Metal Parts Products Manufacturers at China

Metal Parts Products —Stamping & CNC Machining Manufacturers

Precision milling technology promotes the development of mold manufacturing

The mold is an important process equipment. It plays an important role in industrial sectors such as consumer goods, electrical appliances, automobiles, and aircraft manufacturing. 75% of the rough machining of industrial products, 50% of the finishing and 90% of the plastic parts will be completed by the mold. At present, China's mold market demand has reached 50 billion yuan. The annual growth rate of automotive molds, especially cover molds, will exceed 20%; Building material molds have also developed rapidly, and various profiled molds, wall and floor molds have become new growth points for molds. The growth of plastic doors and windows and plastic drainage pipes in the next few years will exceed 30%; The annual growth rate of home appliance molds will exceed 10%; The average annual growth rate of the IT industry is more than 20%, and the demand for molds accounts for 20% of the mold market.

The output value of China's machine tool industry will continue to grow in 2015. China's mold manufacturing market has huge potential. According to statistics, in recent years, China's total annual output value of molds has reached 30 billion U.S. dollars. The increase increased from 25% in 2005 to 50% in 2015. Foreign experts predict that Asia ’s share of global mold manufacturing will increase from 25% in 2005 to 50% in 2015.

China's mold industry has developed rapidly, forming two major bases in East China and South China, and gradually expanding to other provinces. (Shandong, Anhui, Sichuan) From 2006 to 2016, the average annual output value of the mold manufacturing industry increased 14%, and in 2013 it increased 25%. In 2013, China's mold output value was 45 billion yuan. The total output ranks third in the world, with export molds of 336.8 million US dollars, an increase of 33.5% over the previous year. However, China's low-tech molds have been oversupplied, and high-precision and complex high-end molds rely heavily on imports. More than 10 billion US dollars of molds are imported each year. Exports exceed $ 2 billion.

The precision of dense mold is required to be 2μm ~ 3μm. Large molds need to meet the requirements of 8000kN clamping force injection molding machine;
Small molds need to meet the requirements of plastic pipes with a diameter of 1mm.
At present, the use of high-precision milling to produce molds has become a major trend in mold manufacturing. In some foreign mold manufacturers, high-speed machine tools have replaced EDM machines in a large area, and high-speed cutting has greatly improved mold production efficiency.
Machine tool companies target mold manufacturing companies, and some machining center manufacturers sell more than 60% of their machine tools to mold processing companies.
High-speed precision milling has gradually replaced EDM finishing molds, which have been widely adopted by foreign mold manufacturing enterprises. High-speed precision milling production of molds has become a major trend in gradual mold manufacturing, greatly improving mold production efficiency and quality.
The use of high-speed precision milling instead of EDM production molds can significantly improve efficiency, mold accuracy and long service life.

Advantages of high-speed precision milling:
◆ The high speed of the tool, the high feed of the machine tool and the high processing speed greatly improve the metal removal rate;

◆ High-speed precision milling reduces small cutting forces;
◆ Most of the high-speed precision milling heat is taken away by chips, and the workpiece generates less heat;
◆ High-speed precision milling reduces vibration and improves machining quality;
◆ Benefits of high-speed processing applied to mold processing
◆ Rapid roughing and semi-finishing to improve machining efficiency; high-speed and high-precision finishing hard cutting instead of finishing, indicating high quality, improved shape accuracy, 50% higher efficiency than EDM processing, and reduced manual grinding;
◆ Hard milling for the final surface. Improve surface quality and shape accuracy (not only low surface roughness, but also high surface brightness), it is more advantageous for processing complex surfaces;
◆ Avoid surface damage caused by EDM processing and increase mold life by 20%;
◆ Combines CAD / CAM technology to quickly process electrodes, especially complex-shaped, thin-walled electrodes.

Problems to be solved by using high-speed precision milling molds
In China, due to financial and technical reasons, the application of high-speed precision milling to produce molds is still in its early stages. There are also machine tools, tools, processes, and other issues that need to be addressed step by step.
The disadvantage is that the processing cost is high, and the use of tools has higher requirements. Cannot use too large tools, it must be supported by complex computer programming technology, equipment running costs are high.
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