Since the 1980s, driven by the development of the world's manufacturing industry and the advancement of manufacturing technology, cutting technology and cutting tools have gradually entered a new stage of development of high-speed, high-efficiency and innovative processes, and the efficiency of cutting processing has been doubled. The development of the industry has made an important contribution. Innovative and efficient cutting processes and cutting tools have become the basic processes and key technologies in the manufacturing industry, such as automotive, aerospace, mold, power plant equipment manufacturing and Other major industrial sectors and equipment manufacturing. New cutting processes such as high-speed cutting, dry cutting, and hard cutting are changing the traditional processing techniques of some industries and showing great vitality. Up to now, the application of innovative cutting technology and advanced cutting tools to improve processing efficiency and processing quality, reduce manufacturing costs, and thus enhance the competitiveness of enterprises has become the consensus of mechanical processing enterprises in industrialized countries, and has also attracted the attention of China's machinery processing enterprises. Therefore, starting from the application technology of grasping tools and improving the application level of cutting tools in enterprises has important practical significance in China.
Looking back at the history of the development of the United States, Germany, Japan and other manufacturing countries, they are all powerful countries in cutting technology and cutting tools. Even in these countries, they are still the leader in cutting technology and cutting tools.
Today, China has become a major manufacturing country in the world and is moving towards the goal of building and manufacturing a strong country. However, there is still a big gap between China's cutting processing level and the world's advanced cutting technology. The reasons for the backwardness of cutting technology, in addition to the technical gap, there is a long-standing concept of neglecting cutting technology and cutting tools. Companies often charge tool costs in manufacturing costs very low, and tool cutters can buy cheap tools as their performance. The essence of these practices is to sacrifice processing efficiency to reduce part manufacturing costs. However, the economic analysis of the cutting process points out that since the tool cost accounts for only 3% to 5% of the part manufacturing cost, if the tool purchase price is reduced by 30%, the company can only save 1% of the part manufacturing cost. However, if you purchase high-performance tools to improve cutting capacity and improve machining efficiency (assuming a 20% increase), you can save 15% on part manufacturing costs. To date, this theory has been confirmed by many examples of machining. Therefore, the concept of updating is the premise of applying advanced cutting tools to improve the efficiency of cutting processing. Only when the concept is new can high-quality technical resources such as modern cutting technology with less investment and quick effect be found in Chinese enterprises. The gap in technology and the backwardness of concepts not only hinder the development of China's manufacturing industry, but also affect the realization of the ambitious goal of building a manufacturing power, and restrict the technological progress and competitiveness of enterprises. Therefore, whether it is to achieve the grand goal of building and manufacturing a strong country, or for the development of the enterprise itself, it is necessary to update the concept and accelerate the development and application of advanced cutting technology and tools. For enterprises, improving the use technology and level of tools can not only improve the efficiency of current cutting operations, but also lay a foundation for further development and adoption of cutting new technologies in the future, and embark on the road of sustainable development.
In the measures to improve the application level of cutting tools in enterprises, the practices of different companies are different, but they can start from the following three points.
 Zhuzhou Black Diamond Blade |
 Seco Quattromill milling cutter |
 Balzers' CrAlN coating |
Adopt new tool material grades
Use advanced tool structure
- Improve the application ratio of indexable and coated tools
Indexable tools (including some machine-clamps) and coated tools are very mature technologies, and they have a high application ratio in foreign companies, but in most companies in China, the application ratios of the two are not high. High, there is a lot of space for promotion and application. According to the company that has done a good job in the promotion and application of indexable tools, the efficiency of cutting processing has increased by an average of 30% after the promotion of indexable tools. In addition, the newly developed indexable tools have larger rake angles, such as Seco's Quattromill face milling cutter, the insert groove is 10° positive rake angle, plus the positive rake angle of the insert, the maximum cutting after installation The rake angle can reach 35°, which significantly reduces the cutting force and power consumption, and creates favorable conditions for improving the cutting efficiency. Walter's Xtra·tec series of insert-blade drills, shoulder-milling cutters and face-milling inserts have larger rake angles, thanks to the company's Quartec material and Tiger·tec coating. The layer technology is said to increase cutting efficiency by 100%. The indexable tool with a large front angle is suitable for promotion on the old machine tools of most old enterprises in China.
Today, coating technology has entered a new stage of development, becoming an important symbol of modern high-efficiency tools, and has become an effective way to quickly improve tool performance. The application of coated tools can have an immediate effect on improving the cutting efficiency of enterprises. The newly developed coatings have a wear-resistant, heat-resistant coating for high-speed cutting, dry cutting, and hard cutting, a tough coating for interrupted cutting, and a lubricious coating for dry cutting and a reduction in friction coefficient. These new coatings are better suited to the needs of diverse processes. The high-performance coating has broken through the situation of TiAlN series coatings, and there are new coatings of Balzers AlCrN coating and Hitachi TiSiN, AlCrSiN, TiBON, etc. The microhardness of these coatings is 3200-3600Hv. The oxidation resistance temperature is in the range of 900 to 1100 ° C and has a unique property different from that of TiAlN, respectively. The development of new coatings further enhances the performance of coated tools and provides users with more options.
2. Strive to create conditions to apply solid carbide circular cutters
Compared with the similar high-speed steel tools that are commonly used today, the cutting tools such as drills, end mills, and taps made of fine-grained, ultrafine-grained carbide can increase the cutting speed by several times and greatly improve the processing efficiency. . With the five-axis linkage CNC tool grinding machine, the modern solid carbide circular cutter is no longer a standard tool, but a structurally innovative tool. Therefore, the performance of such tools is significantly improved, such as the US SGS company. Equal helix angle end mills can effectively suppress vibration during milling, thus improving processing quality and efficiency. Another example is Hitachi's four-blade rounded end mill. The outer diameter of the two so-called secondary blades is slightly smaller than the nominal size of the milling cutter, so that the four edges are on the elliptical cross section, and the secondary and end edges are connected. The "circle" arc is also part of the ellipse. When cutting, the main blade and the secondary edge cut the chips of different lengths and thicknesses respectively, changing the periodicity of the cutting force, suppressing the vibration of the tool, and increasing the feed rate per tooth of the milling cutter by 0.5-0.7mm, achieving efficient machining. . However, the application of solid carbide tools requires better performance of the machine tool, and there are special requirements for the clamping of the tool. Pay more attention when using it.
1. Apply advanced tools to promote cutting process innovation
One of the characteristics of modern cutting technology development is that the development of advanced cutting tools combined with the innovation of cutting technology or processing methods, to tap the potential of cutting processing from a deeper level, and promote the progress of cutting technology. For example, the CBN tool is used for the new process of hardening the workpiece by the car, which is more efficient and more environmentally friendly. The milling thread is used to replace the tapping with the hard alloy thread milling cutter, which can be fully avoided due to the disadvantage of the tap breaking. Taking advantage of the high-speed cutting of cemented carbide, it is changing the status of low-speed and low-efficiency of screw hole processing; new type of milling cutter, insert milling cutter, drilling and milling cutter, small depth-cutting and large feed milling cutter specially developed for the mold industry The tool has changed the traditional mold processing method and played an important role in improving the efficiency of mold processing. In addition, new technologies such as car-pulling knives, high-speed milling cutters and high-speed milling developed for the machining of aircraft aluminum components in the aerospace sector have driven innovation in processing technology in these industries and achieved remarkable results. .
Play the role of tool manufacturer
At this stage, the work of enterprises to improve tool application technology should rely more on the help of tool manufacturers. Modern tool manufacturers hold a large amount of cutting technology resources and information, and have established a business purpose of improving the efficiency of cutting processing for users. They are the professional team of cutting technology socialization. Their strong scientific research strength, huge development funds, modern technology and equipment, and advanced management concepts have promoted the progress of modern cutting technology. Strengthening the cooperation with tool manufacturers, with their help, to improve the application level and processing efficiency of the tools and shorten the delivery cycle, this is the secret of foreign tool users to gain competitive advantage. We should follow the example, especially for machining difficult-to-machine materials such as austenitic stainless steel, titanium alloy, nickel alloy, etc., and rely on tool manufacturers to give full play to their advantages in tool materials, coatings, tool design, etc. The processing experience can achieve good results. China's tool manufacturers should further accelerate the transformation of business philosophy, improve the ability to serve users, and become a reliable partner for users.
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Hangzhou Finding International Co., Ltd. , http://www.cnrollformingmachines.com