Nine mold development trends in the automotive industry

Core Tip: Mold is the automotive industry on the basis of technology and equipment, automobile production in more than 90% of the parts will need to rely mold forming. Manufacturing an ordinary car is about 1500 sets of molds, which accounts for more than 1,000 sets of stamping dies. In the development of new models, 90 percent of the workload are around to change the body type surface carried out. In the new model development costs, about 60% for the body and the development of stamping technology and equipment. In the vehicle manufacturing costs by about 40% for the body stamping and assembly costs. In the development of domestic automobile mold industry, the mold technology shows the following trends.

First, the simulation (CAE) stamping process more prominent role

In recent years, with the rapid development of computer software and hardware, stamping process simulation (CAE) is playing an increasingly important role. In the United States, Japan, Germany and other developed countries, CAE mold design and manufacturing technology has become an essential part of the process, it is widely used to predict forming defects, optimize the stamping process and die structure and improve the reliability of the mold design, reduce the tryout time. Many domestic automobile mold companies in CAE applications have also made significant progress, get good results. Application of CAE technology can greatly reduce the cost of test mode and shorten the development cycle of stamping dies, it has become an important means to ensure the quality of mold. CAE technology is gradually mold design by experienced design into a scientific design.

Second, mold three-dimensional design to consolidate position

Three-dimensional design of the mold is digitized mold technology an important part, is the basis for mold design, manufacturing and testing integration. Toyota, General Motors and other companies have realized three-dimensional design of the mold, and achieved good effect. Some of the practices of foreign mold three-dimensional design taken we can learn. In addition to mold three-dimensional design is conducive to integrated manufacturing, another advantage is the ease of interference checking, motion interference analysis can solve the two-dimensional design of a problem.

Third, the digital technology has become the mainstream mold

In recent years, the rapid development of digital mold technology is an effective way to solve many of the problems facing the development of automotive die of. The so-called digital die technology is computer technology or computer-assisted technology (CAX) application in mold design and manufacturing process. Summary of domestic and foreign automobile mold enterprise computer-aided technology successes, digital car mold technology mainly includes the following aspects: ① design for manufacturability (DFM), namely to consider and analyze manufacturability in the design to ensure the success of the process. ② mold surface design assistive technology, the development of intelligent profile design. Process ③CAE aided analysis and simulation of stamping, predict and resolve potential defects and forming problems. ④ replace the traditional two-dimensional design with a three-dimensional mold design. ⑤ mold manufacturing process using CAPP, CAM and CAT technology. ⑥ technical guidance in the digital processing solutions tryout process and stamping production problems.

Fourth, the rapid development of mold processing automation

Advanced processing technology and equipment is an important foundation to improve productivity and ensure product quality. In advanced automotive mold companies with dual table CNC machine tools, automatic tool changer (ATC), automatic processing of optical control system, the workpiece line measurement system is no longer uncommon. CNC machining by simple surface machining process development to full-surface and surface structure, the Central low speed to high speed machining process development, process automation technology has developed very rapidly.

Fifth, high-strength steel stamping technology is the future direction of development

High-strength steel in yield ratio due, strain hardening, strain distribution capabilities and other aspects of the crash has excellent properties, the amount used in the car is increasing. Currently, high-strength steel in the automotive stamping parts are mainly used in paint hardened steel (BH Steel), dual-phase steel (DP steel), transformation induced plasticity steel (TRIP steel) and the like. International ultralight vehicle project (ULSAB) is expected to launch in 2010 an advanced concept car (ULSAB-AVC) 97% of the material is high-strength steels, advanced high-strength steel in the vehicle timber account for more than 60%, of which duplex It will account for 74% of the proportion of steel plate of the vehicle. Now uses a lot of steel to IF-based soft steel series of high-strength steel series will be replaced by high-strength low-alloy steel will be replaced by dual-phase steel and ultra high strength steel. At present, the application of domestic auto parts high-strength steel structural members also mostly limited to the beam class member, the tensile strength of the material used more than 500MPa or less. Therefore, quickly mastered high-strength steel stamping technology, it is an important issue of China's automobile mold industry solved.

Sixth, the timely introduction of new mold products

As automotive stamping production efficiency and automation, progressive die stamping parts in the production of automotive applications will be more extensive. Shape complex stampings, especially some of the traditional process requires multiple sub-sequence deputy die punching sized complex stampings, increasingly adopting progressive die forming. Progressive Die Die is a high-tech products, technical difficulties, manufacture high precision, long production cycle. Multi-position progressive die mold product will be one of China's key development.

Seven, mold materials and surface treatment technology will be reused

Quality and performance of the mold material mold quality is an important factor, lifetime and cost impact. In recent years, in addition there have been a variety of high toughness and high wear resistance of cold work tool steel, flame hardening cold work die steel, powder metallurgy cold work tool steel Release outside, on medium and large stamping dies abroad choose cast iron materials, is a worthy Follow trends. Ductile iron has good toughness and wear resistance, weldability, machinability, surface hardening performance are better, and the cost is lower than that of alloy cast iron, so automotive stamping die more often.

Eight, scientific management and information technology is the development direction of mold enterprise

Another important aspect of the automobile mold technology development and management of scientific information. Scientific management of enterprises continue to mold manufacturing time (Just-in- TimeManufacturing) and lean production (LeanProduction) direction, enterprise management more accurate, a substantial increase in production efficiency, ineffective institutions, sectors and staff have been streamlined. With the advancement of modern management techniques, many advanced information management tools, including enterprise resource management system (ERP), customer relationship management (CRM), supply chain management (SCM), Project Management (PM) and other enterprises in the mold widely used.

Nine, fine manufacturing mold is inevitable

The so-called fine mold manufacturing, is the result of the development process and manufacture of mold in terms of, in particular the performance of the stamping process and die structure design rationalization and strict precision mold, mold products of high reliability and technology management sex. Fine mold manufacturing is actually not a single technology, the second is a comprehensive reflection of design, processing and management technologies. Mold manufacturing to achieve fine addition to relying on technical excellence, but also on strict management to protect.