Whether it is to transform a steel plate into a complex-shaped gear, or to make a high-performance fiber material into a streamlined vehicle shell, or just to finely cut a certain kind of blank, it is impossible to leave the machine. This kind of machine used to make machines is called the “parent machine†of the industry. With the development of industrialization, its control method has achieved digital control. It can be said that digital machine tools are the cornerstone of industrial modernization and their technical level represents the comprehensive competitiveness of a country.
In order to consolidate the foundation of China's industry and narrow the gap between China's CNC machine tools and the international community, in 2009, China officially launched the implementation of "high-end CNC machine tools and basic manufacturing equipment," the national science and technology major projects. Over the past eight years, special projects have achieved fruitful results, with an increase in output value of about 70.6 billion yuan. The technical level of China's high-end CNC machine tools has been continuously improved, and manufacturing support for domestically produced manufacturing equipment in key areas has been strong and powerful. High-end CNC machine tools have achieved localization breakthrough.
Significant increase in manufacturing capacity
Through the research and development of CNC lathes with large import volume and wide market demand, China's machine tool companies have independent research and development products that can compete with imported equipment, and their design and manufacturing capabilities have been improved.
"On a machine tool, X-axis motion can process lines, plus the Y-axis can process faces, and with the Z-axis, it can process a three-dimensional thing, but this is far from enough." Wang Decheng, Director of the Institute of Machinery Science The reporter told reporters that “Industry often processes more complex surfaces, and the materials, structures, and processing techniques of many key parts in ships, aircraft, rockets, satellites, and spacecraft have certain specialities and processing difficulties, and cannot be processed by traditional methods. To meet the requirements, multi-axis linkage, high-speed, and high-precision CNC machine tools must be used to meet the processing requirements."
Wang Decheng said that multi-axis linkage is a key technology in CNC machine tools. It can realize simultaneous movement on multiple coordinate axes of a machine tool. The tool or workpiece can be coordinated and controlled at the same time under the control of the CNC system, thus completing complex shapes. Processing. Although China is the world’s largest manufacturing country in the world today, the lack of such high-end CNC machine tools has led to China’s control over high-end manufacturing.
“In the past, China could not make five-axis linkage machine tools, and the CNC system used was also manufactured abroad. In order to manufacture a device on a large ship, many manufacturers scrambled to rush to use only one imported machine tool. For aerospace companies, In a word, foreign high-end CNC machine tools not only restrict us from importing, even if it is imported, its CNC system also has information backdoors, which is a big hidden danger for national defense security,†said Lu Bingheng, a special technical engineer and academician of the Chinese Academy of Engineering.
With the rapid development of China's aerospace, shipbuilding, energy, power, defense, automotive and construction machinery industries, the demand for large-scale, heavy-duty, composite, high-precision high-end CNC machine tools has increased dramatically. Changing the status quo of high-end CNC machine tools is imminent.
In this regard, the "National High-end CNC Machine Tools and Basic Manufacturing Equipment" national science and technology major project focuses on the deployment of large-scale imported machining centers and CNC lathes with large market demand. Machine tool companies have developed a large number of new products that meet market demands. Manufacturing technologies such as gantry machining centers and 5-axis machining centers have matured. The performance of heavy-duty forging equipment is close to the international advanced level. Precision horizontal machining centers have independent intellectual property rights. The core technology of flexible manufacturing systems. By the end of the “Twelfth Five-Year Plan†period, the product design and manufacturing capabilities of China's machine tool companies have been significantly improved, and the international competitiveness of high-end CNC machine tools and equipment has continued to increase.
In the field of high-end numerically-controlled machine tools, China finally has independently developed products that can compete with imported equipment. The successful development of heavy-duty forging and CNC punching equipment such as 80,000-ton large-sized die forging presses and 10,000-ton aluminum sheet tensioning stretchers has been completed. The blank of large-scale integral forming technology in the domestic aviation field; large tank complete welding equipment was successfully applied to the development of a new generation of rockets such as the Long March V, and the first production demonstration line using domestic processing centers and CNC turning centers was established in the aerospace field. More than 100 types of new-generation launch vehicles, docking institutions, lunar exploration projects, and more than 10,000 critical complex parts have achieved remarkable economic and social benefits. The industrialization of CNC forging and forming equipment has achieved remarkable results. Among them, the auto cover press line has a domestic market share of more than 70%, and the global market share has exceeded 30%, which has effectively promoted the autonomy of domestic auto equipment and successfully exported 9 vehicle production lines to the United States.
Technical standards gradually improved
China's machine tool industry has formed a large number of technical standards and specifications. Some of the technical standards have been included in international standards. The industry's international competitive advantage has been significantly enhanced, and it has provided strong support for product development.
Since the implementation of the National Science and Technology Major Project of “High-end CNC Machine Tools and Basic Manufacturing Equipmentâ€, the industry’s technical level has been significantly improved. Lu Bingheng introduced that more than 30 key products such as precision horizontal machining centers developed by China have reached the international advanced level. Among them, the 25-meter vertical column turning vertical milling lathe is a high-end product urgently needed by China for the construction of major national engineering projects. Its technical parameters and technical grades are among the world's leading, with the largest machine specifications and bearing weight in the world, representing the country’s high-end The highest level of CNC heavy machine tools.
What is most worth mentioning is that the independent innovation and reliability of the machine tool industry in China have been significantly improved, and standards and technical specifications have been gradually improved. Through special implementation, the joint development of domestic machine tool backbone enterprises and universities and users is promoted, and the establishment of national/industry standards for reliability evaluation of CNC machine tools is actively organized and promoted in the machine tool industry. The average time between failures of the machine tool host has increased from 400 to 500 hours before the implementation of the special project to approximately 1200 hours, and some products have reached the internationally advanced 2000 hours.
Lu Bingheng introduced that the special achievements formed a large number of technical standards and specifications. Some of the technical standards were taken seriously by international counterparts and included in international standards. The industry’s international competitive advantage has been significantly enhanced, providing strong support for product R&D, and also contributing to the continued development of the national equipment manufacturing industry. The improvement of capabilities plays a safeguard role.
At the end of 2016, the standard of S-shaped test pieces for testing the accuracy of 5-axis linkage machine tools independently proposed by China has passed the examination and approval by the International Standards Committee, becoming China's first standard in the field of high-end CNC machine tool design and testing, achieving a “zero†breakthrough.
In addition, for more than eight years since its special implementation, it has applied for 3956 patents for inventions, established 407 national and industry standards, and researched and developed 2,951 new products and technologies. In the industry research institutes and key enterprises, 18 innovation capability platforms have been built, 70 demonstration projects have been deployed, and more than 5,500 innovative talents have been trained.
Domestic "brain" complements the short board
The CNC system has realized the leap from analog, pulsed to full-digital bus, initially possessed the competitive ability with similar foreign products, and broke through the bottleneck that restricts the development of the CNC machine tool industry in China.
CNC system is the "brain" of machine tool equipment, and it is the key factor that determines the function, performance, reliability, and cost price of CNC machine tools. It is also the bottleneck restricting the development of CNC machine tool industry in China. The weak foundation and “mindlessness of the brain†have always been the shortcomings of “Made in Chinaâ€.
According to experts, CNC systems, servo motors, servo drives, etc. are the most important and critical basic components of manufacturing equipment. To achieve the goal of "Made in China 2025" and form the core competitiveness of "China's wisdom", it is inseparable from the innovation of key technologies such as servo drives and servo motors in CNC systems.
In order to make up for the short board, the deployment of the "National High-tech CNC Machine Tool and Basic Manufacturing Equipment" major national science and technology projects implements the entire industry chain, and the domestic CNC system achieves the original surpass of some technologies. The company has mastered the hardware and software platform design and mass production technology of the CNC system, and has reached the international mainstream product technology level in key technical indicators such as multi-channel, multi-axis linkage and high-speed interpolation.
Through special support, China's numerical control system has achieved a leap from analog, pulsed, and all-digital buses, and has initially had the ability to compete with similar foreign products. The high-end numerical control system, functional components and host product supporting R & D, initially realized with the high-end numerical control machine tools batch support. According to Luo Junjie, deputy director of the Department of Equipment Industry of the Ministry of Industry and Information Technology, in 2016, the numerical control machine tool dedicated to research and development of high-end numerical control system has accumulated more than 1,000 sets of sales, the domestic market share increased from less than 1% before the special start to 5 %about.
At present, the domestic high-end numerical control system has been matched with more than 10 types of more than 600 high-grade CNC machine tools, and it has begun to be applied in key aerospace enterprises. “The quality of functional parts and enterprise products has steadily improved, the series of products has been continuously improved, the testing equipment for rolling functional components has been built from scratch, and the key technical indicators such as static stiffness and the level of test equipment have ranked among the top in the world. As of now, rolling functional components are in the high end. The market share of CNC machine tools reaches 20%, which is 4 times higher than that before the implementation of special projects in 2009. The satisfaction of varieties is 80%, said Luo Junjie.
Lu Bingheng stated that China's CNC machine tools will focus on two key user areas: aerospace, automotive, and common technology research and emphasis on process verification in key areas; the development of key core components and industrialization will be paralleled; accelerating the development of innovation capability platforms and demonstration projects, and strengthening innovative talents. Training and introduction of high-end talents, focusing on solving the problems of CNC system and functional components, reliability and accuracy maintenance, processing efficiency, and improvement of process level, realizing the application of special achievements in scale and complete sets of key areas, and implementation for full implementation "Made in China 2025" provides support.
In the next step, CNC machine tools will be closely linked with other national science and technology projects and local science and technology projects to form a concerted effort to jointly achieve the leap-forward development of the national high-end CNC machine tools and basic manufacturing equipment technology innovation competitiveness.
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