Recently, the 2016 China Gear Industry Market Demand and Technical Support and Product Integration Seminar was held in Luoyang.
The meeting revealed the good news that the gear industry is working together for transformation and upgrading.
There predicament should learn from international experience <br> <br> low excess capacity, is an obstacle to the domestic auto industry to upgrade gear must break.
Professor Xu Zhenyu, the vice president of the School of Economics of Beijing Technology and Business University, was invited to give a special report at this symposium, which provided valuable international experience for resolving the problem of overcapacity in low-end gears.
The fundamental solution to overcapacity is innovation.
Japanese innovation is divided into two types.
One is gradual innovation, which means "introduction + independent innovation." The most unique feature is the establishment of a technological innovation alliance that integrates production, government, and learning.
The second is to establish an innovative system architecture and implementation mechanism that suits the country’s national conditions, economic development level and historical and cultural traditions, and continue to innovate.
In terms of science and technology, Japan has three indicators that have long been ranked first in the world. The first is that Japan’s national research and development funds account for the proportion of GDP, the second is the proportion of research and development expenditures for corporate expenditures in the country’s research and development funds, and the third is the number of Japanese core technology patents. Xu Zhenyu exemplifies: “Japan is a world model in terms of energy conservation and environmental protection. The Japanese auto industry started as a light-duty vehicle. Light-duty vehicles save fuel, have little pollution, and gradually become internationally competitive, helping Japan quickly become a powerful automobile industry.â€
In the period of economic transformation, the state must pay special attention to environmental protection in terms of improving people’s quality of life. Most small and medium-sized enterprises cannot independently undertake high-tech environmental protection development work. This requires the government to provide financial subsidies and cooperation. Both the Japanese central government and local governments have public pilot research institutes that provide free technical guidance to SMEs.
The association is a product of the market economy. It is voluntarily established by the company to safeguard the interests of the enterprise, provides advice and advice to the government, and provides advice and assistance for the transition. It allows companies to survive the period of transition and achieve smooth and orderly industrial transformation. Irreplaceable role. Therefore, Japan pays great attention to the role of the association as a bridge between government and enterprises.
Xu Zhenyu said: "In the process of changing government functions, the government must return many functions that should be undertaken by the association to the association."
Although South Korea's economic growth has slowed down, its ability to withstand risks has increased. In the Asian financial crisis and the US subprime mortgage crisis, South Korea is the country that has suffered the most in Asia, but it is also the first country in East Asia to emerge from the crisis.
"Japanese people design products and Koreans design consumers." Japanese companies have always followed the "Japanese-style" strategy and exported the Japanese model directly to foreign countries. Korean companies have responded to the demand and implemented a "localization" strategy. This is very suitable for consumers in emerging markets. For example, Hyundai Motor Co., Ltd. sells automobiles in India, adapts local culture to change some product specifications, and specifically increases the roof of people wearing headscarves; Samsung also sponsors the Corinthian football team welcomed by low-income people in Brazil. High-earnings favorite Palmeiras football team.
It has been a miracle that South Korea has developed into a powerful automotive industry with its own brand, production, and export volume in the world in less than four decades.
The important experience in the development of the Korean automotive industry is mergers and acquisitions. Taking the opportunity of the outbreak of the Asian financial crisis in 1998, major auto companies eliminated a lot of ills through mergers and acquisitions and savings. The merger of Hyundai and Kia shares the platform to form an economic scale.
The self-innovation model that Hyundai Motor Company insists on is the introduction, digestion, absorption, and innovation.
Li Shengqi, a senior expert in the gear industry, pointed out: “The experiences of Japan and South Korea introduced by Professor Xu Zhenyu have great reference value for the transformation and upgrading of China's automobile gear industry, especially for the extremely valuable collaborative operations of the Chinese automobile gear industry.â€
Industrial upgrading <br> <br> gear manufacturing robot assisted gear with standardized, large quantities of features from the past manual processing gradual integration process automation and information technology, easier to implement intelligent.
In today's wave of smart manufacturing, gear manufacturing companies urgently need to change production patterns and improve factory automation. The urgent gear manufacturing company of Beijing Hanming Technology Co., Ltd., which is engaged in the business of sales of CNC machine tools and robots, is in urgent need. In conjunction with the China Gear Industry Alliance, the China Gear Industry Intelligent Manufacturing Promotion Center was established at the end of 2015. Yang Sen, general manager of Beijing Yanming Technology Co., Ltd., said: “We will build several smart manufacturing demonstration plants in the gear industry, accelerate the automation and informationization process of the entire gear industry, and promote the gradual progress of gear enterprises to intelligent plants.â€
The robot revolution will affect the world manufacturing landscape. China will become the world's largest robot market. The international robot revolution will create a trillion-dollar market. The development, manufacture and application of robots are an important symbol of national science and technology innovation and high-end manufacturing.
Currently, 75% of the world's robotic core infrastructure harmonic reducers, RV reducers and precision bearings market are monopolized by the Japanese Teijin and HarmonicDrive.
Professor Wang Jiaxu, deputy director of the Academic Committee of Chongqing University’s State Key Laboratory of Mechanical Transmission, stated: “We must increase the level of domestic robotics to meet the major demand for the industrialization of robots in the automotive gear and other industries and occupy as many domestic and foreign markets as possible. I am willing to work with my colleagues in the gear industry to overcome the technical problems of joint reduction gears for industrial robots with my team's scientific research results and inline innovation, production, research, and collaborative innovation."
Gear steel self-development capacity is improving <br> <br> industrial gear 100% based on the iron and steel industry. To a large extent, the quality characteristics of the steel itself determine the various properties of the gear.
The development and production capacity of gear steel is one of the main indicators of the basic strength of a national gear industry.
In this seminar, the high-end gear steel special project introduced by Bai Ruijuan, deputy director of the Technical Center of Henan Jiyuan Iron & Steel (Group) Co., Ltd., is a typical case of domestic steel gears to achieve phased results.
From September 2015, Jiyuan started the specialization of high-end gear steel, and by the end of March 2016, it had conducted more than 300 furnace tests. It has achieved preliminary results of a series of gear steel technology breakthroughs and will begin mass production of series gear steel in the fourth quarter of 2016.
Yang Lingping, a heat-treatment engineer at Jinan Huiji Gear Co., Ltd., pointed out in particular: “All kinds of embarrassment and frustration encountered in the quality of steel products are painful! The iron and steel companies must be hardened themselves. Domestic steel companies rely solely on national policies to control and stimulate the market, not for a long time. Only the excellent product quality is the magic weapon for the company to be invincible forever."
Li Shengqi emphasized: "The domestic gear industry must promote the corporate culture of competition and sharing, strengthen the foundation, and coordinate development, and strive to achieve high-end, lightweight, electric, intelligent and networked!"
"Gravity Die Casting. A permanent mould casting process, where the molten metal is poured from a vessle of ladle into the mould, and cavity fills with no force other than gravity, in a similar manner to the production of sand castings, although filling cn be controlled by tilting the die."
Gravity Die Casting
Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminium, Zinc and Copper Base alloys.
The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.
GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.
There are three key stages in the process.
- The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
- Molten metal is poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould [down sprue" that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
- Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.
Advantages
- Good dimensional accuracy
- Smoother cast surface finish than sand casting
- Improved mechanical properties compared to sand casting
- Thinner walls can be cast compared to sand casting
- Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
- Steel pins and inserts can be cast in to the part
- Faster production times compared to other processes.
- Once the tolling is proven, the product quality is very repeatable.
- Outsourced Tooling setup costs can be lower than sand casting.
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