Die & Mold for Mass Production

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1 Associate Professor Su-Jin Kim School of Mechanical Engineering Gyeongsang National University

2 Hyundai Automobile The Empty Car Convoy:

3 Hyundai Manufacturing Plant Korea : Mexico :

4 Supply Chain 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%). Automobile Module Parts SME Infra: Mold, Casting, Forging, Heat, Machining

5 Elanrta (Avante) MD Avante MD 358,000 Cars in ,000 Cars/day? / min

6 Mass Production Sheet metal forming Forging, Die Casting Plastic Injection Die & Mold Sheet metal Plastic

7 Die & Mold

8 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. Diecasting Mold Blow Mold Plastic injection Mold Press Die Forging Die

9 Die & Mold for Automobile 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. Light Plastic Mold Bumper Plastic Mold Wheel Diecasting Mold

10 60 years of Korean Die & Mold 1990s 2000s Huge mold for automobile, Precision mold for electronics, 1,379 die/mold companies. Export $3,228 million >> Import $158 million in s 1980s CAD/CAM & CNC, Wire EDM, Tungsten carbide tool, Die steel Export $210million > import $190 million in 1994 NC machine tools, Korea Die & Mold Industry Cooperative (KODMIC) 1960s 1950s Electric discharge machining, Standard moldmase, Die & Mold training school (Polytechnic II) Milling & lathe (whacheon.com), Injection molding machine(dongsin) Korean war, LG chemical, TaeguTec, 1st Die & Mold companies started business c 30 years history of KODMIC

11 Die & Mold Companies of Korea 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 (6.1%) 2 (0.1%) 145 (10.5%) Gangwon Seoul 53.3% Companies are locating nearby Seoul Incheon Gyeonggi 20 (1.4%) Chunngbuk 509 (36.8%) Daejeon Chungnam 202 (14.5%) Daegu Gyeongbuk 32 (2.4%) Jeonbuk 20 (1.4%) Busan Ulsan Gyeongnam Gwangju Jeonnam 289 (20.9%) 81 (5.9%) 11

12 Die & Mold Companies of Korea 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 Standard Parts, 740 Diecasting Molds, 129 Other, 888 Plastic Molds, 2,948 Press Dies, 2,385 Total $7,086 million in 2012 c 12

13 Export of Korean Die & Mold 1) Korea exports about 37% of its total die and mold production. 2) The export volume ratio is about 63% in Asia. Russia 3% Turkey 3% USA 7% China 17% Japan 17% India 9% Mexico 7% Vietnam 5% Malaysia 4% Indonesia 3% Brazil 3% 13

14 World s Mold Export and Import 1) Korea was the world s second largest die and mold exporting country in ) 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) million $ 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, Export China Korea Japan Germany USA million 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, Import USA Mexico China c 14

15 Demand Industries of Die & Mold 1) Korea Die & Mold companies increased with the automobile and electronics industries using molds for mass production. Office Supplies Household Item Others Automobile Semiconductor IT Device Home Appliance Source : Survey on Mold Industry Status, Korea Die & Mold Industry Cooperative,

16 Supporting Industries of Die & Mold 1) The machine tools and material technologies supporting die and mold are well developed. asis.co.kr CAD/CAM Precise Machining Production CAM NCBrain.com Noldbase Kishin.com NC Machining hwacheon.com Plastic lgchem.com Injection dongshin.net endmill taegutec.co.kr EDM kojin.co.kr Sheet metal posco.co.kr Press simpac.co.kr 16

17 Korea Polytechnic II 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 17

18 Korea Polytechnic II 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 1 st Injection mold Stamping die Precise metrology Mold drafting NC machining Basic machining NC machining 3d Modeling CAD practice 2 nd Mold manufacturing Mold material Product design & post process 3 rd Precise mold design Precise machining Mold element design Mold develop project1 CAM practice Precise part machining Mold develop project 2 Mold manufacturing Mold design, Product design 4 th - Mold develop project 3 Assembly and repairing High speed machining Process analysis 18

19 Korean Die & Mold Industry Cooperative 1) The Korean Die & Mold Industry Cooperative was launched in 1980 and has 553 member companies in ) InterMold Korea began in 1980 and 22th InterMold Korea was held on March koreamold.com intermoldkorea.com 19

20 Mold Valley 1) Bucheon city developed a mold industrial complex named Mold Valley in ) 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 20

21 Korea Mold Makers 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 Plastic Sheet metal 21

22 Specialization Mold maker Outsourcing Standard Mold design NC Machining EDM Mold design NC machining Gun drill EDM Standard mold base Standard elements Polishing assembly Polishing Test injection 22

23 Policy Recommendations C. Korea Mold Technology Center in Mexico 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 8m 1) Technology & 20 equipment Building 1,600 m2 Mexico Korea 23

24 Mold Machining asis.co.kr CAD/CAM NC Machining EDM Assembly / Test Moldbase kishin.com NC Machining hwacheon.com EDM uedm.co.kr Injection dongshin.net CAM ncbrain.com Simulation ncbrain.com Monitoring nicks.co.kr Maps 3d wincapa.com

25 Injection Mold Machining CAD Mold design Injection molding CAM NC Machining

26 Plastic parts 3d design of refrigerator shelf

27 Mold Design Mold : Cavity + Core + Plate + Eject pin + Guide bush NX mold design (6min)

28 Plastic flow analysis Flow: sprue runner gate cavity Analysis: temperature, pressure, time, weld line, air trap Maps-3d Injection molding CAE (3min)

29 CAM 2d CAM for Mold base machining NCBrain 2dCAM for mold base (9min)

30 CAM 3d CAM for core and cavity machining NCBrain AICAM of Korea NCBrin AICAM (16 min):

31 Simulation & Optimization Simulation & Optimization by NCBrain

32 CNC Machining Mold machining by Machining Center

33 EDM (Electrical-Discharge Machining) Discharge spark removes metals Electrodes, dielectric fluid, workpiece Electrode Spark Workpiece EDM: 유니테크 EDM:

34 Plastic Injection Molding Plastic injection molding

35 Progressive Die 순차이송금형 Design: Sheet metal Punch Die structure Material: SKD61 < High speed steel < Tungsten carbide

36 Wire EDM Brass wire cut plates as thick as 0.3 m Used to make hard punch and die - Wire electrode + Workpiece WireEDM WireEDM

37 Press die 프래스금형 Casting Machining AICAM Press:

38 CAD/CAM for Die & Mold 1960s 1970s 1980s 1990s 2000s 2D CAD(AutoCAD) was used for drafting. Manual draft on the paper by pen and ruler. Draft was imported from German and Japen. Die & Mold is designed y 3D CAD(UG), NC data is generated by CAM(PowerMill), and machining is simulated by Simulator(NCBrain). CAD/CAM(Duct) running on UNIX started to be used. Korean CAD/CAM(Omega) was developed at KAIST. Major Company : DelCAM(England), Unigraphics(USA), NCB(Korea) AutoCAD UG PowerMill NCBrain

39 Machine Tools for Die & Mold 1960s 1970s 1980s 2000s 1990s High speed machining and 5-axis machining is start to be used. CNC milling and WireEDM started to be used at Die & Mold industry. WC(tungsten carbide) tool and insert start to be used. Lathe, Milling, EDM machine and HSS(high speed steel) tool were used. Polishing and repairing of used Die & Mold imported from Germany Major Company : Hwacheon, Doosan infracore, Jinyeong(EDM) Milling 1970s CNC 1990s EDM 1970s Endmill

40 Die & Mold Making 1960s 1970s 1980s 2000s 1990s Setting of promotion plan for die/mold industry, Creating the complex of die/mold cooperation in Namdong industrial complex, Introduction of CAD/CAM Introduction of precision machine tools, Foundation of Korea Die and Mold Industry Cooperative Decade of depending on craftmen 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.) Creating the complex of die/mold cooperation, Designation of die/mold business as hightech industry, Split-off of die/mold business from a conglomerate, Exploring overseas markets Major Company : Jeyoung Solutec, Nara M&D, Atech solution, Ilji tech, S-connect, Kishin Co. Press die Mold

41 Reference Su-Jin Kim, GNU : KODMIC: Moldbase: NCBrain: NC Machining: Endmill : EDM :

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