die & mold for mass production - manufacturing...

© GNU Su-Jin Kim

Die & Mold for Mass Production



Associate Professor Su-Jin Kim

School of Mechanical Engineering

Gyeongsang National University

http://ma.gnu.ac.kr/



http://engine.gnu.ac.kr/

http://www.gnu.ac.kr/

© GNU Su-Jin Kim


Hyundai Automobile

• The Empty Car Convoy: https://youtu.be/EPTIXldrq3Q

https://youtu.be/EPTIXldrq3Q

© GNU Su-Jin Kim


Hyundai Manufacturing Plant

• Korea : https://youtu.be/mbGukMPPvl0

• Mexico : https://www.youtube.com/watch?v=1U5OPVOkBlI

https://youtu.be/mbGukMPPvl0

https://www.youtube.com/watch?v=1U5OPVOkBlI

© GNU Su-Jin Kim


Supply Chain

Automobile

Module

Parts

Infra: Mold, Casting, Forging, Heat, Machining

SME

Automobile industry and Metal hot rolling are focused on the 3 Largest companies (CR3:

Automobile 90%, Hot rolling 80%). CR3 of car body parts 15%, Automobile parts 14%,

Cutting and surface treating of metal 30% is low.

SME of Korean metal mechanical industry were supplying mechanical parts to Large

companies (dependency 80%).

© GNU Su-Jin Kim


Elanrta (Avante) MD

Avante MD

358,000 Cars in 2012

1,000 Cars/day ? / min

© GNU Su-Jin Kim


Mass Production

• Sheet metal forming

• Forging , Die Casting

• Plastic Injection

• Die & Mold

Sheet metal Plastic

© GNU Su-Jin Kim


Die & Mold

© GNU Su-Jin Kim


What is Die & Mold

• Die & Mold is the tool used to produce large quantities of same products.

• Automobile, television and home appliances are produced by Die & Mold.

Blow Mold Diecasting Mold

Press Die Forging Die Plastic injection Mold

© GNU Su-Jin Kim


Die & Mold for Automobile

Bumper Plastic

Mold

Light Plastic Mold

Wheel Diecasting

Mold

• Body and main parts of automobile like as hood, door and mainframe are formed by Press Die.

• Bumper, light and interior plastic parts are produced by Plastic Injection Mold.

• Engine and wheel aluminum parts are produced by Diecasting Mold.

© GNU Su-Jin Kim


60 years of Korean Die & Mold

Korean war, LG chemical, TaeguTec, 1st Die & Mold companies started business

1960s

Milling & lathe (whacheon.com), Injection molding machine(dongsin)

Electric discharge machining, Standard moldmase, Die & Mold training school (Polytechnic II)

NC machine tools, Korea Die & Mold Industry Cooperative (KODMIC)

CAD/CAM & CNC, Wire EDM , Tungsten carbide tool, Die steel

Export $210million > import $190 million in 1994

Huge mold for automobile, Precision mold for electronics,

1,379 die/mold companies. Export $3,228 million >> Import $158 million in 2014

1970s

1980s

1990s

2000s

ⓒ 30 years history of KODMIC

1950s

Die & Mold Companies of Korea

11

1) There are around 1,379 Die & Mold companies (over 10 employees) in Korea (2012).

2) 53% of companies are located around Seoul-Incheon. 21% around Busan.

3) The total employees are 36,832 and the average number of employees in a company is 27.

53.3% Companies are

locating nearby Seoul Gyeonggi

81 (5.9%)

32 (2.4%)

20 (1.4%)

509 (36.8%)

289 (20.9%)

202 (14.5%)

20 (1.4%)

85 (6.1%)

Incheon

Seoul

Daejeon

Chungnam

Chunngbuk

Daegu

Gyeongbuk

Busan

Ulsan

Gyeongnam

Jeonbuk

Gwangju

Jeonnam

Gangwon

2 (0.1%)

145 (10.5%)

ⓒ www.koreamold.com

Die & Mold Companies of Korea

12

1) The total production volume was $7,086 million in 2012 based on the companies with 10 or

more employees.

2) The portion of plastic mold and press die is 75.2%. The production volume of plastic molds

is $2,948 million and press die is $2,385 million.

3) The average growth rate was 9.5% during 2009 to 2012

Plastic

Molds, 2,948

Press Dies,

2,385

Diecasting

Molds, 129

Other, 888

Standard

Parts, 740

Total $7,086 million in 2012



Export of Korean Die & Mold

13

1) Korea exports about 37% of its total die and mold production.

2) The export volume ratio is about 63% in Asia.

Japan 17% China 17%

India 9% Mexico 7%

USA 7%

Malaysia 4%

Indonesia 3%

Vietnam 5%

Brazil 3%

Russia 3%

Turkey 3%


World’s Mold Export and Import

14

1) Korea was the world’s second largest die and mold exporting country in 2014

2) Export: China 4,926 > Korea 3,228 > Japan 2,908 > Germany 2,553 > USA 1,431 (2014)

3) Import : USA 3,093 > Mexico 2,630 > China 2,599 (2012, 2013)

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

China Korea Japan Germany USA

million $ Export

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

USA Mexico China

million Import

Demand Industries of Die & Mold

15

1) Korea Die & Mold companies increased with the automobile and electronics industries

using molds for mass production.

※ Source : Survey on Mold Industry Status, Korea Die & Mold Industry Cooperative, 2012

Semiconductor

Office

Supplies

Household

Item Others

Automobile

Home

Appliance

IT Device

Supporting Industries of Die & Mold

16

CAD/CAM Precise Machining Production

asis.co.kr

NC Machining hwacheon.com

CAM NCBrain.com

EDM kojin.co.kr

Noldbase Kishin.com

endmill taegutec.co.kr

Press simpac.co.kr

Injection dongshin.net

Plastic lgchem.com

Sheet metal posco.co.kr

1) The machine tools and material technologies supporting die and mold are well developed.

Korea Polytechnic II

17

1) Department of die & mold opened in 1974 and offers 2 years program.

2) 90 students design and fabricate die & mold to graduate.

incheon.kopo.ac.kr

Korea Polytechnic II

18

1) The education programs : 60% technology training + 40% lecture.

2) Training and education program of the Chihuahua technological school will benchmark the

Department of Die & Mold Design in “Korea Polytechnic II”.

Semester Lecture Practice

1st Injection mold

Stamping die

Precise metrology

Mold drafting

NC machining

Basic machining

NC machining

3d Modeling

CAD practice

2nd Mold manufacturing

Mold material

Product design & post process

Mold develop project1

CAM practice

Precise part machining

3rd Precise mold design

Precise machining

Mold element design

Mold develop project 2

Mold manufacturing

Mold design, Product design

4th - Mold develop project 3

Assembly and repairing

High speed machining

Process analysis

Korean Die & Mold Industry Cooperative

19

1) The “Korean Die & Mold Industry Cooperative” was launched in 1980 and has 553 member

companies in 2014.

2) “InterMold Korea” began in 1980 and 22th InterMold Korea was held on March 10 2015.

koreamold.com intermoldkorea.com

Mold Valley

20

1) Bucheon city developed a mold industrial complex named “Mold Valley” in 2009.

2) 65 die & mold companies are co-working at the mold valley.

3) Korea Mold Center is built at the center of the Valley.

Mold Valley

Bucheon city

Mold Valley

Korea Mold Center

Mold Valley Area : 290,000 m2

Mold: 65 companies Other: 9 companies Employ: 1,700 persons Korea Mold Center

Korea Mold Makers

21

1) Mexican government officers visited Illwoo precision, NCBrain and Keonwoo precision.

2) Die and molds are used for mass productions of automotive structure and instruments

Sheet metal Plastic

Gun drill

22

Specialization

Mold design

NC Machining NC machining

Mold design

EDM EDM

Polishing assembly

Test injection

Polishing

Mold maker Outsourcing Standard

Standard elements

Standard mold base

23

Policy Recommendations

C. Korea Mold Technology Center in Mexico

1) Mexico rent building (80 x 20 x 8 m) for 15 years + Korea establish Mold Technology

Center with 20 equipment

2) Mexican learn Korean mold technology. Korea exports and maintain mold to automotive

company in Mexico

Mexico

Building 1,600 m2

8 m

Korea

Technology &

20 equipment

© GNU Su-Jin Kim


Mold Machining

CAD/CAM NC Machining Assembly / Test

asis.co.kr

NC Machining

hwacheon.com EDM

uedm.co.kr

Moldbase

kishin.com Injection

dongshin.net

Simulation

ncbrain.com

Monitoring

nicks.co.kr

EDM

CAM

ncbrain.com Maps 3d

wincapa.com

http://www.google.co.kr/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=3YSKIGc530fu2M&tbnid=xf49rHssbmfsGM:&ved=0CAUQjRw&url=http://www.innotool.com/pages/shop_equipment11.html&ei=riZpU9TKItje8AWAtoCoCQ&bvm=bv.66111022,d.dGc&psig=AFQjCNFkpCzuW7A5d6fbTTNJgV-hOqxYlQ&ust=1399486302357520

© GNU Su-Jin Kim

Die & Mold for Mass Production NC Machining

Mold design

CAM

CAD

Injection molding

http://ma.gnu.ac.kr

Injection Mold Machining

© GNU Su-Jin Kim


Plastic parts

• 3d design of refrigerator shelf

© GNU Su-Jin Kim


Mold Design

https://youtu.be/biiAK9PA4ks?list=PLZgvgD8C0g2FpjwoW9Wmv0A0_ukR4h3o7

NX mold design (6min)

• Mold : Cavity + Core + Plate + Eject pin + Guide bush

https://youtu.be/biiAK9PA4ks?list=PLZgvgD8C0g2FpjwoW9Wmv0A0_ukR4h3o7

© GNU Su-Jin Kim


Plastic flow analysis

• Flow: sprue runner gate cavity

• Analysis: temperature, pressure, time, weld line, air trap

https://youtu.be/QM_oJkS3cPY?list=PLxI7kGCGGwQehdSOGxqe2RaJroLA_QtOT

Maps-3d Injection molding CAE (3min)

https://youtu.be/QM_oJkS3cPY?list=PLxI7kGCGGwQehdSOGxqe2RaJroLA_QtOT

© GNU Su-Jin Kim


CAM

• 2d CAM for Mold base machining

NCBrain 2dCAM for mold base (9min) https://youtu.be/6yUyD0O-tHA

https://youtu.be/6yUyD0O-tHA



© GNU Su-Jin Kim


CAM

• 3d CAM for core and cavity machining

• NCBrain AICAM of Korea

NCBrin AICAM (16 min): https://youtu.be/5HRnglpDKz4

https://youtu.be/5HRnglpDKz4

© GNU Su-Jin Kim


CNC Machining

• Mold machining by Machining Center

http://www.youtube.com/watch?v=5pteVYeqVHI

http://www.youtube.com/watch?v=5pteVYeqVHI

© GNU Su-Jin Kim


Electrode

Workpiece

Spark

EDM (Electrical-Discharge Machining)

• Discharge spark removes metals

• Electrodes, dielectric fluid, workpiece

EDM: http://www.youtube.com/watch?v=q4FinKsDfww

유니테크 EDM: www.uedm.co.kr

http://www.youtube.com/watch?v=q4FinKsDfww

http://www.uedm.co.kr/

© GNU Su-Jin Kim


Progressive Die 순차이송금형

• Design: Sheet metal Punch Die structure

• Material: SKD61 < High speed steel < Tungsten carbide

© GNU Su-Jin Kim


Wire EDM

http://www.youtube.com/watch?v=pBueWfzb7P0 WireEDM

http://ma.gnu.ac.kr/vod/Machining/WireEDM.wmv WireEDM

- Wire electrode

+ Workpiece

Brass wire cut plates as thick as 0.3 m

Used to make hard punch and die

http://www.youtube.com/watch?v=pBueWfzb7P0

http://ma.gnu.ac.kr/vod/Machining/WireEDM.wmv

http://photo.empas.com/lala000/lala000_43/photo_incview2.tsp?psn=699&pre=photo_view2.html?psn=699

© GNU Su-Jin Kim


Press die 프래스금형

• Casting Machining

AICAM Press: https://youtu.be/B7CQAmUiFVs

https://youtu.be/B7CQAmUiFVs

© GNU Su-Jin Kim


CAD/CAM for Die & Mold

Draft was imported from German and Japen.

1960s

Major Company : DelCAM(England), Unigraphics(USA), NCB(Korea)

Manual draft on the paper by pen and ruler.

2D CAD(AutoCAD) was used for drafting.

CAD/CAM(Duct) running on UNIX started to be used.

Korean CAD/CAM(Omega) was developed at KAIST.

Die & Mold is designed y 3D CAD(UG), NC data is generated by

CAM(PowerMill), and machining is simulated by Simulator(NCBrain).

1970s

1980s

1990s

2000s

AutoCAD NCBrain UG PowerMill

© GNU Su-Jin Kim


Machine Tools for Die & Mold

1960s

Polishing and repairing of used Die & Mold imported from Germany

Major Company : Hwacheon, Doosan infracore, Jinyeong(EDM)

Lathe, Milling, EDM machine and HSS(high speed steel) tool were used.

WC(tungsten carbide) tool and insert start to be used.

CNC milling and WireEDM started to be used at Die & Mold industry.

High speed machining and 5-axis machining is start to be used.

1970s

1980s

1990s 2000s

Milling 1970s CNC 1990s EDM 1970s Endmill

© GNU Su-Jin Kim


Die & Mold Making

1960s

Decade of depending on craftmen

Major Company : Jeyoung Solutec, Nara M&D, Atech solution, Ilji tech, S-connect, Kishin Co.

Introduction of precision machine tools, Foundation of Korea Die and Mold Industry Cooperative

Setting of promotion plan for die/mold industry, Creating the complex of die/mold

cooperation in Namdong industrial complex, Introduction of CAD/CAM

Creating the complex of die/mold cooperation, Designation of die/mold business as high-

tech industry, Split-off of die/mold business from a conglomerate , Exploring overseas

markets

3,675 die/mold companies. 48,171 workers. Business for enhancing

human resource structure. Competitive exhibition of die/mold CAD.

The amounts of production is 5700 billion KRW(older than 9 years Co.)

1970s

1980s

1990s 2000s

Press die Mold

© GNU Su-Jin Kim


Reference

• Su-Jin Kim, GNU : http://ma.gnu.ac.kr

• KODMIC: http://www.koreamold.com

• Moldbase: http://kishin.com

• NCBrain: www.ncbrain.com

• NC Machining: http://hwacheon.com

• Endmill : http://taegutec.co.kr

• EDM : http://www.uedm.co.kr


http://www.koreamold.com/

http://kishin.com/

http://www.ncbrain.com/

http://hwacheon.com/

http://taegutec.co.kr/

http://www.uedm.co.kr/

die & mold for mass production - manufacturing...

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