The pillar industry of the national economy of manufacturing. The country has become a world processing plant, but the per capita labor productivity of China's manufacturing industry is still far from that of developed countries such as the United States, Europe and Japan. It is only one-twentieth of the countries in Europe, the United States and Japan. about. According to the data provided by the National Machine Tool Industry Yearbook, the total labor productivity of China's tool industry in 2004 was RMB 39,366 and the per capita profit was RMB 6,750. It is far lower than the annual per capita labor productivity of millions of yuan in foreign tool companies. Tool cutting technology is one of the important reasons for the low labor rate in the mechanical manufacturing industry. In order to transform China from a manufacturing power to a manufacturing power, the National Knife Association has put forward the grand goal of "developing cutting technology and building a strong country" from the historical responsibility of the country's cutting workers.
At present, the development of cutting tools and related technologies is changing with each passing day. In recent years, the cutting technology of CNC technology has promoted the cutting process into a high-speed cutting stage. In recent years, the tool material coating technology has been greatly developed. For example, the use range of PCD and CBN super-hard tool ceramic tools has been continuously expanded, and the cutting performance of the current high-speed cutting main-coated cemented carbide tools has been greatly improved. In the past two decades, the cutting speed has increased by 5 to 10 times, and the production efficiency has increased by 50% to double. High-speed cutting has a characteristic that when the cutting speed rises to a certain extent, the cutting force decreases as the cutting speed increases due to 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 decreases. However, the phenomenon that is limited by the performance of the tool material is currently only observed with PCD tools for processing aluminum alloy soft materials. High-speed cutting is also suitable for hard cutting, dry cutting and heavy cutting, and an effective means to improve cutting efficiency.
Modern processing tool costs typically only account for 3-4% 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 from the control of processing costs for cost control. We also mentioned that some enterprises use low-performance welding tools on high-efficiency imported equipment, which can not cause the performance of equipment to cause more waste. Some people have calculated that the production efficiency has increased by 20% and the manufacturing cost has been reduced by 15%. Now most companies have calculated this account. Increasing the use of high-speed cutting to increase the production efficiency of the tool to reduce the total production cost, the cutting concept has improved.
Advanced knives have three major technical foundations: innovation in materials and coating structures. High-speed cutting tools rely mainly on tool material coating technology advancements. High-speed cutting increases cutting efficiency but is not the only means. Tool structure innovation also improves effective cutting efficiency. For example, Iscar's large-size milling cutter has a tooth movement of 3.5mm per tooth. Seco's composite hole machining tool can complete drilling and boring end chamfering with one pass. The progress of the crankshaft machining process is more convincing, and the crankshaft broach is invented to increase the crankshaft machining efficiency tenfold. Now there is a higher-efficiency crankshaft high-speed milling cutter that can complete seven spindle neck machining in one pass. Dongfeng Motor Corporation's cutting tool factory has successfully developed high-speed milling cutters for crankshaft broaches for domestic automakers and successfully used them for production. In the 1980s and 1990s, Chengdu Tool Research Institute's coating and material single technology were not dominant. With the independent intellectual property rights tool design technology, combined with the innovative application of coating and material tool structure innovation, high-strength oil pipe thread The tool has achieved a successful transcendence to 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, when there is a big gap between our tool material coating technology and foreign countries, it is more effective and feasible to focus on tool structure innovation. The cutting concept has been improved again by using various means including high-speed cutting tool structure innovation to achieve high-speed cutting.
The use of advanced tools to improve cutting efficiency often highlights two new types of problems: a cutting efficiency improvement effect is greatly diluted by a large number of non-cutting times, and advanced tool costs are overwhelmed when the second processing equipment is less advanced. Japan's MARZAK said that they only have 30% of the processing heart to create benefits for the company. The automatic cutting time of the imported processing core of Dongfang Steam Turbine Works is only about 30%. Cutting technology continues to develop, and people's understanding continues to deepen: Improving processing efficiency is far from enough to rely on high-performance tools, and the potential for improving cutting production efficiency through cutting application technology is still great.
The cutting process is very complicated, and the cutting process is difficult to be accurately described by some formula theorems due to a large number of random factors. However, metal cutting as a traditional technology has its own laws and can be grasped. The key is to use real cutting technology to solve practical problems. In cooperation with the National Knife Association 20 project, we asked the senior expert of the tool industry, Zhao Bingyan Research Institute, to write the "Tools Application Technology Foundation" textbook. Our goal is to learn about the latest developments in the basic knowledge of modern cutting technology, understand the basic concepts of cutting application technology and be able to use the above technical ideas to solve practical problems. We call it the new generation of cutting tools for cutting engineers.
As mentioned earlier, it is not enough to further improve the cutting efficiency by advanced tools. We should also master the use of cutting-related technology to improve overall productivity.
At the 2005 National Knife Association Work Conference held in Xiamen in May 2009, Dongfang Steam Turbine Factory introduced the comprehensive application of cutting application technology to comprehensively improve the cutting machining efficiency experience. This year, the factory strives to promote advanced cutting tools, and only promotes indexable tools to increase production efficiency by 30%. In turn, they worked hard on the innovation of tool structure. They jointly developed advanced tools in Zhuzhou Diamond Cutting Tools Co., Ltd., and also modified old equipment to use advanced tools to improve production efficiency. Recently, they have further optimized the process configuration of the whole plant, strengthened management, and computer simulation of network programming cutting process to further improve production efficiency. With Wang Zheng’s master craftsman, “to benefit 70% of the timeâ€. There are still many ways to reduce non-cutting time, such as off-machine adjustment, quick tool change, random measurement, multi-station processing, setting up loading and unloading stations, and purchasing high reliability equipment to reduce maintenance downtime.
It is necessary to use advanced tools and optimize the entire process by managing application-related technologies to achieve a third advancement in efficient machining.
The use of advanced tools should also pay attention to a reasonable "match" with the processing equipment. We have mentioned that the welding tools used on the equipment do not match, and the best (and often the most expensive) tools on the ordinary equipment are equally unreasonable. Many processing companies have already issued the price of imported tools. How to do? We recommend: innovating the tool structure, improving the tool use conditions, and rationally selecting the tool material coating. Don't just stare at the "best" (most expensive) tool, and improve the productivity department. Only high-performance tools can cut high speed. After years of construction and technological transformation, a number of state-owned and deputy private tool enterprises have developed a series of high-performance hard alloy material coating tools, which can be used by processing enterprises according to the specific conditions. In addition, the reform of the tool structure innovation process, as well as the management of related technologies, also improve the effective means of production efficiency. To be more specific, don't just stare at the best tool. At present, we must pay more attention to the efficiency of cutting application technology to 70% of the time.
In the domestic car production, mold manufacturing, aerospace and other fields, a large number of imported tools are also used. China's material and coating basic technology tool structure innovation has a big gap with foreign countries, and it still has a long way to go to catch up with the world's advanced level. But if we only see this and ignore the important field of cutting application technology, the invisible exaggerates the gap between our cutting technology and foreign countries. We need basic technology application technology. At present, we should start from cutting application technology, work on tool structure innovation, learn to use advanced tool technology to introduce self-developed coating technology, and comprehensively use technical management methods to improve processing efficiency and speed up the world. Level.
Improved performance of cutting tools offers the possibility of efficient high-speed machining development
Another important factor in cutting tools is the need for efficient high-speed machining. The development of cutting tool materials has created relatively good conditions for processing. In addition to high-speed steel and hard alloy, the development of ceramics, cermets and super-hard materials has played an important role. Special ceramics and super-hard materials provide strong support for the development of high-efficiency and high-speed machining. It is worth mentioning that in 1955, GE Corporation of the United States succeeded in synthesizing superhard materials with high temperature and high pressure, which led to major changes in the field of cutting. On this basis, PCD and PCBN appeared very quickly, creating conditions for machining, dry cutting, hard cutting, and ultra-precision cutting.
Another aspect of cutting processing, on the surface technology cutting tools, PVD (Physical Vapor Deposition), CVD (Chemical Vapor Deposition) continue to evolve, from a single layer to a multi-layer, a thousand layers, composite coating, and now developed into nano Coating; coating material, from TiN to Al2O3, TiC, ZrO2, etc., according to processing requirements, in order to improve high temperature resistance, developed TiCN, TiAlN, TiSiN, CrSiN and so on. In order to reduce friction, soft coatings such as MoS2 are deposited, and Molyglide is used by Guehring in Germany. This coating is based on MoS2, which reduces the friction coefficient of cutting. Of course, this depends on the characteristics of the workpiece to be applied separately. Now the coating technology has developed into a super-hard coating (diamond-like, diamond, cubic boron nitride), which further broadens the range of machining. It is particularly worth mentioning that the film coating has developed into a thick film, which is different from natural diamond and is isotropic. It has been applied at home and abroad, partially replacing natural diamond. Nowadays, the synthesis technology of large-particle single crystal diamond has been solved. These changes have a profound impact on China. China has the world's largest synthetic diamond production, which is conducive to the development of efficient processing technology in China.
In order to adapt to high-speed and high-speed machining, auxiliary tools are also very important means, such as the original combined fixture machining heart application, in order to improve its strength, has developed from the groove system to the hole system. At present, the application of the typical EROWA3R combination tool has been developed from electrical processing to mechanical processing, which not only accelerates the rhythm, but also achieves high precision. These tools have evolved from the original mold electrical processing to the cutting processing field. The shank required for the shank cutting tool has also developed a new structure with high efficiency and high precision cutting process, such as hydraulic and plastic. Nowadays, the hot shank is widely used, and the clamping precision is obviously improved, reaching 2~3μm. . The device is now mature. For example, ZOLLER in Germany has installed such a device directly on the tool setting instrument, indicating that the technology has taken a step forward. Tool advancement provides strong support for efficient machining.
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