1、 Mold design and manufactureAssist.Prof.Dr. A. YAYLA作A亞伊拉Mold design and manufacture附件 1：外文資料翻譯譯文 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制造模具和使用模具，但長期未形成產(chǎn)業(yè)。直到 20 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，不僅國有模具企業(yè)有了很大發(fā)展，三資企業(yè)、鄉(xiāng)鎮(zhèn)（個體）模具企業(yè)的發(fā)展也相當迅速。 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，其主要缺口集中于精密、大型、復雜、長壽命模具領域。由于在模具精

2、度、壽命、制造周期及生產(chǎn)能力等方面，中國與國際平均水平和發(fā)達國家仍有較大差距，因此，每年需要大量進口模具。 中國模具產(chǎn)業(yè)除了要繼續(xù)提高生產(chǎn)能力，今后更要著重于行業(yè)內部結構的調整和技術發(fā)展水平的提高。結構調整方面，主要是企業(yè)結構向專業(yè)化調整，產(chǎn)品結構向著中高檔模具發(fā)展，向進出口結構的改進，中高檔汽車覆蓋件模具成形分析及結構改進、多功能復合模具和復合加工及激光技術在模具設計制造上的應用、高速切削、超精加工及拋光技術、信息化方向發(fā)展。 近年，模具行業(yè)結構調整和體制改革步伐加大，主要表現(xiàn)在，大型、精密、復雜、長壽命、中高檔模具及模具標準件發(fā)展速度高于一般模具產(chǎn)品；塑料模和壓鑄模比例增大；專業(yè)模具廠數(shù)量

3、及其生產(chǎn)能力增加；“三資”及私營企業(yè)發(fā)展迅速；股份制改造步伐加快等。從地區(qū)分布來看，以珠江三角洲和長江三角洲為中心的東南沿海地區(qū)發(fā)展快于中西部地區(qū)，南方的發(fā)展快于北方。目前發(fā)展最快、模具生產(chǎn)最為集中的省份是廣東和浙江，江蘇、上海、安徽和山東等地近幾年也有較大發(fā)展。 雖然我國模具總量目前已達到相當規(guī)模，模具水平也有很大提高，但設計制造水平總體上落后于德、美、日、法、意等工業(yè)發(fā)達國家許多。當前存在的問題和差距主要表現(xiàn)在以下幾方面： （1）總量供不應求 國內模具自配率只有 70%左右。其中低檔模具供過于求，中高檔模具自配率只有 50%左右。（2）企業(yè)組織結構、產(chǎn)品結構、技術結構和進出口結構均不合理

4、我國模具生產(chǎn)廠中多數(shù)是自產(chǎn)自配的工模具車間（分廠），自產(chǎn)自配比例高達 60%左右，而國外模具超過 70%屬商品模具。專業(yè)模具廠大多是“大而全”、“小而全”的組織形式，而國外大多是“小而?！?、“小而精”。國內大型、精密、復雜、長壽命的模具占總量比例不足 30%，而國外在 50%以上。2004 年，模具進出口之比為 3.7:1，進出口相抵后的凈進口額達 13.2 億美元，為世界模具凈進口量最大的國家。 （3）模具產(chǎn)品水平大大低于國際水平，生產(chǎn)周期卻高于國際水平 產(chǎn)品水平低主要表現(xiàn)在模具的精度、型腔表面粗糙度、壽命及結構等方面。 （4）開發(fā)能力較差，經(jīng)濟效益欠佳 我國模具企業(yè)技術人員比例低，水平較低

5、，且不重視產(chǎn)品開發(fā)，在市場中經(jīng)常處于被動地位。我國每個模具職工平均年創(chuàng)造產(chǎn)值約合 1 萬美元，國外模具工業(yè)發(fā)達國家大多是 1520 萬美元，有的高達 2530 萬美元，與之相對的是我國相當一部分模具企業(yè)還沿用過去作坊式管理，真正實現(xiàn)現(xiàn)代化企業(yè)管理的企業(yè)較少。 造成上述差距的原因很多，除了歷史上模具作為產(chǎn)品長期未得到應有的重視，以及多數(shù)國有企業(yè)機制不能適應市場經(jīng)濟之外，還有下列幾個原因：（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(jīng)明確頒布了模具行業(yè)的產(chǎn)業(yè)政策，但配套政策少，執(zhí)行力度弱。目前享受模具產(chǎn)品增值稅的企業(yè)全國只有 185 家，大多數(shù)企業(yè)仍舊稅負過重。模具企業(yè)進行技術改造引進設備

6、要繳納共 5 頁 第 1 頁 相當數(shù)量的稅金，影響技術進步，而且民營企業(yè)貸款十分困難。 （2）人才嚴重不足，科研開發(fā)及技術攻關投入太少 模具行業(yè)是技術、資金、勞動密集的產(chǎn)業(yè)，隨著時代的進步和技術的發(fā)展，掌握并且熟練運用新技術的人才異常短缺，高級模具鉗工及企業(yè)管理人才也非常緊張。由于模具企業(yè)效益欠佳及對科研開發(fā)和技術攻關重視不夠，科研單位和大專院校的眼睛盯著創(chuàng)收，導致模具行業(yè)在科研開發(fā)和技術攻關方面投入太少，致使模具技術發(fā)展步伐不大，進展不快。 （3）工藝裝備水平低，且配套性不好，利用率低 近年來我國機床行業(yè)進步較快，已能提供比較成套的高精度加工設備，但與國外裝備相比，仍有較大差距。雖然國內許多

7、企業(yè)已引進許多國外先進設備，但總體的裝備水平比國外許多企業(yè)低很多。由于體制和資金等方面的原因，引進設備不配套，設備與附件不配套現(xiàn)象十分普遍，設備利用率低的問題長期得不到較妥善的解決。 （4）專業(yè)化、標準化、商品化程度低，協(xié)作能力差 由于長期以來受“大而全”“小而全”影響，模具專業(yè)化水平低，專業(yè)分工不細致，商品化程度低。目前國內每年生產(chǎn)的模具，商品模具只占 40%左右，其余為自產(chǎn)自用。模具企業(yè)之間協(xié)作不暢，難以完成較大規(guī)模的模具成套任務。模具標準化水平低，模具標準件使用覆蓋率低也對模具質量、成本有較大影響，特別是對模具制造周期有很大影響。 （5）模具材料及模具相關技術落后 模具材料性能、質量和品

8、種問題往往會影響模具質量、壽命及成本，國產(chǎn)模具鋼與國外進口鋼材相比有較大差距。塑料、板材、設備性能差，也直接影響模具水平的提高。 目前，我國經(jīng)濟仍處于高速發(fā)展階段，國際上經(jīng)濟全球化發(fā)展趨勢日趨明顯，這為我國模具工業(yè)高速發(fā)展提供了良好的條件和機遇。一方面，國內模具市場將繼續(xù)高速發(fā)展，另一方面，模具制造也逐漸向我國轉移以及跨國集團到我國進行模具采購趨向也十分明顯。因此，放眼未來，國際、國內的模具市場總體發(fā)展趨勢前景看好，預計中國模具將在良好的市場環(huán)境下得到高速發(fā)展，我國不但會成為模具大國，而且一定逐步向模具制造強國的行列邁進。“十一五”期間，中國模具工業(yè)水平不僅在量和質的方面有很大提高，而且行業(yè)結

9、構、產(chǎn)品水平、開發(fā)創(chuàng)新能力、企業(yè)的體制與機制以及技術進步的方面也會取得較大發(fā)展。 模具技術集合了機械、電子、化學、光學、材料、計算機、精密監(jiān)測和信息網(wǎng)絡等諸多學科，是一個綜合性多學科的系統(tǒng)工程。模具技術的發(fā)展趨勢主要是模具產(chǎn)品向著更大型、更精密、更復雜及更經(jīng)濟的方向發(fā)展，模具產(chǎn)品的技術含量不斷提高，模具制造周期不斷縮短，模具生產(chǎn)朝著信息化、無圖化、精細化、自動化的方向發(fā)展，模具企業(yè)向著技術集成化、設備精良化、產(chǎn)批品牌化、管理信息化、經(jīng)營國際化的方向發(fā)展。我國模具行業(yè)今后仍需提高的共性技術有：（1）建立在 CAD/CAE 平臺上的先進模具設計技術，提高模具設計的現(xiàn)代化、信息化、智能化、標準化水平

10、。 （2）建立在 CAM/CAPP 基礎上的先進模具加工技術與先進制造技術相結合，提高模具加工的自動化水平與生產(chǎn)效率。 （3）模具生產(chǎn)企業(yè)的信息化管理技術。例如 PDM（產(chǎn)品數(shù)據(jù)管理）、ERP（企業(yè)資源管理）、MIS（模具制造管理信息系統(tǒng)）及 INTERMET 平臺等信息網(wǎng)絡技術的應用、推廣及發(fā)展。（4）高速、高精、復合模具加工技術的研究與應用。例如超精沖壓模具制造技術、精密塑料和壓鑄模具制造技術等。 （5）提高模具生產(chǎn)效率、降低成本和縮短模具生產(chǎn)周期的各種快速經(jīng)濟模具制造技術。 （6）先進制造技術的應用。例如熱流道技術、氣輔技術、虛擬技術、納米技術、高速掃描技術、逆向工程、并行工程等技術在模

11、具研究、開發(fā)、加工過程中的應用 （7）原材料在模具中成形的仿真技術。 （8）先進的模具加工和專有設備的研究與開發(fā)。 （9）模具及模具標準件、重要輔件的標準化技術。 （10）模具及其制品的檢測技術。 （11）優(yōu)質、新型模具材料的研究與開發(fā)及其正確應用。 （12）模具生產(chǎn)企業(yè)的現(xiàn)代化管理技術。 模具行業(yè)在“十一五”期間需要解決的重點關鍵技術應是模具信共 5 頁 第 2 頁 息化、數(shù)字化技術和精密、超精、高速、高效制造技術方面的突破。 隨著國民經(jīng)濟總量和工業(yè)產(chǎn)品技術的不斷發(fā)展，各行各業(yè)對模具的需求量越來越大，技術要求也越來越高。雖然模具種類繁多，但其發(fā)展重點應該是既能滿足大量需要，又有較高技術含量，

12、特別是目前國內尚不能自給，需大量進口的模具和能代表發(fā)展方向的大型、精密、復雜、長壽命模具。模具標準件的種類、數(shù)量、水平、生產(chǎn)集中度等對整個模具行業(yè)的發(fā)展有重大影響。因此，一些重要的模具標準件也必須重點發(fā)展，而且其發(fā)展速度應快于模具的發(fā)展速度，這樣才能不斷提高我國模具標準化水平，從而提高模具質量，縮短模具生產(chǎn)周期，降低成本。由于我國的模具產(chǎn)品在國際市場上占有較大的價格優(yōu)勢，因此對于出口前景好的模具產(chǎn)品也應作為重點來發(fā)展。根據(jù)上述需要量大、技術含量高、代表發(fā)展方向、出口前景好的原則選擇重點發(fā)展產(chǎn)品，而且所選產(chǎn)品必須目前已有一定技術基礎，屬于有條件、有可能發(fā)展起來的產(chǎn)品。Mold design an

13、d manufactureThe mold is the manufacturing industry important craft foundation, in our country, the moldmanufacture belongs to the special purpose equipment manufacturing industry. China although veryalready starts to make the mold and the use mold, but long-term has not formed the industry. Straigh

14、tstabs 0 centuries 80s later periods, the Chinese mold industry only then drives into the developmentspeedway. Recent years, not only the state-owned mold enterprise had the very big development, thethree investments enterprise, the villages and towns (individual) the mold enterprises developmentals

15、o quite rapid . Although the Chinese mold industrial development rapid, but compares with thedemand, obviously falls short of demand, its main gap concentrates precisely to, large-scale, iscomplex, the long life mold domain. As a result of in aspect and so on mold precision, life,manufacture cycle a

16、nd productivity, China and the international average horizontal and thedeveloped country still had a bigger disparity, therefore, needed massively to import the mold everyyear . The Chinese mold industry except must continue to sharpen the productivity, from now on willhave emphatically to the profe

17、ssion internal structure adjustment and the state-of-art enhancement.The structure adjustment aspect, mainly is the enterprise structure to the specialized adjustment, theproduct structure to center the upscale mold development, to the import and export structureimprovement, center the upscale autom

18、obile cover mold forming analysis and the structureimprovement, the multi-purpose compound mold and the compound processing and the lasertechnology in the mold design manufacture application, the high-speed cutting, the superfinishingand polished the technology, the information direction develops .

19、The recent years, the moldprofession 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 letterdevelopment speed is higher than the common mold product; The plastic mold

20、and the compressioncasting mold proportion increases; Specialized mold factory quantity and its productivity increase;The three investments and the private enterprise develops rapidly; The joint stocksystem transformation step speeds up and so on. Distributes from the area looked, take ZhujiangDelta

21、 and Yangtze River delta as central southeast coastal area development quickly to mid-westarea, south development quickly to north. At present develops quickest, the mold produces the mostcentralized province is Guangdong and Zhejiang, places such as Jiangsu, Shanghai, Anhui andShandong also has a b

22、igger development in recent years . Although our country mold total quantityhad at present achieved the suitable scale, the mold level also has the very big enhancement, afterbut design manufacture horizontal overall rise and fall industry developed country and so on Yu De,America, date, France, Ita

23、ly many. The current existence question and the disparity mainly display infollowing several aspects: (1) The total quantity falls short of demand Domestic mold assembling共 5 頁 第 3 頁 oneself rate only ,about 70%. Low-grade mold , center upscale mold assembling oneself rate onlyhas 50% about . (2) Th

24、e enterprise organizational structure, the product structure, the technicalstructure and the import and export structure does not gather Iin our country mold production factoryto be most is from the labor mold workshop which produces assembles oneself (branch factory),from produces assembles oneself

25、 the proportion to reach as high as about 60%, but the overseasmold ultra 70% is the commodity mold. The specialized mold factory mostly is large andcomplete, small and entire organization form, but overseas mostly is small but, is speciallysmall and fine. Domestic large-scale, precise, complex, the

26、 long life mold accounts for the totalquantity proportion to be insufficient 30%, but overseas in 50% above 2004 years, ratio of the moldimport and export is 3.7:1, the import and export balances the after net import volume to amount to1.32 billion US dollars, is world mold net import quantity bigge

27、st country . (3) The mold productlevel greatly is lower than the international standard The production cycle actually is higher than theinternational water broad product level low mainly to display in the mold precision, cavity aspectand so on surface roughness, life and structure .(4) Develops the

28、ability badly, economic efficiency unsatisfactory our country mold enterprisetechnical personnel proportion low The 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 creationoutput value approximat

29、ely ,ten thousand US dollars, overseas mold industry developed countrymostly 15 to10,000 US dollars, some reach as high as 25 to10,000 US dollars, relative is our countryquite part of molds enterprises also continues to use the workshop type management with it, trulyrealizes the enterprise which the

30、 modernized enterprise manages few To create the above disparitythe reason to be very many, the mold long-term has not obtained the value besides the history in asthe product which should have, as well as the most state-owned enterprises mechanism cannot adaptthe market economy, but also has the fol

31、lowing several reasons: . (1) Country to mold industrypolicy support dynamics also insufficiently Although the country already was clear about haspromulgated the mold profession industrial policy, but necessary policy few, carried out dynamics tobe weak. At present enjoyed the mold product increment

32、 duty enterprise nation 185, the majorityenterprise still the tax burden is only overweight. The mold enterprise carries on the technologicaltransformations introduction equipment to have to pay the considerable amount the tax money,affects the technology advancement, moreover privately operated ent

33、erprise loan extremelydifficult . (2) Talented person serious insufficient, the scientific research development and thetechnical attack investment too urine Mold profession is the technology, the fund, the work crowdedindustry, along with the time progress and the technical development, grasps the t

34、alented personwhich and skilled utilizes the new technology exceptionally short, the high-quality mold fitter andthe enterprise management talent extremely is also anxious. Because the mold enterprise benefitunsatisfactory and takes insufficiently the scientific research development and the technica

35、l attack,the scientific research unit and the universities, colleges and institutes eye stares at is creatingincome, causes the moldprofession invests too few in the scientific research development and the technical attack aspect,causes the mold technological development step not to be big, progress

36、es not quick . (3) The craftequipment level to be low, also necessary is not good, the use factor low recent years our countryengine bed profession progressed quickly, has been able to provide the quite complete precisionwork equipment, but compared with the overseas equipment, still had a bigger di

37、sparity. Althoughthe domestic many enterprises have introduced many overseas advanced equipment, but the overallequipment level low are very more than the overseas many enterprises. As a result of aspect the andso on system and fund reason, introduces the equipment not not necessary, the equipment a

38、nd the共 5 頁 第 4 頁 appendix not necessary phenomenon are extremely common, the equipment utilization rate lowquestion cannot obtain the comparatively properly solution for a long time . (4) Specialization,standardization, commercialized degree low, the cooperation ability Because receives large andco

39、mplete small and entire the influence since long ago, mold specialization level low, thespecialized labor division is not careful, the commercialized degree is low. At present domesticevery year produces mold, commodity mold minister 40% About, other for from produce uses foroneself. Between the mol

40、d enterprise cooperates impeded, completes the comparatively large-scalemold complete task with difficulty. Mold standardization level low, mold standard letter use caverare is low also to the mold quality, the cost has a more tremendous influence, specially has verytremendous influence . (5) To the

41、 mold manufacture cycle) the mold material and the moldcorrelation technology falls The mold material performance, the quality and the variety questionoften can affect the mold quality, the life and the cost, the domestically produced molding tool steeland overseas imports the steel products to comp

42、are has a bigger disparity. Plastic, plate, equipmentenergy balance, also direct influence mold level enhancement .At present, our country economy still was at the high speed development phase, on the internationaleconomical globalization development tendency is day by day obvious, this has provided

43、 the goodcondition and the opportunity for the our country mold industry high speed development. On the onehand, the domestic mold market will continue high speed to develop, on the other hand, the moldmanufacture also gradually will shift as well as the transnational group to our country carries on

44、 themold purchase trend to our country extremely to be also obvious. Therefore, will take a broad viewthe future, international, the domestic mold market overall development tendency prospect willfavor, estimated the Chinese mold will obtain the high speed development under the good marketenvironmen

45、t, our country not only can become the mold great nation, moreover certainly graduallywill make the powerful nation to the mold the ranks to make great strides forward. 15 period, theChinese mold industry level not only has the very big enhancement in the quantity and the archerytarget aspect, moreo

46、ver the profession structure, the product level, the development innovationability, enterprises system and the mechanism as well as the technology advancement aspect alsocan obtain a bigger development . The mold technology has gathered the machinery, the electron,chemistry, optics, the material, th

47、e computer, the precise monitor and the information network and soon many disciplines, is a comprehensive nature multi-disciplinary systems engineering. The moldtechnology development tendency mainly is the mold product to larger-scale, preciser, morecomplex and a more economical direction develops,

48、 the mold product technical content unceasinglyenhances, the mold manufacture cycle unceasingly reduces, the mold production faces theinformation, is not having the chart, is fine, the automated direction develops, the mold enterprise tothe technical integration, the equipment excellent, is producin

49、g approves the brand, the managementinformation, the management internationalization direction develops. Our country mold professionstill will have to enhance from now on the general character technology had :(1) To establish in the CAD/CAE platform the advanced mold design technology, enhancesmoder

50、nization which the mold designed, information, intellectualization, standardized level . (2)Establishes in the CAM/CAPP foundation the advanced mold processing technology and theadvanced manufacture technology unifies, raises the automated level and the production efficiencywhich the mold processes

51、. (3) The mold production enterprises information managementtechnology. For example PDM (product data management), ERP (enterprise resource management),MIS (mold manufacture management information system) and information network technology theand so on INTERMET platform application, the promotion an

52、d the development . (4) Are highspeed, Gao Jing, the compound mold processing technology research and the application. For共 5 頁 第 5 頁 example the ultra fine ramming mold manufacture technology, the precise plastic and thecompression casting mold manufacture technology and so on . (5) Enhances the mo

53、ld productionefficiency, reduces the cost and reduces the mold production cycle each kind of fast economicalmold manufacture technology . (6) The advanced manufacture technology application. For examplehot technology and so on flow channel technology, gas auxiliary technology, hypothesizedtechnology

54、, nanotechnology, rapid scanning technology, reversion project, parallel project in themold research, the development, the processing process application . (7) The raw material thesimulation technology which forms in the mold . (8) The advanced mold processing and theappropriation equipment research

55、 and the development . (9) The mold and the mold standard letter,the important auxiliary standardized technology . (10) The mold and its the product examinationtechnology. (11) High quality, the new mold material research and the development and its thecorrect application .(12) The mold production enterprises modern management technology Mold profession in 十15 period needs to solve the key essential technology should be the mold information, the digitizedtechnology and precise, ultra fine, high speed, the