¡¡¡¡ First, the domestic and foreign businesses are more casting molds
National Foundry mold manufacturing enterprises, can be roughly divided into the following categories: The first category is a professional die casting plant (including joint ventures and wholly owned enterprises), these companies advanced equipment, excellent technology, is the main casting mold industry; second category is casting professional factory mold workshop; third category is the rapid development in recent years, private and private mold factory, such small-scale enterprises, the large number of each division, coordinated operations, located in Jiangsu and Zhejiang, Guangdong area, some of which already has a plant a certain strength; the fourth category is also offering a number of other plants die casting mold. In short, the casting mold manufacturing enterprises with diversified and to a high level of development, which is brought about by China's economic development an inevitable trend.
Mold factory in developed countries can be divided into separate mold factory and affiliated some big company mold factory, the general size is not large, but the high degree of specialization, high technology, high production efficiency.
Foreign companies generally do not die more than 100 people, most of them in less than 50 workers. On the personnel structure, design, quality control, marketing staff more than 30%, 5% or less in personnel management. Annual per capita GDP more than 1 million yuan, the maximum can reach more than 200 million yuan. Some private domestic mold enterprises, joint ventures and foreign personnel structure similar, but some of the staff structure of state-owned enterprises is also not reasonable, in per capita output still a big gap, mostly in the 100,000 to 200,000 yuan, a few can reach 40 million yuan.
Foreign mold enterprise high quality of personnel requirements, multi-skill technicians generally able to complete the process from design to tooling; the operator with a variety of skills; marketers understand and master the mold deep. Domestic mold enterprises finer division of labor, the lack of integrated high-quality personnel.
Foreign mold enterprise CAD / CAM / CAE application technology more widely, reverse engineering, rapid prototyping casting molds use is also more. Domestic enterprises in some key mold manufacturers in this regard has been little gap and abroad, and some have reached the international level, but the gap between small and medium enterprises and foreign mold is still very large. However, the material in the mold, with the introduction of foreign technology and improve China's own R & D capabilities, the gap is gradually narrowing.
In the mold manufacturing cycle and prices, foreign mold price is generally 5 to 10 times the domestic mold manufacturing cycle is 2 to 3 times (generally the mold debugging time will come within the manufacturing cycle), should in these two areas He said domestic mold companies still have some competitive advantage.
Second, the casting mold design and manufacturing technology
Although China is casting a big country, but far from casting power, China casting process level, casting quality, technical and economic indicators, there is a big gap compared with developed countries. Casting sand casting method based, where manual, semi-mechanized molding still accounts for a large proportion, but in recent years the rapid development of Chinese die casting industry, holding an annual 7% to 10% growth rate. China's auto industry is also growing, in order to reduce vehicle weight, aluminum cars, light metal magnesium consumption will grow further, which the casting of a higher quality requirements. China casting process equipment with the advanced countries still lags far behind. Before the 1990s, casting mold design using computer rarely, mainly manufacturing equipment mainly ordinary universal. In the 1990s, a huge? Market demand, especially the rapid development of automobile and motorcycle industry, which greatly promoted the development of China casting mold industry. Meanwhile, with the involvement of joint ventures and wholly-owned enterprises, the introduction of foreign advanced mold manufacturing equipment and technology, to promote domestic casting mold design and manufacturing technology gradually improved, some companies have the ability to design and manufacture of precision molds of large capacity, such as FAW Foundry Co. companies die casting plant design and manufacture of die casting machine with a 3400t die-casting mold, weighing a total of 33.5t, it is currently the largest domestic die-casting mold
Since the 90s of the 20th century, major changes in the casting mold design and manufacturing industry are:
1, mold enterprises improve production technology, high-tech design and manufacture application mold rapid manufacturing has become a powerful guarantee of quality mold. CAD / CAM / CAE applications, showing the use of information technology to stimulate and enhance the advantages of mold industry, CAD / CAM / CAE technology has become a widespread mold enterprise applications. Integrated CAD / CAM technology has been widely used in casting molds, two-dimensional design software currently used mainly software AutoCAD, using three-dimensional design more, the main Pro / E, UG, Cimatron and so on.
FAW Die Casting Plant 3D design has reached more than 95% in the three-dimensional design of a three-dimensional virtual assembly technology assembly interference detection check to ensure that the mold design quality to ensure the rationality of design and craftsmanship. Three-dimensional data through CAM software editor, NC code is transmitted directly to the CNC mold processing equipment. The universal application of CNC machine tools, to ensure the precision and quality of the mold parts, greatly improving the accuracy and productivity of the mold. CAE technology is gradually applied to the actual design, production, the use of CAE technology to simulate the filling process metal cooling process analysis, prediction forming defects that may occur during the solidification simulation and early product development, process design optimization greatly shortened test time. FAW Foundry Co., Ltd. die casting plant in a number of large and complex molds, such as engine blocks, cylinder heads, transmission housing mold designs have begun to apply CAE technology flow field, temperature field simulation analysis, process yield is greatly improve.
2, milling is an important means of mold cavity. High-speed machining (HighSpeedMachining, abbreviated HSM) is a high cutting speed, high feed rate and high processing quality as the main feature of the processing technology, the workpiece having a low temperature, low cutting forces, smooth processing, processing quality, high efficiency ( 5 to 10 times that of ordinary milling) and machinable hard materials (up to 60HRC), and many other advantages, which in the mold processing more attention. High-speed processing technology into the mold industry, to improve the precision molds, greatly reducing the mold manufacturing time. The study shows that the general complexity of the mold, HSM machining time can be reduced by more than 30%.
Currently, the mold enterprise in order to shorten the molding cycle, improve? Market competitiveness, high-speed machining technology more and more. HSM ships mainly for large and medium-sized mold processing, such as the Surface Machining car cover mold, die casting mold, large plastic mold, with its curved surface machining accuracy up to 0.01mm. CNC high-speed milling technology in production, can greatly shorten the molding time. After high-speed milling mold of finished surface, only slightly polishing can use, save a lot of grinding, polishing time.
Increase high-speed CNC milling machine, mold is one of the key business equipment investment.
3, EDM is an indispensable process for the manufacture of the casting mold. EDM for deep after quenching, processing small cavity remains effective programs. Sodick's linear motor servo-driven CNC EDM machine has driven fast response, high transmission and positioning accuracy, the advantages of small thermal deformation. P-E3 adaptive control system ÈðÊ¿ÏÄÃ׶û company EDM machine has, PCE energy control system and automatic programming expert systems, has its irreplaceable role in the casting mold manufacturing.
4, sophisticated, complex, large-scale development of mold detection equipment have become increasingly demanding. Now accuracy of precision molds reached 2 ~ 3¦Ìm, precision casting mold has reached 10 ~ 20¦Ìm. Domestic manufacturers use more testing equipment Italy, USA, Germany and other features with a digital scanning coordinate measuring machine. Such as FAW Foundry Co., Ltd. die casting plant has a German production of 1600mm ¡Á 1200mm coordinate measuring machine, with digital scanning, measurement can be achieved from the physical to the mathematical model, output NC code, and ultimately the whole process of mold manufacturing, successfully achieve reverse engineering technology development and applications in mold making. This aspect of the device further comprising: Renishaw's high-speed scanners (CYCLONSERIES2), the scanner can achieve laser probe and touch probe complementary advantages, laser scanning accuracy of 0.05mm, contact probe scanning accuracy of 0.02mm.
Using reverse engineering production mold, with short production cycle, high accuracy, consistency and low price many advantages.
5, rapid prototyping casting mold has entered the practical stage, LOM, SLS and other methods of application reliability and technical indicators have reached similar foreign products.
6, mold blank rapid manufacturing technology. There are real dry sand casting, negative real casting, resin sand solid casting technology.
7, user requirements mold delivery has become shorter, cheaper and cheaper molds. In order to ensure on time delivery to effectively manage and control costs has become a major factor in the survival and development of the mold. The use of advanced information management system, integrated management, to mold enterprises, especially large-scale mold companies, is an extremely tasks to be solved. Such as FAW Die Casting factory basically realized the computer network management, from production planning, technology to develop, to quality control, inventory, statistics, accounting, etc., generally make the computer management system, the factory various departments can share information through a computer network.
The use of information technology and other high technology to transform traditional production mold enterprise has become inevitable.
Third, the casting mold material
Casting mold material were selected timber, processed plastic, aluminum, cast iron, steel and so on.
Wood mold is still widely used in hand-shape or single and small batch production, but with the difference between the requirements of environmental protection and wood processing performance limits will be replaced by solid casting. Solid casting with foam sheet as the material, cut and paste into a pattern, and then cast from the casting, which compared with a wooden mold, short cycle, low cost.
Plastic applications on the rise, especially processed plastic is widely used.
Light weight aluminum die due to the high dimensional accuracy, and therefore wider application. Recently, however, the application was decreasing, and some have been replaced by plastic and cast iron mold.
