Why the cutting efficiency of the tool is not high, how to become a manufacturing power
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First, increase the investment of tools:
The current development of cutting tools and related technologies is changing with each passing day. In recent years, with the joint promotion of numerical control technology and tool technology, cutting machining has entered the stage of high-speed cutting. In recent years, tool materials and coating technology have been greatly developed. For example, the use range of PCD, CBN superhard tools and ceramic tools has been expanding, and the cutting performance of coated carbide tools, which are the main force of high-speed cutting, has been greatly improved. . In the past 20 years, the cutting speed has increased by 5 to 10 times, and the production efficiency has increased by 50% to 100%. One of the characteristics of high-speed cutting is that when the cutting speed rises to a certain extent, the cutting force decreases with the increase of the cutting speed due to the softening of the material, etc., and at the same time, the chip takes away most of the heat and even the temperature rise of the workpiece is reduced. . However, due to the limitations of tool material properties, the latter phenomenon is currently only observed in the processing of aluminum alloys and soft materials with PCD tools. High-speed cutting is also suitable for hard cutting, dry cutting and heavy cutting, and is an effective means to improve cutting efficiency.
Tooling costs in modern processing typically only account for 3% to 4% of manufacturing costs, but it has a much greater impact on total manufacturing costs. In the era of planned economy, mechanical processing enterprises set the cost of tool consumption and control the cost from the control of processing costs. We also mentioned that some enterprises use high-performance imported equipment with low-performance welding tools, which can not cause the performance of equipment to cause more waste. fact. It has been calculated that a 20% increase in production efficiency will reduce manufacturing costs by 15%. Nowadays, most companies have calculated this account. Increasing tool input and increasing production efficiency with high-speed cutting to reduce total production costs is an improvement in cutting philosophy.
Second, the innovative tool structure:
Advanced knives have three technical foundations: material, coating and structural innovation. High-speed cutting tools rely primarily on advances in tool materials and coating technology. High-speed cutting increases cutting efficiency but is not the only means. The structural innovation of the tool is also an effective means to improve the cutting efficiency. For example, Iscar's large-cut milling cutters have a tooth movement of 3.5 mm per tooth. Seco's composite hole machining tools can complete drilling, boring and end chamfering in one pass. The technological progress of crankshaft machining is more convincing, and the invention of the crankshaft broach increases the crankshaft machining efficiency by 10 times. Now there is a more efficient crankshaft high-speed milling cutter that can process seven spindle necks in one pass. Dongfeng Motor Corporation's cutting tool factory has successfully developed crankshaft broaches and high-speed milling cutters for domestic automobile factories and successfully used them for production. In the 1980s and 1990s, the Chengdu Tool Research Institute, based on the fact that coatings, materials and other single technologies were not dominant, the tool design and process technology with independent intellectual property rights, combined with the innovation of coatings, materials and tool structure innovations. The use of high-strength oil pipe thread cutters has achieved a successful transcendence of well-known foreign companies. There are many examples of how tool structure innovations are often more effective at improving cutting efficiency. To improve cutting efficiency, you can't just focus on using the best (and often the most expensive) tools for high-speed cutting. At present, our tool materials and coating technology are still far from the foreign countries. Paying attention to the structural innovation of tools is often a more effective and feasible means to improve cutting efficiency. The use of various means including high-speed cutting and tool structure innovation to achieve efficient cutting is another advancement in cutting concepts.
Third, optimize the processing process:
Two new problems are often highlighted: first, the effect of improving cutting efficiency is diluted by a large amount of non-cutting time, and second, the cost of advanced tools is overwhelmed when the processing equipment is not advanced. Japan's MARZAK says its processing centers are only 30% of the time creating benefits for the company. The Swiss machining center imported by Dongfang Steam Turbine Works has an automatic record cutting time of only about 30%. Cutting technology is constantly evolving, and people's understanding is deepening: it is far from enough to rely on high-performance tools in improving the efficiency of machining. The potential for improving cutting production efficiency through cutting application technology is still great.
It has been said before that it is not enough to further improve the efficiency of cutting machining by relying on advanced tools. We should also master and apply the technology related to the cutting process to improve overall production efficiency. Innovate tool structure, improve tool use conditions, and rationally select tool materials and coatings. In addition, the reform of process methods, as well as management methods and related technologies, are also effective means to improve production efficiency. To be more specific, don't just focus on the best tool. At present, you should pay more attention to cutting application technology and make it 70% of the time.
At the China Knife Association Work Conference held in Xiamen, Dongfang Steam Turbine Factory introduced the experience of comprehensively improving the efficiency of cutting machining by using cutting application technology. In recent years, the company has been striving to promote advanced cutting tools, and only promoting indexable tools has increased production efficiency by 30%. In turn, they worked hard on tool structure innovation, developed advanced tools in cooperation with Zhuzhou Diamond Cutting Tools Co., Ltd., and also modified old equipment to use advanced tools to improve production efficiency. Recently, they have optimized the entire plant process configuration, strengthened management, computer programming and computer simulation of the cutting process to further improve production efficiency. According to Wang Zheng, the chief craftsman of the plant, it is “to benefit 70% of the timeâ€. . There are many ways to reduce non-cutting time, such as off-machine adjustment, rapid tool change, random measurement, multi-station processing, setting up loading and unloading stations, and purchasing highly reliable equipment to reduce maintenance downtime. The use of advanced tools, as well as the optimization of the entire process through management and application of related technologies, to achieve efficient machining is the third advancement of recent cutting concepts.