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As the main equipment of the current machining industry, the machine tool has become a symbol of the development of the domestic machinery processing industry. CNC machine tools are the masters of the manufacturing equipment industry and are the strategic equipment for advanced production technology and military modernization.
High-end CNC machine tools refer to digitalized CNC machine tools with high-speed, precision, intelligence, compound, multi-axis linkage, and network communications. The high-end CNC machine tool is a representative of the world's advanced machine tool equipment. Its development symbolizes that the country's current machine tool manufacturing industry accounts for the advanced stage of the development of the machine tool industry worldwide. Therefore, the internationalization of five-axis linkage CNC machine tools and other high-end machine tool technology as an important national industrialization Sign.
The high-end CNC machine tools, based on the traditional CNC machine tools, can complete the work efficiency of an automated production line, which is the product of the development of science and technology speed. For the country, this is an improvement in the nature of the machine tool manufacturing industry. High-end CNC machine tools integrate a variety of high-end technologies, applied to complex surfaces and automated processing, and have a very close relationship with the equipment manufacturing industry in aerospace, marine, machinery manufacturing, high-precision equipment, military industry, medical equipment industry and other fields. relationship.
"Made in China" "2025" lists CNC machine tools and basic manufacturing equipment as "a strategically important area for accelerating breakthroughs," which calls for strengthening forward-looking deployment and key technological breakthroughs, actively planning to seize manufacturing sites for future technology and industrial competition, and improving international Division of labor and discourse power.
First, the development status of high-end CNC machine tools at home and abroad
The United States, Germany and Japan are the countries with the most advanced skills and experience in the research, design, production and application of CNC machine tools.
The characteristics of the United States are: The government focuses on the machine tool industry, and the US Department of Defense and other departments continue to put forward the development direction of the machine tool, scientific research tasks, and the provision of adequate funding. It also recruits talent from the world, pays special attention to "efficiency" and "innovation," and pays attention to basic scientific research. Haas Automation is one of the world's largest manufacturers of CNC machine tools, with a market share of approximately 40% in North America. All machine tools are manufactured entirely in California, USA, with nearly 100 models of CNC vertical and horizontal machining centers. CNC lathes, turntables, and indexers. Haas is committed to creating more accurate, repeatable, durable, and reasonably priced machine tool products.
On the basis of traditional design and manufacturing technology and advanced technology, German CNC machine tools continue to adopt advanced electronic information technology and innovate and develop on the basis of strengthening scientific research. The main components of the German CNC machine tools, machine, electricity, liquid, gas, light, tool, measurement, numerical control system and other functional components rank the forefront in the world in terms of quality and performance. The highest level of the large-scale gantry processing center is the product of WALDRICH COBURG of Germany, and the domestic one of Beiyi Machine is the technology of Germany's Vaderrich Coburg.
The Japanese government encourages scientific institutions and companies to develop CNC machine tools by planning and formulating regulations and providing sufficient R&D funds. In the area of ​​machine tool components, Japan has studied Germany; in the development of numerical control technology and numerical control systems, the United States has learned and improved and developed the achievements of the two countries with great success. Japanese machine tools should also be world famous for Japanese precision manufacturing.
The difference in structure between domestic products and foreign products is not large, and the new technologies adopted are similar, but there is still a certain gap between advanced technology applications and manufacturing process levels and advanced countries in the world. The new product development capability and manufacturing cycle can not meet the needs of domestic users. The accuracy of parts manufacturing and overall machine accuracy and reliability still need to be greatly improved, especially in the CNC system and functional components such as tool magazines that are matched with large-scale machine tools. Parts such as manipulators and two-axis milling heads need to be supported by foreign manufacturers. The manufacturing capacity of large-scale domestic machine tool manufacturers is very strong, but they are large but not sophisticated. The main reason is that the processing equipment is backward, and the numerical control rate is very low, especially the lack of high-precision level processing equipment. At the same time, domestic companies generally lack the capacity for independent innovation. Because of the market demand characteristics of large-size bedsheets and small batches, the requirements for technological innovation have become higher.
Second, the development status of domestic and foreign numerical control systems
After sustained research and development and innovation, Germany, the United States, Japan and other countries have basically mastered the leading technology of CNC systems. At present, there are two main camps in the field of numerical control technology research and application: one is a professional numerical control system manufacturer represented by FANUC and Siemens; the other is MAZAK and Dema. DMG is a large-scale machine tool manufacturer that independently develops numerical control systems.
Although the domestic high-end numerical control system still has a certain gap in terms of function, performance and reliability compared with foreign countries, in recent years, Huazhong CNC, aerospace numerical control, Beijing Institute of Electrical and Mechanical Technology, Beijing sculpture and other units in multi-axis linkage control, function combination, Networking, intelligence, and openness have also achieved some success.
Third, the development trend of high-end CNC machine tools at home and abroad
At present, the development of CNC machine tools and systems is changing with each passing day. As an important equipment in the field of intelligent manufacturing, in addition to the intelligentization, networking, and flexibility of CNC machine tools, high-speed, high-precision, composite, open, parallel-driven, Greening has also become a technological direction for the development of high-end CNC machine tools in the future.
1, high speed
With the rapid development of industries such as automobiles, defense, aerospace, and aerospace, as well as the application of new materials such as aluminum alloys, the requirements for high-speed machining of CNC machine tools are increasing.
2, new functional components applications
In order to improve the performance of various aspects of CNC machine tools, the application of new functional components with high precision and high reliability becomes inevitable.
In recent years, the application of linear motors has become increasingly widespread, such as: Siemens 1FN1 series three-phase AC permanent magnet synchronous linear motors have been widely used in high-speed milling machines, machining centers, grinding machines, parallel machine tools and dynamic performance and high precision requirements The machine tools, etc.; Germany EX-CELL-O company's XHC horizontal machining center three-way drive uses two linear motors.
3, high reliability
Five-axis linkage CNC machine tool can process complex surfaces and can guarantee that the average time between failures is above 20000h. This is an efficient use of products and raw materials. There are a variety of alarm measures within it to enable operators to deal with problems in a timely manner. It also has super safe protection measures. This is a guarantee for products, and it is also a guarantee for operators and the society. The high reliability of the machine tool allows the machine to be more assured in production and saves the company's raw materials and labor. This is a saving of social resources. However, in foreign countries, the average time between failures of the equipment is more than 30,000 hours, and the gap exists in China. CNC machine tool companies learn more from foreign technology, but also more carefully study more perfect high-end CNC machine tools.
4, high precision
The reason why high-end CNC machine tools can reflect the level of a country's industrial manufacturing industry is precisely because of its high-precision features. With the development of the CAM (Computer Aided Manufacturing) system, high-end CNC machines are capable of not only high speed, high efficiency, and most importantly, machining accuracy has evolved from wire-level accuracy to micro-level accuracy, and its unique reciprocating motion unit enables extremely detailed processing. Groove processing; The use of light, electrochemical energy and other special processing precision can reach nanometer level. At the same time, after the improvement and optimization of the structure, the machining accuracy of the 5-axis linkage CNC machine tool can also enter the ultra-precision era of submicrons and even nanometers.
5. Compounding
With the changing market demands, the manufacturing industry is becoming more and more fierce. This requires more than just single-piece mass production of machine tools. It is also required to be able to complete small-lot and multi-variety production. This requires higher machine tools and mechanization. More personalized production. Developed a compound machine tool with a higher degree of compounding so that it can produce a variety of large and small batches of similar production models. This is a new type of requirement for high-end CNC machine tools. It will also dominate the future development. This will be a new task for the new CNC machine tool.
6, the process of greening
With increasingly stringent environmental and resource constraints, the greening of manufacturing and processing becomes more and more important, and China's resources and environmental issues are particularly prominent. Therefore, in recent years, there has been a continuous and growing development of machine tools that eliminate or minimize the use of coolant and achieve dry cutting and semi-dry cutting. In the 21st century, the major trend of green manufacturing will accelerate the development of various energy-saving and environmental protection machine tools and occupy more world markets.
Fourth, China's high-end numerical control machine tool development analysis
China's machine tool industry occupies an important position in the world's machine tool industry system and the global machine tool market, but at present it cannot be considered as a machine tool powerhouse. Compared with the powerful machine tools in the world, China's machine tool industry still has a certain gap, especially in the competitiveness of medium and high-end machine tools is not strong. In addition, due to the complex economic situation at home and abroad, the development of China's machine tool industry has returned to the new normal, and the requirements for the transformation and upgrading of high-end industries are urgent.
For many years, China has become the world's largest producer, consumer, and importer of machine tool equipment. In the next 10 years, electronics and communications equipment, aerospace equipment, rail transportation equipment, power equipment, automobiles, ships, construction machinery and agricultural machinery will be included.
The rapid development of key industries and the continuous improvement of new materials and technologies will bring new strategic requirements and transformation challenges for CNC machine tools and basic equipment. The demand for CNC machine tools and basic manufacturing equipment will shift from low-to-high grades to high grades, from single units to manufacturing units and complete systems that include robot loading and unloading and on-line inspection functions, from digitization to intelligentization, and personality tailored to universal machine tools. The transformation of machine tools, electronics and communications equipment manufacturing equipment will be the new demand hot spots.
1, on key products
It will focus on the development of key industries such as aerospace equipment, automobiles, and electronic information equipment, and will produce high-end CNC machine tools, advanced forming equipment, and group production lines. Including: electronic information equipment processing equipment, aerospace equipment large-scale structural parts manufacturing and assembly equipment, aerospace engine manufacturing key equipment, marine and marine engineering equipment key manufacturing equipment, rail transportation equipment key parts and components complete processing equipment, automotive key parts processing complete Equipment and production lines, four major automotive assembly production lines, large-capacity power equipment manufacturing equipment, engineering and agricultural machinery production lines and other products.
2, high-end CNC system
Focus on the development of multi-axis, multi-channel, high-precision interpolation, dynamic compensation and intelligent programming, intelligent NC system with self-monitoring, maintenance, optimization, reorganization, etc.; provide a standardized basic platform, allowing developers, different software and hardware modules Involved, an open CNC system with standard interfaces, modularity, portability, extensibility, and interchangeability.
3, the key common technical
In recent years, the research on basic and common technology of machine tools has been continuously strengthened, and product development and technology research have been promoted simultaneously. The maturity of a number of key technologies, such as reliability design and performance test technology of machine tool products and multi-axis linkage processing technology, has been greatly improved. The digital design technology research results are applied in the design of high-precision CNC coordinate boring machines, vertical machining centers, and other products; multi-error real-time dynamic comprehensive compensation and embedded CNC system error compensation software and hardware systems are applied to multiple companies and multiple products. Demonstration applications have been made, so that the accuracy of CNC machine tools has been significantly improved.
In the future, we will focus on digital collaborative design and 3D/4D full manufacturing process simulation technology, precision and ultra-precision machine tool reliability and precision maintenance technology, complex profile and difficult-to-machine materials, efficient processing and forming technology, and 100% on-line inspection technology.
4, in the application of demonstration projects
The national science and technology major project “Intelligent Upscale CNC Machine Tools and Basic Manufacturing Equipment†intelligent upgrading project, aerospace high-end manufacturing equipment application demonstration project, automobile lightweight material key components and assembly new process equipment application demonstration project, ship plane/surface Intelligent processing line application demonstration project.
5. Suggestions on strategic support and protection:
The first is the establishment of a national general technical cooperation innovation center for numerical control machine tools, focusing on solving digital design technology, dynamic and static thermal characteristic test technologies, and reliability and accuracy maintenance and other key control technologies;
The second is to establish a national advanced molding process innovation center and promote the close integration of manufacturing process and manufacturing equipment.
It can slow down the reaction, maintain chemical balance, reduce surface tension, prevent light, thermal decomposition or oxidative decomposition. it mainly includes lead salts, metal soaps, organic tin, organic antimony, organic rare earths, pure organic compounds. Thermal stabilizers commonly used in industry mainly include lead salts, metal soaps, organic tin, organic antimony, organic rare earths, pure organic compounds, etc.
1.1 Organotin
(1) Excellent transparency The biggest advantage of organotin stabilizers is that they have excellent transparency. The use of organotin stabilizers in PVC formulations can produce crystalline products. Because of this, organic tin can be used in bottles, containers, corrugated boards, various types of rigid packaging containers, hoses, profiles, films, etc.
(2) Extraordinary thermal stability In terms of thermal stability, there is no other type of thermal stabilizer that can surpass it. Therefore, it is the preferred stabilizer for rigid PVC, and some varieties have better performance in soft products. Suitable for all PVC homopolymers, such as emulsion, suspension and bulk PVC, as well as vinyl chloride copolymers, graft polymers and polymer blends.
(3) The product is non-toxic. Most organotin stabilizers are non-toxic, and the migration of organotin stabilizers in rigid PVC is minimal. Therefore, organotin stabilizers are the preferred heat stabilizers for PVC for food contact.
(4) Good compatibility. Organotin stabilizers have good compatibility with PVC, so there is generally no precipitation on the metal surface, such as lead salt stabilizers and metal soap stabilizer systems.
(5) Poor lubricity Sulfur-containing tin stabilizers have poor self-lubricity. Therefore, many commercially available sulfur-containing organotins are equipped with lubricants to prevent hot melt from adhering to processing equipment during processing.
(6) High cost Compared with other types of stabilizers, the overall performance of organotin stabilizers is closer to the ideal stabilizer. However, all organotin stabilizers, regardless of their structure, have the main disadvantage that their manufacturing cost is much higher than that of lead stabilizers or metal soap compounds. In recent years, by adopting new synthetic technology, or reducing its usage in formulas, its formula cost has been reduced. In the 1970s, foreign countries developed low-priced tin products, which reduced the tin content, which also reduced the price to a certain extent.
1.2 Lead salt
(1) l Excellent stability experiments proved that among the commonly used basic lead salts, the heat resistance of sulfite is better than that of sulfate, and the heat resistance of sulfate is better than that of phosphite. The tribasic lead sulfate, which is widely used in the PVC industry, has a higher effective lead content and shows better thermal stability than other products.
(2) Excellent insulation. Because lead salt is non-ionic and non-conductive, it is inert, which makes lead salt stabilizers widely used in wire and cable industries.
(3) Excellent weather resistance. Many salt compounds can act as white pigments and can show strong covering power, so they have strong weather resistance.
(4) Poor transparency Transparency is a problem related to weather resistance. When used in wires, cables and record materials, there is no need to care about transparency, because most of these products are white or very dark black.
(5) Inexpensive lead salt stabilizer is the lowest price among all stabilizers. Therefore, despite the continuous introduction of new stabilizers, lead salt stabilizers still dominate the stabilizer market after half a century. The composite lead salt introduced to solve the dust and dispersion problem has increased in price, but still maintains a competitive advantage with other types of stabilizers.
(6) The toxicity of the toxic lead salt stabilizer limits its application in many occasions with strict hygiene requirements. For example, many countries have revised the lead content standards in drinking water, and it is no longer possible to use lead salt in PVC water pipes.
(7) Poor dispersibility The dispersibility of salt lead is poor, but the newly launched one-package product is equipped with lubricants, which solves the dispersibility problem to a certain extent. Because of the above characteristics of lead salt stabilizers, they are especially suitable for high-temperature processing. They are widely used in various opaque hard and soft products and cable materials, such as various pipes, plates, indoor and outdoor profiles, foam plastics, artificial leather, and wires. Cables, records, welding rods, etc. The most important lead salt stabilizers are tribasic lead sulfate, dibasic lead phosphite, and dibasic lead stearate.
1.3 Organic antimony
(1) Better stability. The organic antimony stabilizer has basically the same color stability and lower melt viscosity as organotin at the same temperature. In the twin-screw extrusion process, the effect is particularly outstanding when used in combination with calcium stearate. .
(2) The price of organic antimony stabilizer is much lower than that of methyl tin or butyl tin. In addition, the amount of organic antimony used is relatively low, so the use of organic antimony can achieve a better performance/price balance.
(3) The product is non-toxic. In the United States, when a twin-screw extruder is used to manufacture PVC pipes, the PVC water supply pipe manufactured with a formula composed of antimony stabilizers, calcium stearate and other lubricants conforms to the U.S. NSF (National Sanitation Foundation) )Regulation.
(4) Poor transparency and light stability. The transparency of organic antimony compounds is not as good as organotin stabilizers, and it is also lower than the barium/fu and calcium/zinc metal soap system. It is close to lead salts and has poor light stability, so antimony is stable. The agent is mostly used for indoor products without color requirements. The antimony stabilizer itself is also required to be stored in an opaque container.
(5) Poor lubricity. Antimony stabilizers have poor lubricity. Therefore, its use must be combined with a large amount of lubricant without exception.
1.4 Metal soap
(1) The tin soap stabilizer Fu soap is the best type of metal soap. Its advantages are also reflected in the absence of initial coloring, and can produce colorless and transparent products; excellent light stability; it has the effect of preventing precipitation and adhesion. . However, because tin salt is toxic, there are strict regulations on its manufacture and use in the Labor Safety and Health Law. In recent years, the use of Fuzao has shown a downward trend.
(2) Zinc soap stabilizerThe thermal stability of zinc-based stabilizer to PVC is extremely poor. The sample with zinc soap suddenly turns black when heated, that is, the so-called "Zine burning" phenomenon occurs, but it has the following advantages: The initial coloring is excellent; the effect of preventing fouling is good; it can improve the weather resistance; many zinc soaps are recognized as non-toxic stabilizers, so they can be used in non-toxic formulations with calcium soaps.
(3) Barium soap stabilizer Barium compounds have good thermal stability and good lubricity, but the red initial coloration occurs during processing, and it is easy to cause sticking to the roller.
(4) The stability of calcium soap stabilizer is poor, but it is recognized as a non-toxic additive in the world and has excellent lubricity.
(5) Other metal soap stabilizers used in the industry include magnesium stearate, file stearate, aluminum stearate, potassium stearate, etc., among which magnesium stearate is similar to calcium stearate and can be used Materials that are in contact with food; aluminum stearate is similar to zinc stearate, and is approved by the U.S. FDA and the Japanese Vinyl Chloride Food Hygiene Association for food packaging; Stearic Acid files and potassium stearate are also non-toxic products and belong to lead salts , Tin soap and barium soap substitute.
(6) The performance requirements of the composite metal soap stabilizer processing industry for stabilizers are various, and a single metal soap often cannot meet the use requirements, so the use of composite stabilizers has become a trend. A single metal soap compound is rarely used in the PVC industry, and it is usually a compound of several metal soaps. This compound is not a simple addition of properties, but takes advantage of the synergy between the components. The composite metal soap stabilizer generally includes the stabilizer main body (i.e. metal soap), solvent (organic solvent, plasticizer, liquid non-metal stabilizer, etc.), functional additives (auxiliary stabilizer, transparency modifier, light stabilizer, Lubricants, etc.). According to the form, it is divided into solid compound and liquid compound. According to the main component, it can be divided into calcium/zinc compound stabilizer, barium/fu compound stabilizer, barium/zinc compound stabilizer, etc. Among them, the calcium/zinc composite stabilizer has a pivotal role in replacing toxic metals because it is non-toxic.
1.5 Rare earth stabilizer
(1) Excellent thermal stability The thermal stability of rare earth stabilizers is better than traditional lead salt series and barium/zinc, barium/ho/zinc stabilizers. In some applications, rare earth stabilizers can partially or completely replace organotin.
(2) Good transparency. The refractive index of rare earth stabilizers is very close to that of PVC Resin, which can replace traditional organotin and be used in the field of products with higher transparency requirements.
(3) Excellent weather resistance. Rare earth elements can absorb 230-320nm ultraviolet light. Therefore, rare earth stabilizers have anti-photoaging effects and are suitable for outdoor products such as PVC corrugated boards and window materials.
(4) Excellent electrical insulation properties. Some rare earth multifunctional stabilizers can be used to replace lead salt stabilizers in cable material formulations, and their electrical insulation properties are comparable to lead salts.
(5) Non-toxic, safe and hygienic. Rare earth elements are low-toxic elements and have no toxic hazards to the human body in their production, processing, transportation and storage. Rare earth stabilizers are non-toxic products and can be used in food packaging and medical packaging products.
(6) The processing performance is slightly worse. In the case of a large amount of rare earth stabilizer, the roll release of the material is not ideal, and there is a tendency to press out. Generally, better results can be achieved by using stearic acid or calcium stearate in combination.
In summary, rare earth stabilizers can be used for water pipes, injection pipe fittings, window frame profiles, door panels, wire ducts, foam products, artificial leather, cable materials, soft and hard transparent products, food packaging materials, etc.
1.6 Auxiliary stabilizers Auxiliary stabilizers include phosphite, epoxy soybean oil, hindered phenols, etc., which mainly rely on the synergistic effect between metal stabilizers to improve the stabilizing effect, and are generally called co-stabilizers. In addition to compounds such as mesaminocrotonic acid ester, 2-phenyl saccharin, vein derivatives, and diketone can be used in combination with metal stabilizers to improve the effect of metal stabilizers, they also have a certain stabilizing effect. Such compounds are usually called pure organic stabilizers. With the development of PVC stabilizers today, the progress of metal stabilizers is relatively slow, and the research and development of auxiliary stabilizers are unprecedentedly active, which has constituted a major trend in the field of PvC stabilizers. Auxiliary stabilizers are rarely used alone, and are often used in conjunction with primary stabilizers to improve initial coloration or improve long-term stability.
Lead Salt Stabilizer, Compound Stabilizer,Pvc Stabilizer,Titanium Dioxide Anatase
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