The United States, Germany and Japan are the countries with the most advanced technology and richest experience in the research, design, manufacture and use of CNC machine tools. Because of its different social and historical conditions and government development strategies, each has its own characteristics.
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American CNC machine tool development
The successive governments of the United States have attached great importance to the machine tool industry. The US Department of Defense and other departments have been continually proposing the development direction and scientific research tasks of the machine tools because of their military needs, and providing sufficient funds. At the same time, they are recruiting talents from around the world, especially in the development. And "innovation", focusing on basic research. Machine tool technology continues to innovate, such as the world's first CNC machine tool developed in 1952, the machining center was created in 1958, the FMS was developed in the early 1970s, and the open CNC system was first established in 1987. Since the United States firstly combined the production requirements of automobiles and bearings, it has fully developed a large number of automatic lines required for production automation, and electronic and computer technology are leading in the world. Therefore, the design, manufacture and numerical control system of the CNC machine tools are solid and consistent. Scientific research and innovation, so its high-performance CNC machine technology has also been leading the world. However, its shortcoming lies in the emphasis on basic scientific research and neglect of applied technology. In addition, the government-led relaxation in the 1980s caused the growth of CNC machine tool production to slow down. In 1982, it was overtaken by Japan, and imported in large quantities. Since the 1990s, the government has corrected the past bias, and CNC machine tools have turned from technology to utility, and production has gradually picked up.
The US machine tool industry started 50 years later than the UK, but soon surpassed the UK in manufacturing technology, ranking first in the world. In 1896, Ford built the first car. In order to cope with the mass production of the car, Gleason developed a complete set of equipment and tools for gear processing and measurement. Other companies have also developed many new and efficient automatic machine tools. In 1934, the world's first automatic line of combined machine tools was developed. In 1948, the world's first automatic line with an annual output of 30 million sets of bearings was established, which led to a rapid increase in vehicle production. In 1950, the output of automobiles reached 8 million (compared with 2.07 million in China in 2000). Since then, the US machine tool industry has developed rapidly, ranking first in the world for machine tool technology advancement, production, and production scale. Although in the mid-1980s, the US economy was in recession, the machine tool industry was once in a downturn and was overtaken by Japan and Germany. However, the government quickly took measures to reverse the situation.
At present, the US machine tool manufacturing industry is still in the world's leading position in high-efficiency automated machine tools, automatic production lines, NC machine tools, FMS and other machine tool technologies and industrial production. Mainly distributed in the Midwest and Northeastern states, the main consumer users are automobile manufacturing, aviation industry, construction industry and medical equipment manufacturing.
The reason why the US machine tool technology can maintain a long-term lead in the world, the government has played a vital role in guiding the strengthening of research and development and continuous innovation. Mainly manifested in:
First of all, plan, measure and provide adequate funding for major scientific research projects. For example, it provides a lot of money for the research and development of NC machine tools. Providing $100 million in funding for the development of a new generation of NC systems.
Second, the organization guides scientific research cooperation between relevant research units and enterprises. For example, the development of a new generation of NC systems was developed by the National Manufacturing Science Center in collaboration with the US Air Force; the development of CIM, the government organization General Motors, Boeing Aircraft Corporation and related machine tool industry companies jointly developed.
Once again, after the new product is developed, organize the use of orders and promote the further deepening of scientific research. For example, after the first NC milling machine was developed by the Massachusetts Institute of Technology in 1952, the military department immediately organized 100 units for production and continuous improvement, thus accelerating the continuous improvement of NC machine tool technology. Another example: After the United States G&L Company developed the world's first VARLA4 parallel mechanism machine tool in 1994, it timely organized relevant university research and analysis and used it in the enterprise to further improve its technology.
Due to the lack of skilled workers in the United States and the relatively high wages of workers, machine tool users demand that machine tool builders have more flexible machine tools and can be programmed repeatedly to reduce the need for skilled workers. Due to the increasingly fierce competition in the automotive industry, the vehicle model renewal cycle is also getting shorter and shorter. The automotive industry requires flexible machine tools, wide use range and short commissioning period to meet the requirements of small batch production and fast replacement. The demand for high-speed machine tools in the US aviation, automotive and mold industries is increasing. Due to environmental reasons, many customers require machine tools to reduce the amount of coolant used. All of the above shows that technological advancement is the main factor affecting the development of the US machine tool industry.
For example, electronic, high-speed, and precision have become the mainstream of the development of the US machine tool industry: for example, American companies can effectively integrate suppliers and customers' procurement and inventory systems through network enterprise-to-business services; large-scale automobile companies (GM, Ford, Dai Müller/Chrysler and Aerospace (boeing, Lockheed) are designed and developed on a global scale with related systems through this network service; manufacturing process management, remote monitoring, troubleshooting and after-sales service in the machine tool industry Popularization; the milling machine spindle adopts hydraulic bearing molds, and uses non-contact replacement ball bearings; linear motors get rid of application restrictions and enter commercialization.
Focusing on the future, the US machine tool manufacturing has the following obvious development trends:
First, the pursuit of machine tools with higher processing efficiency. Because improving the efficiency of the machine tool is equivalent to shortening the machining cycle of the part, there are two ways to shorten the machining cycle. One way is to increase the cutting speed, that is, increase the spindle speed. At present, the spindle speed of the lathe and turning center is above 8000r/min, and the spindle speed of the machining center is generally 15000~20000r/min, and there are 40,000r/min and 60,000r/min. Similarly, the delivery speed has been greatly improved, up to 20m/min or even 60m/min. As the cutting speed increases, the structural rigidity and dynamic characteristics of the machine tool are significantly improved, and the dynamic balance design of the high-speed spindle and the tool system is also improved; the other way is to reduce the non-machining time. Because there is a lot of useless time in the processing of parts, such as workpiece handling, loading and unloading, installation adjustment, tool change and spindle lifting and lowering speed, the development of composite machine tools has recently developed rapidly, and its core is in one Various operations such as turning, milling, drilling, boring, tapping, reaming and reaming are required on the machine. The main trend in the development of lathe technology is multi-function machine tools. The current multi-functional machine tool is actually a machining center with turning function. In terms of grinding, the current technical focus is on the development of a PC-based grinding control system. A grinding machine can perform internal, external and step shaft grinding, or it can speed up the production process by different cycles of the machine. Fast and dimensional accuracy and surface roughness are guaranteed.
Second, the pursuit of more safe and reliable and environmentally friendly machine tools. Due to the increased speed of the machine tool, the safety and health of the operator has also been mentioned as a priority. At present, high-end machine tools developed in the United States almost always have safety warning devices in places that may harm people. Dry cutting and micro-lubricant cutting methods are becoming more and more widely used because they can greatly reduce the volatilization of lubricants, and almost all the machine tools are closed. Some machines can't even see the chips, so even if there are Excessive oil mist and fumes are also easy to collect. At the same time, the environment and position of the machine operator at work will be considered very comfortable. In addition, non-polluting clean processing technology has also received great attention.
Third, the machine tool component industry has developed rapidly. The machine tool parts are developing rapidly and the variety is complete. The main products are ball screw pair, precision bearings, various turntables, tool changers, various pneumatic, hydraulic devices, linear guides and spindle components. The development of these accessory parts has effectively promoted the development of machine tool mainframes, which not only helps to improve the speed and performance of machine tools, but also greatly shortens the production cycle of the mainframe and reduces production costs.
Fourth, the pursuit of a more complete control system. Higher speed processors and more precise control devices make the machine's functions and performance perfect and powerful. Technology intensive has entered the stage of rapid development, and the key to integration is the open structure. The application of PCC technology has changed the way the machine works, pushing the CNC to the control center and not limited to the scope of the machine controller. Control software is growing faster and even improved several times a year. CNC manufacturers have provided some open-structure CNC systems. At present, CNC controllers with open structures in machinery manufacturing plants account for 10% to 20%. The part program can be developed offline and then transferred to the programming system on the production floor. It runs on the CNC controller. The operator can observe and test the tool operation and machining process, and can also make necessary corrections to the machining process. 30% of the controllers sold by GEFANUC in the United States are open-ended, realizing true CAM/CNC integration, and tending to be intelligently controlled and accessible. The technical foundations of virtual manufacturing and paperless production are already in place, and with the help of information technology, the application of such software will develop at a faster rate.
Fifth, the pursuit of higher machine tool appearance quality. At present, machine tool manufacturers pay more attention to the beauty of machine tool modeling and the harmony of color tone, and the machine tool products are more developed towards crafts.
German CNC machine tool development
The German government has always attached importance to the important strategic position of the machine tool industry and has been vigorously supported in many aspects. Although the development of the German machine tool industry is later than that of the United States, the machine tool industry has developed rapidly because of its ability to learn advanced technology from the United States and the United Kingdom, and to strengthen scientific experiments and research and analysis, especially in advanced technology. First of all, pay attention to "reality" and "effectiveness." Germany pays special attention to scientific experiments, combining theory with practice, and paying equal attention to basic scientific research and applied technology research. Secondly, adhere to the "people-oriented" and continuously improve the quality of personnel. The company cooperates closely with the university research department to conduct in-depth research on the commonality and characteristics of the user's products, processing technology, machine tool layout research and CNC machine tools, and strives for excellence in quality. The quality and performance of CNC machine tools in Germany are good, advanced and practical, and the products are exported all over the world. Especially large, heavy, precision CNC machine tools. Finally, Germany pays special attention to the advanced and practical use of CNC machine tools and accessories. Its machines, electricity, liquid, gas, light, tools, measurement, CNC systems, and various functional components are among the best in the world in terms of quality and performance. For example, Siemens' CNC system is world-famous and has become the best choice for most users.
Similarly, the German Machine Tool Association (VDW) provides German companies with all possible market support, from market information and statistics to reports on various products and forecasts for key areas such as the automotive industry. VDW uses the China Machine Tool Association to provide direct access to German companies interested in seeking partners in China; provides import certification and other trade information for all types of equipment and services; organizes Chinese personnel to conduct technical training activities in Germany as needed Organize German business delegations to participate in large metal processing exhibitions in China, and contact the German government to provide official support.
Japan's CNC machine tool development
The Japanese government attaches great importance to the development of the machine tool industry. On the one hand, it guides the development of the industry through planning and formulation of regulations (such as “machine vibration methodâ€, “electromechanical lawâ€, “machine letter methodâ€, etc., on the other hand, it provides sufficient R&D funding to encourage Scientific research institutions and enterprises vigorously develop CNC machine tools. Studying Germany on the importance of talents and machine tool components, learning the United States in quality management and CNC machine tool technology, and combining the experience of the two countries to form their own development characteristics and then come to the fore.
Since the first CNC machine tool was developed in 1958, Japan's output in 1978 (7,342 units) exceeded that of the United States (5,688 units), and its output and export volume ranked first in the world for a long period of time (2001 production of 46,604 units). 27,409 units were exported, accounting for 59%). The strategy is to imitate the latter, and the mid-range CNC machine tools with large and wide output have a large number of exports, occupying most of the world market share, and further strengthening scientific research in the 1980s to develop high-performance CNC machine tools. Japan FANUC Corporation adopts this strategy. Under the guidance of the Japanese government, it has developed a variety of low-to-medium-high-grade CNC systems that are required by the Japanese government. It is the world's largest supplier of CNC machine tools. The company has 3,674 employees, more than 600 researchers, 7,000 sets of monthly production capacity, 50% of sales in the world market, and 80% in Japan. It has played a major role in accelerating the development of CNC machine tools in Japan and the world. enhancement.
At the same time as FANUC, there are many other machining accessories companies. Under the guidance of the government, these Japanese companies pay special attention to the development of key technologies and core products. This division of labor cooperation has improved the efficiency of the Japanese CNC machine tool industry and avoided the internal competition caused by the US CNC machine tool industry because various manufacturers want to become industry standards, thus preserving external competitiveness. In addition, the Japanese government also encourages some CNC machine tools and automation equipment manufacturers that are small in scale but have their own unique technological advantages to develop their own patented technology.
Taiwan, China
The development of modern CNC machine tools enterprises is increasingly dependent on the supply chain, which has been proved by the development experience of machine tool industry in countries and regions around the world. For example, the machine tool industry in Taiwan is a good example.
The machine tool industry in Taiwan is an assembly type. In addition to precision parts such as spindles, machine tool manufacturers basically do not perform other machining. Casting, sheet metal, heat treatment, painting and other processes are all completed by the collaborative factory. For example, about 70 cooperative factories of Youjia Company are located in Taichung.
It can be seen that the development advantage of the machine tool industry in Taiwan is that it has formed a complete and complete range of machine tool parts (parts). These parts and components are concentrated in the range of less than 100 kilometers around the machine tool factory, and the parts supply is on time and complete. More than 90% of the manufacturers in the machine tool industry in Taiwan are concentrated in the Taichung area. There is not too long a distance between them. Almost one is next to each other, so that they can achieve accurate supply and reduce inventory, even in some Zero inventory is achieved by the manufacturer or certain links. The developed machine tool parts industry and the convenient and perfect supply chain are the advantages and pride of the machine tool industry in Taiwan. It is even better than Japan and Germany in the convenience of obtaining parts.
In addition, with the increasing competition in the market, machine tool companies in Taiwan generally attach importance to research and development, and annual R&D investment is more than 4% of turnover. A company with good foundation and strong financial strength can achieve more than 5% of its annual investment in research and development.
Current situation in China
The development of China's numerical control technology started in the 1950s. Through the introduction of numerical control technology during the "6th Five-Year Plan" period, the organization of the "seven-five" period absorbed and absorbed "scientific and technological breakthroughs", and China's numerical control technology and numerical control industry have achieved considerable results. Especially in recent years, China's numerical control industry has developed rapidly. The average annual growth rate of domestic CNC machine tool production and consumption from 1998 to 2004 was 39.3% and 34.9% respectively. Despite this, the development momentum of imported machine tools is still strong. Since 2002, China has become the world's largest machine tool consumer and the largest importer of machine tools for three consecutive years. In 2004, China's machine tool mainframe consumption reached US$9.46 billion. The gap between foreign high-end and large-scale CNC machine tools and research and development is more obvious. More than 70% of such equipment and most of the functional components are imported.
It can be seen that China's domestic CNC machine tools, especially medium and high-end CNC machine tools, still lack market competitiveness. The main reason is that the research and development depth of domestic CNC machine tools is not enough, the manufacturing level is still backward, service awareness and capacity are lacking, CNC, system production. Inadequate application promotion and lack of CNC talents. We should clearly understand the situation, fully understand the shortcomings of domestic CNC machine tools, strive to develop advanced technologies, and increase technical innovation and training services to shorten the gap with developed countries.
Abstract The United States, Germany and Japan are the countries with the most advanced technology and richest experience in the research, design, manufacture and use of CNC machine tools. Because of its different social and historical conditions and government development strategies, each has its own characteristics. American CNC machine tools develop American calendar...