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1、Mold design and manufactureThe 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 i
2、ndustry. Straight stabs 0 centuries 80s 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 enterpr
3、ises development also quite rapid .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, lif
4、e, 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 except must continue to sharpen the productivity, from now on will have e
5、mphatically 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 improvemen
6、t, 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 superfinishing and polished the technology, the inf
7、ormation 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 moldat present domestically to have an greater output the mold s
8、tandard letter mainly is the mold frame, the guidance, the throwout lever pushes the tube, the elastic part and so on. These products not only the domestic necessary massive need, the exportation prospect very is also good, should continue vigorously to develop. The nitrogen cylinder and the hot flo
9、w channel part main dependence import, should raise the level in the existing foundation, forms the standard and organization scale production.(5) the other high-tech content moldsoccupiesin the mold total quantity green 8% compression casting mold, large-scale thin wall precise compression casting
10、technology content high, the difficulty is big. The magnesium alloy compression casting mold at present although just started, but the prospects for development were good, have the representation. The meridian rubber tire mold also is the development direction, detachable mold technology difficulty
11、is biggest. With fast takes shape some fast pattern making technologies and the corresponding fast economical mold which the technology unifies has the very good prospects for development. These high-tech content molds in 十 15 period also should the prioritize .模具设计与制造模具是制造业的重要工艺基础，在我国，模具制造属于专用设备制造业
12、。中 国虽然很早就开始制造模具和使用模具，但长期未形成产业。直到20世纪80 年代后期，中国模具工业才驶入开展的快车道。近年，不仅国有模具企业有了很 大开展，三资企业、乡镇（个体）模具企业的开展也相当迅速。虽然中国模具工业开展迅速，但与需求相比，显然供不应求，其主要缺口集 中于精密、大型、复杂、长寿命模具领域。由于在模具精度、寿命、制造周期及 生产能力等方面，中国与国际平均水平和兴旺国家仍有较大差距，因此，每年需 要大量进口模具。中国模具产业除了要继续提高生产能力，今后更要着重于行业内部结构的调 整和技术开展水平的提高。结构调整方面，主要是企业结构向专业化调整，产品 结构向着中高档模具开展，向
13、进出口结构的改进，中高档汽车覆盖件模具成形分 析及结构改进、多功能复合模具和复合加工及激光技术在模具设计制造上的应 用、高速切削、超精加工及抛光技术、信息化方向开展。近年，模具行业结构调整和体制改革步伐加大，主要表现在，大型、精密、 复杂、长寿命、中高档模具及模具标准件开展速度高于一般模具产品：塑料模和 压铸模比例增大；专业模具厂数量及其生产能力增加；“三资”及私营企业开展 迅速；股份制改造步伐加快等。从地区分布来看，以珠江三角洲和长江三角洲为 中心的东南沿海地区开展快于中西部地区，南方的开展快于北方。目前开展最快、 模具生产最为集中的省份是广东和浙江，江苏、上海、安徽和山东等地近几年也 有较
14、大开展。虽然我国模具总量目前已到达相当规模，模具水平也有很大提高，但设计制 造水平总体上落后于德、美、日、法、意等工也兴旺国家许多。当前存在的问题 和差距主要表现在以下几方面：（1）总量供不应求国内模具自配率只有70%左右。其中低档模具供过于求，中高档模具自配率只有 50%左右。（2）企业组织结构、产品结构、技术结构和进出口结构均不合理我国模具生产厂中多数是自产自配的工模具车间（分厂），自产自配比例高达60% 左右，而国外模具超过70%属商品模具。专业模具厂大多是“大而全”、“小而 全”的组织形式，而国外大多是“小而专”、“小而精”。国内大型、精密、复 杂、长寿命的模具占总量比例缺乏30%,而
15、国外在50%以上。2004年，模具进出 口之比为3.7:1,进出口相抵后的净进口额达13. 2亿美元，为世界模具净进口 量最大的国家。（3）模具产品水平大大低于国际水平，生产周期却高于国际水平产品水平低主要表现在模具的精度、型腔外表粗糙度、寿命及结构等方面。（4）开发能力较差，经济效益欠佳我国模具企业技术人员比例低，水平较低，且不重视产品开发，在市场中经 常处于被动地位。我国每个模具职工平均年创造产值约合1万美元，国外模具工 业兴旺国家大多是1520万美元，有的高达2530万美元，与之相对的是我国 相当一局部模具企业还沿用过去作坊式管理，真正实现现代化企业管理的企业较 少。造成上述差距的原因很
16、多，除了历史上模具作为产品长期未得到应有的重 视，以及多数国有企业机制不能适应市场经济之外，还有以下几个原因：（1）国家对模具工业的政策支持力度还不够虽然国家已经明确公布了模具行业的产业政策，但配套政策少，执行力度弱。目 前享受模具产品增值税的企业全国只有185家，大多数企业仍旧税负过重。模具 企业进行技术改造引进设备要缴纳相当数量的税金，影响技术进步，而且民营企 业贷款十分困难。（2）人才严重缺乏，科研开发及技术攻关投入太少模具行业是技术、资金、劳动密集的产业，随着时代的进步和技术的开展，掌握 并且熟练运用新技术的人才异常短缺，高级模具钳工及企业管理人才也非常紧 张。由于模具企业效益欠佳及对
17、科研开发和技术攻关重视不够，科研单位和大专 院校的眼睛盯着创收，导致模具行业在科研开发和技术攻关方面投入太少，致使 模具技术开展步伐不大，进展不快。（3）工艺装备水平低，且配套性不好，利用率低近年来我国机床行业进步较快，已能提供比拟成套的高精度加工设备，但与国外 装备相比，仍有较大差距。虽然国内许多企业已引进许多国外先进设备，但总体 的装备水平比国外许多企业低很多。由于体制和资金等方面的原因，引进设备不 配套，设备与附件不配套现象十分普遍，设备利用率低的问题长期得不到较妥善 的解决。（4）专业化、标准化、商品化程度低，协作能力差由于长期以来受“大而全”“小而全”影响，模具专业化水平低，专业分工
18、不细 致，商品化程度低。目前国内每年生产的模具，商品模具只占40%左右，其余为 自产自用。模具企业之间协作不畅，难以完成较大规模的模具成套任务。模具标 准化水平低，模具标准件使用覆盖率低也对模具质量、本钱有较大影响，特别是 对模具制造周期有很大影响。（5）模具材料及模具相关技术落后模具材料性能、质量和品种问题往往会影响模具质量、寿命及本钱，国产模 具钢与国外进口钢材相比有较大差距。塑料、板材、设备性能差，也直接影响模 具水平的提高。目前，我国经济仍处于高速开展阶段，国际上经济全球化开展趋势日趋明显, 这为我国模具工业高速开展提供了良好的条件和机遇。一方面，国内模具市场将 继续高速开展，另一方面
19、，模具制造也逐渐向我国转移以及跨国集团到我国进行 模具采购趋向也十清楚显。因此，放眼未来，国际、国内的模具市场总体开展趋 势前景看好，预计中国模具将在良好的市场环境下得到高速开展，我国不但会成 为模具大国，而且一定逐步向模具制造强国的行列迈进。“十一五”期间，中国 模具工业水平不仅在量和质的方面有很大提高，而且行业结构、产品水平、开发 创新能力、企业的体制与机制以及技术进步的方面也会取得较大开展。模具技术集合了机械、电子、化学、光学、材料、计算机、精密监测和信息 网络等诸多学科，是一个综合性多学科的系统工程。模具技术的开展趋势主要是 模具产品向着更大型、更精密、更复杂及更经济的方向开展，模具产
20、品的技术含 量不断提高，模具制造周期不断缩短，模具生产朝着信息化、无图化、精细化、 自动化的方向开展，模具企业向着技术集成化、设备精良化、产批品牌化、管理 信息化、经营国际化的方向开展。我国模具行业今后仍需提高的共性技术有： （1）建立在CAD/CAE平台上的先进模具设计技术，提高模具设计的现代化、信 息化、智能化、标准化水平。（2）建立在CAM/CAPP基础上的先进模具加工技术与先进制造技术相结合，提高 模具加工的自动化水平与生产效率。（3）模具生产企业的信息化管理技术。例如PDM （产品数据管理）、ERP （企业 资源管理）、M1S （模具制造管理信息系统）及INTERMET平台等信息网络
21、技术的 应用、推广及开展。（4）高速、高精、复合模具加工技术的研究与应用。例如超精冲压模具制造技 术、精密塑料和压铸模具制造技术等。（5）提高模具生产效率、降低本钱和缩短模具生产周期的各种快速经济模具制 造技术。（6）先进制造技术的应用。例如热流道技术、气辅技术、虚拟技术、纳米技术、 高速扫描技术、逆向工程、并行工程等技术在模具研究、开发、加工过程中的应 用（7）原材料在模具中成形的仿真技术。（8）先进的模具加工和专有设备的研究与开发。（9）模具及模具标准件、重要辅件的标准化技术。（10）模具及其制品的检测技术。（11）优质、新型模具材料的研究与开发及其正确应用。（12）模具生产企业的现代化管
22、理技术。模具行业在“十一五”期间需要解决的重点关键技术应是模具信息化、数字化技 术和精密、超精、高速、高效制造技术方面的突破。随着国民经济总量和工业产品技术的不断开展，各行各业对模具的需求量越 来越大，技术要求也越来越高。虽然模具种类繁多，但其开展重点应该是既能满 足大量需要，又有较高技术含量，特别是目前国内尚不能自给，需大量进口的模 具和能代表开展方向的大型、精密、复杂、长寿命模具。模具标准件的种类、数 量、水平、生产集中度等对整个模具行业的开展有重大影响。因此，一些重要的 模具标准件也必须重点开展，而且其开展速度应快于模具的开展速度，这样才能 不断提高我国模具标准化水平，从而提高模具质量，
23、缩短模具生产周期，降低成 本。由于我国的模具产品在国际市场上占有较大的价格优势，因此对于出口前景 好的模具产品也应作为重点来开展。根据上述需要量大、技术含量高、代表开展 方向、出口前景好的原那么选择重点开展产品，而且所选产品必须目前已有一定技 术基础，属于有条件、有可能开展起来的产品。根据“十一五”模具行业开展规划，“十一五”期间模具产品开展重点主要 有如下几类：（1）汽车覆盖件模具冲压模具占模具总量的40%以上。汽车覆盖件模具主要为汽车配套，也包括为农 用车、工程机械和农机配套的覆盖件模具，它在冲压模具中具有很大的代表性， 模具大都是大中型，结构复杂，技术要求高。尤其是为轿车配套的覆盖件模具
24、， 要求更高，可以代表冲压模具的水平。此类模具我国已有一定的技术基础，已为 中档轿车配套，但水平还不高，能力缺乏，目前满足率只有一半左右。中高档轿 车覆盖件模具主要依靠进口，已成为汽车开展的瓶颈，极大的影响着车型开发。（2）精密冲压模具多工位级进模和精冲模代表了冲压模具的开展方向，精度要求寿命要求极高，主 要为电子工业、汽车、仪器仪表、电机电器等配套。这两种模具，国内己有相当 基础，并己引进了国外技术及设备，个别企业生产的产品已到达世界水平，但大 局部企业仍有较大差距，供应总量缺乏，进口很多。（3）大型精密塑料模具塑料模具占模具总量近40%,而且这个比例还在上升。塑料模具中为汽车和家电 配套的
25、大型注塑模具，为集成电路配套的塑封模，为电子信息产业和机械及包装 配套的多层、多腔、多材质、多色精密注塑模，为新型建材及节水农业配套的塑 料异型材挤出模及管路和喷头模具等，目前虽然已有相当技术基础并正在快速发 展，但技术水平与国外仍有较大差距，总量供不应求，每年的进口额达几亿美元。（4）主要模具标准件目前国内已有较大产量的模具标准件主要是模架、导向件、推杆推管、弹性元件 等。这些产品不但国内配套大量需要，出口前景也很好，应继续大力开展。氮气 缸和热流道元件主要依靠进口，应在现有基础上提高水平，形成标准并组织规模 化生产。（5）其他高技术含量的模具占模具总量给8%的压铸模具中，大型薄壁精密压铸技
26、术含量高，难度大。镁合 金压铸模具目前虽然刚起步，但开展前景好，有代表性。子午线橡胶轮胎模具也 是开展方向，其中活络模技术难度最大。与快速成型技术相结合的一些快速制模 技术及相应的快速经济模具具有很好的开展前景。这些高技术含量的模具在“十 一五”期间也应重点开展。standard letter development speed is higher than the common mold product; The plastic mold and the compression casting mold proportion increases; Specialized mold facto
27、ry 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 Zhujiang Delta and Yangtze River delta as central southeast coastal area development qu
28、ickly 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 qua
29、ntity 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 dis
30、play in following several aspects:(1) the total quantity falls short of demanddomestic mold assembl ing oneself 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 st
31、ructure and the import and export structure does not gatherin 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
32、% 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 insuf
33、ficient 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 1ower than the
34、international standardthe 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 mo
35、ld enterprise technical personnel proportion lowthe level is lower, also does not take the product development, frequently is 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 develope
36、d country mostly 15 tolO, 000 US dollars, some reach as high as 25 tolO, 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 fewTo create the above di
37、sparity 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 p
38、olicy support dynamics also insufficientlyalthough 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 s
39、till 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 pers
40、on serious insufficient, the scientific research development and the technical attack investment too urinemold 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
41、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
42、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 not to be big, progresses not quick .(3) the craft equipment level
43、 to be low, also necessary is not good, the use factor low-recent years our country engine bed profession progressed quickly, has been able to provide the quite complete precision work equipment, but compared with the overseas equipment, still had a bigger disparity. Although the domestic many enter
44、prises have introduced many overseas advanced equipment, but the overall equipment level low are very more than the overseas many enterprises. As a result of aspect the and so on system and fund reason, introduces the equipment not not necessary, the equipment and the appendix not necessary phenomen
45、on are extremely common, the equipment utilization rate low question cannot obtain the comparatively properly solution for a long time .(4) specialization, standardization, commercialized degree low, the cooperation abilitybecause receives large and complete small and entire“ the influence since lon
46、g ago, mold specialization level low, the specialized labor division is not careful, the commercialized degree is low. At present domestic every year produces mold, commodity mold minister 40% About, other for from produce uses for oneself. Between the mold enterprise cooperates impeded, completes t
47、he comparatively large-scale mold complete task with difficulty. Mold standardization level low, mold standard letter use cave rare is low also to the mold quality, the cost has a more tremendous influence, specially has very tremendous influence .(5) to the mold manufacture cycle) the mold material
48、 and the mold correlation technology fallsthe mold material performance, the quality and the variety question often can affect the mold quality, the life and the cost, the domestically produced molding tool steel and overseas imports the steel products to compare has a bigger disparity. Plastic, pla
49、te, equipment energy balance, also direct influence mold level enhancement .At present, our country economy still was at the high speed development phase, on the international economical globalization development tendency is day by day obvious, this has provided the good condition and the opportunity for the our country mold industry high speed development. On the one hand, the domestic mold market will continue high speed to develop, on the ot