Domestic mold into the international market to participate in the global market competition

Date of issue:2011-05-28


Despite the arrival of the post-crisis era, China's industrial market prospects are still good. Hardware die industry faces big challenge however. With the reform and opening up, the focus of the global manufacturing industry has shifted to China, which provides a strong impetus for the development of China's mold industry and also puts forward higher and higher requirements for mold manufacturers. Luo baihui pointed out that at present, Chinese mold manufacturing enterprises must focus on improving the product grade and reducing the manufacturing cost, and realize the strategic transformation from "mold power" to "mold power".


"Although the scale of our molds is only second to that of Japan and the United States, most of them are concentrated in the middle and low end fields, with low technical level and added value. On the contrary, many middle and high end molds are still dependent on imports. The future is the core competitiveness of the product, domestic and foreign are the same, China's mold industry to develop, I am afraid that our enterprises and the government need to work hard in technology research and development innovation. Dongguan chang 'an town blue light mold, blue light precision (Hong Kong) co, LTD. General manager zhang chengjun said.


"Changan is the capital of moulds in China. As far as I know, due to the financial crisis, life is not so good now. Jinyuan securities machinery industry analyst liu wei said.


The explanation given by zhang chengjun to the author is that this situation is mainly caused by the lack of core competitiveness of the enterprise, the product grade is not high enough and is greatly affected by the financial crisis. The mold industry is different from other industries. It was not affected very much at the end of last year, but it was obviously affected in the first four months of this year. In may, the market began to recover slowly. Our enterprise has confidence in the future.


Confidence not only from the mold industry itself in the important position in the manufacturing industry, but also from the huge market rigid demand.


The rapid development of automobile industry brings good opportunities for the development of China's mould industry. Automobile molds made in China, such as automobile cover parts molds, instrument panel molds, bumper molds and automobile electronic molds, have been widely used in the production of automobile parts. At the same time, with the rapid development of the automobile industry, automobile molds and welding fixtures have gradually been effectively combined and matched, and the integration trend of automobile body mold clamps has been strengthened, which can reduce the matching cycle and user costs.


Ten years ago, China's automobile mold is mainly faw, second automobile, tianqi, nanjing automobile, chengfei and Taiwan's mold team as the industry's iconic enterprises, today's automobile mold enterprises have developed to dozens of, a number of rapid rise of private enterprises have a considerable scale. Both in terms of technology and production capacity, these enterprises greatly exceed the iconic enterprises of that year.


From the automobile stamping die distribution in the country, we can see that China's automobile die has developed from the spark of the past to today's all over the country. In the past three years, more than half of the molds and fixtures required by dozens of self-owned brands and joint-venture brands listed in China are developed and manufactured by Chinese mold enterprises, and many OEM (original equipment manufacturer) manufacturers of cars have handed over the most complicated complete vehicle molds of b-class cars to Chinese mold enterprises for production.


At present, there are more than 100 domestic automobile body mold manufacturing enterprises with a certain scale, among which 20 enterprises with an output value of over 100 million yuan. The number of large numerical control machine tool exceeds 800, already approach or exceed Germany, United States, Japan.


Before 2002, domestic mold enterprises mainly produce truck and van mold, car mold only in the production of structural parts of the level of mold; The production capacity of welding clamp enterprises is also limited to the production of internal parts welding jig and component assembly jig. From 2003 to 2007, domestic mold enterprises gradually began to produce complete body in white mold, welding enterprises also have the production capacity from chassis assembly four doors, side assembly to body in white main welding line, and in the main technology has been close to the international advanced level.


Many enterprises in China have realized the 3d solid processing of stamping dies. This greatly improves the mold quality, improves the efficiency and shortens the manufacturing cycle. In recent years, with the continuous introduction of advanced processing means such as high-speed multi-functional CNC machine tools and high-strength cutting tools, rapid development has been achieved in the application fields of unmanned high-speed machining, fine machining of mold surface, five-axis linkage machining and computer virtual machining. Advanced technologies such as simulation and virtual reality have been applied in the early stage of die clamp development.


Due to the rapid development of the industry, the technology and management of China's mold industry has entered the fast lane, and has the ability to challenge developed countries mold manufacturing industry. Five years ago, the value of China's import and export of molds was 5.8:1, while the ratio of import and export in 2007 was 1.45:1. The export value of molds exceeded 1.4 billion us dollars, which marked that China's mold industry entered the international market in a large-scale era.


Japan Toyota, Germany Volkswagen and other international leading automobile manufacturers, have a special stamping, welding, assembly, coating process personnel. They work with body designers at the r&d center to analyze the product's workability.


From the car body design to tooling manufacturing are following the principle of unity, the degree of integration is very high, very conducive to the overall control of the body quality, cost, cycle. China's mold, welding clamps industry is mostly a fight on their own, mold manufacturers, welding clamps manufacturers are difficult to communicate, many problems are stranded in the production preparation stage of automobile manufacturers, seriously restricting the body in white product quality and output cycle.


Due to the limitation of mould material and special structure, there is still a gap between the stamping technology level of automobile body mould in China and the same industry abroad. This is mainly reflected in the experience and experience of process designers. The types of vehicle types contacted by domestic process designers are too different from those of foreign process designers, resulting in some constraints on process design ideas.


Foreign stamping process design of spiral sand washer is a very professional job, a clear division of responsibilities, need through the team cooperation to complete the design process of complex sand washer, generally includes the early stage of the product manufacturability analysis, predict process scheme, model building, process analysis, the feasibility of the model of optimization design process over and over again.


Taking the overall side circumference of a car as an example, the common side circumference mold generally has 5 ~ 6 working procedures. Four years ago, Toyota changed the siding process from 5 processes to 4 processes, and increased efforts in mold development and product development, achieving a big leap in the industry. At present, the research direction is to complete the stamping process of the whole side jaw crusher manufacturer through three processes, which not only needs to improve the stamping process, but also needs the collaborative research and development of synchronous engineering. When designing the product of the whole side of the car, the feasibility of the stamping process should be fully considered.


Some international advanced enterprises have a high level of welding development ability, and formed a small number of advanced vehicle welding technology platform enterprises as the core, many professional degree of small and medium-sized welding enterprises as a collaborative network pattern. The application of 3d digital process planning and simulation software in foreign automobile companies such as Toyota, Volkswagen, Peugeot and gm has been nearly ten years. In China, there is a lack of unified digital information management means for the process planning of welding lines with large output and high degree of automation, so the planning ability of such high automatic welding lines has not been formed.


At present, the equipment of Chinese automobile body-in-white manufacturing industry is close to the world leading level in both quantity and advanced quality. According to incomplete jaw crusher manufacturers, only to the automobile mold industry as an example, the domestic large CNC machine ownership has exceeded 800, but because we started late, the accumulation of insufficient, manufacturing technology water cone crusher and the international advanced level is still a big gap. In order to make our country become a powerful country by mold, the industry needs to make indomitable efforts.


Our country automobile mold industry necessary backwardness, the material type, the material performance is not stable. These problems include: the variety of standard parts, quality is not high; The gap of manufacturing technology level leads to higher processing cost than foreign manufacturers; Edge technologies such as induction quenching/laser quenching/nitriding/titanization need to be developed; Lack of data feedback and experience accumulation of stamping process after debugging, and lack of effective measures to integrate the debugging and dressing process of bench workers into the early stage of design; Lack of systematic management procedures and the ability to escalate.


Two oil shocks helped to make cars lighter for the first time; Protect the earth's environment, promote the second car lightweight. The application of high strength steel is promoted by realizing the light weight of automobile and meeting the requirements of automobile safety regulations. Japan, Europe automobile manufacturers high - strength steel plate application time is long, the scope is very broad. The materials show that the application proportion of high strength steel of a Japanese automobile company was 15% in 1980, more than 30% in 1990 and 50% in 2000. The application of high strength steel plate for domestic automobile parts is limited to structural parts and beam parts, the tensile strength of materials is mostly below 500mpa, and the stamping parts of newly developed models can reach up to 980mpa. How to quickly accumulate the technology of manufacturing high strength steel plate stamping parts is an urgent problem for us to solve.


In the United States, the mold industry is considered "the cornerstone of American industry"; In Japan, the mold industry is praised to the "rich society into the driving force" such a high status. In China by the state council, which had the equipment manufacturing industry adjustment and revitalization of planning, and raising the level of technology in mold and its manufacturing equipment as its key content, 16 major r&d projects in national basic equipment features (key parts) of the project about the special mould project, also reflected the important status in the manufacturing of die and mould industry.


In addition, a series of central stimulus plan to boost domestic demand also brings opportunities to the mold market. Have point out that in the automotive, aerospace, medical equipment, new energy, seized $4 trillion with a total investment of construction project of business opportunities, the national strategic and emerging industries are real orders into the mold industry, also need to market segment, target customers, diversified business, mould manufacturing as the core, extending chain, actively provide mould downstream industry equipment, products, meet the growing market differentiation.


Although the prospect is very good, but the mold market itself is also a global competitive market. At present, the foreign developed country mold manufacturer also settles in China in succession. This will aggravate the competition situation of Chinese mould market undoubtedly. In the past, China's biggest advantage over other countries was its cheap Labour. According to hisaichi hashimoto, a professor at the Japan institute of policy studies, Chinese molds are generally "one-third of the cost and one-half of the quality" compared with Japanese molds. However, with the promulgation and implementation of the new labor law, the labor cost increases, and the advantages of Chinese enterprises are gradually lost. Luo baihui stressed, "the mold industry should pay attention to structural adjustment, vigorously develop high value-added products, take the fine, specialized, strong line, in the 'blue sea' to create new growth points. Japanese and American enterprises spare no effort to enhance their competitive edge in the high-end mold field, while China must also upgrade its products and rely on technological upgrading to reduce production costs, which has been agreed in the industry.


According to introducing, changan town also pays attention to this very much, believe to be able to have very big progress through effort. "But also have a problem now, scientific research and innovation are of great investment in manpower and material resources, it is still difficult for private enterprises, private enterprises and China die market occupied very big one part, hope the government can see this, give us a platform, technically on the capital requires the power of the government." "Mr. Zhang said. Facing the crisis, the government and enterprises need to cooperate with each other to jointly deal with the industry problems faced by the metal mold industry.