Global mold manufacturing power seven Qiong on Sword

First, the quality of Italian mold high quality and high efficiency Italian mold enterprise's production technology level is first class in the world. According to Luo Baihui, managing director of the International Mould and Hardware & Plastics Industry Suppliers Association, applying high-tech to the design and manufacture of molds has become a powerful guarantee for the rapid manufacture of high-quality molds in Italy. In the Italian mold industry, CAD/CAE/CAM, high-speed cutting processing technology, rapid prototyping technology and rapid tooling technology have become common applications.

1. The wide application of CAD/CAE/CAM shows that the use of information technology drives and enhances the superiority of the mold industry. In the application of CAD, it has already surpassed the initial stage of getting rid of drawing board and 2D drawing. At present, 3D design has reached 70% to 89%. The application of software such as PRO/E, UG, CIMATRON is very common. Applying these software not only can complete 2D design, but also can obtain 3D model at the same time, have guaranteed for NC programming and CAD/CAM integration. With 3D design, assembly interference checks can also be performed during design to ensure the rationality of the design and process. The universal application of CNC machine tools ensures the precision and quality of the mold parts. 30 to 50 people's mold companies generally have more than 10 CNC machine tools. Parts processed by CNC machine tools can be assembled directly, which greatly reduces the number of fitters. CAE technology has gradually matured in Italy. The CAE analysis software was used in the injection mold design to simulate the plastic die process, analyze the cooling process, and predict possible defects in the molding process. The CAE software was used in the die design to simulate the metal deformation process, analyze the distribution of stress and strain, and predict defects such as cracking, wrinkling, and spring back. CAE technology is playing an increasingly important role in the design of molds. After COMAU of Italy applied CAE technology, the test time was reduced by more than 50%.

2. In order to shorten the molding cycle and improve market competitiveness, high-speed cutting technology is commonly used. High-speed cutting is a processing technique characterized by high cutting speed, high feed rate, and high processing quality, and its machining efficiency is several times or even more than ten times higher than that of conventional cutting processes. At present, the Italian mold enterprises are widely used in the production of CNC high-speed milling, more three-axis linkage, there are some five-axis linkage, the number of rotation is generally 15,000 to 30,000 r / min. Using high-speed milling technology, can greatly reduce the time of molding. After high-speed milling, the mold surface after finishing can be used with only a little polishing, which saves a lot of grinding and polishing time. Italian mold companies attach great importance to technological progress and equipment updates. Equipment depreciation period is generally 4 to 5 years. The increase of CNC high-speed milling machines is one of the key investments for mold and equipment enterprises.

3, rapid prototyping technology and rapid tooling technology has been widely used. Due to increasingly fierce market competition, product replacements are accelerating, rapid prototyping and rapid tooling technology have emerged, and they have quickly gained widespread adoption. In Italy and other European and American mold exhibitions, rapid prototyping technology and rapid tooling technology occupy a very prominent position, there are various types of rapid prototyping equipment such as SLA, SLS, FDM and LOM, as well as agencies and companies that provide prototype manufacturing services. .

Many of the Italian mold companies combine rapid prototyping and rapid tooling with mold making, which uses prototyping to prototype prototype parts. The mold is then quickly made based on the prototype. Many plastic mold manufacturers use rapid prototype cast silicone rubber molds for small quantities of plastic parts, making them ideal for product trials.

Italy's plastics and rubber processing machinery and mold manufacturing industry is one of the 10 specialized machinery manufacturing industries of the Italian Machinery Manufacturing Alliance, and Italy's plastics and rubber processing machinery and mold manufacturing industry has more than 500 European patents, with a high degree of specialization, leading technology, and diverse products. At the same time provide customers with various value-added services. According to Luo Baihui, Italy's mold enterprises have annual per capita sales of more than 100,000 US dollars. At present, the output value of Italy's plastics and rubber processing machinery and mold manufacturing industry accounted for 16.5% of the total output value of the 10 manufacturing industries in the machinery manufacturing alliance. At the same time, the export destination of Italian plastics and rubber processing machinery and mould products is still dominated by the EU, and the export amount accounts for 47% of the total export volume.

Italian mould companies have advanced technology and advanced management to make their large-scale, precision and complex moulds play an extremely important role in promoting the development of automobiles, electronics, telecommunications, household appliances and other industries, and also bring good mold enterprises. Economic benefits.

Second, the German mold technology exquisite Germany has always been superb processing skills and production of precision machinery, tools and known for its mold industry also fully reflects this feature. After many years of practical exploration in the industrial field where the mold has a complex connotation, the German mold manufacturers have formed a consensus that the entire industry must coordinate, work together, tap the potential of development, and jointly promote the spirit of innovation, common technological progress, complement each other and play a good role. The overall advantage to achieve the industry's success. In addition, in order to meet the needs of the rapid development of today's new products, not only large companies have established new development centers in Germany, but many small and medium-sized enterprises also do so, and actively carry out research and development work for customers. In terms of research, Germany has always been very active and has become an important basis for its unbeaten position in the international market. In the fierce competition, the German mold industry has maintained its strong position in the international market for many years, and its export rate has been stable at around 33%. According to the statistics of German tool and tool industry association, the German Association of Machinery Manufacturers (VDMA), there are about 5,000 mold companies in Germany. In 2003, the German mold output value reached 4.8 billion euros. Among them, there are 90 (VDMA) member mold companies, and the output value of these 90 backbone mold companies accounts for 90% of the German mold output value.

Third, the United States mold is facing changes in the United States currently has about 7,000 mold companies, more than 90% of small businesses with less than 50 people. Due to the high degree of industrialization, the US mold industry has long been a mature high-tech industry and is in the forefront of the world. American mold steel has achieved standardized production and supply, mold design and manufacturing generally use CAD/CAE/CAM technology, processing technology, inspection and testing supporting advanced equipment, and the development of large-scale, complex, precise, long-life, high-performance molds has reached the leading level. However, since the 1990s, the U.S. economy has faced major adjustments and major changes in the post-industrial era and is also facing strong international competition - from cost pressure, time pressure, and competitive pressure.

Fourth, Japan masters core technology Japan's mold industry has always maintained the status of the world's largest mold country and mold powerhouse. At the peak of 1998, its domestic mold output reached 1.8954 trillion yen. However, in the 10 years since then, although the annual output value has either increased or decreased, the overall situation has stagnated. Until now, it has not recovered or exceeded the level of 1998. The number of mold manufacturers has also been decreasing year by year. According to Luo Baihui, secretary-general of the International Mould and Metals and Plastics Industry Suppliers Association, Japan not only controls core technologies in many areas, but also controls the most lucrative links in the industry chain, leaving only a majority of joint ventures in other global markets. The profits of the assembly process, this “industry-building country” economic model is also worthy of learning by Chinese companies. The current need to be vigilant is that international hedge funds and capitalists are exaggerating losses and taking away funds, which will have a serious impact on the development of the global economy. If Japanese capital is pumped away, global industrial associations will be affected. Very big impact.

Due to the global financial crisis and the devastating earthquake, the major automobile manufacturers and semi-conductors in Japan will decline. At present, many companies have orders for only 20 to 40% of their best years. Many factories are underemployed. They only start work for 3 to 4 days a week, and some have started to close down. The number of companies is decreasing month by month. Faced with this situation, people in the Japanese mold industry are very worried about the brain drain, especially worries that some older and experienced personnel will flow abroad. The brain drain will bring disadvantages to the future development of the Japanese industry. How to actively respond to the current difficulties has become a major issue for the Japanese mold industry. The Japanese mold industry and even the relevant government departments have already considered many aspects of their mold industry's future development.

In terms of the private sector, Japan has already proposed six major development directions. 1 Use as much new technology as possible to improve the level of digitalization and information; 2 Exploit molds to use new fields, such as various new energy sources, new materials, and medical care. Aerospace and other fields; 3 extension of the mold industry chain; 4 to carry out diversification; 5 update knowledge; 6 do a good job in development and production and research combined.

At the government level, the Ministry of Economy, Trade and Industry of Japan has organized the "Study Committee for the Strategy of SST Materials" and issued a "Strategy Technology Strategy" that is a guideline. The goal of implementing this technology strategy is clear: "To grasp the lifeline of the world's manufacturing industry by grasping important technologies in the form of materials."

Fifth, China's automobile mold uprising In recent years, China's mold industry structure, whether it is corporate organizational structure, product structure, technology structure and import and export structure, are in the direction of rationalization. In order to update and improve the level of equipment, mold processing companies need to import several billion yuan of equipment every year. The investment in innovation and development is still insufficient. The improvement of comprehensive R&D capabilities in the mold industry has lags behind the increase in production capacity. The main problems are the weak ability to innovate; the overall efficiency is low; the degree of specialization, standardization, and commercialization is low. Poor cooperation; mold materials and mold related technology behind; corporate organizational structure, product structure, technical structure and import and export structure are not reasonable enough; compared with the international advanced level, mold management companies behind the management more backward than the technology. According to Luo Baihui, secretary-general of the International Mould and Metals and Plastics Industry Suppliers Association, the development trend of China's mold industry in the next decade is: mold products are developing towards large-scale, sophisticated, complex, economical, and rapid development; the technological content of molds is continuously improving. The mold manufacturing cycle is continuously shortened; the mold production is in the direction of informationization, graphlessness, refinement, and automation; the mold companies are developing in the direction of technology integration, equipment excellence, product branding, management information, and business internationalization. .

At present, the mold processing enterprises with a mold output value of over 100 million yuan nationwide are mainly concentrated in the automotive panel mold field. For example: FAW Mold Manufacturing Co., Ltd. for automobile panel molds, Wuxi Guosheng Precision Mold Co., Ltd. for precision stamping molds, Haier Mold Company for large-scale plastic molds, Tongling Sanjia Technology Co., Ltd. for plastic profile molds, and rubber tires. In terms of molds, Guangdong Giant Wheel Mould Co., Ltd., Jieyang Tianyang Mould Co., Ltd., and Hong Kong Long Kee Group and Panqi Industry Co. In the billions of dollars in mold enterprises, foreign capital accounts for a considerable proportion.

The mold is the mother of the machine. Automotive molds are the "predecessors" of the car. According to the functional classification of automotive molds, it can be divided into five categories: stamping molds and injection molds. As a cold die car body large-scale cover mold, is the most iconic technology equipment in automotive molds. Due to the complicated manufacturing technology of large-scale outer cover molds, high dimensional and surface precision requirements, and the requirement for high-precision numerical control equipment such as five-axis high-speed machining centers, its manufacturing technology has been controlled by multinational specialized companies for a long time. Most of the large-scale car body outer cover molds of domestic car companies basically rely on imports. According to Luo Baihui, the secretary-general of the International Mould and Hardware and Plastics Industry Suppliers Association, a mold base for car exterior covers with a domestic first-class level is quietly emerging in Jinqiao, Pudong, Shanghai. A few days ago, it was learned from Shanghai Sekoli Auto Mould Technology Application Co., Ltd. that the company had been reluctant to make ends meet, and that it had achieved its goal of “catch up with the mold” and “improve the mold” in only six years. At present, it has established Mainly used in large body outer cover molds, multi-position stamping parts molds, thermoformed ultra-high strength steel molds, progressive stamping stamping parts molds supplemented by product positioning, initially formed including the body side panels and mold plate mold in The development capability of the large car body covers. In 2010, it completed the independent development and manufacture of 293 mold sets with an output value of 100 million yuan.

At the beginning of its establishment, Shanghai Secco established its vision of becoming a world-class automotive mold supplier. Faced with the three major problems of capital, technology and talent, the company has planned a "three-step" strategic development plan. After three years of "experience", we have basically completed the accumulation of funds and mold peripheral technology, thus achieving the first-phase goal of "taking care of the mold".

According to Guo Shuijun, deputy director of the company's technical center, in 2008, the company took the initiative of “new born calf is not afraid of tiger” for the first time to undertake the independent development of the Shanghai General Motors' four-door inner and outer panel molds. To this end, the company formed a team led by doctors, engineering and technical personnel as the main development team, struggling to overcome difficulties, and in the door plate mold development boldly adopted the open drawing technology, increased the material utilization rate of 8%. "The four molds were successfully developed at the start. There is no precedent for the mold industry at home and abroad." At present, the company has independently developed external cover molds for nearly 6 models including SAIC's own brand models.

In the automotive panel molds, the development of the most difficult side is the body side panels, fenders molds, in particular, the technology, the complex body side enclosure plate mold integrates all four doors and three cover technology. Guo Shuijun said, "The product is characterized by large parts, large differences in height, poor rigidity. There are complex laps and fits around, with the top cover, glass laps, front and front enclosure lap, after and back cover , taillights, rear bumper with lap joints, the middle with the front door, rear door with face, curvature, change, shape the most complex.” In order to ensure that the independent brand models side panel mold one-time development is successful, the development team to carry out early Technical seminars, in response to various technological problems in the development process, took corresponding measures to overcome numerous problems and finally succeeded in one fell swoop.

In order to further improve the self-developing capability and manufacturing capability of the auto body panel molds, the company through project development, summed up the development experience and accumulated data, has now established a stamping process, CAE, structural design, mold manufacturing database and 3D standard library. In order to deepen project management, strengthen the digital operation and control of the system engineering, introduced the E-MAN mold manufacturing management system, and built an information platform. Over the years, the company has continuously strengthened the construction of a talented highland, and has introduced and trained a group of high-level professional and technical talents and skilled talents. At present, the entire development team has reached more than 200 people. Shanghai Seculi has become a rising star in the Chinese automotive mold industry.

6. Singapore focuses on developing IT molds Singapore is a small country with a population of only 3 million. In the 1980s and 1990s, the government attached importance to and supported the development of precision molds, and introduced many policies to make the mold industry grow rapidly and promote the Singapore economy. The rapid development. Singapore has more than 1,000 types of molds and related companies for precision machining. The annual production value of molds exceeds 4.5 billion tons. It has considerable influence and role in the Asian mold industry. There are more than 10 listed companies in the mold industry. The molds produced by more than 65% of Singapore's enterprises are all supported by IT-related industries. The molds produced are not large, but they are all high-precision, high-level molds. Singapore mold companies are mainly concentrated in semiconductor frames / packaging molds, metal stamping molds, plastic molds, silicone rubber molds and other fields.

7. Australian auto stamping die has space Australia has enjoyed rapid economic development in recent years and has continued to grow in the coming years. However, as the basic industry mold manufacturing industry, especially the stamping mold manufacturing capacity can not keep up with the needs of economic development, for which urgent need to import stamping mold manufacturing technology and capabilities from abroad, and China's mold industry in this area happens to have a greater advantage, the market The outlook is promising. The specific analysis is as follows: China's stamping mold companies have higher levels of technology and equipment than Australia. At present, there are 56 CNC milling machines in China's top four automotive die-casting enterprises, of which 35 are large ones and 5 are high-speed ones (where the number of spindle rotations is 20,000 rpm/minute). It has 143 computer workstations, 200 sets of various software, and 8 sets of analysis software and reverse engineering software. There are 5 large-scale coordinate measuring machines, 30 debugging presses (1600 tons, 1400 tons, 1300 tons, 800 tons, 600 tons), 16 research and distribution presses, and cranes with 30 tons and 15 tons, which far exceed Australia. Equipment level.

China has complete die design and manufacturing technicians and programmers, skilled CNC machine operators, fitters and mold debuggers. China's labor wage level is lower than that of Australia. Currently, it has the ability to manufacture stamping dies for cars. The company's production capacity is more than 200 sets to 400 sets of large and medium-sized stamping dies. Moreover, the equipment load of enterprises is not high enough to fully manufacture molds for Australia.

The software used in Australian automotive mold design and manufacturing is mostly ug, pro-e, catia, and euclid. The software used by Chinese mold companies is basically the same and can be shared. Both the CAE analysis software and the simulation molding analysis software have similarities. This provided us with good conditions for the development of Sino-foreign cooperation.

The Australian Mould Association, the Adelaide Model Office, and the Melbourne Mould Association have all placed great hopes on the Chinese mold market and manufacturing companies. This will create favorable conditions for China to export molds to Australia.