Li Dongru, deputy director of the Science and Technology Industry Department of China Machinery Industry Federation, gave a speech at the 2011 Spring Abrasives Information Exchange Conference and the 53rd China Corundum Silicon Carbide Fair ![]()
First, the development status of China's machinery industry in the first decade of the 21st century is the golden age of China's machinery industry development. China's machinery industry sales reached 1.5 trillion US dollars, surpassing Japan's 1.2 trillion US dollars and the US's 1 trillion US dollars, ranking first in the world. The output of automobiles, power generation equipment, machine tools, tractors and construction machinery ranks first in the world. ![]()
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Import and export trade achieved a surplus of imports and exports totaling 222.9 billion US dollars - 513.8 billion US dollars, an increase of 231%; in 2006, the machinery industry ended the foreign trade deficit and achieved a foreign trade surplus; in 2008, the foreign trade surplus reached 47.7 billion US dollars; in 2009, The international financial turmoil should be ringing, and the surplus will still reach US$3.1 billion. The structure of export products will be further improved. The export of high-tech products such as construction machinery, CNC machine tools and automobiles will continue to grow. The export volume of power generation equipment has accounted for nearly 15% of the total output. Energy saving and consumption reduction is obvious. The comprehensive energy consumption per 10,000 yuan of industrial added value of the whole industry is 0.66 tons of standard coal - 0.43 tons of standard coal, a decrease of 34.6%; the industrial added value of 10,000 yuan of steel consumption is 0.47 tons - 0.38 tons, a decrease of 18.2%. The material utilization rate is improved and the energy saving effect is obvious. Informatization level has improved the R&D design informatization has reached a high level. The backbone enterprises generally use 3D design; CAE, CAPP, PDM coverage rate exceeds half; financial management exceeds 90%; cost, procurement, sales, inventory and human resource management, main The application of information technology such as production planning is obvious. Products began to develop in the direction of digitalization, automation and intelligence. The organizational structure has changed. The situation of small and scattered has changed, and the concentration of production has been continuously improved. The sales volume of SAIC, Dongfeng, FAW and Changan accounted for 70% of the national total, and the production concentration of the top ten auto companies reached 86%; the output of power generation equipment of Harbin, Dongfang and Shanghai reached 68.7%. Huarui, Jinfeng and Dongqi accounted for 70% of wind power equipment production; Xugong, Zoomlion, Sany, Liugong, Longgong and Shantui have accounted for half of the total sales of China's construction machinery market. . The national economic security capacity has been significantly enhanced. It has made remarkable achievements in the fields of power equipment, engineering machinery, mining metallurgical equipment, petrochemical general equipment, agricultural machinery, automobile industry, etc., and its ability to provide equipment support for the national economy has been significantly enhanced. Among the machine tools, large-scale, precision, high-speed CNC machine tools and the matching CNC systems and functional components have made rapid progress. The self-sufficiency rate of CNC machine tools has reached 60%. Five-axis linkage gantry machining machines and turning and milling machine tools have been developed. Ultra-precision machining machine tools, flexible manufacturing systems, and large-scale stamping automatic production lines. There are problems in achieving the results, in the entire machine tool industry including the abrasives industry, mainly in the current, light and long-term; heavy speed, light quality; heavy manufacturing, light research and development; heavy host, light supporting; heavy materials, light talent The problem. Such a result results in weak independent innovation capability and low development expenditure; low-end overcapacity and high-end production capacity are seriously insufficient; the rapid development of the industry is still at the expense of excessive resource consumption; extensive development mode leads to low production efficiency and operating efficiency. . Second, the development strategy of the "12th Five-Year" development of the machinery industry In accordance with the overall requirements of "mainly attacking high-end, innovation-driven, strengthening the foundation, and green as the first", improve the quality and efficiency of development. Strengthen independent innovation, accelerate the formation of high-level independent technologies, standards and brands, and enhance the support of independent innovation for industrial upgrading. Transforming the development mode, from quantity scale to quality and efficiency, realizing the transformation of product structure from low-end to mid-to-high-end; focusing on developing strategic emerging industries such as high-end equipment and new energy vehicles, promoting high-end traditional industries and high-tech industrialization . Opportunities and Challenges Key construction and technological transformation of key areas of national economy such as electricity, petrochemicals, and metallurgy will bring huge demands. The financial crisis has had a major impact on the global industrial structure, which has intensified our competitive pressure in the field of high-end equipment. The constraints on energy, resources and the environment are strengthened, and the production model shifts to energy conservation and emission reduction, green manufacturing, and growth by relying on technology/management innovation and the quality of workers. “Efficient, low-pollution, energy recovery, and resource reusability†are prioritized, taking a new road to industrialization with a low carbon economy and resource recycling. During the "Twelfth Five-Year Plan" period, China will vigorously develop strategic emerging industries. The relevant departments are preparing development plans. It puts forward the urgent need for China's industrial transformation and upgrading and strategic emerging industries, and cultivates the high-end equipment manufacturing industry as the pillar industry of the national economy and promotes the transformation of China's equipment manufacturing industry from large to strong. It is embodied in the development of smart manufacturing and green manufacturing. We will expand and strengthen aviation equipment and satellite and application industries, accelerate the development of trunk aircraft, develop new regional aircraft, and promote the industrialization of regional aircraft; vigorously develop general aircraft and helicopters, build a general aviation industry system; and develop and produce aero engines; Support aviation equipment, aviation maintenance and service development; enhance the specialized production capacity of the aviation industry. Accelerate the development of marine engineering equipment, vigorously develop marine oil and gas development equipment, actively promote the industrialization of marine wind energy utilization equipment, seawater desalination and comprehensive utilization equipment, and steadily promote the development of marine mineral resources such as wave energy and marine renewable energy utilization equipment and seabed metal minerals. R&D of equipment. Accelerate the upgrading of the industrial scale and technical level of marine engineering equipment, expand the international market share, improve the industrial chain, and enhance the capacity for independent development. Promote the development and application of satellites, closely focus on the major needs of national economic and social development, strengthen the construction of space transportation systems, applied satellite systems, satellite ground and application systems, promote the development of adjacent space resources, and promote satellites in land, agriculture, water conservancy, meteorology, Marine, environmental protection, communications and broadcasting industry sectors and regional development applications, the construction of satellite manufacturing, launch services, ground equipment manufacturing, operation services industry chain. Improve the level of rail transit equipment, rely on the national high-speed heavy-duty railway construction and urban rail transit project construction, and vigorously develop high-speed trains, heavy-duty trains, intercity train equipment and their transportation of "high speed, heavy load, energy saving, environmental protection and safety" System, establish and improve R & D design, manufacturing, test verification platform and standard system, and vigorously explore the international market, so that China's rail transit equipment has reached the world's leading level. Enhance the level of intelligent manufacturing equipment, focus on the development needs of key areas of national economy such as advanced manufacturing, transportation, environmental protection, energy and comprehensive utilization of resources, and focus on promoting intelligent instrumentation and control systems, key basic components, high-end CNC machine tools and basic manufacturing equipment and intelligence. The development of special equipment will realize the automation, intelligence, precision and greenness of the production process, and promote the overall technical level of the equipment manufacturing industry. Third, the mechanical industry "12th Five-Year" key tasks to optimize the adjustment structure, vigorously promote the autonomy of high-end equipment, break through the bottleneck constraints of key infrastructure components, inhibit the blind expansion of production capacity, and prevent excessive duplication of construction. Enhance independent innovation, promote product digitalization and enterprise informationization, promote the construction of industry science and technology innovation system, strengthen industry basic technology research, promote advanced quality management methods, and improve product advanced standards system. Develop emerging industries, develop energy-saving environmental protection equipment, high-end equipment manufacturing, new energy, new materials, new energy vehicles and other strategic emerging industries; vigorously develop CNC machine tools, key infrastructure components, new energy equipment, marine engineering equipment, modern agricultural equipment, Modern manufacturing services and remanufacturing have become new growth points. Expand international cooperation, actively introduce technology, talents and strategic partners; vigorously expand international cooperation, make full use of overseas resources and develop markets; expand exports and increase the technological content, added value and complete sets of export products. Promote energy conservation and emission reduction, promote material saving, electricity saving, fuel saving, coal saving in the production process, optimize traditional processes, apply green manufacturing processes, transform and use energy-saving equipment to minimize energy consumption in production processes; The degree of greening reduces energy consumption during product use, provides energy efficient products for the society, and promotes energy conservation and efficient use. Fourth, the machine tool industry "12th Five-Year" development key machine tool host, develop high-precision working machine for machine tool manufacturing; focus on the development of heavy-duty, ultra-heavy CNC machine tools for aerospace, shipbuilding, power generation equipment manufacturing, multi-axis linkage And composite processing machine tools, high-speed and high-efficiency machining machines, precision CNC machine tools. Develop efficient, high-reliability, flexible automated production lines for the manufacture of critical automotive components. CNC system, focusing on high-performance motion control technology, servo drive technology, process application software, automation programming and other technical research; development of high-performance CNC system, compact CNC system. Functional components, high-speed / high-precision spindle unit, power tool holder, tool magazine and high-speed tool change mechanism, high-speed / high-precision CNC rotary table and compound swing angle milling head, high-speed / precision / heavy-duty ball screw and linear guide. Tools and abrasive tools, focusing on the development of high-speed / high-efficiency / tool and tool systems for aerospace, automotive, marine, energy equipment, rail transit and other important areas; grinding wheel manufacturing technology, abrasive preparation technology, grinding wheel dressing technology research, development of high-speed Heavy duty, precision abrasives and superabrasives. V. Abrasives Industry Development Opportunities and Countermeasures Development Opportunities Abrasives as an "teeth" are an important part of machine tools. The machining accuracy, roughness and surface quality of mechanical parts are often achieved by grinding for final processing. Conventional abrasive tools are difficult to meet the high requirements of high material removal rate, heavy load, grinding heat generation and surface quality, resulting in poor processing quality, frequent dressing, low material removal rate and high processing cost. By increasing the grinding feed rate, increasing the metal removal rate per unit time, and achieving high-speed grinding in the ultra-high-speed zone, the grinding time is greatly reduced, the grinding rate is greatly improved, and the higher processing of the parts is obtained. Accuracy while achieving a high metal removal rate. High-speed and efficient grinding has become the development direction. 1. Status quo There are more than 2000 abrasive grinding tool manufacturers in China; the total industrial output value exceeds 60 billion yuan. It is estimated that by 2015, China, India and Russia will become the markets with the largest sales growth of abrasives and abrasive products. China will surpass the United States as the world's largest producer of abrasives. 2, the gap between the high-end products can not meet the market demand, 90% rely on imports; low-end general-purpose product structural excess, causing accumulation, default on payment and price war. The production capacity of the whole industry has reached a large scale, but the actual production is relatively scattered; overcapacity, low efficiency consumes a lot of resources and energy, and the economic benefits are not high. The independent research and development capabilities are weak, lacking all kinds of high-quality talents; new product design and development, manufacturing processes and equipment are far from the advanced level of foreign countries. The product variety is small, the technical content is low, the quality is unstable; the lack of brand-name products with certain international influence is difficult to compete with foreign companies and multinational companies. The scale structure of the enterprise is unreasonable. Large enterprises are big but not strong, and the industrial belts are not obvious; small enterprises are scattered and not specialized, and their mutual cooperation ability is poor, and their competitiveness is low. 3. The technology development trend is high speed and ultra high speed. The CBN grinding wheel for machining camshafts and crankshafts has a speed of 160 m/s and a maximum speed of 200 m/s. Efficient. Greatly improve the grinding ability of the grinding wheel to meet the large amount of grinding. Precision. The grinding wheel is manufactured to a micron level, meeting the dynamic balancing requirements at high speeds and the precision machining requirements of the user. Specialized. In order to obtain the best comprehensive performance, we design and manufacture special-purpose grinding wheels for different processing materials and processing requirements. Super hardened. Due to the obvious advantages of the super-hard grinding wheel, the grinding tools for the key parts of the foreign engine are developed to superhard abrasives such as diamond or CBN. Complete service. When the manufacturer of the abrasive tool provides the product to the user, it also provides the user with a complete solution solution. 4. Key tasks Develop high-speed and high-efficiency precision grinding tools for the automotive industry. The key components of automobile engines and transmissions, as well as all kinds of high-speed and high-efficiency precision grinding tools for steering gear processing, including crankshaft group grinding wheels, superhard material honing stone, ceramic microcrystalline corundum grinding wheels, etc., are 70% dependent on imports. Developed a series of high-efficiency precision abrasive tools, grinding process database, grinding wheel dressing technology and finishing equipment, high-speed grinding wheel safety design and testing technology, high-speed grinding process cooling method and device, providing / overall technical solutions. The processing efficiency is increased by 50%, and the processing cost is reduced by 10-30%. Develop aerospace efficient precision abrasive tools. Titanium alloys, superalloys, carbon fiber composites, and hard-to-wear or high-temperature resistant ceramic coatings are becoming more and more widely used in aerospace applications. The key components of aerospace and important parts and structural parts have different shapes and structures, complex profiles, many shaped sections and free-form surfaces, and high requirements for machining accuracy, surface roughness and surface quality. In the grinding process, the grinding material has large grinding force, high grinding temperature, easy to cause large residual tensile stress, poor surface roughness and low life of the grinding wheel, which directly affects the machining accuracy, surface integrity and processing efficiency of the parts. Develop a complete set of abrasive tools for key parts of aero-engines. Urgently needed to develop products: grinding machine precision / high efficiency grinding wheel (worm wheel), blade head grinding grinding wheel, blade precision grinding wheel and polishing belt, crankshaft group grinding wheel and high speed CBN grinding wheel, camshaft high speed CBN grinding wheel, spray Oil nozzle small hole honing stone, ceramic microcrystalline corundum grinding wheel for heavy duty grinding, tool grinding wheel, silicon double face grinding/polishing abrasive, optical glass polishing wheel, high railway track grinding wheel, high efficiency precision coating grinding With super hard grinding wheel laser trimmer. Development measures to adjust industrial structure, inhibit production capacity of low-level products, optimize export structure; adjust product structure, actively develop high-speed/high-efficiency/precision abrasive tools and new abrasives; increase R&D investment, establish R&D institutions or develop test conditions; accelerate personnel training To enhance the ability to innovate; implement brand strategy, actively adopt advanced foreign standards, promote technological progress; strengthen technological transformation, promote cleaner production, and promote energy conservation and emission reduction.
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