模仁放電加工製程改善之研究

The Kaizen on Mold Making Of EDM Process

王逸琦(Yi-Chi Wang)；王瓊僥(Chiung-Yao Wang)

放電加工 ； 預先校正 ； 交換夾具 ； 二次開發 ； EDM ； pre-calibration ； exchange fixture ； the second development

建國科大理工期刊

36卷2期（2017 / 04 / 01）

41 - 66

繁體中文

塑膠射出成型是製造業大量生產塑膠件普遍常用的一種方式，而塑膠射出製程必須要有模具才能達成。模具開發其主要組件的模仁的加工步驟有熱處理、研磨加工、銑床加工、線切割加工、放電加工(Electrical Discharge Machining, EDM ) 製程， 因有局部的加工區域必須由放電加工才能完成，因放電加工是最後一站，加工錯誤重新加工的成本除了放電加工還包含了前述的製程，由於放電加工製程中程式編輯、補正值輸入是人員來操作，加工異常次數無法有效降低或完全排除，工件設定時間也無法縮短，相對的影響員工的工作士氣以及成就成。隨著模具開發的需求與維修日益增加，過多的人工作業流程操作反而容易增加人員的疲勞程度， 本文將案例中現有的流程步驟，收集加工異常的記錄資料，加以整理出重複發生之異常比例，並參考目前市面上現有的輔助工具，導入該案例中尋求有效的改善方案，本文利用市售標準品交換夾具、機外預先校正系統、變更作業流程，以及軟體的二次開發應用，將放電加工製程予以改善，以提升模具廠競爭的優勢。

Plastic inject ion molding is a commonly used method for massive production of plastic products in the manufacturing industry, however, mold is necessary for the mold injection process of plastic. In the mold development process, the processing steps of its main part, mo ld core, include heat treatment, grinding machining, mil ling machining, wire cutting machining and Electrical Discharge Machining (EDM), which was named so because partial processing area needs to be finished by electrical discharge machining. Since e lectrical discharge machining is the final station, therefore, its rework cost due to wrong processing will, in addition to electrical discharge machining, also include the previously mentioned processes. Since the program editing and compensation value input in the electrical discharge machining were mainly operated by personnel, therefore, abnormal machining counts cannot be effectively reduced or totally released, and the setup time of work piece cannot reduced either. As the mold development need and maintenance increases constantly, excessive manual operation flows could easily enhance people's fatigue, therefore, in this paper, the presently existed flows and steps of the cases under study and the abnormal processing data were collected and summarized to come out with the proportion of repeatedly occurred abnormity, meanwhile, assisted too l presently existed in the market was introduced into the case in study to find out effective improvement project. In t his paper, exchange clamping too l for standard product sol d in the market, out-of-machine pre-calibration system, change operation flow, and secondary development application of software were used to improve the process of electrical discharge machining so as to enhance t he competitive advantage of the mo ld company.