Present situation and development countermeasures of forging industry in China
In stamping, at present, about 90% of the stamping lines in major domestic automobile factories use a double-acting stretcher (or multi-link single-acting stretcher) and 4-6 single-acting presses to form a stamping assembly line. The stamping production of large plates is completed by manual loading and unloading, which has low production efficiency and the highest production cycle is only 3-5 times/minute. Personal safety and poor workpiece environment; In the process of manual loading, unloading and conveying of workpieces, it is easy to cause defects such as scratches on workpieces and poor quality of stamping parts; The whole stamping line is about 60 meters long and needs about 20-24 operators. It occupies a large area and has high labor cost. The manufacturing cost of stamping parts is 2-3 times higher than that of foreign countries, which is one of the important factors for the serious lack of market competitiveness of China automobile industry. In China, 90% of stamping lines use manual loading and unloading, and another 10% of stamping lines realize single-machine online automation, with the highest production beat of 6-8 times per minute. However, the application of large-scale multi-position press, which represents the international level of stamping technology today, is still blank in China's automobile industry. This is also the main gap between China's stamping industry and western developed countries, which greatly restricts the development of China's automobile industry.
In hot forging, large-scale free forging equipment has excess capacity, scattered equipment layout, extremely low utilization rate, low degree of mechanization and automation, large machining allowance for forgings, poor working conditions and high labor intensity. Three 800T double-machine linkage rapid forging units have been designed and manufactured in China, but the degree of automation is not high; Domestic metallurgical industry introduces a small number of fast forging units and precision forging production lines; At present, only a few large companies, such as FAW and No.2 Automobile, have introduced the automatic line of hot die forging machine from abroad, and most of them still adopt the mode of combining steam die forging hammer with press die forging, which has a low degree of automation. The die forging of small and medium-sized parts is mainly based on die forging hammer, which is basically operated by hand. The practical application of die forging manipulator in hammer head is rare, and the high-speed automatic hot forging machine mainly depends on imports.
With the development of industrial technology in China, especially the rapid development of automobile industry represented by cars, the output and quality of automobile parts are constantly improving. However, we must clearly realize that there is still a big gap between China and the international advanced level, and with China's accession to the WTO, major international automobile companies will inevitably have a serious impact on China's automobile industry, and the competition among domestic counterparts will become increasingly fierce. The development of China automobile industry cannot be separated from the strong support of equipment industry. Forging equipment manufacturing industry must adapt to the requirements of mass production in automobile industry and develop towards automation and high efficiency.
Large-scale free forging is developing towards numerical control, high precision and specialization; Small and medium-sized free forgings are gradually replaced by precision forging and cold-warm extrusion.
Vigorously develop the automatic line technology of hot die forging for press.
The stamping of automobile panel is developing towards the direction of single machine online automation, especially the large multi-station press. According to foreign experience, it is necessary for enterprises with automobile output above 6.5438+0.5 million to use large-scale multi-station press for continuous automatic stamping to reduce the cost of stamping parts. It can be considered that whoever grasps and uses the large-scale multi-station automatic press first will occupy a competitive advantage in the output, quality and cost of the automobile. China's forging industry must improve its core competitiveness and technical level, adhere to the principle of "China equipment, China equipment", and develop large-scale multi-position presses with first-class technology, first-class quality and domestic price, so as to support the development of automobile industry, improve international competitiveness and revitalize national industries.
Four. General situation of Jinan No.2 Machine Tool Group Co., Ltd. and development level of forging equipment
Our Jinan No.2 Machine Tool Group Co., Ltd. was established in 1937. In 1950s, we developed the first mechanical press and gantry planer in China, heavy forging equipment with mechanical press as the main body, and metal cutting machine represented by milling planer and CNC gantry boring and milling machine. The domestic market share is over 80%, and it is exported to more than 40 countries and regions in the world. It is known as the "King of Forging and Longmen Family" in China. Now it is one of the 520 key enterprises in China and the vanguard of forging industry in China. Developed six categories of products: forging equipment, CNC machine tools, automation products, casting equipment, environmental protection machinery and building materials machinery. The enterprise covers an area of 10 1 10,000 square meters, has1/kloc-0 production plants and 8 wholly-owned subsidiaries, with more than 4,700 employees, including nearly 800 engineers and technicians, and its total assets exceed 1 1 billion yuan.
Establish a technological innovation mechanism, implement the product development strategy of "forging equipment automation and metal cutting machine tool numerical control", and form and continuously develop core technologies and products. In order to master the world's advanced forging equipment development and manufacturing technology as soon as possible, we implemented high-tech grafting, expanded cooperative production with nine companies from the United States, Germany, France, Japan and Sweden, and more than ten domestic universities and research institutes. Industry-University-Research joined hands to speed up the "industrialization" of products, rapidly develop and improve high-tech products such as CNC forging equipment, CNC metal cutting machine tools and automation equipment, and promote the diversified development of products. At the same time, we will strengthen the construction of state-level enterprise technology centers, constantly improve the ability of independent technological innovation and development, develop 40 or 50 new products every year, 90% of which reach the international or domestic advanced level, and the output value of technological progress products accounts for more than 70% of the newly added industrial output value. In 2000, enterprises ranked in the top 50 in the comprehensive evaluation of enterprise technology centers recognized by the state, and they were also selected as the first "Top Ten Excellent Machinery Enterprises in China" and "Top 30 Core Competitiveness of China Machinery Industry".
After introducing the design and manufacturing technology of mechanical press from VERSON Company in the 1980s, the stamping automation technology from ISI Robot Company in the 1990s was introduced. During the period of 1996 -200 1, we cooperated with Komatsu Company of Japan and Moeller Van Gatton Company of Germany to produce large-scale stamping lines, which further developed the core technology and competitiveness of forging equipment, consolidated the dominant position of domestic technology and market, and the products entered international markets such as Europe and America. We have also completed the research and development of loading and unloading machinery, the key equipment for stamping automation of large-scale automobile panels, and jointly designed and manufactured more than 20 single-machine online stamping automation production lines, such as Shanghai GM, and achieved a series of achievements in several key technical fields, such as automatic die changing technology and field bus. The automation technology of single line has reached the international level. Our company also imported the technical data of large-scale multi-position presses from American VERSON Company, and cooperated with German Mueller Vangarton Company to produce two 2000T multi-position presses and exported them to the North American market, which has the technical level and ability to develop, design and manufacture large-scale multi-position presses. At present, large, medium, small, high, medium and low-grade forging equipment and automatic auxiliary machinery series have been formed, including: single-acting, double-acting and single-point, double-point and four-point closed mechanical presses, and various stamping production lines formed by them; Fully automatic stamping line, large multi-station press; Open press, CNC sheet bending machine, CNC shearing machine; Cold extruder, multi-station cold extruder, finishing press; Single machine automatic and on-line automatic stamping device, automatic uncoiling blanking line, turret punch. At the same time, more than 30 series and 100 varieties of CNC machine tools have developed rapidly, forming the ability to provide "high-tech CNC package", which can provide a complete set of equipment for automatic stamping workshop.
Implement transformation from a high starting point and build a world-class manufacturing strength of forging equipment. After the technical transformation of the Seventh Five-Year Plan, the Eighth Five-Year Plan and the Double Plus, the investment in technical transformation was more than 300 million yuan, the construction of the national enterprise technology center was strengthened, and the means of scientific research, design, processing and testing were perfect. More than 300 sets of key equipment and instruments such as large MAAG gear shaper and large CNC machine tools have been added, and the main production equipment is *** 1200 sets. It has three world-class stamping commodity factories such as heavy pressure machine factory, three CNC machine tool commodity factories such as domestic first-class CNC machine tool factory, three blank factories such as China machine tool industry metal structure sample factory, 1 automation equipment factory and 1 specialized processing factory. A powerful manufacturing system has been built, with the annual production capacity of 570 standard sets of various machine tools, which can manufacture the world's largest nominal super-heavy mechanical press and heavy metal cutting machine tools.
Promote management innovation and improve the ability to adapt to market demand. Deepen the management of human resources, strengthen the political and professional training of cadres and workers, establish a salary system for post technical benefits, and improve the competitive incentive mechanism. Implement "life project" and "excellent project", establish and operate a strict quality assurance system, pass the international quality certification of DNV company ISO 900/KLOC-0, and the product quality reaches the international advanced level. Implement "concurrent engineering" and "agile manufacturing engineering", introduce MRPII, and establish a rapid production response mechanism. Strengthen product target cost control and quality comparison procurement to improve enterprise quality. The management level and comprehensive strength of the enterprise rank in the forefront of the national machine tool industry, which provides reliable management guarantee for manufacturing high-quality and high-level forging equipment.
Relying on core technology and core competence, it has provided a large number of advanced equipment for the domestic market. In recent years, our domestic market share of large and heavy mechanical presses has increased to 90%, and we have introduced the first fully automatic stamping production line, first-class intelligent control precision heavy stamping production line and other advanced forging equipment to the market. Since 1997, it has successfully provided seven high-level heavy-duty stamping lines for the headquarters of American General Motors and its branches in Britain, Canada, Thailand and China, creating a precedent for the export of domestic large-scale heavy forging equipment. From 65438 to 0998, presses were exported to African markets in batches. In 2000, we cooperated with Mueller Vangarton of Germany to win the third stamping line of Shanghai GM, two heavy stamping lines of American GM and two large multi-position presses of Mexico. Self-export has also made a major breakthrough, and signed the export contract of 17 mechanical press with German agents. SC2 series presses began to enter the international market in batches, especially the 2000-ton heavy machinery press designed and manufactured by ourselves successfully entered the American market, which marked a major breakthrough in international marketing. In 2000, the total contract value of CNC machine tools increased by 350% over the previous year. The order amount of large-scale CNC gantry boring and milling machine jumped to the first place in the national machine tool industry, and the market share of 200 1 was further improved. After heavy forging equipment, it has become an emerging leading product and won the bid for key national projects such as Shanghai maglev train.
Joining WTO will bring great opportunities and challenges to China's forging industry, automobile, household appliances, aerospace and other user industries, and promote the upgrading and development of forging technology, equipment and market structure. It can be predicted that in the near future, the automatic forging technology will dominate the competitive pattern of China forging equipment market. Relying on the core competence of the enterprise, we have confidence and determination. Together with social peers, we will transform traditional industries with information technology, promote the development and upgrading of forging technology and equipment in China, and strongly support the development of national industries such as automobiles while enhancing international competitiveness.