The global automotive industry is rapidly evolving, with a strong focus on green, low-carbon, energy-efficient, and environmentally friendly technologies. One of the key strategies in this transformation is vehicle lightweighting. According to data from international authorities, about 60% of a car’s fuel consumption is attributed to its weight. Reducing the vehicle's mass by 10% can lead to a 6% to 8% decrease in fuel use. For non-loaded conditions, up to 70% of fuel is used just to move the body, with body panels and structural parts accounting for over 30% of the total vehicle mass. Therefore, achieving a lighter vehicle body is crucial for improving fuel efficiency and supporting environmental sustainability.
Hot stamping technology offers significant advantages for producing ultra-high-strength automotive components. These parts are not only extremely strong and hard but also significantly lighter—up to 35% thinner than conventional steel plates. Additionally, hot stamping minimizes material rebound, ensuring high precision. Unlike traditional cold stamping, which often requires multiple molds and processes, hot stamping allows complex parts to be formed in one step, reducing both mold count and production complexity. However, this process demands precise control over cooling rates during quenching, making equipment and mold design critical.
In 2011, under the national science and technology major project “Ultra-High-Strength Automotive Structural Parts Hot Stamping Technology and Equipment Production Line,†our company partnered with Changchun Weifute Auto Parts Co., Ltd. to develop and implement this advanced technology. The project led to breakthroughs in both technical development and production line implementation, using domestic equipment to replace imported systems. This marked a significant milestone in China’s automotive manufacturing sector, filling a technological gap and enabling large-scale application of the production line.
This article explores the domestic production line for ultra-high-strength structural parts, detailing its composition, key equipment, performance metrics, and comparing it with similar foreign systems. The results show that the production line meets or even exceeds the standards of developed countries in several aspects, proving the technological advancement of Chinese manufacturing.
**Production Line Composition**
The project team focused on innovative research into hot stamping technology and equipment, solving common challenges and developing proprietary solutions. A key component was the energy-saving ring-type bottom-end anti-oxidation heating furnace, designed with independent intellectual property rights. Alongside this, a high-speed, automated central control system was established, integrating water-cooled molds and variable-speed hydraulic presses. The entire production line incorporates expertise from various fields such as hydraulics, industrial furnaces, heat treatment, automation, and stamping dies. It uses fieldbus network control to ensure stable and reliable operation, capable of producing 600,000 units annually. The line is cost-effective, replacing imported systems and offering energy savings of nearly 30%. It also enables in-mold quenching, allowing the formation of complex parts that were previously difficult to produce under high temperatures, expanding the scope of hot stamping applications.
**Key Equipment and Performance Indicators**
The production line includes essential components like the anti-oxidation continuous heating furnace, high-speed conveyor, high-speed hot stamping hydraulic press, and water-cooled molds. Each plays a critical role in ensuring efficient and accurate manufacturing.
1. **Energy-Saving Ring-Type Heating Furnace**
This furnace uses an electric hybrid ring-type bottom method, filled with oxidation-resistant gas. It features a special high-temperature resistant material with minimal expansion. Advanced temperature testing techniques ensure optimal thermal distribution, while reliability tests confirm long-term performance. Key performance indicators include uniform heating and high operational stability.
2. **High-Speed Conveyor**
Designed for flexibility and reliability, the conveyor uses a linear reciprocating motion mechanism. It integrates PLC control and Modbus communication for seamless coordination with other equipment. High-temperature end pickers work with the conveying system to handle hot steel plates efficiently. A temperature monitoring system ensures process optimization and mold performance tracking.
3. **High-Speed Hot Stamping Hydraulic Press**
The hydraulic press is engineered for precision and durability, using computer simulations to optimize stiffness and performance. Its sealing system ensures stable pressure during high-speed operations, while closed-loop control technology allows precise pressure and speed adjustments. The press achieves ±0.1mm repeatability, meeting strict production requirements.
4. **Water-Cooled Molds**
These molds feature internal cooling channels optimized for even temperature distribution. New cooling pipe technologies improve mold life and reduce manufacturing costs. The materials used offer high thermal conductivity and stability, with a cooling rate of at least 100°C/s and a service life exceeding 200,000 cycles.
**Production Line Level Comparison**
After testing at Changchun Weifute Auto Parts Co., Ltd., the production line demonstrated excellent performance. Compared to similar foreign systems, it matches or surpasses advanced international standards in several areas. Table 3 highlights these comparisons, showing the competitive edge of the domestic solution.
**Conclusion**
This production line represents a major advancement in the automotive industry, offering high efficiency, safety, and environmental benefits. By breaking foreign technology monopolies, it supports the growth of China’s auto manufacturing and parts industries, reduces reliance on imports, and promotes advancements in machine tool and mold-making technologies.
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