Dongguan Best Instrument Technology Co., Ltd , https://www.best-tester.com
With the joint promotion of numerical control technology and tool technology, the cutting process has entered the stage of high-speed cutting. In the past 20 years, the cutting speed has increased by 5~10 times, and the cutting efficiency has been improved by at least 50%. After the cutting speed is increased to a certain value, the cutting force decreases as the cutting speed increases, and the temperature rise of the workpiece decreases at a higher cutting speed. Nowadays, new carbide coated tools and various superhard tools have been widely used in the automotive, aerospace, aerospace and mold industries. High-speed machining of various materials, including dry cutting, heavy cutting and hard cutting, effectively improves machining efficiency and product quality.
Tooling costs only 3-4% of manufacturing costs in modern processing, but it has a much greater impact on total manufacturing costs. Processing efficiency increased by 20%, processing costs can be reduced by 15%, while tool prices are reduced by 20%, processing costs can only be reduced by 0.6%, and tooling life is doubled. Processing costs are only reduced by 1.5%. In the era of planned economy, some processing enterprises have established tool consumption quotas for cost control, and even low-performance welding tools are used on high-efficiency imported equipment. It is difficult to exert equipment performance and cause more waste. More and more people now realize that increasing the input of tools for high-speed machining is an effective means to improve processing efficiency and reduce production costs. This is an improvement in the cutting philosophy in recent years.
A few years ago, some people in foreign countries predicted that "superhard tools, high-toughness ceramic materials and super-hard coatings are the future of cutting." The speed of milling aluminum alloy with PCD tools in modern automobile manufacturing and aerospace industry is 4000~7000m/min; the speed of CBN tool fine iron cylinder bore reaches 2000m/min, and it is also successfully used for roughing of hardened rolls; The ultra-hard coated grade has a hardness of Hv4000 and can withstand temperatures of 800 to 1100 °C. With the rapid development of superhard tool materials and coating technology, high-speed cutting will be more widely used.
Advanced knives have three technical foundations: material, coating and structural innovation. At present, China's tool materials and coating technology are still far from the foreign countries. In the case of using conventional processing equipment, focusing on the structural innovation of the tool is also an effective and more feasible means to improve cutting efficiency.
High-speed cutting is only one of the means to improve cutting efficiency. We should use high-speed cutting and tool structure innovation to achieve high-efficiency cutting. From high-speed cutting to high-efficiency cutting, it is another improvement in cutting concept.
We noticed that the cutting speed has increased by 5 to 10 times in the past 20 years, but the processing efficiency has only increased by 50% to double. One of the reasons is that the effect of improved cutting efficiency is offset by a large amount of non-cutting time. Japan's MAZAK says their processing centers are only 30% of the time creating benefits for the company. The cutting time automatically recorded on the imported Swiss machining center of Dongfang Steam Turbine Works is only about 30%. Cutting technology is constantly evolving, and people's understanding is also deepening: in the effort to improve processing efficiency, not only high-speed cutting and high-efficiency cutting, but also the potential for improving cutting production efficiency through cutting application technology.
In recent years, Dongfang Steam Turbine Works has promoted indexable tools to increase 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. In 2006, they optimized the process configuration of the whole plant, strengthened management, and used network programming and computer simulation of the cutting process to reduce non-cutting time, “to 70% of the time to benefitâ€. There are many ways to reduce the ratio of non-cutting time, such as off-machine adjustment, automatic loader, random measurement, setting loading and unloading station, and purchasing high reliability equipment to reduce maintenance downtime, optimize process configuration and balance process in management. It is an effective method to shorten the workpiece turnover and waiting time.
While using advanced tools to achieve efficient cutting, it is also necessary to apply relevant techniques and management tools to optimize the entire process to achieve efficient machining.
From high-speed cutting to efficient cutting to efficient machining, we call this process three advancements in cutting concepts. Putting forward these three cutting concepts to point out a variety of ways to achieve the goal of "developing cutting technology, building and manufacturing a strong country", each enterprise should adopt appropriate methods according to their own conditions to effectively improve the efficiency of processing.
Expansion of modern cutting technology concept
In the past, we have referred to cutting technology mainly as tool technology and cutting application technology. With the continuous updating of cutting concepts, modern cutting technology also involves the field of tool management, related technology and advanced management. It also guides us to apply modern cutting technology to improve production efficiency as well as advanced cutting concepts.