Truong Hai Automobile Joint Stock Company (THACO) and how they improve localization rate of the automotive industry

After more than two decades of development, THACO has become a multi-industry group, of which Mechanics and Automotive are the 2 main businesses.
Developing mold production technology in Vietnam automobile industry
The mold manufacturing industry in Vietnam is mainly used in consumer industries, not yet applied to manufacture components to increase the localization rate of the automotive industry because of difficulties in production. quantity and limitations of technological capacity. In order to contribute to solving this problem, Truong Hai Automobile Joint Stock Company (Thaco) has proposed and was approved by the Ministry of Science and Technology (S&T) to implement the state-level science and technology project "Design research, manufacturing molds for truck parts ”, code DTĐ.C.CN-52/16. Over 3 years of implementation, Thaco has mastered the design and technology of manufacturing 3 types of typical molds used in the automotive industry (combined dies, injection molds) to produce a number of components. , helping to increase the localization rate, improve technology content and lower mold production costs, as well as products made from molds, contributing to improving the competitiveness of Vietnamese automobile enterprises when AFTA integration.
Researching, designing and successfully manufacturing molds for some truck parts
The development strategy of Vietnam's automobile industry to 2025, the vision to 2035 of the Government and the master plan on development of supporting industries to 2020, and the vision to 2030 of the Ministry of Industry and Trade to "prioritize the development of the field of components and spare parts to serve the needs of localization, especially the mechanical and automobile industry." However, the development of Vietnam's auto industry in general and additive industries in particular still face many difficulties and challenges, partly due to the lack of initiative in mold making technology. Currently, domestic enterprises only meet the production requirements of molds for manufacturing consumer mechanical products and in part on orders from foreign joint venture companies. For products with high technical requirements (washing machines, refrigerators, air conditioners, cars, motorbikes, etc.), it is still necessary to import semi-finished products/molds from foreign countries for production. In addition, local mold manufacturing enterprises are now operating in a closed state, without coordination and cooperation to design and produce in-depth one or several products of the same type. type, so although there have been units investing a number of relatively modern technology lines, but there are also overlaps that make resources scattered. Also due to small production, even alloy steel imported to make molds has a very high price. This explains why the cost of manufacturing molds of Vietnamese enterprises is always high, resulting in production efficiency, as well as limited competitiveness.

In the world, the technology of making molds is almost complete for all kinds of combined dies, deep drawing and molds for plastic injection molding technology. In the automotive industry, businesses have widely applied these molds to manufacture body parts, trunks and interior and exterior details. Especially, in the modern mold making industry, CAD / CAM / CNC technology and many modern software tools have been applied, helping to quickly change from traditional production methods to public production. turmeric. Thus, in order to quickly raise the localization rate, help improve the competitiveness of Vietnam's automobile industry in ASEAN in particular, the world in general, the research and mastery of advanced technologies. , thereby actively designing and manufacturing molds for automobile parts in the country is essential.

The problem is that most Vietnamese automobile manufacturers and assemblers have relatively low output, especially trucks, while in the mold industry, the production of products must big enough. As one of the leading enterprises of Vietnam's automobile industry, with the goal after 2019, THACO will exceed 120,000 vehicles/year, of which over 50% are trucks, so the problem developing the mold manufacturing industry to increase the localization rate of Thaco's trucks is feasible. The urgent task is to research, design and manufacture a number of molds used in the automotive industry, as a premise to develop the mold manufacturing industry for this industry in Vietnam, contributing to meet the needs. Current and future bridges. To solve this problem, Thaco proposed and was approved by the Ministry of Science and Technology to implement the state-level science and technology project "Researching, designing and manufacturing molds for some truck parts", code number DTĐ.C.CN. -52/16. After 3 years of implementation, Thaco has completed its objectives, mastered many advanced technologies, effectively meeting the mold manufacturing needs of enterprises in particular and Vietnam's automobile industry in general.

In the process of deploying the project, Thaco chose to design 3 types of molds for typical automotive components: the combined mold used to make truck exhaust shackles, deep drawing molds to manufacture parts. driver seat frame and injection molding used to make steering wheel parts for truck's cabin. These are 3 types of details with complex structures and using different materials, designed on the NX Unigraphics Siemens software, processing technology using 3/5 axis CNC milling machines. Especially, the design and manufacture of molds of these 3 parts will allow the deployment of other details and components of Thaco's trucks and buses.
Figure 1. Details of truck suspension hanger manufactured using combined mold technology.
Combined mold technology: the process of machining steps is performed on a single feed embryo and integrates many sheet stamping operations on a press journey. Designing and manufacturing combined dies is a complex process, requiring designers to master all the technologies in plate stamping, and also master the current advanced manufacturing technology. . Combined mold is a mold consisting of several pairs of pestles and mortars arranged on the same mold base, performing various tasks (stamping, bending, embossing, stamping ...) after a journey of the machine. squeeze. Each working position (a pair of pestle, mortar) performs one or more separate steps, thanks to the automatic workpiece feeding mechanism, the workpiece is shifted and sequentially moved through the positions to complete the workpiece. create.
Deep drawing technology: in the deep drawing process, the towel ring part of the workpiece becomes cylindrical and has a height. Because the metal volume does not change, when stamping into cylinders, the height of details is greater than the width of the rim. Deep drawing occurs due to plastic deformation accompanied by the movement of most metal into height. The advantage of the deep drawing die is that it is possible to process thin-wall components from simple to complex that other methods such as rolling, drawing, forging, casting ... cannot do it, the machining parts are of high precision. , glossy surface. Especially, the process of stamping is almost not producing embryos such as forging and casting if accurate calculation of the original workpiece, the details of the stamping work can be used immediately or just through a few small stages.
Injection molding technology: molten plastic or glass fiber is added to fill the mold. When the mixture is cooled and hardens inside the mold, the mold is opened and the product is ejected from the mold. The cycle time depends on the weight of the product, the temperature of the mold cooling water and the efficiency of the mold cooling system. The quality and productivity of the product depends on the quality of the injection molding machine, especially the quality of the molds.
Figure 2. Automotive plastic component injection molding machine.

Figure 3. Combined die and injection mold during machining.
Developing Vietnam's automobile industry: The goal is not far away
On the basis of designing the design and technology of making molds for many parts, truck components, typically the light truck KIA Frontier, Thaco has applied the results of the project to mass produce molds for all types. Details of all other truck lines. The process of implementing the project not only helps Thaco train 2 masters, 5 professional engineers to calculate and design molds, but also brings practical effects on S&T, helping businesses improve. capacity, mastering the technology of designing and manufacturing molds used in the automobile industry, thereby contributing to raising the localization rate of trucks, further enhancing the level of science and technology as a model in the industry. automobile industry in Vietnam. According to detailed calculations, the topic has contributed to raising the localization rate of the car, the content value value of RVC of 3 products, contributing to the increase of the localization rate of the whole car to 0.990%; increase production technology content for all 3 types of combined dies, claws and injection molds to 56, 41 and 53%, respectively.
In 2018, Vietnam entered the integration of AFTA (ASEAN Free Trade Area) while Vietnam's automobile industry, especially supporting industries, was still weak. An important requirement to ensure competitiveness with enterprises in the bloc is that automotive products must reach a localization rate of 40% or more. But in fact, most of the automobile businesses in Vietnam have just stopped at assembling, because the supporting industry is still very fragmented, leading to the localization rate of automobiles in Vietnam at less than 20%. Consequently, many Vietnamese enterprises have to switch to importing cars to sell, turning Vietnam into a consumption market of other countries, so the ability to invest in developing supporting industries is even more difficult. Therefore, the fact that Thaco boldly proposed and successfully implemented the S&T tasks mentioned above is a remarkable effort.
The results of the project contribute to reducing product costs by 25 to 29% compared to imported molds of similar quality, helping to reduce production costs of components from these 3 molds from 12 to 18%. , not only help create new jobs, gradually regain domestic market share, but furthermore will contribute to the formation of supporting industry clusters (Cluster) for the automotive industry in particular, the mechanical industry. The country's gas industry in general, effectively serves the goal of improving the competitiveness of Vietnamese cars in the intra-ASEAN market.

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