I. Technical status and development trend of die-casting molds at home and abroad 1.1 Current situation of die-casting molds at home and abroad China's die-casting industry is an emerging industry. In the 1980s, only a few Chinese units had die-casting machines below 1,000 tons, only domestically. It can manufacture a maximum of 630 tons of die casting machines, and most of die casting machine clamping mechanisms are still fully hydraulic and are very backward. The die-casting field is limited to individual military or large-scale state-owned enterprises, and the die-casting industry is very backward. With the development of the Chinese motorcycle industry in the late 1980s, China successively introduced a large number of 500 to 1000 tons of die casting machines abroad. The first 1,000 ton of die casting machines in China was also successfully developed in 1990. As a result, the Chinese die-casting industry has developed rapidly. This also pulled China's die-casting mold business.
In the 1990s, most of the die-casting molds relied on imports, especially Taiwan. China's die-casting mold enterprises, especially the Ningbo Beilun die-casting mold enterprise's rapid development has really started. It was at the end of the 1990s that basically started with die casting molds for motorcycle parts. It should be said that these are basically small-scale die-casting molds, basically 280 From the tons of die casting machines to the 800-ton die casting machines, the die-casting mold companies are in the initial stages of processing equipment, testing equipment and other hardware, as well as die-casting talents. The mold manufacturing level is relatively low.
Since 2000, with the start of development of China's auto industry, China has begun to introduce more than 1,000 tons of die-casting machines. Domestic foreign-funded enterprises such as Lijin and other die-casting machine companies have also begun to produce more than 1,000 tons of die-casting machines. During this period, the company introduced basically 1,000 to 1600 tons of die casting machines, and the molds were basically all introduced along with the equipment, and few were able to produce in China. After undergoing a round of introduction, due to the high price of foreign die casting molds, individual companies began to seek domestic mold enterprises that can copy auto parts in order to reduce costs. For this reason, some of the larger mold companies, including Huiwang Company, spotted the market, actively responded to challenges, increased investment in advanced and large-scale equipment, purchased advanced detection equipment such as three-dimensional detection, and began to copy automobile parts die-casting molds. . In this process, enterprises absorbed and gradually began to transform, and mainly used in the production of medium-sized die casting molds, including automotive manual transmission housing, which led to the rapid development of mold enterprises, significantly improved the level of mold enterprise equipment, mold manufacturing level and manufacturing capacity improve. At present, such molds have basically no companies introduced from abroad.
With the rapid development of the domestic auto industry in recent years, especially the rise of domestic national brand cars, the Chinese auto industry has become increasingly competitive. The original car cylinders of the original foreign-funded enterprises were basically low-pressure cast or imported from abroad. Due to the large investment in the die-casting car cylinders, and because foreign companies proceeded from their own interests, there was very little domestic production. The auto gearboxes are all imported and used as tools to make money from China. With the domestic auto companies, such as Geely company has successfully developed the automatic gearbox and automotive die-casting cylinders, other domestic companies have also sought localization in order to reduce costs and improve competitiveness. In the past two or three years, the domestic automobile industry and related die-casting companies have purchased large-scale die casting machines ranging from 2,000 tons to 3,800 tons, basically based on the production of automatic transmission housings and automobile engine blocks. However, there are few mold enterprises capable of producing automobile cylinders and automatic gearboxes in China, such as 1.3, 1.4, 1.6, 1.8, 2.0, 2.4 displacement auto four-cylinder and 3.2 displacement V6 cylinder die casting molds. Only Huiwang company is a family, and most of these molds mainly depend on imports. The price of imported molds is 1-2 times that of domestic ones. With the many favorable policies announced by the state this year, China’s auto industry has seen rapid growth in small-displacement vehicles in the first half of this year, while small-displacement vehicles are dominated by families. Small-displacement car engine blocks are required to use die-casting for cost reduction. The demand for automatic files will gradually become mainstream. Therefore, there is a huge market for automobile engine block and automatic transmission housing die casting molds. Domestic demand for large-scale precision die-casting molds will increase.
On the other hand, the competition in the foreign mold and die market has become increasingly fierce. Especially due to the financial crisis, the automobile industry has become more competitive. In order to reduce costs, mold prices must be reduced, so the foreign mold industry is also trying to reduce production costs. The mold industry is an industry with high labor costs. Foreign labor costs are more than ten times that of China and Southeast Asia, and more than 70% of labor costs are non-core technical personnel. Therefore, the foreign mold industry is gradually shifting the mold to areas with low labor costs. This is followed by the trend of foreign companies that use molds to speed up the transfer abroad. Therefore, whether it is domestic or foreign, large-scale precision die-casting mold has a broad market prospect.
1.2 Comparison of current technology at home and abroad The mold is a production tool. The quality of the mold directly affects the production and efficiency of the die-casting enterprise. The mold is the production base of the die-casting enterprise. This point has gradually been recognized by the die-casting industry. Even manufacturers of die-casting machines are claiming that die-casting is about 70% on the die and 30% on the die-casting machine. Therefore, whether it is in the country or abroad, for die-casting companies in the choice of mold, especially when selecting a large-scale precision die-casting mold, the first consideration should be the quality of the mold. The quality of the mold should include a number of elements, such as the dimensional accuracy of the mold, the die-casting yield of the mold, the production efficiency of the die-casting, the reliability of the mold, and the life of the mold. However, for the precision of mold manufacturing, China's die-casting mold enterprises generally pay more attention. With the introduction of advanced equipment, as well as the introduction of advanced design and manufacturing software, this gap is shrinking. However, for the latter points, there is a big gap between China's die-casting mold enterprises and foreign countries.
Judging from the current situation of domestic mold and die enterprises, most of them are only concerned with the casting and drainage system of the mold, that is, they only pay attention to whether or not the product can be cast, and there is insufficient attention to the reliability of the mold, the production efficiency of the mold, and the mold life. It can be said that due to the equipment level of die-casting mold enterprises, the introduction of testing equipment, and the application of processing software in recent years, the precision of mold processing has generally been improved, and the impact of the casting system on the quality of die-casting products has also been recognized. However, for factors such as mold structure, mold strength calculation, and arrangement of mold cooling water passages, which affect mold die casting production yield, mold reliability, production efficiency, and mold life, most of them have insufficient attention, resulting in frequent problems when the mold is used, or The extremely low efficiency has seriously affected the production, quality and efficiency of die-casting enterprises. Germany and Japan are constantly researching and improving around the last few points. In die casting production rate, die casting production efficiency, mold reliability, and mold life mold, China's die casting molds and foreign molds have a wide gap. This makes most companies willing to import foreign molds at prices several times, rather than using domestic molds.
In the case of large-scale precision die casting molds, the gap between molds capable of producing automobile engine blocks and automatic transmission housings is even greater. Due to the fact that the product quality directly affects the performance of the engine and the transmission, the cost of the sequential processing after the addition is very large. Therefore, the die casting yield, the die casting production efficiency, and the reliability of the die are more demanding. Therefore, in the last two years in China, only a few mold manufacturers including Huiwang have been successfully developed, and due to the high prices of foreign molds, the development of the automotive industry is severely restricted. In foreign countries, such large-scale precision die-casting molds are mainly concentrated in Japan, Germany and Italy. Germany and Japan have higher mold design level and research level than Italy, but due to high prices, market share in China is not high. Only Japanese and German-owned companies are provided. Due to the low price of such molds in Italy, there are more such molds produced in Italy including abroad. The Italian molds, from the current use in China, are not high in design level and manufacturing level. However, due to the late start of Chinese die-casting mold manufacturing enterprises and the lack of technology accumulation, especially for many companies that have not engaged in die-casting production and have no dedicated die-casting talents, as well as having little knowledge of large-scale die-casting molds, when undertaking such molds, Molds can be manufactured, but most of the development is unsuccessful. Mainly in several aspects: First, there are major problems in the use of molds, high failure rate, slider stuck, core fracture and so on even mold cracking; Second, the die casting production efficiency is extremely low, resulting in high cost of die-casting The third is that the rate of finished castings is not stable, and after the products are processed, there are air holes, shrinkage holes, and leaks, which cause a lot of scrap. Fourth, it is unable to adapt to automatic die-casting production. As the level of equipment for die-casting enterprises has increased in recent years, more and more companies have introduced fully-automatic die-casting equipment to meet the requirements of fully automatic die-casting production. In terms of die-casting molds, mold cooling has been achieved. As well as the requirements for mold reliability and other aspects are higher, such large-scale precision die-casting molds are still mainly imported, and it is difficult for domestic die-casting mold enterprises to compete with foreign companies.
Of course, some domestic excellent die-casting molds, including Hui-wan molds, are aware of this problem. Therefore, under the premise of paying attention to the design of the die-casting and casting system, the die-casting production rate and mold reliability are closely related to the die. In terms of mold production efficiency and mold life, we have actively carried out research work, increased research investment, and have achieved certain achievements. For example, Huiwang Company has successfully developed a magnesium alloy die casting mold for automobile IP dashboards, an automatic transmission housing, an automobile four-cylinder body, and currently the largest and most complex V6 cylinder die casting mold in China. Die-casting molds, and took a lot of export high-end molds. These molds have absorbed many advanced technologies from Japan and Germany and have achieved excellent results. The mold level has been significantly improved. Although there are still some gaps in the details of molds with advanced countries such as Japan and Germany, the overall level of molds has been greatly improved, and some have reached the international level and are well received by users.
Therefore, accelerating the development and research of large-scale precision die-casting molds, improving the level of mold design and manufacturing, surpassing Italy, reducing the gap between the mold level in Japan and Germany, and occupying the domestic market, opening up the international market, and boosting the overall level of China's die-casting molds. Both have far-reaching significance. At the same time, improving the level of China's large-scale precision die-casting molds is also of great significance to enhancing the competitiveness of the Chinese auto industry and improving the development capabilities and manufacturing levels of the automotive industry.
Second, China's large-scale research and development direction of precision die-casting mold Although China's large-scale precision die-casting mold has made great progress after several years of efforts, but there is still a certain gap with foreign advanced countries. In order to further adapt to the current requirements of die-casting enterprises for large-scale precision die-casting molds and to meet the rapid development of the automotive industry, for the needs of large-scale precision die-casting molds, die-casting mold enterprises must improve their capabilities from various aspects such as technology and management, and upgrade the large precision die-casting molds. Design, manufacturing level. To promote the overall level of China's die casting mold.
The level of die-casting mold mainly depends on the following aspects: First, the dimensional accuracy of the mold production product; Second, the mold production yield of the mold; Third, the mold production efficiency; Fourth, the reliability of the mold production; Service life. Therefore, we should focus on the above points and carry out work to improve the level of China's large-scale precision die casting molds.
1) According to the dimensional accuracy of the first mold production product, that is, the manufacturing precision of the mold, Chinese die-casting mold enterprises attach great importance, but it is only achieved by purchasing advanced equipment. In fact, this is far from enough. Mold manufacturing companies should improve from two aspects. The first is to improve the level of processing equipment, and the second is to improve the management level. For the first point, most companies can understand, but for the second point, China's die-casting mold manufacturing enterprises generally do not realize that, in fact, only good equipment, if management can not keep up, can not make high-precision Mold. For example, tool wear, machine tool accuracy decline or changes, etc. will affect the machining accuracy. In view of this, we must start with management, such as the establishment of a tool library, all detection before use, regular inspection of the machine tool accuracy, etc., only to grasp all aspects in order to ensure the quality of the process to ensure the quality of the mold.
2) In order to increase the yield of mold production castings, most mold companies in China only pay attention to the mold casting system. Many companies purchase mold flow analysis software and begin to pay attention in the early stage of design. Of course, the impact of the casting system on the casting yield is very large, but most companies do not pay enough attention to the temperature balance of the mold, that is, the arrangement of the mold cooling water. In fact, mold balance issues not only affect the yield of mold die casting production. The same is true for the production efficiency of the mold. The mold temperature field in die-casting production directly affects the quality of the product, and only when the mold is cooled properly can it be ensured that the production of fully automatic die-casting can be ensured because under the condition of fully automatic production, it is impossible to manually adjust the mold temperature to meet the die-casting production. required. For this, Japanese and German companies attach great importance, such as the Japanese company manufacturing mold cooling water valve installed to control, and some use of high pressure cooling system, for the core of the small 4mmm are cooled, and installed temperature sensing device , control the amount of cooling water or pressure through temperature changes. Faiwang company in the production of Japan or Germany mold, in the trial mode, the customer requires the cooling water must be in place, and in the trial process focus on mold temperature field changes, and adjusted to meet the automatic production acceptance criteria . The control of mold cooling water is the focus of the die casting process. With the improvement of the overall strength of China's die-casting enterprises, the level of automation will be increased to align with foreign companies. Especially in recent years, powerful enterprise groups have invested in die-casting. Basically, the starting point is very high. Basically, the way of casting islands is fully automated. The die-casting machine is basically fully automatic. Therefore, the requirements for the die are very high, and we Most of the molds made by the die casting mold in the country cannot meet the demand and there is a big gap. Therefore, we must increase the study of mold cooling, and increase the research to adapt to automatic die-casting mold production. This is a problem that China's die-casting mold enterprises and die-casting enterprises pay close attention to, and it is also one of the key research directions for large precision die-casting molds in the future.
3) For the production efficiency of the mold, foreign companies attach great importance to it. On the one hand, as the previous issue focuses on cooling in the mold, reducing the temperature balance of the mold by spraying, reducing the spraying time, reducing the cooling time of the casting on the mold, and increasing the production The rhythm improves the efficiency of die-casting production; on the other hand, it focuses on the rapid disassembly and assembly of molds, as well as the reduction of time for mold maintenance and replacement of wearing parts. The traditional way of installing and dismantling large-scale die-casting molds, such as the use of manual pressure plates, is very time consuming and usually requires a shift. In foreign countries, whether it is a die-casting machine or a die-casting mold, this problem is highly valued, including the positioning of the mold, the clamping of the mold, the mounting of the ejector lever, the connection of the stroke switch, the connection of the pulling cylinder, the connection of the cooling water pipe, etc. Quick connection, and if the mold needs several oil cylinders or limit switch joints in the mold string, parallel connection, to do a very user-friendly. In the core replacement and other small links have been enough effort, fully consider the use of mold, mold production efficiency. Installation or disassembly is very rapid, saving time and increasing production efficiency. Therefore, this is a problem that China's die-casting mold companies and die-casting companies are focusing on, and it is also one of the research directions for large-scale precision die-casting molds.
4) For the reliability of mold production, there is a gap between China's die-casting molds and developed countries. In fact, mold reliability is very important for die-casting production. This point, China's die-casting mold manufacturing companies, including many die-casting companies, also pay less attention to this issue. Many die-casting mold manufacturing companies often only consider economic benefits when designing and manufacturing molds. The molds are often made smaller. Especially for large-scale die-casting molds, the force applied by the molds is very large. The intensity of the design of foreign large-scale die-casting molds is first. Large enough, the plate is generally selected P20 or 4140 forged steel, and heat treatment, such molds during the use period, the mold is absolutely reliable, long life. In China, cast iron or cast steel is widely used. Our molds are usually produced at the very beginning. After the molds are used for a period of time, the molds will have such problems. Sliders will emerge, and even die cracking and cracking will occur. The molds are reliable. Poor sex, seriously affecting die-casting production. On the other hand, foreign advanced molds generally pay attention to the improvement of details. Such as a domestic Japanese joint venture company a cylinder die casting mold, the trip switch from the entrance to the trip switch cover all with a special wax seal up, to ensure that a little moisture can not go. It is understood that the mold from the use of the mold to scrap, has never affected the production of the trip switch failure, which left a deep impression on the use of units. German companies are constantly improving their mold structure, mold design, and manufacturing processes to ensure that the level of molds is improved. For example, considering that the slides are prone to aluminum or debris, cleaning the molds will squeezing the molds and using advanced technology. The slider structure ensures that the mold is safe and reliable. This point, China's die-casting mold manufacturers must have enough awareness, mold is a tool, safety, reliability is very important.
5) In order to improve the service life of the mold, on the one hand, we must learn from foreign companies, strengthen the mold structure, mold strength, etc., and study and optimize mold materials, heat treatment, and surface treatment. On the other hand, advanced mold companies in Japan and Germany have begun to conduct research on mold processing. Advanced machining centers and advanced processing techniques have been introduced to perform hard processing of mold cavities and reduce hard layers on the mold surface. Greatly improved die life. We should also strengthen research in this area and increase our mold manufacturing level. Huiwang Company has purchased two large-scale five-axis machining centers for DMG in Germany and has begun to study the hard machining of mold cavities.
To sum up, we should closely consider the above five aspects, consider the aspects of die casting production, increase the level of design and manufacturing, pay attention to the details of the mold, improve the convenience of mold use and maintenance, and increase the efficiency of die-casting production, in the interest of customers. This is our future R&D direction and direction. Only in this way, can we raise the level of our die-casting molds before we can upgrade the level of large-scale precision die-casting molds in China so as to raise the overall level of the die-casting industry.
Third, the development forecast of China's large-scale precision die-casting mold With the rapid development of the automotive industry and the acceleration of the localization process, the demand for large-scale, precision and complex die-casting parts such as automotive cylinders, dashboards, and automatic transmission housings will increase. The greater the size, the greater the demand for large, sophisticated and complex die-casting molds. At the same time, under the special historical background of the former economic crisis, China's die-casting industry and die-casting mold industry, despite difficulties and challenges, have also brought opportunities. In the period of rapid economic development in the world and in China, enterprises may not pay much attention to the reduction of costs, and when the economic situation is not good, reducing costs and increasing the competitive power will become urgent for enterprises. This is precisely the opportunity for China's die-casting mold manufacturing companies. It should be said that the current situation will bring challenges to excellent mold manufacturing companies and bring opportunities. Take the cylinder mold as an example. Previously, due to the limitation of the domestic mold level, such molds were commonly used for import, while the imported molds were close to twice ours, and the current industry was declining. If we continue to adopt import costs, it will certainly remain high. To reduce costs, we must seek domestic procurement. After all, the cost of Chinese manufacturing is far lower than that of foreign companies.
Therefore, as long as we increase research and development efforts, improve the level of mold design and manufacturing, and reach the level of similar foreign products, we will not only occupy the domestic market, but also open up the international market. The prospects are very broad. It is believed that with the rise of some large-scale die-casting mold enterprises in China, as well as the increase in research and development efforts and investment, the level of large-scale precision die-casting molds in China will soon catch up with the advanced level in the world and contribute to the development of China's die-casting industry.
Author: Jinhui: Ningbo Beilun Hui Wang Mold Industrial Co., Ltd.
In the 1990s, most of the die-casting molds relied on imports, especially Taiwan. China's die-casting mold enterprises, especially the Ningbo Beilun die-casting mold enterprise's rapid development has really started. It was at the end of the 1990s that basically started with die casting molds for motorcycle parts. It should be said that these are basically small-scale die-casting molds, basically 280 From the tons of die casting machines to the 800-ton die casting machines, the die-casting mold companies are in the initial stages of processing equipment, testing equipment and other hardware, as well as die-casting talents. The mold manufacturing level is relatively low.
Since 2000, with the start of development of China's auto industry, China has begun to introduce more than 1,000 tons of die-casting machines. Domestic foreign-funded enterprises such as Lijin and other die-casting machine companies have also begun to produce more than 1,000 tons of die-casting machines. During this period, the company introduced basically 1,000 to 1600 tons of die casting machines, and the molds were basically all introduced along with the equipment, and few were able to produce in China. After undergoing a round of introduction, due to the high price of foreign die casting molds, individual companies began to seek domestic mold enterprises that can copy auto parts in order to reduce costs. For this reason, some of the larger mold companies, including Huiwang Company, spotted the market, actively responded to challenges, increased investment in advanced and large-scale equipment, purchased advanced detection equipment such as three-dimensional detection, and began to copy automobile parts die-casting molds. . In this process, enterprises absorbed and gradually began to transform, and mainly used in the production of medium-sized die casting molds, including automotive manual transmission housing, which led to the rapid development of mold enterprises, significantly improved the level of mold enterprise equipment, mold manufacturing level and manufacturing capacity improve. At present, such molds have basically no companies introduced from abroad.
With the rapid development of the domestic auto industry in recent years, especially the rise of domestic national brand cars, the Chinese auto industry has become increasingly competitive. The original car cylinders of the original foreign-funded enterprises were basically low-pressure cast or imported from abroad. Due to the large investment in the die-casting car cylinders, and because foreign companies proceeded from their own interests, there was very little domestic production. The auto gearboxes are all imported and used as tools to make money from China. With the domestic auto companies, such as Geely company has successfully developed the automatic gearbox and automotive die-casting cylinders, other domestic companies have also sought localization in order to reduce costs and improve competitiveness. In the past two or three years, the domestic automobile industry and related die-casting companies have purchased large-scale die casting machines ranging from 2,000 tons to 3,800 tons, basically based on the production of automatic transmission housings and automobile engine blocks. However, there are few mold enterprises capable of producing automobile cylinders and automatic gearboxes in China, such as 1.3, 1.4, 1.6, 1.8, 2.0, 2.4 displacement auto four-cylinder and 3.2 displacement V6 cylinder die casting molds. Only Huiwang company is a family, and most of these molds mainly depend on imports. The price of imported molds is 1-2 times that of domestic ones. With the many favorable policies announced by the state this year, China’s auto industry has seen rapid growth in small-displacement vehicles in the first half of this year, while small-displacement vehicles are dominated by families. Small-displacement car engine blocks are required to use die-casting for cost reduction. The demand for automatic files will gradually become mainstream. Therefore, there is a huge market for automobile engine block and automatic transmission housing die casting molds. Domestic demand for large-scale precision die-casting molds will increase.
On the other hand, the competition in the foreign mold and die market has become increasingly fierce. Especially due to the financial crisis, the automobile industry has become more competitive. In order to reduce costs, mold prices must be reduced, so the foreign mold industry is also trying to reduce production costs. The mold industry is an industry with high labor costs. Foreign labor costs are more than ten times that of China and Southeast Asia, and more than 70% of labor costs are non-core technical personnel. Therefore, the foreign mold industry is gradually shifting the mold to areas with low labor costs. This is followed by the trend of foreign companies that use molds to speed up the transfer abroad. Therefore, whether it is domestic or foreign, large-scale precision die-casting mold has a broad market prospect.
1.2 Comparison of current technology at home and abroad The mold is a production tool. The quality of the mold directly affects the production and efficiency of the die-casting enterprise. The mold is the production base of the die-casting enterprise. This point has gradually been recognized by the die-casting industry. Even manufacturers of die-casting machines are claiming that die-casting is about 70% on the die and 30% on the die-casting machine. Therefore, whether it is in the country or abroad, for die-casting companies in the choice of mold, especially when selecting a large-scale precision die-casting mold, the first consideration should be the quality of the mold. The quality of the mold should include a number of elements, such as the dimensional accuracy of the mold, the die-casting yield of the mold, the production efficiency of the die-casting, the reliability of the mold, and the life of the mold. However, for the precision of mold manufacturing, China's die-casting mold enterprises generally pay more attention. With the introduction of advanced equipment, as well as the introduction of advanced design and manufacturing software, this gap is shrinking. However, for the latter points, there is a big gap between China's die-casting mold enterprises and foreign countries.
Judging from the current situation of domestic mold and die enterprises, most of them are only concerned with the casting and drainage system of the mold, that is, they only pay attention to whether or not the product can be cast, and there is insufficient attention to the reliability of the mold, the production efficiency of the mold, and the mold life. It can be said that due to the equipment level of die-casting mold enterprises, the introduction of testing equipment, and the application of processing software in recent years, the precision of mold processing has generally been improved, and the impact of the casting system on the quality of die-casting products has also been recognized. However, for factors such as mold structure, mold strength calculation, and arrangement of mold cooling water passages, which affect mold die casting production yield, mold reliability, production efficiency, and mold life, most of them have insufficient attention, resulting in frequent problems when the mold is used, or The extremely low efficiency has seriously affected the production, quality and efficiency of die-casting enterprises. Germany and Japan are constantly researching and improving around the last few points. In die casting production rate, die casting production efficiency, mold reliability, and mold life mold, China's die casting molds and foreign molds have a wide gap. This makes most companies willing to import foreign molds at prices several times, rather than using domestic molds.
In the case of large-scale precision die casting molds, the gap between molds capable of producing automobile engine blocks and automatic transmission housings is even greater. Due to the fact that the product quality directly affects the performance of the engine and the transmission, the cost of the sequential processing after the addition is very large. Therefore, the die casting yield, the die casting production efficiency, and the reliability of the die are more demanding. Therefore, in the last two years in China, only a few mold manufacturers including Huiwang have been successfully developed, and due to the high prices of foreign molds, the development of the automotive industry is severely restricted. In foreign countries, such large-scale precision die-casting molds are mainly concentrated in Japan, Germany and Italy. Germany and Japan have higher mold design level and research level than Italy, but due to high prices, market share in China is not high. Only Japanese and German-owned companies are provided. Due to the low price of such molds in Italy, there are more such molds produced in Italy including abroad. The Italian molds, from the current use in China, are not high in design level and manufacturing level. However, due to the late start of Chinese die-casting mold manufacturing enterprises and the lack of technology accumulation, especially for many companies that have not engaged in die-casting production and have no dedicated die-casting talents, as well as having little knowledge of large-scale die-casting molds, when undertaking such molds, Molds can be manufactured, but most of the development is unsuccessful. Mainly in several aspects: First, there are major problems in the use of molds, high failure rate, slider stuck, core fracture and so on even mold cracking; Second, the die casting production efficiency is extremely low, resulting in high cost of die-casting The third is that the rate of finished castings is not stable, and after the products are processed, there are air holes, shrinkage holes, and leaks, which cause a lot of scrap. Fourth, it is unable to adapt to automatic die-casting production. As the level of equipment for die-casting enterprises has increased in recent years, more and more companies have introduced fully-automatic die-casting equipment to meet the requirements of fully automatic die-casting production. In terms of die-casting molds, mold cooling has been achieved. As well as the requirements for mold reliability and other aspects are higher, such large-scale precision die-casting molds are still mainly imported, and it is difficult for domestic die-casting mold enterprises to compete with foreign companies.
Of course, some domestic excellent die-casting molds, including Hui-wan molds, are aware of this problem. Therefore, under the premise of paying attention to the design of the die-casting and casting system, the die-casting production rate and mold reliability are closely related to the die. In terms of mold production efficiency and mold life, we have actively carried out research work, increased research investment, and have achieved certain achievements. For example, Huiwang Company has successfully developed a magnesium alloy die casting mold for automobile IP dashboards, an automatic transmission housing, an automobile four-cylinder body, and currently the largest and most complex V6 cylinder die casting mold in China. Die-casting molds, and took a lot of export high-end molds. These molds have absorbed many advanced technologies from Japan and Germany and have achieved excellent results. The mold level has been significantly improved. Although there are still some gaps in the details of molds with advanced countries such as Japan and Germany, the overall level of molds has been greatly improved, and some have reached the international level and are well received by users.
Therefore, accelerating the development and research of large-scale precision die-casting molds, improving the level of mold design and manufacturing, surpassing Italy, reducing the gap between the mold level in Japan and Germany, and occupying the domestic market, opening up the international market, and boosting the overall level of China's die-casting molds. Both have far-reaching significance. At the same time, improving the level of China's large-scale precision die-casting molds is also of great significance to enhancing the competitiveness of the Chinese auto industry and improving the development capabilities and manufacturing levels of the automotive industry.
Second, China's large-scale research and development direction of precision die-casting mold Although China's large-scale precision die-casting mold has made great progress after several years of efforts, but there is still a certain gap with foreign advanced countries. In order to further adapt to the current requirements of die-casting enterprises for large-scale precision die-casting molds and to meet the rapid development of the automotive industry, for the needs of large-scale precision die-casting molds, die-casting mold enterprises must improve their capabilities from various aspects such as technology and management, and upgrade the large precision die-casting molds. Design, manufacturing level. To promote the overall level of China's die casting mold.
The level of die-casting mold mainly depends on the following aspects: First, the dimensional accuracy of the mold production product; Second, the mold production yield of the mold; Third, the mold production efficiency; Fourth, the reliability of the mold production; Service life. Therefore, we should focus on the above points and carry out work to improve the level of China's large-scale precision die casting molds.
1) According to the dimensional accuracy of the first mold production product, that is, the manufacturing precision of the mold, Chinese die-casting mold enterprises attach great importance, but it is only achieved by purchasing advanced equipment. In fact, this is far from enough. Mold manufacturing companies should improve from two aspects. The first is to improve the level of processing equipment, and the second is to improve the management level. For the first point, most companies can understand, but for the second point, China's die-casting mold manufacturing enterprises generally do not realize that, in fact, only good equipment, if management can not keep up, can not make high-precision Mold. For example, tool wear, machine tool accuracy decline or changes, etc. will affect the machining accuracy. In view of this, we must start with management, such as the establishment of a tool library, all detection before use, regular inspection of the machine tool accuracy, etc., only to grasp all aspects in order to ensure the quality of the process to ensure the quality of the mold.
2) In order to increase the yield of mold production castings, most mold companies in China only pay attention to the mold casting system. Many companies purchase mold flow analysis software and begin to pay attention in the early stage of design. Of course, the impact of the casting system on the casting yield is very large, but most companies do not pay enough attention to the temperature balance of the mold, that is, the arrangement of the mold cooling water. In fact, mold balance issues not only affect the yield of mold die casting production. The same is true for the production efficiency of the mold. The mold temperature field in die-casting production directly affects the quality of the product, and only when the mold is cooled properly can it be ensured that the production of fully automatic die-casting can be ensured because under the condition of fully automatic production, it is impossible to manually adjust the mold temperature to meet the die-casting production. required. For this, Japanese and German companies attach great importance, such as the Japanese company manufacturing mold cooling water valve installed to control, and some use of high pressure cooling system, for the core of the small 4mmm are cooled, and installed temperature sensing device , control the amount of cooling water or pressure through temperature changes. Faiwang company in the production of Japan or Germany mold, in the trial mode, the customer requires the cooling water must be in place, and in the trial process focus on mold temperature field changes, and adjusted to meet the automatic production acceptance criteria . The control of mold cooling water is the focus of the die casting process. With the improvement of the overall strength of China's die-casting enterprises, the level of automation will be increased to align with foreign companies. Especially in recent years, powerful enterprise groups have invested in die-casting. Basically, the starting point is very high. Basically, the way of casting islands is fully automated. The die-casting machine is basically fully automatic. Therefore, the requirements for the die are very high, and we Most of the molds made by the die casting mold in the country cannot meet the demand and there is a big gap. Therefore, we must increase the study of mold cooling, and increase the research to adapt to automatic die-casting mold production. This is a problem that China's die-casting mold enterprises and die-casting enterprises pay close attention to, and it is also one of the key research directions for large precision die-casting molds in the future.
3) For the production efficiency of the mold, foreign companies attach great importance to it. On the one hand, as the previous issue focuses on cooling in the mold, reducing the temperature balance of the mold by spraying, reducing the spraying time, reducing the cooling time of the casting on the mold, and increasing the production The rhythm improves the efficiency of die-casting production; on the other hand, it focuses on the rapid disassembly and assembly of molds, as well as the reduction of time for mold maintenance and replacement of wearing parts. The traditional way of installing and dismantling large-scale die-casting molds, such as the use of manual pressure plates, is very time consuming and usually requires a shift. In foreign countries, whether it is a die-casting machine or a die-casting mold, this problem is highly valued, including the positioning of the mold, the clamping of the mold, the mounting of the ejector lever, the connection of the stroke switch, the connection of the pulling cylinder, the connection of the cooling water pipe, etc. Quick connection, and if the mold needs several oil cylinders or limit switch joints in the mold string, parallel connection, to do a very user-friendly. In the core replacement and other small links have been enough effort, fully consider the use of mold, mold production efficiency. Installation or disassembly is very rapid, saving time and increasing production efficiency. Therefore, this is a problem that China's die-casting mold companies and die-casting companies are focusing on, and it is also one of the research directions for large-scale precision die-casting molds.
4) For the reliability of mold production, there is a gap between China's die-casting molds and developed countries. In fact, mold reliability is very important for die-casting production. This point, China's die-casting mold manufacturing companies, including many die-casting companies, also pay less attention to this issue. Many die-casting mold manufacturing companies often only consider economic benefits when designing and manufacturing molds. The molds are often made smaller. Especially for large-scale die-casting molds, the force applied by the molds is very large. The intensity of the design of foreign large-scale die-casting molds is first. Large enough, the plate is generally selected P20 or 4140 forged steel, and heat treatment, such molds during the use period, the mold is absolutely reliable, long life. In China, cast iron or cast steel is widely used. Our molds are usually produced at the very beginning. After the molds are used for a period of time, the molds will have such problems. Sliders will emerge, and even die cracking and cracking will occur. The molds are reliable. Poor sex, seriously affecting die-casting production. On the other hand, foreign advanced molds generally pay attention to the improvement of details. Such as a domestic Japanese joint venture company a cylinder die casting mold, the trip switch from the entrance to the trip switch cover all with a special wax seal up, to ensure that a little moisture can not go. It is understood that the mold from the use of the mold to scrap, has never affected the production of the trip switch failure, which left a deep impression on the use of units. German companies are constantly improving their mold structure, mold design, and manufacturing processes to ensure that the level of molds is improved. For example, considering that the slides are prone to aluminum or debris, cleaning the molds will squeezing the molds and using advanced technology. The slider structure ensures that the mold is safe and reliable. This point, China's die-casting mold manufacturers must have enough awareness, mold is a tool, safety, reliability is very important.
5) In order to improve the service life of the mold, on the one hand, we must learn from foreign companies, strengthen the mold structure, mold strength, etc., and study and optimize mold materials, heat treatment, and surface treatment. On the other hand, advanced mold companies in Japan and Germany have begun to conduct research on mold processing. Advanced machining centers and advanced processing techniques have been introduced to perform hard processing of mold cavities and reduce hard layers on the mold surface. Greatly improved die life. We should also strengthen research in this area and increase our mold manufacturing level. Huiwang Company has purchased two large-scale five-axis machining centers for DMG in Germany and has begun to study the hard machining of mold cavities.
To sum up, we should closely consider the above five aspects, consider the aspects of die casting production, increase the level of design and manufacturing, pay attention to the details of the mold, improve the convenience of mold use and maintenance, and increase the efficiency of die-casting production, in the interest of customers. This is our future R&D direction and direction. Only in this way, can we raise the level of our die-casting molds before we can upgrade the level of large-scale precision die-casting molds in China so as to raise the overall level of the die-casting industry.
Third, the development forecast of China's large-scale precision die-casting mold With the rapid development of the automotive industry and the acceleration of the localization process, the demand for large-scale, precision and complex die-casting parts such as automotive cylinders, dashboards, and automatic transmission housings will increase. The greater the size, the greater the demand for large, sophisticated and complex die-casting molds. At the same time, under the special historical background of the former economic crisis, China's die-casting industry and die-casting mold industry, despite difficulties and challenges, have also brought opportunities. In the period of rapid economic development in the world and in China, enterprises may not pay much attention to the reduction of costs, and when the economic situation is not good, reducing costs and increasing the competitive power will become urgent for enterprises. This is precisely the opportunity for China's die-casting mold manufacturing companies. It should be said that the current situation will bring challenges to excellent mold manufacturing companies and bring opportunities. Take the cylinder mold as an example. Previously, due to the limitation of the domestic mold level, such molds were commonly used for import, while the imported molds were close to twice ours, and the current industry was declining. If we continue to adopt import costs, it will certainly remain high. To reduce costs, we must seek domestic procurement. After all, the cost of Chinese manufacturing is far lower than that of foreign companies.
Therefore, as long as we increase research and development efforts, improve the level of mold design and manufacturing, and reach the level of similar foreign products, we will not only occupy the domestic market, but also open up the international market. The prospects are very broad. It is believed that with the rise of some large-scale die-casting mold enterprises in China, as well as the increase in research and development efforts and investment, the level of large-scale precision die-casting molds in China will soon catch up with the advanced level in the world and contribute to the development of China's die-casting industry.
Author: Jinhui: Ningbo Beilun Hui Wang Mold Industrial Co., Ltd.
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