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DY-1000巖心鉆機(jī)液壓動(dòng)力頭設(shè)計(jì)
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DY-1000巖心鉆機(jī)液壓動(dòng)力頭設(shè)計(jì)
課題類別
畢業(yè)論文
一、 論文資料的準(zhǔn)備
1.選題背景
全液壓動(dòng)力頭巖心鉆機(jī)是現(xiàn)今較為先進(jìn)的巖心鉆機(jī),在國(guó)外發(fā)達(dá)國(guó)家它已逐漸替代立軸鉆機(jī)成為地質(zhì)勘探的主流設(shè)備。二十世紀(jì)七八十年代我國(guó)部分科研院所也曾進(jìn)行過(guò)全液壓巖心鉆機(jī)的設(shè)計(jì)，并制造出樣機(jī)，但由于當(dāng)時(shí)的工業(yè)制造基礎(chǔ)較差，液壓元件質(zhì)量性能不過(guò)關(guān)，導(dǎo)致鉆機(jī)性能不穩(wěn)，滲油漏油現(xiàn)象嚴(yán)重，故障率高，維修困難，全液壓巖心鉆機(jī)最終沒(méi)有得到全面推廣使用。
時(shí)至今日，隨著改革開(kāi)放后外資企業(yè)涌入，獨(dú)資合資企業(yè)在全國(guó)各地的紛紛建立， 我國(guó)生產(chǎn)制造液壓元件的技術(shù)水平也大幅提高，在國(guó)內(nèi)生產(chǎn)的液壓元件中就有很多是國(guó)際知名品牌，質(zhì)量性能完全能滿足鉆機(jī)使用工況，目前在國(guó)內(nèi)選擇到可靠的液壓元件已不成問(wèn)題。
在此工業(yè)基礎(chǔ)條件下，在國(guó)家提高地質(zhì)裝備水平政策的引導(dǎo)下，在各地地質(zhì)裝備專項(xiàng)資金的扶持下，經(jīng)過(guò)近幾年的蓬勃快速發(fā)展，目前，國(guó)內(nèi)生產(chǎn)全液壓動(dòng)力頭巖心鉆機(jī)的單位已有二十幾家，并初具規(guī)模。在國(guó)內(nèi)市場(chǎng)上該類鉆機(jī)已經(jīng)由進(jìn)口為主逐漸轉(zhuǎn)變?yōu)閲?guó)產(chǎn)鉆機(jī)占據(jù)大半江山。在國(guó)內(nèi)眾多專家及研制單位的積極推動(dòng)下，加之國(guó)產(chǎn)鉆機(jī)克服了一些進(jìn)口鉆機(jī)售價(jià)高、使用成本高、售后服務(wù)周期長(zhǎng)等弊端，用戶也逐漸認(rèn)識(shí)到該類鉆機(jī)的突出優(yōu)勢(shì)。同時(shí)部分廠家生產(chǎn)的全液壓動(dòng)力頭巖心鉆機(jī)已經(jīng)走出國(guó)門(mén)，出口到多個(gè)國(guó)家?，F(xiàn)在全液壓動(dòng)力頭巖心鉆機(jī)市場(chǎng)需求趨于平穩(wěn)。
2. DY系列全液壓動(dòng)力頭式巖心鉆機(jī)的特點(diǎn)
全液壓動(dòng)力頭式巖心鉆機(jī)之所以能成為巖心鉆機(jī)的發(fā)展方向，是因?yàn)槠渑c機(jī)械立軸式巖心鉆機(jī)相比具有以下顯著優(yōu)點(diǎn)：一是給進(jìn)行程長(zhǎng)，能達(dá)到3.5m，是機(jī)械立軸式鉆機(jī)給進(jìn)行程的6-7倍，一次給進(jìn)就可打滿3m長(zhǎng)的巖心內(nèi)管，不用頻繁倒桿，避免鉆進(jìn)過(guò)程中可能造成的巖心斷裂、巖心堵塞等事故；二是便于斜孔施工，施工效率高；三是卷?yè)P(yáng)機(jī)布置靈活、排繩方便；四是塔機(jī)一體，安裝、搬家快速方便。該型鉆機(jī)的缺點(diǎn)是設(shè)備購(gòu)置成本高（相對(duì)于立軸鉆機(jī)而言），液壓控制系統(tǒng)復(fù)雜，易出現(xiàn)滲油`漏油故障，機(jī)臺(tái)一般維修人員難以勝任維修工作。國(guó)內(nèi)企業(yè)研發(fā)的全液壓動(dòng)力頭巖心鉆機(jī)，雖然結(jié)構(gòu)各具特色，但其基本功用都能滿足鉆探工藝要求，總體結(jié)構(gòu)大致相似，都具有全液壓動(dòng)力頭式巖心鉆機(jī)共有的特點(diǎn)。有的企業(yè)開(kāi)發(fā)全液壓動(dòng)力頭式巖心鉆機(jī)是從仿制國(guó)外產(chǎn)品開(kāi)始的，起點(diǎn)相對(duì)較高；有的企業(yè)則是根據(jù)鉆探施工的要求走自主創(chuàng)新的路子，邊生產(chǎn)推廣邊完善設(shè)計(jì)!DY系列全液壓動(dòng)力頭巖心鉆機(jī)屬自主研發(fā)的產(chǎn)品，設(shè)計(jì)時(shí)充分考慮了國(guó)內(nèi)鉆探施工的實(shí)際，尊重鉆探技術(shù)工人現(xiàn)有的操作習(xí)慣，鉆機(jī)的結(jié)構(gòu)新穎，鉆機(jī)性能參數(shù)先進(jìn)合理，并有多項(xiàng)技術(shù)獲國(guó)家專利.鉆機(jī)質(zhì)量可靠，性能穩(wěn)定，外形美觀,性價(jià)比高，得到用戶的廣泛認(rèn)可。
DY系列鉆機(jī)除具有全液壓動(dòng)力頭鉆機(jī)共有的特點(diǎn)，如采用全液壓驅(qū)動(dòng)，所有執(zhí)行機(jī)構(gòu)均可實(shí)現(xiàn)無(wú)級(jí)調(diào)速；動(dòng)力頭變速箱與鉆塔裝為一體，便于斜孔施工。此外還具有以下特點(diǎn)：
(1)為便于斜孔施工，鉆機(jī)具有鉆塔滑移觸地功能!施工斜孔時(shí)鉆塔要傾斜一定角度，位于鉆塔底座上的夾持器也隨之上升一定高度，不方便起下鉆操作!為方便施工，將整個(gè)鉆塔安裝在可調(diào)節(jié)傾角的滑架上，當(dāng)滑架帶動(dòng)鉆塔傾斜到規(guī)定角度后，觸地油缸推動(dòng)鉆塔在滑架上下移，直至鉆塔底座觸及地面，再將鉆塔用螺栓緊固在滑架上!這樣進(jìn)行斜孔施工時(shí)，操作夾持器就非常方便了!
（2）鉆機(jī)采用自行設(shè)計(jì)的液壓卡盤(pán)和液壓夾持器，結(jié)構(gòu)合理，性能可靠，維護(hù)方便。液壓卡盤(pán)采用液壓夾緊液壓松開(kāi)機(jī)構(gòu)，使用硬質(zhì)合金卡瓦，夾緊力大，工作可靠。液壓夾持器采用液壓油缸做動(dòng)力，操作省力，夾緊松開(kāi)卡瓦動(dòng)作迅速，夾持可靠，獲國(guó)家實(shí)用新型專利。
(3）動(dòng)力頭變速箱設(shè)有2擋機(jī)械變速，增大了鉆機(jī)變速范圍!動(dòng)力頭變速箱結(jié)構(gòu)緊湊，易損件少，使用變量液壓馬達(dá)驅(qū)動(dòng)，采用恒扭矩$恒功率調(diào)速方式，動(dòng)力頭輸出轉(zhuǎn)速可連續(xù)無(wú)級(jí)調(diào)節(jié)，調(diào)速范圍廣， 適用于金剛石繩索取心、沖擊回轉(zhuǎn)等多種鉆探工藝的需要。為增強(qiáng)提鉆的方便性，鉆機(jī)動(dòng)力頭變速箱在提鉆時(shí)要讓開(kāi)孔口位置。其讓開(kāi)孔位的方式是：松開(kāi)機(jī)械鎖緊裝置，用側(cè)移油缸推動(dòng)其移動(dòng)到側(cè)面。提鉆完成后再用側(cè)移油缸拉動(dòng)其復(fù)位，然后鎖緊機(jī)械裝置再開(kāi)始工作!該機(jī)構(gòu)操作便捷、省力、安 全， 穩(wěn)定性好，在斜孔施工時(shí)，其實(shí)用性尤為突出。 鉆機(jī)動(dòng)力頭在鉆塔上的移動(dòng)采用導(dǎo)軌、滑板結(jié)構(gòu)方式，剛性大，對(duì)動(dòng)力頭的導(dǎo)向性好，滑板與導(dǎo)軌的間隙可以調(diào)節(jié)，磨損后可以補(bǔ)償、更換，動(dòng)力頭式變速箱的設(shè)計(jì)獲國(guó)家實(shí)用新型專利。
（4）鉆機(jī)附件簡(jiǎn)單實(shí)用，質(zhì)量輕，便于搬遷!鉆機(jī)配備的附件有：鉆機(jī)底梁和鉆桿架!為縮減機(jī)臺(tái)鋪設(shè)時(shí)間，鉆機(jī)配有鉆機(jī)底梁。在鉆孔位置平整場(chǎng)地修筑地基完成后，將鉆機(jī)底梁放在地基上，然后將鉆機(jī)安放到鉆機(jī)底梁上，用螺栓緊固為一體，可快速完成鉆機(jī)底梁的鋪設(shè)和鉆機(jī)安裝到位，節(jié)省輔助 工作時(shí)間。為減輕起下鉆時(shí)的勞動(dòng)強(qiáng)度，為鉆機(jī)配備了鉆桿架!起鉆時(shí)，將卸下的鉆桿立根下端抬到鉆桿架滑車上，松開(kāi)卷?yè)P(yáng)機(jī)，滑車會(huì)在立根自重的作用下在鉆桿架導(dǎo)軌上滑移，鉆桿也隨之邊滑移邊下 降放平，摘下提引器后將鉆桿立根抬起擺放在鉆桿架內(nèi)，即完成一個(gè)立根的提升擺放!有了鉆桿架滑車的幫助，縮短了抬鉆桿時(shí)間，減輕了工人勞動(dòng)強(qiáng)度。
（5）鉆機(jī)結(jié)構(gòu)新穎；整體布局合理，解體性好，部件質(zhì)量輕，搬遷運(yùn)輸方便!特別是分體式巖心鉆機(jī)將液壓動(dòng)力站與鉆機(jī)分裝在不同的底盤(pán)上， 部件布局更加靈活。鉆機(jī)部分裝有主卷?yè)P(yáng)機(jī)、繩索取心絞車、鉆塔、動(dòng)力頭變速箱、操作臺(tái)、閥組箱、夾持器等部件；液壓動(dòng)力站部分裝有電機(jī)、油泵、油箱、冷卻器、電控柜等部件，兩者用液壓快速接頭和針式電纜接頭連接。
3. DY系列全液壓動(dòng)力頭式巖心鉆機(jī)的結(jié)構(gòu)和組成部件
DY系列各種型號(hào)的全液壓動(dòng)力頭式巖心鉆機(jī)性能參數(shù)雖有區(qū)別，但鉆機(jī)結(jié)構(gòu)和組成部件大致相 同。該系列鉆機(jī)主要由鉆機(jī)底盤(pán)、鉆塔、主卷?yè)P(yáng)機(jī)、繩索取心絞車、液壓動(dòng)力站、操作臺(tái)液壓管線、動(dòng)力頭變速箱等部件組成。
3.1底盤(pán)
底盤(pán)是承載鉆機(jī)各組成部件的結(jié)構(gòu)件，是由型材焊接而成!底盤(pán)按結(jié)構(gòu)分可分為整體式和分體式兩種。
整體式底盤(pán)鉆機(jī)所有部件都裝在同一底盤(pán)上，一同運(yùn)輸搬遷，可加裝拖輪拖行。履帶式鉆機(jī)的底盤(pán)也屬于整體式。
分體式底盤(pán)是將液壓動(dòng)力站部分和鉆機(jī)部分分裝在兩個(gè)底盤(pán)上，兩者間動(dòng)力傳動(dòng)和控制是通過(guò)裝有快速接頭的液壓膠管和電纜來(lái)完成，便于拆卸。分體式底盤(pán)中的兩個(gè)底盤(pán)都裝有拖輪，鉆機(jī)在工地上搬遷移位時(shí)，可使用其他車輛牽引移位。鉆機(jī)底盤(pán)上安裝有絲杠式千斤頂，可以很方便的升降，便于車輪的安裝或拆卸。施工時(shí)拆除車輪，把鉆機(jī)底盤(pán)坐在鉆機(jī)底梁上固定即可。鉆機(jī)動(dòng)力站在施工時(shí)不用拆卸拖輪，用千斤頂頂起底盤(pán)使拖輪離開(kāi)地面即可工作。
3.2鉆塔
采用桅桿式鉆塔，由矩形方管焊接而成，裝在滑架上，分為上下兩節(jié)可折疊。其主要功用是配合卷?yè)P(yáng)機(jī)完成起吊鉆具、取心等工作。鉆塔主要由支架、底座、滑架、下塔身、導(dǎo)軌、上塔身、天車、游動(dòng)滑車、起塔油缸、伸縮式支撐桿等組成，鉆塔采用液壓油缸控制起落。
動(dòng)力頭移動(dòng)導(dǎo)軌用螺釘和銷釘固定在下塔身上，下塔身通過(guò)支架、滑架、起塔油缸、伸縮式支撐桿與鉆機(jī)底盤(pán)連接。通過(guò)調(diào)整支撐桿的長(zhǎng)度，可使鉆塔45°-90°之間用機(jī)械方法固定。鉆塔在滑架上能整體滑移，具有觸地功能，方便斜孔施工。鉆塔有效高度9m，可升6m的鉆桿。鉆具較輕時(shí)可使用單繩升降鉆具，在鉆具較重時(shí)可利用游動(dòng)滑車使用雙繩升降鉆具。
3.3主卷?yè)P(yáng)機(jī)
鉆機(jī)的主卷?yè)P(yáng)機(jī)由卷筒、支架、液壓馬達(dá)、減速器、制動(dòng)器等組成。液壓馬達(dá)為定量斜軸式柱塞馬達(dá)，通過(guò)行星減速器帶動(dòng)卷筒正轉(zhuǎn)或反轉(zhuǎn)用于升降鉆具。主卷?yè)P(yáng)機(jī)設(shè)有液壓平衡閥和液壓制動(dòng)器雙重制動(dòng)裝置，升降鉆具平穩(wěn)，制動(dòng)可靠。升降速度可無(wú)級(jí)調(diào)速。
3.4液壓動(dòng)力站
鉆機(jī)的液壓動(dòng)力站是該系列鉆機(jī)的核心部件，它主要由電動(dòng)機(jī)、液壓油泵、油箱、冷卻器、液壓控制閥、電氣柜等組成。
該動(dòng)力站2個(gè)液壓油泵，分為主泵和副泵。由于主泵和動(dòng)力頭液壓馬達(dá)都是液控變量， 通過(guò)調(diào) 節(jié)控制壓力的大小，可以無(wú)級(jí)改變主泵和動(dòng)力頭液壓馬達(dá)的排量大小，從而實(shí)現(xiàn)動(dòng)力頭轉(zhuǎn)速的無(wú)級(jí)調(diào)速和恒扭矩、恒功率的扭矩輸出。結(jié)合動(dòng)力頭變速箱的二級(jí)機(jī)械變速，使動(dòng)力頭的輸出轉(zhuǎn)速和扭矩范圍寬變化較大，能適應(yīng)多種不同鉆進(jìn)工藝的要求。改變主泵的排量也實(shí)現(xiàn)了對(duì)主卷?yè)P(yáng)機(jī)、液壓絞車、給進(jìn)油缸等機(jī)構(gòu)的無(wú)級(jí)調(diào)速。
3.5 操作臺(tái)
鉆機(jī)的操作臺(tái)主要由操作臺(tái)體、電控箱、液壓閥、壓力表、電流表、電壓表、轉(zhuǎn)速表、泥漿泵壓力表等組成。電控箱通過(guò)動(dòng)力站的電器柜，控制主泵電機(jī)、副泵電機(jī)、冷卻器電機(jī)、泥漿泵電機(jī)的啟動(dòng)和關(guān)閉。壓力表用來(lái)顯示各液壓油泵的工作壓力、先導(dǎo)系統(tǒng)的壓力、給進(jìn)油缸的加壓力或減壓力，反映鉆機(jī)液壓系統(tǒng)各部分工作壓力的狀態(tài)。電流表和電壓表顯示主泵電機(jī)的工作電流和工作電壓，反映鉆機(jī)運(yùn)轉(zhuǎn)負(fù)荷的狀態(tài)。轉(zhuǎn)速表顯示動(dòng)力頭回轉(zhuǎn)輸出轉(zhuǎn)速，泥漿泵壓力表顯示泥漿泵的工作壓力。
3.6動(dòng)力頭
鉆機(jī)的動(dòng)力頭主要由變速箱、液壓馬達(dá)、液壓卡盤(pán)等組成，是鉆機(jī)的回轉(zhuǎn)機(jī)構(gòu)。其變速箱具有2擋機(jī)械變速， 因而有2組不同的輸出轉(zhuǎn)速和輸出扭矩。液壓馬達(dá)與變速箱的輸入軸連接，通過(guò)改變馬達(dá)的排量可以改變馬達(dá)的輸出轉(zhuǎn)速!變速箱的輸出軸為空心軸，稱為芯管，內(nèi)部可以通過(guò)鉆桿，芯管的上端裝有液壓卡盤(pán)，用以卡緊或松開(kāi)鉆桿!卡盤(pán)的夾持力可以根據(jù)需要在一定范圍內(nèi)進(jìn)行調(diào)節(jié)，可有效地避免打滑現(xiàn)象和提高卡瓦的使用壽命!變速箱的輸出轉(zhuǎn)速和扭矩通過(guò)卡盤(pán)傳遞給鉆桿，帶動(dòng)鉆桿回轉(zhuǎn)鉆進(jìn)。松開(kāi)動(dòng)力頭變速箱緊固螺栓后，動(dòng)力頭變速箱在液壓油缸的推動(dòng)下能整體側(cè)移，讓開(kāi)孔口位置，便于起大鉆，非常便于斜孔施工。
二、本課題的目的（重點(diǎn)及擬解決的關(guān)鍵問(wèn)題）
1）進(jìn)行巖心鉆機(jī)液壓動(dòng)力頭的設(shè)計(jì)首先要求我們學(xué)會(huì)綜合運(yùn)用“機(jī)械設(shè)計(jì)”課程及其他所修相關(guān)課程理論知識(shí)和生產(chǎn)實(shí)際知識(shí)解決過(guò)程實(shí)際問(wèn)題的能力，并通過(guò)實(shí)際設(shè)計(jì)訓(xùn)練使所學(xué)理論知識(shí)得以鞏固和提高。
2）通過(guò)巖心鉆機(jī)液壓動(dòng)力頭的設(shè)計(jì)，我們要學(xué)會(huì)學(xué)習(xí)和掌握一般鉆機(jī)設(shè)計(jì)的基本方法和程序、培養(yǎng)獨(dú)立設(shè)計(jì)能力，為將來(lái)的學(xué)習(xí)和實(shí)際工作打下良好的基礎(chǔ)。
3）通過(guò)巖心鉆機(jī)液壓動(dòng)力頭的設(shè)計(jì)，還可以增，強(qiáng)我們進(jìn)行機(jī)械設(shè)計(jì)工作基本技能的能力，包括：設(shè)計(jì)計(jì)算、繪圖、查閱和使用規(guī)范、手冊(cè)、圖冊(cè)等相關(guān)資料。
三、主要內(nèi)容、研究方法、研究思路
1、主要內(nèi)容：
（1）對(duì)全液壓巖心鉆機(jī)進(jìn)行初步了解。熟知巖心鉆機(jī)發(fā)展的一般情況、鉆機(jī)的特點(diǎn)及設(shè)
計(jì)要求以及鉆機(jī)的“三化“原則等。
（2）對(duì)全液壓巖心鉆機(jī)進(jìn)行總體的設(shè)計(jì)，對(duì)其整體參數(shù)進(jìn)行規(guī)劃，學(xué)習(xí)其工作的主要原理以及其主要部件的功能和作用。
（3）對(duì)給進(jìn)機(jī)構(gòu)進(jìn)行分析、設(shè)計(jì)和選擇，對(duì)給進(jìn)機(jī)構(gòu)的液壓缸進(jìn)行設(shè)計(jì)選擇并熟知其整個(gè)工作過(guò)程及原理。
（4）對(duì)全液壓巖心鉆機(jī)的鉆塔進(jìn)行設(shè)計(jì)和校核。包括鉆塔及升降工具、塔身強(qiáng)度穩(wěn)定性及剛度驗(yàn)算及校核等。
（5）對(duì)卡盤(pán)的功能與結(jié)構(gòu)進(jìn)行分析，保證其在整機(jī)上準(zhǔn)確的安裝于滿足其功能。
（6）對(duì)動(dòng)力頭進(jìn)行設(shè)計(jì)計(jì)算，主要包括動(dòng)力頭的的主要作用和功能，變速箱的總體設(shè)計(jì)、變速箱傳動(dòng)齒輪的選取及校核、變速箱傳動(dòng)軸及軸承的選取和校核以及動(dòng)力頭的泵和電機(jī)的選擇等。
2、研究方法：
1)認(rèn)真學(xué)習(xí)和參考已有資料，并適當(dāng)與實(shí)際相結(jié)合，
2認(rèn)真查詢和使用正確的標(biāo)準(zhǔn)和規(guī)范。
3）學(xué)會(huì)使用計(jì)算機(jī)進(jìn)行輔助設(shè)計(jì)，比如：計(jì)算機(jī)輔助計(jì)算、計(jì)算機(jī)繪圖等。
3、研究思路
：
設(shè)計(jì)過(guò)程要獨(dú)立思考、精益求精、學(xué)會(huì)理論聯(lián)系實(shí)際，把握總體設(shè)計(jì)進(jìn)度，每一個(gè)階段的設(shè)計(jì)都要認(rèn)真檢查，避免出現(xiàn)重大失誤而影響下一階段的工作。
四、總體安排和進(jìn)度（包括階段性工作內(nèi)容及完成日期）
熟悉整理資料（12天）
方案選擇及總體設(shè)計(jì)計(jì)算（15天）
確定計(jì)算草圖（12天）
完成相關(guān)的分析、計(jì)算（20天）
完成設(shè)計(jì)圖紙（15天）
完成畢業(yè)設(shè)計(jì)說(shuō)明書(shū)（14天）
準(zhǔn)備論文及答辯（7天）
成果修改上交（6天）
五、主要參考文獻(xiàn)
【1】 王嘉.冷沖模設(shè)計(jì)與制造實(shí)例 北京：機(jī)械工業(yè)出版社，2009.
【2】 柯旭貴.沖壓工藝與模具設(shè)計(jì) 北京：機(jī)械工業(yè)出版社，2012.
【3】 王新華.簡(jiǎn)明沖模設(shè)計(jì)手冊(cè) 北京：機(jī)械工業(yè)出版社，2008.
【4】 王芳.冷沖壓模具設(shè)計(jì)指導(dǎo) 北京：機(jī)械工業(yè)出版社，1999.
【5】 濮良貴.機(jī)械設(shè)計(jì)（第八版） 北京：高等教育出版社，2006.
【6】 周宏甫.機(jī)械制造技術(shù)基礎(chǔ) 北京：高等教育出版社，2010.
【7】 葉邦彥.機(jī)械工程英語(yǔ) 北京：機(jī)械工業(yè)出版社，2005.
【8】 Arley.朗文英漢雙解詞典 外語(yǔ)教學(xué)與研究出版社，2002
【9】 王伯平.互換性與測(cè)量技術(shù)基礎(chǔ) 北京：機(jī)械工業(yè)出版社，2008
【10】 朱輝. 畫(huà)法幾何及工程制圖 上海：上海科學(xué)技術(shù)出版社，2007.
指導(dǎo)教師意見(jiàn)：
指導(dǎo)教師簽名： 日期：
教研室意見(jiàn)：
教研室主任簽名： 日期：
系意見(jiàn)：
系領(lǐng)導(dǎo)簽名： 日期：
系蓋章
畢業(yè)設(shè)計(jì)（論文）外文資料翻譯
1、 外文原文
Mold design and manufacture
The mold is the manufacturing industry important craft foundation, in our country, the mold manufacture belongs to the special purpose equipment manufacturing industry. China although very already starts to make the mold and the use mold, but long-term has not formed the industry. Straight stabs 0 centuries 80's later periods, the Chinese mold industry only then drives into the development speedway. Recent years, not only the state-owned mold enterprise had the very big development, the three investments enterprise, the villages and towns (individual) the mold enterprise's development also quite rapid .
Although the Chinese mold industrial development rapid, but compares with the demand, obviously falls short of demand, its main gap concentrates precisely to, large-scale, is complex, the long life mold domain. As a result of in aspect and so on mold precision, life, manufacture cycle and productivity, China and the international average horizontal and the developed country still had a bigger disparity, therefore, needed massively to import the mold every year .
The Chinese mold industry except must continue to sharpen the productivity, from now on will have emphatically to the profession internal structure adjustment and the state-of-art enhancement. The structure adjustment aspect, mainly is the enterprise structure to the specialized adjustment, the product structure to center the upscale mold development, to the import and export structure improvement, center the upscale automobile cover mold forming analysis and the structure improvement, the multi-purpose compound mold and the compound processing and the laser technology in the mold design manufacture application, the high-speed cutting, the superfinishing and polished the technology, the information direction develops .
The recent years, the mold profession 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 letter development speed is higher than the common mold product; The plastic mold and the compression casting mold proportion increases; Specialized mold factory quantity and its productivity increase; "The three investments" and the private enterprise develops rapidly; The joint stock system transformation step speeds up and so on. Distributes from the area looked, take Zhujiang Delta and Yangtze River delta as central southeast coastal area development quickly to mid-west area, south development quickly to north. At present develops quickest, the mold produces the most centralized province is Guangdong and Zhejiang, places such as Jiangsu, Shanghai, Anhui and Shandong also has a bigger development in recent years .
Although our country mold total quantity had at present achieved the suitable scale, the mold level also has the very big enhancement, after but design manufacture horizontal overall rise and fall industry developed country and so on Yu De, America, date, France, Italy many. The current existence question and the disparity mainly display in following several aspects:
(1) The total quantity falls short of demand
Domestic mold assembling oneself rate only ,about 70%. Low-grade mold , center upscale mold assembling oneself rate only has 50% about .
(2) The enterprise organizational structure, the product structure, the technical structure and the import and export structure does not gather
Iin our country mold production factory to be most is from the labor mold workshop which produces assembles oneself (branch factory), from produces assembles oneself the proportion to reach as high as about 60%, but the overseas mold ultra 70% is the commodity mold. The specialized mold factory mostly is "large and complete", "small and entire" organization form, but overseas mostly is "small but", "is specially small and fine". Domestic large-scale, precise, complex, the long life mold accounts for the total quantity proportion to be insufficient 30%, but overseas in 50% above 2004 years, ratio of the mold import and export is 3.7:1, the import and export balances the after net import volume to amount to 1.32 billion US dollars, is world mold net import quantity biggest country .
(3) The mold product level greatly is lower than the international standard
The production cycle actually is higher than the international water broad product level low mainly to display in the mold precision, cavity aspect and so on surface roughness, life and structure .
(4) Develops the ability badly, economic efficiency unsatisfactory our country mold enterprise technical 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 creation output value approximately ,ten thousand US dollars, overseas mold industry developed country mostly 15 to10,000 US dollars, some reach as high as 25 to10,000 US dollars, relative is our country quite part of molds enterprises also continues to use the workshop type management with it, truly realizes the enterprise which the modernized enterprise manages few
To create the above disparity the reason to be very many, the mold long-term has not obtained the value besides the history in as the product which should have, as well as the most state-owned enterprises mechanism cannot adapt the market economy, but also has the following several reasons: .
(1) Country to mold industry policy support dynamics also insufficiently
Although the country already was clear about has promulgated the mold profession industrial policy, but necessary policy few, carried out dynamics to be weak. At present enjoyed the mold product increment duty enterprise nation 185, the majority enterprise still the tax burden is only overweight. The mold enterprise carries on the technological transformations introduction equipment to have to pay the considerable amount the tax money, affects the technology advancement, moreover privately operated enterprise loan extremely difficult .
(2) Talented person serious insufficient, the scientific research development and the technical attack investment too urine
Mold profession is the technology, the fund, the work crowded industry, along with the time progress and the technical development, grasps the talented person which and skilled utilizes the new technology exceptionally short, the high-quality mold fitter and the enterprise management talent extremely is also anxious. Because the mold enterprise benefit unsatisfactory and takes insufficiently the scientific research development and the technical attack, the scientific research unit and the universities, colleges and institutes eye stares at is creating income, causes the mold profession invests too few in the scientific research development and the technical attack aspect, causes the mold technological development step not to be big, progresses not quick .
(3) The craft equipment level to be low, also necessary is not good, the use factor low
recent years our country engine bed profession progressed quickly, has been able to provide the quite complete precision work equipment, but compared with the overseas equipment, still had a bigger disparity. Although the domestic many enterprises have introduced many overseas advanced equipment, but the overall equipment level low are very more than the overseas many enterprises. As a result of aspect the and so on system and fund reason, introduces the equipment not not necessary, the equipment and the appendix not necessary phenomenon are extremely common, the equipment utilization rate low question cannot obtain the comparatively properly solution for a long time .
(4) Specialization, standardization, commercialized degree low, the cooperation ability
Because receives "large and complete" "small and entire" the influence since long ago, mold specialization level low, the specialized labor division is not careful, the commercialized degree is low. At present domestic every year produces mold, commodity mold minister 40% About, other for from produce uses for oneself. Between the mold enterprise cooperates impeded, completes the comparatively large-scale mold complete task with difficulty. Mold standardization level low, mold standard letter use cave rare is low also to the mold quality, the cost has a more tremendous influence, specially has very tremendous influence .
(5) To the mold manufacture cycle) the mold material and the mold correlation technology falls
The mold material performance, the quality and the variety question often can affect the mold quality, the life and the cost, the domestically produced molding tool steel and overseas imports the steel products to compare has a bigger disparity. Plastic, plate, equipment energy balance, also direct influence mold level enhancement .
At present, our country economy still was at the high speed development phase, on the international economical globalization development tendency is day by day obvious, this has provided the good condition and the opportunity for the our country mold industry high speed development. On the one hand, the domestic mold market will continue high speed to develop, on the other hand, the mold manufacture also gradually will shift as well as the transnational group to our country carries on the mold purchase trend to our country extremely to be also obvious. Therefore, will take a broad view the future, international, the domestic mold market overall development tendency prospect will favor, estimated the Chinese mold will obtain the high speed development under the good market environment, our country not only can become the mold great nation, moreover certainly gradually will make the powerful nation to the mold the ranks to make great strides forward. "15" period, the Chinese mold industry level not only has the very big enhancement in the quantity and the archery target aspect, moreover the profession structure, the product level, the development innovation ability, enterprise's system and the mechanism as well as the technology advancement aspect also can obtain a bigger development .
The mold technology has gathered the machinery, the electron, chemistry, optics, the material, the computer, the precise monitor and the information network and so on many disciplines, is a comprehensive nature multi-disciplinary systems engineering. The mold technology development tendency mainly is the mold product to larger-scale, preciser, more complex and a more economical direction develops, the mold product technical content unceasingly enhances, the mold manufacture cycle unceasingly reduces, the mold production faces the information, is not having the chart, is fine, the automated direction develops, the mold enterprise to the technical integration, the equipment excellent, is producing approves the brand, the management information, the management internationalization direction develops. Our country mold profession still 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, enhances modernization which the mold designed, information, intellectualization, standardized level .
(2) Establishes in the CAM/CAPP foundation the advanced mold processing technology and the advanced manufacture technology unifies, raises the automated level and the production efficiency which the mold processes .
(3) The mold production enterprise's information management technology. For example PDM (product data management), ERP (enterprise resource management), MIS (mold manufacture management information system) and information network technology the and so on INTERMET platform application, the promotion and the development .
(4) Are high speed, Gao Jing, the compound mold processing technology research and the application. For example the ultra fine ramming mold manufacture technology, the precise plastic and the compression casting mold manufacture technology and so on .
(5) Enhances the mold production efficiency, reduces the cost and reduces the mold production cycle each kind of fast economical mold manufacture technology .
(6) The advanced manufacture technology application. For example hot technology and so on flow channel technology, gas auxiliary technology, hypothesized technology, nanotechnology, rapid scanning technology, reversion project, parallel project in the mold research, the development, the processing process application .
(7) The raw material the simulation technology which forms in the mold .
(8) The advanced mold processing and the appropriation equipment research and the development .
(9) The mold and the mold standard letter, the important auxiliary standardized technology .
(10) The mold and its the product examination technology.
(11) High quality, the new mold material research and the development and its the correct application .
(12) The mold production enterprise's modern management technology □
Mold profession in "十15" period needs to solve the key essential technology should be the mold information, the digitized technology and precise, ultra fine, high speed, the highly effective manufacture technology aspect breakthrough
Along with the national economy total quantity and the industry product technology unceasing development, all the various trades and occupations to the mold demand quantity more and more big, the specification more and more is also high.
Although mold type many, but its development should be with emphasis both can meet the massive needs, and has the comparatively high-tech content, specially at present domestic still could not be self-sufficient, needs the massive imports the mold and can represent the development direction large-scale, precise, is complex, the long life mold. The mold standard letter type, the quantity, the level, the production a and so on have the significant influence to the entire mold profession development. Therefore, some important mold standard letters also must the prioritize, moreover its development speed should quickly to the mold development speed, like this be able unceasingly to raise our country mold standardization level, thus improves the mold quality, reduces the mold production cycle, reduces the cost. Because our country mold product holds the bigger price superiority in the international market, therefore regarding the exportation prospect good mold product also should take key develops. According to the above required quantity big, the technical content is high, represents the development direction, the export prospect good principle choice prioritize product, moreover chooses the product to have at present to have the certain technology base, belongs has the condition, has the product which the possibility develops .
According to "十15" the mold profession development plan, "十15" the period mold product development mainly has following several kind of the automobile cover mold
(1)Ramming mold to occupy
The mold total quantity dish with emphasis above 40%. Automobile cover mold mainly for automobile necessary, also includes for the agriculture with the vehicle, the project machinery and the farm machinery necessary cover mold, it has the very big representation in the ramming mold, the mold mostly is large and middle scale, structure complex, the specification is high. For the passenger vehicle necessary cover mold, the request is in particular higher, may represent the ramming mold the level. This kind of mold our country had the certain technology base, already for middle-grade passenger vehicle necessary, but the level is not high, the ability is insufficient, at present satisfying rate only has one about the half. Center the upscale passenger vehicle cover mold main dependence import, has become the bottleneck which the automobile develops, enormous influence vehicle type development .
(2)The precise ramming mold
Multi- locations level was entering the mold and fine represents the ramming mold development direction, the precision request life request has been extremely high, mainly for the electronics industry, the automobile, the instrument measuring appliance, the electrical machinery electric appliance and so on formed a complete set. These two kind of molds, domestic had the suitable foundation, and has introduced the overseas technology and the equipment, the individual enterprise produces the product has achieved the world level, but the majority of enterprises still had a bigger disparity, the supply total quantity insufficient, the import were very many
(3) The large-scale precise plastic mold
Plastic mold accounts for the mold total quantity 10%, moreover this proportion also is rising. In the plastic mold necessary large-scale casts the mold for the automobile and the electrical appliances, necessary models for the integrated circuit seals the mold, for the electronic information industry and the machinery and the packing necessary multilayer, the multi- cavities, the multi- material qualities, the multicolor precise note , and saves water the agricultural necessary plastic different molding for the new building materials to squeeze out the mold and the pipeline and the nozzle mold and so on, at present although had the suitable technology base and fast is developing, but the technical level and overseas still had a bigger disparity, the total quantity falls short of demand, Every year import amount reaches several hundred million US dollar.
(4) The main mold standard to imitatee
At present domestically to have an greater output the mold standard letter mainly is the mold frame, the guidance, the throwout lever pushes the tube, the elastic part and so on. These products not only the domestic necessary massive need, the exportation prospect very is also good, should continue vigorously to develop. The nitrogen cylinder and the hot flow channel part main dependence import, should raise the level in the existing foundation, forms the standard and organization scale production.
(5) The other high-tech content molds
Occupiesin the mold total quantity green 8% compression casting mold, large-scale thin wall precise compression casting technology content high, the difficulty is big. The magnesium alloy compression casting mold at present although just started, but the prospects for development were good, have the representation. The meridian rubber tire mold also is the development direction, detachable mold technology difficulty is biggest. With fast takes shape some fast pattern making technologies and the corresponding fast economical mold which the technology unifies has the very good prospects for development. These high-tech content molds in "十15" period also should the prioritize .
2、 外文資料翻譯譯文
模具設(shè)計(jì)與制造
模具是制造業(yè)的重要工藝基礎(chǔ)，在我國(guó)，模具制造屬于專用設(shè)備制造業(yè)。中國(guó)雖然很早就開(kāi)始制造模具和使用模具，但長(zhǎng)期未形成產(chǎn)業(yè)。直到20世紀(jì)80年代后期，中國(guó)模具工業(yè)才駛?cè)氚l(fā)展的快車道。近年，不僅國(guó)有模具企業(yè)有了很大發(fā)展，三資企業(yè)、鄉(xiāng)鎮(zhèn)（個(gè)體）模具企業(yè)的發(fā)展也相當(dāng)迅速。
雖然中國(guó)模具工業(yè)發(fā)展迅速，但與需求相比，顯然供不應(yīng)求，其主要缺口集中于精密、大型、復(fù)雜、長(zhǎng)壽命模具領(lǐng)域。由于在模具精度、壽命、制造周期及生產(chǎn)能力等方面，中國(guó)與國(guó)際平均水平和發(fā)達(dá)國(guó)家仍有較大差距，因此，每年需要大量進(jìn)口模具。
中國(guó)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(nèi)部結(jié)構(gòu)的調(diào)整和技術(shù)發(fā)展水平的提高。結(jié)構(gòu)調(diào)整方面，主要是企業(yè)結(jié)構(gòu)向?qū)I(yè)化調(diào)整，產(chǎn)品結(jié)構(gòu)向著中高檔模具發(fā)展，向進(jìn)出口結(jié)構(gòu)的改進(jìn)，中高檔汽車覆蓋件模具成形分析及結(jié)構(gòu)改進(jìn)、多功能復(fù)合模具和復(fù)合加工及激光技術(shù)在模具設(shè)計(jì)制造上的應(yīng)用、高速切削、超精加工及拋光技術(shù)、信息化方向發(fā)展。
近年，模具行業(yè)結(jié)構(gòu)調(diào)整和體制改革步伐加大，主要表現(xiàn)在，大型、精密、復(fù)雜、長(zhǎng)壽命、中高檔模具及模具標(biāo)準(zhǔn)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)量及其生產(chǎn)能力增加；“三資”及私營(yíng)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(lái)看，以珠江三角洲和長(zhǎng)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(guó)模具總量目前已達(dá)到相當(dāng)規(guī)模，模具水平也有很大提高，但設(shè)計(jì)制造水平總體上落后于德、美、日、法、意等工業(yè)發(fā)達(dá)國(guó)家許多。當(dāng)前存在的問(wèn)題和差距主要表現(xiàn)在以下幾方面：
（1）總量供不應(yīng)求
國(guó)內(nèi)模具自配率只有70%左右。其中低檔模具供過(guò)于求，中高檔模具自配率只有50%左右。
（2）企業(yè)組織結(jié)構(gòu)、產(chǎn)品結(jié)構(gòu)、技術(shù)結(jié)構(gòu)和進(jìn)出口結(jié)構(gòu)均不合理
我國(guó)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(dá)60%左右，而國(guó)外模具超過(guò)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(guó)外大多是“小而?！薄ⅰ靶《?。國(guó)內(nèi)大型、精密、復(fù)雜、長(zhǎng)壽命的模具占總量比例不足30%，而國(guó)外在50%以上。2004年，模具進(jìn)出口之比為3.7:1，進(jìn)出口相抵后的凈進(jìn)口額達(dá)13.2億美
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