During the Tenth Five-Year Period, China's mold industry has grown rapidly, with an average annual growth rate of 20%. In 2005, the sales of molds in China's mold industry was 61 billion yuan, an increase of 25% over the previous year. With an import share of more than 2 billion US dollars, China's mold market capacity has reached about 80 billion yuan. During the "Eleventh Five-Year Plan" period, the world ’s manufacturing base accelerated its transfer to China. The rapid upgrading of China ’s manufacturing industry has accelerated the development of the mold industry. In 2010, the sales of China ’s mold industry exceeded 112 billion yuan. Luo Baihui, the person in charge of the China Chamber of Commerce, said that in 2011, the global economy has further rebounded, the mold industry will still be in steady development, and the demand for high-quality precision molds will continue to rise.
At present, the scale of China's mold industry ranks in the forefront of the world, but most of them are concentrated in the low and medium-level fields, and the technical level and added value are relatively low. According to the data provided by the China Mold Industry Association, the precision and complex stamping molds and plastic molds, car cover molds, electronic connector molds and other electronic product molds urgently needed by China's manufacturing industry still rely heavily on imports, and the import and export deficit of mold products exceeds 10 More than billions of dollars. In the future, the core competitiveness of the product will be the same, both at home and abroad. The Chinese mold industry will continue to develop. I am afraid that both our company and the government need to work hard on technology research and development and innovation. Luo Baihui analysis pointed out, "The mold industry should pay attention to structural adjustment, vigorously develop high value-added products, follow the refined, specialized, and strong lines, and create new growth points in the blue ocean."
Japan's mold production capacity accounts for about 20% of Asia, and more than 70% of the labor cost of the mold industry is non-core technical personnel. Therefore, the Japanese mold industry is gradually shifting mold parts with low technical content to regions with low labor costs, such as China and Southeast Asia, which only produce products with higher technical content in their own countries. Japan's mold prices are now about 20% lower than in 1998, which undoubtedly enhances the competitiveness of Japanese molds in the world mold market. Facing the challenges of foreign advanced technology and high-quality products, Luo Baihui pointed out that Chinese mold companies must be one step ahead of the research and development, talent construction, and back-end inspection and information services of the mold industry chain in order to make the mold industry and the entire industry The upgrading of the manufacturing industry will make the industrial chain more tight and complete.
At present, a new round of expansion by international mold manufacturing giants investing and setting up factories in China is in full swing. Germany's Haila Jilin settled in Japan; Japan's Toyota Mold set up a factory in Tianjin; Finland's Belrose Company put into production in Shenzhen. The attractive "big cake" of the Chinese mold market attracted the attention of international mold companies like a magnet. As the focus of global manufacturing shifts to China, it has provided a powerful impetus for the development of China's mold industry, and has also put forward higher and higher requirements for domestic mold manufacturers. Luo Baihui believes that China's current mold manufacturing enterprises must focus on improving product grades and reducing manufacturing costs to achieve a strategic transformation from a "mold power" to a "mold power".
Under the premise of the rapid development of the manufacturing industry today, China has become a big country in mold manufacturing, and the domestic mold industry has developed rapidly. Not only is China's mold industry huge in scale, but also increasingly rich in grades. According to reports, at present, the proportion of high-level molds represented by large-scale, precise, complex and long-life molds has reached more than 35%, the length of large-scale progressive molds has exceeded 3m, and automobile cover molds have been able to produce B-level vehicle molds; The precision of precision mold processing can reach 0.5 microns; precision progressive mold can be used on high-speed punch presses of 2000-2500 times / minute or more; plastic mold precision reaches micron level, which meets the needs of IT industry development; single set weight reaches 120T 4, the tire flexible mold with a diameter of 4 meters has become the largest mold, etc .; hot runner molds and gas-assisted molds have reached the international level; while CAD / CAM technology has become popular, CAE technology has become more and more widely used, CAD / CAE The / CAM integrated technology has been developed and achieved good results; new achievements in mold new structures, new varieties, new processes and new materials have continuously emerged, and the number of patents has increased.
Multi-position progressive die and fine die represent the development direction of stamping dies, with extremely high precision and longevity requirements. They are mainly used for IT electronics and information industry, semiconductor precision components, terminal connectors, and mobile phone cases. Luo Baihui's analysis believes that IT molds have a considerable foundation in China and have introduced advanced foreign technology and equipment. The products produced by individual companies have reached the world level, but most companies still have a certain gap. The total supply is also in short supply. Import More. For ultra-large-scale integrated circuits, for lead frames with 100 or more lead pins and gaps of 0.2 mm or less, for precision micro connectors with precision of 5 mm or more, for micro motor cores with diameters of 1.6 mm or less, and for picture tubes and electronics The matching of precision molds is the top priority of development. Luo Baihui said that the focus of the development of the mold industry in the future is not only to meet a large number of needs, but also to have a high technical content, especially the molds that are currently not self-sufficient in China and require a large number of imports, and large, precise, complex, and long-life that can represent the development direction. In addition, due to the large price advantage of China's mold products in the international market, mold products with good export prospects will also become the focus of development.
Luo Baihui said that there are many types of molds and different technical requirements. During the "Twelfth Five-Year Plan" period, mold technology should be developed towards industrialization, and six key technologies should be widely promoted as the development guide for mold industry technology.
1. Digital mold design and manufacturing and enterprise information management technology
Digital mold design and manufacturing and enterprise information management technology are internationally recognized effective technical means to improve the overall level of the mold industry, which can greatly improve mold production efficiency and product quality, and enhance the overall level and efficiency of enterprises. Large-scale, precise, and complex molds are represented by high-tech molds, which are currently imported in large quantities. Imported molds occupy about 50% of the domestic high-end mold market. Compared with the international advanced level of such high-tech molds, we still have a gap of about 5-10 years. The gap is mainly manifested in the aspects of precision, life, manufacturing cycle, use stability and reliability, etc. The backwardness of mold digital design and manufacturing technology is one of the most important causes of product backwardness.
Although this technology has been applied in different levels in China, high-end software mainly relies on imports, the domestic development capability is weak, and the application level is low. According to Luo Baihui, the key technologies included in this technology are: mold optimization design and CAD / CAM / CAE integration technology, especially 3D design and computer simulation simulation analysis technology, mold modularization, integration, collaborative design technology ; Mold enterprise ERP, PDM, PLM, MES and other information management technology; rapid prototyping and rapid molding technology; virtual network technology and the establishment of public service platforms. Through the breakthrough of these key technologies, the independent innovation ability and market competitiveness of mold companies can be greatly improved, the domestic market satisfaction rate of high-tech molds can be effectively improved, and a large number of exports can be made, thereby improving the overall level of China's mold industry and corporate efficiency.
2.Design and manufacturing technology for large and precision stamping dies
Die size and precision have always been important development trends. The application of stamping forming technology for high-strength plates and laser welding plates of unequal thickness has become more and more common. Hot stamping of high-strength steel plates and stamping technology of large aluminum alloy plates are used in automobile production Applications are also increasing; due to the increasing speed of high-speed punches, the pitch of integrated circuits is getting finer, the accuracy of connectors is getting higher, and the size is getting smaller, so ultra-precision machining is further developing. However, at present, the molds of middle and high-end cars and super large-scale integrated circuits and precision electronic products in China are mainly imported. The large-scale multi-position progressive molds for automotive parts have just started. The technology has just started in China, and it is basically blank. The level of mold production technology has become an important factor affecting the improvement of the independent innovation capability of automobiles and high-end electronic products in China. The improvement of large and precision stamping die production technology will not only improve the performance and independent innovation capabilities of automobiles and high-end electronic products, but also drive the overall level of the die industry.
According to Luo Baihui, the main key technologies included in this technology are: production technology for large-scale automotive cover molds; production technology for large-scale multi-position progressive molds for automotive parts; production technology for cold stamping molds for high-strength plates and unequal thickness welded plates High-strength plate hot-press forming and mold production technology; thick-plate fine blanking mold production technology; molds with an accuracy of 0.001mm are used for lead frames and leadframes with ultra-large-scale integrated circuits with a lead pin of 100 or more and a pitch of 0.15mm or less. Precision micro-connectors with accuracy higher than 5μm, and mold manufacturing technology for super-large (Φ400mm or more) extra small (Φ16mm) special type (Φ12mm pen type, etc.) motor cores and high-requirement picture tubes, electron guns, etc.
3. Design and manufacturing technology for large and precision plastic molds
With the social progress and the rapid development of industry, users have become increasingly demanding of plastic molds, and the proportion of plastic molds has also increased year by year, and their proportion has accounted for about 45% of the total molds. As the foundation of modern industry, the mold must not only meet the needs of production parts, but also the needs of production components, but also meet the requirements of product lightweighting and energy saving and environmental protection. At present, the automotive, light industry, mechanical and electrical, telecommunications, building materials and other industries and emerging industries such as aerospace, new energy, medical and other industries have increasing demands for plastic parts and components, and they have become more demanding. Therefore, vigorously developing large-scale and precision plastic mold production technology has become one of the important links to improve China's mold manufacturing level. The importance of some new plastic forming technologies and the development of corresponding molds is particularly prominent, and this is of great significance for improving the efficiency of industrial production, energy saving and consumption and environmental protection.
According to Luo Baihui, the main key technologies included in this technology are: hot runner technology and its reasonable application in precision injection molds; multi-injection head plastic packaging mold production technology; injection molding machines with a clamping force of 1,000 tons or more and 200 tons or more Production technology of large-sized plastic molds for hot presses and precision injection molds with an accuracy of more than 0.01mm; production technology of multi-color and multi-material molds; production technology of combined molds for metal and plastic parts; production technology of laminated molds for different plastic parts; Production technology of injection molds that do not need to be processed on the surface of plastic parts; in-mold assembly and decoration technology and hot-pressing rapid seamless forming technology; forming technology and mold technology of new plastic and multilayer composite materials; gas and liquid auxiliary Injection technology and mold technology; plastic profile extrusion and high-speed extrusion mold production technology.
4. Design and manufacturing technology for large-scale precision casting molds
The casting molds are supporting the casting process. There are mainly pressure casting molds (die-casting molds), low-pressure casting molds, gravity casting molds, boxless extrusion casting molds, and precision casting molds. The mold level has a great influence on the level of castings, and large precision casting Die production technology is also very difficult. At present, due to the low level of casting molds, the phenomenon of "fat and big ears" and low quality of castings is still quite common. There are also many large-scale precision casting mold imports. The improvement of this mold production technology will be of great significance to improve the quality of castings, develop new castings, and improve the level of near-net processing. According to Luo Baihui, the main key technologies included in this technology are: magnesium alloy die-casting molds and large die-casting molds supporting die-casting machines with a clamping force of more than 2,000 tons, and precision die-casting mold production technologies with an accuracy of more than 0.03 mm; Manufacturing technology for low-pressure casting molds greater than 10 kg with a precision of 0.05mm and gravity casting molds with a precision of 0.07mm; production technology for boxless extrusion molding casting molds for automatic molding lines.
5.Design and manufacturing technology of high-grade radial tire active mold
Automobile radial tires have their unique pattern shapes. The active molds of high-grade radial tires need to be designed as special and complex three-dimensional structures. The requirements for out-of-roundness, uniformity, and geometric accuracy are particularly strict to ensure the comfort of automobile tires. Degree, high speed and safety, reflecting the tire's grip performance, heat dissipation performance, cornering performance, anti-skid performance and drainage performance. It is the most personalized and the only "dynamic" mold in the mold family. In order to accurately reflect the tire pattern design on the tire through the tire mold, the design and manufacturing process of modern tire molds should use CAD / CAM / CAE technology to convert the tire pattern master map into tire mold parameters to complete the tire mold pattern shape and structure. Digitize the design, digitally program the manufacturing process, generate NC programs, and carry out precision machining by CNC machine tools. The entire design and manufacturing process is completely transmitted on the internal local area network through digital information. Digital design, digital transmission, digital processing, digital inspection and digital inspection are required. Management and a series of sophisticated technology. According to Luo Baihui, the main key technologies included in this technology are: aluminum alloy precision casting and forging technology; pattern block combination processing and precision sliding coordination control technology; mold clamping concentricity and accuracy control technology; CAD / CAM / CAE technology and CNC precision machining and composite machining technology; high-speed parallel machining technology; comprehensive heat treatment and surface treatment technology of mold, vacuum processing technology; intelligent networked manufacturing technology of molds, etc.
6. Production technology of high-grade mold standard parts
Standard mold parts are the basis of molds. The widespread use of standard mold parts can not only shorten the mold production cycle and improve mold quality, but also reduce mold production costs and facilitate mold maintenance. At present, China's mold standard parts production lags behind the mold production. Some high-end mold standard parts are still blank, so they have to be imported in large quantities. Here, only the two standard mold parts that have the greatest impact on mold production are selected as breakthroughs. This is the high-pressure nitrogen cylinder for molds with a service life of 1 million times and the hot runner and system with temperature control of ± 1 ° C. In addition, the oblique head mechanism plays a very important role in the stamping die, and the oil-free lubricating pusher and pusher tube is also very important in precision plastic molds. It also belongs to the high-end mold standard parts that should be vigorously developed. The breakthroughs in production technology of these products will help raise the level of large precision molds in China. According to Luo Baihui, the key technologies are: precision machining technology for pistons, piston rods and cylinders; high-reliability sealing and safety technology; hot runner material and precision temperature control technology; hot runner nozzle precision machining technology; plastic in mold Three-dimensional computer simulation and analysis technology for flow in the cavity; design technology of new high-grade oblique stern; research and development and processing technology of oil-free lubricating and wear-resistant materials.