China's mold standardization of high-end intelligent development, optimistic outlook

The prospects for the development of China's mold standard parts industry are optimistic. The mold standard part is an important part of the mold and is the basis of the mold. It has very important technical and economical significance for shortening the mold design and manufacturing cycle, reducing the mold production cost, and improving the mold quality. The experience of foreign industrialized countries proves that the professional production and commercial supply of mould standard parts has greatly promoted the development of the mould industry. According to Luo Baihui, the Secretary-General of the International Modeling Association, extensive application of standard parts can shorten the design and manufacturing cycle by 25-40%; it can save social hours due to user-made standard parts and reduce the waste of raw materials and energy; it can be used for mold CAD/ The foundation of the application of modern technologies such as CAM; can significantly improve the manufacturing precision and performance of the mold. Generally, the use of professionally produced standard parts will improve the matching accuracy and position accuracy by at least one order of magnitude compared with self-made standard parts, and ensure interchangeability, increase the service life of the mold, and then promote the internal economic system, operating mechanism, and industrial structure of the industry. The reform of production management has achieved specialization and large-scale production, and has driven the formation and development of the mold standard commodity market. It can be said that without the specialization and commercialization of mold standard parts, there will be no modernization of the mold industry.

In recent years, with the rapid development of China's mold industry, the standardization, specialization, and commercialization of mold parts have reached a relatively high level and significant progress has been made. Since the establishment of the National Mold Standardization Technical Committee in 1983, it has organized experts to formulate, revise, and review mold standards. A total of more than 90 standards have been issued, including 22 standard stamping standards and more than 20 plastic mold standards. The issuance and implementation of these standards have promoted the technological progress and development of the mold industry, resulting in great social and economic benefits. The research, development and production of modular standard parts are in full swing, regardless of product types, varieties, specifications, or the technical performance and quality levels of the products. Luo Baihui said that at present, the level of standardization and application of molds in China is still relatively low, with an optimistic estimate of less than 30%, and there is still a large gap compared with foreign industrial developed countries (70-80%). Although production and sales companies are increasing year by year, most of them are small-scale, outdated equipment, backward technology, high cost, and low efficiency. Only ordinary small and medium standard punch die sets and plastic die sets, guide posts, guide bushes, push rods, die springs, pneumatic components and other products are highly commercialized, and they can basically meet the needs of the domestic market and have some exports. And those with high technical content, advanced structure, excellent performance, high quality, and convenient replacement have personalized products, such as ball lock type quick change punch and fixing plate, solid lubrication guide plate and guide sleeve, wedge mechanism and its components There are very few domestic manufacturers of high-grade plastic mold standard parts and nitrogen main springs. Due to the lack of funds, technical reform projects are difficult to implement, production efficiency is low, and the delivery period is long. The contradiction between supply and demand is increasingly prominent. Therefore, a considerable amount of mold standard parts must be imported from abroad every year, and its cost accounts for about 3-8% of the annual mold import amount. There are still many problems in terms of technical standards, scientific and technological development, and product quality for domestic standard mold parts. For example, product standards are confusing, with few functional components and low technical content, poor applicability; small technological changes, obsolete equipment, backward technology, low level of specialization, and unstable product quality; shortage of professionals, poor management, and low production efficiency , Long lead times; uneven distribution of production and sales outlets, operating specifications and less variety, lack of supply; some units in order to compete for market, do not talk about quality, shoddy, shoddy goods flood the market. There is also the need to seriously study and urgently resolve the phenomenon of cost-cutting, blind price cuts, and disruption of the market.

Luo Baihui pointed out that the automotive and motorcycle industry is the largest market for molds, and household appliances, electronic communications, construction equipment, instrumentation, plastics and rubber and other industries also have a considerable market for molds. From the perspective of long-term development, China's mold industry will inevitably undergo profound changes along with the advent of the era of knowledge-based economy. Molding of the mold structure, standardization of parts and components, standardization of specialized production and supply of commercial products will also develop in the future. The inevitable trend. With the increasing application of mold standard parts, in the future market economy mold standard parts will become a very active and rapid development of products, Luo Baihui convinced that the development prospects of the mold standard parts industry is very optimistic and beautiful.

The standardization degree and application level of Chinese mold standard parts to the high-end development mold is an important indicator of the level of the mold industry. Molds are specialized forming tools. Although they are highly personalized, they are also industrial products. Therefore, standardization is very important. In countries where industry is more developed, importance is attached to standardization because it brings quality, efficiency, and efficiency to industry. The survival and development of the mold standard parts industry in China is facing serious challenges. However, as long as we unite and unite in one heart, we must face the reality, speed up reforms, seize opportunities, meet challenges, survive in competition, and rely on advancements in science and technology, convinced that in the near future, China's mold standard parts industry will take root. The revolution will usher in a better tomorrow.

Due to the late start of Chinese mold standardization work, slow progress, and the influence of old concepts such as “large and complete”, “small and complete”, and “self-produced and self-provisioned” in the past, Chinese mold standard parts have long been varieties. The specifications are small, the production scale is small, and the circulation is not smooth. Even the current production of more molds, guides, putter push tubes, elastic components, etc., is also more mid-range products, less high-end products. Some high-grade mold standard parts produced by foreign-funded enterprises will affect their promotion and application due to their high price. Luo Baihui pointed out that mold standard parts are suitable for socialized large-scale professional production, but China has been scattered, chaotic, and poor for a long time. The so-called "dispersion" is mainly due to the excessive number of production sites of mold standard parts, and it is rarely able to form economic batches. The so-called “chaos” is mainly due to the chaos of the standard. Enterprises often have to produce according to national standards, standards and past several standards and certain corporate standards, and they must comply with foreign standards such as Japan, Germany, the United States, Switzerland, and certain foreign countries. The standard production of a company. At the same time, the market for mold standard parts is also chaotic, and disorderly competition has caused many adverse consequences. The so-called "bad" is the poor quality of mold standard parts and the poor efficiency of enterprises. In recent years, with the intervention of foreign companies, although this situation has improved, it has not yet fundamentally changed. There is still a big gap between production and demand. Some companies do not work hard on quality and level, but only make a fuss about the price, resulting in excessive price cuts that result in cutting corners, mischiefs, and declining quality. As a result, many companies have reduced the overall profitability of mold standard parts, and some companies have even lost money. the edge of.

The sales process plays an important role in the market for standard mould parts. At present, although there are nearly 100 sales outlets in the country, most of them are small in scale, have little inventory, and have small sales. Even if they are more than 50 business units in the joint sales network of mold standard parts of China Die & Mould Industry Association Standards Committee, The same problem exists. Individual units plan to launch online sales and e-commerce, but this work will start soon and it will take time to form scale.

Now we use the standard mold products such as the cold stamp die holder, injection mold holder and push rod push tube with the largest coverage and the most extensive coverage as an example to conduct a preliminary analysis of the production and demand conditions.

Cold die frame Cold die frame is one of the most widely used mold standard parts, and its use coverage is about 80%. Cold die holders can be divided into two categories: cast iron formworks and steel plate formworks. They can be divided into two types: sliding formworks and rolling formworks. There are more than 30 enterprises that have produced a certain amount of cold die racks in the country, of which only 3 are producing more than 100,000 sets per year, including: Xiaoshan Precision Mold Standard Parts Factory, Jiangsu Zhenjiang Chuanshan Formwork Factory, and Shaanxi Luohe Tools & Dies General factory. The total annual production of the three die sets totaled about 400,000 sets, accounting for about half of the national total. From the perspective of demand, there are about 1 million sets of cold punches each year in the country, so there are still many gaps. The contradiction between the production and demand of the steel plate formwork and the precision formwork in the notch is the greatest, so the self-produced and self-proportioned proportion is the largest.

Injection molds Injection mold racks produce more dispersion than cold stamping molds, and more manufacturers. It is estimated that there are more than 40 manufacturers of injection molds in the country. Most of them have annual production of less than 1,000 sets, and there are less than 10 companies with more than ten thousand sets of capacity, including Longji Group, Dongguan Mingli Steel Mold Products Co., Ltd., and Desheng. The production scale of the company and Guangdong Shunde New Qiangsheng Mould Co., Ltd. belongs to the first phalanx. The annual output value of the injection mold base of each enterprise exceeds 100 million yuan, and some can reach several hundred million yuan. Suzhou Zhongchong Heavy Industry Steel Mould Company, Shenzhen South Mould Factory, Shenzhen Xinglonghua Industrial Company, Shenzhen Xinglong Machinery Mould Co., Ltd., Kunshan Zhongda Mould Co., Ltd., Zhejiang Yarun Mold Mould Co., Ltd., Sichuan Jiangdong Machinery Factory, Nantong Longteng Machinery Co., Ltd., Kunshan Hongshun Large Formwork Co., Ltd., etc. belong to the second square array, and the annual output value of the injection mold base exceeds 10 million yuan. A total of more than 10 companies have achieved an annual output value of more than 2 billion yuan in injection molds, accounting for more than 90% of the country's total output. According to needs, at present, the country needs about more than 3 billion yuan for injection molding. However, the domestic market has not reached this scale. This is mainly due to the higher ratio of self-produced and self-produced injection mold stands and more exports. In northern China and the vast central and western regions, due to the low level of professionalism and historical reasons, some old concepts have not yet been fundamentally changed. Therefore, most of the injection mold bases required by the mold production units are still self-produced and rarely purchased. . Therefore, the market for injection molds is currently concentrated in the Pearl River Delta, followed by the Yangtze River Delta, with Guangdong being the most concentrated, followed by Zhejiang, Jiangsu, Shanghai, and Shandong.

As mold users' requirements for the production cycle of molds are getting shorter and shorter, enterprises that produce large and medium-sized injection mold bases have begun to develop deep processing such as pre-excavating cavities and deep holes, and have achieved good results.

Due to the complicated process and low price, the push rod push tube is the best among many mold standard parts, and its use coverage is almost 100%. Japan-based Pan-Industrial (Dalian) Co., Ltd. is China's largest manufacturer of push-pull push-pull tubes. Its products are of superior quality, are expensive, and are exported in large quantities. Guangzhou Power Mould Standard Parts Co., Ltd. currently has an annual capacity of 30 million cigarettes. It is the largest domestic-funded enterprise and has a variety of push-pull tube production specifications and grades. It can meet the needs of different levels. Dongguan City Expands Precision Hardware Products Factory, Zengcheng Fuqiang Mould Industrial Co., Ltd., Anhui Lida Mould Standards, Tianjin Hedong Zhenhua Mould Standard Parts Factory and Tianjin Gonghua Mould Standard Parts Co., Ltd. have an annual output of about 10 million pieces. Ability. The output of the above seven companies accounted for about 80% of the national total, putting the market to push and control the basic balance between production and demand. The production enterprises have noticed the importance of improving processes, increasing varieties, improving product quality and grades, and further developing specialized production. In particular, several top companies are trying to improve their competitiveness by using advanced technology for technological transformation.

In addition to the above-mentioned cold die racks, injection mold bases and push rod push tubes, the coverage of the use of elastic elements is also very high, almost 100%. However, the nitrogen cylinder springs are basically imported. There is no standard in the country and trial production is under way. In addition, 14 module standard parts such as formwork modules, guides, standard convex dies and sprue bushings are also produced by some companies in China. However, there are few varieties and specifications, and the use coverage is low, and many self-produced products are used. There are no standards for domestic hot runner components, and only individual companies produce or supply them for their own use. At present, the middle and high grade hot runner components are basically imported from abroad. The products that are produced and used for their own use are those with lower performance and poorer stability, and are used for molds that require less. There are many mold standard parts that can be purchased from the market abroad, and there is no professional production in the country. Therefore, in the development of variety specifications, the prospects are very broad.

The standard parts of molds should be expanded in variety and accuracy to achieve interchangeability. Among them, major types, such as formworks, guides, push rods, elastic components, etc., must be mass-produced on an economic scale. In 2005, the use rate of mold standard parts reached 60%, and in 2010 it reached over 70% (standardization of 60% of large-size mold parts), basically meeting the market needs, mold bases, guides, putters, push tubes, elastic components, standards Components, small standard components (such as standard male and female molds, sprue bushings, retaining rings, pull hooks, etc.) and hot runner components are the focus of development. We can see the arduous tasks and bright prospects of mold standardization and mold standard parts. The guiding ideology of the mold standardization work proposed by the Standards Committee of China Die and Mould Industry Association is: Standardization is the basis, and specialization is the direction. Commercialization is the key.

It is particularly necessary to give priority to intelligent tooling and intelligent tooling. Water channel slope protection module box / color brick module box / hexagonal slope protection module box The so-called smart manufacturing equipment is a manufacturing equipment with sensing, analysis, decision-making and control capabilities, intelligent mold is also a sensing, analysis, decision-making and control functions, with sensing, Temperature control function of the stamping die, die-casting mold, with temperature control functions, injection parameters and mold flow control state and other intelligent control methods to create injection molds, etc. are all smart molds.

The International Model Association Secretary-General Luo Baihui pointed out at the 2011 International Forum on Mould Machinery Equipment Industry that with the low cost of human resources in China and the continuous development of science and technology, automation and intelligent manufacturing will inevitably become important developments in modern manufacturing. In the direction, smart molds are bound to develop rapidly. Producing products with intelligent molds can further improve product quality and production efficiency, save more materials, realize automated production and green manufacturing. Therefore, although the current total amount of smart mold is still not much, but it represents the new direction of the development of mold technology, will play an increasingly important role in the industry product structure adjustment and development mode changes. The development of intelligent molds will inevitably have a powerful driving role in promoting the rapid improvement of the entire mold industry. Therefore, it is particularly necessary to prioritize the development of intelligent molds in the development of the industry.

Intelligent mold for emerging strategic industries. These types of molds mainly include molds for lightweight energy-saving and emission-reduction of automobiles, high-gloss traceless and in-mold models for water channel slope protection module/color brick module/hexagonal protection module module through intelligent control methods such as injection parameters and in-mold flow status. Assembling decorative molds, laminating molds and rotating molds, multi-color multi-material injection molds, multi-layer co-extrusion compound molds, multi-functional composite high-efficiency molds, LED new light source supporting molds, and high-efficiency energy-saving motor helium sheet metal stamping dies.

For the new generation of information technology industry, it has precision and ultra-precision molds with functions such as sensing. Such molds include large-scale integrated circuit lead frame precision multi-position progressive die, multi-cavity multi-injection lead frame precision rubber and plastic packaging die, electronic components and connectors high-precision high-speed multi-position progressive die, a new generation Electronic components and efficient multi-row precision multi-position progressive die and multi-functional compound forming mold, a new generation of electronic products, plastic parts, intelligent forming mold, high-precision multi-layer light guide plate mold and IOT sensor ultra-precision molds.

Medical device precision ultra-precision molds for the biological industry. Water channel slope protection module/color brick module/hexagonal slope module This type of mold is mainly used to manufacture precision ultra-precision medical instruments injection molds, biological and medical industry advanced component metals (such as stainless steel) through intelligent control methods such as plastic injection parameters and in-mold flow status. Etc.) Powder injection molds, biochip molds, etc.