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Analysis of the development of Japanese cutting tool industry and its output value
The output value of hardware tools in Japan in 2000 increased by 10.9% compared with 1999, reaching 377.121 billion yen. Among them, high-speed steel cutting tools, diamond tools, CBN tools have double-digit growth; cemented carbide tools accounted for about 50% of the total output value of the tool, and the output value of cemented carbide tools increased by 9.3% in 2000. After entering 2001, as the demand of the semiconductor industry and the machine tool industry turned weak, the tool industry was affected by it, and production and sales began to decline. Among them, the demand for PCB drill bits for processing printed circuit boards is the most serious, and the reduction of high-speed steel tools is generally similar. At present, each tool manufacturer pays close attention to the demand trend of the automotive industry. The industry is the main user of cutting tools, and its demand changes have a significant impact on the tool industry. At the same time, the pressure to reduce costs is also enormous. The market size of global cutting tools is about 1.1 trillion yen, of which 400 billion yen is in the United States and Europe, and 300 billion yen in the Asian region. It is estimated that the annual growth rate of demand for tools in the world will be 3% from 2003 to 2.6% in 2006. The expansion of users is mainly concentrated in the United States and Asia. Therefore, the Japanese tool industry will vigorously explore the export of Japanese tools for overseas markets in 2000. The proportion has reached 20% for the first time. Large-scale users generally demand to strengthen supply capacity and after-sales service. In order to adapt to this situation, Japanese tool companies have vigorously carried out industrial restructuring activities such as mergers or business cooperation. In 1999, Toshiba Tungaloy and US Kennametal Hertel, Fuji Seiko and Germany Guhring signed a business cooperation agreement. In 2000, Mitsubishi Materials Corporation acquired Kobelco Tools Co., Ltd. and established MCC Kobelco Tools Co., Ltd. as a subsidiary of Mitsubishi. The acquisition and merger activities of these large manufacturers have formed a new supply system for cutting tools worldwide. Accelerate the pace of product development The automotive industry is a major demand for cutting tools, and its usage accounts for about 60% of tool products. The demand trend of the automotive industry is the focus of the tool industry. In addition, in recent years, the booming IT industry has rapidly increased the demand for small-diameter tool products. In the field of cutting and processing, high-precision, high-speed, high-efficiency machining has received unprecedented attention. With the strengthening of people's environmental awareness, dry cutting technology has made great progress, and the development of dry cutting tools has been extremely remarkable. The pace of new product development for tooling and indexable structures is further accelerated. The material of the cutting tool is still dominated by coated cemented carbide in recent years, and the change is not obvious. However, the coating technology itself has made great progress, and the composite coating with excellent heat resistance and wear resistance is large. Appearance, the application of coatings such as TiC, TiN, TiCN, TiAlN has become quite popular. Coated tools have become the hallmark of modern tools, and the proportion in the tool has exceeded 50%. As a tool for high-speed machining, it must be made of high-hardness materials with excellent wear resistance. Among these materials, ceramics are the most ideal. Variety. Ceramic knives have high hardness under high temperature conditions, excellent resistance to plastic deformation, and are less prone to oxidative wear. However, its shortcomings are also obvious, that is, the texture is brittle and easy to damage. Recently, new ceramic varieties have been developed, and their shortcomings have been greatly reduced. For example, coated ceramics and FRC ceramics with SiC reinforcing fibers have been put on the market. Now, new ceramic tools can be used for high-speed cutting of Ni-based superalloys. Processing. Sumitomo Electric has developed a new type of tool material, which is a special ceramic coating on the CBN200/CBN80 (cubic boron nitride sintered body). This special coating improves the wear resistance of the material by 30%. Tool life has been greatly extended. This new tool is mainly used for high-speed machining of high-hardness hardened steel and cast iron commonly used in the automotive industry. The company plans to achieve sales of 1.2 billion yen in two years. Development of ultra-fine grain tool materials In order to achieve high-speed and high-precision machining, various manufacturers are developing new tool materials sintered from fine-grained metal powder. As is known, diamond is the tool material with the highest hardness. However, when the cutting temperature exceeds 800 °C, the diamond tool will diffuse with other carbon solid solution substances such as Fe, Co, and Ni. Therefore, diamond tools are not suitable for steel cutting. When processing high-hardness materials, tool materials such as cemented carbide and cermet should be used. Especially, ultra-fine grained cemented carbide (particle size below 1μm) should be used. This material has high hardness and good toughness and cutting tool. High reliability and excellent performance. Ultra-fine grained carbide tools have excellent performance, and even if they are used in unstable machining such as low-speed or intermittent cutting, the tool will not cause abnormal damage such as chipping or breakage. Since the 1990s, the application of ultra-fine grained carbide tools has been extensive, especially in the high-speed cutting of difficult-to-machine materials. After entering the new century, these materials have been coated and their performance has been further improved. At present, such tools are being used in a large number of high-hardness steel, stainless steel and Fe-based, Ni-based Co-based and other superalloys. CBN cutters are second only to diamonds in hardness, and their properties are superior to those of ceramic tools. Therefore, they are suitable for the machining of high hardness materials such as hardened steel and chilled cast iron, as well as sintered structures, sintered stainless steel, and Co-based superalloys. With the strengthening of environmental awareness, dry cutting technology has received great attention. The tool used for dry cutting must have the following characteristics: in terms of thermal properties, coating materials with good heat resistance and heat dissipation; in terms of lubrication effect, coating materials with excellent lubricating properties; in terms of chip removal performance, Design a tool shape that facilitates chip breaking and chip removal. So far, Japanese tool manufacturers have developed a variety of cutting tools for dry machining, such as AQUA's AQUA drill series, Sumitomo's AC1000 coated inserts, ZX coated end mills, and Hitachi Tools' epoch end mills. Knives and MG coated blades. The prosperous tool re-grinding industry In recent years, due to the rising prices of raw materials, and in order to save resources, the development of technology based on the recycling of hard-metal scrapped blades and recycling resources is very active, and tool manufacturers are actively participating in this. Project. Large-scale carbide tool manufacturers such as Mitsubishi Materials, Sumitomo Electric, Toshiba Tungaloy, Dijet, Hitachi Tools, Japan Tungsten, Fuji Mould, etc., in order to ensure a stable supply of resources and reduce production costs, the used tools are reused. Measures. Among them, Hitachi Tools Co., Ltd. is vigorously carrying out the recycling business of scrapped tools nationwide in Japan. The Narita branch is the main production base for the company's cemented carbide tools. It is now in the process of constructing a new workshop for the recycling of scrapped tools. It will be merged with the original workshops in Osaka to form the recycling of old tools from Hitachi. center. Tool regrind is one of the effective forms of reusing resources, and the regrind industry has become increasingly large. According to statistics, there are 500 to 600 companies engaged in tool re-grinding in Japan, including tool manufacturing plants, mechanical processing plants, and various commercial regrind institutions. Although the exact re-grinding market size is still unclear, in the economic downturn, users are demanding to reduce tool costs. Therefore, the general trend of tool re-grinding market is expanding, roughly estimating its market size. It is roughly between 20 billion and 30 billion yen. Enhancing competitiveness in foreign markets While meeting the domestic demand, Japanese tool manufacturers have launched a marketing strategy to enter the international market. Mitsubishi Materials Corporation cooperates with MA Ford in the United States to produce tools for mold and aircraft parts processing, hoping to improve Mitsubishi's competitiveness in foreign markets. At present, the company's sales ratio of aircraft manufacturing tools is 3%, and the ratio will increase to 10% after 3 years. NMC Kobelco Tools Co., Ltd. is reorganizing with Mitsubishi Materials Co., Ltd. Pushed to the foreign city of Changshen Steel Co., Ltd. to set up a tool department for the production of molds and auto parts (production of carbide end mills, drill bits) and gear processing tools (centered on gear tools), all kinds of tools from planning to Production is quickly determined by the department, which shortens the production cycle and improves sales efficiency. Toshiba Tungaloy introduced the company's internal IT and statistical quality management system, which greatly reduced the product failure rate. This kind of management method was implemented after the implementation of GE and Toshiba in the United States, and the effect of reducing production costs was extremely significant. The medium-term goal of Toshiba's tool manufacturing is to develop and produce small-part machining tools (TAC tools) and integrated tools for IT and semiconductor processing. By 2002, the company's PCB drill bit production capacity will increase by 70%, the main production base is located in the mainland of China and Taiwan Province, the current monthly output of 6 million, is planned to increase to 10 million monthly output by 2002. The company expands the production and competitiveness of micro drills and mold processing tools by expanding foreign production bases. In February 2001, Kyocera acquired Daimler, a large US tool company, and took this opportunity to expand its sales of PCB bit products to the world. The company plans to account for 40% of the US PCB bit market and 10% of the Asian market (including Japan). Fuji Seiko Co., Ltd. has established Dalian Fuji Tools Co., Ltd., a joint venture in Dalian, China. In the new century, the company will strengthen the production capacity of cemented carbide tools in Dalian Branch, and its monthly production value will increase from the current 25 million yen to 42 million yen. In addition to supplying the tools required by local sewing machine manufacturers, orders for Japanese joint ventures such as automobiles and motorcycles in China have also grown rapidly. At the same time, the company has to resell some of its products to Japan to meet the growing demand of Japanese domestic users. Strengthen the production of cemented carbide tools for mold processing. According to ISTA (International Special Tooling Association) statistics on the world mold market in the 1990s, the United States is about 120 billion US dollars, Europe is more than 100 billion US dollars, and Japan is more than 10 billion US dollars. The production cycle of high-speed milling of molds is only one-third of the traditional electric machining method, so the demand for precision tools in the mold industry is quite large. The Japanese tool industry has always attached importance to the development and production of mold processing tools. Hitachi Tools Co., Ltd. has been committed to the development and production of mold processing tools for many years, and plans to further expand the production of such tools and strengthen quality management in the future. In the summer of 2000, the company signed a business cooperation agreement with UNION, and decided to jointly develop PCB drill bits, which can take advantage of Hitachi Tools's advantages in hard alloy materials, and rely on UNION's technical expertise in micro-bit production to achieve mutual benefits. Good results. UNION Tools will strengthen the production of carbide end mills for tooling. The company's leading product is PCB drill bit. Its annual sales in Japan are 9.5 million, and the annual sales volume in foreign countries is 13 million, accounting for 50% of the domestic market and 40% of the world market. At present, the demand for semiconductor-related industries has declined, and the sales volume of PCB drill bits has dropped by 30%. On the contrary, the demand for mold processing tools is growing. UNION intends to expand the production of mold processing tools to compensate for the vacancies in the semiconductor industry. . In order to meet the needs of IT-related industries for micro-machining and precision mold processing, OSG has strengthened the production capacity of Φ0.1~Φ6mm carbide end mills, and the monthly output has increased from 50,000 to 80,000. In order to expand the domestic market in Japan, OSG and Toyota/Gram, the developer of CAD/CAM systems, signed a cooperation agreement to sell products. In expanding foreign markets, OSG has incorporated Taiwan's Dabao Precision Tools Co., Ltd. as a subsidiary to strengthen its production and sales operations in Asia. Strengthening after-sales service to expand market share Dijet is vigorously exploring the US market. The company's sales in the US market have recently decreased by 50% compared with the highest year. Therefore, the company decided to further increase its sales network in the US to strengthen its end users. Contact and launch the online sales business in April 2004. With the strengthening of the sales mechanism, after 2 to 3 years, its sales are expected to reach 1.2 billion yen, equivalent to 2.4 times the current. Foreign-funded tool companies in Japan are also vigorously pursuing strategies to expand sales. For example, ISCAR Japan began selling non-standard tool products from Ingersoll in the United States from March 2001. This shows that ISCAR has started to operate other types of tool products in addition to general-purpose tools. These non-standard products are targeted at heavy machinery manufacturers. ISCAR has established a new business unit in 2001. The sales of the new business unit for the first year is estimated to be 100 million yen. Sandvik Japan established a technical service center in Kobe in March 2001 to strengthen its product sales offensive. The company will provide its advanced tool products to the IT, mold, aircraft and other industries, while vigorously enriching the after-sales service content to expand market share. KennametalHertel Japan will continue to expand its sales network, and plans to hold a monthly user technology seminar, focusing on the development of new outlets around the business outlets. In the face of the severe challenges of the market environment, Japanese tool companies are firmly grasping users. A key link, actively carry out distinctive marketing strategies.