China Mold Association Technical Committee Cai Zijin (pen) Gao Peng (pen)
Chinese classification number: TG241 Literature ID: A Article number: 1009- 279X ( 2010) S0- 0034- 04
1 China's casting molds and the main
1. 1 development
( 1) industry, the main problems
1. 1 development
( 1) industry, the main problems
1.
Problems
1. 1 Development
( 1) Industrial situation
In recent years, with China's manufacturing industry, especially the rapid development of the automobile industry
Rapid development, casting market demand rose sharply, driving the casting mold
Productive casting mold industry, the total amount of production of the mold in the punch molds, plastic molds ranked third
Total amount of production in China's molds, molds and molds, casting molds accounted for about 30% of the total amount of molds and molds in China. Casting molds accounted for about 8% of China's total molds, annual sales of about
8 billion yuan. As the market for large, complex, high-quality, high-performance casting
piece requirements, drive China's casting mold in the production scale and manufacturing quality
quantity and the enhancement of its technological level, and gradually formed a complete range of categories, with
set of perfect and widely distributed industrial structure. According to the China Mould Industry
Association of Management Committee compiled 5 national mold factory basic
statistics 6, the last four years the casting mold annual average growth rate of
up to 24% (Table 1).
Table 1 Summary of China's casting mold production
Year
Statistical enterprises
P
Output value
P million
Represented with the previous year
Growth of P%
Annual output value of more than $ 10 million
Enterprises P
2005 64 56 933 25. 90 19
2006 63 70 769 24. 30 24
2007 58 77 764 9. 88 25
2008 68 105 172 35. 24 32
On the whole, the production of small and medium-sized casting molds can fully meet the
demand in China, and large, complex and precise casting molds depend on the production of the industry. The large, complex, precision casting molds rely on imported
the situation has been greatly improved; medium and low-grade molds in excess of demand, large
and demanding casting molds are still imported quite a lot (the main importing countries are Japan
Mainland, South Korea, Germany, Italy, the U.S.); Happily, the use of large, complex casting molds in the country has changed from the original large number of imported molds to the current
many of them have been imported. The introduction of large, complex casting molds has increased from a large number of original
Received: 2009- 12- 10
Author's introduction: Cai Zijin, male, born in 1946, former deputy general manager of Guangzhou Cavity Mould Manufacturing Co.
Gao Peng, male, born in 1952, deputy general manager of Luoyang North Enterprise Group Co., Ltd. of Arms Group, professor-level senior engineer, member of Technical Committee of China Die Association.
Domestic substitution, and a small amount of export, and the export volume is increasing every year.
( 2) enterprise situation
China's casting mold production plants are numerous, the scale is not very large, to small
type mold enterprises, the number of people not more than 300 people, the annual output value of more than
5,000 million yuan of enterprises is very small, the production efficiency of the enterprise annual
average productivity of only 20 ~ 300,000 yuan, the mold grade is mostly
Middle, middle, high, and low, the mold is not a good choice. In the middle,
low grade. Die service life and manufacturing cycle is shown in table 2 and table 3.
Table 2 China's die casting die service life of 10,000 die times
Die aluminum alloy
Small, medium and large
Die zinc alloy die magnesium alloy
10 ~ 20 6 ~ 15 6 ~ 10 20 ~ 15 ~ 20
Table 3 casting die manufacturing cycle month
Middle, small, large, extra-large, large, large, large, large, large, large, large, large and large, large, large and medium-sized die manufacturing cycle months
Medium, small, large and extra-large
Die casting mold 2~ 3 3~ 4 4~ 7
Low-pressure casting mold 1~ 3 3~ 4
Gravity casting mold 1~ 3 3~ 4
At present, all kinds of casting molds used in China mainly come from the mold
Manufacturing professional factory or the mold workshop (sub-factory) attached to the foundry enterprise.
Specialized manufacturing plant to serve the whole society, take on the various industries need all kinds of
Types of casting molds. Relatively speaking, the more advanced equipment, better technology
good and larger enterprises, is the main
China's commodity casting mold suppliers, its strength and technical status best reflect the current level of domestic.
Dotted, a large number of casting mold manufacturing factory is the vast majority of
minute private enterprises, they have a strong ability to adapt to the market and capital
capital multiplication, the market demand to reflect the agile, large output, viability
strong. Compared with other kinds of mold field, foreign investors into less.
Casting mold manufacturers are concentrated in China's coastal economic development
Developed provinces, cities and automotive, motorcycle production base. Such as Zhejiang Province has been called
China's die-casting mold production township 0 Beilun, / casting mold township 0
Xiangshan, respectively, the production of die-casting molds, gravity and low-pressure casting molds. Guangdong Province
casting mold production is mainly in Guangzhou, Dongguan, Shenzhen, Foshan and other places, factory
relatively decentralized, due to the economic opening up earlier, the absorption of foreign advanced technology
quickly, more externally oriented enterprises, the mold export volume is larger. East China production
producers are mainly concentrated in Shanghai, Suzhou, Changzhou, Kunshan, Nantong, etc.
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Land, by virtue of the close proximity to China's industrial and automotive industry town of regional advantages,
development momentum is strong, enterprises generally start from a high point, the quality of the staff is good, the development of
Development momentum. In addition to a better industrial base in Changchun, Dalian, Yantai,
Chongqing and other places casting mold output is also a lot.
( 3) product situation
Die casting mold products are aluminum, zinc, magnesium, copper and other alloys die casting,
which aluminum alloy die casting proportion is the largest, accounting for about 60%, the typical products
automotive transmission shell, clutch shell, engine block, motorcycle
car crankcase, engine bracket, motor cover, oil oil filter base
and so on.
Gravity, low-pressure casting mold products are ferrous metals, aluminum, copper
and other alloy castings, typical products are engine block, cylinder head, exhaust
pipe, rear sedan chair, reducer, crankshafts, transmission housing and so on.
( 4) the face of the market situation
Casting molds for a wide range of product applications, almost involved in all
all industrial manufacturing areas, including automotive parts castings with its large number of
multiple varieties, the requirements of the first place. To die casting, for example, the world's countries
Die casting of automobile parts in the whole die-casting industry occupies the largest share
(Table 4).
Table 4 countries automotive parts die casting parts accounted for die casting total production ratio
Japan Australia Spain Germany United States China
80 80 65 65 48 64
Currently, is at the time of China's automobile industry into a period of high-speed growth, the output of
continuously for many years of substantial growth in the production in 2009 is estimated to reach 13
million vehicles, the production of automobile industry in China is the largest share of the whole die-casting industry
(Table 4). p>
Million units, strongly increasing the demand for casting molds, can be predicted to the future
China's casting mold production will still get mainly from the domestic automobile industry
strong thrust. China's motorcycle production for many consecutive years in the world
First, annual output of more than 20 million units, motorcycle engines required
Medium-sized, complex die-casting molds have been almost all from the domestic manufacturing. At the same time
China's huge home appliance industry, the construction industry and the rapid expansion of the
Communication industry to the casting mold manufacturing enterprises to provide a sustained, steadily increasing
growth of the domestic demand for a huge market. In addition, in the wave of economic globalization
wave, the process of industrial development of the international division of labor is being formed, foreign business based on
cost pressure in China to purchase a large number of castings, and even set up
casting production bases in China, China is assuming the international metal casting and manufacturing
products of manufacturing tasks. At the same time, with the quality of China's molds and foreign
gradually narrow the gap, low prices also drive foreign mold purchases
dramatic increase in the huge overseas mold market demand for the industry's prosperity
played a catalytic role. Can be predicted for a long period of time in the future
Inside, China's casting mold industry, whether it is the domestic or international market development
Space is very large. But it should also be clearly seen, China's casting mold
manufacturing level with foreign countries there is a gap, by the current international financial crisis
influence, the international casting market shrinkage, foreign casting mold manufacturing industry
overcapacity, thus intensifying the competition within the industry, coupled with the existence of domestic
with the uncontrolled bidding between enterprises, the good and the bad of the various The export
strategy of enterprises, to the entire casting mold manufacturing industry has brought about adverse effects.
1. 2 The main problems
( 1) large, complex casting molds are still mainly in the imitation, elimination
absorption stage, the core technology of independent innovation is not much, the quality of the mold
quantity, processing accuracy, reliability, stability and service life
than in advanced industrial countries, there is still a gap between the mold debugging Long time, resulting in
casting industry is still a large number of annual introduction of large high-end molds from abroad.
( 2) the number of domestic casting mold production plant is very large, the general gauge
mould is small, there is no outstanding foreign counterparts to compete with the high level of
enterprises, the lack of leading enterprises, the industry is not a clear division of labor specialization.
( 3) The degree of standardization of enterprises is low, casting molds of standard
parts of the commercial production and use of the coverage is far lower than the stamping die and plastic
mold.
( 4) the national standard of die-casting mold was revised in March 2004
promulgated, but the content is relatively simple, guidance is not strong, low-pressure and heavy
force casting molds of the national standard has not been developed.
( 5) mold digital design and manufacturing is to improve the casting mold production
Enterprises the overall level of effective technical means, which three-dimensional design and computer
Computer simulation and analysis of the application of technology, showing more and more
superiority. At present, the domestic fully integrated CADPCAMPCAE
casting mold manufacturing enterprises are very few, and the choice of software is mainly
reliant on imports, three-dimensional design and the application of CAE technology and popularity
degree of far less than the domestic manufacturers of plastic molds.
( 6) The performance and stability of domestic hot work mold steel is still not
satisfactory, the manufacture of export molds and casting molds with high requirements of the basic
still use imported steel, to a large extent, affecting the competitiveness of the mold enterprises in the market
market.
2 China's casting molds and the international advanced level of the main gap
( 1) China's casting mold manufacturing history is short, inexperienced
Casting molds are mainly used in the automotive industry, foreign dozens of
year history, China's first ten years of scale, the demand for large-scale, complex
miscellaneous, precision casting mold design and manufacturing Insufficient experience, is still
in the learning and imitation stage, the structure of the more complex are mostly made of compound
mold-based, not much innovation. Manufacturing process generally exists in the quality control
not rigorous enough, poor manufacturing accuracy, as well as the design of the mold's thermal
balance analysis, cooling system settings, quick change of parts, installation of fast,
production safety and other considerations are not well thought out. Although a variety of casting products
molds have been able to manufacture the basic domestic, for the more difficult molds on the
scale manufacturers have the courage to undertake, but often due to the size is not in place,
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Commissioning time is long, the use of the failure rate is high and the life of the undesirable make the Users lack
lack of confidence in purchasing. To the heart of the car)))) engine block die-casting mold
For example, China engaged in the cylinder block die casting production of not less than 20
manufacturers, but now running the mold is almost all from Japan, Europe, the United States to introduce. Germany
a professional mold factory, as early as 1984 has been the production of cylinder
die casting mold, has produced more than 50 sets, and China nearly 3
years before the domestic cylinder die-casting mold, so far the output of the factory
accumulative
count only about 10 sets.
( 2) equipment and the corresponding supporting gap
Foreign advanced industrial countries with a slightly larger mold manufacturers often have
a larger number of large, medium-sized 5-axis or 3-axis high-speed machining centers
machine tools, equipped with a number of high-precision testing equipment, heat treatment supporting professional
factory with a large load, 10 Par above the vacuum furnace for the heat
in the block. Vacuum furnace for hot
treatment of inserts, some mold factories also have a workshop dedicated to mold testing, at the same time, hot
mold steel (part of the 3D forging), high-quality standard parts and accessories supply
smooth. Compared with the domestic mold manufacturers of the above key equipment regardless of the number of
quantity, grade and specifications there is a large gap, and the manufacture of export casting
molds and large-scale high-end molds almost all have to eat / feed 0 $ $ $
Use of foreign software for the design, the use of imported machine tools, cutting tools, testing
equipment for processing and testing, purchase of imported Hot work steel, installed in the
mold concrete on the standard parts and all kinds of accessories should also be imported, so the mold
manufacturing cost is large.
( 3) the talent gap
Domestic enterprises in the mastery and use of new technologies in the talent can not meet the
development needs, mold senior technical personnel, high-skilled employees, business
management and foreign trade and economic talent shortage, talent shortage leads to enterprises
between the scramble to dig for employment, affecting the development of the mold enterprise and stability. Especially
lack of excellent composite talents, such as: proficient technical operators, proficient
technical process managers, skilled in the use of information technology for
design and analysis, understanding of casting technology and the principles of the relevant equipment, mastering debugging
repair processing technology designers. Foreign mold enterprises engaged in management
and technical staff tend to be higher proportion ( 25% ~ 35% ), employees
quality awareness, the community has a more complete specialized education and skills training
training, the enterprise to strengthen the position of the staff training. Recently, Japan's development of mold technology for the next few years
advocated: / can not rely on the skills of
mold design, production technology 0, which means that the number of technical mold engineering
personnel requirements for a greater number and higher level.
( 4) the gap in technical indicators (Table 5)
Table 5 domestic and foreign casting mold technical indicators comparison table
International advanced level of domestic advanced level of domestic general level
Cavity machining accuracy Pmm 0. 01~ 0. 03 0. 02~ 0. 05 0. 05~ 0. 08
Surface roughness of type position RaPLm 0. 2~ 0. 4 0. 4~ 0. 8 0. 8~ 1. 6
Manufacturing
Weekly
Period
P
Monthly
Die casting mold
Gravity, low pressure casting mold
Medium, small 1~ 2 2~ 3 2~ 4
Large 2~ 2~ 3 3~ 4~ 6
Large 2~ 2~ 2~ 3~ 3~ 4~ 6
Models for die-castings 3 3~ 4 4~ 6
Extra large 3~ 5 4~ 7
Medium and large 2~ 3 2~ 4 3~ 5
Use
Life
Life
P
10,000 cycles
Die casting mold (medium)
Die casting Zn 30~ 100 20~ 30 10 ~ 20
Die casting Al 12~ 25 10~ 15 5~ 8
Die casting Mg > 20 15~ 20
Die casting Cu > 3 1~ 3 0. 3~ 1
3 China's casting molds and the main task of the development objectives
Implement the scientific concept of development, relying on technological innovation, promote the application of
Modern information technology to enhance the enterprises' development, and to promote the use of information technology.
Modern information technology to enhance the design, processing and management level,
Increase investment, improve the level of equipment and core competitiveness of enterprises,
Highlighted to strengthen the backbone of enterprises, and promote the sustained and healthy
Rapid development of casting mold industry. In the / Twelfth Five-Year 0 period, to maintain the annual output of casting mold
double-digit growth, cultivate the creation of 3 ~ 5 annual output value of more than 100 million yuan enterprises
industry. Large, complex casting mold development and manufacturing level and mold use
life to reach the level of the current international advanced industrial countries; to do small and medium-sized
casting molds to meet the needs of domestic production, large-scale casting molds within the
supporting rate of more than 70%, and to increase the amount of mold exports.
4 products and technology and other aspects of the development of key and major issues
( 1) casting and forming theory and technology of systematic research
At present, the design of casting mold theory and technological development constraints on the
level of further enhancement, mold casting system, slag exhaust system,
replenishment system and temperature control system design is still generally in the imitation and analogous
The design of the mold is still in the mold, and the mold is also in the design of the mold. In the imitation and analogous
practice, often resulting in design errors, or increase the difficulty of debugging the mold
and difficult to improve the casting pass rate.
The 12th Five-Year Plan period should accelerate and systematic
unified research on metal casting molding theory, sequential solidification precise temperature control technology,
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Gas distribution in the casting process and the emission mechanism, rapid solidification technology.
(2) Accelerate the new, special molding process of casting mold
Research and development
Currently, there are special performance requirements for some of the quality casting
parts, such as high-strength parts, high abrasion parts, thin-walled parts and high airtight casting
parts of the mold research is very little to meet the needs of the military, aerospace and aviation industries
This part of the casting molds, this part of the casting mold, the gas distribution and emission mechanism, rapid solidification techniques. Industry needs, this part of the casting molds abroad has not reached full maturity stage
stage. Accelerate the research and development of new, special process casting mold, in these
fields with the international advanced level of technology close to the synchronous development, the most favorable
in order to seize the high end of the casting mold heights, thus driving the general mold technology
technology and product quality enhancement, manufacturing with characteristics, core technology
molds. Among them, vacuum die-casting, semi-solid metal casting, metal extrusion
casting, metal liquid forging mold development, research and promotion is a key
points of the subject.
( 3) accelerate the application of new materials casting mold research and development
Take full advantage of China's magnesium alloy resources, expanding magnesium alloy
die casting applications. Carry out magnesium alloy die casting production process research,
to magnesium alloy instead of other metal large-scale die casting feasibility study,
and related mold technology research, the focus of this topic should be around the large-scale
magnesium alloy die casting mold research and development.
( 4) attack casting mold manufacturing key technologies
Currently, China's casting mold manufacturing level of advanced industrial countries
home the most obvious gap in the service life, some of the key advanced manufacturing
making technology has not been well grasped, should be the following topics for research: mold
mold use process to fully explore the heat-resistant steel The performance of the mold
mold inserts
failure analysis and improve the service life of casting molds; thickness greater than
than 200 mm of hot-working steel heat treatment quenching research; casting mold
mold inserts, such as research on the surface treatment technology.
( 5) large, complex, precision die-casting mold research and development and manufacturing
casting mold in the large, complex, precision automotive die-casting molds
still a large number of imports, affecting the development of the automotive industry, should be imported mold
mould
mould to analyze, digest and imitation, we can grasp the current urgent need and difficulty
large typical mold to carry out Attack: the development of bridge engine block die-casting
mold R & D and manufacturing; automatic wave automobile transmission die-casting mold research
development and manufacturing.
5 China's casting mold development proposals
( 1) suggests that through the enterprise's own development and growth and government
support, strong industry backbone enterprises, in the / Twelfth Five-Year Plan period focus on fostering
and the creation of 3 ~ 5 annual output value of more than one hundred million yuan of enterprises, to carry out the difficulty of large, high
terminal casting die of the development and research and strengthen the competitiveness of the international market. International market competitiveness.
( 2) It is recommended to continue to support the relevant institutions of higher learning and scientific research institutions
structures to accelerate the research and development of CAE software for casting molds, in particular to
Joint casting industry manufacturers and the corresponding mold manufacturers*** with the
Development to encourage the promotion of the application of economic policy should be given to the appropriate
support, and application process of continuous improvement. And in the application process of continuous improvement and enhancement. The start is not
counted too early in Japan, South Korea in the casting CAE software development practices,
as well as Huangyan, Ningbo area through the local funding to promote the application of domestic plastic
material mold CAE software experience is worth learning.
( 3) proposed in the / Twelfth Five-Year period, play the role of mold industry associations
, organizing forces, with reference to the North American Foundry Institute standards and ISO
international standards, the national standards of die-casting molds for the second revision,
and began to formulate the national standards of low-pressure casting molds and gravity casting molds
national standards.
( 4) suggests that the state in the steel industry focus on supporting 2 ~ 3
production plants, these plants can only do / small, special, fine 0. Accelerate
upgrading smelting, forging technology, for the research and development of the new mold steel species, eagerly looking forward to
To the market to provide casting mold industry needs high quality and low-cost domestic
heat-resistant. mold steel.
( 5) In order to improve the overall technical level of the industry, it is recommended that the state or casting
casting mold manufacturers are relatively concentrated in the region to establish a casting mold technology
Institute, heat treatment centers, steel surface treatment centers, casting mold
trial base, casting mold testing and identification centers and other technological research and
service platform.
2009 Annual Meeting of Guangdong Provincial Special Processing Society was held in Shenzhen
January 9, 2010, by the Guangdong Provincial Mechanical Engineering Society of Special Processing Branch hosted by Shenzhen Foster CNC Machine Tools Co. Guangdong Provincial Association of special machining of the directors, member representatives, special guests and other nearly 100 people attended the meeting
Meeting. Guangdong Provincial Mechanical Engineering Society Xu Hongjia Secretary General, Guangdong Provincial Mechanical Engineering Society of special machining branch chairman, Guangdong University of Technology, School of Electrical and Mechanical Engineering
President Guo Zhongning Professor respectively made a passionate speech.
At the annual meeting, experts and scholars on the current direction of development of special machining technology and research results made a wonderful report, the annual meeting of the organizer Shenzhen Fu
ster company on the development of the company's products and technology to the representatives of the meeting, Nanjing Ming Kodak, Guangzhou Nankong, Beijing Ao Hengda and other representatives of the enterprise made a speech on the development of technology
Development.
The organizer of the annual meeting organized experts and representatives to visit the production site of Foster and observe the new product demonstration.
( Shenzhen Foster CNC Machine Tools Co., Ltd)
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