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一、CHINASMOLDINDUSTRYDUETOHISTORICALREASONSFORTHEFORMATIONOFCLOSED,“BIGANDCOMPLETE“ENTERPRISEFEATURES,MOSTENTERPRISESINCHINAAREEQUIPPEDWITHMOLDWORKSHOP,INFACTORYMATCHINGSTATUSSINCETHELATE70SHAVEAMOLDTHECONCEPTOFINDUSTRIALIZATIONANDSPECIALIZATIONOFPRODUCTIONPRODUCTIONEFFICIENCYISNOTHIGH,POORECONOMICRETURNSMOLDPRODUCTIONINDUSTRYISSMALLANDSCATTERED,CROSSINDUSTRY,CAPITALINTENSIVE,PROFESSIONAL,COMMERCIALANDTECHNICALMANAGEMENTLEVELARERELATIVELYLOWACCORDINGTOINCOMPLETESTATISTICS,THEREARENOWSPECIALIZEDINMANUFACTURINGMOLD,THEPRODUCTSUPPORTINGMOLDFACTORYWORKSHOPFACTORYNEAR17000,ABOUT600000EMPLOYEES,ANNUALOUTPUTVALUEREACHED20BILLIONYUANMOLDHOWEVER,THEEXISTINGCAPACITYOFTHEMOLDANDDIEINDUSTRYCANONLYMEETTHEDEMANDOF60,STILLCANNOTMEETTHENEEDSOFNATIONALECONOMICDEVELOPMENTATPRESENT,THEDOMESTICNEEDSOFLARGE,SOPHISTICATED,COMPLEXANDLONGLIFEOFTHEMOLDALSORELYMAINLYONIMPORTSACCORDINGTOCUSTOMSSTATISTICS,IN1997630MILLIONUSDOLLARSWORTHOFIMPORTSMOLD,NOTINCLUDINGTHEIMPORTOFMOLDTOGETHERWITHTHEEQUIPMENTIN1997ONLY78MILLIONUSDOLLARSEXPORTMOLDATPRESENTTHETECHNOLOGICALLEVELOFCHINADIEINTHEAPPLICATIONOFCAEDESIGNANDANALYSISOFMOLDCALCULATION,ITWASJUSTSTARTED,MOSTOFTHEGAMEISSTILLINTRIALSTAGESANDANIMATIONINTHEAPPLICATIONOFCAMTECHNOLOGYMANUFACTURINGMOLDS,FIRST,THELACKOFADVANCEDMANUFACTURINGEQUIPMENT,ANDSECOND,THEEXISTINGPROCESSEQUIPMENTINCLUDINGTHELAST10YEARSTHEINTRODUCTIONOFADVANCEDEQUIPMENTORCOMPUTERSTANDARDIBMPCANDCOMPATIBLES,HPWORKSTATIONS,ETCDIFFERENT,ORBECAUSEOFDIFFERENCESINBYTES,PROCESSINGSPEEDDIFFERENCES,DIFFERENCESINRESISTANCETOELECTROMAGNETICINTERFERENCE,NETWORKINGISLOW,ONLYABOUT5OFTHEMOLDMANUFACTURINGEQUIPMENTOFRECENTWORKINTHISTASKINTHEAPPLICATIONPROCESSPLANNINGCAPPTECHNOLOGY,BASICALLYABLANKSTATE,BASEDONTHENEEDFORALOTOFSTANDARDIZATIONWORKINTHEMOLDCOMMONTECHNOLOGY,SUCHASMOLDRAPIDPROTOTYPINGTECHNOLOGY,POLISHING,ELECTROFORMINGTECHNOLOGIES,SURFACETREATMENTTECHNOLOGYASPECTSOFCAD/CAMTECHNOLOGYINCHINAHASJUSTSTARTEDCOMPUTERAIDEDTECHNOLOGY,SOFTWAREDEVELOPMENT,ISSTILLATLOWLEVEL,THEACCUMULATIONOFKNOWLEDGEANDEXPERIENCEREQUIREDMOSTOFOURMOLDFACTORY,MOLDPROCESSINGEQUIPMENTSHOPOLD,LONGINTHELENGTHOFCIVILIANSERVICE,ACCURACY,LOWEFFICIENCY,STILLUSETHEORDINARYFORGING,TURNING,MILLING,PLANING,DRILLING,GRINDINGANDPROCESSINGEQUIPMENT,MOLD,HEATTREATMENTISSTILLINUSESALTBATH,BOXTYPEFURNACE,OPERATINGWITHTHEEXPERIENCEOFWORKERS,POORLYEQUIPPED,HIGHENERGYCONSUMPTIONRENEWALOFEQUIPMENTISSLOW,TECHNOLOGICALINNOVATION,TECHNOLOGICALPROGRESSISNOTMUCHINTENSITYALTHOUGHINRECENTYEARSINTRODUCEDMANYADVANCEDMOLDPROCESSINGEQUIPMENT,BUTARETOOSCATTERED,ORNOTCOMPLETE,ONLYABOUT25UTILIZATION,EQUIPMENT,SOMEOFTHEADVANCEDFUNCTIONSARENOTGIVENFULLPLAYLACKOFTECHNOLOGYOFHIGHQUALITYMOLDDESIGN,MANUFACTURINGTECHNOLOGYANDSKILLEDWORKERS,ESPECIALLYTHELACKOFKNOWLEDGEANDBREADTH,KNOWLEDGESTRUCTURE,HIGHLEVELSOFCOMPOUNDTALENTSCHINASMOLDINDUSTRYANDTECHNICALPERSONNEL,ONLY8OFEMPLOYEES12,ANDTHETECHNICALPERSONNELANDSKILLEDWORKERSANDLOWERTHEOVERALLSKILLLEVELBEFORE1980,PRACTITIONERSOFTECHNICALPERSONNELANDSKILLEDWORKERS,THEAGINGOFKNOWLEDGE,KNOWLEDGESTRUCTURECANNOTMEETTHECURRENTNEEDSANDSTAFFEMPLOYEDAFTER80YEARS,EXPERTISE,EXPERIENCELACKOFHANDSONABILITY,NOTEASE,DONOTWANTTOLEARNTECHNOLOGYINRECENTYEARS,THEBRAINDRAINCAUSEDBYPERSONNELNOTONLYDECREASETHEQUANTITYANDQUALITYLEVELS,ANDPERSONNELSTRUCTUREOFTHEEMERGENCEOFNEWFAULTS,LEAN,MAKEMOLDDESIGN,MANUFACTURINGDIFFICULTTORAISETHETECHNICALLEVELMOLDINDUSTRYSUPPORTINGMATERIALS,STANDARDPARTSOFPRESENTCONDITIONOVERTHEPAST10YEARS,ESPECIALLYTHE“EIGHTHFIVEYEAR“,THESTATEORGANIZATIONOFTHEMINISTRIESHAVEREPEATEDLYMATERIALRESEARCHINSTITUTE,UNIVERSITIESANDSTEELENTERPRISES,RESEARCHANDDEVELOPMENTOFSPECIALSERIESOFDIESTEEL,MOLDSANDOTHERMOLDSPECIFICCARBIDESPECIALTOOLS,AUXILIARYMATERIALS,ANDSOMEPROMOTIONHOWEVER,DUETOTHEQUALITYISNOTSTABLEENOUGH,THELACKOFTHENECESSARYTESTCONDITIONSANDTESTDATA,SPECIFICATIONSANDVARIETIESLESS,LARGEMOLDSANDSPECIALMOLDSTEELANDSPECIFICATIONSAREREQUIREDFORTHEGAPINTHESTEELSUPPLY,SETTLEMENTAMOUNTANDSPORADICUSERSOFMASSPRODUCEDSTEELSUPPLYANDDEMANDCONTRADICTION,YETTOBEEFFECTIVELYADDRESSEDINADDITION,INRECENTYEARSHAVEFOREIGNSTEELMOLDSETUPSALESOUTLETSINCHINA,BUTPOORCHANNELS,TECHNICALSERVICESSUPPORTTHEWEAKANDPRICESAREHIGH,FOREIGNEXCHANGESETTLEMENTSYSTEMANDOTHERFACTORS,PROMOTETHEUSEOFMUCHCURRENTMOLDSUPPORTINGMATERIALSANDSPECIALTECHNIQUESINRECENTYEARSDESPITETHEPOPULARIZATIONANDAPPLICATION,BUTFAILEDTOMATUREPRODUCTIONTECHNOLOGY,MOSTSTILLALSOINTHEEXPLORATORYSTAGETESTS,SUCHASDIECOATINGTECHNOLOGY,SURFACETREATMENTTECHNOLOGYMOLD,MOLDGUIDELUBRICATIONTECHNOLOGYDIESENSINGTECHNOLOGYANDLUBRICATIONTECHNOLOGY,MOLDTOSTRESSTECHNOLOGY,MOLDANDOTHERANTIFATIGUEANDANTICORROSIONTECHNOLOGYPRODUCTIVITYHASNOTYETFULLYFORMED,TOWARDSCOMMERCIALIZATIONSOMEKEY,IMPORTANTTECHNOLOGIESALSOLACKTHEPROTECTIONOFINTELLECTUALPROPERTYCHINASMOLDSTANDARDPARTSPRODUCTION,THEFORMATIONOFTHEEARLY80SONLYSMALLSCALEPRODUCTION,STANDARDIZATIONANDSTANDARDMOLDPARTSUSINGTHECOVERAGEOFABOUT20,FROMTHEMARKETCANBEASSIGNEDTO,ISJUSTABOUT30VARIETIES,ANDLIMITEDTOSMALLANDMEDIUMSIZESTANDARDPUNCH,HOTRUNNERCOMPONENTSANDOTHERSUPPLIESJUSTTHEBEGINNING,MOLDANDPARTSPRODUCTIONANDSUPPLYCHANNELSFORPOOR,POORACCURACYANDQUALITY3、DIEPRODUCTSFACTORYMOLDFACTORYORWORKSHOP,INORDERTOSUPPLYTHEPRODUCTWORKSASTHEMAINTASKSNEEDEDTODIEDIEFUNDEDENTERPRISESBRANCH,THEORGANIZATIONALMODELANDPROFESSIONALMOLDFACTORYISSIMILARTOSMALLBUTTHEMAINTOWNSHIPMOLDBUSINESS,ANDPROFESSIONALMOLDFACTORYISSIMILAROFWHICHTHELARGESTNUMBEROFFIRSTCLASS,MOLDPRODUCTIONACCOUNTSFORABOUT70OFTOTALOUTPUTCHINASMOLDINDUSTRY,DECENTRALIZEDMANAGEMENTSYSTEMTHEREARE19MAJORINDUSTRYSECTORSMANUFACTUREANDUSEOFMOLD,THEREISNOUNIFIEDMANAGEMENTOFTHEDEPARTMENTONLYBYCHINADIEITISTHENTRAMSFERREDTOTHEIMPRESSIONTHOUGHAPASSAGETHEMATERIALINTHISPASSAGEISTERMEDTHESPRUE,ANDTHEBUSHISCALLEDASPRUEBUSH4、RUNNERANDGATESYSTEMSTHEMATERIALMAYBEDIRECTLYINJECTEDINTOTHEIMPRESSIONTHOUGHTHESPRUEBUSHORFORMOULDSCONTAININGSEVERALIMPRESSIONSITMAYPASSFROMTHESPRUEBUSHHOLETHROUGHARUNNERANDGATESYSTEMTHEREFOREENTERINGTHEIMPRESSION5、REGISTERRINGIFTHEMATERIALISTOPASSWITHOUTHIDRANCEINTOTHEMOULDTHEMOZZLEANDSPRUEMUSTBECORRECTLYALIGNEDTOENDURETHATTHISISSOTHEMOULDMUSTBECENTRALTOTHEMACHINEANDTHISCANBEACHIEVEDBYINCLUDINGAREGICTERRING6、GUIDEPILLARSANDBUSHESTOMOULDANEVENWALLEDARTICLEITISNECESSARYTOENSURETHATTHECAVITYANDCOREAREKEPTINALIGNMEMTTHISISDONEBYINCORPORATINGGUIDEPILLARSONONEMOULDPLATEWHICHTHENENTERCORRESPONDINGGUIDEBUSHESINTHEOTHERMOULDPLATEASTHEMOULSCLOSES7、FIXEDHALFANDMOVINGHALFTHEVARIOUSMOULDPARTSFALLNATURALLYINTOTWOSECTIONSORHALVESHENCE,THATHALFATTACHEDTOTHESTATIONARYPLATENOFTHEMACHINEINDICATEDBYTHECHAINDOTTEDLINEISTERMEDTHEFIXEDHALF,THEOTHERHALFOFTHEMOULDATTACHEDTOTHEMOVINGPLATENOFTHEMACHINEISKNOWNSIMPLYASTHEMOVINGHALFNOWITHASTOBESITUSTEDGENERALLYTHECOREISSITUATEDINTHEMOVINGHALFANDTHEOVERRIDINGREASONWHYTHISISSO,ISASFOLLOWSTHEMOULDINGASITCOOLS,WILLSHRINKONTOTHECOREANDREMAINWITHITASTHEMOULDOPENSTHISWILLOCCURIRRESPECTIVEOFWHETHERTHECOREISINTHEFIXEDHALFORTHEMOVINGHALFHOWEVER,THISSHRINKAGEONTOTHECOREMEANSTHATSOMEFORMOFEJECTORSYSTEMISALMOSTLYCERTAINLYNECESSARYMOTIVATIONFORTHISEJECTORSYSTEMISEASILYPROVIDEDIFTHECOREISINTHEMOVINGHALFMOREOVER,INTHECASEOFOURSINGLEIMPRESSIONBASICMOULD,WHEREADIRECTSPRUEFEEDTOTHEUNDERSIDEOFTHEMOULDINGISDESIREDTHECAVITYMUSTBEINTHEFIXEDHALFANDTHECOREINTHEMOVINGHALF8、METHODSOFINCORPORATINGCAVITYANDCOREWEHAVENOWSEENTHATINGENERALTHECOREISINCORPORSTEDINTHEMOVINGHALFANDTHECAVITYINTHEFIXEDHALFHOWEVER,THEREAREVARIOUSMETHODSBYWHICHTHECAVITYANDCORECANBEINCORPORATEDINTHEIRRESPECTIVEHALVESOFTHEMOULDTHESEREPRESENTTWOBASICALTERNATIVESITHEINTEGERMETHODWHERETHECAVITYANDCORECANBEMACHINEDFORMSTEELPLATESWHICHBECOMEPARTOFTHESTRUCTURALBUILDUPOFTHEMOULD,ORIITHECAVITYANDCORECANBEMACHINEDFORMSMALLBLOCKSOFSTEEL,TERMEDINDERTS,ANDSUBSEQUENTLYBOLSTEREDTHECHOICEBETWEENTHESEALTERNATIVESCONSTITUTESANIMPORTANTDECISIONONTHEPARTOFTHEMOULDDESIGNERTHEFINALRESULT,NEVERTHELESS,WILLBETHECONTAINSTHECOREISTERMEDTHECOREPLATEANDTHEPLATEORASSEMBLYWHICHCONTAINSTHECAVITYISTERMEDTHECAVITYPLATE9、CAVITYFABRICATIONWHENADECISIONFORMAKINGAMOLDISMADE,THECOSTISPREDICATEDONPRODUCINGASPECIFIEDQUANTITYOFPARTSWITHOUTADDITIONALTOOLINGEXPENDITURESOMETIMES,THEANTICIPATESAREQUANTITIESAREEXCEEDEDOTHERTIMES,THEYALLSHORTOFREQUIREMENTS,ANDCOSTLYREPAIRSBECOMENECESARYINORDERTOSUPPLYTHENEEDSINTHEMAKINGOFCAVITIESBYMACHINING,GRINDING,ORELECTRICDISCHARGEMACHINING,THEREISCONSTANTDRIVETOIMPROVETHERATEOFMETALREMOVALCUTTINGTOOLSASWELLASMACHINETOOLSAREDEVELOPEDFORHEAVIERANDFASTERCUTSGRINDINGWHEELSARETAILORMADEFORSPECIALSTEELSTOALLOWDEEPERCUTSPERPASSANDEDMMACHINESAREREVAMPEDTOBURNTHEMETALATANACCELERATEDPACEITISFULLYAPPRECIATEDTHATFASTERMENTALREMOVALRATELEADSTOMOREECONOMICALMANUFACTURE,BUTATTHESAMETIMEITMASTBERECOGNIZEDTHATTHENEWERCAVITYFABRICATIONISASSOCIATEDWITHGENERATIONOFMOREHEATANDINDIRECTLYWITHHIGHERSTRESSESTHATIFNOTRELIEVEDCANCAUSEPREMATUREGAILURESUPPLIERSOFTOOLSTEELCAUTIONTHEUSERAGAINSTFABRICATINGSTRESSESANDSTRONGLYADVISEASTRESSRELIEVINGOPERATIONWHENASTEELISTOBEHEATTREATEDANDAPREHEATCYCLEIAPARTOFTHEHEATTREATINGSPECIFICATION,THENTHEMETALREMOVALSTRESSESWILLBEELIMINATEDAGREATNUMBEROFCAVITIESAREMADEOFPREHARDENEDSTEEL,ANDTHEREFOREWOULDNOTBEHEATTREATEDFORTHOSECAVITIES,ASTRESSRELIEVINGOPERATIONSHOULDBECARRIEDOUTIMMEDIATELYAFTERFABRICATONTHESTRESSRELIEVINGTEMPERATUREASARULEISABOUT100FBELOWTHETEMPRINGHEATANDISHELDFOR30MINFOREACHINCHOFSTEELTHICKNESSITISBESTTOCHECKTHESTRESSRELIEVINGHEATANDTIMEWITHTHEMAKEROFTHESTEELTHEINFORMATIONABOUTFABRICATIONSTRESSHASALWAYSBEENEMPHASIZEDBYTHESTEELMAKERS,BUTFORSOMEREASONITHASNOTBEENGIVENTHEATTENTIONITDESERVESSINCEATOOLDRAWINGSHOULDCOVERALLTHEREQUIREMENTSOFATOOLELEMENT,ITWOULDBETHEAPPROPRIATEPLACEFORANOTESUCHASTHEFOLLOWINGNOTEFORHEATTREATEDSTEEL“NOTEUSEPREHEATANDHARDENTORC_”NOTEFORPREHARDENEDSTEEL“NOTESTRESSRELIEVE_FFOR_HOURSPER_INCHOFTHICKNESS”EVERYEFFORTSHOULDBEMADETOELIMINATETHEINVISIBLESOURCEOFPROBLEMS,NAMELY，FABRICATINGSTRESSESMOLDCAVITIESCANBEPRODUCEDBYAVARIETYOFPROCESSESTHEPROCESSTOBEUSEDISDETERMINEDFIRSTOFALLBYTHELOWESTCOSTATWHICHTHECAVITYCANBEPRODUCEDFORTHEDESIREDENDRESULTOTHERFACTORSINCLUDEPRECISIONOFREPAIRABILITYFREQUENTLY,ACOMBINATIONOFPROCESSESISEMPLOYEDINORDERTOMEETALLTHESPECIF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ENCONVENIENTTOSPERCIFYANEVENNUMBEROFIMPRESSIONSWHENCONSIDERINGTHISTYPEOFMOULD,ASIMPRESSIONSPOSITIONEDONOPPOSITESIDESOFTHEMOULDSCENTRELINESERVETOBALANCETHEMOULD五、MOULDCOOLINGONEFUNDAMENTALPRINCIPLEOFINJECTIONMOLDINGOSTHATHOTMATERIALENTERSTHEMOULS,WHEREITCOOLSRAPIDLYTOATEMPERATUREATWHICHITSOLIDIFIEDSUFFICIENTLYTORETAINTHESHAPEOFTHEIMPRESSIONTHETEMPERATUREOFTHEMOULDOSTHEREFOREIMPORTANTASITGOVERNSAPORTIONOFTHEOVERALLMOLDINGCYCLEWHILETHEMELTFLOWSMOREFREELYINAHOTMOULD,AGREATERCOOLINGPERIODISREQUIREDBEFORETHESOLIDIFIEDMOLDINGCANBEEJECTEDALTERNATIVELY,WHILETHEMELTSOLIDIFIESQUICKLYINACOLDMOULDITMAYNOTREACHTHEEXTREMITIESOFTHEIMPRESSIONACOMPROMISEBETWEENTHETWOEXTREMESMUSTTHEREFOREBEACCEPTEDTOOBTAINTHEOPTIMUMMOLDINGCYCLETHEOPERATINGTEMPERATUREFORAPARTICULARMOULDWILLDEPENDONANUMBEROFFACTORSWHICHINCLUDETHEFOLLOWINGTYPEANDGRADEOFMATERIALTOBEMOLDEDLENGTHOFFLOWWITHINTHEIMPRESSIONWALLSECTIONOFTHEMOLDINGLENGTHOFTHEFEEDSYSTEM,ETCITISOFTENFOUNDADVANTAGEOUSTOUSEASLIGHTLYHIGHERTEMPERATURETHANISREQUIREDJUSTTOFILLTHEIMPRESSION,ASTHISTENDSTOIMPREOVETHESURFACEFINISHOFTHEMOLDINGBYMINIMIZINGWELDLINES,FLOWMARKSANDOTHERBLEMISHESTOMAINTAINTHEREQUIREDTEMPERATUREDIFFERENTIALBETWEENTHEMOULDANDPLASTICMATERIAL,WATEROROTHERFLUIDISCIRCULATEDTHROUGHHOLESORCHANNELSWITHINTHEMOULDTHESEHOLESORCHANNELSARETERMEDFLOWWAYSORWATERWAYSANDTHECOMPLETESYSTEMOFFLOWWAYSISTERMEDTHECIRCUITDURINGTHEIMPRESSIONFILLINGSTAGETHEHOTTERTMATERIALWILLBEINTHEVICINITYOFTHEENTRYPOINT,IETHEGATE,THECOOLESTMATERIALWILLBEATTHEPOINTFARTHESTFROMTHEENTRYTHETEMPERATUREOFTHECOOLANTFLUID,HOWEVER,INCREASESASITPASSESTHOUGHTHEMOULDTHEREFORETOACHIEVEANEVENCOOLINGRATEOVERTHEMOLDINGSURFACEITISNECESSARYTOLOCATETHEINCOMINGCOOLANTFLUIDADJACENTTOHOTMOLDINGSURFACESANDTOLOCATETHECHANNELSCONTAININGHEATEDCOOLANTFLUIDADJACENTTOCOOLMOLDINGSURFACESHOWEVER,ASWILLBESEENFROMTHEFOLLOWINGDISCUSSION,ITISNOTALWAYSPRACTICABLETOADOPTTHEIDEALIZEDAPPREACHANDTHEDESIGNERMUSTUSEAFAIRAMOUNTOFCOMMONSENSEWHENLAYINGOUTCOOLANTCIRCUITSIFUNNERCESSARILYEXPENSIVEMOULDSARETOBEAVOIDEDUNITSFORTHECIRCULATIONOFWATERANDOTHERFLUIDSARECOMMERCIALLYAVAILABLETHESEUNITSARESIMPLYCONNECTEDTOTHEMOULDVIAFLEXIBLEHOSES,WITHTHESEUNITSTHEMOULDSTEMPERATURECANBEMAINTAINEDWITHINCLOSELIMITSCLOSETEMPERATURECONTROLISNOTPOSSIBLEUSINGTHEALTERNATIVESYSTEMINWHICHTHEMOULDISCONNECTEDTOACOLDWATERSUPPLYITISTHEMOULDDESIGNERSRESPONSIBILITYTOPROVIDEANADEQUATECIRCULATINGSYSTEMWITHINTHEMOULDINGENERAL,THESIMPLESTSYSTEMSARETHOSEINWHICHHOLESAREBOREDLONGITUDINALLYTHROUGHTHEMOULDPLATESHOWEVER,THISISNOTNECESSARILYTHEMOSTDFFICIENTMETHODFORAPARTICULARMOULDWHENUSINGDRILLINGSFORTHECIRCULATIONOFTHECOOLANT,HOWEVER,THESEMUSTNOTBEPOSITIONEDTOOCLOSETOTHEIMPRESSIONSAYCLOSERTHAN16MMASTHISISLIKELYTOCAUSEAMARKEDTEMPERATURE66VARIATIONACROSSTHEIMPRESSION,WITHRESULTANTMOLDINGPROBLEMSTHELAYOUTOFACIRCUITISOFTENCOMPLICATEDBYTHEFACTTHATFLOWWAYSMUSTNOTBEDRILLEDTOOCLOSETOANYOTHERHOLEINTHESAMEMOULDPLATEITWILLBERECALLEDTHATTHEMOULDPLATEHASALARGENUMBEROFHOLESORRECESSERS,TOACCOMMODATEEJECTORPINS,GUIDE
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