消失模生产厂家的技术难题之一。如何高效、快捷、准确地实现该类模具的开发，是普及消失模铸造技术的瓶颈。本文研究的重点是：基于Unigraphics软件平台，面向模具开发的全过程，探索出具备复制性、操作性、可靠性的实用解决方案。基于UG/Modeling模块，针对箱体这类复杂产品造型和分模设计总结出一套行之有效的操作方法；以Windows操作系统和UG软件为平台，综合运用UG/OpenMenuScript、UG/OpenUIStyler、UG/OpenAPI和VisualC++6.0等UG二次开发工具实现了发泡模具标准汽室的二次开发，提高了同类型模具的设计效率；阐述了模型质量的定义以及与下游应用的关系，通过列举和分析在实际工作过程中遇到的大量模型质量问题，将模型质量问题划分为真实性、结构性、精度三大类，根据三年UG操作经验，针对性地总结出解决方法；基于UG/Manufacturing模块，实现复杂深腔模具的高效加工，解决薄壁锻铝材变形的问题。针对这类复杂箱体LFC泡塑模，从毛坯制备到最终的模具总装试模，形成了一套成熟的工艺路线。笔者为主要设计人员，参与山西华恩集团18686型变速箱泡塑模项目，成功开发出两套不同材质（锻、铸）复杂变速箱泡塑模具，并已投入大批量生产，实现了减轻铸件重量和提高铸件尺寸精度两个重要指标，受到客户好评。关键词：Unigraphics计算机辅助设计变速箱发泡模具消失模UG二次开发模型质量数控加工AbstractLostFoamCasting(LFC)hasbeenappliedsuccessfullytoproductionofautomotivegear-boxbyadozenoffoundryinChina.Butfoam-mold’sdesignandmanufactureofcomplexgear-boxisstillatechnicalproblemformanyLFCfoundries.Howtodevelopfoam-moldefficientlyandeffectively,whichisbottle-necktopromoteLFC’sapplication.Emphasisinthispaperisthat:baseonUGplatform,weexplorefeasible、repeatable、dependableresolutionfocusedonwholefoammolddevelopment.BaseonUG/Modeling,wesummarizeasetofoperationalmethodspecializedinthreedimensionalmodelingandmolddesignofcomplexgear-box;3Dparameterizedstandardpartofsteam-baseisbuiltonUGCADplatformbyutilizingUGre-developmenttools:UG/OpenAPI,MenuScript,UIStyler,andVisualC++6.0,whichimprovethequality,efficiency,andstandardizationleveloftheaotumotivegear-boxmolddesignandshortenitsdesignperiod;BaseonourrichmanipulatedexperienceonUG,wesummarizethecategory、originandresolutionofmodelquality,whichwealwaysmeetinsubsequentprocesse;BaseonUG/Manufacturing,weachieveeffectiveandefficientmanufactureofdeep、narrowmoldcavityandassemblefoam-moldsuccessfully.Specializedforcomplexgear-boxfoammold,weformamaturetechnicalroutine.Twosetoffoam-moldwedevelopedhavebeenappliedsuccessfullyinmassproductionof18686-Cautomotivecase,whichimproveprecisionandlightenweightofcasting,achievemoremarketsandcustomersforShanxiHuaenCorporation.KeyWords:UnigraphicsCADGear-BoxFoamMoldLFCUGre-devlopmentModelQualityCNC目录摘要..................................................................IABSTRACT...........................................................................................................................II1绪论...............................................................11.1课题提出与目标........................................................................................................11.2模具CAD/CAM技术................................................................................................11.3UGCAD/CAM系统模块功能简介..........................................................................31.4消失模铸造及其发展...................................................................................
