Comparative analysis of technological advantages for seven major mold powerhouses in the world
Time：2019-04-19 09:43:33 / Popularity： / Source：
- Quality and efficiency of Italian mold
1. Extensive application of CAD/CAE/CAM shows superiority of using information technology to drive and enhance mold industry.
In the application of CAD, it has surpassed initial stage of removing drawing board and two-dimensional drawing. At present, 3D design has reached 70% to 89%. Applications such as PRO/E, UG, and Cimatron are common. Application of these software not only completes 2D design, but also obtains 3D model, which guarantees integration of NC programming and CAD/CAM. With 3D design, it is also possible to check assembly interference during design to ensure rationality of design and process. Universal application of CNC machine tools ensures machining accuracy and quality of plastic moulded parts. Mold manufacturer of 30 to 50 people generally has more than 10 CNC machine tools. Parts machined by CNC machine tools can be assembled directly, reducing number of assembly fitters. CAE technology has matured in Italy. CAE analysis software is applied in injection moulding die design to simulate custom plastic molding process, analyze cooling process, and predict defects that may occur during moulding process. CAE software is applied in moulding die design to simulate metal deformation process, analyze distribution of stress and strain, and predict defects such as cracking, wrinkling and rebound. Role of CAE technology in moulding die design is increasing. After applying CAE technology, Italian COMAU has reduced test time by more than 50%.
2. In order to shorten molding cycle and improve market competitiveness, high-speed cutting technology is widely used.
High-speed cutting is a processing technology characterized by high cutting speed, high feed rate and high processing quality. Its processing efficiency is several times or even ten times higher than traditional cutting process. At present, Italian mold manufacturer widely use CNC high-speed milling in production. There are many three-axis linkages, and some are five-axis linkage. Number of revolutions is generally between 15,000 and 30,000 r/min. High-speed milling technology can greatly reduce molding time. After high-speed milling, mold surface can be used with only a little polishing, saving a lot of grinding and polishing time. Italian mold manufacturer attach great importance to technological advancement and equipment renewal. Equipment depreciation period is generally 4 to 5 years. Addition of CNC high-speed milling machines is one of the key points of equipment investment in mold manufacturer.
3. Rapid prototyping technology and rapid mold technology have been widely used.
Due to increasingly fierce market competition, product upgrading has been accelerating, rapid prototyping and rapid mold technology have emerged, and quickly gained widespread application. At European and American mold fairs in Italy, rapid prototyping technology and rapid mold technology occupy a very prominent position. There are various types of rapid prototyping equipment such as SLA, SLS, FDM and LOM, as well as organizations and companies specializing in prototyping services. .
Many of Italian molding factory combine rapid prototyping technology with rapid prototyping technology for mold making, which is prototype of manufacturing parts using rapid prototyping technology. Mold is quickly manufactured based on prototype. Many plastic mold manufacturer use rapid prototyping silicone rubber molds for small quantities of plastic moulded parts, which is very suitable for trial production.
Italian plastics rubber processing machinery and mold manufacturing industry is one of 10 specialized machinery manufacturing industries of Italian Machinery Manufacturing Alliance, and Italian plastics rubber processing machinery and mold manufacturing industry has more than 500 European patents, with high degree of specialization, leading technology and diverse products, while providing customers with various value-added services. According to Luo Baihui, Italian mold manufacturer have annual sales of more than $100,000 per person. At present, output value of Italian plastics rubber processing machinery and mold manufacturing industry accounts for 16.5% of the total output value of 10 industries of Machinery Manufacturing Alliance. At the same time, export destination of Italian plastic rubber processing machinery and mold products is still dominated by EU, and export value accounts for 47% of the total export share.
Italian molding factory has advanced technology and advanced management, which makes it produce large, precise and complex molds, which plays an extremely important role in promoting development of automobiles, electronics, communication, home appliances and other industries, and also brings good economic benefits to mold manufacturer.
- Superb German mold technology
- American molds facing change
- Japanese mold mastering masters core technology
Due to global financial crisis and devastating earthquake, use of Japanese molds in automotive industry and semiconductor industry will be declining. At present, orders of many companies are only 20-40% of their best years. Many factories are underemployed, and only 3 to 4 days per week are started. Some have started to close down, and number of enterprises has decreased month by month. Faced with this situation, Japanese mold industry people are very worried about brain drain, especially worrying that some older and experienced talents are going abroad. Brain drain will bring disadvantages to future development of Japanese industry. How to actively respond to current difficulties has become a major issue in Japanese mold industry. Japanese mold industry and even relevant government departments have already considered future development direction of mold industry.
From perspective of people, Japan has proposed six major development directions. 1 Use as many high-tech as possible to improve level of digitization and informationization. 2. Develop new areas of mold use, such as various new energy sources, new materials and medical, aerospace and other fields; 3 extending mold industry chain; 4 carrying out diversified operations; 5 updating knowledge; 6 doing a good job in development and integration of production, education and research.
At government level, Ministry of Economy, Trade and Industry of Japan has organized “Study on Technology Strategy of Prime Form Technology” and issued “Technology Strategy for Prime Form”. Goal of implementing this technology strategy is clear: "grasp lifeline of world's manufacturing industry by mastering important technologies of prime shape."
- Up-and-coming Chinese auto molding
At present, mold manufacturing companies with a mold output value of over 100 million yuan are mainly concentrated in the field of automotive panel parts. For example: FAW Mould Manufacturing Co., Ltd. for automotive panel moulds, Wuxi Guosheng Precision Mold Co., Ltd. for precision stamping dies, Haier Mould Co., Ltd. for large custom plastic molding, Tongling Sanjia Technology Co., Ltd. for plastic profile moulds, Guangdong Giant Wheel Mould Co., Ltd. and Jieyang Haotian Mould Co., Ltd. for rubber tire molds, Hong Kong Longji Group and Panqi Industrial Co., Ltd for mold standard parts. In the mold manufacturer of over 100 million yuan, foreign capital accounts for a considerable proportion.
Mold is "mother of machine". Auto molding are “first movers” in manufacture of automobiles. Auto molding are classified into five categories according to their functions such as stamping dies and injection molds. As a cold die, large auto body molding of car body is the most iconic craft equipment in auto molding. Due to complicated manufacturing technology of large auto body molding, high dimensional and surface precision requirements, and high-precision CNC equipment such as five-axis high-speed machining centers, manufacturing technology has long been controlled by multinational professional companies. Most of large-scale auto body molding of domestic car companies rely on imports.
- Singapore focuses on developing IT molds
- Australian automotive stamping dies have space
China has complete die design and manufacturing technicians and programmers, skilled CNC machine operators, fitter assembly and mold commissioners. China's labor wages are lower than Australia's. At present, it has ability to manufacture car stamping dies. Company's production capacity is 200 to 400 sets of large and medium-sized stamping dies per year, and enterprise equipment load is not high, and it is fully capable of manufacturing molds for Australia.
Software used in design and manufacture of auto molding in Australia is mostly ug, pro-e, CATIA and euclid. It is basically same as software used by mold manufacturers in China. It can be shared. CAE analysis software and simulation molding analysis software have similarities. This provides good conditions for our cooperation in China and foreign countries.
Australian Mold Association, Adelaide Model Office, and Melbourne Mold Association all have great hopes for Chinese mold market and manufacturing companies. This will create favorable conditions for China to export molds to Australia.
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