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With the joint promotion of numerical control technology and tool technology, cutting machining has entered the era of high-speed cutting. In the past two decades, the cutting speed has increased by 5 to 10 times, and the cutting efficiency has increased by 50% to double. When 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 high-speed machining of various materials in the automotive, aerospace, aerospace and mold industries, including dry cutting, heavy cutting and hard cutting. Processing efficiency and product quality.
Tooling costs only 3% to 4% of manufacturing costs in modern processing, but it has a much greater impact on total manufacturing costs. The processing efficiency is increased by 20%, the processing cost can be reduced by 15%, and the tool cost is reduced by 20%. The processing cost can only be reduced by 0.6%, and the tool life is doubled. The processing cost is 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. Nowadays more and more people 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 reaches 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 HV400O 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.
Second, the update of the cutting concept has promoted the continuous improvement of processing efficiency (idea)
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.
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, from the early crankshaft machining to the internal milling process, and the invention of the crankshaft broach in the 1990s has increased the crankshaft machining efficiency 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 1990s, Chengdu Tool Research Institute, under the condition that the single technology of coating and material is not dominant, the tool design and process technology with independent intellectual property rights, combined with the comprehensive application of innovative technologies of coating, material and tool structure. In the high-strength oil pipe thread cutter, it has achieved a successful transcendence to foreign well-known enterprises. There are many examples of tool structure innovations that also effectively 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 twenty 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 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 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. They also optimized the entire plant process configuration, enhanced management, computer simulation using network programming and cutting process to reduce non-cutting time, "to 70% of the time to benefit." There are many ways to reduce the ratio of non-cutting time, such as machine adjustment, automatic loader, random measurement, setting of loading and unloading stations, equipment with high reliability, reducing maintenance downtime, etc., optimizing process configuration and performing processes in management methods. Balancing to reduce workpiece turnaround and wait time is an effective method.
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.
Third, talent, innovation, foundation, practice (return to the true story)
The cutting concept has made three advances, providing us with new ideas for better use of cutting technology, related technologies and management methods to improve processing efficiency. In order to better enhance these three concepts and achieve results, we should pay attention to personnel training, technological innovation, basic learning, and practice.
The current development of CNC technology and cutting technology is changing with each passing day. Parallel machine tool, linear motor, five-axis linkage plus CNC rotary spindle, super hard tool, new coating, high speed spindle of 40000r/min, cutting speed of 7000m/min, feed speed of 20m/min, more like cutting wood The scene of cutting steel is dazzling...
Advanced tool products emerge in an endless stream, and advertising is overwhelming. In the face of suppliers' services for users to create benefits, some processing companies implement "buy-seeking" to improve production efficiency. But after we spend money without much effort to improve production efficiency or solve the processing problems, will it feel a little dazed?
The domestic tool industry is striving to catch up with the world's advanced level. Objectively speaking, it is mainly tracking advanced technologies and products. Most of the tools used in CNC machining in the car, mold, aerospace and other industries are still products of foreign companies. The lack of independent innovation has widened the gap between us and the world's advanced level, facing the market competition of high-end tool products. Is there some helplessness?
Recalling the 1950s and 1960s, a group of labor models, skilled craftsmen and experts and scholars created a large number of advanced tools, which played a significant role in promoting the machinery manufacturing industry in the early days of the founding of the People's Republic of China. For example, the group drills created by Ni Zhifu of Beijing Yongding Machinery Factory, the universal tool tires created by Wang Chonglun of Angang Machinery General Factory and the deep hole nesting knives created by Ma Xueli of Wuhan Heavy Machine Tool Plant. Comrade Ni Zhifu caused a sensation when performing group drills in Eastern European countries. Forty years have passed, cutting technology has undoubtedly made great progress, but when we catch up with the world's advanced level and enjoy the most advanced tools for high-efficiency processing, we feel that there is a lack of contrast to the situation at the time - innovation power and innovation The lack of talent.
The problem is that we pay more attention to the advanced level of foreign tools, but pay less attention to the support of its advanced nature - talent, innovation, foundation, and practice. We must improve the cutting level and use advanced cutting tools. To develop advanced cutting tools to catch up with the world's advanced level, we must start from the basics.
First of all, we must cultivate talents with innovative power, and learning and practice are the only way for talents to grow. Metal cutting as a traditional technology has a relatively systematic theoretical basis to effectively guide us in cutting. However, the cutting process is very complicated and is affected by many random factors. It is difficult to accurately describe and have uncertainty with some formulas and theorems. The key lies in the combination of theory and practice. It is necessary to gradually enhance the ability to apply the basic knowledge of cutting theory to solve practical problems in practice.
Foreign tool companies pay great attention to the basic knowledge of cutting theory, but our college mechanical engineering has reduced the original 160-time cutting principle and tool design to less than 20 hours. Some college graduates do not have basic cutting theory foundations. How to develop our cutting technology?
In order to strengthen the training of comprehensive cutting knowledge, we have compiled the “Tools Application Technology Foundation†textbook for the China Knife Association 20 project, which is used for the modern tool training and seminars organized by the China Knife Association, and attempts to incorporate the basic technology related to tool application into the training. And the content of the discussion, in order to arouse everyone's common concern and pay attention to the basic knowledge of the tool. The textbook starts with the introduction of the three components of the cutting technology system and the application technology of the tool. The machinability of the workpiece material, the tool material and coating and the selection basis, the geometric parameters and structure of the tool cutting and the selection, the selection and improvement of the cutting parameters. The path of cutting and the like has been systematically explained. The textbook also combines the development of modern cutting technology to add technology related to high-speed cutting, which is the dynamic balancing technology, safety technology and clamping technology of high-speed rotating tools.
Our goal is to train companies to understand the basics and latest developments in modern cutting technology, to master the basic theories of cutting application technology and to solve practical problems – we call them cutting engineers and a new generation of tool kings. Through talents to innovate, to practice, to catch up with the world's advanced level. From high-speed cutting to high-efficiency cutting to efficient machining, the machining efficiency increases with each advancement of the cutting concept. Now we should calm down and start from the fundamental issues, pay attention to talents, innovation, foundation, and practice - call for new enhancements in cutting concepts, to drive greater advancement in cutting technology and further improvement in processing efficiency, and to catch up with the world's advanced level.
Fourth, the conclusion
In the past few years, we have focused on cutting technology and focused on cutting concepts, and have promoted three advancements in cutting concepts from high-speed cutting, high-efficiency cutting to high-efficiency machining, and further improved the cutting efficiency. The current thinking is to start from the root, on the basis of the high development of cutting technology and the continuous updating of cutting concepts, the cutting concept comes back to the original, calling for a new improvement in cutting concept from the cutting level of cutting technology - cutting concept - talent base. "Ten years of trees, a hundred years of tree people", we must overcome the thoughts of floating psychology and quick success, and work hard to create a large number of cutting engineers who master the basics of advanced cutting technology, understand advanced cutting concepts, have the ability to innovate and solve practical problems. And a new generation of knives. This is the fundamental way to further improve the productivity of cutting and to catch up with the advanced level of cutting tools.
First, the cutting process has entered the era of high-speed cutting (technical articles)