During the "Eleventh Five-Year Plan" period, China's molds have experienced rapid development. Although in the second half of 2008, the domestic and foreign markets of our molds have also been affected by the international financial crisis. According to Luo Baihui, head of the International Mould and Hardware & Plastic Industry Suppliers Association, the impact was mainly from the tightening of consumer and investment product markets. In particular, the tightening of foreign products in these products caused the export of products to be hindered. As a result, orders for molds once used to produce these products were substantially reduced, cancelled, or postponed. Some countries and regions also imposed anti-dumping restrictions on Chinese exports, and some even had products Closed and closed down without a way out. This situation is only one-sided, because the impact of the mold industry is lagging behind, China's mold has become a leader in the recovery of the world mold industry. In 2010, the production and demand of China's mold market was buoyant, and the growth rate reached a double digit. The total sales of molds in China reached around 112 billion yuan, an increase of nearly 15% over the previous year. Among them, the development speed of mold export is higher than the overall development speed of the entire industry, and the trade surplus is realized for the first time.
In recent years, China's plastic molds have developed rapidly. At present, the proportion of plastic molds in the entire mold industry is about 30%, and the proportion in the import and export of molds is as high as 50 to 70%. With the rapid development of the national economy, such as machinery, automobiles, home appliances, electronic information and building materials, the ratio will continue to increase. According to reports, the production of an ordinary car requires more than 200 pieces of interior decoration molds, and only about 50% of large and medium-sized plastic molds required for the manufacture of bumpers, dashboards, fuel tanks, and steering wheels can be satisfied. A large number of plastic building materials instead of traditional materials has also become a trend. It is expected that in 2011, the penetration rate of plastic doors, windows and plastic pipes will reach 30% to 50%, and the market share of plastic drainage pipes will exceed 50%, which will greatly increase the demand for molds. . Luo Baihui said that the overall trend of the mold market is steady upward. In the future mold market, the development speed of plastic molds will be higher than other molds, and the proportion in the mold industry will gradually increase.
The rapid development of the mold industry gives a strong support to the manufacturing industry. The proportion of molds that can drive its related industries is about 1:100, that is, the mold development is 100 million yuan, which can drive related industries to 10 billion yuan. The mold is to promote the transformation and development of the equipment manufacturing industry. And the key support of the upgrade; At the same time, the rapid development of the manufacturing industry has also promoted the development of the mold industry. Luo Baihui pointed out that in the automotive industry, mold equipment is an important guarantee for the upgrading of automotive products, the research, development and production of energy-saving and environmentally-friendly vehicles and the promotion of the development of independent automotive brands. In the field of home appliances, the formation of home appliance parts depends on various types of molds such as sheet metal stamping, plastics, foaming, and adsorption. The level of mold manufacturing is the technical guarantee for realizing the transformation and upgrading of household appliances in China (such as low noise, energy and water saving, and multiple rooms). In the field of aviation equipment, the research and development and industrialization of sheet metal equipment and aircraft interior trim mold technology have a key role in aerospace manufacturing, lightening the weight of aircraft, and saving fuel. In the field of electronic special equipment and supporting industries for emerging industries, such as IT molds, computer peripheral molds, media digital product molds, optoelectronic communication product molds, network product molds, watch gift molds, etc., have become increasingly demanding. In the field of medical device manufacturing, precision and ultra-precision molds play a decisive role. In the field of rail transportation, the EMUs run the core components of ultra-high speed (more than 300 km/h) precision bearing mold core technology, railway heavy-duty trucks and urban rail transport vehicles bearing, gear transmission, high-speed EMU gear box precision casting mold Etc. are necessary for the development of rail transit.
Judging from the industrial layout, the Pearl River Delta and the Yangtze River Delta are the areas where China's mold industry is most concentrated. Recently, the Bohai Rim region is rapidly developing, and molds in the Midwest are also rising. Since the “Eleventh Five-Year Planâ€, there have been more than 50 mold production clusters have been further developed and gradually formed scale. There are also some “Mold Cityâ€, which focuses on the development of modern service industry, showing a good momentum of development. The development of cluster-based production methods is mainly reflected in the development of mold production clusters. At present, some new production clusters have begun to serve various services platforms and service forms for SMEs in the mold industry. Service content is also increasing. More and more abundant, service output rose faster. According to incomplete statistics, there have been more than 2,000 companies that have entered the mold production clusters (mold towns, mold parks, etc.), and the total output has reached 30 billion yuan, of which the mold accounts for about two-thirds.
At present, the geographical characteristics of China's mold industry are obvious, mainly as follows: the development of the southeast coastal areas is faster than that of the central and western regions, and the development of the south is faster than the north. The areas where mold production is most concentrated are in the Pearl River Delta and the Yangtze River Delta, accounting for more than two-thirds of the national mold output value. The geographical distribution of plastic molds and molds is similar to that of the entire industry. Plastic molds in Zhejiang, Jiangsu, and Guangdong are located in the forefront of the country, and its production value in the total mold output value of the country reaches 70%. It can be seen that in the first five months of 2008, the output values ​​of the three provinces of Guangdong, Jiangsu, and Zhejiang totaled 23.58 billion yuan, accounting for 64.89% of the industry's total output value, and it has a strong regional advantage.
Zhejiang mold industry is mainly concentrated in Ningbo City and Taizhou City, Ningbo Yuyao, Ninghai, Cixi and Zhangzhou mainly produce plastic molds, Beilun is mainly die-casting molds, and Xiangshan and Zhoushan are mainly cast and stamping molds. Taizhou mold enterprises are mainly concentrated in Huangyan and Luqiao, and plastic molds account for the majority.
Zhejiang Province has gradually formed a mold industry cluster, effectively stimulating the rapid development of the local or surrounding areas. Since the development and construction in 1997, the agglomeration effect of Yuyao Mould City has been continuously highlighted, and an industrial cluster with large scale and high grade has been formed. At present, Die City has more than 1,300 die companies and employs 45,000 people. The average growth rate of the industry in the past five years reached 31.5%. A total of 91 molds have been evaluated as national quality molds by the China Mold Association, and the number ranks first in counties (cities, districts) across the country. Yuyao Mould has won this award in 2008 after being selected as one of China’s top 100 industry clusters in 2007. Coincidentally, in July 2008, Huangyan plastic mold was selected as one of the top 50 Chinese industrial cluster brands, adding luster to the Zhejiang mold industry. The selection of Huangyan plastic molds will further promote the construction of local and even China's plastic abrasive industry clusters, stimulate the development of upstream and downstream industries of plastic molds, and lay a solid foundation for the further construction of plastic mold industry clusters.
Luzhou is the birthplace of the home appliance mold industry in China. According to Luo Baihui, head of the International Mould and Hardware and Plastics Industry Suppliers Association, in recent years, Zhangzhou home appliance supporting companies have developed rapidly. There are nearly 100 mold manufacturers in Ganzhou, more than 20 enterprises above designated size, and employs 7,000 people. They are mainly engaged in refrigerator vacuum forming molds and foam mold manufacturing. At present, Ganzhou has become the largest refrigerator manufacturing equipment and mold production base in the country. Sales volume of key main equipment such as refrigerator box and door foam line, foam mold, and plastic mold has accounted for 80% of the domestic market. Representative enterprises include Anhui Hanpeng Equipment Mould Manufacturing Co., Ltd. (formerly China Yangzi Group Zhangzhou Equipment Mould Manufacturing Co., Ltd.), Zhangzhou Hongda Mould Manufacturing Co., Ltd., Ganzhou Jingwei Mould Manufacturing Co., Ltd., and Ganzhou Kechuang Mould Manufacturing Co., Ltd. Bojing Mold Equipment Manufacturing Co., Ltd.
In 2010, the mold industry in Quzhou achieved a sales income of approximately 450 million yuan. It owns a provincial-level enterprise technology center, eight municipal-level enterprise technology centers, and a number of patents. It has established joint production with domestic and foreign colleges and universities and research institutes. Research and Joint Research on Independent Innovation System". Each year we independently research and develop new products, new technologies, and new technologies.
In recent years, with the rapid development of the home appliance mold industry in Zhangzhou, the competition among the mold enterprises has also intensified. Mold companies and refrigerator companies generally use competitive bidding. Each mold has a number of mold companies participating in the bidding, and bidders with lower bids win the bid. Therefore, the phenomenon of vicious competition among enterprises has occurred from time to time. Part of the mold manufacturing has become unprofitable, directly affecting the efficiency and sustainable development of the entire industry. At the same time, Zhangzhou mold industry still lacks senior skilled workers and management talents. Due to the decline in profits of mold companies in recent years, investment in technology funds has decreased, resulting in little progress in science and technology. The company lacks core competition technologies and the overall innovation capability of the industry is weak. The standardization level of molds and the use of standard parts are relatively low, which has a great impact on the quality and cost of the molds. Companies have their own politics, and the overall coordination ability is weak.
The “12th Five-Year Plan†of Zhangzhou Home Appliances pointed out the development direction of the mold industry in Zhangzhou. That is, the establishment of an industrial park featuring plastic and foamed moulds will rely on the advantages of existing groups to further improve the quality and grade of the products. It will continue to maintain the leading position in molds such as refrigerators and foams, focusing on large precision molds and high speeds. Stamping dies, progressive dies, etc. achieve a leapfrog development. In addition, Zhangzhou mold industry must also be based on the industrial chain, improve professional support services.
At the same time, if the Zhangzhou mold industry wants to achieve rapid development, it must also strengthen its industrial layout orientation, link backbone enterprises and leading products, and encourage home appliance mold makers, especially mold companies with leading positions in the country, to focus on Zhangzhou. Actively introduce supporting enterprises, including manufacturers of collaborative parts, industrial design agencies, logistics companies, etc., to form an integrated home appliance equipment industry system that integrates talents, capital, leading products, accessories, R&D, design, marketing, and logistics, and to improve household appliances and equipment manufacturing. The overall competitiveness of the industry cluster.
The “12th Five-Year Plan†of Zhangzhou Home Appliances predicts that by 2015, there will be 50 mold manufacturing enterprises in Shengzhou, with a mold industry scale of over RMB 1.5 billion.
As an important enterprise in the mold industry in Quzhou, Shengzhou Hongda Mould Manufacturing Co., Ltd. believes that Quzhou City should also set up relevant associations to strengthen communication and understanding among enterprises, and gradually build an honesty system to strengthen inter-firm cooperation on the basis of mutual benefit. The full cooperation. Enterprises in the association can undertake business in the name of coalition. According to the company's situation and their own characteristics, they can negotiate internal professional division of work, avoid vicious competition, reduce internal consumption, safeguard corporate interests, give full play to their respective advantages, and do their best to avoid weaknesses. In addition, in the face of fierce market competition, Quzhou mold industry can not only do low-end products, rely on low prices to obtain orders. We must strengthen cooperation with universities and scientific research institutes, establish an innovation system that integrates enterprises as the mainstay, market orientation, and “production, study, and researchâ€, have independent intellectual property rights and master core technologies, and make high-end molds with high technological content. Only in this way can we win the market, grasp the market initiative, and enhance the ability of independent innovation. At the same time, companies should take active and effective measures to reduce the brain drain, strengthen staff training, and improve the quality of the entire company.
Now, China's mold industry has emerged a large number of mold enterprises with an annual production value exceeding 100 million yuan, such as: Shenzhen Qunda International Mold Group, Dongjiang Mold Group, Easy Molding Technology Group, Xunxing Mold Group, Yinbaoshan New Industry, Dongguan Jun Art Mould Group, Weiying Group, Fuyu Mold Making, Maosen Group, Foshan Shengdu Mould, Benda Mould, 100-year Mould, New Mould Technology Group, Heyuan Longji Group, Guangdong Giant Wheel Mould, Shanghai Haofeng Mould Group, Chunxu Group, Zhejiang Huangyan Dow Mould Group, Huangyan Mould Group, Hongzheng Machinery Mould Group, Taizhou Mould Group, Zhongda Mould Group, Hushi Mould Group, Jiangsu Yuda Mould Group, Jiangyin Mould Group (US$12 million acquisition of U.S. thinking Weier Company), Kunshan Hongyun Precision Mould Group, Hunan Mould Company, Huda Sanjia Mould Industry Company, Hunan Xiaoguang Mould Company, Hunan Asia Pacific Industrial Company, Hunan Yutong Group, Schindler Group, Sichuan Chengfei Integrated Technology, Pushi Mould Group, Guangan Guangqian Group, Shaanxi Mould Group, Hubei Vanguard Mould Group, Yunnan Zhaotong Zhang Die Group, Fujian Wuyou Mould Technology Group, Hebei Xinglin Auto Body Mould Group, Shandong Dongao Mould Group, Tianjin Tongguang Group, etc. According to the current development of the international mold industry, the world's largest mold enterprise has now reached an annual output value of more than 4 billion US dollars, becoming a multinational corporation.
Mold enterprises not only provide a variety of products and services, they must also know how to combine their core competences and technical expertise with other various favorable competitive resources to make up for their own deficiencies and limitations. In the survival principle of mold enterprises, "exclusive" has been replaced by "cooperation" and inclusive. Therefore, mold companies need to change the cooperation model with other companies or organizations. The modes of mutually beneficial cooperation between enterprises include:
A. Supply chain, especially the cooperation between companies and suppliers. In the value-added chain of the company, the cost of the supply process is relatively high, so the dynamic interconnection of the supply chain is very important.
B. Strategic network type refers to enterprises forming a strategic network by establishing value chains with suppliers, distributors, and end users. The competition at this time also becomes a competition between strategic networks;
C. Cooperative and joint ventures, the performance of companies through the formation of competitors with competitors, as well as with suppliers or other operating groups to form an associate organization, so as to create more value in the market competition;
D. Virtual organization type is the use of information technology to dynamically link various resources, capabilities, and ideologies into an organic corporate network organization, creating value at the lowest cost and fastest speed.
In addition to the Southern Stamping Dies Association in Shenzhen, Shenzhen, the Western Auto Body Production Technology Alliance, the Chengdu Auto Body Process Equipment Industry Technology Innovation Alliance, was established in the Chengdu Qingyang Industrial Development Zone. The alliance takes Sichuan Chengfei Integrated Science and Technology Co., Ltd. as a leader and Southwest Jiaotong University, Sichuan University and other universities as its technical support to form a product chain of cluster-type automotive body and key components and processes that are led by core enterprises. It is built for the international and domestic markets. The auto body craft equipment and ancillary product production gathering base. The biggest advantage of the alliance lies in the formation of a profit community consisting of loose enterprises previously distributed in different links of the industry chain. The 13 member units cover production, R&D, and sales, which is conducive to a certain scale effect. According to reports, the alliance companies will develop more than three kinds of new car body car cover molds each year to achieve a production value of more than 1 billion yuan, and will drive 10 to 15 automotive mold castings, steel and other supporting manufacturing enterprises, 40 to 50 other automobile body craft equipment enterprises have formed a scale of 2 billion yuan in auto body process equipment industry. Luo Baihui believes that at present, these first-class international large-scale mold enterprises and mold alliances have formed the own aircraft carrier enterprise formation in China's mold industry.
In order to effectively enhance the competitive strength of our country's mold industry in the international market, we can't just emphasize the “small and specialized, small and precise, small and special, small and new†mold manufacturing companies, but must develop the “scale effect†of the mold industry. "I refer to the important agenda of industrial development. We must focus on cultivating a number of leading enterprises in the industry based on the priorities of the industry's development. Enterprises should be encouraged to improve their product quality, grades, and labor productivity, and accelerate restructuring and reorganization to increase the industry's production concentration. They also enable enterprises to have the ability to develop products, inspect quality, improve technology, expand export, and increase economic efficiency. , driving the industry's overall level and competitiveness. To develop clustered production in previous years, on the one hand, continue to support and encourage qualified areas to speed up the construction of mold and mold industry, mold industry parks and other mold production bases with higher levels and greater capabilities, through market operations, Gradually form a relatively complete mold production industrial chain in the region; on the other hand, we will use automotive covering molds, precision stamping dies, large-scale and precision plastic molds, major mold standard parts, and high-tech molds as the main targets of service. Guided by the formation of regional mold manufacturing network with greater strength and higher level.
Now, some regions are actively exploring the industrial alliances and network production between mould and mould enterprises. This is a very good direction of development. It must be promoted and implemented in the industry in accordance with the principle of “joint cooperation, complementary advantages, and win-win cooperationâ€. Good correlation between production and demand, promote the specialization of the mold industry, the development of commercialization, and large-scale production of mold standard parts, and promote the continuous improvement of the use rate of mold standard parts and the continuous development of the industry. Key and key enterprises need to establish their own technological R&D centers and increase scientific and technological input. They must not only produce products in accordance with customer drawings and technical requirements, but also actively cooperate with users, and propose suggestions for improving mold design based on the development of mold technology. , to improve and develop products, to form products with independent intellectual property rights and independent brands.
From the perspective of industrial technological progress, since the “Eleventh Five-Year Planâ€, under the support and guidance of government policies, the mold industry has invested a lot, and the level and strength of enterprise equipment have greatly improved. The rapid development of the mold industry has also promoted the formation of key enterprises in the industry. There are now 110 key mold companies that have been identified and awarded by the China Mold Association. The formation of the industry backbone team has played a leading role in the development of the industry. In recent years, advances in science and technology have led to a significant increase in the level of mold products, and the trend toward high-end development has become more apparent. Some mold products have reached or are close to the advanced level in the world, among which are representative giant molds with a single mold weight of 120 tons, ultra-precision molds with a machining accuracy of 0.3-0.5 μm, and a service life of 300-400 million times. Life molds, high-speed precision stamping dies that can be used with high-speed punches of 2500 times per minute, multi-functional compound molds that realize multi-material and multi-process forming, and complex molds that can realize intelligent control.
As the home appliance market continues to grow bigger and stronger, gradually expanding market demand determines that companies need to invest more manpower and material resources to expand production scale, resulting in increased production costs. The promotion and application of laminated molds will completely change this situation. Taking the outer lid of the automatic washing machine with a capacity of 5kg as an example, the output of the outer lid of the same type is about 1 million pieces, and the cost of a common mold for producing each outer lid is about 3.6 yuan, and after the stack mold production technology is adopted, The production cost of each item will be reduced to 3 yuan, which will save 600,000 yuan for the company.
Qingdao Haier Mould Co., Ltd. is the first company in China to develop laminated mold R&D and industrialization. After three years of development, its products have gone from small to large (more than 40 tons of mold weight), from simple to complex, from single cavity to multi-cavity development process. Now, Haier's mold lamination technology is very mature. Ten-month stacking molds have been used for the production of washing machine rear covers, and the output has approached 1 million pieces. In 2010, Haier Mold developed a washing machine outer lid cover laminated mold to obtain the "China Die and Mold Industry Association Fine Model Award".
According to Mr. Zhao Xijin of Qingdao Haier Mould Co., Ltd., through long-term production verification, by the end of 2010, Haier has developed nearly 300,000 laminated molds for various household appliances such as washing machines, refrigerators, and air conditioners, with an output value of more than 30 million yuan. Applied to injection molding production, this technology saves costs of 24 million yuan for production companies. The laminated molds developed by Haier Mould are used in trims, countertops, and ice boxes in refrigerators, large covers and small covers for washing machines, and front panels for air conditioners. Some front and rear shells of televisions are also widely used.
Laminated mold technology is a cutting-edge technology that is different from ordinary injection mold technology. In a pair of molds, multiple cavities are overlapped in the mold clamping direction. This mold usually has multiple parting surfaces, and one or more cavities can be arranged on each parting surface. Simply put, laminated molds are equivalent to stacking multiple single-layer molds and mounting them on an injection molding machine for injection molding. The laminated mold structure is composed of a plurality of systems such as a stack mold hot runner system, a special mold rack system, a bearing guide system, a two-way ejector system, and an opening and closing mold linkage system.
Stacked mold technology has the following characteristics:
1. The production efficiency of laminated molds exceeds that of ordinary single-layer molds by one or more times, which greatly reduces the production cost of injection molding. From the point of view of structural characteristics, the laminated mold combines multiple pairs of cavities in a pair of dies, and fully utilizes common injection molding equipment to satisfy production. The mold filling, holding pressure and cooling time are the same as those of the single-layer mold, which determines that the production efficiency of the stack mold will be more than double or more than the ordinary single-layer mold, and the production per unit time will be greatly improved.
2. Laminated molds can be installed on the same injection molding machine as a single-layer mold, eliminating the need to invest in additional machinery and equipment, thereby saving the cost of machinery, equipment, plant, and new labor.
3. Stack mold manufacturing requirements are basically the same as ordinary molds. According to statistics, the manufacturing cycle of one pair of double-layer molds is 5% to 10% shorter than that of two single-layer molds.
4. Stacked molds are suitable for large-scale production of flat-shaped large-scale products, small multi-cavity thin-walled products, and the larger the volume, the lower the production cost of the product.
Taking the cabinet air conditioner front panel of Haier Mould as an example (product size: 804×500×130.5mm) as an example, the benefits of stack molds and ordinary single-layer molds are compared. Through the comparison of major data, it was found that 400,000 pieces of air-conditioning front panel were produced, and stack mold technology saved 37,700 yuan in injection cost compared to single-layer mold technology. When the equipment is the same, the delivery time can be reduced by half. The low cost and high efficiency of laminated molds are fully reflected.
Two-color injection molding is a technology that can produce a surface with high gloss and has two layers of different color matching plastic parts at a time. The application of this technology can greatly improve the appearance of the whole product. According to Mr. Cha Hongda, chief engineer of the Yangtze River Delta Mold City, a large-scale two-color injection molding adopts a rotary large-scale two-color injection molding machine. After the mold is closed, the outer plastic injection is performed. After molding, the cavity is rotated with the plastic parts and the rotating table is rotated. °, after the mold is closed again, the inner plastic injection is performed, and finally the mold is ejected. In continuous production, the outer injection and the inner injection are performed at the same time, so the molding cycle is basically similar to the conventional injection molding. Large-scale two-color injection molding technology can be combined with high-light non-melt-injection injection molding technology. In the production, high-temperature and high-pressure hot water or steam heating molds are used, and the cooling medium is quickly switched after the injection is completed to rapidly cool the mold to obtain a surface without melting marks and has High gloss two-color plastic parts can significantly improve the overall appearance of the machine.
Compared with common molds and small-size two-color/two-component injection molds that have been widely used today, large-scale two-color injection molds have great differences in product characteristics, mold structure, operation sequence, gate setting, and flow channel layout. increase. Due to the injection molding inside and outside, the large-sized two-color injection mold requires two sets of cavities and two sets of cores, in which two sets of cavities must be identical and can be interchangeable with two sets of cores; two gating systems are set The core side belongs to the reverse mounting structure; the ejection is also on the core side and is ejected by hydraulic pressure. Coupled with the cooling system, the complexity of the entire core side structure is greatly increased.
In the optimization design of plastic parts, the outer shape of the first molding needs to be as simple as possible. The second molding inner layer can design ribs, columns and other structures, but it must fully consider the layout of the gate and the flow pattern, and it needs to pass the CAE. Analysis to optimize the design. In order to make the exterior surface of the plastic part have the effect of color gradient, the wall thickness of the peripheral edge of the outer edge can adopt a gradual design from thin to thick.
In the molding process, when the large-scale two-color injection molding technology is molded for the second time, the plastic flows along the surface of the first-formed plastic part, and defects such as air bubbles, chromatic aberrations, and running plastics are likely to occur. It is necessary to repeatedly debug the injection molding process parameters. Precise control, combined with molding conditions to improve and optimize the mold.
According to Zhang Minglei, Qingdao Hisense Mould Co., Ltd., Hisense Mould Co., Ltd. began to develop large-scale two-color injection molds in the first half of 2009. After working hard, it broke through a series of key technologies and developed the world's first advanced large-scale bicolor high-gloss light in China. Injection molds have been successfully applied to Hisense's large-size LED-backlit LCD TVs. At present, Hisense Mould Company has fully mastered the product optimization, mold development, and process control technologies for large-size two-color high-gloss injection molds. It has developed T29 and T39 two series of more than ten large-scale two-color high-gloss injection molds that can be produced for the largest size. Reached 55 inches of LED-backlit LCD TV shell, production pass rate reached more than 90%.
The large-size two-color high-gloss injection molding technology has high production efficiency and good surface quality. The inner and outer colors can be flexibly matched according to needs, which can greatly improve the appearance and grade of the whole product. At present, the technology is being applied more and more widely on large-size LED-backlit LCD TVs. In the future, it will also have broad market prospects for high-end refrigerators, air conditioners and other home appliances.
With the promotion of high-tech driven and pillar industries, China's plastic molds have formed a huge industrial chain, from the upstream raw and auxiliary materials industry and processing and testing equipment to downstream machinery, automobiles, motorcycles, home appliances, and electronic communications. , Construction and building materials, and other major application industries, the development of a plastic mold life. At present, the application of plastic products has become increasingly widespread, providing a vast market for plastic molds, and at the same time it also puts forward higher requirements for molds. Large-scale, high-precision, multi-functional composite molds will be favored. At the same time, the demand for plastics in the construction, home appliances, and automotive industries is large. It is estimated that only the automotive and motorcycle industries require more than 100 billion yuan in molds each year; color TV molds also have a market of about 2.8 billion yuan each year.
From the point of view of marketing, the mold market is further developed and new growth points have been spotlighted. In the domestic market, automobile lightweighting, new energy, medical devices, aerospace, energy conservation and emission reduction have become important new growth points for the mold industry. In the international market, in addition to the traditional markets of Europe, the United States, Japan, and Southeast Asia, the development of emerging markets such as Brazil, India, Russia, and Australia has achieved results. At present, China's mold exports have reached more than 40 countries and regions.
In view of the global situation, the recent major earthquakes in Japan and political turmoil in Libya have produced a “butterfly effect†on the global mold industry chain, showing that the world today is still in a post-crisis era, and the development opportunities and challenges of the Chinese mold industry coexist. The current mold industry presents the following features:
1. China is still in the middle and low end of the global industrial chain of work, and its products are in the middle and low grades; mold is also the same. Due to the shrinking market capacity, the mold enterprise competition has intensified. The fierce price war and the sharp decrease in the prices of mould products have led to a decline in the efficiency of enterprises and the quality of their products.
2. In the development and production of tissue molds, developed countries generally adopt technologies and management methods such as concurrent engineering and project management, and have strengthened the control over workflows, shortened the cycle of mold development and ensured quality. The tightening of the market has affected the development of new products for enterprises, especially the slowdown in the development of new models of automobiles. This has directly affected the development and production of molds, and the mold industry, which has a large proportion of automotive molds, has been greatly affected.
3. In terms of professional production, developed countries are more common. Professional division of labor is an inevitable trend of increasing production efficiency, shortening mold design and manufacturing cycle, and guaranteeing product quality. It helps to highlight its core business and helps to accumulate experience in product development, production management and service to provide high levels in the short term. Quality, low cost molds.
4. In the application of high-tech, developed countries have applied more extensive and deeper applications in various high and new technologies and have higher levels, including digital mold technology (three-dimensional design, manufacturability design (DFM), CAPP, CAM, CAT ......), forming process simulation (CAE) technology, high-speed machining technology, automated processing technology, new material forming technology, surface treatment technology, new (multi-functional composite) mold technology, information management technology and so on. The continuous development and extensive application of high and new technology have made the design and manufacturing of molds reach an unprecedented height.
5. In terms of research and innovation of new technologies, including innovations in forming methods, innovations in improvement of forming quality, innovations in new material forming technologies, etc., China has yet to grasp the initiative, basically tracking the progress of technological development in developed countries.
Faced with the challenges, the Chinese government has adopted a series of positive measures such as expanding domestic demand, adjusting the structure, and ensuring the people's livelihood, such as increasing investment in infrastructure and stimulating production and consumption of investment products; implementing electrical appliances to the countryside, cars to the countryside, and building materials to the countryside Preferential policies such as tax deductions and taxation fees have played a positive role in product development and market expansion, thereby reducing the impact on the manufacturing industry including the mold industry. On the other hand, enterprises have strengthened management to varying degrees, adopted some measures to reduce risks, strengthened the management of cash flows, strengthened cost accounting and reduced costs, actively explored markets, strengthened research and development, increased product mix adjustment, and strengthened enterprise production. Management standardization, informationization, etc. achieved good results. The overall level of the industry has improved rapidly. Mainly reflected in the large-scale, sophisticated, complex, long-life mold as the main representative of the proportion of high-grade mold continues to rise, scientific and technological progress is obvious, the product level has been greatly improved. At the 13th International Mould Technology and Equipment Exhibition in May 2010, there were a total of 181 molds that received the "Premier Award", of which 55 were first prizes and 64 were second prizes. Not only were the numbers larger than before. The number of projects that have reached the international level is increasing, innovation is evident, and patents are increasing. The gap between the average price of imports and exports of moulds is continuously narrowing, reflecting the improvement of the overall level of China's mold industry and technological progress.
In recent years, the state has proposed to develop small and medium-sized enterprises to “grasp the large and smallâ€, providing a good opportunity for the further development of the mold industry. In the process of further opening up, the development of China's mold industry (including foreign-funded or Sino-foreign joint ventures) will facilitate the expansion of exports and increase the international competitiveness of China's manufacturing industry, and gradually change China's position in the international industry in the low-end position . The technological content and added value of China’s export molds have risen over the previous year. Compared with imported molds, the gap between technology and price has also continuously narrowed, which fully reflects the technical progress of China's mold industry and the improvement of the competitiveness of the international market.
China's export mold market is mainly Hong Kong, the United States and Japan, followed by Germany, India, China Taiwan, France, Brazil, South Korea and Vietnam. It is expected that by 2018, China will realize the export of a single product from middle and low-grade molds for export to a composite export of high-end mold products and moldmaking technology. By then, China's mold will transition from a "manufacturing powerhouse" to an "innovating powerhouse."
The most important thing in the "Twelfth Five-Year Plan" is to grasp the guiding ideology and clarify the overall tasks: adhere to the scientific concept of development, take the structural adjustment as the main line, rely on technological progress, and take the lead of "good", drive innovation, and do a good job of informatization. With the integration of industrialization, to improve the overall strength of the industry and the core competitiveness of enterprises as the main goal, deepen the reform, open up the market, work hard, strive to change the development mode, enhance the soft power, and better improve the overall level of the equipment manufacturing industry. China has achieved low-carbon economy and national defense modernization services, laying a solid foundation for China's mold industry to step into the world's mold power.
In recent years, China's plastic molds have developed rapidly. At present, the proportion of plastic molds in the entire mold industry is about 30%, and the proportion in the import and export of molds is as high as 50 to 70%. With the rapid development of the national economy, such as machinery, automobiles, home appliances, electronic information and building materials, the ratio will continue to increase. According to reports, the production of an ordinary car requires more than 200 pieces of interior decoration molds, and only about 50% of large and medium-sized plastic molds required for the manufacture of bumpers, dashboards, fuel tanks, and steering wheels can be satisfied. A large number of plastic building materials instead of traditional materials has also become a trend. It is expected that in 2011, the penetration rate of plastic doors, windows and plastic pipes will reach 30% to 50%, and the market share of plastic drainage pipes will exceed 50%, which will greatly increase the demand for molds. . Luo Baihui said that the overall trend of the mold market is steady upward. In the future mold market, the development speed of plastic molds will be higher than other molds, and the proportion in the mold industry will gradually increase.
The rapid development of the mold industry gives a strong support to the manufacturing industry. The proportion of molds that can drive its related industries is about 1:100, that is, the mold development is 100 million yuan, which can drive related industries to 10 billion yuan. The mold is to promote the transformation and development of the equipment manufacturing industry. And the key support of the upgrade; At the same time, the rapid development of the manufacturing industry has also promoted the development of the mold industry. Luo Baihui pointed out that in the automotive industry, mold equipment is an important guarantee for the upgrading of automotive products, the research, development and production of energy-saving and environmentally-friendly vehicles and the promotion of the development of independent automotive brands. In the field of home appliances, the formation of home appliance parts depends on various types of molds such as sheet metal stamping, plastics, foaming, and adsorption. The level of mold manufacturing is the technical guarantee for realizing the transformation and upgrading of household appliances in China (such as low noise, energy and water saving, and multiple rooms). In the field of aviation equipment, the research and development and industrialization of sheet metal equipment and aircraft interior trim mold technology have a key role in aerospace manufacturing, lightening the weight of aircraft, and saving fuel. In the field of electronic special equipment and supporting industries for emerging industries, such as IT molds, computer peripheral molds, media digital product molds, optoelectronic communication product molds, network product molds, watch gift molds, etc., have become increasingly demanding. In the field of medical device manufacturing, precision and ultra-precision molds play a decisive role. In the field of rail transportation, the EMUs run the core components of ultra-high speed (more than 300 km/h) precision bearing mold core technology, railway heavy-duty trucks and urban rail transport vehicles bearing, gear transmission, high-speed EMU gear box precision casting mold Etc. are necessary for the development of rail transit.
Judging from the industrial layout, the Pearl River Delta and the Yangtze River Delta are the areas where China's mold industry is most concentrated. Recently, the Bohai Rim region is rapidly developing, and molds in the Midwest are also rising. Since the “Eleventh Five-Year Planâ€, there have been more than 50 mold production clusters have been further developed and gradually formed scale. There are also some “Mold Cityâ€, which focuses on the development of modern service industry, showing a good momentum of development. The development of cluster-based production methods is mainly reflected in the development of mold production clusters. At present, some new production clusters have begun to serve various services platforms and service forms for SMEs in the mold industry. Service content is also increasing. More and more abundant, service output rose faster. According to incomplete statistics, there have been more than 2,000 companies that have entered the mold production clusters (mold towns, mold parks, etc.), and the total output has reached 30 billion yuan, of which the mold accounts for about two-thirds.
At present, the geographical characteristics of China's mold industry are obvious, mainly as follows: the development of the southeast coastal areas is faster than that of the central and western regions, and the development of the south is faster than the north. The areas where mold production is most concentrated are in the Pearl River Delta and the Yangtze River Delta, accounting for more than two-thirds of the national mold output value. The geographical distribution of plastic molds and molds is similar to that of the entire industry. Plastic molds in Zhejiang, Jiangsu, and Guangdong are located in the forefront of the country, and its production value in the total mold output value of the country reaches 70%. It can be seen that in the first five months of 2008, the output values ​​of the three provinces of Guangdong, Jiangsu, and Zhejiang totaled 23.58 billion yuan, accounting for 64.89% of the industry's total output value, and it has a strong regional advantage.
Zhejiang mold industry is mainly concentrated in Ningbo City and Taizhou City, Ningbo Yuyao, Ninghai, Cixi and Zhangzhou mainly produce plastic molds, Beilun is mainly die-casting molds, and Xiangshan and Zhoushan are mainly cast and stamping molds. Taizhou mold enterprises are mainly concentrated in Huangyan and Luqiao, and plastic molds account for the majority.
Zhejiang Province has gradually formed a mold industry cluster, effectively stimulating the rapid development of the local or surrounding areas. Since the development and construction in 1997, the agglomeration effect of Yuyao Mould City has been continuously highlighted, and an industrial cluster with large scale and high grade has been formed. At present, Die City has more than 1,300 die companies and employs 45,000 people. The average growth rate of the industry in the past five years reached 31.5%. A total of 91 molds have been evaluated as national quality molds by the China Mold Association, and the number ranks first in counties (cities, districts) across the country. Yuyao Mould has won this award in 2008 after being selected as one of China’s top 100 industry clusters in 2007. Coincidentally, in July 2008, Huangyan plastic mold was selected as one of the top 50 Chinese industrial cluster brands, adding luster to the Zhejiang mold industry. The selection of Huangyan plastic molds will further promote the construction of local and even China's plastic abrasive industry clusters, stimulate the development of upstream and downstream industries of plastic molds, and lay a solid foundation for the further construction of plastic mold industry clusters.
Luzhou is the birthplace of the home appliance mold industry in China. According to Luo Baihui, head of the International Mould and Hardware and Plastics Industry Suppliers Association, in recent years, Zhangzhou home appliance supporting companies have developed rapidly. There are nearly 100 mold manufacturers in Ganzhou, more than 20 enterprises above designated size, and employs 7,000 people. They are mainly engaged in refrigerator vacuum forming molds and foam mold manufacturing. At present, Ganzhou has become the largest refrigerator manufacturing equipment and mold production base in the country. Sales volume of key main equipment such as refrigerator box and door foam line, foam mold, and plastic mold has accounted for 80% of the domestic market. Representative enterprises include Anhui Hanpeng Equipment Mould Manufacturing Co., Ltd. (formerly China Yangzi Group Zhangzhou Equipment Mould Manufacturing Co., Ltd.), Zhangzhou Hongda Mould Manufacturing Co., Ltd., Ganzhou Jingwei Mould Manufacturing Co., Ltd., and Ganzhou Kechuang Mould Manufacturing Co., Ltd. Bojing Mold Equipment Manufacturing Co., Ltd.
In 2010, the mold industry in Quzhou achieved a sales income of approximately 450 million yuan. It owns a provincial-level enterprise technology center, eight municipal-level enterprise technology centers, and a number of patents. It has established joint production with domestic and foreign colleges and universities and research institutes. Research and Joint Research on Independent Innovation System". Each year we independently research and develop new products, new technologies, and new technologies.
In recent years, with the rapid development of the home appliance mold industry in Zhangzhou, the competition among the mold enterprises has also intensified. Mold companies and refrigerator companies generally use competitive bidding. Each mold has a number of mold companies participating in the bidding, and bidders with lower bids win the bid. Therefore, the phenomenon of vicious competition among enterprises has occurred from time to time. Part of the mold manufacturing has become unprofitable, directly affecting the efficiency and sustainable development of the entire industry. At the same time, Zhangzhou mold industry still lacks senior skilled workers and management talents. Due to the decline in profits of mold companies in recent years, investment in technology funds has decreased, resulting in little progress in science and technology. The company lacks core competition technologies and the overall innovation capability of the industry is weak. The standardization level of molds and the use of standard parts are relatively low, which has a great impact on the quality and cost of the molds. Companies have their own politics, and the overall coordination ability is weak.
The “12th Five-Year Plan†of Zhangzhou Home Appliances pointed out the development direction of the mold industry in Zhangzhou. That is, the establishment of an industrial park featuring plastic and foamed moulds will rely on the advantages of existing groups to further improve the quality and grade of the products. It will continue to maintain the leading position in molds such as refrigerators and foams, focusing on large precision molds and high speeds. Stamping dies, progressive dies, etc. achieve a leapfrog development. In addition, Zhangzhou mold industry must also be based on the industrial chain, improve professional support services.
At the same time, if the Zhangzhou mold industry wants to achieve rapid development, it must also strengthen its industrial layout orientation, link backbone enterprises and leading products, and encourage home appliance mold makers, especially mold companies with leading positions in the country, to focus on Zhangzhou. Actively introduce supporting enterprises, including manufacturers of collaborative parts, industrial design agencies, logistics companies, etc., to form an integrated home appliance equipment industry system that integrates talents, capital, leading products, accessories, R&D, design, marketing, and logistics, and to improve household appliances and equipment manufacturing. The overall competitiveness of the industry cluster.
The “12th Five-Year Plan†of Zhangzhou Home Appliances predicts that by 2015, there will be 50 mold manufacturing enterprises in Shengzhou, with a mold industry scale of over RMB 1.5 billion.
As an important enterprise in the mold industry in Quzhou, Shengzhou Hongda Mould Manufacturing Co., Ltd. believes that Quzhou City should also set up relevant associations to strengthen communication and understanding among enterprises, and gradually build an honesty system to strengthen inter-firm cooperation on the basis of mutual benefit. The full cooperation. Enterprises in the association can undertake business in the name of coalition. According to the company's situation and their own characteristics, they can negotiate internal professional division of work, avoid vicious competition, reduce internal consumption, safeguard corporate interests, give full play to their respective advantages, and do their best to avoid weaknesses. In addition, in the face of fierce market competition, Quzhou mold industry can not only do low-end products, rely on low prices to obtain orders. We must strengthen cooperation with universities and scientific research institutes, establish an innovation system that integrates enterprises as the mainstay, market orientation, and “production, study, and researchâ€, have independent intellectual property rights and master core technologies, and make high-end molds with high technological content. Only in this way can we win the market, grasp the market initiative, and enhance the ability of independent innovation. At the same time, companies should take active and effective measures to reduce the brain drain, strengthen staff training, and improve the quality of the entire company.
Now, China's mold industry has emerged a large number of mold enterprises with an annual production value exceeding 100 million yuan, such as: Shenzhen Qunda International Mold Group, Dongjiang Mold Group, Easy Molding Technology Group, Xunxing Mold Group, Yinbaoshan New Industry, Dongguan Jun Art Mould Group, Weiying Group, Fuyu Mold Making, Maosen Group, Foshan Shengdu Mould, Benda Mould, 100-year Mould, New Mould Technology Group, Heyuan Longji Group, Guangdong Giant Wheel Mould, Shanghai Haofeng Mould Group, Chunxu Group, Zhejiang Huangyan Dow Mould Group, Huangyan Mould Group, Hongzheng Machinery Mould Group, Taizhou Mould Group, Zhongda Mould Group, Hushi Mould Group, Jiangsu Yuda Mould Group, Jiangyin Mould Group (US$12 million acquisition of U.S. thinking Weier Company), Kunshan Hongyun Precision Mould Group, Hunan Mould Company, Huda Sanjia Mould Industry Company, Hunan Xiaoguang Mould Company, Hunan Asia Pacific Industrial Company, Hunan Yutong Group, Schindler Group, Sichuan Chengfei Integrated Technology, Pushi Mould Group, Guangan Guangqian Group, Shaanxi Mould Group, Hubei Vanguard Mould Group, Yunnan Zhaotong Zhang Die Group, Fujian Wuyou Mould Technology Group, Hebei Xinglin Auto Body Mould Group, Shandong Dongao Mould Group, Tianjin Tongguang Group, etc. According to the current development of the international mold industry, the world's largest mold enterprise has now reached an annual output value of more than 4 billion US dollars, becoming a multinational corporation.
Mold enterprises not only provide a variety of products and services, they must also know how to combine their core competences and technical expertise with other various favorable competitive resources to make up for their own deficiencies and limitations. In the survival principle of mold enterprises, "exclusive" has been replaced by "cooperation" and inclusive. Therefore, mold companies need to change the cooperation model with other companies or organizations. The modes of mutually beneficial cooperation between enterprises include:
A. Supply chain, especially the cooperation between companies and suppliers. In the value-added chain of the company, the cost of the supply process is relatively high, so the dynamic interconnection of the supply chain is very important.
B. Strategic network type refers to enterprises forming a strategic network by establishing value chains with suppliers, distributors, and end users. The competition at this time also becomes a competition between strategic networks;
C. Cooperative and joint ventures, the performance of companies through the formation of competitors with competitors, as well as with suppliers or other operating groups to form an associate organization, so as to create more value in the market competition;
D. Virtual organization type is the use of information technology to dynamically link various resources, capabilities, and ideologies into an organic corporate network organization, creating value at the lowest cost and fastest speed.
In addition to the Southern Stamping Dies Association in Shenzhen, Shenzhen, the Western Auto Body Production Technology Alliance, the Chengdu Auto Body Process Equipment Industry Technology Innovation Alliance, was established in the Chengdu Qingyang Industrial Development Zone. The alliance takes Sichuan Chengfei Integrated Science and Technology Co., Ltd. as a leader and Southwest Jiaotong University, Sichuan University and other universities as its technical support to form a product chain of cluster-type automotive body and key components and processes that are led by core enterprises. It is built for the international and domestic markets. The auto body craft equipment and ancillary product production gathering base. The biggest advantage of the alliance lies in the formation of a profit community consisting of loose enterprises previously distributed in different links of the industry chain. The 13 member units cover production, R&D, and sales, which is conducive to a certain scale effect. According to reports, the alliance companies will develop more than three kinds of new car body car cover molds each year to achieve a production value of more than 1 billion yuan, and will drive 10 to 15 automotive mold castings, steel and other supporting manufacturing enterprises, 40 to 50 other automobile body craft equipment enterprises have formed a scale of 2 billion yuan in auto body process equipment industry. Luo Baihui believes that at present, these first-class international large-scale mold enterprises and mold alliances have formed the own aircraft carrier enterprise formation in China's mold industry.
In order to effectively enhance the competitive strength of our country's mold industry in the international market, we can't just emphasize the “small and specialized, small and precise, small and special, small and new†mold manufacturing companies, but must develop the “scale effect†of the mold industry. "I refer to the important agenda of industrial development. We must focus on cultivating a number of leading enterprises in the industry based on the priorities of the industry's development. Enterprises should be encouraged to improve their product quality, grades, and labor productivity, and accelerate restructuring and reorganization to increase the industry's production concentration. They also enable enterprises to have the ability to develop products, inspect quality, improve technology, expand export, and increase economic efficiency. , driving the industry's overall level and competitiveness. To develop clustered production in previous years, on the one hand, continue to support and encourage qualified areas to speed up the construction of mold and mold industry, mold industry parks and other mold production bases with higher levels and greater capabilities, through market operations, Gradually form a relatively complete mold production industrial chain in the region; on the other hand, we will use automotive covering molds, precision stamping dies, large-scale and precision plastic molds, major mold standard parts, and high-tech molds as the main targets of service. Guided by the formation of regional mold manufacturing network with greater strength and higher level.
Now, some regions are actively exploring the industrial alliances and network production between mould and mould enterprises. This is a very good direction of development. It must be promoted and implemented in the industry in accordance with the principle of “joint cooperation, complementary advantages, and win-win cooperationâ€. Good correlation between production and demand, promote the specialization of the mold industry, the development of commercialization, and large-scale production of mold standard parts, and promote the continuous improvement of the use rate of mold standard parts and the continuous development of the industry. Key and key enterprises need to establish their own technological R&D centers and increase scientific and technological input. They must not only produce products in accordance with customer drawings and technical requirements, but also actively cooperate with users, and propose suggestions for improving mold design based on the development of mold technology. , to improve and develop products, to form products with independent intellectual property rights and independent brands.
From the perspective of industrial technological progress, since the “Eleventh Five-Year Planâ€, under the support and guidance of government policies, the mold industry has invested a lot, and the level and strength of enterprise equipment have greatly improved. The rapid development of the mold industry has also promoted the formation of key enterprises in the industry. There are now 110 key mold companies that have been identified and awarded by the China Mold Association. The formation of the industry backbone team has played a leading role in the development of the industry. In recent years, advances in science and technology have led to a significant increase in the level of mold products, and the trend toward high-end development has become more apparent. Some mold products have reached or are close to the advanced level in the world, among which are representative giant molds with a single mold weight of 120 tons, ultra-precision molds with a machining accuracy of 0.3-0.5 μm, and a service life of 300-400 million times. Life molds, high-speed precision stamping dies that can be used with high-speed punches of 2500 times per minute, multi-functional compound molds that realize multi-material and multi-process forming, and complex molds that can realize intelligent control.
As the home appliance market continues to grow bigger and stronger, gradually expanding market demand determines that companies need to invest more manpower and material resources to expand production scale, resulting in increased production costs. The promotion and application of laminated molds will completely change this situation. Taking the outer lid of the automatic washing machine with a capacity of 5kg as an example, the output of the outer lid of the same type is about 1 million pieces, and the cost of a common mold for producing each outer lid is about 3.6 yuan, and after the stack mold production technology is adopted, The production cost of each item will be reduced to 3 yuan, which will save 600,000 yuan for the company.
Qingdao Haier Mould Co., Ltd. is the first company in China to develop laminated mold R&D and industrialization. After three years of development, its products have gone from small to large (more than 40 tons of mold weight), from simple to complex, from single cavity to multi-cavity development process. Now, Haier's mold lamination technology is very mature. Ten-month stacking molds have been used for the production of washing machine rear covers, and the output has approached 1 million pieces. In 2010, Haier Mold developed a washing machine outer lid cover laminated mold to obtain the "China Die and Mold Industry Association Fine Model Award".
According to Mr. Zhao Xijin of Qingdao Haier Mould Co., Ltd., through long-term production verification, by the end of 2010, Haier has developed nearly 300,000 laminated molds for various household appliances such as washing machines, refrigerators, and air conditioners, with an output value of more than 30 million yuan. Applied to injection molding production, this technology saves costs of 24 million yuan for production companies. The laminated molds developed by Haier Mould are used in trims, countertops, and ice boxes in refrigerators, large covers and small covers for washing machines, and front panels for air conditioners. Some front and rear shells of televisions are also widely used.
Laminated mold technology is a cutting-edge technology that is different from ordinary injection mold technology. In a pair of molds, multiple cavities are overlapped in the mold clamping direction. This mold usually has multiple parting surfaces, and one or more cavities can be arranged on each parting surface. Simply put, laminated molds are equivalent to stacking multiple single-layer molds and mounting them on an injection molding machine for injection molding. The laminated mold structure is composed of a plurality of systems such as a stack mold hot runner system, a special mold rack system, a bearing guide system, a two-way ejector system, and an opening and closing mold linkage system.
Stacked mold technology has the following characteristics:
1. The production efficiency of laminated molds exceeds that of ordinary single-layer molds by one or more times, which greatly reduces the production cost of injection molding. From the point of view of structural characteristics, the laminated mold combines multiple pairs of cavities in a pair of dies, and fully utilizes common injection molding equipment to satisfy production. The mold filling, holding pressure and cooling time are the same as those of the single-layer mold, which determines that the production efficiency of the stack mold will be more than double or more than the ordinary single-layer mold, and the production per unit time will be greatly improved.
2. Laminated molds can be installed on the same injection molding machine as a single-layer mold, eliminating the need to invest in additional machinery and equipment, thereby saving the cost of machinery, equipment, plant, and new labor.
3. Stack mold manufacturing requirements are basically the same as ordinary molds. According to statistics, the manufacturing cycle of one pair of double-layer molds is 5% to 10% shorter than that of two single-layer molds.
4. Stacked molds are suitable for large-scale production of flat-shaped large-scale products, small multi-cavity thin-walled products, and the larger the volume, the lower the production cost of the product.
Taking the cabinet air conditioner front panel of Haier Mould as an example (product size: 804×500×130.5mm) as an example, the benefits of stack molds and ordinary single-layer molds are compared. Through the comparison of major data, it was found that 400,000 pieces of air-conditioning front panel were produced, and stack mold technology saved 37,700 yuan in injection cost compared to single-layer mold technology. When the equipment is the same, the delivery time can be reduced by half. The low cost and high efficiency of laminated molds are fully reflected.
Two-color injection molding is a technology that can produce a surface with high gloss and has two layers of different color matching plastic parts at a time. The application of this technology can greatly improve the appearance of the whole product. According to Mr. Cha Hongda, chief engineer of the Yangtze River Delta Mold City, a large-scale two-color injection molding adopts a rotary large-scale two-color injection molding machine. After the mold is closed, the outer plastic injection is performed. After molding, the cavity is rotated with the plastic parts and the rotating table is rotated. °, after the mold is closed again, the inner plastic injection is performed, and finally the mold is ejected. In continuous production, the outer injection and the inner injection are performed at the same time, so the molding cycle is basically similar to the conventional injection molding. Large-scale two-color injection molding technology can be combined with high-light non-melt-injection injection molding technology. In the production, high-temperature and high-pressure hot water or steam heating molds are used, and the cooling medium is quickly switched after the injection is completed to rapidly cool the mold to obtain a surface without melting marks and has High gloss two-color plastic parts can significantly improve the overall appearance of the machine.
Compared with common molds and small-size two-color/two-component injection molds that have been widely used today, large-scale two-color injection molds have great differences in product characteristics, mold structure, operation sequence, gate setting, and flow channel layout. increase. Due to the injection molding inside and outside, the large-sized two-color injection mold requires two sets of cavities and two sets of cores, in which two sets of cavities must be identical and can be interchangeable with two sets of cores; two gating systems are set The core side belongs to the reverse mounting structure; the ejection is also on the core side and is ejected by hydraulic pressure. Coupled with the cooling system, the complexity of the entire core side structure is greatly increased.
In the optimization design of plastic parts, the outer shape of the first molding needs to be as simple as possible. The second molding inner layer can design ribs, columns and other structures, but it must fully consider the layout of the gate and the flow pattern, and it needs to pass the CAE. Analysis to optimize the design. In order to make the exterior surface of the plastic part have the effect of color gradient, the wall thickness of the peripheral edge of the outer edge can adopt a gradual design from thin to thick.
In the molding process, when the large-scale two-color injection molding technology is molded for the second time, the plastic flows along the surface of the first-formed plastic part, and defects such as air bubbles, chromatic aberrations, and running plastics are likely to occur. It is necessary to repeatedly debug the injection molding process parameters. Precise control, combined with molding conditions to improve and optimize the mold.
According to Zhang Minglei, Qingdao Hisense Mould Co., Ltd., Hisense Mould Co., Ltd. began to develop large-scale two-color injection molds in the first half of 2009. After working hard, it broke through a series of key technologies and developed the world's first advanced large-scale bicolor high-gloss light in China. Injection molds have been successfully applied to Hisense's large-size LED-backlit LCD TVs. At present, Hisense Mould Company has fully mastered the product optimization, mold development, and process control technologies for large-size two-color high-gloss injection molds. It has developed T29 and T39 two series of more than ten large-scale two-color high-gloss injection molds that can be produced for the largest size. Reached 55 inches of LED-backlit LCD TV shell, production pass rate reached more than 90%.
The large-size two-color high-gloss injection molding technology has high production efficiency and good surface quality. The inner and outer colors can be flexibly matched according to needs, which can greatly improve the appearance and grade of the whole product. At present, the technology is being applied more and more widely on large-size LED-backlit LCD TVs. In the future, it will also have broad market prospects for high-end refrigerators, air conditioners and other home appliances.
With the promotion of high-tech driven and pillar industries, China's plastic molds have formed a huge industrial chain, from the upstream raw and auxiliary materials industry and processing and testing equipment to downstream machinery, automobiles, motorcycles, home appliances, and electronic communications. , Construction and building materials, and other major application industries, the development of a plastic mold life. At present, the application of plastic products has become increasingly widespread, providing a vast market for plastic molds, and at the same time it also puts forward higher requirements for molds. Large-scale, high-precision, multi-functional composite molds will be favored. At the same time, the demand for plastics in the construction, home appliances, and automotive industries is large. It is estimated that only the automotive and motorcycle industries require more than 100 billion yuan in molds each year; color TV molds also have a market of about 2.8 billion yuan each year.
From the point of view of marketing, the mold market is further developed and new growth points have been spotlighted. In the domestic market, automobile lightweighting, new energy, medical devices, aerospace, energy conservation and emission reduction have become important new growth points for the mold industry. In the international market, in addition to the traditional markets of Europe, the United States, Japan, and Southeast Asia, the development of emerging markets such as Brazil, India, Russia, and Australia has achieved results. At present, China's mold exports have reached more than 40 countries and regions.
In view of the global situation, the recent major earthquakes in Japan and political turmoil in Libya have produced a “butterfly effect†on the global mold industry chain, showing that the world today is still in a post-crisis era, and the development opportunities and challenges of the Chinese mold industry coexist. The current mold industry presents the following features:
1. China is still in the middle and low end of the global industrial chain of work, and its products are in the middle and low grades; mold is also the same. Due to the shrinking market capacity, the mold enterprise competition has intensified. The fierce price war and the sharp decrease in the prices of mould products have led to a decline in the efficiency of enterprises and the quality of their products.
2. In the development and production of tissue molds, developed countries generally adopt technologies and management methods such as concurrent engineering and project management, and have strengthened the control over workflows, shortened the cycle of mold development and ensured quality. The tightening of the market has affected the development of new products for enterprises, especially the slowdown in the development of new models of automobiles. This has directly affected the development and production of molds, and the mold industry, which has a large proportion of automotive molds, has been greatly affected.
3. In terms of professional production, developed countries are more common. Professional division of labor is an inevitable trend of increasing production efficiency, shortening mold design and manufacturing cycle, and guaranteeing product quality. It helps to highlight its core business and helps to accumulate experience in product development, production management and service to provide high levels in the short term. Quality, low cost molds.
4. In the application of high-tech, developed countries have applied more extensive and deeper applications in various high and new technologies and have higher levels, including digital mold technology (three-dimensional design, manufacturability design (DFM), CAPP, CAM, CAT ......), forming process simulation (CAE) technology, high-speed machining technology, automated processing technology, new material forming technology, surface treatment technology, new (multi-functional composite) mold technology, information management technology and so on. The continuous development and extensive application of high and new technology have made the design and manufacturing of molds reach an unprecedented height.
5. In terms of research and innovation of new technologies, including innovations in forming methods, innovations in improvement of forming quality, innovations in new material forming technologies, etc., China has yet to grasp the initiative, basically tracking the progress of technological development in developed countries.
Faced with the challenges, the Chinese government has adopted a series of positive measures such as expanding domestic demand, adjusting the structure, and ensuring the people's livelihood, such as increasing investment in infrastructure and stimulating production and consumption of investment products; implementing electrical appliances to the countryside, cars to the countryside, and building materials to the countryside Preferential policies such as tax deductions and taxation fees have played a positive role in product development and market expansion, thereby reducing the impact on the manufacturing industry including the mold industry. On the other hand, enterprises have strengthened management to varying degrees, adopted some measures to reduce risks, strengthened the management of cash flows, strengthened cost accounting and reduced costs, actively explored markets, strengthened research and development, increased product mix adjustment, and strengthened enterprise production. Management standardization, informationization, etc. achieved good results. The overall level of the industry has improved rapidly. Mainly reflected in the large-scale, sophisticated, complex, long-life mold as the main representative of the proportion of high-grade mold continues to rise, scientific and technological progress is obvious, the product level has been greatly improved. At the 13th International Mould Technology and Equipment Exhibition in May 2010, there were a total of 181 molds that received the "Premier Award", of which 55 were first prizes and 64 were second prizes. Not only were the numbers larger than before. The number of projects that have reached the international level is increasing, innovation is evident, and patents are increasing. The gap between the average price of imports and exports of moulds is continuously narrowing, reflecting the improvement of the overall level of China's mold industry and technological progress.
In recent years, the state has proposed to develop small and medium-sized enterprises to “grasp the large and smallâ€, providing a good opportunity for the further development of the mold industry. In the process of further opening up, the development of China's mold industry (including foreign-funded or Sino-foreign joint ventures) will facilitate the expansion of exports and increase the international competitiveness of China's manufacturing industry, and gradually change China's position in the international industry in the low-end position . The technological content and added value of China’s export molds have risen over the previous year. Compared with imported molds, the gap between technology and price has also continuously narrowed, which fully reflects the technical progress of China's mold industry and the improvement of the competitiveness of the international market.
China's export mold market is mainly Hong Kong, the United States and Japan, followed by Germany, India, China Taiwan, France, Brazil, South Korea and Vietnam. It is expected that by 2018, China will realize the export of a single product from middle and low-grade molds for export to a composite export of high-end mold products and moldmaking technology. By then, China's mold will transition from a "manufacturing powerhouse" to an "innovating powerhouse."
The most important thing in the "Twelfth Five-Year Plan" is to grasp the guiding ideology and clarify the overall tasks: adhere to the scientific concept of development, take the structural adjustment as the main line, rely on technological progress, and take the lead of "good", drive innovation, and do a good job of informatization. With the integration of industrialization, to improve the overall strength of the industry and the core competitiveness of enterprises as the main goal, deepen the reform, open up the market, work hard, strive to change the development mode, enhance the soft power, and better improve the overall level of the equipment manufacturing industry. China has achieved low-carbon economy and national defense modernization services, laying a solid foundation for China's mold industry to step into the world's mold power.
Symons cone crusher, also called hydraulic cone crusher, compound cone crusher, is widely used for the metallurgical industry, construction material industry, road building industry,
chemical industry and silicate industry etc. It can be used as secondary, tertiary or quaternary crushing.can crush materials of above medium hardness, such as iron ores, copper ores, limestone, quartz, granite, gritstone, etc. The paryicle size is even and using this symons crusher decreases the circulating, and using multi-cylinder hydraulic clearing system can decrease downtime and save the working strength.
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