Cai Zijin and Gao Peng, Technical Committee of China Model Association (text).

China Library ClassificationNo.: TG24 1 Document IDNo.: A DocumentNo.:1009-279X (2010) S0-0034-04.

1 Present situation and main problems of casting dies in China

question

Development of 1 1

(1) Industry Overview

In recent years, with the rapid development of manufacturing industry in China, especially the automobile industry,

With the rapid development, the market demand for castings has risen sharply, resulting in the casting mold system.

With the prosperity of manufacturing industry, the total output is second only to stamping dies and plastic dies, ranking third.

Our casting molds account for about 8% of the total molds in China, with an annual sales of about.

8 billion yuan. Due to the market demand for large, complex, high-quality and high-performance castings

The requirements of parts drive the production scale and manufacturing quality of casting molds in China.

With the improvement of quantity and technical level, a complete series has been gradually formed, with.

A complete and widely distributed industrial structure. According to China mold industry

The five professional mold factories in China compiled by the Association Management Committee are basically

According to the statistics of situation 6, the average annual growth rate of casting molds has been relatively high in recent 4 years.

Up to 24% (table 1).

Table 1 General Situation of Casting Mould Production in China

age

Statistical enterprise

P page

output value

P ten thousand yuan

Compared with last year

Increase P%

The annual output value exceeds100000 yuan.

P enterprise

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

Generally speaking, the manufacture of small and medium-sized casting molds can fully meet the requirements.

Domestic demand, large-scale, complex and precise casting molds depend on imports.

The situation has been greatly improved; The supply of middle and low-grade molds exceeds demand, and the quantity is large.

Moreover, the demanding casting molds are still imported (the main importing country is Japan)

Japan, Korea, Germany, Italy, the United States); Fortunately, it is used in China.

Large and complex casting molds have been introduced from the initial introduction to the present.

Date of receipt: 2009- 12- 10

About the author: Cai Zijin, male, born in 1946, former vice president of Guangzhou Cavity Mould Manufacturing Co., Ltd.

General manager, senior engineer, member of technical committee of China Mould Association, casting mould technology department.

Deputy director.

Gao Peng, male, was born in 1952, Luoyang North Enterprise Group Co., Ltd.

Deputy general manager of the company, professor-level senior engineer, member of technical committee of China Model Association.

Domestic substitution, and a small amount of exports, and the export volume increased year by year.

(2) Enterprise profile

There are many casting mold factories in China, which are not very large in scale, but very small.

A mold enterprise with no more than 300 employees and an annual output value of more than.

There are few enterprises with 50 million yuan, and many enterprises with high production efficiency.

The average productivity is only 200,000 ~ 300,000 yuan, and the mold grade is mostly medium.

Low grade. The service life and manufacturing cycle of the die are shown in Table 2 and Table 3.

Table 2 Service life of die-casting dies in China: ten thousand times.

Pressing aluminum alloy

Small, medium and large

Pressing zinc alloy and magnesium alloy

10~ 20 6~ 15 6~ 10 20~ 15~ 20

Table 3 Month of manufacturing cycle of casting mould

Medium and small, large and extra large.

Die casting dies 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 molds.

A manufacturing professional factory or mold workshop (branch factory) attached to a foundry enterprise.

Professional manufacturers serve the whole society and undertake the needs of various industries.

Types of casting molds. Relatively speaking, the equipment is advanced and the technology is superior.

Good large-scale enterprises are the main commodities of casting molds in China.

Suppliers, their strength and technical status can best reflect the current domestic level.

The vast majority of casting mold manufacturing professional factories are scattered and numerous.

They are private enterprises with strong market adaptability and capital.

Strong proliferation ability, quick response to market demand, large output and strong viability.

Strong. Compared with other kinds of mold fields, foreign investment is less.

Foundry mold production enterprises are concentrated in the economically developed coastal areas of China.

Up to 100 provinces, cities and automobile and motorcycle production bases. For example, Zhejiang Province is called

Beilun, the hometown of die casting mold production in China, is the hometown of casting mold.

Xiangshan is rich in die-casting molds, gravity and low-pressure casting molds. Guangdong Province

Casting molds are mainly produced in Guangzhou, Dongguan, Shenzhen, Foshan and other places.

Relatively dispersed, because the economy opened earlier and absorbed advanced foreign technology.

Fast, more export-oriented enterprises, more mold exports. Born in eastern China.

Manufacturers are mainly concentrated in Shanghai, Suzhou, Changzhou, Kunshan and Nantong.

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Land, by virtue of its geographical advantages near the industrial and automobile industrial centers of China,

The development momentum is strong, enterprises generally have a high starting point and good staff quality.

Show great momentum. In addition, Changchun, Dalian, Yantai,

There are also a lot of casting molds in Chongqing and other places.

(3) Product introduction

Die-casting die products are aluminum, zinc, magnesium, copper and other alloy die castings.

Among them, aluminum alloy die casting accounts for the largest proportion, accounting for about 60%, which is a typical product.

There are automobile gearbox housing, clutch housing, engine cylinder block and motorcycle.

Crankcase, engine bracket, motor cover, oil filter base

Wait a minute.

The products of gravity and low pressure casting molds are ferrous metal, aluminum and copper.

Such as alloy castings, typical products are engine cylinder block, cylinder head and exhaust gas.

Tube, rear vehicle, reducer, crankshaft, transmission housing, etc.

(4) Facing the market situation

Casting mold products have a wide range of applications, involving almost all

In the field of industrial manufacturing, there are a large number of castings of automobile parts.

There are many varieties, and the requirements are strictly ranked first. Taking die casting as an example, countries all over the world

Die-casting automobile parts occupy the largest share in the whole die-casting industry.

(Table 4)

Table 4 Proportion of die-casting parts of automobile parts to total die-casting output in various countries%

Japanese, Australian, Spanish, German, American and China.

80 80 65 65 48 64

At present, China's automobile industry is entering a period of rapid growth, with increasing output.

It has increased substantially for many years, and the output in 2009 is estimated to reach 1.300.

Ten thousand vehicles, strongly increasing the demand for casting molds, can be predicted to the future.

The production of casting molds in China will still mainly come from the domestic automobile industry.

Powerful thrust. China's motorcycle production has been the first in the world for many years.

First, the annual output is more than 20 million, which is needed by motorcycle engines.

Almost all medium-sized and complex die-casting dies are made in China. the same

At that time, China's huge home appliance industry, construction industry and communication industry expanded rapidly.

The communication industry has provided continuous and steady growth for foundry mould manufacturing enterprises.

Dragon's huge domestic demand market. In addition, in the wave of economic globalization,

In the tide, the international division of labor in the process of industrial development is taking shape, and foreign investors take

Under the pressure of cost, a large number of castings are purchased at home, even at home.

China is undertaking international metal castings and systems by establishing a foundry production base.

The production and manufacturing tasks of commodities. At the same time, with the improvement of mold quality at home and abroad

The gradual narrowing of the gap and low prices have also driven the procurement of foreign molds.

Rapid increase, huge overseas mold market demand for industry prosperity.

It played a role in adding fuel to the flames. Can predict the future for a long time.

At home and abroad, China's casting mould industry has developed in both domestic and international markets.

There's plenty of room. However, it should also be clearly seen that China's casting molds

Affected by the current international financial crisis, the manufacturing level still lags behind that of foreign countries.

Influence, the international casting market shrinks, and foreign casting mold manufacturing industry appears.

Overcapacity, which intensifies the competition within the industry, coupled with domestic existence.

With the disorderly bidding among enterprises, enterprises with mixed quality export.

This strategy has brought bad influence to the whole casting mould manufacturing industry.

The main problem of 1 2

(1) Large and complex casting molds are still being imitated and eliminated.

In the absorption stage, there are not many core technologies of independent innovation, and the mold quality is poor.

Quantity, machining accuracy, reliability, stability and service life.

Compared with advanced industrial countries, there is still a gap, and the mold debugging time is long, which leads to

The foundry industry still imports a large number of large-scale high-end molds from abroad every year.

(2) There are a large number of foundry mold manufacturers in China, which are generally standardized.

The model is small, and there is no high level that can compete with excellent foreign counterparts.

Enterprises, lack of pilot enterprises, the professional division of labor within the industry is not obvious.

(3) The enterprise has a low degree of standardization, and the casting mold is standard.

The coverage of commercial production and use of parts is much lower than that of molds and plastics.

Go to hell.

(4) The national standard for die casting dies was revised in March 2004.

Promulgated and implemented, but the content is relatively simple, the guiding force is not strong, and the pressure is low and heavy.

The national standard for die casting dies has not yet been formulated.

(5) Digital mold design and manufacturing is to improve the production of casting molds.

Effective technical means for the overall level of the enterprise, including three-dimensional design and design.

The application of computer simulation analysis technology is increasing.

Advantages At present, the integration of CADPCAMPCAE has been fully realized in China.

There are few casting mould manufacturing enterprises, and the selected software is mainly

Relying on the application level and popularization of import, 3D design and CAE technology.

The degree is far less than that of domestic plastic mold manufacturers.

(6) At present, the performance and stability of domestic hot-working die steel have not been improved.

Satisfied, when manufacturing export molds and requesting casting molds, they are basically.

Or choose imported steel, which greatly affects the market of mold enterprises.

Domain competitiveness.

2 The main gap between China's casting molds and the international advanced level

(1) The manufacturing history of casting dies in China is short and the experience is insufficient.

Casting molds mainly serve the automobile industry, and there are dozens of them abroad.

With a history of 2000 years, China has only begun to take shape in recent ten years, and its demand is large and complicated.

Miscellaneous, investment casting mold design and production experience is insufficient, basically still

In the stage of learning imitation, most of the more complex structures are made of complex materials.

Molding is the main thing, and there are not many innovations. Quality control is very common in the manufacturing process.

The system is not rigorous enough, the manufacturing accuracy is poor, and the mold design is hot.

Balance analysis, cooling system setting, quick replacement of parts, quick installation,

Safety in production is not well considered. Although various cast products

Basically, molds can be made in China. For more difficult molds,

Large manufacturers have the courage to undertake, but often because the scale is not in place,

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Long debugging time, high failure rate, unsatisfactory service life and short service life for users.

Lack of confidence in purchasing. Die casting die for engine block.

For example, there are no fewer than 20 domestic manufacturers engaged in cylinder die casting.

Domestic, but now almost all molds are imported from Japan, Europe and America. morality

A professional mold factory in China produced cylinder blocks as early as 1984.

More than 50 sets of die-casting dies have been produced, compared with nearly 3 in China.

In 2006, the domestic cylinder die-casting mold was produced, and the output of each factory is tired so far.

Rice is only about 10 sets.

(2) the gap between the equipment and the corresponding supporting facilities

Foreign advanced industrial countries often have larger mold manufacturers.

There are many large and medium-sized five-axis or three-axis high-speed machining centers.

Machine tool, equipped with multiple high-precision testing equipment, heat treatment supporting specialty.

The factory has vacuum furnace heating inserts with heavy load above 10 Par.

Processing, some mold factories also have workshops dedicated to mold testing, at the same time, hot

Die steel (part of 3D forging), high-quality standard parts and accessories supply.

Safe. Compared with the same period last year, domestic mold manufacturers are not short of the above key equipment.

There is a big gap in quantity, grade and specification, and export castings are manufactured.

Mold manufacturing and large-scale high-end molds almost all need to eat/foreign feed 0 $ $.

Use foreign software for design, use imported machine tools, tools and inspection.

Equipment processing and testing, purchasing imported hot-processed steel, and installing it in

Standard parts and various accessories on the mold body should also be imported, so the mold

The manufacturing cost is very high.

(3) the talent gap

Talents who master and apply new technologies in domestic enterprises can't meet the demand.

Development needs, mold senior technical personnel, highly skilled employees, enterprises

Lack of managers and foreign trade talents leads to enterprises.

Employment competition has affected the development and stability of mold enterprises. special

Lack of excellent compound talents, such as skilled operation and mastery.

Technical process manager, able to skillfully use information technology to establish

Give consideration to analysis, understand the principle of casting process and related equipment, and master debugging.

The designer of the restoration technology. Engaged in management work in foreign-funded mold enterprises

The proportion of technicians is often high (25% ~ 35%), while employees

Strong sense of quality, professional education and skills training in society are relatively complete.

Training, strengthen on-the-job training for employees within the enterprise. Recently, Japan has not.

In recent years, the development of mold technology advocates that/can be independent of skills.

Mold design and production technology is 0, which means technical mold engineering.

The number and level of personnel are more demanding.

(4) the gap of technical indicators (Table 5)

Table 5 Comparison Table of Technical Indicators of Foundry Moulds at Home and Abroad

International advanced level, domestic advanced level and domestic general level.

The machining accuracy of cavity PMM is 0.01~ 0.030.02 ~ 0.050.05 ~ 0.08.

The profile surface roughness raplm is 0.2 ~ 0.40.4 ~ 0.80.8 ~1.6.

manufacture

manufacture

week

period

P

moon

Compression mould

Gravity and low pressure casting mold

Small and medium-sized 1~ 2 2~ 3 2~ 4

Large 2~ 3 3~ 4 4~ 6

Extra large 3~ 5 4~ 7

Medium and large 2~ 3 2~ 4 3~ 5

manufacture

use

life

life

P

Ten thousand times

Die casting mold (medium-sized)

Die casting zinc 30~ 100 20~ 30 10~ 20

Die casting aluminum12 ~ 2510 ~15 ~ 8

Die casting Mg > 20 15~ 20

Die casting Cu > 3 1~ 3 0. 3~ 1

3 China casting mold development goals and main tasks

Implement Scientific Outlook on Development, rely on scientific and technological innovation and promote the application of science and technology.

Modern information technology has improved the design, processing and management level of enterprises.

Increase investment, improve the equipment level and core competitiveness of enterprises,

Highlight and expand key enterprises to promote the sustained and healthy development of casting mould industry

Rapid development. During the "Twelfth Five-Year Plan" period, the annual output of casting molds will remain unchanged.

Double-digit growth has cultivated 3-5 enterprises with an annual output value exceeding 100 million yuan.

Industry. Development and manufacturing level of large and complex casting molds and its application

The service life has reached the current international advanced industrial country level; Medium and small.

The casting mold fully meets the domestic production needs, and the large casting mold is made in China.

The internal matching rate is above 70%, and the die export volume increases.

4. Development priorities and major issues of products and technologies.

Systematic research on the theory and technology of (1) casting forming.

At present, the development of the theory and technology of casting mold design is restricted.

Further improve the liquid level, pouring system, slag discharge and exhaust system,

The design of feeding system and temperature control system is generally still in the stage of imitation and analogy.

This practice often leads to design errors or increases the difficulty of mold debugging.

And it is difficult to improve the casting qualification rate. During the "Twelfth Five-Year Plan" period, this system should be accelerated.

Keywords metal casting forming theory, sequential solidification precise temperature control technology,

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Gas distribution and emission mechanism and rapid solidification technology in casting process.

(2) Accelerate the new and special molding process of casting mold.

R&D

At present, there are some high-quality castings with special performance requirements in China

Parts, such as high strength parts, high wear-resistant parts, thin-walled parts and high air tightness castings.

There is little research on the mold of parts, which can not meet the needs of military industry, aerospace and aviation.

Industry demand, this part of the casting mold has not yet reached a fully mature stage abroad.

Duan. Accelerate the research and development of new and special casting molds, in these

It is most conducive to the synchronous development of this field with the international advanced technology level.

Only in this way can we seize the commanding heights of high-end casting molds and promote universal mold technology.

The improvement of technology and product quality will create distinctive and core technologies.

Mould. Among them, vacuum die casting, semi-solid metal casting, metal extrusion

It is very important to develop, research and popularize molds for casting and metal liquid die forging.

Point the question.

(3) Accelerate the research and development of new material casting molds.

Make full use of the advantages of magnesium alloy resources in China to develop magnesium alloys.

Application of die casting. Study on die casting technology of magnesium alloy,

Discussion on the feasibility of replacing other metals with magnesium alloy for large die casting,

As well as the technical research of related molds, this topic should focus on large scale.

Development of die casting die for magnesium alloy.

(4) Overcome the key technology of casting mould manufacturing.

At present, the manufacturing level of casting molds in China is compared with that of advanced industrial countries abroad.

The most obvious gap between home and home lies in the service life and some key advanced systems.

Manufacturing technology has not been well mastered, so the following topics should be studied: mold

Fully explore the performance of heat-resistant steel in the process of use; Contour insertion

Failure analysis and research on improving the life of casting mold: large thickness

Study on heat treatment hardenability of 200 mm hot-working steel: casting mold

Research on surface treatment technology such as insert.

(5) R&D and manufacturing of large, complex and precise die casting dies.

At present, large, complex and precise automobile die-casting dies are used in casting dies.

Still a large number of imports, affecting the development of the automobile industry, dealing with imported models.

With analysis, digestion and imitation, we can grasp the urgent needs and difficulties at present.

In order to solve the key problems, a typical large-scale mold, the die casting of the engine block of the bridge car, was developed.

R&D and mold manufacturing; Research on Die-casting Die for automatic wave Automobile Gearbox

Hair making.

Five Suggestions on the Development of Foundry Moulds in China

(1) It is suggested that through the development of enterprises themselves and the government's

Support and expand the backbone enterprises in the industry, and focus on cultivating them during the/Twelfth Five-Year Plan period.

It is difficult to build 3-5 enterprises with an annual output value exceeding 100 million yuan.

Develop and solve the key problems of end casting mold to improve the competitiveness in the international market.

(2) It is suggested to continue to vigorously support relevant institutions of higher learning and scientific research institutions.

Accelerate the research and development of CAE software for casting molds, especially

The manufacturer of the combined casting industry is the same as the manufacturer of the corresponding mold.

Development, in order to encourage the popularization and application, should be given appropriate care in economic policy.

Support, and constantly improve and improve in the process of application. Let's begin. no

It is too early for Japan and South Korea to develop casting CAE software.

And promote the application of domestic plastics in Huangyan and Ningbo through local funding.

The experience of CAE software for material mould is worth learning.

(3) It is suggested to play the role of mold industry association during the Twelfth Five-Year Plan period.

The role of organizational strength, refer to the standards of North American Foundry Society and ISO.

International standard, the second revision of the national standard for die casting dies,

And set out to formulate national standards for low-pressure casting molds and gravity casting molds.

National standards.

(4) It is suggested that the state should support 2~ 3 enterprises in the steel industry.

Production sites, these sites can only be/small, professional and accurate. Accelerated lifting

Improve smelting and forging technology, develop new die steel research and development, and hot cutting cycle.

When the market can provide domestic products with high quality and low price needed by the casting mould industry.

Heat-resistant die steel.

(5) In order to improve the overall technical level of the industry, it is suggested that the state or the Association for Science and Technology.

Casting mold technology is established in areas where mold manufacturers are relatively concentrated.

Research institute, heat treatment center, steel surface treatment center, casting mold

Technical research on mold testing base and casting mold testing and appraisal center.

Service platform.

In 2009, the annual meeting of Guangdong Special Processing Society was held in Shenzhen.

20 10 65438+2009109 was hosted by Guangdong mechanical engineering society special processing branch and undertaken by Shenzhen foster CNC machine tool co., ltd.

The annual meeting of Guangdong Special Processing Society was held in Shenzhen. Nearly 100 people including directors, member representatives and special guests of Guangdong Special Processing Society attended the meeting.

Discuss it. Secretary-General of Guangdong Mechanical Engineering Society, Chairman of Special Processing Branch of Guangdong Mechanical Engineering Society, and Xu Hongjia of Mechanical and Electrical Engineering College of Guangdong University of Technology.

Professor Guo Zhongning, Dean, delivered warm speeches respectively.

At the annual meeting, experts and scholars made wonderful special reports on the current development direction and research results of special processing technology. The organizer of the annual meeting is Shenzhen Fu.

The company introduced the technical development of the company's products to the delegates, and representatives from Nanjing Mingkeda, Guangzhou Nanfeng, Beijing Aohengda and other enterprises made technical introductions.

Development speech.

The organizers of the annual meeting organized experts and representatives to visit the production site of Foster Company and observe the demonstration of new products.

(Shenzhen Foster CNC Machine Tool Co., Ltd.)

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