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A Common Basic Technology: Die/Mold Technology. Dr. Weng-Sing Hwang President Metal Industries Research and Development Centre August 4, 2006. Contents. 1. Why Die/Mold is a Common Technology 2. Why Die/Mold is an Important Basic Technology

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a common basic technology die mold technology

A Common Basic Technology:Die/Mold Technology

Dr. Weng-Sing Hwang

President

Metal Industries Research and Development Centre

August 4, 2006

contents
Contents

1. Why Die/Mold is a Common Technology

2. Why Die/Mold is an Important Basic Technology

3. Current Status of Taiwanese Die/Mold Technology

4. Strategies for A+ Die/Mold Technology

5. Conclusions

1 why die mold is a common technology
1. Why Die/Mold is a Common Technology

1 What is a Die/Mold

(1). Forming methods for components/parts:

Machining: Extra material is removed by tools, including turning, milling and grinding.

Die/Mold Manufacturing: Material is shaped through constraining or extruding die/mold. Die/Mold is the prerequisite for mass production.

a. Molds: Material is formed during molten state, such as plastics injection molding and casting mold;

b. Dies : Material is formed during solid state, such as stamping, forging and extrusion.

Rotate sand wheel

Rotate workpiece

Rotate milling cutter

Feed

Feed workpiece

Feed workpiece

Move tool

slide4

Basic Structure of Bending Stamping Die-V Type

Workpiece (before forming)

shank

Upper die

punch

guide plate

Lower die

Die

Die set

Workpiece (after forming)

slide5

Plastics Injection Molding Process

Step 1: plasticization

Step 2: Injection

Step 3: Ejection

die mold foundation of industrial products
Die/Mold-- Foundation of Industrial Products

*Die/Mold are the key tools to make components & parts. They are also called the mother of industrial products. Through mold & die, the components & parts are able to be made in low cost, mass production and uniform quality.

*Though total production value of mold & die is not very high, each set of mold can create the production value at 10~50 times. Production value derived from mold & die in Taiwan area is estimated to exceed NT$1.8 trillion.

slide8

Demand of Die/Mold for Auto Parts

Aluminum frame structure

Adhesive bonding of Structure

  • Each automobile requires 1700 sets of stamping die, 500 sets of plastic injection mold and 1000 sets of casting mold.
  • Expense of mold & die is about NT$3~5 billion.

Aluminum casting parts

Wear-resistant transmission parts

Rocker arm/bearing

Magnesium casting parts

slide9

Demand of Die/Mold for Notebook Components

Casing, frame

(Aluminum, magnesium, die casting, sheet hydroforming)

IO terminal (stainless steel→titanium)

(precision stamping)

HDD Parts、 CD Yoke

(Press forging)

Plastic casing

(Injection mold)

Every Notebook requires about 50 sets of mold & die for mechanical and casting parts.(Excluding purchased parts, such as flat panel, hard disc, thermal module)

30um fine line

(Micro welding, hydro static extrusion)

Heat pipe with 0.5mm thickness

Battery can

(Deep drawing)

CPU, IC Thermal module

(Counter pressure, press forging)

Thickness precision<±0.015mm

slide12

Connector

Parts Manufactured through Die/Mold

Global production value of connector:

US$36.429 billion

Production value of connector in Taiwan: US$3.125 billion

Import value from Japan in 2004 US$0.31 billion

●Game machine(such as Sony’s PS2、Microsoft Xbox)

●MP3(iPod)

●Computer (Desktop, NB)

●Cell phone

●Digital camera

●PDA

●Printer

●PCMCI PC Card Kit

●Optical connector

●Automobile

●LCD TV

Classification of Connector

1.Rectangular(A)

2.Circular(A)

3.Memory card(A)

4.Board-to-Board(A)

5.FPC/FFC(A)

6.Coxial(B)

7.RF Coxia(B)l

8.Module(A)

9.Card Edge(A)

10.Antenna(B)

11.LAN(B)

12.ECU(B)

13.HID Lamp(B)

14.Board-to-Wire(A)

15.Optical(C)

PS:A-Domestic technologies are matured

B-Part of domestic technologies is matured

C-Rely on importation

Applied Products

Technical bottleneck

  • Forming parameters
  • Machining precision of mold & die
  • Tolerance control of die/mold parts
  • Assembly tolerance of die/mold
slide13

Extrusion of battery can requires ten stages of die process and each stage can not tolerate any defect.

Technical Difficulties

Too small

Too large

Too large

Too small

Too small

Material holding pressure

Die clearance

Punch R

Too large

Wrinkles on flange drawing

Breakage on punch

radius

Die center misalignment

Typical example of NG extrusion parts

Breakage on side wall

slide14

Surface Treatment and Heat Treatment

for Die/Mold

Proper heat treatment/surface treatment can prolong die/mold life. It then improve productivity and hence competitiveness.

IC packaging die

Previous method: Hard Cr electroplating

R&D result:Cr-flon treatment

Benefit:

Previous method had to clean mold for 2 hours after 500 shots. New coating upgrades to clean mold for 1 hour after 800 shots and increases die life for more than 50%.

Nitriding hot forging die for crank shaft of motorcycle/ion increases service life by 3-4 times

slide15

A+ Die/Mold Technology must Combine Theory and Practice

Progressive die for precision terminal (280 pieces components)Component precision: 1-3μmPrecision after mold & die assembly: 8μm

*Die/Mold technology is an integral technology. It includes material flow, control theory, precision processing, heat treatment, surface treatment, structure/mechanism, heat dissipation and tribology as well as knowledge in forming machine.

*Excellence in individual technology can not produce a good die/mold. It must take integral thinking, take care of every single element and facilitate good coordination among elements to complete a good mold & die. Therefore the ultimacy of mold & die technology is often considered more of an art than a technology.

slide16

3. Current Status of Taiwanese Die/Mold Industry

Die/Mold Structure

Ejection pin (Ⅱ)

Ejection pin

Ejection plate

Ejection pin (Ⅰ)

Die set

QFP-48 Press Die

Punch back plate

Punch plate

Punch plate

Ejection block

Upper die plate

Guide pin

Stripper die plate

spring

Stripper bolt

Die plate

Die insert

slide17

Contents of Generic Technology for

Die/Mold

Manufacturing

Process

Material

Inspection/

Certification

Design

Process design & simulation

Mold & die material specification

Mold & die structure/ mechanism

Mold & die stiffness/ strength

Product material forming property

Mold & die surface treatment

Mold & die heat treatment

Mold & die machining

Design & selection of surface treatment

Design and selection of heat treatment

Material selection

Measurement method

Design and selection of jig & fixture

Surface polishing

Machining process

Tools selection

Jigs & fixture selection

slide18

Comparison of Manufacturing Level for Domestic & Foreign Mold & Die

Manufacturing precision

Price competition

After-sale service

Product life

Inspection ability

Design capability

Production speed

Taiwan

Taiwan

USA

Japan

Germany

South Korea

South Korea

Mainland China

others

Singapore

Source: Taiwan Mold & Die Industry Association; MIRDC’s ITIS project

slide19

Taiwan still relies on import for precision die/mold

Industry must enhance basic technology to set up the

key technologies of ultra precision mold & die

DVD, optical, precision elements of MEMS

dimensional precision ±1μm (every mold)

dimensional precision ±1μm (mold)

Imported components

& parts exceeded

NT$200 billion

in 2003

(Ex.): Production value of TFT-LCD

尺寸精度±1μm (每m)

特徵精度0.1m

2002 (actual): NT$ 3500 billion

(V)

超精

密級

Characteristic precision 0.1μm

(Technical bottleneck of Taiwanese mold & die industry)

Characteristic precision 0.1μm

Ultra precision level

2006(target):NT$ 1 trillion 370 billion

(10家)

(Tech)

尺寸精度±3μm(每m)

2002(actual):NT$1 trillion

dimensional precision ±3μm (everymold)

(汽車零件、3C精密 薄殼產品….)

(IV)

Precision level

Auto parts, 3C precision thin-wall products

2006(estimate): NT$ 1 trillion

100

manufacturers

Casing of home appliances, stationery

(一般家電外殼、文具….)

(III)Secondary

precision level

(日用品、家具….)

Daily goods, furniture

(II)General level

Agriculture, industrial usage

(農、工業用途….)

(I)Cheap level

Total Number of Taiwan Mold & Die Manufacturers: 3,526

slide20

Current Status of Taiwanese Die/Mold Industry

*Production value of Taiwanese die/mold industry amounted NT$50 billion in 2003, roughly accounting for 4.3% of total global production value. The production value ranked the 8th place in 2003. However, it took the 6th place in 2002. Additionally the ranking of production value came behind Japan, USA, Mainland China, Germany, Italy, France and South Korea.

*Main competitive advantages of Taiwanese die/mold industry include quick production speed and excellent quality. Taiwan is second to Japan in Asia. The complete and flexible production system of Taiwanese mold & die industry is the target to be followed by other countries. In average, the price of Taiwanese mold & die is about 70% of that of Japan, while Mainland China is about 70% of Taiwan and South Korea is about 90% of Taiwan.

*The import unit price of Taiwanese die/mold is 2~3 times of export unit price, indicating the technical level is required to be upgraded.

*Taiwan has 3,500 mold & die manufacturers. In terms of technical level, less than 10 manufacturers can be classified as ultra-precision level (with size precision ±1μm), under 100 manufacturers can be listed as precision level (with size precision ±3μm). Regular mold & die facing the competition from Mainland China, Korea and South East Asia, its capabilities require to upgrade.

*As product requires higher and higher precision, the domestic mold & die technology is not sufficient to meet the requirements so that the imported components & parts exceed NT$200 billion per year.

slide21

Problems Faced by Domestic Mold & Die Industry

*The average number of employee for domestic mold & die industry is 12 persons. It relies on passing experience. It has weak theoretical base and insufficient R&D capabilities.

*Transformation of Taiwanese product manufacturer is focused on R&D. In the development stage, die/mold is developed in Taiwan and is relocated to low cost area in mass production stage. Die/Mold manufacturer must enhance innovative R&D capabilities, basic technology, and talented people (Otherwise 40% of manufacturers, about 1,400 makers, is estimated to withdraw from market).

*Some system manufacturers sets up its own die/mold shop as domestic die/mold makers are not equipped with the development capabilities. However, they also face the same problems, including the upgrading of basic technology, knowledge and talents.

* The capability in basic research to facilitate the development of die/mold technology becomes weaker and weaker in educational and research systems. The number of department, professor and graduate student to be dedicated to study of Ph. D and master thesis as well as B.S. program are gradually decreased.

slide22

Problems Faced by Domestic Die/Mold Industry—Can’t do or Won’t do

*Ultra precision die/mold (dimensional precision ±1μm, V level) must be comprehensively upgraded from material, equipment, manufacturing process and inspection.

→Domestic die/mold industry has the difficulty to establish R&D by itself.

→MIRDC takes the leading role to invest and work with other academic & research institutes for joint R&D.

*The basic technical data for precision die/mold (precision ±3μm, IV level) are not sufficient so the development time is too long and the cost cannot be controlled.

*The establishment of basic technology, sponsored by government, will prevalently increase the assurance for development, shorten the development schedule, increase the development willingness and further facilitate the overall industrial upgrading.

slide23

4. Strategies for A+ Die/Mold Technology

Develop the basic common technology for A+ die/mold to upgrade the domestic die/mold industry.

Definition of A+ die/mold:

● Precision requirements:

-- Precision level (IV level): ≦± 3μ m

-- Ultra-precision (V level): ≦±1μ m

● Long life span

● High product yield rate: easy for use and maintenance

  • High product complexity: 3D profile or compound machining
  • Short delivery: delivery accuracy 95%
slide24

Development Strategy of Die/Mold Technology

Micro Die/Mold Project

Break through technical bottleneck

Provide common lab. and assist the development

Common/Basic Technology Research

Optical,

MEMS

V ultra precision level

Dimensional precision under 1 μm

10 makers

VI ultra precision level

Dimensional preciison under 3μm

Collaborative Development

Platform

Auto,

3C

100 makers

Knowledge database

Manpower cultivation

Ⅲ secondary precision level

Provide JDM environment

Bring about rapid upgrading of overall capabilities

Dimensional precision 3~10μm

200 makers

Home

Appliance

Ⅱgeneral level

10~20μm

Case Consultation

3000 makers

Daily

Goods

I cheap level

Total 3,500 makers

strategy of establishing common basic technology for precision die mold
Strategy of Establishing Common/Basic Technology for Precision Die/Mold

MIRDC:

- Collect & compile technical information and identify the insufficiency

- Study of localized technologies

- Demonstration and promotion

1. Responsible for collection and analysis of the related basic technologies

2. Technical certification

3. Study of localized basic technologies

4. Set up promotion mechanism and network

5. Promotion and service providing

6. Integrate domestic academic & research resources, provide the services and assist the industry to upgrade

7. Set up, maintain and update the knowledge database website

8. Introduce foreign advanced technologies and facilitate them to be localized

※15-20% of annual budget is used to conduct the industrial & academic cooperation and international cooperation

slide27

Strategy of Establishing Common/Basic Technology for Precision Die/Mold (Cont.)

Academic sector: Set up localized knowledge and conduct manpower cultivation

1. Analysis and comparison of domestic & foreign mold & die machining and the related forming theoretical models

2. Practicability analysis and comparison for localization

3. R&D of applicable theoretical models for localization

4. Conduct long-term cooperation with non-profit organizations, set up focus research capabilities and become long-term R&D and service partner

Stamping die, forging die, material and heat treatment have been identified with specific manufacturers to discuss the details. The cooperative targets of injection mold, die casting mold, machining, inspection and knowledge database are still under discussion.

slide28

Strategy of Establishing Common/Basic Technology for Precision Die/Mold (Cont.)

Industrial sector: Provide technical information and verification services

1. Participate R&D led by institution with target on suppliers and equipment makers, such as machine tool maker, tooling factory, heat treatment plant, material manufacturer and software company.

2. Manufacturers actively provide their related technical information or corporation technology development program formulates the topics to locate the manufacturers to conduct the cooperative research.

3. Research results are included in knowledge database for public sharing.

4. If the industry, actually develops mold & die, is willing to share the results publicly, then joins the R&D of institution, otherwise conducts the related technical development through industrial technology development program.

slide29

Cooperation of Industry, Academic and Research Sectors for Ultra Precision Level Die/Mold

Equipment

makers

System Makers

Other

Institutions

  • 設備開發建置

MIRDC

Design Co.

(Design Dept.)

Academic

Institutions

Through specific cases, MIRDC cooperate with product company, die/mold makers, equipment makers and other academic & research institutions to conduct systematic development.

  • Market analysis, forecast and specifications setup for new products with development potentiality
  • Manufacturing technology R&D
  • Planning of manufacturing & assembly production line
  • Prototype and small batch production
  • Cultivation of manufacturing/mold & die technical talents
  • Establishment of product specifications
  • Design of prototype product
  • System simulation and analysis
  • Development and setup of equipment
  • Development and setup of equipment
  • Complimentary technical research
  • Basic research
  • Theory and simulation analysis
  • Setup of experimental equipment
  • Database establishment
  • Mass production and assembly
  • Technical evaluation and suggestion
  • Guide of manufacturing technology design
  • Prototype test
benefits to the industry
Benefits to the Industry

Industry

Knowledge database of common basic technology for die/mold

Shorten Development time

25-75%

Knowledge database of specific products

Save setup cost

NT$20-50 million

Shorten manpower cultivation time

10 years → 5 years

Education/training material for manpower cultivation

Increase confidence of developing new product

Save trial times to 2 times

Trial & Error → Theory & Prediction

slide31

5. Conclusions

*Die/Mold technology tremendously affects the economic development in the nation. It is the industry that is greatly supported for development by the advanced countries as well as developing countries. It is the industry to be developed in Taiwan.

Target: unit price of die/mold reaches 85% of that of Japan in 2010.

*Die/Mold industry in Taiwan needs more theoretical bases and talents, which will enable the upgrading to precision level die/mold. Previous research did not offer too much assistance in the upgrading of overall industrial technology and the development of national competitiveness due to limited budget and talents.

*The research of basic technology for from A to A+ mold/die, supported by government and compilation of knowledge-base and database will not only benefit die/mold makers, but also offer tremendous assistance to the industry which is to be transformed into design-oriented industry.

*This project has gained excellent response. Currently MIRDC has conducted the research planning with some industry, academic and research institutions. In the future, the concerted effort will facilitate sound and smooth implementation of this project.

slide32

5. Conclusions (cont.)

*Common/basic technology for precision level die/mold is to collect & compile the domestic & foreign information and conduct R&D to modify and localize information. They can be used in manpower cultivation and in knowledge-base for collaborative development platform to speed up the development time.

*Ultra precision level mold & die is the key for future product development.The comprehensive development of material, machining, manufacturing process, inspection and equipment is a key to the production of ultra precision die/mold.The development of ultra precision die/mold must have the concerted effort of industry, academic and research sectors. First specific vehicle product is to be developed. Then the whole industry is thus promoted and developed.

slide38

Mold & Die Industry Development Projects

in Asian Countries

1.Common Ground of Mold & Die Industry Development Projects in Japan and Korea

-Enhance export competitiveness-mold & die industry supports the product development

-Government sponsors the research of future competitive ability: micro-fabrication, precision upgrading and intelligent

-Application of IT-shorten delivery and reduce cost

-Upgrade development capabilities of new technology and new product: new material forming and mold & die design & machining, new product development

-Cultivation of high class design talents

2. Mainland China

-Mold & die industry is continuously listed as national important industry

-Increase import tariff of mold & die tremendously

3. Singapore

-Allocate S$2 million to conduct the planning of TDM (PDM of mold & die industry) system

-Allocate S$3 million to conduct the cultivation planning of mold & die design & manufacturing engineers and invest S$500 million to set up precision machinery and mold & die cultivation system

4. Thailand

-With Singapore’s assistance, Premier directly supervises to develop the auto and its components & parts

-Allocate THB$60 million to conduct the cultivation planning of mold & die talents and estimate to invest THB$1.69 billion to cultivate 7,000 persons within 5 years

general status of mold die development in japan

超微細、超複雜、高耐久、超高速用模具開發

  • 新興材料對應模具開發
  • 高速省能源型機械開發
  • 複合特殊技術開發
  • 技術力強化
  • 短交期化/成本削減
  • 海外市場開拓

Source: Die and Mold Technology (Nov. 2004)/compiled by MIRDC’s ITIS project

General Status of Mold & Die Development in Japan

Strength of Japanese mold & die industry

  • Development of mold & die for ultra-fine, ultra-complicated, durable and high speed purpose
  • New emerging materials response to development of mold & die
  • Development of high speed & energy saving type machine
  • Development of hybrid special technology

Target of industry development

Enhance technical capability

Short delivery/cost reduction

Explore foreign market

  • Application of IT
  • Increase the design completeness of high class products
development project of mold die technology in japan
Development Project of Mold & Die Technology in Japan
  • Estimated amount: Japanese Yen 4 billion
  • Duration: 2003~2005(three years)

Application of automobile & industry machinery

汽車及產業機械應用

Thixomolding technology for high fusion point metal

Casting die of high functional material

Forging die of high functional material

Mold & die forming technology for new materials

Forming technology of flexible molds for poor machinability light metal

Plastic injection mold of new material

Development of exhaust part for high precision injection mold

RP/RT hybrid mold manufacturing technology

For example: mobile phone battery housing/ SD memory card

Main targets of development for mold & die machining technologies

如︰手機電池殼/SD記憶卡

Micro free curve & complicated shape, including aspherical lens/ micro remote device/hologram optical element

Required high precision/high speed transfer technology of DNA analytical instrument and high density LSI

DNA分析儀器及高密度LSI等所需高精密/高速大量轉寫技術

Ultra micro forming mold

Nano size mold & die forming technology

Ultra-precision/3 Dimension

Ultra precision plastic injection mold

Asymmetrical aspherical shape optical parts

Forming technology of complicated shape mold & die

High precision stamping die

Ultra-precision machining/measurement technology

Utilize ultrasonic micro/nano mold & die forming technology

  • High precision blanking of LSI lead frame
  • High precision extrusion of motor housing for CD ROM
  • High precision groove machining of fluid dynamic bearing for Hard Disk Drive(HDD)

Source: Die and Mold Technology (Nov. 2004)/compiled by MIRDC’s ITIS project

mold die technology development project in korea
Mold & Die Technology Development Projectin Korea

Source: Ministry of Commerce, Industry and Energy/compiled by MIRDC’s ITIS project

development target and strategy of mold die industry in taiwan
Development Target and Strategy of Mold & Die Industry in Taiwan

Production value of precision level mold & die makers doubles

NT$100 million

Future(2008)

IV & V class integration

mold & die, focus on mold

& die of the development

stage, number of mold & die

makers for precision level

doubles

Total production value

Strategic Measures

Implement industry’s type with focus on joint design & manufacturing (JDM)

800

Major Focuses

-Construction of collaborative design development environment

-Cultivation of design engineers

- Assistance of IV level technical upgrading

- R&D and promotion of V level technology

Current status (2004)

Traditional mold & die

technology of Ⅲ &IV class,

focus on mold & die for OME

product, about 100 mold & die

makers for precision level

566

Year

2004

2008

import information of import components parts
Import Information of Import Components & Parts

Import Value in 2004

Unit: NT$100 million

slide45

Connector

Applied Industries of Components & Parts by Mold & Die

Global production value of

connector:

US$36.429 billion

Production value of

connector in Taiwan:

US$3.125 billion

Technical bottleneck

-Forming parameters control of mold & die

-Machining precision control of mold & die

-Assembly tolerance control of mold & die

-Tolerance control of mold & die parts

Connector’s classification

1.Rectangular(A)

2.Circular(A)

3.Memory card(A)

4.Board-to-Board(A)

5.FPC/FFC(A)

6.Coxial(B)

7.RF Coxia(B)l

8.Module(A)

9.Card Edge(A)

10.Antenna(B)

11.LAN(B)

12.ECU(B)

13.HID Lamp(B)

14.Board-to-Wire(A)

15.Optical(C)

註:A-Domestic technologies are matured

B-Part of domestic technologies is matured

C-Rely on importation

slide46

Analysis of Basic Research for Generic Mold & Die Technology

Fish Bone Chart of Application for Deep Drawing Die Technology

Design and analysis of mold & die

Assembly and measurement of mold & die

Mold & die machining & manufacturing

Assembly platform

Size measurement

CAD technology

Material property

EDM

Machining

Radius contour measurement

CAE analysis

Assembly tools

Design database

Grinding

WEDM

Strip layout

Process design

CAM technology

Polishing

Measurement of surface coarseness

Deep Drawing Die Technology

Quick die change

Transfer press

Vacuum heat treatment

Ion nitriding

Safety device

Sensing technology

CVD

PVD

Transfer fingers

Feeder

Surface coating technology

TRJ

Lubricant selection

Heat treatment and surface treatment of mold & die

Trial and finished products

slide47

Main Development of Mold & Die Technology at MIRDC

(S & T Project)

Development of micro-fabrication

system

World leading institution

Development of production system

for value-added heightening products

World class institution

•Fine wire∮<17μm

L>300m/min

•Aspect ratio L/D > 8

•Optical pick-up head

•4mm prismatic batter can

  • Long copper probe

Domestic leading institution

R&D of system integration

technology

Domestic first class institution

•Strip cold forging progressive die

•Deep drawing die for sheet metal Kc 〉60

•High speed drawing transfer die spm 〉200

•casting rapid die with wrought like material

Increase industry

competitiveness

•Upgrade mold & die technology

•unit price of precision stamping die increases 4 times

•Die casting mold enters into security parts market

•Forging die enters into S4 level market

•Prolong mold & die life and increase production value more than NT$5 billion

•Localized process and integration of mold & die technology replace import machine

•Upgrade mold & die technology

•unit price of precision stamping die increases 4 times

•Die casting mold enters into security parts market

•Forging die enters into S4 level market

•Prolong mold & die life and increase production value more than NT$5 billion

•Localized process and integration of mold & die technology replace import machine

Construct development

infrastructure of mold & die

•Development of localized software to increase the efficiency of 40%

•Promote mold & die design manual more than 3,000 volumes

•cultivation of mold & die talents accounts for more than 25% of mold & die design talents

Innovative mold & die

technology

Industrial application oriented

Establish mold & die technology for generic

demand

Establish mold & die technology for generic

demand

2000

2001

2002

2003

2004

1998

1994

1995

1996

1997

1999

slide48

Cheng Kung Univ.-Motor

-Analysis & Research of Thinning Design for Penny Motor

Yunlin Univ.-Micro EDM

  • -R&D of equipment & manufacturing process for micro EDM

Chung Hsing Univ.-Mirror Machining

  • -Use mirror machining system at Chung Hsing to jointly develop product and conduct industrial service

Kaohsiung First Univ.-Mold & Die

- MIM Research

  • -Technical consulting center of mold & die design & manufacturing process

Kaohsiung Univ. of Applied Science-Optical mold & die

  • -Micro plastic injection mold technology
  • -Design and inspection of backlight module

-Cultivation of mold & die talents

Established Strategic Alliance with Academic & Research Sectors

MIRDC

international cooperation

Origin Co. in Japan

-Analysis & Control technology of micro resistance sealing welding process

LFT in Germany

-R&D of Metals Formability in the application of micro/meso manufacturing

Daido Machinery in Japan

  • -R&D of micro forging process
  • -Design & Development of mini-cassette change former

LEM in Japan

  • -Design & Development of Micro-press

NIU in America

  • -R&D of micro-forging process
  • -Design & Development of Micro-forging die

GIT in America

  • -Research & application of Spatial error compensation technology

Others (under negotiation)

  • -Japan AIST/Korea KIMM, etc.
  • -Micro-manufacturing related system technologies

Zyvex Co. in America

  • -Micro-Assembly Statistics Technology
International Cooperation

Material

MIRDC

Equipment

Manufacturing Process

Assembly

project target and expected benefit
Project Target and Expected Benefit
  • Unit price of mold & die reaches 85% of that of Japan in 2010.
  • Enhance basic technology of precision level mold & die, speed up technical upgrading and increase the design & development speed & efficacy. Mold & die makers for precision level double to 200 makers in 2008 and 300 makers in 2010 respectively.
  • Systematically set up the basic technology of ultra-precision level mold & die to establish international competitiveness for main stream market in the future. Mold & die makers for ultra-precision level increase to 500 makers in 2010.
  • Number of member for generic knowledge database of mold & die exceeds 300 in 2010.
  • Combine academic resources to set up 5 basic technology service centers for mold & die in Taiwan in providing the industry with convenient services.

Project Target

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Generic Basic Technology of A+ Mold & Die

FY95(Framework setup)

FY96(Long-term cultivation)

  • Study of Basic Mold & die Design technology
    • Setup of precision design reference data, design criterion, upgrading of simulation snalytical capabilities and upgrading of assembly precision for stamping die, injection mold, forging die, die casting mold and PIM mold
  • Study of Basic Manufacturing & Inspection technologies for Mold & Die

- Size precision, profile precision, polishing,

residual stress and strain, measurement and

control of assembly precision

  • Basic Technology Study of Materials and treatment for Mold & die

- Influence of material micro structure and micro

element, selection specifications, life pgrading

and assurance, deformation control and size

control

  • Demonstration and Promotion

- Selection of demonstration cases and collection

& setup of information, promotional activities

of project and recruit & service of knowledge

database members, promotion of island service

center, promotion of international cooperation,

promotion of cooperative research with industry,

academic & research sectors

  • Study of Basic Technology for Ultra0Precision Level Mold & Die
    • Selection of R&D Vehicle, labor of division for R&D institutions, introduction of foreign cooperative institutions
  • Compilation and Research Planning of Basic Mold &Die Technology
    • Affecting variable analysis and theoretical formula
    • Database of domestic & foreign key variables
    • Related framework of basic technical system
    • Research planning and sorting of localized technical information
  • Planning of basic mold & die technology database
    • To be equipped with functional framework of mold & die knowledge database and authorization framework to use mold & die knowledge platform
    • To ve equipped with knowledge management process and searching function
  • Demonstration and Promotion
    • Set up stamping die demonstration cases
    • Complete more than 2 symposiums and panel discussions
    • Complete the planning of service spots for mold & die technology in northern, central and southern region
    • Complete one case of cooperative research planning with foreign institution
estimated benefit
Estimated Benefit
  • Facilitate the doubling of value-added for mold & die industry and the doubling of export unit price for mold & die in 2010 with production value exceeds NT$90 billion.
  • Knowledge database of generic basic technology for precision level mold & die can assist the industry to speed up the upgrading, reduce R&D cost and shorten the development time of mold & die to 30% and increase the development speed and efficacy. The knowledge database can decrease total development cost of NT$2 billion for industry every year (20 xNT$1 million x 100 makers).
  • Assist mold & die makers to transform and participate the collaborative design & development model of product manufacturer by over 100 makers/times. The value of developed product exceeds NT$10 billion.
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Expected Benefit in 2006

‧Comprehensively compile the basic technology capabilities of mold & die, provide R&D basis for domestic upgrading & transformation and reduce the setup cost of industry more than NT$0.1 billion.

‧One setup case is to verify the effectiveness of basic technology knowledge database. Effectively upgrade the development efficiency of mold & die and reduce the cost of industry more than NT$0.1 billion.

‧The knowledge database is obtained after compiling & analyzing the basic mold & die technology that can be served as reference to the SOP and training material of mold & die makers, product development & design database of each maker & product as well as upgrading & development of industry’s technology.

‧Through member system, common knowledge database of basic mold & die technology facilitates the participation and information acquisition of users. Additionally common knowledge database can decrease the setup time and cost and update at any time.

budget
Budget

※Subcontracting research includes the cooperation with industry and academic sectors under contract and international collaboration