Mold manufacturing is a typical single-piece, low-volume production method. However, mold manufacturing companies in Japan are responsible for the production of nc-machine tools, machining centers (mc), or cnc EDM equipment. According to the Nagoya gold company staff, due to the use of advanced machining equipment such as CNC machine tools, machining centers, greatly shortened the delivery time of the mold and reduced production costs. The delivery time of the front and rear lampshade injection molds produced by the company is three months, of which the time for cad and cam is about 100 hours each, the machining time is about 100 hours, and the remaining time is polishing and assembly. In this small-scale mold factory, which mainly produces automobile front and rear taillight lampshade injection molds, EDM forming equipment accounts for about 1/3 of the more than 20 machining equipments. CNC milling machines and machining centers account for about 2/3, only 1 The deep bore gun drilling machine is semi-automatic equipment.related information
In Japan's mold manufacturing companies, copy milling machines are rarely used because of the low accuracy of copy milling machines, which increases the amount of polishing work and time. Second, the production of profiling parts increases production costs and time. The use of EDM machines in some mold factories is also decreasing.
At the Toshiba Machine Tool Plant, several copy milling machines were used for ordinary milling. Its staff pointed out: As high-speed milling technology has developed rapidly, and the machining accuracy and efficiency have been continuously improved, and the production cycle has been shortened, the electrodes of electric discharge machining tools not only take time, but also increase the production cost and are likely to be replaced.
In Japan's mold manufacturing industry, the profile milling process has been replaced. Regarding high-speed milling, it is a hot topic in the Japanese mold manufacturing industry and the machine tool industry. One of the key technologies is to require high-precision, high-speed machine tool spindles, and the second is to use high-speed cutting, high temperature resistant milling cutters.
The high-speed milling center model used by Nagoya Gold is Makinoa 77 (three-axis CNC), which uses a special high-speed pneumatic bearing milling head with a speed of up to 20,000 rpm. In the production of forging-based Wanneng Industry Co., Ltd., a forging die is machined using a Matsuura FFX-5 high-speed cnc milling machine (milling cutter rotation speed up to 30,000 rpm, milling accuracy 0.01 mm) manufactured by a joint venture between Switzerland and Japan. The milling machine is also equipped with a dedicated cam. software. Japan okuma metal cutting machine tool company developed and produced a five-axis high-speed mold machining center okumamicr-bi-hp (n = 30000rpm, f = 30m/min), and equipped with the cad / cam software for the machine and products.
Japan's mold industry recession needs to take warning
According to reports, in recent years, the output value of the Japanese mold industry has decreased year by year. Experts believe that the Japanese mold industry has reached the point where it cannot be reformed.
According to industry insiders, compared with other manufacturing industries, the Japanese mold industry has a heavier cost burden on mold processing equipment and a heavier cost burden on mold processing equipment. Therefore, the depreciation rate of equipment directly affects the revenue, plus the main customers,from the car. As semiconductors and other industries gradually moved out of the country, the mold industry in the country had to shift its business focus overseas.
Japan's mold production capacity accounts for about 40% of the world's total, ranking first in the world. However, after peaking at a peak value of 1.87 trillion yen in 1998, it has shown a recession. In addition, based on the large-scale development of molds in other Asian countries and regions, regardless of cost or technology in this region are quite competitive, affected by the establishment of a versatile mold production system, Japan's mold prices have also dropped by about 20% in recent years.
At present, the operating dilemma of the Japanese mold industry can be roughly summed up as order instability, price cuts for orders, inability to cope with the shortened delivery time, high technology, and increasingly stringent quality requirements. In view of this development background, in addition to making more efforts in high-precision machining technology, how to distinguish it from general molds and create high-value-added processing products is the direction of the Japanese mold industry, which is also the face of other Asian countries and regions. New topic.