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2 Development situation and environment
The Chinese super-hard materials industry developed on the basis of complete independence and independence, using all kinds of super-hard material products produced by technology and technology with completely independent intellectual property rights, has made great progress in the world, and has formed an unassailable status in the world. It has formed a strong position in rough processing and general processing tools in various application fields. It can be said that China's superhard materials industry enjoys a high reputation in the world.
However, because the high-end work machine tools using super-hard materials tools are mostly subject to the developed countries, the raw materials required for super-hard materials are also constrained by the insufficient fineness of materials in the domestic supporting industrial fields, combined with the technological blockade, trade discrimination and barriers of developed countries to China. Restrictions, in terms of high-end work machine supporting tools, precision fine materials and processing tools, China is in a relatively passive position, and there is a big gap between the products and the high-end tools that are imported with the work machine. We can only track development and continue to replace it.
2.1 Global product competition pattern
China basically dominates the global market for superhard materials and enjoys a full say. China's synthetic diamond sales accounted for more than 90% of the world market during the “Twelfth Five-Year Plan†period, and cubic boron nitride accounted for 70% of the world market. From the quality index of single crystal itself, it is also equal to or higher than that of developed countries. It has been the case for many years. It can be said that China's superhard materials have made outstanding contributions to the development of the world's manufacturing industry. It can also be said that China's superhard materials are The world has a good reputation. We have squeezed similar products from developed countries into small market areas with special requirements, which is something we should be proud of. However, we also clearly see that the small market is very demanding, the product price is often high, and the added value is very high. It can be described as a high-end market. The market is still owned by the British Element Six and Sandvik in the United States. The monopoly of Hyperion and Iljin of South Korea, and even the high-end market of China, are also monopolized by these three companies. Although the number is not large, the import volume has continued to grow slowly in recent years, and their unit prices tend to It is 3 to 5 times ours, and the image of the strong is well known in the industry. All in all, China occupies a large market with a large volume, but the product segmentation is not enough. The sophisticated and high value-added small market is occupied by developed countries.
In addition to the above three companies, composite superhard materials include US Synthtic, Mega, and Sumitomo Corporation of Japan. The quality of composite superhard material PDC for oil and gas drilling in China is comparable to that of foreign high-end products, and has been recognized in the international market, but in high-end drill applications, such as deep oil and gas directional wells and horizontal wells for drilling more than 4,000 meters. The share of possession is still small. One of the reasons is that trial costs are huge and most drill manufacturers are reluctant to take the initiative. It shows that the confidence of China's high-end composite super-hard materials brand is still insufficient. PCD and PCBN blanks for precision metal cutting tools, combined with single crystal and polycrystalline blanks for fine wire drawing die, have a much larger gap with developed countries, even though most of the domestic market uses imported products.
Superhard material products are used in various fields of national economy and people's livelihood, and their varieties and specifications are numerous. According to its function and consumption, it can be roughly divided into: sawing and drilling tools, grinding and cutting tools, precision cutting tools, wire drawing dies, acoustic and photoelectric heat and other functional components.
China's superhard materials products are the world's first-class sawing and drilling tools. The international operation of such products has taken a substantial step, breaking the precedent of only developed countries setting up factories in China. We have also established marketing networks, set up factories, and even established R&D centers in developed countries. We have truly achieved the competitive landscape of you and me and achieved unprecedented results. These products are all metal bond tools, accounting for 60% to 70% of the total output value of superabrasive products. During the “Twelfth Five-Year Plan†period, the pre-alloyed powder was further used, and the rare earth metal was added to the carcass. New technologies such as welding, diamond ordering and even orientation in the carcass, and innovation in matrix structure, innovative new technology for energy-saving and high-efficiency production, and new high-value-added, high-performance new products are produced. The world's advanced level has greatly improved the industry's product structure, improved efficiency and expanded the international market. However, the product subdivision is not enough. For example, there are big gaps between developed and special tools such as rescue and disaster relief, high-speed and efficient demolition of dangerous bridges, underwater shipwreck cutting and salvage.
China's second-largest grinding and cutting tools in superhard materials are among the world's second-class products, accounting for about 15% of the total output value of super-hard abrasive products (increased growth trend, the proportion will be gradually expanded in the future), to 125 High-speed, high-precision, high-efficiency ceramic CBN grinding wheel with m/s and above, high-precision end face grinding disc, high-tech products represented by ultra-precision, ultra-thin IC and micro-cut grinding wheel for IT industry, the quality level and application surface have been greatly expanded. The level reached or approached the world's advanced level, not only entered the production line in the field of high-precision processing, but also replaced the imported products with more and higher speed and higher price, and began to sell to the international market, effectively promoting The industry product structure adjustment.
The world-class high-end grinding and cutting tool manufacturing technology is still monopolized by a few industrialized countries such as Japan, Germany and Austria. Foreign superhard abrasive tools have entered the development stage of ultra-high speed, high efficiency, precision and green. High-performance grinding tools require advanced manufacturing and inspection equipment to ensure performance and quality stability. With the development of high-end, high-performance grinding and cutting tool products, the development trend of foreign manufacturing and testing equipment is automation, intelligence and energy saving. Briefly read as follows:
(1) In terms of ultra-high speed. Research work has been carried out in foreign countries on the aspects of lightweight substrate, abrasive arrangement, binder modification and safety performance testing. For example, Austria's TYROLIT has developed a lightweight manufacturing technology for grinding wheels with the goal of reducing centrifugal force during high-speed grinding, and developed a lightweight, high-strength CBN mill based on carbon fiber reinforced composite (CFRP). With the application of grinding line speed of 200 m / s; Germany's WINTER uses abrasive directional arrangement technology to increase the amount of abrasive involved in grinding, thereby increasing the sharpness of the working layer. Japan has modified the ceramic bond by adding metal oxides. The high-strength ceramic bond has been successfully applied to CBN grinding wheels with a speed of 300 m/s. The developed countries such as the European Union and the United States attach great importance to the safety of superhard abrasives. Research on testing techniques has established mandatory safety standards (EN 13236..2010 safety requirements for super-hard material grinding wheels).
At present, the research foundation of ultra-high speed in China is still very poor. The lightweight of the substrate is the basic condition for ultra-high speed. The research in this aspect has just started in China, and the use speed of 200 m/s is still in the laboratory stage (there is no such high speed in China). Grinding machines), not practically used in production, only a few applications have a grinding speed of 160 m/s, mostly 100-125 m/s.
(2) Efficient aspects. On the one hand, foreign countries can achieve high-efficiency machining by greatly improving the grinding capacity of the grinding wheel and satisfying the grinding process with large margin or high feed rate. For example, the CNC tool opens the main groove grinding wheel with resin/metal composite bonding agent, the cutting depth is 3~4 mm, and the feed speed can reach 100 mm/min. Efficient cutting of the Quad Flat No-lead Package (Quad Flat No-lead Package) with a 58 mm diameter integral resin ultra-thin cutting wheel with a cutting feed rate of 60-80 mm/min.
On the other hand, through the comprehensive balance of the self-sharpening ability and the life of the grinding wheel, the manufacturing process can be free from trimming, reducing the non-production processing time and achieving efficient processing. For example, if the surface of the LED epitaxial wafer is thinned, the high self-sharpening bonding agent can be used to avoid trimming during the processing, save a lot of non-grinding processing time and improve efficiency (this type of grinding wheel has been successfully developed and started to supply in the market) The hard alloy centerless grinding wheel adopts high self-sharpening formula design, which realizes the whole processing process except for the machine trimming, and saves the non-machining time; and the ceramic CBN end grinding wheel realizes the double-end grinding of the connecting rod. Free of trimming and so on. These are already industrialized technologies in foreign countries.
The country has been tracking foreign developments, which varieties in which areas are replaced by domestic products, and foreign countries are launching higher-end products. The situation in which high-end applications are dominated by foreign products has not changed much.
(3) Precision. First, the precision difference between the grinding wheel and the grinding wheel at home and abroad is still relatively large. For example, the foreign 1A1R base type ultra-thin cutting wheel has a symmetry of 0.01mm or less, which can meet the requirements of high-precision group cutting. However, there is no processing equipment for solving this problem in China. Processing technology, the current product processing symmetry is 0.02 mm. Batch processing of thickness of 0.05 mm integral ultra-thin cutting wheel is currently only available in small batches in China.
Second, the precision of precision and ultra-precision of grinding wheel machining workpieces is even greater. The grinding wheel of 8000#~36000# has no domestic product supply market, mainly imported. Another example is the use of 5000# and finer-grained diamond grinding wheels to achieve precision-free grinding of PCD and PCBN cutting edges. Currently, there are mainly Japan Ashia and Austrian TYROLIT. The domestic application can only be applied in the low-end field. There is still a big gap between the grinding wheel and the grinding edge quality; the 5000# used in the bearing channel super-finishing research is made of fine ceramic CBN oil stone, which is mainly occupied by Japanese products in the domestic market. The preparation technology of CBN super essential oil stone; the surface grinding wheel for ultra-precision machining of sub-micron or even nano-scale abrasive grain grinding wheel is currently only in the stage of technical exploration and preliminary research. In addition to the industry's own manufacturing technology, this type of problem is also one of the important factors in the refinement of the raw materials of the supporting industry. The particle size of the commercially available binder is coarser than the abrasive grain size.
(4) Greening aspects. Some industrialized countries have carried out research work on the greening of abrasive manufacturing and grinding applications. For example, in the green application of abrasive tools, Germany's WENDT company has developed ultra-precision bonded abrasives to replace the traditional free abrasive processing, achieving high-efficiency, ultra-precision and green processing. , greatly improving the material removal rate while avoiding the environmental hazard caused by the processing waste liquid.
The use of super-hard abrasives instead of ordinary abrasive tools to achieve improved processing environments such as dry grinding, elimination of dust, and reduction of grinding residues is currently being promoted in China. The typical representative is the deburring process in the engine casing. By using the electroplated super-hard grinding wheel instead of the ordinary resin grinding wheel, not only the high-efficiency machining is realized, but also the machining environment is greatly improved because the electroplated super-hard abrasive has no grinding residue dust. However, this is only a small number of applications, rather than forming a certain scale of application, and the alternative development space is huge.
(5) Automation and intelligence. The automation of foreign production equipment is high, automatic weighing, forming, loading and unloading molds, transshipment, online testing applications, and production process data acquisition systems, making the production process intelligent is relatively easy. Domestic diamond saw blade manufacturers have introduced foreign high-level equipment such as cold pressing and laser welding at high automation level for many years (currently, such high-end equipment has been developed in China, which has little difference with foreign similar equipment, and has been applied in some enterprises. And blocked the import, but the reliability and stability of its long-term use still need to be verified), the super-hard tool manufacturers introduce foreign high-end grinding machines to be automated, and the basis for the intelligent production of the two types of products in the next five years is better; The manufacture of superhard abrasives and other products is basically in a semi-automatic and manual production state. The automation has not yet been fully realized, and the intelligentization has basically not started. A small number of companies have begun to prepare 3D printing workshops for superhard material tools and metal powder for superhard material tools.
Other products, such as oil and gas drilling tools, precision PCD for machining, PCBN raw materials and cutting tools, high wear-resistant and high-precision diamond wire drawing die for wire and cable and screen industry, the high-end market is mainly based on developed countries. Domestic products are gradually replaced. For example, high-hardness complex formation exploration and drilling, offshore oil and gas field drilling are gradually adopting domestic PDC composite sheets and drill bits. Most of the high-speed high-efficiency and high-precision car parts are turned (about 85%). Domestic PCD and PCBN cutting tools have been used (but Raw materials are mainly imported), high temperature and high pressure and CVD diamond wire drawing cores have begun to be widely promoted, and so on.
2.2 Opportunities and Challenges for Industry Product Development
The global strategy of American industrial reengineering, German industry 4.0, and China manufacturing 2025, etc., advocates a new environment of green environmental protection and intelligent manufacturing, creating a new round of super-hard materials, such as environmentally-friendly basic materials and high-precision and efficient tools. An important period of strategic opportunity. We must seize opportunities, meet challenges, win strategic initiatives, build and enhance competitive advantages, achieve future development, and strive to further strengthen the status of the original advantageous areas in 2020. The original second-rate products have basically reached the world's advanced level.
2.2.1 Opportunities
(1) Key support in national policy, “The 12th Five-Year National Strategic Emerging Industry Development Plan†has clearly stated in the “Key Development Directions and Main Tasksâ€: “We must vigorously develop new functional materials and actively develop superhard. Materials and products". It laid a good policy foundation for future development. New materials are still one of the key support areas in the national “13th Five-Year Plan†proposal. Superhard materials are also part of the new materials, and the equipment manufacturing industry serving the super-hard materials industry is also in the field. Focus on support. If the proposal points out: accelerate the construction of a manufacturing power, implement the "Made in China", implement intelligent manufacturing engineering, build a new manufacturing system, and promote a new generation of information and communication technology, high-end CNC machine tools and robots, aerospace equipment, marine engineering equipment. And high-tech ships, advanced rail transit equipment, energy-saving and new energy vehicles, power equipment, agricultural machinery and equipment, new materials, biomedicine and high-performance medical equipment and other industries have grown. The future development of the industry and its service areas has been upgraded to the national level, which will not only be strongly supported by the policy, but also have a broad market space.
(2) During the “Thirteenth Five-Year Plan†period, the state will expand infrastructure construction space, implement major public facilities and infrastructure projects, and accelerate the improvement of infrastructure networks such as water conservancy, railways, highways, waterways, civil aviation, general aviation, pipelines, and postal services. Promote the construction of the “Belt and Road†and promote the interconnection of infrastructure and the construction of international channels. Infrastructure construction at home and abroad will require a large amount of building materials, which will lead to the development of diamond tools for building materials processing and infrastructure engineering.
(3) The development of equipment fields such as high-end CNC machine tools has fully recognized the importance of system development including functional components and tools. Without the support of high-end tools, high-end machine tools will be difficult to bring benefits. The development of machine tools in the direction of high speed, high efficiency and high precision will inevitably lead to the development of grinding tools. We must encourage and guide independent innovation of enterprises, keep up with the pace of development of the manufacturing industry, seize development opportunities, improve product performance, highlight differentiation, strengthen the development of subdivided special products, and increase the added value of products; The advantages of providing complete grinding solutions enhance the competitiveness of industry products.
(4) The Fifth Plenary Session of the 18th CPC Central Committee emphasized that to realize the development goals of the "13th Five-Year Plan" period, to solve the development problems, and to develop the advantages of development, we must firmly establish and implement the development concept of innovation, coordination, green, openness and sharing. . Innovation is the first driving force for development; coordination is the requirement for sustainable and healthy development; green is the necessary condition for sustainable development and the important embodiment of the people's pursuit of a better life; openness is the only way for the country to prosper and develop; sharing is the essence of socialism with Chinese characteristics Claim. Adhere to green development and focus on improving the ecological environment. Support green cleaner production, promote the green transformation of traditional manufacturing, promote the establishment of a green low-carbon recycling industrial system, and encourage the upgrading of technological and technological equipment.
Super-hard materials and various kinds of products are green, high-speed, high-efficiency and high-precision products. They are an excellent choice for replacing traditional cutting and polishing tools with high energy consumption, heavy pollution and resources. They are also irreplaceable long life. Tools (also known as semi-permanent tools) are the necessary tools and strong support for the development of intelligent manufacturing in all types of manufacturing industries. They will be developed rapidly during the 13th Five-Year Plan period and in the longer term.
(5) China's super-hard materials products basically reach or close to the world's advanced level, with outstanding features of low price and high cost performance, and can be used in most high-demand processing occasions. With the emergence of pressures on the cost reduction of the processing industry and the strong demand for cost reduction, the demand for medium and high-end products is on the rise. Structural adjustment has become an increasingly prominent theme of enterprise development. Opportunities for vigorously developing medium and high-end products have arrived.
2.2.2 Challenge aspects
In general, the advantages of counterparts in developed countries are: basic research is advanced, high-end manufacturing equipment is leading, manufacturing technology is fine, social supporting materials and parts are high, and it is easy to encourage the government to set trade barriers (such as establishing market access standards, anti-dumping Etc.), the international marketing network is perfect, the service is in place, and so on.
Our main issues are outlined below:
(1) The competitiveness of medium and high-end products is weak. Imports of diamonds continued to grow, and imports of various types of products remained high. The unit price ratio of import and export products is 2, and the maximum value is up to 20. Precision grinding tools and cutting tools are not only difficult to cut into the international high-end market, but also the domestic high-end market is dominated by high-end products in developed countries.
(2) The degree of product specialization and the degree of refinement are insufficient. The degree of specialization of superhard material single crystals varies greatly according to the purpose of use. Most of them are classified by the performance of materials themselves, and are rarely classified according to fine professional use. Compared with foreign high-end products, except for sawing and drilling tools, abrasive tools and tool tools The level of roughing and semi-finishing is acceptable, and finishing is quite different.
(3) The overcapacity of medium and low-end products, serious homogenization, increasingly fierce competition, and falling prices; the international marketing network is imperfect, expanding international space efficiency and low profits; while prices continue to rise, labor costs continue to rise. Corporate profitability has been severely squeezed.
(4) The product application laboratory is lacking or not perfect, which not only affects the new product development cycle, but also difficult to grasp the performance parameters of the product, resulting in half of the market development.
(5) The research on basic common technology is backward, and it is difficult to make breakthroughs in product research; the research on cutting-edge technology is not enough, and the innovation and future sustainable development are insufficient.
(6) Insufficient innovation ability and lack of senior talents. The innovation of China's second-rate products is basically following the international high-end products. There are few unique innovations in the world. The high-end talents are few, but the existing employment mechanism is difficult for them to devote themselves to innovation. Of course, the innovation ability of my industry is also restricted by the constraints of domestic high-end machine tools and the poor supporting basic materials.
Superhard Materials Industry Development Plan (3): Guiding Thoughts and Objectives ( click to read )
Superhard materials industry development plan (finished) (2)
Abstract 2 The development situation and environment in China's super-hard materials industry developed on the basis of complete independence and independence, using various technologies and processes with completely independent intellectual property rights to produce all kinds of super-hard materials products, all the way triumphantly, has formed in the world Inciting big country status...
Superhard Materials Industry Development Plan (1): Major achievements in the superhard materials industry during the 12th Five-Year Plan period ( click to read )