Domestic machine tool tools open the industry chain of downstream heavy application

Core Tip: The rapid development of the downstream industry of the machine tool industry, the requirements of high precision, high reliability and high stability of machine tools in aerospace, shipbuilding, automobile manufacturing, power generation equipment and other important fields have spurred the development of China's machine tool tools to the high end, but The status quo of China's aerospace, automotive and other fields of machine tools and equipment mainly rely on imports is criticized by the industry. Since the implementation of the “High-end CNC Machine Tool and Basic Manufacturing Equipment” technology special project (hereinafter referred to as “04 Special Project”), it has made breakthroughs in many “high, precise and sharp” topics, and its research and development results have been localized in major areas of China's machine tools. It paved a solid road.

Entering aerospace

        For a long time, the aerospace industry, as a representative of high-tech technology, has been striving for excellence in machine tools and equipment, but the five-axis machine tools in the aerospace industry mainly rely on imports. Recently, Shenyang Machine Tool (Group) Co., Ltd. (hereinafter referred to as "Shenyang Machine Tool") 04 special results five-axis linkage horizontal machining center products through its user unit - Chengdu Aircraft Industry (Group) Co., Ltd. (hereinafter referred to as "Chengfei" ") Acceptance, the core functional components of the product, the precision swing head, the precision rotary table, etc. are all designed and manufactured by themselves, with complete independent intellectual property rights. The achievement of this achievement greatly encouraged the domestic machine tool enterprises.

        The five-axis linkage horizontal machining center is one of the special projects undertaken by Shenyang Machine Tool. The five-axis linkage machining center is initially applied in the aerospace key areas such as Chengdu aircraft manufacturing enterprises, marking the domestic high-end CNC machine tools starting to serve domestic key areas. “The implementation of major special projects will closely link Shenyang Machine Tool and Chengfei for the first time. On the one hand, Chengfei will provide on-site processing technology requirements and improvement information to Shenyang Machine Tools. On the other hand, Shenyang Machine Tool will provide in-depth information based on Chengfei. Understand the user's needs, clarify the direction of the main attack, make multiple corrections, trial and error, and finally reach the agreed goals. Through the joint efforts of both parties, the method of cutting the S test piece has been adopted by the Ministry of Industry and Information Technology, and as a verification of the machining accuracy of the five-axis linkage machining center. The method, which is promoted in the whole industry, fills the gap in the domestic method of verifying the machining accuracy of the five-axis linkage machining center.” In cooperation with Chengfei, participated in the 2009 ZX04001-041 five-axis linkage for the processing of titanium alloy aerospace structural parts. Machining center, 2009ZX04001-043 high-speed five-axis linkage machining center with AB axis, key assembly equipment and technology for 2013ZX04001-101 carrier rocket structure, 2014ZX04014-031 five-axis linkage CNC machine tool precision evaluation technology and standard design Liu Feng, director of five-axis CNC machine tool design for Shenyang Machine Tool with R&D . At present, with the support of the special project of 04, many aviation manufacturing enterprises of AVIC have signed a contract with Shenyang Machine Tool to purchase a five-axis linkage machining center, using CNC machines with domestic CNC systems and functional components. Both parties expect to use the domestic CNC machine tools to play an exemplary role in the domestic industry, and further promote the application of domestic high-end CNC machine tools in key domestic areas.

Power car manufacturing

        On June 5-6 this year, the “Special Large Servo Press” project, which was undertaken by Jinan No. 2 Machine Tool Group, passed the acceptance and appraisal in Dalian. This project relies on the domestic 25,000 kN large servo press provided by Chery Automobile Dalian Factory, breaking the monopoly of foreign high-end markets such as Japan and Germany, marking the full integration and simultaneous development of domestic auto stamping technology and the latest international technology. .

        Stamping is the first process of automobile manufacturing. Modern automobile manufacturing technology is developing rapidly, new materials and composite materials are widely used, and the requirements for flexibility and intelligence of stamping equipment are getting higher and higher. The large servo stamping technology completely breaks through the concept of traditional mechanical press. It adopts the servo motor drive technology to eliminate the flywheel, clutch and brake. The servo motor directly provides the punching energy. In the stamping process, it can be operated according to different materials and different process requirements. The stepless adjustment of speed and forming force has the characteristics of high quality, high efficiency, energy saving and environmental protection.

Overweight shipbuilding industry

        The manufacture of large marine diesel crankshafts represents the level of a national shipbuilding industry. At present, the annual cost of importing crankshafts in China is as high as hundreds of millions of dollars, but the high price is not the most troublesome problem in China's shipbuilding industry. The biggest problem is that “one axis is hard to find”. The passive situation of ships and other axes has caused China's shipbuilding industry to give up millions of tons of shipbuilding orders every year.

        The crankshaft is a key component of the marine diesel engine. It has high weight, high precision requirements, demanding performance and complicated manufacturing process. The processing equipment required is extremely difficult to manufacture. The 04 special project undertaken by Qizhong Numerical Control Equipment Co., Ltd. (hereinafter referred to as “Qizhong CNC”) is a multi-functional CNC heavy-duty crankshaft milling machine. The machining accuracy error is less than 0.02 mm. Semi-finishing and finishing of the main journal, flange and crank neck of the crankshaft of a marine low-speed diesel engine. In the development process of the machine tool, an innovative overall layout scheme was proposed. The two sets of tool holders and a set of cyclone tool holders were combined to form a complete “one for two” machine tool, which can process two machines simultaneously on one machine. The different journals of the large crankshaft. The successful application of this solution can double the ergonomics and solve the problem of low utilization rate of the cyclone tool holder and low machining efficiency of the crankshaft caused by a conventional machine tool with a cyclone tool holder. Focusing on the key technology of “separate opening and closing CNC cyclone cutting tool holder”, China has mastered the manufacturing technology of heavy-duty marine crankshaft processing machine tools with independent intellectual property rights, and got rid of the situation that large-scale marine crankshafts rely heavily on imports.

Increasing color power

        The 04 special project “Super Heavy-duty CNC Horizontal Boring Lathe for Supercritical Nuclear Power Half-Speed ​​Rotor Processing” undertaken by Wuhan Heavy Machinery Machine Group Co., Ltd., a subsidiary of China Ordnance Industry Group, passed the final acceptance of technology.

        In the process of research and development, the company has obtained the overall scheme technology of super heavy-duty CNC horizontal multi-function composite processing machine tool, super heavy-duty high-precision static pressure spindle head box technology, new technology of super long bed manufacturing technology, dual-channel three-channel control technology, mast A breakthrough in five key core technologies, such as feed multi-axis synchronization technology. The successful development of this special project broke the monopoly and clamping of the semi-speed rotor of Japanese and Korean supercritical nuclear power to China, and realized the localization of nuclear power semi-speed rotor.

        The ultra-heavy-duty CNC horizontal boring lathe developed by the project is the core processing equipment for the localization of supercritical nuclear power semi-speed rotor. It solves the problem of 1100 MW supercritical nuclear power half-speed rotor processing of large nuclear power plants in China, and has completely independent intellectual property rights to fill The domestic gap has realized the domestic manufacturing of China's supercritical nuclear power half-speed rotor, which has made China enter the first stage of supercritical nuclear power half-speed rotor processing and manufacturing.

        Where is the problem?

        "The development of China's machine tool industry is based on the development model of the former Soviet Union. Under the effect of the planned economy and the long-term supply of machine tools, the machine tool enterprises have formed what kind of products are produced, and what equipment is used by users. Wang Jianyu, director of the Machinery Division of the Equipment Industry Department of the Ministry of Industry and Information Technology, said frankly that the research and development of China's machine tool products is out of the actual needs of users, coupled with the lack of a perfect machine tool product inspection and verification system, the user as a new product testing ground, the quality of domestic machine tools, The reliability is not satisfactory, and it is difficult to meet the production requirements of the majority of users. Therefore, when formulating research content and assessment indicators for special projects, it is necessary to reflect the requirements of special high-tech and advanced, and to consider the special research results to be industrialized, and to play its due role in actual production, and accelerate the reversal of users. The inherent understanding of domestic high-end CNC machine tools, strengthening the evaluation of the results of the project is a necessary means to urge the project units to seriously complete the task, and put forward the assessment criteria for the actual use period of the host products.

        In addition, China lacks the environment for machine tool design and manufacturing and process experiment research in the basic technology of CNC machine tool design and manufacture; in the core technology of CNC machine tools, most of the domestically developed products are imitation of foreign advanced products, and the introduction of technology The digestion and absorption capacity is poor, so there are few patents in the core technology, and the original core technology cannot be mastered. The gap between the basic technology and common technology of China's machine tool industry and the international advanced level has caused the industry's independent innovation ability to be poor, thus affecting the implementation performance of the 04 special project.

Key technologies help industrialize products

        Since the implementation of the major special projects, it has effectively promoted the domestic high-end CNC machine tools. With the support of special funds, the key technologies of CNC machine tools in China have made breakthroughs in research and development. CNC machine tool enterprises should make full use of the favorable policies of the country, take product quality as the foundation of development, and promote product upgrades with technological innovation. Driven by major national special projects, through the integration of scientific and technological resources, the organization of "production, learning, research, and use" cooperation, strengthen industrial chain collaboration, carried out a series of key key technologies for joint research and integration innovation, and achieved a number of major At the same time of the achievements of science and technology and industrialization, it has promoted the improvement of independent innovation capability of enterprises. Major projects are closely related to the development of the machine tool industry, and have become the main boosters and important means for the future industrial transformation and upgrading and transformation of development methods.

        “Shenyang machine tool has mastered the optimization design method of the whole machine structure, the dynamic performance evaluation method of the whole machine and key components, the high rigidity of the key components, the lightweight design and manufacturing technology, the key technology of digital design, the servo parameter optimization technology, the error compensation technology, and the high speed. Key technologies such as linear feed technology and kinematics optimization design method for five-axis linkage CNC machine tools, and gradually applied in high-end CNC machine tools, effectively improve product quality and dynamic and static characteristics of machine tools." Liu Feng told reporters that these The key technology has played an active role in the industrialization of high-end CNC machine tools. For example, 2009ZX04001-041 is a five-axis linkage machining center for titanium alloy aerospace structural parts processing. The virtual prototype design, complete machine and key of high-end CNC machine tools formed in the subject The dynamic performance evaluation method of components and the five-axis linkage error compensation technology effectively promote the industrialization of the gantry series, vertical series and bridge series five-axis machining centers, serving the national key enterprises, such as Chengfei (Group) and Jiangxi Hongdu Group, Changhe Aircraft (Group) Co., Ltd., Shenyang Fei (Group) Co., Ltd.

Skilled in exploration and strengthening the construction of skill teams

        With the implementation of special projects, the importance of talents has become more and more prominent, and the construction of talent teams plays a vital role in improving the ability of technological innovation. Enterprises must accelerate the transformation from a production-oriented talent structure to an innovation-oriented type. "The major special topics have high technical requirements for skilled personnel, and the requirements are at the international leading level. The technical personnel who need to participate in the work have solid theoretical and practical experience. And the spirit of serious research." Liu Feng told reporters that the major R&D and implementation process has provided good opportunities and conditions for the training of young scientists and technicians, and trained a group of key scientific research teams, especially young and middle-aged technical backbones. They have further exercise in actual scientific research activities, and have a deep understanding of the important significance of the combination of theory and practice of scientific research work, enhancing the trust, sense of belonging, mission and sense of accomplishment of scientific and technological personnel, and effectively improving them. The structure of scientific and technological talents has provided talent guarantee for the sustainable development of the machine tool industry.

        The major project has been in existence for five years since its establishment in 2009, which has made China's CNC machine tools have made important breakthroughs in many fields, and has promoted the training of the entire machine tool industry, enterprises, users and skilled personnel, but China's domestic production. There is still a long way to go before the high-end machine tools, and more efforts are needed to cater to the growing social needs.

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        Review 04 special events

        ※04 special project passed the deliberation of the State Council executive meeting

        On December 24, 2008, the State Council executive meeting reviewed and approved in principle the special implementation plan for 04. The meeting held that the implementation of the 04 special project is of great significance for improving the independent innovation capability and core competitiveness of China's CNC machine tools and basic manufacturing equipment industry, driving the structural adjustment of the equipment manufacturing industry and the development of related industries, and expanding domestic demand. After a scientific, democratic and rigorous argumentation, the special implementation plan has been basically mature and has the conditions for launching and implementing. Relevant departments should further improve the plan according to the opinions put forward by the meeting and pay close attention to the organization and implementation. According to the spirit of the meeting, the Ministry of Industry and Information Technology will organize a special implementation management office (funding) meeting with other departments of the special leading group as soon as possible to discuss the research organization, management methods and implementation plan, and prepare for the special leadership group meeting.

※ Delivery of the first iconic product XKA28105×300 CNC portal milling machine

        On September 29, 2010, Beijing No.1 Machine Tool Plant held the delivery ceremony of the first special machine tool XKA28105×300 CNC gantry milling machine in the third branch of Harbin Steam Turbine Works Co., Ltd., the user unit. This heavy-duty bridge gantry five-axis turning and milling machine tool has a gantry span of 10.5 meters, a maximum machining height of 7.5 meters, and a spindle power of 105 kW. It is equipped with a high-power and high-torque A/C mechanical transmission angle milling head to achieve five coordinates. The linkage processing, equipped with a 9.5-meter-diameter turning-milling two-speed CNC rotary table, with a load capacity of 300 tons, is the ultra-heavy-duty CNC gantry mobile moving beam five-axis linkage turning and milling lathe with the largest width in China.

※ "The five-axis linkage machining center for titanium alloy aerospace structural parts" passed the acceptance test.

        On October 12, 2012, the “Five-Axis Machining Center for Titanium Alloy Aerostructures”, led by Zhongjie Machine Tool Co., Ltd., passed the acceptance test at the Chengdu Chengfei Group. The vertical five-axis linkage machining center developed by this project is the first five-axis linkage machining machine developed by the domestic machine tool industry to detect the “S test piece” of the aviation industry. The successful development of this machine tool has typical demonstration significance for improving the research ability of China's high-end CNC machine tools and breaking the monopoly of foreign manufacturing equipment in the aviation field.

※DL250 horizontal boring lathe passed the expert identification into the Chinese machine tool benchmark

        In June 2013, DL250, a horizontal boring lathe manufactured by Wuzhong, passed the appraisal of the national expert group and became one of the top ten landmark equipments for China's “high-end CNC machine tools and basic manufacturing equipment technology special projects”. “High-end CNC machine tools and basic manufacturing equipment major projects” is one of the 16 national science and technology major projects identified in the national medium- and long-term science and technology development plan. DL250 is a machine tool used for nuclear power equipment processing. Nuclear power is a key development industry in China. The supercritical nuclear power half-speed rotor is the core component of the nuclear power plant generator set. The processing of this part requires a combined processing machine with a load of 500 tons and functions of turning, milling and grinding. Before the advent of the DL250, there were no such machines in China, and foreign machines had a maximum load of only 400 tons.

※The subject of "Vertical Milling and Rolling Compound Machining Center" passed the acceptance

        On January 12, 2014, the “Vertical Milling and Car Compounding Processing Center” project led by Shaanxi Qinchuan Machine Tool Group Co., Ltd. passed the acceptance test at the user site Xi’an Sanhang Power Technology Co., Ltd. Tested by the National Machine Tool Quality Supervision and Inspection Center, the geometric accuracy, positional accuracy, and work accuracy of the research and development products have reached the requirements of the task contract. The machine tool MTBF exceeds 900 hours. The user said that the VMT80 vertical milling and turning machining center can use the same effect as similar foreign machine tools, and can replace the imported ones to realize the multi-coordinate linkage CNC turning and milling complex processing of the complex structure parts of the whole blade disk type aeroengine. The successful development and putting into use of the machine tool can provide equipment for the processing of complex curved parts such as aero engine casings, integral blade discs, blower impellers and blades.

※ "Large servo press" passed the acceptance

        On June 5-6, 2014, the National Science and Technology Major Project “High-end CNC Machine Tool and Basic Manufacturing Equipment” undertaken by Jinan No. 2 Machine Tool Group – “Large Servo Press” project passed the acceptance and appraisal in Dalian. The project has achieved a new breakthrough in domestic stamping technology, which is of great significance to breaking the monopoly of foreign high-end markets and promoting the autonomy of domestic automobile industry equipment. The product provides a safe, reliable and flexible production solution, which meets the needs of the test of multiple process curve molds of two automatic stamping production lines and multi-station presses.

※A number of domestic machine tool tools 04 special results passed the acceptance

        In late August 2014, in accordance with the work schedule of the 04 special office, Xi'an, Kunming and Wuxi held separate special project acceptance meetings. The acceptance will be held in the main user units of the project, and the technical and financial experts of the 04 special office will organize the acceptance according to the requirements of the relevant documents. The Ministry of Science and Technology, the Ministry of Industry and Information Technology and the relevant personnel of the provincial and municipal labor committees attended the meeting. Among them, Xi'an: "Titanium alloy, high-temperature alloy processing high-efficiency indexable tool series and super-hard tool" subject; Kunming: "high-end CNC machine tool digital design key technology and tool set research and development and typical product application" topic; Wuxi: "Electric The subject of control technology and key equipment development and application of common rail diesel engine injection system.

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