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譯文題目： the mold designing and manufacturing
模具設計與制造
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年 3 月 4 日
The mold designing and manufacturing
The mold is the manufacturing industry important craft foundation, in our country, the mold manufacture belongs to the special purpose equipment manufacturing industry. China although very already starts to make the mold and the use mold, but long-term has not formed the industry. Straight stabs 0 centuries 80's later periods, the Chinese mold industry only then drives into the development speedway. Recent years, not only the state-owned mold enterprise had the very big development, the three investments enterprise, the villages and towns (individual) the mold enterprise's development also rapid quietly.
The mold designing and manufacturing The mold is the manufacturing industry important craft foundation, in our country, the mold manufacture belongs to the special purpose equipment manufacturing industry. China although very already starts to make the mold and the use mold, but long-term has not formed the industry. Straight stabs 0 centuries 80's later periods, the Chinese mold industry only then drives into the development speedway. Recent years, not only the state-owned mold enterprise had the very big development, the three investments enterprise, the villages and towns (individual) the mold enterprise's development also rapid quietly. Although the Chinese mold industrial development rapid, but compares with the demand, obviously falls short of demand, its main gap concentrates precisely to, large-scale, is complex, the long life mold domain. As a result of in aspect and so on mold precision, life, manufacture cycle and productivity, China and the international average horizontal and the developed country still had a bigger disparity, therefore, needed massively to import the mold every year .
The Chinese mold industry must continue to sharpen the productivity, from now on will have emphatically to the profession internal structure adjustment and the state-of-art enhancement. The structure adjustment aspect, mainly is the enterprise structure to the specialized adjustment, the product structure to center the upscale mold development, to the import and export structure improvement, center the upscale automobile cover mold forming analysis and the structure improvement, the multi-purpose compound mold and the compound processing and the laser technology in the mold design manufacture application, the high-speed cutting, the super finishing and polished the technology, the information direction develops .
The recent years, the mold profession structure adjustment and the organizational reform step enlarges, mainly displayed in, large-scale, precise, was complex, the long life, center the upscale mold and the mold standard letter development speed is higher than the common mold product; The plastic mold and the compression casting mold proportion increases; Specialized mold factory quantity and its productivity increase; "The three investments" and the private enterprise develops rapidly; The joint stock system transformation step speeds up and so on. Distributes from the area looked,take Zhejiang Delta and Yangtze River delta as central southeast coastal area development quickly to mid-west area, south development quickly to north. At present develops quickest, the mold produces the most centralized province is Guangdong and Zhejiang, places such as Jiangsu, Shanghai, Anhui and Shandong also has a bigger development in recent years.
Although our country mold total quantity had at present achieved the suitable scale, the mold level also has the very big enhancement, after but design manufacture horizontal overall rise and fall industry developed country and so on Yu De, America, date, France, Italy many. The current existence question and the disparity mainly display in following several aspects:
(1) The total quantity falls short of demand Domestic mold assembling one rate only, about 70%. Low-grade mold, center upscale mold assembling oneself rate only has 50% about.
(2) the enterprise organizational structure, the product structure, the technical structure and the import and export structure does not gather
in our country mold production factory to be most is from the labor mold workshop which produces assembles oneself (branch factory), from produces assembles oneself the proportion to reach as high as about 60%, but the overseas mold ultra 70% is the commodity mold. The specialized mold factory mostly is "large and complete", "small and entire" organization form, but overseas mostly is "small but", "is specially small and fine". Domestic large-scale, precise, complex, the long life mold accounts for the total quantity proportion to be insufficient 30%, but overseas in 50% above 2004 years, ratio of the mold import and export is 3.7:1, the import and export balances the after net import volume to amount to 1.32 billion US dollars, is world mold net import quantity biggest country .
(3) The mold product level greatly is lower than the international standard
The production cycle actually is higher than the international water broad product level low mainly to display in the mold precision, cavity aspect and so on surface roughness, life and structure.
(4) Develops the ability badly, economic efficiency unsatisfactory our country mold enterprise technical personnel proportion low
The level is lower, also does not take the product development, and is frequent in the passive position in the market. Our country each mold staff average year creation output value approximately, ten thousand US dollars, overseas mold industry developed country mostly 15 to10, 000 US dollars, some reach as high as 25 to10, 000 US dollars, relative is our country quite part of molds enterprises also continues to use the workshop type management with it, truly realizes the enterprise which the modernized enterprise manages few
To create the above disparity the reason to be very many, the mold long-term has not obtained the value besides the history in as the product which should have, as well as the most state-owned enterprises mechanism cannot adapt the market economy, but also has the following several reasons:
(1) Country to mold industry policy support dynamics also insufficiently
Although the country already was clear about has promulgated the mold profession industrial policy, but necessary policy few, carried out dynamics to be weak. At present enjoyed the mold product increment duty enterprise nation 185; the majority enterprise still the tax burden is only overweight. The mold enterprise carries on the technological transformations introduction equipment to have to pay the considerable amount the tax money, affects the technology advancement, moreover privately operated enterprise loan extremely difficult.
(2) Talented person serious insufficient, the scientific research development and the technical attack investment too urine
mold profession is the technology, the fund, the work crowded industry, along with the time progress and the technical development, grasps the talented person which and skilled utilizes the new technology exceptionally short, the high-quality mold fitter and the enterprise management talent extremely is also anxious. Because the mold enterprise benefit unsatisfactory and takes insufficiently the scientific research development and the technical attack, the scientific research unit and the universities, colleges and institutes eye stares at is creating income, causes the mold profession invests too few in the scientific research development and the technical attack aspect, causes the mold technological development step doe not to be big, progresses does not be quick.
The mould is important handicraft equipment，occupies decisive position in industrid departments such as consumer goods，electrical equipment electron，automobile , aircraft fabrication. The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods，electrical equipment electron，automobile , aircraft fabrication. Industrial product part rough process 75%, the finish machining 50% and plastic part 90% will be completed from the mould. The Chinese mould market demand already reaches scale of 500 hundred million yuan at present. The automobile mould , the annual growth rate covering piece of mould especially will exceed 20 %; Also prompt building material mould development，various heterotype material the mould，wall surface and floor mould become new mould growth point, plastic doors and windows and plastic drain-pipe increase to exceeding 30 by in the upcoming several years %; The home appliance mould annual growth rate will exceed 10 %; The IT industry year increases % speed equally exceeding 20，the need to the mould accounts for 20 of mould marketplace %.2004 annual Chinese machine tools implements industry output value.
will continue to increase. Our country mould fabrication market potential is enormous. The basis data counts， in recent years，our country mould year gross output value reaches 3 billion U. S. dollar，entrance exceeds 1 billion U. S. dollar，exceed 100 million U. S. dollar outlet. Increase by from 25% to increase to 2005 50% of 1995. The expert foretells that abroad: Asia portion being occupied by in mould fabrication in the whole world, will from 25% to increase to 2005 50% of 1995.
Chinese mould industry has been expanding by leaps and bounds，has formed east China and two big South China bases, and has expanded gradually arriving at other province. In 2002 (Shandong，Anhui，Sichuan) in 1996，mould manufacturing industry output value annual average growth 14% , grows by 25% in 2003. In 2003 our country mould output value is 45 billion RMB. The gross product place occupies the world the 3rd，exports a mould increases 33.5% compared to last year 336,800,000 U. S. dollar. But, contents low our country technology moulds already pile up in excess of requirement，very most support of accurate，complicated top grade mould imports. Every year the entrance mould exceeds 1 billion U. S. dollar. Exceed 100 million U. S. dollar outlet.
Precise mould accuracy requires that 3 mu ms，large-scale moulds require that 8000 satisfied kN agree well with model force injection machine request in 2 ~；The minitype mould needs the request satisfying the diameter 1 mm silent stock tube. At present, adopt quick-cutting to produce a mould already becoming the general trend that the mould makes, a few moulds have produced a manufacturer in abroad，high-speed machine tool large area has substituted the electric spark machine tool，quick-cutting has improved the mould efficacy greatly. Machine tool enterprise aims at mould manufacturing enterprises，some treating centres 60% all above of the machine tool producing a factory sells treating enterprise to a mould. The mould fabrication enterprise substituting the electric spark finish machining mould gradually in abroad has adopt quick-cutting already commonly , quick-cutting has produced a mould already becoming the general trend that the mould makes gradually，has improved the mould efficacy and mass greatly. Adopt quick-cutting to replace electric spark producing a mould , can get on the stick obviously , improves mould accuracy，life time growing.
The mould marketplace has the intense need, but technology to be unable to keep abreast with to high speed treating. Starting is late，the basis is relatively poor，overall engineering level not being taller than，develops slowlyRequire that one by one, aspect coordinated growth，the product mimic inkstone throwing into combining with enlarging, each comprehensive utilization aspect strengths drive quick-cutting application in making in the mould.. Our hope，effort passing every aspect, before the market demand push go down， pass technological progress, look like automobile，machine tool，home appliance，before long，not only our country being going to become a mould producing Great Power, and be going to become a mould producing the powerful country.
Industry to the level of mold, material application is the key. Due to improper selection and use of materials, causing premature die failure, which accounts for more than 45% failure die. In the mold material, commonly used cold work tool steel with CrWMn, Cr12, Cr12MoV and W6Mo5Cr4V2, flame hardened steel (such as Japan, AUX2, SX105V (7CrSiMnMoV), etc.; used a new type of hot work die steel American H13, Sweden QRO80M, QRO90SUPREME, etc.; used a pre-hardened plastic mold steel (such as the U.S. P20), age-hardening steel (such as the U.S. P21, Japan NAK55, etc.), heat treatment hardened steel (such as the United States, D2, Japan, PD613, PD555, Sweden wins the White 136, etc.), powder die steel (such as Japan KAD18 and KAS440), etc.; panel drawing die used HT300, QT60-2, Mo-Cr, Mo-V cast iron, large-scale mold with HT250. more regular use of Precision Die Hard Steel Results YG20 and other alloys and carbide. in the mold surface treatment, the main trends are: the infiltration of a single element to the multi-element penetration, complex permeability (such as TD method) development; by the general diffusion to the CVD, PVD, PCVD, ion penetration , the direction of ion implantation, etc.; can use the coating are: TiC, TiN, TiCN, TiAlN, CrN, Cr7C3, W2C, etc., while heat from the air treatment means to the development of vacuum heat treatment. In addition, the current strengthening of the laser, glow plasma Nitriding and electroplating (plating) enhanced anti-corrosion technologies are also more and more attention.
In the forming process, the main function of composite stamping die, superplastic forming, plastic precision molding technology, plastic mold gas-assisted injection technology and hot runner technology, high-pressure injection molding technology. On the other hand, with the continuous development of advanced manufacturing technology and raise the level of mold industry as a whole, in the mold industry, there are some new design, production, management ideas and models. Concrete are: to adapt to the characteristics of mold-piece production flexible manufacturing technologies; to create the best management and effective teamwork, lean production; to enhance rapid response capabilities of Concurrent Engineering, Virtual Manufacturing and global agile manufacturing, manufacturing of new production networks philosophy; extensive use of standard parts common parts of the division of work mode of production; meet the environmental requirements of sustainable development and green design and manufacturing.
The 21st century, in the new situation of economic globalization, with capital, technology and labor market re-integration of equipment manufacturing in China after joining the WTO will become the world's equipment manufacturing base. In the modern manufacturing industry, no matter which industry, engineering equipment, are increasingly used to provide the products from the mold industry. In order to meet the user's high-precision mold manufacturing, short delivery time, the urgent demand low-cost, mold industry is extensive application of modern advanced manufacturing technology to speed up the mold industry, technological progress, to meet the basic sectors of the mold process equipment urgent needs.
模具設計與制造
模具是制造業(yè)的重要工藝基礎，在我國，模具制造屬于專用設備制造業(yè)。中國雖然很早就開始做模具和使用模具，但長期還沒有形成行業(yè)。直到0世紀80年代后期，中國模具工業(yè)才駛入發(fā)展的快車道。近年來，不僅國有模具企業(yè)有了非常大的發(fā)展，三個投資企業(yè)、鄉(xiāng)鎮(zhèn)（個人）模具企業(yè)的發(fā)展也迅速。
雖然中國模具工業(yè)發(fā)展迅速，但與需求相比，顯然供不應求，其主要差距集中在，大規(guī)模，是復雜的，長期的生活型。由于模具精度、壽命、制造周期和生產率等方面的結果，中國與國際平均水平和發(fā)達國家仍有較大差距，因此，每年都需要大量進口模具。
中國模具行業(yè)必須繼續(xù)提高生產率，從現在開始就對行業(yè)內部結構的調整和藝術的提高起到了一定的促進。結構調整方面，主要是企業(yè)結構調整、產品結構向中高檔模具開發(fā)、進口和出口結構改善、中高檔汽車覆蓋件模具成形分析及結構改進、多功能復合模具及激光技術在模具設計制造中的應用、高速切削、超精加工和拋光技術，信息方向發(fā)展。
近年來，模具行業(yè)結構調整和組織改革步伐加大，主要表現在，規(guī)?；?、精細化、壽命長、中高檔模具和模具標準的字母發(fā)展速度高于普通模具；塑料模具和擠壓鑄造模具比例增加；專業(yè)模具廠數量和生產效率提高；“三投資”和民營企業(yè)發(fā)展迅速。從區(qū)域分布看，以浙江三角洲和長江三角洲為中心的東南沿海地區(qū)發(fā)展迅速向中西部地區(qū)，南部發(fā)展迅速向北部。目前發(fā)展最快，模具生產最集中的省份是廣東和江蘇，山東、上海、安徽、浙江等地也在近幾年有了較大的發(fā)展。
雖然我國模具總量目前達到了適宜的規(guī)模，模具水平也有很大的提高，但設計制造水平整體上升和下降工業(yè)發(fā)達國家等于美國、日、法國、意大利等多。當前存在的問題和差距主要表現在以下幾個方面：
（1）總的數量供不應求，國內模具只裝配一個比例，約70%。低品位模具，中高檔模具裝配自身率僅為50%左右。
（2）企業(yè)組織結構、產品結構、技術結構和進出口結構不凝聚
在我國模具生產廠最為從產自組裝的模具車間（分廠），從生產裝配自身的比例達到高達60%左右，而國外模具超70%是商品模具。專業(yè)模具廠大多是“大而全”、“小而全”的組織形式，但國外大多是“小而精”，“特別是小而精”。國內大型、精密、復雜，為總量的比例不足30%，長壽命模具占50%以上，但在海外2004年，模具的進出口比例為3.7:1，進出口相抵凈進口額達13億2000萬美元，是世界模具凈進口量最大國。
（3）模具產品的水平大大低于國際標準
生產周期實際高于國際水產品水平低主要表現在模具精度、腔面粗糙度、表面粗糙度、壽命和結構等方面。
（4）發(fā)展能力差，經濟效益不理想，我國模具企業(yè)技術人員比例偏低
水平較低，也不采取產品開發(fā)，在市場中經常處于被動地位。我國每個模具職工平均年創(chuàng)造產值約一萬美元，國外模具工業(yè)發(fā)達國家大多是15，000美元，有的達到25000美元，高，相對的是我國相當一部分模具企業(yè)還沿用作坊式管理，真正實現企業(yè)現代化管理的幾
要創(chuàng)造上述差距的原因很多，模具長期沒有得到歷史上應該具備的價值，以及大多數國有企業(yè)的機制不能適應市場經濟，但也有以下幾個原因：
（1）國家對模具工業(yè)的政策支持力度還不夠
雖然國家已經明確出臺了模具行業(yè)的產業(yè)政策，但必要的政策很少，進行力度較弱。目前享受模具產品增值稅企業(yè)185家；大多數企業(yè)仍為稅負過重。模具企業(yè)進行技術改造引進設備必須支付相當數量的稅金，影響技術進步，而且民營企業(yè)貸款難度極大。
（2）人才嚴重不足，科研開發(fā)和技術攻擊投入過大
模具行業(yè)是技術、資金、勞動密集型的產業(yè)，隨著時代的進步和技術的發(fā)展，掌握了新技術的人才，高素質的模具裝配和企業(yè)管理人才十分焦慮。由于模具企業(yè)效益不理想和科研開發(fā)和技術攻關，科研單位和高校、大專院校和研究院的目光盯在創(chuàng)造收入，導致模具行業(yè)在科研開發(fā)和技術攻擊方面投入過多，導致模具技術發(fā)展的步伐不大，進展不快。
模具作為重要的工藝裝備，在消費品、電器電子、汽車、飛機制造等工業(yè)部門中，占有舉足輕重的地位。工業(yè)產品零件粗加工的75%，精加工的50%及塑料零件的90%將由模具完成。目前中國模具市場需求已達500億元之規(guī)模。汽車模具、特別是覆蓋件模具年增長速度將超過20%；建材模具也迅速發(fā)展，各種異型材模具、墻面和地面模具成為模具的新增長點，今后幾年塑料門窗和塑料排水管增長將超過30%；家電模具年增長速度將超過10%；IT業(yè)年均增長速度超過20%，對模具的需求占模具市場的20%。2004年中國機床工具工業(yè)產值將繼續(xù)增長。我國模具制造市場潛力巨大。根據資料統(tǒng)計，近年來，我國模具的年總產值達到30億美元，進口超過10億美元，出口超過1億美元。增長從1995年的25%增加到2005年的50%。國外專家預言：亞洲在全球模具制造中占據的份額，將從1995年的25%增加至2005年的50%。
中國模具工業(yè)發(fā)展迅速，形成了華東和華南兩人基地，并且逐漸擴大到其他省份。（山東，安徽，四川) 1996年~2002年，模具制造業(yè)產值年平均增長14%, 2003年增長25%。2003年我國模具產值為450億人民幣總產量位居世界第3，出口模具3.368億美元，比上年增長33.5%。但是，我國技術含量低的模具已供過于求，精密、復雜的高檔模具很大部分依靠進口。每年進口模具超過10億美元。出口超過1億美元，精密模具精度要求在2~3u m，大型模具需要滿足8000kN合模力注塑機的要求；小型模具需滿足直徑1mm 塑料管的要求。目前，采用高速切削生產模具已經成為模具制造的大趨勢，在國外一些模具生產廠家，高速機床大面積取代電火花機床，高速切削大大提高了模具生產效率。機床企業(yè)瞄準模具生產企業(yè)，有的加工中心生產廠機床的60%以上賣給模具加工企業(yè)。高速切削逐漸取代電火花精加工模具在國外的模具制造企業(yè)已經普遍釆用，高速切削生產模具已經逐漸成為模具制造的大趨勢，大大提高了模具生產效率和質量。釆用高速切削替代電火花生產模具，可以明顯提高效率、提高模具精度、使用籌命長。
模具市場對高速加工有強烈要求，但是技術跟不上。起步晚，基礎較差，整體技術水平不高，發(fā)展緩慢。需要各個方面協(xié)調發(fā)展，產學研結合，加大投入，綜合利用各個方面力量推動高速切削在模具制造中的應用。我們希望，通過各方面的努力，在市場需求的推動下，通過技術進步，像汽車、機床、家電一樣, 在不遠的將來，我國不但要成為模具生產大國，而且要成為模具生產強國。
模具工業(yè)要上水平，材料應用是關鍵。因選材和用材不當，致使模具過早失效，大約占失效模具的45%以上。在模具材料方面，常用冷作模具鋼有CrWMn、Cr12、Cr12MoV和W6Mo5Cr4V2，火焰淬火鋼(如日本的AUX2、SX105V(7CrSiMnMoV)等；常用新型熱作模具鋼有美國H13、瑞典QRO80M、QRO90SUPREME等；常用塑料模具用鋼有預硬鋼(如美國P20)、時效硬化型鋼(如美國P21、日本NAK55等)、熱處理硬化型鋼(如美國D2，日本PD613、PD555、瑞典一勝白136等)、粉末模具鋼(如日本KAD18和KAS440)等；覆蓋件拉延模常用HT300、QT60-2、Mo-Cr、Mo-V鑄鐵等，大型模架用HT250。多工位精密沖模常采用鋼結硬質合金及硬質合金YG20等。在模具表面處理方面，其主要趨勢是：由滲入單一元素向多元素共滲、復合滲(如TD法)發(fā)展；由一般擴散向CVD、PVD、PCVD、離子滲入、離子注入等方向發(fā)展；可采用的鍍膜有：TiC、TiN、TiCN、TiAlN、CrN、Cr7C3、W2C等，同時熱處理手段由大氣熱處理向真空熱處理發(fā)展。另外，目前對激光強化、輝光離子氮化技術及電鍍(刷鍍)防腐強化等技術也日益受到重視。
在成形工藝方面，主要有沖壓模具功能復合化、超塑性成形、塑性精密成形技術、塑料模氣體輔助注射技術及熱流道技術、高壓注射成形技術等。另一方面，隨著先進制造技術的不斷發(fā)展和模具行業(yè)整體水平的提高，在模具行業(yè)出現了一些新的設計、生產、管理理念與模式。具體主要有：適應模具單件生產特點的柔性制造技術；創(chuàng)造最佳管理和效益的團隊精神，精益生產；提高快速應變能力的并行工程、虛擬制造及全球敏捷制造、網絡制造等新的生產哲理；廣泛采用標準件通用件的分工協(xié)作生產模式；適應可持續(xù)發(fā)展和環(huán)保要求的綠色設計與制造等。
總結進入21世紀，在經濟全球化的新形勢下，隨著資本、技術和勞動力市場的重新整合，我國裝備制造業(yè)在加入WTO以后，將成為世界裝備制造業(yè)的基地。而在現代制造業(yè)中，無論哪一行業(yè)的工程裝備，都越來越多地采用由模具工業(yè)提供的產品。為了適應用戶對模具制造的高精度、短交貨期、低成本的迫切要求，模具工業(yè)正廣泛應用現代先進制造技術來加速模具工業(yè)的技術進步，滿足各行各業(yè)對模具這一基礎工藝裝備的迫切需求。