模具是定(ding)形、定(ding)值、精(jing)密(mi)、高效且經(jing)濟的(de)(de)生(sheng)產工(gong)具，其發展水平體現了國家商品生(sheng)產的(de)(de)發展程度，為加快商品上(shang)市(shi)，搶占(zhan)市(shi)場先機(ji)，就必須(xu)縮短模具的(de)(de)生(sheng)產周(zhou)期。傳統模具是典型(xing)的(de)(de)單件(jian)生(sheng)產，裝配主要采用修配，工(gong)作零件(jian)的(de)(de)互(hu)換性較(jiao)差、生(sheng)產周(zhou)期較(jiao)長。

 
      模(mo)(mo)具(ju)(ju)(ju)的(de)(de)(de)標(biao)準(zhun)化有利于(yu)(yu)設計水平(ping)、質量(liang)和(he)效率的(de)(de)(de)提高，從而使(shi)模(mo)(mo)具(ju)(ju)(ju)生產(chan)由(you)單件(jian)生產(chan)轉為成(cheng)批、通用(yong)(yong)的(de)(de)(de)專業(ye)化生產(chan)，降低生產(chan)成(cheng)本(ben)，縮(suo)短(duan)制造(zao)周期(qi)。模(mo)(mo)具(ju)(ju)(ju)零(ling)(ling)件(jian)可分為結(jie)構零(ling)(ling)件(jian)和(he)工(gong)藝(yi)零(ling)(ling)件(jian)，模(mo)(mo)具(ju)(ju)(ju)結(jie)構零(ling)(ling)件(jian)的(de)(de)(de)標(biao)準(zhun)在(zai)模(mo)(mo)具(ju)(ju)(ju)生產(chan)中已得(de)到廣(guang)泛的(de)(de)(de)推廣(guang)，裝配時調(diao)整少(shao)，甚(shen)至不調(diao)整，對(dui)于(yu)(yu)縮(suo)短(duan)制造(zao)周期(qi)、降低采購成(cheng)本(ben)和(he)提高模(mo)(mo)具(ju)(ju)(ju)質量(liang)，有著極(ji)大的(de)(de)(de)促進(jin)作(zuo)用(yong)(yong)。由(you)于(yu)(yu)模(mo)(mo)具(ju)(ju)(ju)工(gong)藝(yi)零(ling)(ling)件(jian)的(de)(de)(de)差異性大，裝配過程(cheng)研配工(gong)作(zuo)較復雜，所(suo)以對(dui)模(mo)(mo)具(ju)(ju)(ju)工(gong)藝(yi)零(ling)(ling)件(jian)制造(zao)的(de)(de)(de)標(biao)準(zhun)化研究可以將模(mo)(mo)具(ju)(ju)(ju)制造(zao)經驗(yan)進(jin)行總(zong)結(jie)和(he)推廣(guang)，加速(su)模(mo)(mo)具(ju)(ju)(ju)商品(pin)化進(jin)程(cheng)，使(shi)得(de)模(mo)(mo)具(ju)(ju)(ju)的(de)(de)(de)流(liu)水線制造(zao)成(cheng)為可能，為企業(ye)帶來巨大生產(chan)力。

      一套雙槽門板修(xiu)邊(bian)模(mo)的(de)(de)(de)鑲(xiang)(xiang)塊(kuai)(kuai)數量在(zai)100塊(kuai)(kuai)以上(shang)(shang)，為保證模(mo)具裝(zhuang)(zhuang)配(pei)精度(du)，傳(chuan)統(tong)制造工(gong)藝將鑲(xiang)(xiang)塊(kuai)(kuai)單獨完成底面銑(xian)削、磨削后，進行(xing)靠山面、結(jie)合(he)面的(de)(de)(de)精加(jia)(jia)工(gong)，再由鉗工(gong)研(yan)修(xiu)底面和(he)結(jie)合(he)面，安裝(zhuang)(zhuang)在(zai)底板上(shang)(shang)合(he)銑(xian)型(xing)面和(he)輪廓。該工(gong)藝的(de)(de)(de)主要弊(bi)端為：①生產(chan)組(zu)織上(shang)(shang)，底板加(jia)(jia)工(gong)完成后才能(neng)安裝(zhuang)(zhuang)鑲(xiang)(xiang)塊(kuai)(kuai)，最后在(zai)底板上(shang)(shang)合(he)銑(xian)，不能(neng)做到(dao)制造過(guo)程(cheng)中的(de)(de)(de)并行(xing)生產(chan)，耽誤(wu)制造周期。②鑲(xiang)(xiang)塊(kuai)(kuai)裝(zhuang)(zhuang)配(pei)時(shi)鉗工(gong)研(yan)修(xiu)工(gong)作(zuo)量大(da)，鑲(xiang)(xiang)塊(kuai)(kuai)拼裝(zhuang)(zhuang)質量取決于鉗工(gong)的(de)(de)(de)經驗和(he)技能(neng)水平。③占用了(le)大(da)型(xing)CNC臺機的(de)(de)(de)數控加(jia)(jia)工(gong)時(shi)間(jian)，機床有(you)等待(dai)時(shi)間(jian)，增加(jia)(jia)了(le)制造成本(ben)。④由于鑲(xiang)(xiang)塊(kuai)(kuai)數量多，在(zai)鉗工(gong)拼裝(zhuang)(zhuang)時(shi)存在(zai)累計(ji)誤(wu)差，從而使得(de)單件(jian)鑲(xiang)(xiang)塊(kuai)(kuai)的(de)(de)(de)結(jie)合(he)面、螺釘孔和(he)銷孔偏差大(da)，互換(huan)性差，更換(huan)時(shi)必須回(hui)原廠修(xiu)配(pei)制造，加(jia)(jia)大(da)了(le)維護成本(ben)。

      （1）鑲塊(kuai)的(de)(de)(de)標(biao)準化制(zhi)造的(de)(de)(de)難點　①加(jia)工(gong)的(de)(de)(de)工(gong)序內容多，不(bu)僅有型面(mian)、輪廓(kuo)加(jia)工(gong)，還有結合面(mian)、靠山面(mian)、標(biao)識(shi)平面(mian)和孔加(jia)工(gong)等(deng)。②加(jia)工(gong)型面(mian)復雜，型面(mian)起伏大(da)(da)(da)，對(dui)于不(bu)同區域需(xu)采(cai)用不(bu)同的(de)(de)(de)加(jia)工(gong)策略。③毛坯不(bu)規則，毛坯余(yu)量不(bu)均(jun)勻，從而(er)使得單件制(zhi)造過程中耗費的(de)(de)(de)裝夾、對(dui)刀(dao)時間長，對(dui)機床操作人員(yuan)來說，頻(pin)繁(fan)的(de)(de)(de)裝夾、換刀(dao)和程序調(diao)用，勞動(dong)強(qiang)度加(jia)大(da)(da)(da)，還大(da)(da)(da)大(da)(da)(da)增加(jia)了出錯的(de)(de)(de)可能性(xing)。④對(dui)工(gong)藝編程人員(yuan)的(de)(de)(de)要求較(jiao)高，編程人員(yuan)不(bu)僅要掌握扎(zha)實的(de)(de)(de)建模、刀(dao)具(ju)和編程知識(shi)，還需(xu)要有模具(ju)設計和裝配(pei)制(zhi)造的(de)(de)(de)工(gong)藝經(jing)驗。

 
      （2）鑲(xiang)塊標準化(hua)制(zhi)(zhi)造(zao)(zao)(zao)工藝(yi)方(fang)案　在提(ti)高單個鑲(xiang)塊制(zhi)(zhi)造(zao)(zao)(zao)精度的前提(ti)下保證(zheng)整體合模精度，雖(sui)然增加了鑲(xiang)塊的制(zhi)(zhi)造(zao)(zao)(zao)成本，但可以(yi)有效地縮短工藝(yi)流程，減(jian)少(shao)工藝(yi)等待(dai)時間(jian)(jian)，將(jiang)順(shun)序生(sheng)產組(zu)織(zhi)方(fang)式變為(wei)并行生(sheng)產方(fang)式，改變模具單件配做制(zhi)(zhi)造(zao)(zao)(zao)理念，將(jiang)鑲(xiang)塊視為(wei)商品化(hua)制(zhi)(zhi)造(zao)(zao)(zao)產品來生(sheng)產，保證(zheng)了單個鑲(xiang)塊的互換性，減(jian)少(shao)了維護等待(dai)時間(jian)(jian)，提(ti)升了后期服務滿意度，縮短了模具整體制(zhi)(zhi)造(zao)(zao)(zao)周期。
對比表(biao)1、表(biao)2的(de)新舊加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)方(fang)案可(ke)以看到，修邊(bian)模(mo)具(ju)鑲(xiang)塊的(de)工(gong)(gong)(gong)(gong)(gong)(gong)藝(yi)(yi)流(liu)程(cheng)縮短，裝(zhuang)夾(jia)次數(shu)(shu)減(jian)少(shao)，加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)集中化(hua)(hua)程(cheng)度(du)提高(gao)，減(jian)少(shao)了(le)(le)累(lei)計誤差，充(chong)(chong)分發揮了(le)(le)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)中心自動化(hua)(hua)、高(gao)精(jing)度(du)的(de)優(you)勢，減(jian)少(shao)了(le)(le)手工(gong)(gong)(gong)(gong)(gong)(gong)出(chu)錯(cuo)。采用(yong)新工(gong)(gong)(gong)(gong)(gong)(gong)藝(yi)(yi)方(fang)案的(de)優(you)點有：①制(zhi)(zhi)造過(guo)程(cheng)自動化(hua)(hua)，采用(yong)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)中心單(dan)元，充(chong)(chong)分利用(yong)了(le)(le)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)中心刀(dao)庫高(gao)效自動換刀(dao)功能，一(yi)次裝(zhuang)夾(jia)即(ji)可(ke)完成粗、精(jing)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，避免(mian)了(le)(le)基準轉換誤差。②制(zhi)(zhi)造工(gong)(gong)(gong)(gong)(gong)(gong)藝(yi)(yi)標準化(hua)(hua)，規(gui)(gui)定了(le)(le)鑲(xiang)塊統一(yi)的(de)裝(zhuang)夾(jia)定位方(fang)法，按標準工(gong)(gong)(gong)(gong)(gong)(gong)藝(yi)(yi)流(liu)程(cheng)數(shu)(shu)控(kong)（CNC）加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)。③加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)數(shu)(shu)據規(gui)(gui)范(fan)(fan)化(hua)(hua)，將(jiang)鑲(xiang)塊上(shang)產(chan)品制(zhi)(zhi)造信息（PMI）顯式表(biao)述(shu)，根(gen)據鑲(xiang)塊功能、精(jing)度(du)和(he)工(gong)(gong)(gong)(gong)(gong)(gong)藝(yi)(yi)要求建立統一(yi)涂色(se)標準。④數(shu)(shu)控(kong)編程(cheng)模(mo)板(ban)化(hua)(hua)，制(zhi)(zhi)訂的(de)標準工(gong)(gong)(gong)(gong)(gong)(gong)藝(yi)(yi)規(gui)(gui)則(ze)最終是靠數(shu)(shu)控(kong)程(cheng)序來體現，為提高(gao)編程(cheng)效率，規(gui)(gui)范(fan)(fan)程(cheng)序質量，減(jian)少(shao)人(ren)為差錯(cuo)，各個工(gong)(gong)(gong)(gong)(gong)(gong)序均(jun)采用(yong)標準的(de)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)模(mo)板(ban)，實現數(shu)(shu)控(kong)程(cheng)序的(de)規(gui)(gui)范(fan)(fan)。