Car rapid prototyping

Automobile rapid prototyping\automobile prototype parts\automobile rapid prototype parts\full vehicle trial production\trial production samples\automotive RP parts trial production

Rapid prototyping (also called rapid prototyping) manufacturing technology (Rapid Prototyping & Manufacturing, RP & M) is a new type of manufacturing technology developed in the 1980s. At present, the rapid prototyping field we are talking about can cover the following manufacturing technologies:

Laser rapid prototyping

CNC machining forming

Silicone mold making and vacuum injection molding small batch production

Low pressure reaction injection (RIM) molding and small batch production of plastic parts

The automobile industry is my country's pillar industry, and my country is becoming an important base for global automobile manufacturing. After China's accession to the WTO, the pressure on domestic automobile manufacturing has increased, and automobile research and development has become more and more important, and trial production is an important part of automobile development. As an important means, RP&M technology is increasingly applied to automobile development. RP prototypes can be used for visualization of CAD digital models, design evaluation, interference inspection, and even some functional tests. In addition, trial-produced parts can enable users to intuitively understand the appearance and performance of products that have not been put into mass production and can make timely evaluations, so that the factory can improve products in time according to user needs and market research, and create favorable conditions for product sales and avoid The possible loss due to blind production. Practice has proved that RP&M can optimize product design, shorten product development cycles, and reduce development costs, thereby improving the competitiveness of enterprises.

Shenzhen Kaiao Mould Technology Co., Ltd. (formerly Shenzhen Yinhua Company) is the first Sino-foreign joint venture to apply and promote RPM technology in mainland China, and is recognized by the Ministry of Science and Technology as a national rapid prototyping research and application service center and a national CAD application Engineering Demonstration Enterprise Company, Shenzhen High-tech Enterprise, Shenzhen CAD Technology Consulting Service Center. He has rich practical experience in engineering application in automobile trial production.

One. Laser rapid prototyping SLA

Laser rapid prototyping technology is based on the principle of 3D technology and computer-controlled layered scanning and rapid discrete accumulation molding. The material is liquid photosensitive resin. After scanning by ultraviolet laser irradiation, the layered polymerization reaction is solidified and the accumulation is completed. Molding in this way eliminates the need for time-consuming and costly mold or special tool design and machining, which greatly improves production efficiency and manufacturing flexibility.

Features of SLA rapid prototyping:

1. High processing accuracy, generally up to 0.1mm/100mm;

2. It can manufacture parts with complex shapes (such as hollow parts) and particularly delicate (such as jewelry, handicrafts, etc.), suitable for fine parts and toy accessories.

3. The parts are manufactured at a high speed and can be scanned in layers of 0.1-0.15mm;

4. The surface quality is good, it can produce very fine detail and thin wall structure, and the post-processing is easy;

5. The processing is in place, and many details that cannot be processed by CNC can be processed, thereby reducing the workload of post-processing;

6. Disadvantages: The photosensitive resin material selected for laser molding is relatively single, and the toughness and strength of the SLA prototype is not as good as the CNC sample, and the buckle is easy to break.

Two. CNC machining forming

The CNC prototype model is a product of modern industry. It integrates advanced technologies such as computer-aided design (CAD), computer-aided manufacturing (CAM) and computer digital control (CNC). Material is cut and excavated. After the workpiece is clamped once, the digital control system can control the machine tool to automatically select and replace the tools according to different procedures, automatically change the spindle speed, feed, and the motion path of the tool relative to the workpiece and other auxiliary functions to complete several surfaces of the workpiece in sequence. In the multi-process processing, the entire processing process is automatically controlled by the program, and is not affected by the operator's human factors.

CNC rapid sample processing material selection: ABS (imported, domestic, black, flame retardant, etc.), POM (Saigang), PMMA (acrylic), PA (nylon), PC, PP, bakelite, aluminum alloy, magnesium Alloy, zinc alloy, copper, etc.

The advantages of CNC prototypes: fast processing speed, low cost, and high processing accuracy can be achieved. Moreover, the wide selection of materials can ensure the consistency of the materials of the prototype model and the materials of the mass-produced parts. The prototype has a strong sense of reality, and the surface quality can reach a very high level. After subsequent processing such as grinding, polishing, sandblasting, painting, screen printing, UV, electroplating, etc., the production effect is completely comparable to the products produced by the mold, or even better. high.

Three. Silicone mold making and vacuum injection molding small batch production

Vacuum injection molding, also known as vacuum complex molding. The castable is degassed, stirred, preheated, and molded under vacuum conditions, and a secondary solidification molding process is performed for 2-3 hours in a thermostat at 60°C-80°C. It is suitable for small batch trial production in the product development process, with complex structure, uniform wall thickness, and trial production samples that meet certain functional requirements.

Technical Parameters:

Applicable mold: silicone mold (10-20 pieces of life).

Casting material: two-component polyurethane PU. Currently used materials: AXSON polyurethane resin, Hei-cast polyurethane resin.

Physical properties: similar to ABS, PP-like, nylon-like, PMMA/PC-like transparent parts, soft rubber parts (40-90shord D), high temperature resistant parts (150°C), fireproof materials, etc.

General working time: 1-4 hours/piece.

Standard copy accuracy: ±0.20mm/100mm.

Pouring sample thickness: minimum 0.5mm, best 1.5mm-5mm.

The largest casting workpiece: 2000mmX1200mmX1000mm.

Four. Low pressure reaction injection (RIM) molding and small batch production of plastic parts

Low pressure perfusion, also known as low pressure reaction injection molding (Reaction Injection Moulding, RIM). It is a new process used in the production of rapid molding products. After mixing two-component polyurethane materials, it is injected into the rapid mold under normal temperature and low pressure environment, and formed through chemical and physical processes such as polymerization, crosslinking, and curing of the material. Products. It has the advantages of high efficiency, short production cycle, simple process and low cost. It is suitable for small batch trial production in the product development process, as well as small batch production, simple structure covering parts and large thick wall and uneven wall thickness production.

Technical Parameters:

Applicable molds: ABS molds (more than 100 pieces); resin molds (more than 300 pieces); aluminum alloy molds (more than 1,000 pieces).

Casting material: two-component polyurethane PU. Currently used materials: HD-PU4210, DCP-RIM, AXSON-RIM 875.

Physical properties: similar to PP/ABS. The product has the characteristics of aging resistance, strong impact resistance, high consistency, and easy loading and unloading.

Injection pressure: about 10MPa. Flow control: 600g/s.

General working time: 15-30 minutes/piece. The demolding temperature can be controlled below 40℃. After demolding, the parts will be cured at 80℃ for 2-4 hours. The performance is best.

Standard copy accuracy: ±0.20mm/100mm.

Pouring sample thickness: the best pouring thickness is 4~6mm, and the maximum pouring thickness is 10mm.

The largest casting workpiece: 2000mmX1200mmX1000mm, 10KG.

Fives. Three-coordinate detection

Three-coordinate measurement technology has become an important means of modern manufacturing, especially mold industry design, development, manufacturing and quality assurance with its high precision, flexibility, and excellent digitization capabilities. Keao currently uses the Platinum FaroArm 2.4m articulated arm measuring instrument produced by FARO, USA, with a measurement accuracy of ±0.03mm. The coordinate measuring machine can use the input of 3D digital model to measure and compare the positioning, size, related geometric tolerances, curves and curved surfaces of the molded sample or mold with the digital model, and output a graphical report to reflect the product intuitively and clearly. Quality, thus forming a complete sample test report.

The following is the rapid prototyping production process of various auto parts

Car lights production process

1) Prototype: CNC processing, the lamp holder and reflector decoration parts are made of ABS or PC board, and the lampshade is made of PMMA board.

2) Mold: Silicone mold.

3) Note type: Vacuum injection type, the lamp holder and reflector decoration parts are made of PU resin Hei-cast8150 (like ABS material);

The lampshade material is PU resin AXSON-PX521HT (transparent heat-resistant high-strength material).

4) Post-processing: painting\vacuum coating.

5) Inspection: splicing tooling and jigs, three-coordinate inspection.

6) Precision control:

Prototype parts: main positioning hole ±0.3mm, general mounting hole ±0.5mm, other dimensions ±0.8mm.

Note type parts: main positioning hole ±0.5mm, general mounting hole ±0.8mm, other dimensions ±1.2mm.

Car dashboard manufacturing process

1) Prototype: CNC machining, material is ABS plate.

2) Mold: A surface is characterized by epoxy resin mold, and the structure of B surface is a silicone mold.

3) Injection type: vacuum injection type, the material is PU resin Hei-cast8150 (like ABS material).

4) Post-treatment: sandblasting\painting\coating.

5) Inspection: splicing tooling and jigs, three-coordinate measurement.

6) Precision control:

   Prototype parts: main positioning hole ±0.3mm/1000mm, general mounting hole ±0.5mm/1000mm, other sizes ±1.0mm/1000mm.

   Note type parts: main positioning hole ±0.5mm/1000mm, general mounting hole ±0.8mm/1000mm, other dimensions ±1.5mm/1000mm.

Manufacturing process of front and rear bumper of automobile

1) Prototype: CNC machining, material is ABS plate.

2) Mold: Epoxy resin mold or ABS mold.

3) Note type: low pressure infusion, the material is PU resin HD-RIM4210/1100, DCP-RIM, AXSON-RIM 875/900.

4) Post-processing: sandblasting\painting.

5) Inspection: splicing tooling and jigs, three-coordinate measurement.

6) Precision control:

   Prototype parts: main positioning hole ±0.3mm/1000mm, general mounting hole ±0.5mm/1000mm, other sizes ±1.0mm/1000mm.

   Note type parts: main positioning hole ±0.5mm/1000mm, general mounting hole ±0.8mm/1000mm, other dimensions ±1.5mm/1000mm.

Manufacturing process of automobile air conditioner

1) Prototype: CNC machining, material is ABS plate. Some parts (such as dials, tie rods) are made of POM material.

2) Mold: Silicone mold.

3) Injection type: vacuum injection type, the material is PU resin Hei-cast8150 (like ABS material).

4) Post-processing: sandblasting\painting.

5) Inspection: splicing tooling and jigs, assembly assembly inspection.

6) Precision control: prototype: ±0.15mm/100mm. Note type parts: ±0.20mm/100mm.

Car door and guard plate production process

1) Prototype: CNC machining, material is ABS plate.

2) Mold: Silicone mold.

3) Injection type: vacuum injection type, the material is PU resin Hei-cast8150 (like ABS material).

4) Post-processing: sandblasting\painting.

5) Inspection: splicing tooling and jigs, three-coordinate measurement.

6) Precision control:

   Prototype parts: main positioning hole ±0.3mm/1000mm, general mounting hole ±0.5mm/1000mm, other sizes ±1.0mm/1000mm.

   Note type parts: main positioning hole ±0.5mm/1000mm, general mounting hole ±0.8mm/1000mm, other dimensions ±1.5mm/1000mm.

Inlet panel production process

1) Prototype: CNC machining, material is ABS plate.

2) Mold: Silicone mold.

3) Injection type: vacuum injection type, the material is PU resin Hei-cast8150 (like ABS material).

4) Post-processing: sandblasting\painting\plating.

5) Inspection: splicing tooling and jigs, three-coordinate measurement.

6) Precision control:

   Prototype parts: main positioning hole ±0.3mm/1000mm, general mounting hole ±0.5mm/1000mm, other sizes ±1.0mm/1000mm.

   Note type parts: main positioning hole ±0.5mm/1000mm, general mounting hole ±0.8mm/1000mm, other dimensions ±1.5mm/1000mm.

Air duct and air outlet manufacturing process

1) Prototype: CNC machining, material is ABS plate.

2) Mold: Silicone mold with paraffin wax model cavity.

3) Injection molding: vacuum injection molding, one-time injection molding of integral samples. The material is PU resin Hei-cast8150 (like ABS material).

4) Post-processing: sandblasting\painting.

5) Inspection: splicing tooling and jigs, assembly assembly inspection.

6) Precision control: prototype: ±0.15mm/100mm. Note type parts: ±0.20mm/100mm.

CCB bracket production process

1) Production: CNC machining, the material is aluminum alloy.

2) Post-treatment: sandblasting\oxidation.

3) Inspection: positioning fixture, three-coordinate measurement.

4) Precision control:

The main positioning hole is ±0.3mm/1000mm, the general mounting hole is ±0.5mm/1000mm, and other dimensions are ±1.0mm/1000mm.

Intake Manifold Manufacturing Process

In order to ensure as much as possible the special requirements of the parts such as impact strength and air tightness, vacuum injection molding is used for overall overmolding.

Specific steps are as follows:

1) Make ABS molds that can disappear models. CNC machining the ABS mold of the inner cavity of the intake manifold, and the inner wall of the mold cavity is polished and polished.

2) Make a disappearable model. Using the above-mentioned mold, vacuum injection molding is used, and industrial paraffin wax with high melting point is used for injection molding. The molded wax model is the core of the inner cavity of the intake manifold. As shown below.

3) Prototype the ontology. CNC machined the prototype of the shape of the intake manifold (solid model). When making, increase the wall thickness of the part to 6mm as much as possible to increase the impact resistance of the part.

4) Make the body silicone mold. Use the body prototype to remake the silicone mold.

5) Vacuum injection. The wax mold core formed in the second step is fixed in the body silicone mold, and the high temperature resistant material YU-Heng5236 polyurethane is used for vacuum injection molding. The molded part is not only the intake manifold body containing the wax mold core, and then the parts are heated to above 90°C in the baking furnace to decompose the wax mold core at high temperature, melt and flow out, and the production is completed.

6) Material description (with photos):

YU-Heng5236A/B is a polyurethane resin infusion glue with high temperature resistance. The viscosity of the resin is low after mixing and the use time is long. This is conducive to easy pouring and good gloss after hardening. It is also a kind of resin with good weather resistance, which is not easy to be brittle when the temperature is lower than minus 20 ℃. It is also an excellent heat insulation, sound insulation and insulation material. The main physical properties are as follows:

Tensile strength: 20-25KG/CM²

Bending strength: 5-7KG/CM²

Impact resistance: 10-15KG/CM²

Heat distortion temperature: 150℃