At present, the impact of the international financial crisis continues to exist, and the country's package of plans and measures to deal with the financial crisis are being implemented. The current situation of the machine tool market and the future development trend under the new situation have become the primary concern of enterprises. To this end, the China Machine Tool Industry Association conducted research work in nine industries, including automobiles, ships, power generation, aviation, railways, textiles, agricultural machinery, petroleum machinery, and weapons, from August to September 2009, due to time and manpower reasons. Research on these industries is only focused on areas that are closely related to machine tool requirements. The results of the survey have been summarized, and only the survey results of the four major industries that have a greater degree of integration with the machine tool industry will be published. The analysis conclusions are for reference only.
Development of application fields and analysis of machine tool requirements 1. Automotive industry 1. Overview of the development of the automotive industry In 2008, the growth rate of production and sales fell sharply year-on-year. In 2008, affected by the international financial crisis, China's auto industry ended the continuous double-digit growth of production and sales in the six years from 2002 to 2007. The production and sales increased by 5.21% and 6.70%, respectively, down 16.81% and 15.14 respectively over the same period of the previous year. percentage point.
In 2009, the production and sales grew rapidly, and the huge potential of the market was fully demonstrated. In 2009, thanks to the implementation of various measures in the national “Automotive Industry Adjustment and Revitalization Planâ€, the automobile market recovered rapidly and presented an unprecedented high-speed development situation. From January to September, the production and sales of automobiles were 9,921,700 and 9,662,700, an increase of 32.01% and 34.24%, which exceeded the total of 267,600 and 282,200 in 2008. From the current trend, in 2009 China's automobile production and sales will exceed 13 million, making it a veritable automobile production and sales country. As an important pillar industry of the national economy, the leading role of the automobile industry in economic and social development will continue to be fully utilized.
The ability of independent innovation has been further improved, and product structure adjustment has achieved fruitful results. According to the statistics from January to September this year, due to national policy support, passenger cars below 1.6L performed well, and cumulative sales accounted for 70% of total passenger car sales. The market share was the highest in history and contributed to the rapid growth of production and sales. Nothing. Small-displacement passenger cars are growing into the mainstream of production and sales, indicating that China's auto industry product structure adjustment has achieved great results. The statistics from January to September also showed that the sales volume of the self-owned brand sedan market reached 29%, and continued to maintain the growth trend, indicating that China's auto industry's independent innovation capability has made great progress.
The scale of investment in fixed assets continued to maintain rapid growth. In the auto industry, the fixed assets investment during the 10th Five-Year Plan period will be 235 billion yuan, the investment in the 11th Five-Year Plan will exceed 400 billion yuan, and the investment in the 11th Five-Year Plan to the 13th Five-Year Plan will reach 1.5 trillion yuan. In addition, in accordance with the "Automotive Industry Adjustment and Revitalization Plan", the new central government investment fund of 10 billion yuan will be added during the three-year plan implementation period to support the technological progress and technological transformation of automobile production enterprises, which will drive the automobile and parts enterprises 1000-2000. The corresponding investment of 100 million yuan. According to incomplete investigations, the projects currently under construction and newly built in China will increase the annual production capacity of millions of engines and millions of complete vehicles. Such as Beiqi Foton Cummins engine, Huatai Automobile Ordossky Land, Beiqi Foton South Production Base, Shenyang Mitsubishi Engine, Changchun FAW Toyota, Brilliance Auto, Guangzhou Auto Passenger Vehicle Project, Wuling, Nanjing Auto and Geely Changsha Automobile Production Base all have engines or New project for the car. In addition, several domestic automakers such as FAW, SAIC and Dongfeng will increase their production capacity by 65% ​​compared with the current level in 2013. Changan Automobile Engine, Liuzhou Wuling Liuji Power, Shanghai General Powertrain and other domestic automobile engine companies will expand their production capacity by 60% in 2013. All these new projects will trigger new machine tool requirements. According to the current investment plan and investment scale, according to the empirical data provided by the industry, if the average annual investment is 100 billion yuan and the equipment accounts for 70%, of which machine tools account for 50%, the automotive industry provides about 35 billion machine tools per year. Yuan market.
2. Demand for machine tools in the automotive industry The main body of machine tool consumption in the automotive industry is divided into two levels. One is the four lines used for the production of complete vehicles, namely stamping, welding, painting and assembly lines; the second is the engine, Automotive parts processing including transmissions, steering systems, brake systems, transmission systems, and suspension systems. Among the four lines of the whole vehicle production, only the press line requires a machine tool, and the current domestic press line can fully meet the requirements. The focus of machine tool consumption is on the second level, that is, the processing of auto parts, which accounts for about 70% of the total equipment value of the whole vehicle. Some experts have estimated that the demand for machine tools for auto parts processing is 10 times larger than that of OEMs.
As the engine of the car core, its processing equipment is one of the most important car equipment. As new models accelerate into the market, the requirements for flexibility in the engine production line are stronger. Usually, an engine production line must meet the requirements for producing three models. The lightweight of the car makes the engine block and cylinder head material change from cast iron to aluminum alloy, which puts some new higher requirements on the machine tool.
The main components that make up the engine are the cylinder block, the cylinder head, the crankshaft, the camshaft, the connecting rod, and the like. Most of the equipment for processing these parts are high-efficiency, high-performance, high-reliability CNC machine tools and special CNC machine tools. Among them, the flexible production lines for cylinder and cylinder head processing are mostly composed of horizontal machining centers; the crankshaft processing equipment is mainly for truck-lawing machine tools, CNC crankshaft internal milling or external milling machines, CNC crankshaft grinding machines, crankshaft polishing machines, etc.; camshaft processing equipment is mainly It is a camshaft CNC lathe, a camshaft grinder, etc.; the connecting rod processing is mostly a special equipment, such as a double-face grinder.
At present, the value of imported equipment accounts for 90% or even 95% of China's automobile engine production. The localization rate of tools used in engine production lines is over 10%. The gap between domestic machine tools is mainly manifested in three aspects. The first is the lack of integration technology, the lack of technology to integrate process systems and logistics systems into flexible manufacturing units or production lines. Second, the reliability and stability of domestic machine tools still needs to be improved. Especially in the mass production mode of automobiles, the contradiction is particularly prominent; the third is that the service of domestic enterprises to users still stays in the after-sales service stage, and the automotive industry generally requires the provision of overall process equipment solutions. These gaps and problems should cause the machine tool manufacturers to pay full attention.
China's auto industry is in an unprecedented period of rapid development, and still shows strong development potential under the impact of the international financial crisis. The automobile industry has become the mainstay of machine tool consumption, and the relevant analysis believes that its proportion has accounted for 40% of the total machine tool consumption. The machine tool industry should firmly grasp the strategic opportunity period of the automobile industry in the next 10 years of development, aim at the current direction of automobile development, and aim at the world's automobile manufacturing technology to encourage and support small-displacement vehicles, energy-saving and environmental protection, new energy vehicles and other hot projects. And the development of cutting-edge technology in equipment, significantly increase the market share of domestic machine tools, and gradually achieve import substitution, and common development with the domestic automotive industry.
Second, the ship industry Overview of the development of the shipbuilding industry In 2008, orders for newly accepted ships decreased significantly year-on-year. In 2008, the shipbuilding completion volume of China's shipbuilding industry was 28.81 million DWT, up 52.2% year-on-year; the order for hand-held ships was 204.6 million DWT, up 28.7% year-on-year. However, affected by the impact of the international financial crisis, orders for newly accepted ships fell by 40.9% year-on-year to 58.18 million DWT.
The production and operating environment in 2009 has not improved significantly. In 2009, the shipbuilding industry conscientiously implemented the central government's package plan to cope with the financial crisis and promote the steady development of the economy, and achieved remarkable results. All economic indicators maintained steady growth. From January to September, the national shipbuilding completion volume was 27.78 million DWT, a year-on-year increase of 65%. From January to October, the national industrial enterprises above designated size achieved a total industrial output value of 443.8 billion yuan, a year-on-year increase of 31.5%, an increase of 29.7 percentage points; The export delivery value was 205.7 billion yuan, a year-on-year increase of 19.2%, an increase of 43.9 percentage points. Due to the impact of the international financial crisis, the global shipping market demand has shrunk sharply. The production and business environment of the shipbuilding industry has not improved significantly as a whole, mainly in the following aspects. First, the new orders for ships were 16.92 million DWT, a year-on-year decrease of 70%. Second, the difficulty of delivery has continued to spread. In 2009, 18% of the ships that should be completed in 2009 were delayed due to shipowners. It is also very common to reduce the contract price and modify the ship type. The ship's forward orders account for 30%, and the risk of uncertainty is higher. Third, the ship price continued to decline. The ship market under the reversal of supply and demand continued its downward trend since the fourth quarter of last year. The Clarkson new ship price composite index has fallen to 142 points at the end of September, compared with 190 points in August 2008. The highest drop was 48 points, the main ship type price fell by more than 30%, and the individual ship type even exceeded 40%.
Marine supporting equipment, high-tech marine equipment and offshore engineering equipment are the development priorities. Facing the severe production and business environment, China's shipbuilding industry will further increase the pace and intensity of industrial restructuring and product optimization and upgrading in accordance with the objectives and requirements of the Shipbuilding Industry Adjustment and Revitalization Plan, focusing on the development of high-tech value-added ships. Marine engineering equipment, supporting the supporting capabilities of marine equipment and marine low-speed diesel engines. Among them, marine supporting equipment and marine low-speed diesel engines will become the focus of investment, and also the main selling point of the machine tool market in the shipbuilding industry in the next few years.
Marine equipment refers to power equipment, deck machinery, ship boilers and marine electrical equipment. The power unit includes intelligent diesel engine, energy-saving and environment-friendly medium and low speed diesel engine, LNG marine dual fuel engine, ship shafting (reduction box, bearing, intermediate transmission shaft), super large propeller and large-scale high-efficiency water jet propulsion device. Deck machinery includes rudder equipment, anchor equipment, mooring equipment, and ship lifting machinery. Marine electrical equipment includes high-power medium and high voltage generators and power supply equipment. In addition, there are ship boilers, refrigeration and air conditioning units, and marine pumps and valves.
Marine equipment has a very large market development space. According to analysts, if the delivery target in 2010 can be achieved, the global civilian ship market capacity will reach 140 billion US dollars; according to the marine equipment accounted for 50% of the ship price, then the global marine equipment market size will reach 70 billion US dollars; According to China's shipbuilding tonnage accounting for 35% of the world, China's marine equipment market will reach 24.5 billion US dollars. The development of marine supporting equipment in China's shipbuilding industry has lagged behind the manufacturing capacity of the whole ship. The localized loading rate of marine supporting equipment is less than 50%. In 2007, China's ship supporting equipment manufacturing enterprises completed the total industrial output value of 21.38 billion yuan, accounting for only ships. 8.3% of the total industrial output value. Taking diesel engines as an example, in 2007, China's marine low-speed diesel engines produced 3.09 million horsepower and imported 2.89 million horsepower, which is far from the target of 12 million horsepower in 2011. The output of medium-speed diesel engines is 930 and 470 are imported. 48% and 34%. The key parts of diesel engine such as marine deck machinery and marine crankshaft are about 50%, and the equipment gap of marine cabin equipment and ship communication and navigation automation system is larger.
Comprehensive various factors can be expected to develop marine supporting equipment, improve the shipping rate of domestically-made marine supporting equipment, and achieve the three-year mainstream ship type domestic equipment loading rate of more than 65% required for the three-year adjustment and revitalization plan, marine low-speed machine, medium The domestic market satisfaction rate of auxiliary equipment such as speed machines and deck machinery and other development targets will not only greatly improve the comprehensive strength of China's shipbuilding industry, but also greatly enhance the ability to withstand market risks. It can be expected that marine equipment will become the focus of the shipbuilding industry in the next few years.
Investment in fixed assets such as marine ancillary equipment is expected to increase by 20%. In 2006, the total industrial output value of the shipbuilding industry was 172.2 billion yuan, and the investment in fixed assets was 19.96 billion yuan. In 2007, the total industrial output value was 2,570 yuan, and the fixed assets investment was about 30 billion yuan. In 2008, the total industrial output value was 414.3 billion yuan. 45 billion yuan. As the statistics of fixed assets investment in the shipbuilding industry are incomplete, according to the preliminary estimates of the demand for fixed assets investment-equipment procurement-metal processing machine tools in the general machinery industry, the annual consumption of machine tools in the shipbuilding industry in 2008 is estimated to be 5-6 billion yuan. In 2009, thanks to the national package to deal with the international financial crisis, fixed asset investment still increased by 55.5% from January to May. According to the opinions of the State Council's batch forwarding and reforming committee and the Ministry of Industry and Information Technology, the shipbuilding industry will strictly implement the shipbuilding industry adjustment and revitalization plan and the medium and long-term development plan of the shipbuilding industry in the next three years. The relevant departments of land, sea, environmental protection and finance at all levels will no longer accept new docks. The application for the slipway project will suspend the approval of the expansion project of the shipyard and shipyard of the existing shipbuilding enterprise. It can be predicted that from 2009 to 2012, investment projects for capacity expansion will be strictly suppressed, and marine supporting equipment, high-tech ships, offshore equipment, etc. will meet the investment and adjustment plan of the ship industry and the medium and long-term development plan of the shipbuilding industry. It will increase by about 20% year by year.
2. Demand for machine tools in the shipbuilding industry In the face of the current severe situation in the shipbuilding industry, the demand for heavy metal forming equipment and welding equipment required for the construction of the three major ship types is not expected to increase dramatically. However, there will be demand for special and special processing machines required for the manufacture of offshore engineering equipment, which is the growth point of heavy machine tools.
The main key components of marine supporting equipment, such as high-power low-speed diesel engines, crankshafts, large-scale marine propellers, etc., have been planned, and the investment is basically in place. The ordering of heavy-duty and super-heavy metal processing machines is basically completed, and the capability is very fast. form. Therefore, the growth rate of demand for heavy-duty and super-heavy metal processing machine tools will slow down in the next few years, but the demand for large, medium and general-purpose CNC machine tools will maintain a certain growth trend.
The key components of marine diesel engine mainly include machine base, frame, cylinder block, connecting rod, cylinder head, cylinder liner, piston, camshaft and cam assembly, bearing bush, intake and exhaust valve, air cooler, and oil pump. At present, the domestically produced low-speed diesel engine has a power of 49,680 hp, a length of 15.6 m, a height of 12.4 m, a cylinder diameter of φ900 mm, a crankshaft weight of 21t, and a self-weight of 1,253 tons. The planned maximum power will reach 100,000 hp. The machining accuracy is based on the PA6BV-280 (7140kW) marine diesel engine. The highest machining accuracy of the cylinder block is IT5-6; the highest machining accuracy of the camshaft is IT6; the highest machining accuracy of the cylinder head is IT6; the highest machining accuracy of the cylinder is IT6; the highest piston Machining accuracy is IT4.
The main processing equipment for the low and medium speed diesel engine mounts and frames are CNC gantry milling machines and CNC vertical lathes.
The main processing equipment of cylinder block (body) is CNC gantry milling machine and gantry machining center. The specifications are mostly gantry width 2~5m, the maximum requirement is not less than 8m, positioning accuracy and repeat positioning accuracy requirements ≤0.016/1000mm and ≤0.01mm .
The main processing equipment for the cylinder head is a horizontal machining center, a vertical machining center and a vertical turning and milling center. Horizontal machining center specifications are mostly in demand of 500, 630, 800 specifications. 630 horizontal machining centers require positioning accuracy X, Y, Z axis ≤ 0.008 mm, and repeat positioning accuracy ≤ 0.004 mm.
The main processing equipments for connecting rods and cranks are CNC gantry milling machines, large CNC vertical lathes, heavy duty CNC sleepers, vertical and horizontal machining centers.
The main processing equipment for camshafts are camshaft milling machines and camshaft grinding machines.
The main processing equipment for heavy crankshafts are horizontal crankshaft lathes, vertical lathes, floor boring machines, portal milling machines, crankshaft milling machines, horizontal turning and milling centers, crankshaft grinding machines and other equipment. The low-speed machine crankshaft adopts the assembled structure, the crankshaft and the crank are processed in one piece, and after the hot assembly, the whole machining is required. The heavy-duty turning-milling combined machining center, the numerical control crank vertical lathe, the numerical control vertical lathe, the numerical control floor boring and milling machine, and the hot-loading fine are required. Equipment for processing heavy-duty crankshaft cyclone machining centers.
The main processing equipment for large marine propellers includes five-axis CNC milling machine, five-axis CNC vertical milling lathe and seven-axis five-link turning and milling machine. This type of equipment is one of the iconic products to measure the level of machine tool manufacturing in a country. At present, the largest processing diameter of processing propeller equipment in the world is 11m (produced in Korea), followed by 10.4m equipment produced in Germany and Japan, and the equipment produced in China is 9m. With the development of large ships in China, there is also a need for a seven-axis five-link CNC lathe milling machine capable of processing 11 m diameter propellers. Modern large ships require higher propulsion efficiency and lower noise, and higher requirements are placed on the machining accuracy and surface roughness of key parts such as propellers. In addition, due to the complexity and particularity of the blade surface machining, there are new requirements for the function and processing performance of the machine tool. For example, the impact of excessive tympanic torque on the life of the machine during large-scale propeller machining is still a problem to be overcome; the anti-interference collision function of the seven-axis five-link CNC milling machine; the rapid calculation and measurement of the machining allowance based on the three-dimensional digital model Planning, automatic measurement of trajectories, and online quality assessment.
Third, the aviation industry Industry Development Overview Major economic indicators achieved double-digit growth in 2008. According to the published data, China Aviation Industry Corporation achieved a total revenue of 166 billion yuan in 2008, a year-on-year increase of 12.31%, and realized profits and income of 7.2 billion yuan, an increase of 11.58% compared with 1999, compared with less than 40 billion yuan in 1999. Growth (although the data belongs to China Aviation Industry Corporation, it can be regarded as the data of the entire aviation industry in China).
Major economic indicators continued to show steady development in 2009. From January to September 2009, China Aviation Industry Corporation's total revenue and profit increased by 11.43% and 34.85%, respectively. The growth rate was higher than the average level of central enterprises and military industrial groups. The comprehensive benefit index increased by 2.7 percentage points year-on-year.
China's aviation industry will enter the golden period of development. First of all, the large aircraft project was included in the 16 major special projects of the National Medium- and Long-Term Plan for Science and Technology Development (2006-2009), which established the basic development strategy for developing the civil aircraft industry, exploiting the civil aircraft market and becoming a major aviation country and aviation power. It demonstrates the firm will and determination of the country to develop civil aircraft represented by large aircraft. In 2008, China's aviation industry system reform, the aviation first and second group merged into China Aviation Industry Corporation, the new formation of China Commercial Aircraft Co., Ltd., is the country's major efforts and attempts to achieve this strategic vision. The civil aircraft industry will use this as a starting point to form an emerging industry in China. This emerging industry has enormous potential and business opportunities. According to the latest forecast of Boeing in 2009, China needs 3,770 new aircraft in the next 20 years, with a total value of 400 billion US dollars. The ARJ21-700 regional aircraft with China's independent intellectual property rights, although it is in the airworthiness forensics phase, has 240 orders, which is also a good proof. Large passenger aircraft and regional aircraft are only part of the classification of civil aircraft. The civil aircraft category includes not only large-scale trunk passenger and cargo transport aircraft and commercial aircraft of regional aircraft, but also widely used in industry, agriculture, forestry, fisheries, mining, construction, etc. General-purpose aircraft in many fields, including medical and health, disaster relief, meteorological exploration, marine monitoring, scientific experiments, remote sensing mapping, education and training, culture and sports, business flights, private aviation, tourism and other fields. In these areas, the demand for aircraft applications is increasing with the rapid development of the economy, and the application field of aircraft will be further expanded. Second, the results of independent innovation are numerous. The new advanced military aircraft, trainer aircraft and helicopter gunships represented by æ¼10, æ¼11, æžé¾™, Feibao, Falcon, Mountain Eagle, K8, and Zhi 8, Wuzhi 10 will become the main force of our military equipment. The R&D and manufacturing of ARJ-700, Xinzhou 60, Xinzhou 600, Xinzhou 700 and other multi-purpose helicopters such as Zhi 9, Zhi 11 and EC 120 have also made significant progress and have been or will be introduced to the market. These achievements have laid a solid foundation for the development of China's aviation industry. Third, the aviation engine R&D and manufacturing bottlenecks have achieved major breakthroughs. The latest developments of aero-engines such as Kunlun, Qinling and Taihang have already or will soon end the bottleneck that restricts the development of China's aviation industry for a long time. The era of domestically produced aircraft using domestic engines has arrived. Although the aero engine is a component of the aircraft, it is indeed the core "crown diamond". The breakthrough of this technology is of decisive significance for the development of China's aviation industry. Fourth, the prospects for international cooperation are broad and the international market has great potential. The practice of world civil aircraft production is global procurement. Although the current international financial crisis has adversely affected the subcontract production of China's aviation industry, the development prospects of the international air transport industry are still optimistic, and its fast and convenient features are also other transportation industries. Can not be replaced. China's aviation products are characterized by high quality and low price, which is especially suitable for the needs of developing countries. Take the K8 trainer as an example. Up to now, more than 300 aircraft have been exported, and more than 150 orders have been hand-held, worth more than RMB 5 billion to meet the three-year production needs of the company. After the 60th anniversary of the National Day military parade, global orders have shown rapid growth. .
The total investment of large aircraft will reach 200 billion yuan. According to the relevant person in charge of China Commercial Aircraft Co., Ltd., the large aircraft project will invest 60 billion yuan within 3 to 5 years, of which 30 billion yuan will be used as the preliminary research and development expenses, and another 30 billion yuan will be used for capacity building, and finally put into the market, relevant The total investment will reach 200 billion yuan, equivalent to the total investment of the Three Gorges Project. Such a large investment scale is not the entire investment of China's aviation industry, as well as the investment of China Aviation Industry Corporation, which is responsible for large-scale transport aircraft missions, and the investment costs for military aircraft and various general-purpose aircraft. An emerging fast-growing industry with huge potential for development should have a very large investment scale. It is not difficult to draw such a conclusion when reviewing the scale of investment in the automobile industry after China entered the WTO.
2. Demand for machine tools in the aerospace industry Aircraft is the most complex and technologically advanced product ever produced by humans. A large aircraft consists of 3 to 5 million parts, and due to its well-known reasons, the complexity of the parts and the near-rigid quality requirements, a large number of high-tech and high-quality equipment will be involved.
The demand for large machine tools for machine tools, first of all because of its emerging industries, involves areas that we have not been involved in before, giving the machine tool industry a new development opportunity. Secondly, due to its "big" aircraft, the original part of the manufacturing equipment will not be able to meet its specifications. Third, the large aircraft, including the entire civil aircraft category, has its own special requirements and standards in terms of safety, economy, environmental protection, comfort, airworthiness, etc. due to its own commercial nature. The equipment will not be able to meet the processing technology requirements of its parts. Fourth, with the development of the materials industry, more and more new materials and high-tech composite materials are adopted by the aircraft manufacturing industry, and they need to be equipped with appropriate manufacturing equipment. Fifth, in order to improve safety and reliability, the use of overall manufacturing technology under the design idea of ​​minimizing the total number of parts is the development trend of the world aviation manufacturing industry, which undoubtedly puts forward new requirements for the variety, function and performance of machine tools. Sixth, the above five aspects are only the direct demand of the aviation manufacturing industry for machine tools. In fact, the aviation manufacturing industry is an industry closely related to other industries, covering almost all of machinery, electronics, materials, metallurgy, instrumentation, and chemicals. The industrial category, the resulting demand for related links will also be a large market, and should also be highly concerned.
The requirements of the aviation industry for machine tools almost cover all the latest achievements of modern machine tools, which is why domestic machine tools are difficult to enter their core manufacturing. The machine tool industry should firmly grasp the rare opportunity for the aviation industry to enter the golden development period, vigorously improve the technical content and manufacturing level of the products, and do our best to make our efforts and responsibilities for the great development of China's aviation industry.
There are many types of aircraft parts, and the requirements for machine tools according to the two types of structural parts and engine parts are as follows.
Machine tools required for machining of structural parts:
3~5 axis gantry boring and milling machine, 5-axis gantry boring and milling machine with A/C axis (spindle speed 6000~8000r/min for machining ferrous metal; 15000～24000r/min electric spindle for machining aluminum alloy; main motor power 20～ 75kW; positioning accuracy 0.02mm). Future demand specifications are getting larger, requiring workbench sizes up to 5000mm x 20000mm. Mainly used for the processing of beam, siding and frame parts.
Five-axis linkage fixed beam gantry mobile profiled composite machining center. The two side milling heads oscillate around the A-axis by ±12°, the positioning accuracy of the oscillating is 16′′, and the repeating positioning accuracy is 6′′. Dedicated to the processing of wing girders.
The workbench is a vertical plus and CNC vertical milling of (2000 ~ 4000) mm × (800 ~ 2000) mm. (Spindle power 50kW; spindle speed 6000~8000-15000r/min) is mainly used for the processing of wing longitudinal wall, half frame, rib and joint parts.
The table can be turned over with a 2200mm×4000mm 5-axis horizontal plus, which is mainly used to process medium-precision high-precision parts that were originally processed on the gantry milling machine.
5-axis overhead gantry profile milling machine. The width of the spindle is <1000mm, and the spindle speed is 30,000 to 40000r/min.
(φ520~φ1200) mm×(2000~4000)mm turning and milling composite machining center. Used to machine the main struts and cushioning struts of the landing gear.
Skin stretcher and skin roll forming machine. The skin stretching machine has a pulling force of 1000t, the outer table has a size of 4000 mm×610 mm, and the upper table has a stroke of 2000 mm. The maximum size of the sheet material for the skin roll forming machine is 12000 mm×12 mm, and the minimum bending radius of the sheet is 120 mm. In addition, a three-roller leveling machine and a profile bending machine are required.
The machine tool required for the machining of engine structural parts (taking a domestic large thrust turbofan engine as an example).
CNC vertical car and CNC precision vertical car. Chuck diameter φ1000~φ1250mm; maximum turning diameter φ1400mm; maximum turning height 1000mm; spindle power 60kW; positioning accuracy (highest) X, Z=0.008mm; repeat positioning accuracy (highest) X=0.0035mm, Z=0.005mm.
CNC horizontal lathe. Specifications φ800~φ1600×1000~1500mm; positioning accuracy (highest) Z=0.01mm, X=0.0075mm; repeat positioning accuracy (highest) Z=0.008mm, X=0.006mm.
CNC vertical round table grinder. Workbench φ1000mm; positioning accuracy 0.006mm; repeat positioning accuracy 0.003mm.
Vertical Machining Center. Workbench 500-2000×1000-1600mm; positioning accuracy (highest) X, Y, Z=±0.005mm; repeat positioning accuracy X, Y, Z=±0.003mm.
Vertical conversion machining center. Processing range φ1000 mm×1350mm; positioning accuracy X, Y, Z=0.01mm; repeated positioning accuracy X, Y, Z=0.005mm.
Four-axis vertical conversion machining center. Workbench 1000 mm×1000mm; spindle speed 15000r/min; positioning accuracy 0.008mm; repeat positioning accuracy 0.004mm.
Four-axis vertical conversion machining center with B axis. Workbench 900×450mm; B-axis swing range ±90°; Positioning accuracy X, Y, Z=0.01mm; B-axis 0.002°; C-axis 0.003°; Repeat positioning accuracy X, Y, Z=0.005mm; B-axis 0.001 °; C axis 0.002 °.
Four-axis vertical conversion machining center with A-axis. CNC rotary table φ110mm; A-axis swing range +16°~120°; each linear axis positioning accuracy is 0.006mm; each linear axis repeat positioning accuracy is 0.003mm; spindle speed is 15000r/min; spindle power is 45kW.
CNC slow feed to the grinding machine. Worktable 1200×600mm; grinding wheel spindle speed 50~8000r/min; positioning accuracy 0.005mm; repeat positioning accuracy 0.002mm.
CNC wire cutting machine. Workbench φ1000mm; positioning accuracy X, Y, Z = 0.01mm; repeat positioning accuracy X, Y, Z = 0.005mm.
Electric spark honeycomb grinding machine. Workbench φ1000mm; positioning accuracy X, Y, Z = 0.01mm; repeat positioning accuracy X, Y, Z = 0.005mm.
Horizontal five-axis machining center. Workbench 1000 mm×1000 mm; A-axis range 180°; B-axis range ±360°; Positioning accuracy X, Y, Z<0.008mm; A, B-axis <8′′; Repeat positioning accuracy X, Y, Z<0.004mm ; A, B axis <4".
Vertical five-axis machining center. Workbench 1200mm × 800mm; X / Y / Z stroke 800 mm / 500 mm / 630mm; positioning accuracy X, Y, Z ≤ 0.003mm; B, C axis ≤ 3"; repeat positioning accuracy X, Y, Z ≤ 0.002mm .
Precision twin-spindle turning and milling machining center. X/Y/Z stroke 400 mm /200 mm /650mm; first spindle speed 30000r/min; back spindle speed 5000r/min; milling spindle speed 6000r/min; B-axis swing angle range +95°~-110°; The library capacity is 30; the positioning accuracy of each linear axis is 0.006 mm; the repeating positioning accuracy of each linear axis is 0.003 mm.
Turning and milling composite machining center. X/Y/Z stroke 630 mm /320 mm /500mm; B-axis swing angle range -10°~ +100°; A-axis speed (vehicle mode/milling mode) 3000/150 (r•min-1).
Thread rolling machine. The maximum rolling diameter is φ80mm.
CNC super precision lathe. The maximum diameter of bar material is φ24mm; the spindle speed range is 0~5000r/min; the number of cutters is 8; the X/Z axis stroke is 180 mm /400mm; the positioning accuracy is X, Z=0.004mm; the repeat positioning accuracy is X, Z=0.004mm; The processing roundness is 0.4 μm.
Multi-stage electric pulse small hole machining machine. Specification φ0.5~φ3mm, depth 15mm; stroke 400mm×300 mm×275mm; positioning accuracy X, Y, Z, W=0.02mm; A, C, F=20′′; repeat positioning accuracy X, Y, Z, W = 0.012 mm; A, C, F = 20".
CNC EDM high speed small hole machine tool. X/Y/Z/W stroke = 800 mm / 630 mm / 300 mm / 300 mm; positioning accuracy X, Y, Z, W = 0.02 mm; B axis = 20' / 360 °; repeat positioning accuracy X, Y, Z , W = 0.01 mm; B axis = 10' / 360 °.
Five-axis blade machining center. The spindle speed is 12000r/min; the X/Y/Z stroke is 800 mm /500 mm / 630mm; the B-axis swing range is -40° to +95°; the A-axis swing range is 360°.
CNC coordinate boring machine. Workbench (540~900) mm×(320~720)mm; positioning accuracy (maximum) 0.002mm; repeat positioning accuracy (maximum) 0.001mm.
CNC vertical round table grinder. Specification φ1000mm; positioning accuracy 0.005mm; repeat positioning accuracy 0.002mm.
IV. Power Generation Industry 1. Overview of Power Generation Industry In order to scientifically develop China's power industry, the state has formulated “optimal development of thermal power, orderly development of hydropower, active development of nuclear power, accelerated development of gas power, and vigorous development of wind power during the “Eleventh Five-Year Plan†period. "The policy."
At present, China's power generation installed capacity of 800 million kW ranks second in the world, of which thermal power generation is about 600 million kW, hydropower generation is about 175 million kW, nuclear power is about 0.1 billion kW, wind power is about 0.1 billion kW, and annual power generation is nearly 4 trillion kW. Time. China's subcritical and supercritical thermal power generating units account for 75% of thermal power generation, and the self-manufactured 700,000 kW ultra-large hydroelectric generating units have promoted the rapid development of hydropower generation, 600,000 kW nuclear power units and 1 million kW pressurized water reactor nuclear power units. Nuclear power generation capacity has been formed, and wind power has already ranked fourth in the world. China's thermal power and hydropower equipment have entered the world's advanced ranks.
2. The demand for machine tools in the power generation equipment manufacturing industry The equipment needed for different energy power generation has many things in common, so China's “three major powers†​​have the ability to manufacture thermal power, hydropower and nuclear power equipment. The processing of power generation equipment requires general machine tools and special machine tools.
The rotor of generator and steam turbine requires CNC heavy-duty horizontal lathe, CNC root groove milling machine; stator demand CNC large-scale floor milling and boring machine, CNC gantry boring and milling machine, large stator special machine tool; steam turbine blade demand multi-axis linkage machining center. There are many domestic high-end CNC machine tools that can meet the needs of power generation equipment, but there are still some to rely on imports, such as CNC rotor slot milling machines.
Nuclear power steam generators and thermal power boilers require machine tools including ultra-heavy-duty CNC vertical lathes, super-heavy-duty CNC horizontal lathes, large-diameter boring and floor boring and milling machines, five-link CNC boring and milling machines, CNC gantry boring and milling machines, and multi-axis linkages. Milling center and so on. The processing equipment for pressure vessels, voltage regulators, main pumps and drive mechanisms of nuclear power reactor cores is still dominated by imported machine tools.
China's nuclear power equipment manufacturing industry is a new economic growth point, requiring new materials, new processes, new technologies, and new equipment. It requires larger specifications, greater load bearing capacity, and higher rigidity and reliability for machine tools. The machine tool industry should focus on nuclear power as a key service target, and strive to improve the reliability and stability of machine tools to meet the needs of the power industry.
3. Analysis and forecast of demand for machine tools in power generation equipment manufacturing In 2008, the accumulated investment in fixed assets of the electrical and electronic industry reached 240.49 billion yuan, a year-on-year increase of 46.6%. The funds for the purchase of equipment were 103 billion yuan, a year-on-year increase of 54.4%. There is no classified statistical data on the purchase of machine tool capital. According to the purchase of equipment funds in the electrical and electronic equipment host industry, accounting for 20%, of which 25% of the purchase of machine tools is calculated, and the purchase of machine tools is about 5 billion yuan. In addition, other companies outside the electrical and electronic appliance industry to buy machine tools accounted for about 8% of the industry's purchase of equipment, about 8 billion yuan. In total, the electrical and electronic industry bought about 13 billion yuan in machine tool equipment in 2008, accounting for about 10% of the annual consumption of metal processing machines in the country.
According to the statistics of the electrical and electronic industry from January to June 2009, it is estimated that the industry's annual purchase of machine tools in 2009 will be roughly the same as last year, still about 13 billion yuan.
Development of application fields and analysis of machine tool requirements 1. Automotive industry 1. Overview of the development of the automotive industry In 2008, the growth rate of production and sales fell sharply year-on-year. In 2008, affected by the international financial crisis, China's auto industry ended the continuous double-digit growth of production and sales in the six years from 2002 to 2007. The production and sales increased by 5.21% and 6.70%, respectively, down 16.81% and 15.14 respectively over the same period of the previous year. percentage point.
In 2009, the production and sales grew rapidly, and the huge potential of the market was fully demonstrated. In 2009, thanks to the implementation of various measures in the national “Automotive Industry Adjustment and Revitalization Planâ€, the automobile market recovered rapidly and presented an unprecedented high-speed development situation. From January to September, the production and sales of automobiles were 9,921,700 and 9,662,700, an increase of 32.01% and 34.24%, which exceeded the total of 267,600 and 282,200 in 2008. From the current trend, in 2009 China's automobile production and sales will exceed 13 million, making it a veritable automobile production and sales country. As an important pillar industry of the national economy, the leading role of the automobile industry in economic and social development will continue to be fully utilized.
The ability of independent innovation has been further improved, and product structure adjustment has achieved fruitful results. According to the statistics from January to September this year, due to national policy support, passenger cars below 1.6L performed well, and cumulative sales accounted for 70% of total passenger car sales. The market share was the highest in history and contributed to the rapid growth of production and sales. Nothing. Small-displacement passenger cars are growing into the mainstream of production and sales, indicating that China's auto industry product structure adjustment has achieved great results. The statistics from January to September also showed that the sales volume of the self-owned brand sedan market reached 29%, and continued to maintain the growth trend, indicating that China's auto industry's independent innovation capability has made great progress.
The scale of investment in fixed assets continued to maintain rapid growth. In the auto industry, the fixed assets investment during the 10th Five-Year Plan period will be 235 billion yuan, the investment in the 11th Five-Year Plan will exceed 400 billion yuan, and the investment in the 11th Five-Year Plan to the 13th Five-Year Plan will reach 1.5 trillion yuan. In addition, in accordance with the "Automotive Industry Adjustment and Revitalization Plan", the new central government investment fund of 10 billion yuan will be added during the three-year plan implementation period to support the technological progress and technological transformation of automobile production enterprises, which will drive the automobile and parts enterprises 1000-2000. The corresponding investment of 100 million yuan. According to incomplete investigations, the projects currently under construction and newly built in China will increase the annual production capacity of millions of engines and millions of complete vehicles. Such as Beiqi Foton Cummins engine, Huatai Automobile Ordossky Land, Beiqi Foton South Production Base, Shenyang Mitsubishi Engine, Changchun FAW Toyota, Brilliance Auto, Guangzhou Auto Passenger Vehicle Project, Wuling, Nanjing Auto and Geely Changsha Automobile Production Base all have engines or New project for the car. In addition, several domestic automakers such as FAW, SAIC and Dongfeng will increase their production capacity by 65% ​​compared with the current level in 2013. Changan Automobile Engine, Liuzhou Wuling Liuji Power, Shanghai General Powertrain and other domestic automobile engine companies will expand their production capacity by 60% in 2013. All these new projects will trigger new machine tool requirements. According to the current investment plan and investment scale, according to the empirical data provided by the industry, if the average annual investment is 100 billion yuan and the equipment accounts for 70%, of which machine tools account for 50%, the automotive industry provides about 35 billion machine tools per year. Yuan market.
2. Demand for machine tools in the automotive industry The main body of machine tool consumption in the automotive industry is divided into two levels. One is the four lines used for the production of complete vehicles, namely stamping, welding, painting and assembly lines; the second is the engine, Automotive parts processing including transmissions, steering systems, brake systems, transmission systems, and suspension systems. Among the four lines of the whole vehicle production, only the press line requires a machine tool, and the current domestic press line can fully meet the requirements. The focus of machine tool consumption is on the second level, that is, the processing of auto parts, which accounts for about 70% of the total equipment value of the whole vehicle. Some experts have estimated that the demand for machine tools for auto parts processing is 10 times larger than that of OEMs.
As the engine of the car core, its processing equipment is one of the most important car equipment. As new models accelerate into the market, the requirements for flexibility in the engine production line are stronger. Usually, an engine production line must meet the requirements for producing three models. The lightweight of the car makes the engine block and cylinder head material change from cast iron to aluminum alloy, which puts some new higher requirements on the machine tool.
The main components that make up the engine are the cylinder block, the cylinder head, the crankshaft, the camshaft, the connecting rod, and the like. Most of the equipment for processing these parts are high-efficiency, high-performance, high-reliability CNC machine tools and special CNC machine tools. Among them, the flexible production lines for cylinder and cylinder head processing are mostly composed of horizontal machining centers; the crankshaft processing equipment is mainly for truck-lawing machine tools, CNC crankshaft internal milling or external milling machines, CNC crankshaft grinding machines, crankshaft polishing machines, etc.; camshaft processing equipment is mainly It is a camshaft CNC lathe, a camshaft grinder, etc.; the connecting rod processing is mostly a special equipment, such as a double-face grinder.
At present, the value of imported equipment accounts for 90% or even 95% of China's automobile engine production. The localization rate of tools used in engine production lines is over 10%. The gap between domestic machine tools is mainly manifested in three aspects. The first is the lack of integration technology, the lack of technology to integrate process systems and logistics systems into flexible manufacturing units or production lines. Second, the reliability and stability of domestic machine tools still needs to be improved. Especially in the mass production mode of automobiles, the contradiction is particularly prominent; the third is that the service of domestic enterprises to users still stays in the after-sales service stage, and the automotive industry generally requires the provision of overall process equipment solutions. These gaps and problems should cause the machine tool manufacturers to pay full attention.
China's auto industry is in an unprecedented period of rapid development, and still shows strong development potential under the impact of the international financial crisis. The automobile industry has become the mainstay of machine tool consumption, and the relevant analysis believes that its proportion has accounted for 40% of the total machine tool consumption. The machine tool industry should firmly grasp the strategic opportunity period of the automobile industry in the next 10 years of development, aim at the current direction of automobile development, and aim at the world's automobile manufacturing technology to encourage and support small-displacement vehicles, energy-saving and environmental protection, new energy vehicles and other hot projects. And the development of cutting-edge technology in equipment, significantly increase the market share of domestic machine tools, and gradually achieve import substitution, and common development with the domestic automotive industry.
Second, the ship industry Overview of the development of the shipbuilding industry In 2008, orders for newly accepted ships decreased significantly year-on-year. In 2008, the shipbuilding completion volume of China's shipbuilding industry was 28.81 million DWT, up 52.2% year-on-year; the order for hand-held ships was 204.6 million DWT, up 28.7% year-on-year. However, affected by the impact of the international financial crisis, orders for newly accepted ships fell by 40.9% year-on-year to 58.18 million DWT.
The production and operating environment in 2009 has not improved significantly. In 2009, the shipbuilding industry conscientiously implemented the central government's package plan to cope with the financial crisis and promote the steady development of the economy, and achieved remarkable results. All economic indicators maintained steady growth. From January to September, the national shipbuilding completion volume was 27.78 million DWT, a year-on-year increase of 65%. From January to October, the national industrial enterprises above designated size achieved a total industrial output value of 443.8 billion yuan, a year-on-year increase of 31.5%, an increase of 29.7 percentage points; The export delivery value was 205.7 billion yuan, a year-on-year increase of 19.2%, an increase of 43.9 percentage points. Due to the impact of the international financial crisis, the global shipping market demand has shrunk sharply. The production and business environment of the shipbuilding industry has not improved significantly as a whole, mainly in the following aspects. First, the new orders for ships were 16.92 million DWT, a year-on-year decrease of 70%. Second, the difficulty of delivery has continued to spread. In 2009, 18% of the ships that should be completed in 2009 were delayed due to shipowners. It is also very common to reduce the contract price and modify the ship type. The ship's forward orders account for 30%, and the risk of uncertainty is higher. Third, the ship price continued to decline. The ship market under the reversal of supply and demand continued its downward trend since the fourth quarter of last year. The Clarkson new ship price composite index has fallen to 142 points at the end of September, compared with 190 points in August 2008. The highest drop was 48 points, the main ship type price fell by more than 30%, and the individual ship type even exceeded 40%.
Marine supporting equipment, high-tech marine equipment and offshore engineering equipment are the development priorities. Facing the severe production and business environment, China's shipbuilding industry will further increase the pace and intensity of industrial restructuring and product optimization and upgrading in accordance with the objectives and requirements of the Shipbuilding Industry Adjustment and Revitalization Plan, focusing on the development of high-tech value-added ships. Marine engineering equipment, supporting the supporting capabilities of marine equipment and marine low-speed diesel engines. Among them, marine supporting equipment and marine low-speed diesel engines will become the focus of investment, and also the main selling point of the machine tool market in the shipbuilding industry in the next few years.
Marine equipment refers to power equipment, deck machinery, ship boilers and marine electrical equipment. The power unit includes intelligent diesel engine, energy-saving and environment-friendly medium and low speed diesel engine, LNG marine dual fuel engine, ship shafting (reduction box, bearing, intermediate transmission shaft), super large propeller and large-scale high-efficiency water jet propulsion device. Deck machinery includes rudder equipment, anchor equipment, mooring equipment, and ship lifting machinery. Marine electrical equipment includes high-power medium and high voltage generators and power supply equipment. In addition, there are ship boilers, refrigeration and air conditioning units, and marine pumps and valves.
Marine equipment has a very large market development space. According to analysts, if the delivery target in 2010 can be achieved, the global civilian ship market capacity will reach 140 billion US dollars; according to the marine equipment accounted for 50% of the ship price, then the global marine equipment market size will reach 70 billion US dollars; According to China's shipbuilding tonnage accounting for 35% of the world, China's marine equipment market will reach 24.5 billion US dollars. The development of marine supporting equipment in China's shipbuilding industry has lagged behind the manufacturing capacity of the whole ship. The localized loading rate of marine supporting equipment is less than 50%. In 2007, China's ship supporting equipment manufacturing enterprises completed the total industrial output value of 21.38 billion yuan, accounting for only ships. 8.3% of the total industrial output value. Taking diesel engines as an example, in 2007, China's marine low-speed diesel engines produced 3.09 million horsepower and imported 2.89 million horsepower, which is far from the target of 12 million horsepower in 2011. The output of medium-speed diesel engines is 930 and 470 are imported. 48% and 34%. The key parts of diesel engine such as marine deck machinery and marine crankshaft are about 50%, and the equipment gap of marine cabin equipment and ship communication and navigation automation system is larger.
Comprehensive various factors can be expected to develop marine supporting equipment, improve the shipping rate of domestically-made marine supporting equipment, and achieve the three-year mainstream ship type domestic equipment loading rate of more than 65% required for the three-year adjustment and revitalization plan, marine low-speed machine, medium The domestic market satisfaction rate of auxiliary equipment such as speed machines and deck machinery and other development targets will not only greatly improve the comprehensive strength of China's shipbuilding industry, but also greatly enhance the ability to withstand market risks. It can be expected that marine equipment will become the focus of the shipbuilding industry in the next few years.
Investment in fixed assets such as marine ancillary equipment is expected to increase by 20%. In 2006, the total industrial output value of the shipbuilding industry was 172.2 billion yuan, and the investment in fixed assets was 19.96 billion yuan. In 2007, the total industrial output value was 2,570 yuan, and the fixed assets investment was about 30 billion yuan. In 2008, the total industrial output value was 414.3 billion yuan. 45 billion yuan. As the statistics of fixed assets investment in the shipbuilding industry are incomplete, according to the preliminary estimates of the demand for fixed assets investment-equipment procurement-metal processing machine tools in the general machinery industry, the annual consumption of machine tools in the shipbuilding industry in 2008 is estimated to be 5-6 billion yuan. In 2009, thanks to the national package to deal with the international financial crisis, fixed asset investment still increased by 55.5% from January to May. According to the opinions of the State Council's batch forwarding and reforming committee and the Ministry of Industry and Information Technology, the shipbuilding industry will strictly implement the shipbuilding industry adjustment and revitalization plan and the medium and long-term development plan of the shipbuilding industry in the next three years. The relevant departments of land, sea, environmental protection and finance at all levels will no longer accept new docks. The application for the slipway project will suspend the approval of the expansion project of the shipyard and shipyard of the existing shipbuilding enterprise. It can be predicted that from 2009 to 2012, investment projects for capacity expansion will be strictly suppressed, and marine supporting equipment, high-tech ships, offshore equipment, etc. will meet the investment and adjustment plan of the ship industry and the medium and long-term development plan of the shipbuilding industry. It will increase by about 20% year by year.
2. Demand for machine tools in the shipbuilding industry In the face of the current severe situation in the shipbuilding industry, the demand for heavy metal forming equipment and welding equipment required for the construction of the three major ship types is not expected to increase dramatically. However, there will be demand for special and special processing machines required for the manufacture of offshore engineering equipment, which is the growth point of heavy machine tools.
The main key components of marine supporting equipment, such as high-power low-speed diesel engines, crankshafts, large-scale marine propellers, etc., have been planned, and the investment is basically in place. The ordering of heavy-duty and super-heavy metal processing machines is basically completed, and the capability is very fast. form. Therefore, the growth rate of demand for heavy-duty and super-heavy metal processing machine tools will slow down in the next few years, but the demand for large, medium and general-purpose CNC machine tools will maintain a certain growth trend.
The key components of marine diesel engine mainly include machine base, frame, cylinder block, connecting rod, cylinder head, cylinder liner, piston, camshaft and cam assembly, bearing bush, intake and exhaust valve, air cooler, and oil pump. At present, the domestically produced low-speed diesel engine has a power of 49,680 hp, a length of 15.6 m, a height of 12.4 m, a cylinder diameter of φ900 mm, a crankshaft weight of 21t, and a self-weight of 1,253 tons. The planned maximum power will reach 100,000 hp. The machining accuracy is based on the PA6BV-280 (7140kW) marine diesel engine. The highest machining accuracy of the cylinder block is IT5-6; the highest machining accuracy of the camshaft is IT6; the highest machining accuracy of the cylinder head is IT6; the highest machining accuracy of the cylinder is IT6; the highest piston Machining accuracy is IT4.
The main processing equipment for the low and medium speed diesel engine mounts and frames are CNC gantry milling machines and CNC vertical lathes.
The main processing equipment of cylinder block (body) is CNC gantry milling machine and gantry machining center. The specifications are mostly gantry width 2~5m, the maximum requirement is not less than 8m, positioning accuracy and repeat positioning accuracy requirements ≤0.016/1000mm and ≤0.01mm .
The main processing equipment for the cylinder head is a horizontal machining center, a vertical machining center and a vertical turning and milling center. Horizontal machining center specifications are mostly in demand of 500, 630, 800 specifications. 630 horizontal machining centers require positioning accuracy X, Y, Z axis ≤ 0.008 mm, and repeat positioning accuracy ≤ 0.004 mm.
The main processing equipments for connecting rods and cranks are CNC gantry milling machines, large CNC vertical lathes, heavy duty CNC sleepers, vertical and horizontal machining centers.
The main processing equipment for camshafts are camshaft milling machines and camshaft grinding machines.
The main processing equipment for heavy crankshafts are horizontal crankshaft lathes, vertical lathes, floor boring machines, portal milling machines, crankshaft milling machines, horizontal turning and milling centers, crankshaft grinding machines and other equipment. The low-speed machine crankshaft adopts the assembled structure, the crankshaft and the crank are processed in one piece, and after the hot assembly, the whole machining is required. The heavy-duty turning-milling combined machining center, the numerical control crank vertical lathe, the numerical control vertical lathe, the numerical control floor boring and milling machine, and the hot-loading fine are required. Equipment for processing heavy-duty crankshaft cyclone machining centers.
The main processing equipment for large marine propellers includes five-axis CNC milling machine, five-axis CNC vertical milling lathe and seven-axis five-link turning and milling machine. This type of equipment is one of the iconic products to measure the level of machine tool manufacturing in a country. At present, the largest processing diameter of processing propeller equipment in the world is 11m (produced in Korea), followed by 10.4m equipment produced in Germany and Japan, and the equipment produced in China is 9m. With the development of large ships in China, there is also a need for a seven-axis five-link CNC lathe milling machine capable of processing 11 m diameter propellers. Modern large ships require higher propulsion efficiency and lower noise, and higher requirements are placed on the machining accuracy and surface roughness of key parts such as propellers. In addition, due to the complexity and particularity of the blade surface machining, there are new requirements for the function and processing performance of the machine tool. For example, the impact of excessive tympanic torque on the life of the machine during large-scale propeller machining is still a problem to be overcome; the anti-interference collision function of the seven-axis five-link CNC milling machine; the rapid calculation and measurement of the machining allowance based on the three-dimensional digital model Planning, automatic measurement of trajectories, and online quality assessment.
Third, the aviation industry Industry Development Overview Major economic indicators achieved double-digit growth in 2008. According to the published data, China Aviation Industry Corporation achieved a total revenue of 166 billion yuan in 2008, a year-on-year increase of 12.31%, and realized profits and income of 7.2 billion yuan, an increase of 11.58% compared with 1999, compared with less than 40 billion yuan in 1999. Growth (although the data belongs to China Aviation Industry Corporation, it can be regarded as the data of the entire aviation industry in China).
Major economic indicators continued to show steady development in 2009. From January to September 2009, China Aviation Industry Corporation's total revenue and profit increased by 11.43% and 34.85%, respectively. The growth rate was higher than the average level of central enterprises and military industrial groups. The comprehensive benefit index increased by 2.7 percentage points year-on-year.
China's aviation industry will enter the golden period of development. First of all, the large aircraft project was included in the 16 major special projects of the National Medium- and Long-Term Plan for Science and Technology Development (2006-2009), which established the basic development strategy for developing the civil aircraft industry, exploiting the civil aircraft market and becoming a major aviation country and aviation power. It demonstrates the firm will and determination of the country to develop civil aircraft represented by large aircraft. In 2008, China's aviation industry system reform, the aviation first and second group merged into China Aviation Industry Corporation, the new formation of China Commercial Aircraft Co., Ltd., is the country's major efforts and attempts to achieve this strategic vision. The civil aircraft industry will use this as a starting point to form an emerging industry in China. This emerging industry has enormous potential and business opportunities. According to the latest forecast of Boeing in 2009, China needs 3,770 new aircraft in the next 20 years, with a total value of 400 billion US dollars. The ARJ21-700 regional aircraft with China's independent intellectual property rights, although it is in the airworthiness forensics phase, has 240 orders, which is also a good proof. Large passenger aircraft and regional aircraft are only part of the classification of civil aircraft. The civil aircraft category includes not only large-scale trunk passenger and cargo transport aircraft and commercial aircraft of regional aircraft, but also widely used in industry, agriculture, forestry, fisheries, mining, construction, etc. General-purpose aircraft in many fields, including medical and health, disaster relief, meteorological exploration, marine monitoring, scientific experiments, remote sensing mapping, education and training, culture and sports, business flights, private aviation, tourism and other fields. In these areas, the demand for aircraft applications is increasing with the rapid development of the economy, and the application field of aircraft will be further expanded. Second, the results of independent innovation are numerous. The new advanced military aircraft, trainer aircraft and helicopter gunships represented by æ¼10, æ¼11, æžé¾™, Feibao, Falcon, Mountain Eagle, K8, and Zhi 8, Wuzhi 10 will become the main force of our military equipment. The R&D and manufacturing of ARJ-700, Xinzhou 60, Xinzhou 600, Xinzhou 700 and other multi-purpose helicopters such as Zhi 9, Zhi 11 and EC 120 have also made significant progress and have been or will be introduced to the market. These achievements have laid a solid foundation for the development of China's aviation industry. Third, the aviation engine R&D and manufacturing bottlenecks have achieved major breakthroughs. The latest developments of aero-engines such as Kunlun, Qinling and Taihang have already or will soon end the bottleneck that restricts the development of China's aviation industry for a long time. The era of domestically produced aircraft using domestic engines has arrived. Although the aero engine is a component of the aircraft, it is indeed the core "crown diamond". The breakthrough of this technology is of decisive significance for the development of China's aviation industry. Fourth, the prospects for international cooperation are broad and the international market has great potential. The practice of world civil aircraft production is global procurement. Although the current international financial crisis has adversely affected the subcontract production of China's aviation industry, the development prospects of the international air transport industry are still optimistic, and its fast and convenient features are also other transportation industries. Can not be replaced. China's aviation products are characterized by high quality and low price, which is especially suitable for the needs of developing countries. Take the K8 trainer as an example. Up to now, more than 300 aircraft have been exported, and more than 150 orders have been hand-held, worth more than RMB 5 billion to meet the three-year production needs of the company. After the 60th anniversary of the National Day military parade, global orders have shown rapid growth. .
The total investment of large aircraft will reach 200 billion yuan. According to the relevant person in charge of China Commercial Aircraft Co., Ltd., the large aircraft project will invest 60 billion yuan within 3 to 5 years, of which 30 billion yuan will be used as the preliminary research and development expenses, and another 30 billion yuan will be used for capacity building, and finally put into the market, relevant The total investment will reach 200 billion yuan, equivalent to the total investment of the Three Gorges Project. Such a large investment scale is not the entire investment of China's aviation industry, as well as the investment of China Aviation Industry Corporation, which is responsible for large-scale transport aircraft missions, and the investment costs for military aircraft and various general-purpose aircraft. An emerging fast-growing industry with huge potential for development should have a very large investment scale. It is not difficult to draw such a conclusion when reviewing the scale of investment in the automobile industry after China entered the WTO.
2. Demand for machine tools in the aerospace industry Aircraft is the most complex and technologically advanced product ever produced by humans. A large aircraft consists of 3 to 5 million parts, and due to its well-known reasons, the complexity of the parts and the near-rigid quality requirements, a large number of high-tech and high-quality equipment will be involved.
The demand for large machine tools for machine tools, first of all because of its emerging industries, involves areas that we have not been involved in before, giving the machine tool industry a new development opportunity. Secondly, due to its "big" aircraft, the original part of the manufacturing equipment will not be able to meet its specifications. Third, the large aircraft, including the entire civil aircraft category, has its own special requirements and standards in terms of safety, economy, environmental protection, comfort, airworthiness, etc. due to its own commercial nature. The equipment will not be able to meet the processing technology requirements of its parts. Fourth, with the development of the materials industry, more and more new materials and high-tech composite materials are adopted by the aircraft manufacturing industry, and they need to be equipped with appropriate manufacturing equipment. Fifth, in order to improve safety and reliability, the use of overall manufacturing technology under the design idea of ​​minimizing the total number of parts is the development trend of the world aviation manufacturing industry, which undoubtedly puts forward new requirements for the variety, function and performance of machine tools. Sixth, the above five aspects are only the direct demand of the aviation manufacturing industry for machine tools. In fact, the aviation manufacturing industry is an industry closely related to other industries, covering almost all of machinery, electronics, materials, metallurgy, instrumentation, and chemicals. The industrial category, the resulting demand for related links will also be a large market, and should also be highly concerned.
The requirements of the aviation industry for machine tools almost cover all the latest achievements of modern machine tools, which is why domestic machine tools are difficult to enter their core manufacturing. The machine tool industry should firmly grasp the rare opportunity for the aviation industry to enter the golden development period, vigorously improve the technical content and manufacturing level of the products, and do our best to make our efforts and responsibilities for the great development of China's aviation industry.
There are many types of aircraft parts, and the requirements for machine tools according to the two types of structural parts and engine parts are as follows.
Machine tools required for machining of structural parts:
3~5 axis gantry boring and milling machine, 5-axis gantry boring and milling machine with A/C axis (spindle speed 6000~8000r/min for machining ferrous metal; 15000～24000r/min electric spindle for machining aluminum alloy; main motor power 20～ 75kW; positioning accuracy 0.02mm). Future demand specifications are getting larger, requiring workbench sizes up to 5000mm x 20000mm. Mainly used for the processing of beam, siding and frame parts.
Five-axis linkage fixed beam gantry mobile profiled composite machining center. The two side milling heads oscillate around the A-axis by ±12°, the positioning accuracy of the oscillating is 16′′, and the repeating positioning accuracy is 6′′. Dedicated to the processing of wing girders.
The workbench is a vertical plus and CNC vertical milling of (2000 ~ 4000) mm × (800 ~ 2000) mm. (Spindle power 50kW; spindle speed 6000~8000-15000r/min) is mainly used for the processing of wing longitudinal wall, half frame, rib and joint parts.
The table can be turned over with a 2200mm×4000mm 5-axis horizontal plus, which is mainly used to process medium-precision high-precision parts that were originally processed on the gantry milling machine.
5-axis overhead gantry profile milling machine. The width of the spindle is <1000mm, and the spindle speed is 30,000 to 40000r/min.
(φ520~φ1200) mm×(2000~4000)mm turning and milling composite machining center. Used to machine the main struts and cushioning struts of the landing gear.
Skin stretcher and skin roll forming machine. The skin stretching machine has a pulling force of 1000t, the outer table has a size of 4000 mm×610 mm, and the upper table has a stroke of 2000 mm. The maximum size of the sheet material for the skin roll forming machine is 12000 mm×12 mm, and the minimum bending radius of the sheet is 120 mm. In addition, a three-roller leveling machine and a profile bending machine are required.
The machine tool required for the machining of engine structural parts (taking a domestic large thrust turbofan engine as an example).
CNC vertical car and CNC precision vertical car. Chuck diameter φ1000~φ1250mm; maximum turning diameter φ1400mm; maximum turning height 1000mm; spindle power 60kW; positioning accuracy (highest) X, Z=0.008mm; repeat positioning accuracy (highest) X=0.0035mm, Z=0.005mm.
CNC horizontal lathe. Specifications φ800~φ1600×1000~1500mm; positioning accuracy (highest) Z=0.01mm, X=0.0075mm; repeat positioning accuracy (highest) Z=0.008mm, X=0.006mm.
CNC vertical round table grinder. Workbench φ1000mm; positioning accuracy 0.006mm; repeat positioning accuracy 0.003mm.
Vertical Machining Center. Workbench 500-2000×1000-1600mm; positioning accuracy (highest) X, Y, Z=±0.005mm; repeat positioning accuracy X, Y, Z=±0.003mm.
Vertical conversion machining center. Processing range φ1000 mm×1350mm; positioning accuracy X, Y, Z=0.01mm; repeated positioning accuracy X, Y, Z=0.005mm.
Four-axis vertical conversion machining center. Workbench 1000 mm×1000mm; spindle speed 15000r/min; positioning accuracy 0.008mm; repeat positioning accuracy 0.004mm.
Four-axis vertical conversion machining center with B axis. Workbench 900×450mm; B-axis swing range ±90°; Positioning accuracy X, Y, Z=0.01mm; B-axis 0.002°; C-axis 0.003°; Repeat positioning accuracy X, Y, Z=0.005mm; B-axis 0.001 °; C axis 0.002 °.
Four-axis vertical conversion machining center with A-axis. CNC rotary table φ110mm; A-axis swing range +16°~120°; each linear axis positioning accuracy is 0.006mm; each linear axis repeat positioning accuracy is 0.003mm; spindle speed is 15000r/min; spindle power is 45kW.
CNC slow feed to the grinding machine. Worktable 1200×600mm; grinding wheel spindle speed 50~8000r/min; positioning accuracy 0.005mm; repeat positioning accuracy 0.002mm.
CNC wire cutting machine. Workbench φ1000mm; positioning accuracy X, Y, Z = 0.01mm; repeat positioning accuracy X, Y, Z = 0.005mm.
Electric spark honeycomb grinding machine. Workbench φ1000mm; positioning accuracy X, Y, Z = 0.01mm; repeat positioning accuracy X, Y, Z = 0.005mm.
Horizontal five-axis machining center. Workbench 1000 mm×1000 mm; A-axis range 180°; B-axis range ±360°; Positioning accuracy X, Y, Z<0.008mm; A, B-axis <8′′; Repeat positioning accuracy X, Y, Z<0.004mm ; A, B axis <4".
Vertical five-axis machining center. Workbench 1200mm × 800mm; X / Y / Z stroke 800 mm / 500 mm / 630mm; positioning accuracy X, Y, Z ≤ 0.003mm; B, C axis ≤ 3"; repeat positioning accuracy X, Y, Z ≤ 0.002mm .
Precision twin-spindle turning and milling machining center. X/Y/Z stroke 400 mm /200 mm /650mm; first spindle speed 30000r/min; back spindle speed 5000r/min; milling spindle speed 6000r/min; B-axis swing angle range +95°~-110°; The library capacity is 30; the positioning accuracy of each linear axis is 0.006 mm; the repeating positioning accuracy of each linear axis is 0.003 mm.
Turning and milling composite machining center. X/Y/Z stroke 630 mm /320 mm /500mm; B-axis swing angle range -10°~ +100°; A-axis speed (vehicle mode/milling mode) 3000/150 (r•min-1).
Thread rolling machine. The maximum rolling diameter is φ80mm.
CNC super precision lathe. The maximum diameter of bar material is φ24mm; the spindle speed range is 0~5000r/min; the number of cutters is 8; the X/Z axis stroke is 180 mm /400mm; the positioning accuracy is X, Z=0.004mm; the repeat positioning accuracy is X, Z=0.004mm; The processing roundness is 0.4 μm.
Multi-stage electric pulse small hole machining machine. Specification φ0.5~φ3mm, depth 15mm; stroke 400mm×300 mm×275mm; positioning accuracy X, Y, Z, W=0.02mm; A, C, F=20′′; repeat positioning accuracy X, Y, Z, W = 0.012 mm; A, C, F = 20".
CNC EDM high speed small hole machine tool. X/Y/Z/W stroke = 800 mm / 630 mm / 300 mm / 300 mm; positioning accuracy X, Y, Z, W = 0.02 mm; B axis = 20' / 360 °; repeat positioning accuracy X, Y, Z , W = 0.01 mm; B axis = 10' / 360 °.
Five-axis blade machining center. The spindle speed is 12000r/min; the X/Y/Z stroke is 800 mm /500 mm / 630mm; the B-axis swing range is -40° to +95°; the A-axis swing range is 360°.
CNC coordinate boring machine. Workbench (540~900) mm×(320~720)mm; positioning accuracy (maximum) 0.002mm; repeat positioning accuracy (maximum) 0.001mm.
CNC vertical round table grinder. Specification φ1000mm; positioning accuracy 0.005mm; repeat positioning accuracy 0.002mm.
IV. Power Generation Industry 1. Overview of Power Generation Industry In order to scientifically develop China's power industry, the state has formulated “optimal development of thermal power, orderly development of hydropower, active development of nuclear power, accelerated development of gas power, and vigorous development of wind power during the “Eleventh Five-Year Plan†period. "The policy."
At present, China's power generation installed capacity of 800 million kW ranks second in the world, of which thermal power generation is about 600 million kW, hydropower generation is about 175 million kW, nuclear power is about 0.1 billion kW, wind power is about 0.1 billion kW, and annual power generation is nearly 4 trillion kW. Time. China's subcritical and supercritical thermal power generating units account for 75% of thermal power generation, and the self-manufactured 700,000 kW ultra-large hydroelectric generating units have promoted the rapid development of hydropower generation, 600,000 kW nuclear power units and 1 million kW pressurized water reactor nuclear power units. Nuclear power generation capacity has been formed, and wind power has already ranked fourth in the world. China's thermal power and hydropower equipment have entered the world's advanced ranks.
2. The demand for machine tools in the power generation equipment manufacturing industry The equipment needed for different energy power generation has many things in common, so China's “three major powers†​​have the ability to manufacture thermal power, hydropower and nuclear power equipment. The processing of power generation equipment requires general machine tools and special machine tools.
The rotor of generator and steam turbine requires CNC heavy-duty horizontal lathe, CNC root groove milling machine; stator demand CNC large-scale floor milling and boring machine, CNC gantry boring and milling machine, large stator special machine tool; steam turbine blade demand multi-axis linkage machining center. There are many domestic high-end CNC machine tools that can meet the needs of power generation equipment, but there are still some to rely on imports, such as CNC rotor slot milling machines.
Nuclear power steam generators and thermal power boilers require machine tools including ultra-heavy-duty CNC vertical lathes, super-heavy-duty CNC horizontal lathes, large-diameter boring and floor boring and milling machines, five-link CNC boring and milling machines, CNC gantry boring and milling machines, and multi-axis linkages. Milling center and so on. The processing equipment for pressure vessels, voltage regulators, main pumps and drive mechanisms of nuclear power reactor cores is still dominated by imported machine tools.
China's nuclear power equipment manufacturing industry is a new economic growth point, requiring new materials, new processes, new technologies, and new equipment. It requires larger specifications, greater load bearing capacity, and higher rigidity and reliability for machine tools. The machine tool industry should focus on nuclear power as a key service target, and strive to improve the reliability and stability of machine tools to meet the needs of the power industry.
3. Analysis and forecast of demand for machine tools in power generation equipment manufacturing In 2008, the accumulated investment in fixed assets of the electrical and electronic industry reached 240.49 billion yuan, a year-on-year increase of 46.6%. The funds for the purchase of equipment were 103 billion yuan, a year-on-year increase of 54.4%. There is no classified statistical data on the purchase of machine tool capital. According to the purchase of equipment funds in the electrical and electronic equipment host industry, accounting for 20%, of which 25% of the purchase of machine tools is calculated, and the purchase of machine tools is about 5 billion yuan. In addition, other companies outside the electrical and electronic appliance industry to buy machine tools accounted for about 8% of the industry's purchase of equipment, about 8 billion yuan. In total, the electrical and electronic industry bought about 13 billion yuan in machine tool equipment in 2008, accounting for about 10% of the annual consumption of metal processing machines in the country.
According to the statistics of the electrical and electronic industry from January to June 2009, it is estimated that the industry's annual purchase of machine tools in 2009 will be roughly the same as last year, still about 13 billion yuan.
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