Strong growth in metal forgings industry

The forging industry has become an important basic industry in the manufacturing industry. With the rapid development of the national economy, the output value of China's metal forging industry will maintain an average annual growth rate of around 20% in the next five years. Luo Baihui, secretary-general of the International Mould, Hardware and Plastic Industry Suppliers Association, pointed out at the 2011 China International Forging Summit that after China's accession to the World Trade Organization, the global manufacturing industry gradually shifted to China, and the output value of the metal forging industry passed the annual average of 30 consecutive years. The golden time of % has become a pivotal basic industry in manufacturing. In the next five years, the automotive, aerospace, military, shipbuilding, home appliances, electronics, energy, chemical and other industries will maintain a strong growth momentum, and the metal forging industry still has huge room for development.

In the national economy and national defense construction, the forging and pressing industry is an indispensable and important part, producing various important basic parts for various mechanical products and military equipment. In automobiles, airplanes, armored vehicles, missiles, and other important parts, all the important parts that are heavily loaded or need to work under high temperature and high pressure are forged pieces made of metal materials that have been subjected to pressure.

Luo Baihui said that China's forgings production has entered the world's largest producer, but there are still some gaps in terms of equipment composition, grades, technical levels, and forging varieties, precision, and craftsmanship.

Disparity between China's forging industry and advanced countries in the world 1.Disparity of forgings category Japan is the most advanced country in the forging industry in the world today. Its die forgings account for 82.6% of the total, free forgings account for 5.5%, and annulars account for 11.9%. China Die forgings accounted for 65%, free forgings accounted for 35%; Japan in the forgings of cold forgings accounted for 5.8%, China accounted for about 1% (excluding standard parts); Japanese aluminum forgings accounted for 1.9%, China accounted for 0.1%.

2. Labor productivity Japan's total labor productivity is 175 tons/person. In India, it was 16.5 tons/person. year. The full labor productivity of the most representative automobile forging companies in China is 50 tons/person. In 2000, the statistics in Wenzhou, Zhejiang Province was approximately 18.7 tons/year. people.

3. Energy Consumption and Environmental Protection The total amount of energy in China is the third highest in the world, and energy consumption is the second largest in the world, accounting for 10% of the world's total consumption. Energy efficiency is only 32%, Japan is 57%, and CO2 emissions per million US dollars of GDP is 3077.7 tons, which is 11.8 times that of Japan and 1.4 times that of India.

4, die life China's hot forging die life is generally 4000-6000, mainly by the process design, forging equipment, heating, lubrication and other factors, foreign die life in the 10000-15000, die life is the main factor affecting the cost of the forgings, Increasing the life of forging die is the common mission of forging companies.

China's forging equipment and technology reach the world level Information from China National Machinery Industry Corporation shows that its 16,500-ton free-forging hydraulic press developed by China's Heavy Machinery Research Institute has completely independent intellectual property rights and is put into use at Shanghai Heavy Machinery Co., Ltd. The month is operating normally. This indicates that China's large-scale forging equipment and large forgings have reached the world advanced level.

16500 tons large-scale free-forging hydraulic press put into use, so that free forgings up to a single maximum 600 tons of production capacity, in addition to meet the urgent needs of the national economic development of large-scale free forgings, will also lay the foundation for China's large-scale forging equipment and large forgings exports .

Due to historical reasons, our country has been lagging behind in the development of large-scale free-forging equipment and forging technology. It is unable to meet the demand for high-quality large-scale free forgings for economic development.

It is understood that the traditional free-forging hydraulic press is divided into hydraulic press and hydraulic press. In the early large-scale free-forging hydraulic presses, the domestic hydraulic technology failed to meet production requirements, and the transmission method of the pump-reservoir station was generally adopted. The five free-forging hydraulic presses with a capacity of over 10,000 tons currently used in China are all hydraulic presses. The 16500-ton free-forging hydraulic press independently developed by the China Heavy Machinery Research Institute adopts the technical solution of a full hydraulic system directly driven by an oil pump. Because the pressure of the hydraulic press is large and the press speed is smoothly and controllable, the deformation rhythm of the forging is more easily controlled, so that Forging quality has been significantly improved.

China National Machinery Industry Corporation currently has more than 20 research institutes and more than 7,000 scientific and technical personnel engaged in the development, development, technical consultation and service of major technologies and equipment. The main areas involved are electrical appliances, heavy mining, and general petrochemical applications. The autumn forgings of construction machinery, machine tools, instrumentation, and basic parts will be anatomized in the spring by a Corvette Corvette new sports car. You will find that 80% of the parts are forged parts; the latest American F -35 fighters, of which 80% of the parts are forging parts. Luo Baihui, secretary-general of the International Model Association, stated that in the world’s automotive, aircraft, weapons, ships, power, metallurgy, electronics, and household appliances, all important components that are heavily loaded or need to work under high temperatures and pressures are used. Pressed metal forgings. The forging industry as the basic industry of the machinery manufacturing industry has an important influence on the equipment manufacturing industry and national defense construction. The manufacturing and manufacturing capabilities of the forging industry have also become an important indicator of a country's industrial level. As an industrial power, the United States, Japan, and European countries have always maintained a world-class level in forging technology.

With the shift of global manufacturing to China, the Chinese forging industry has also experienced rapid growth of 30% for many years from 2001-2006. In 2007, the output value of the forging industry fell back to 20%. In 2008, the economic situation at home and abroad was further turbulent. The prices of upstream raw materials and the downstream consumer goods market continued to decline. Will the cold weather in China's forging industry also come?

The high-growth profit-making industry has turned over the old newspapers of 2007. The outlook for the high-profile triumphal songs contrasts sharply with the current adjustment of the “global economic crisis”. If you quote the analysis data of the previous year, you will find that the forging industry is still “high-speed growth” and “broad prospects”: annual output of 3.7 million tons of forgings, the world’s largest output, more than 40,000 forging companies, 1.4 million employees, forecasts The growth rate of the industry is over 20%, and the development space is huge, with the most promising and most promising markets...

“Specializes in forging enterprises, the gross profit rate in 2008 was only 11%, has dropped to the lowest level in the calendar year,” said Mr. Zhang Jin, Secretary-General of the Forging and Pressing Association, “The industry’s reasonable gross margin should be 20%-30%, such an industry It is healthy. Under the present circumstances, industrial investment is large, and the benefits are low. No one is willing to invest.” For the forging industry where the value of production equipment is in the tens of millions or even hundreds of millions, such a meager profit makes the recovery investment become Distant things.

The cost pressure brought by rising iron ore prices is being further transmitted from the upstream steel industry to the forging industry; the rising cost of electricity caused by rising coal prices continues unabated. Affected by the economic downturn and monetary tightening policies, domestic consumer spending has been restrained to a certain extent, and the automotive industry, the big forge of the forging industry, has lowered its expectations. Even in the general consumer products field, the decrease in the demand for production equipment caused by the decline in potential consumption levels will also have an impact on the forging industry. At the same time, the decline of export-oriented companies has also led to a reduction in demand for forgings.

The extensive position of the forging industry in the equipment manufacturing industry has now become the disadvantage of being under pressure everywhere.

"The hammer hits the gold with two rings." This sentence describes the past forging industry. “At that time, it was a few dollars to go down.” said an old worker with 30 years experience in the forging industry (the free-forging hammers were controlled by foot). Today, the forging business landscape is no longer the same year. The overcapacity of low-end forgings formed during the market's rising period has turned into a power to compete for prices, making many under-ordered companies miserable.

Technology has yet to continue to enhance the prosperity of the past few years, and it does not seem to bring too much accumulation to the forging industry. China's current annual output of 3.7 million tons of forgings, free forgings accounted for 27% of about 1 million tons, die forgings accounted for 73% of about 270 million tons. Compared with previous years, the proportion of die forgings has increased (previously only 65%), but there are still gaps compared with advanced countries.

Forging Power Strategy Recommendation 1. Resolve large-scale forgings required for major equipment in China There are more than 140 hydraulic machines with 8MN or more in China, including 9 sets of 60MN-125MN presses, 600MW sub-critical thermal power units, and 700MN water motors for all large forgings. Capacity, 150 MN hydraulic machine put into use, the corresponding supporting equipment and process level will be able to manufacture 550-600 tons of steel ingots, produce 300 tons of high-quality forgings, and gradually meet the import of 700MW hydropower, 1000MW nuclear power and supercritical thermal power units Big forgings.

Should be highly valued this year, due to market demand, many places blindly on the 20MN-60MN free-forging hydraulic press, has begun to appear more than demand, the signs of vicious competition, the production of free forgings high energy consumption, environmental pollution, can not Then blindly launched.

2. Intensify the transformation of die forging production to form the leading force for forging a powerful country. China's die forgings production enterprises, some of the backbone enterprises adopt hot die forging presses, and are equipped with manipulators and multi-station hot forming presses. In addition, most companies still use dual-disc friction presses equipped with air hammers to prepare the manual production process, so that forging accuracy, mold life, forgings quality and stability are affected. As a result, forging also faces a domestic good development opportunity for global procurement due to the development of the automotive industry. Therefore, forging companies should increase their technological transformation and vigorously adopt clutch-type screw presses and hot die forging presses that can control the energy to be controlled. , And with wedge cross-rolling, roller forging billet process, workpiece transfer gradually to the manual operation to the automated operation transition. From new materials (non-quenched and tempered steel) applications, shearing, heating, mold preheating, lubrication, forging process control, heat treatment and cleaning of forgings, and continuous transformation. China's forging industry has increased the overall competitiveness on the basis of having a considerable capacity.