Japanese mould enterprises still have advantages

2022-07-31
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Japanese mold enterprises still have the advantage of "a hundred feet dead but not stiff". Recently, there have been repeated reports that the Japanese mold industry is shrinking, pointing out that Japan is planning to transfer the mold manufacturing industry to other countries. Recently, we have repeatedly reported that Japan's mold industry is shrinking, pointing out that Japan is planning to transfer its mold manufacturing industry to other countries. In fact, Japanese tool and die enterprises are actively carrying out competitive marketing strategies to meet the severe challenges of the market environment. The advantages of Japanese tool and die enterprises still exist

abroad: vigorously explore overseas markets

Japan's output value of mechanical tools and dies in 2000 increased by 10.9% over 1999, reaching 377.211 billion yen. Among them, high speed steel cutting tools, diamond tools and CBN tools all have two digit growth; Cemented carbide tools account for about 50% of the total output value of tools. In 2000, the output value of cemented carbide tools increased by 9.3%. After entering 2001, with the weak demand of the semiconductor industry and the machine tool industry, the production and sales of the tool and mold industry began to decline. Among them, the demand for PCB drill 21 and stretching fixture [grip] used for processing printed circuit boards has declined most seriously, and the production reduction of high-speed steel tools is generally similar. At present, the tool manufacturers are very concerned about the demand trends of the automotive and it electronics industries, which are the main users of cutting tools, and their demand changes have a very obvious impact on the tool and die industry; At the same time, the pressure to reduce costs is also enormous. The global market scale of cutting tools is about 1.1 trillion yen, including 400billion yen in the United States and Europe, and 300billion yen in Asia. It is estimated that the annual growth rate of world tool demand will be 3% in 2003 and 2.6% in 2006. The expansion of users is mainly concentrated in the United States and Asia. Therefore, Japan's tool and die industry will vigorously explore overseas markets. In 2000, the proportion of Japanese tool exports reached 20% for the first time

domestic: vigorously carry out merger and reorganization

large users generally require to strengthen supply capacity and after-sales service. In order to adapt to this situation, Japanese tool and die enterprises have vigorously carried out industry restructuring activities such as enterprise merger or business cooperation. In 1999, Toshiba tungaloy signed business cooperation agreements with kennametalhertel of the United States, Fuji Seiko and guhring of Germany. In 2000, Mitsubishi Integrated Materials Co., Ltd. acquired Shengang Tools Co., Ltd. and established MCC Shengang Tools Co., Ltd. as a subsidiary of Mitsubishi. The acquisition and merger activities of these large manufacturers have formed a new cutting tool supply system worldwide

the advantages of Japanese tool and die enterprises still exist Accelerate the pace of product development

the automotive industry is a major demand for cutting tools, accounting for about 60% of tool products. The demand trend of the automotive industry is the focus of the tool industry. In addition, the booming it mold industry in recent years has led to a rapid growth in the demand for small-diameter cutting tools. In the field of cutting, high-precision, high-speed and high-efficiency machining have received unprecedented attention. With the strengthening of people's awareness of environmental protection, dry cutting technology has made great progress, and the development results of dry cutting tools are very significant. The pace of new product development of cutting tools based on coating treatment and indexable structure has been further accelerated

in recent years, the material of cutting tools is still mainly coated cemented carbide, and the change is not obvious; However, the coating technology itself has made great progress. A large number of composite coatings with excellent heat resistance and wear resistance have appeared. The application of tic, tin, TiCN, TiAlN and other coatings has been quite popular. Coated cutting tools have become the symbol of modern cutting tools, accounting for more than 50% of the cutting tools

as a tool for high-speed machining, it must be made of high hardness materials with excellent wear resistance. Among these materials, ceramics is the most ideal variety. Ceramic cutting tools have high hardness and excellent resistance to plastic deformation at high temperature, and are not prone to oxidative wear. But its shortcomings are also obvious, that is, the texture is brittle and easy to damage. Recently, new varieties of ceramics have been developed, and their shortcomings have been greatly reduced. For example, coated ceramics and FRC ceramics with SiC reinforced fibers have been successively put on the market. Now, new ceramic tools can also be used for high-speed cutting of Ni based superalloys

Sumitomo Electric Co., Ltd. has developed a new tool material, that is, cbn200/cbn80 (sintered body of cubic boron nitride when the oil delivery hand wheel is closed) of the company is coated with a special ceramic coating, which improves the wear resistance of the material by 30% and greatly prolongs the tool life. This new type of cutting tool is mainly used for high-speed machining of high hardness quenched steel and cast iron commonly used in the automotive industry. The company plans to make the sales of this product reach 1.2 billion yen within two years

strengthen the production of cemented carbide tools for mold processing

II Development of ultra-fine grain tool materials in order to achieve high-speed and high-precision machining, manufacturers are vigorously developing new tool materials sintered from fine grain metal powder. As we all know, diamond is the tool material with the highest hardness, but when the cutting temperature exceeds 800 ℃, diamond tools will have diffusion reaction with other carbon solid solution substances such as Fe, Co, Ni, etc. Therefore, diamond tools are not suitable for steel cutting. When machining high hardness materials, cutting tool materials such as cemented carbide and cermet should be selected, especially ultra-fine Grain Cemented Carbide (particle size below 1m), which has excellent properties such as high hardness, good toughness and high reliability of cutting tools. Because of its excellent performance, ultrafine grained cemented carbide tools will not produce abnormal damage such as edge collapse or damage even if they are used in unstable cutting fields such as low-speed or intermittent cutting. Since the 1990s, ultra-fine grain cemented carbide tools have been widely used, especially in the high-speed cutting of difficult to machine materials. After entering the new century, the properties of these materials have been further improved after coating treatment. At present, these tools are widely used for cutting high hardness steel, stainless steel, Fe based, Ni based and Co based superalloys. The hardness of CBN tools is second only to diamond, and its performance is superior to that of ceramic tools. Therefore, CBN tools are suitable for cutting high hardness materials such as quenched steel and chilled cast iron, as well as materials such as sintered structure, sintered stainless steel and Co based superalloy

with the strengthening of environmental protection awareness, dry cutting technology has received great attention. The tools used for dry cutting must have the following characteristics: in terms of thermal characteristics, coating materials with good heat resistance and heat dissipation shall be used; In terms of lubricating effect, coating materials with excellent lubricating performance are used; In terms of chip removal performance, the tool shape that is convenient for chip breaking and chip removal should be designed. So far, Japanese tool manufacturers have developed a variety of cutting tools for dry machining, such as the aqua drill bit series of bueryue company, ac1000 coated blades and ZX coated end mills of Sumitomo company, epoch end mills and Mg coated blades of Hitachi tools company, etc

III The booming tool regrinding industry

in recent years, due to the rising price of raw materials, and in order to save resources, the technology development based on the premise of recycling cemented carbide scrap blades and recycling resources has been very active, and tool manufacturers have also actively participated in this cause

in order to ensure the stable supply of resources and reduce production costs, such large cemented carbide tool manufacturers as Mitsubishi integrated materials, Sumitomo Electric, Toshiba tungaloy, DIJET, Hitachi tools, Japan tungsten and Fuji molds have taken measures to reuse the used tools. Among them, Hitachi Tools Co., Ltd. is making great efforts to carry out the recycling business of scrapped tools for three times in Japan. Narita branch is the main production base of the company's cemented carbide tools. Now, it is building a new workshop for the reuse of scrapped tools in the factory. It will be merged with the relevant workshops originally located in Osaka to form Hitachi's old tool reuse center

tool regrinding is one of the effective forms of reusing resources, and the regrinding industry has increasingly formed a scale. According to statistics, there are 500 ~ 600 companies engaged in tool regrinding in Japan, including tool manufacturers, mechanical processing plants and various commercial regrinding institutions. Although the exact size of the regrinding market is not clear at present, in the case of economic depression, there is a high demand from users to reduce the tool cost. Therefore, the general trend of the tool regrinding market is expanding. It is roughly estimated that the market size is between 20billion and 30billion yen

IV Enhance competitiveness in foreign markets

while meeting domestic demand, Japanese tool manufacturers have launched a marketing strategy to vigorously enter the international market. Mitsubishi Integrated Materials Co., Ltd. cooperates with Ma Ford company of the United States to produce tools for mold and aircraft parts processing, hoping to improve Mitsubishi's competitiveness in foreign markets. At present, the company's sales proportion of cutting tools for aircraft manufacturing is 3%, and this proportion will increase to 10% in three years. Through the reorganization with Mitsubishi Integrated Materials Co., Ltd., NMC Shengang Tools Co., Ltd. is vigorously promoting its coated tool products to the foreign market. The company has set up a new tool department for mold and auto parts processing (producing carbide end mills and drill bits) and a gear processing tool Department (focusing on gear tools). All kinds of tools are quickly determined by the Department from planning to production, thus shortening the production cycle and improving the sales efficiency

Toshiba tungaloy company has introduced the company's it and statistical quality management system, which has greatly reduced the product nonconformity rate. After the implementation of this management method in Ge, Toshiba and other companies in the United States, the effect of reducing production costs is very significant. The medium-term goal of Toshiba's tool production is to pay close attention to the development and production of small part processing tools (TAC tools) and integrated tools for it and semiconductor processing. By 2002, the production capacity of PCB drill bits of the company will be increased by 70%. The main production bases are located in mainland China and Taiwan Province. At present, the monthly output is 6million, and it is planned to increase to 10million by 2002. The company helps people further understand the equipment by expanding foreign production bases, so as to enhance the production and competitive strength of micro drill bits and mold processing tools. Kyocera acquired daikom, a large American tool company, and took this opportunity to vigorously expand the sales of its PCB drill bit products to all parts of the world. The company plans to occupy 40% of the PCB bit market in the United States and 10% of the Asian market (including Japan). Fuji Seiko has established a joint venture Dalian Fuji Tools Co., Ltd. in Dalian, China. In the new century, the company will strengthen the production capacity of carbide cutting tools of Dalian Branch, and its monthly output value will increase from the current 25million yen to 42million yen. In addition to supplying the cutting tools required by local sewing machine manufacturers, the orders of Japanese joint ventures in China such as automobiles and motorcycles have also increased rapidly. At the same time, the company has to resell some of its products to Japan to meet the growing needs of domestic users in Japan

v According to the statistics of ISTA (internationalspecialtoolingassociation) on the world mold Market in the 1990s, the United States is about 120billion dollars, Europe is more than 100billion dollars, and Japan is more than 10billion dollars. The production cycle of mold high-speed milling is only one third of that of traditional EDM, so the demand for precision tools in the mold industry is quite large. Japan's tool industry has always attached importance to mold processing knives

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