Manufacturing is the pillar industry of the national economy. Now China 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 and regions such as the United States, Europe and Japan. It is only for developed regions and countries such as Europe, America and Japan. About one-twentieth. According to the data provided by the China 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 of foreign tool companies. The backwardness of cutting tools and cutting technology is one of the important reasons for the low labor rate in the machinery manufacturing industry. In order to transform China from a manufacturing power to a manufacturing power, the Chinese Knife Association put forward the grand goal of "developing cutting technology and building a strong country" from the historical responsibility of Chinese cutting workers.
The development of cutting tools and related technologies is changing with each passing day. In recent years, cutting machining has entered the stage of high-speed cutting under the joint promotion of numerical control technology and tool technology. In recent years, tool materials and coating technology have been greatly developed. For example, PCD, CBN superhard tools and ceramic tools have been expanding in scope, and the cutting performance of coated carbide tools, which are the main force of high-speed cutting, 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. 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 the temperature rise of the workpiece is reduced because the chip takes away most of the heat. However, the phenomenon that is limited by the performance of the tool material is currently only observed in the processing of aluminum alloy 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 3-4% of manufacturing costs, but it has a much greater impact on total manufacturing costs. In the era of planned economy, mechanical processing enterprises have set the cost of tool consumption from the control of processing costs for cost control. We have also mentioned the fact 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 production efficiency has increased by 20% and manufacturing costs have been reduced by 15%. Nowadays, most companies have calculated this account. Increasing tool input with high-speed cutting to improve production efficiency and reduce total production costs is an improvement in cutting philosophy.
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 broaching tool has increased the machining efficiency of the crankshaft tenfold. 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 the single technology of coatings and materials was not dominant, the tool design and process technology with independent intellectual property rights, combined with the innovation of coating, material and tool structure innovation technology. 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 high-speed cutting is another advancement in cutting concepts.
The use of advanced tools to improve cutting efficiency often highlights two new types of problems: First, the effect of improved cutting efficiency is greatly diluted by a large number of non-cutting times, and second, the cost of advanced tools is overwhelmed when processing equipment is less advanced. . Japan's MARZAK said that only 30% of their processing centers are 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 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.
The cutting process is very complicated, and the cutting process is difficult to accurately describe with some formulas and theorems simply by the influence of 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 conjunction with the 20th project of the China Knife Association, 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 train companies to understand the basics and latest developments in modern cutting technology, to understand the basic concepts of cutting application technology and to use the above techniques and ideas to solve practical problems. We call it cutting engineers and A new generation of knives.
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.
At the 2005 China Knife Association Work Conference held in Xiamen in May this year, Dongfang Steam Turbine Factory introduced the experience of comprehensive application of cutting application technology to improve the efficiency of cutting machining. 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, and cooperated with Zhuzhou Diamond Cutting Tool Co., Ltd. to develop advanced tools, 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, computer programming and computer simulation of the cutting process to further improve production efficiency. In the words of Wang Zheng’s master craftsman, it is “to benefit from another 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 the recent cutting concept.
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 are not matched, and it is also unreasonable to pursue the best (and often the most expensive) tools on ordinary equipment. Many processing companies have issued the call for the price of imported tools. . How to do? Our recommendations are: innovation in tool structure, improved tooling conditions, rational selection of tool materials and coatings, not just focusing on the "best" (most expensive) tools, improving productivity, only high performance tools and high speed cutting One way. After years of construction and technological transformation, a number of state-owned and deputy-shared private tool companies have developed a series of excellent hard alloy materials and coated tools, which can be reasonably selected by processing enterprises according to specific conditions. Furthermore, the reform of tool structure and the reform of process methods, as well as management tools and related technologies, are also effective means to improve production efficiency. To put it more clearly, 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.
At present, imported knives are widely used in domestic car production, mold manufacturing, aerospace and other fields. In China, there is still a big gap between the basic technology of materials and coatings and the innovation of tool structure, and there is still a long way to go to catch up with the world's advanced level. However, if we only see this and ignore the important field of cutting application technology, it will inevitably exaggerate the gap between our cutting technology and foreign countries. We must combine basic technology and applied technology. At present, we should start with cutting application technology, work hard on tool structure innovation, learn to use imported and self-developed coating technology and advanced tool material technology, and comprehensively apply technology and management methods to improve processing. Efficiency, speed up to catch up with the world's advanced level.
Increased performance of cutting tools offers the possibility of efficient high-speed machining development
Cutting tools are another important factor if high-speed machining is required. The development of current cutting tool materials has created relatively good conditions for the processing needs. In addition to high-speed steel and hard alloys, the development of ceramics, cermets and super-hard materials has played an important role. In particular, 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 soon appeared, creating conditions for cutting, dry cutting, hard cutting, and ultra-precision cutting of difficult-to-machine materials.
Another aspect of cutting is the application of surface technology to cutting tools. PVD (Physical Vapor Deposition) and CVD (Chemical Vapor Deposition) are constantly evolving. From single layer to multi-layer, multilayer, composite coating, now It has also developed into a nano-coating; the coating material has evolved from TiN to Al2O3, TiC, ZrO2, etc. According to the processing requirements, in order to improve the high temperature resistance, TiCN, TiAlN, TiSiN, CrSiN and the like have been developed. In order to reduce the friction, a soft coating such as MoS2 is deposited, and Molyglide, which is used by Guehring, Germany, is mainly composed of MoS2, which can reduce the friction coefficient during cutting. Of course, this should be applied to the required processing according to the characteristics of the workpiece. Nowadays, 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 develops 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 is already the world's largest producer of synthetic diamond, which is conducive to the development of efficient processing technology in China.
In order to adapt to high-efficiency high-speed machining, auxiliary tools are also very important means. For example, in the application of the original combined fixture in the machining center, in order to improve its strength, it has developed from a groove system to a hole system. At present, the application of EROWA and 3R combination tools has been developed from electrical processing to machining centers, which not only speeds up the rhythm, but more importantly achieves high precision. These tools have evolved from the original die electrical machining to cutting. Processing field. The shank required for the cutting tool with shank also develops new structures in the process of high-efficiency, high-precision machining, such as hydraulic and plastic, and nowadays it is widely used with hot-mounted shank. The clamping accuracy is significantly improved to 2 to 3 μm. Now that the device has matured, for example, ZOLLER in Germany has installed such a device directly on the tool setting instrument, indicating that this technology has taken a step forward. Advances in tools have provided strong support for efficient processing.
The development of cutting tools and related technologies is changing with each passing day. In recent years, cutting machining has entered the stage of high-speed cutting under the joint promotion of numerical control technology and tool technology. In recent years, tool materials and coating technology have been greatly developed. For example, PCD, CBN superhard tools and ceramic tools have been expanding in scope, and the cutting performance of coated carbide tools, which are the main force of high-speed cutting, 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. 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 the temperature rise of the workpiece is reduced because the chip takes away most of the heat. However, the phenomenon that is limited by the performance of the tool material is currently only observed in the processing of aluminum alloy 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 3-4% of manufacturing costs, but it has a much greater impact on total manufacturing costs. In the era of planned economy, mechanical processing enterprises have set the cost of tool consumption from the control of processing costs for cost control. We have also mentioned the fact 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 production efficiency has increased by 20% and manufacturing costs have been reduced by 15%. Nowadays, most companies have calculated this account. Increasing tool input with high-speed cutting to improve production efficiency and reduce total production costs is an improvement in cutting philosophy.
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 broaching tool has increased the machining efficiency of the crankshaft tenfold. 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 the single technology of coatings and materials was not dominant, the tool design and process technology with independent intellectual property rights, combined with the innovation of coating, material and tool structure innovation technology. 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 high-speed cutting is another advancement in cutting concepts.
The use of advanced tools to improve cutting efficiency often highlights two new types of problems: First, the effect of improved cutting efficiency is greatly diluted by a large number of non-cutting times, and second, the cost of advanced tools is overwhelmed when processing equipment is less advanced. . Japan's MARZAK said that only 30% of their processing centers are 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 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.
The cutting process is very complicated, and the cutting process is difficult to accurately describe with some formulas and theorems simply by the influence of 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 conjunction with the 20th project of the China Knife Association, 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 train companies to understand the basics and latest developments in modern cutting technology, to understand the basic concepts of cutting application technology and to use the above techniques and ideas to solve practical problems. We call it cutting engineers and A new generation of knives.
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.
At the 2005 China Knife Association Work Conference held in Xiamen in May this year, Dongfang Steam Turbine Factory introduced the experience of comprehensive application of cutting application technology to improve the efficiency of cutting machining. 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, and cooperated with Zhuzhou Diamond Cutting Tool Co., Ltd. to develop advanced tools, 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, computer programming and computer simulation of the cutting process to further improve production efficiency. In the words of Wang Zheng’s master craftsman, it is “to benefit from another 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 the recent cutting concept.
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 are not matched, and it is also unreasonable to pursue the best (and often the most expensive) tools on ordinary equipment. Many processing companies have issued the call for the price of imported tools. . How to do? Our recommendations are: innovation in tool structure, improved tooling conditions, rational selection of tool materials and coatings, not just focusing on the "best" (most expensive) tools, improving productivity, only high performance tools and high speed cutting One way. After years of construction and technological transformation, a number of state-owned and deputy-shared private tool companies have developed a series of excellent hard alloy materials and coated tools, which can be reasonably selected by processing enterprises according to specific conditions. Furthermore, the reform of tool structure and the reform of process methods, as well as management tools and related technologies, are also effective means to improve production efficiency. To put it more clearly, 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.
At present, imported knives are widely used in domestic car production, mold manufacturing, aerospace and other fields. In China, there is still a big gap between the basic technology of materials and coatings and the innovation of tool structure, and there is still a long way to go to catch up with the world's advanced level. However, if we only see this and ignore the important field of cutting application technology, it will inevitably exaggerate the gap between our cutting technology and foreign countries. We must combine basic technology and applied technology. At present, we should start with cutting application technology, work hard on tool structure innovation, learn to use imported and self-developed coating technology and advanced tool material technology, and comprehensively apply technology and management methods to improve processing. Efficiency, speed up to catch up with the world's advanced level.
Increased performance of cutting tools offers the possibility of efficient high-speed machining development
Cutting tools are another important factor if high-speed machining is required. The development of current cutting tool materials has created relatively good conditions for the processing needs. In addition to high-speed steel and hard alloys, the development of ceramics, cermets and super-hard materials has played an important role. In particular, 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 soon appeared, creating conditions for cutting, dry cutting, hard cutting, and ultra-precision cutting of difficult-to-machine materials.
Another aspect of cutting is the application of surface technology to cutting tools. PVD (Physical Vapor Deposition) and CVD (Chemical Vapor Deposition) are constantly evolving. From single layer to multi-layer, multilayer, composite coating, now It has also developed into a nano-coating; the coating material has evolved from TiN to Al2O3, TiC, ZrO2, etc. According to the processing requirements, in order to improve the high temperature resistance, TiCN, TiAlN, TiSiN, CrSiN and the like have been developed. In order to reduce the friction, a soft coating such as MoS2 is deposited, and Molyglide, which is used by Guehring, Germany, is mainly composed of MoS2, which can reduce the friction coefficient during cutting. Of course, this should be applied to the required processing according to the characteristics of the workpiece. Nowadays, 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 develops 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 is already the world's largest producer of synthetic diamond, which is conducive to the development of efficient processing technology in China.
In order to adapt to high-efficiency high-speed machining, auxiliary tools are also very important means. For example, in the application of the original combined fixture in the machining center, in order to improve its strength, it has developed from a groove system to a hole system. At present, the application of EROWA and 3R combination tools has been developed from electrical processing to machining centers, which not only speeds up the rhythm, but more importantly achieves high precision. These tools have evolved from the original die electrical machining to cutting. Processing field. The shank required for the cutting tool with shank also develops new structures in the process of high-efficiency, high-precision machining, such as hydraulic and plastic, and nowadays it is widely used with hot-mounted shank. The clamping accuracy is significantly improved to 2 to 3 μm. Now that the device has matured, for example, ZOLLER in Germany has installed such a device directly on the tool setting instrument, indicating that this technology has taken a step forward. Advances in tools have provided strong support for efficient processing.
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