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While the automobile industry is developing at a rapid pace, foreign auto manufacturers are optimistic about the Chinese market and have entered China to purchase auto parts. With the international automakers beginning to implement the global procurement strategy for parts and the localization strategy of international multinational auto companies, our automotive molds have also ushered in a golden age of development.
Basic realization of localization of automobile mold
According to Chang Shiping, deputy general manager and chief engineer of Tianjin Automotive Mould Co., Ltd., after the 1980s, China began to introduce the production equipment and processing technology of automobile molds from abroad. However, during this period, the development of Chinese automobiles was slow and slow, and automobiles The models are mainly imported from abroad, and most of them introduce molds at the same time. The domestic automobile mold production capacity is backward, and it is basically self-produced. At most, there are some industry productions among automobile manufacturers, and there is almost no independent professional automobile mold factory. In the late 1990s, with the country's emphasis on the automotive industry, many automotive and mold manufacturers began to pay attention to the research and development and manufacturing of automotive molds, and began to increase investment in automotive molds. Automobile mold companies emerged in large numbers and gradually became an independent company. In the industry, automotive molds began to gradually form commodities into the market. With the commercialization of automotive molds, customer requirements are higher, how to meet customer needs has become the pursuit of mold manufacturers. Chang Shiping told reporters: "The primary goal of the automotive mold industry is to replace imports and achieve localization of automobile molds." However, due to the large number of joint venture automobile companies in China, many automobile molds were imported from abroad at the time, and domestic automobile molds could only assist. And the role of the supporting role.
In recent years, China's automobile molds have made great progress. In the world, it has already come to the forefront and has become a big mold country. However, China's automotive mold exports are still very small, which shows that our automotive molds are far less developed than plastic mold exports. “The main reason for the low export of automobile molds in China is because the threshold of automotive mold technology is relatively high.†In Chang Shiping’s view, in the development process of previous automobile molds, foreign customers’ entry thresholds were high, and domestic automobile mold project management and design Weak manufacturing technology, lack of practical production experience, and poor international marketing capabilities all restrict the rapid development of China's automotive molds. But in general, the development speed of China's automotive molds is still very fast. "China has basically been able to produce all kinds of automobile molds. What is lacking is not equipment and technology, but mature and high-end talents. It can be said that at present, we are not different from automobile molds in developed countries such as Germany and Japan. Big, the main difference is not technology, but management and experience." As Chang Shiping said, in addition to the actual design and manufacturing inspection of special high-end automotive molds, China can basically achieve the localization of automotive molds, and also Started to expand the share of mold exports.
Large-scale and complicated become the development trend of automobile molds
Automobile molds, especially cover molds, are large and medium-sized molds. Large-scale is a major feature of automobile molds. The weight of a single mold can reach 40 to 50 tons, that is, small and medium molds are also in tons. “Before the exterior panels of the door, etc., used to be a standard mold. Nowadays, due to the general use of the overall side wall technology, the tonnage and countertop of the press line are getting larger and larger, and other smaller parts may also be combined with two or more parts. In a set of molds, this has led to the enlargement and complication of key automotive molds," Chang Shiping said.
"In addition to large-scale, automotive molds also have a processing feature, which is mainly based on free-form surface processing, which requires the dynamic precision of the processing machine is very high, and at the same time, in order to reduce the residual amount of processing and ensure the processing efficiency, the high-speed and high-small pitch Precision machining has become the most commonly used technology. According to Chang Shiping, when the automobile mold is enlarged, it will bring many new problems. The geometric size is large, and the machining accuracy is difficult to guarantee by the accuracy of the machine. For example, the day and night that was not noticed. The change in temperature difference will now seriously affect the accuracy of mold processing. In the north, the temperature difference between day and night is more than 10 °C. This temperature difference brings about the shrinkage and expansion of the mold, which is enough to make the upper and lower molds match the tolerance. Therefore, it is generally necessary to use a constant temperature for large mold processing shops.
Another feature of large-scale automotive molds is that there are many complex cavities, so the requirements for machining depth, verticality, flatness, etc. are very high, and the requirements for high rigidity, high precision, high dynamic static of machine tools and props are also very high. high. These characteristics are combined, which makes the processing of automotive molds very difficult. Chang Shiping told reporters: "Automotive molds must consider all the precision problems in the design stage. The processing process is the process to ensure the realization of various requirements. After the processing, it is necessary to undergo a lot of modification and subsequent processing to perfect, so that not only the quality There is no guarantee that the processing cycle will be severely lengthened."
In addition to high-speed machining, another feature of mold processing is ultra-hard machining. Because the hardness requirements of the surface of the mold are very high, if the quenching treatment is performed after finishing, the thermal deformation of the mold will be caused, and the precision of the mold cannot be guaranteed. In order to achieve high hardness and high precision of parts, it is often practiced after quenching. Chang Shiping believes that in the process of automotive mold processing, it is necessary to achieve large size, high speed, high precision, and ultra-hard processing (hardness can reach HRC60 or above), which makes the machining of automotive molds very difficult. .
For complex cavities and multi-functional composite molds, with the complexity of the shape of the parts, it is necessary to improve the design and manufacture level of the molds. The multi-grooves and various materials are formed in a set of molds or assembled into components. The composite mold needs to be realized by deepening the machining program in the machining programming stage, improving the comprehensive cutting ability of the machining process for the high-depth cavity and improving the processing stability.
"The requirements of domestic automotive users for automotive molds are firstly low-cost, because in the cost of automobile manufacturing and development, molds are absolutely big. Nowadays, the variety of cars and new cars are developing more and more. The development cost is often the success of new cars. The essential". Chang Shiping said, "As the output of China's automobile single-vehicles is gradually increasing, it has also raised higher and higher requirements for the long life of automobile molds."
With the improvement of automobile production and the improvement of the performance of stamping equipment, in order to pursue the stamping efficiency, the speed of stamping is also getting faster and faster, which requires the mold to perform better in terms of thermal deformation, high precision and high stability. The higher the accuracy of the car mold, the better the stability and the longer the service life. With the improvement of the manufacturing level of automotive molds and the maturity of the automotive molds, China's automotive molds have been able to solve these hard-wearing needs of customers and have reached the world level.
Automotive mold processing, high demand, high speed and high precision machining center
As automotive molds move to higher levels, higher demands are placed on processing equipment. The increasing size of molded parts and the improvement of stamping productivity require a multi-cavity, large-tonnage automobile mold weighing 50-70t, which requires mold processing equipment to have a larger workbench than before, large Y-axis and Z-axis. The journey must also have large load-bearing, high rigidity and high consistency. As the hardness of the die steel material increases, the mold processing equipment is required to have thermal stability and high reliability. The refinement of mold processing makes the compounding and high efficiency of processing equipment more attractive. High-speed milling has many advantages such as high-hardness materials that can be processed, smooth processing, small cutting force, and small temperature rise and deformation of the workpiece, which makes mold companies pay more and more attention to high-speed machining.
“For automotive molds, the most important processing equipment is the gantry machining center, some of which are five-axis or five-sided machining. Relatively speaking, the five-sided machining is the most widely used, but no matter what equipment is used, it must meet the car. The mold has high-speed, super-hard, high-precision, high-rigidity and other processing characteristics." Chang Shiping said. Since automotive mold processing is basically 24 hours of continuous processing, high reliability is also placed on the reliability of processing equipment. Programmatic and unmanned is also a feature of automotive mold processing, which requires processing equipment with more functions and better automation configuration. Equipment such as automatic tool change and automatic alignment can reduce the needs of the processing staff.
“In order to ensure the precision and consistency of the machining, it is hoped that the whole machining can be completed in one time when the mold is processed. However, it is found that it is very difficult to realize such a requirement in the actual machining process. Therefore, the requirements for the machine tool are higher. High feed rate is required, high speed is required for finishing, super hard machining is required after quenching, and five-axis machining is required. If these functions are embodied on one machine, the cost of the machine tool is too high, and At the same time, only a few simple functions may be used. Other functions are idle, and the cost of several machine tools can only be utilized at the same time, which causes a great waste." According to Chang Shiping, it is most commonly used now. The method is divided into process, such as roughing and finishing, or roughing, semi-finishing and finishing. “In general, the more functions, the higher the cost of the machine tool, and the efficiency is not obvious. It is just to reduce the number of clamping times, reduce the processing preparation time, spend more money on the equipment and improve the efficiency. This is not cost effective compared to disproportionate."
In the outbreak of this financial crisis, China's auto industry has not been affected much, but it has turned against the trend. In 2009, China's automobile production and sales have won the top spot in the world. But for the automotive mold industry, 2009 was a very bad year, experiencing the biggest decline since the creation of the industry. In response to the financial crisis, major automakers at home and abroad have cut their investment in research and development of new vehicles, and orders for auto molds have shrunk dramatically. With the recovery of the world economy, the vacancy of a large number of molds in 2009 will be effectively filled in 2010 and in the next few years, and the automotive mold market will also usher in its own spring.
Automotive mold processing demand high speed, high precision and high reliability equipment
The automobile industry is one of the pillar industries in China, and it is also the largest customer of China's mold enterprises. The body and various parts are inseparable from mold forming. At present, China's annual automobile production and sales have grown at an extremely fast rate. The development of China's automobile industry has greatly promoted the development of China's automobile mold industry. Today, China has entered a large automobile manufacturing country, and the demand for auto parts is larger than that of the whole vehicle. More than 90% of these parts are produced by molds. These strong market demands have greatly promoted the development of the automobile mold industry.