In metal processing, achieving efficient processing is an eternal pursuit of all manufacturers, including tool manufacturers. In recent years, with the rapid development stage of the automobile manufacturing industry, diversification and individualization have become the main features of its development, and improving the ability of auto manufacturers to quickly respond to changes in market demand is an important means of winning competition. At the same time, engine and gearbox manufacturers have also put forward more urgent demands for efficient machining.
Machine tools, tooling, processes, and even programming software, cutting fluids, etc. all affect the machining efficiency, but the main elements that make up the machining are: machine tools, tooling and tools. Among them, the tool plays a role in the final removal of the material and is an important factor in the ability to achieve efficient processing. In particular, the tools are selective, use the limits of existing production equipment, shorten the processing time through tools, and have a direct impetus to achieve efficient processing. According to the old saying, "All rights reserved must be the first to sharpen its tools." Nowadays, in the modern manufacturing industry, it has been given more extensive connotations. To improve processing efficiency and constantly optimize the "weapons" - the tool is critical, the following briefly introduces several ways to optimize the tool.
"Lee" its material, change the cutting speed For a long time, tool suppliers are constantly researching and developing tools with longer service life and faster cutting speed to realize higher feed speeds and improve machining efficiency. To change the cutting speed, the key is to change the cutting material base material and surface coating. At present, the tool supplier's choice of tool materials mainly focuses on hard alloys and some CBNs, and continues to increase research and development efforts to launch new products. Take the tool material introduced by Sumitomo Corporation as an example:
For general carbon steel and alloy steel cutting, early carbide coating material cutting speed V = 100 ~ 250m/min, and Sumitomo new material AC700G/AC820P through the parent metal and coating technology innovation in processing The SCM420 driveshaft has increased the cutting speed to V=390m/min. At the same time, with superior fracture resistance, when processing SCM425 gears, it can achieve 5mm depth of cut, the feed amount reaches 0.5mm/rev, which is 1.5~2.7 times of the service life of the original material.
For quenched steel (HRC58~62) material products, such as bearings, shaft keys, and gears, most of them adopt the method of turning before heat treatment and grinding, and the efficiency is low and the size is not easy to guarantee. Some users also use CBN (Cubic Boron Nitride) material processing, but the cutting speed is low (80 ~ 150m/min) moc.861ehcoaz.www, processing efficiency and surface quality is not high. Sumitomo launched a new material BNC100 cutting speed of 100 ~ 300m/min, and maintain a high linear velocity while the feed value to 0.1 ~ 0.35mm/rev. Similarly, in the car mold milling, BN700 round edge milling inserts developed by Sumitomo Corp. with BRC arbors, processing SKD quenched to HRC47~52 materials and NAK pre-hardened steel HRC40~45 materials can achieve 150~400m/min respectively. And ultra-high-speed finishing of 200~800m/min, the processing time is shortened 3~5 times, and the surface finish is excellent. "Lee" its structure, change the tool cutting allowance and feed "Lei" its structure mainly refers to constantly optimize the body structure and blade geometry design, from the cutting force to improve the cutting edge method and strength to achieve processing efficiency New breakthroughs, taking Japan BIG and Sumitomo products as examples:
1. The FCM fast peak milling cutter BIG performs a double rake angle design with a 20° axial rake angle and a large radial rake angle on the cutter, which not only cuts lightly, but also has extremely low resistance. Applied to the clamp type end mill, the back angle will not be too large, which will not affect the sharpness of the cutting edge, but also increase the strength of the cutting edge, not easy to collapse.
For example, on the BT40 spindle machine, cutting S50C material, φ32mm milling cutter, cutting depth 9mm, speed 1500r/min, feed up to 550mm/min. Due to the light cutting speed, ARCHEAN.net has a good right angle and beautiful wall surface after processing, the straight angle can be 0.01mm, and the roughness Ra is 0.51mm. This product not only achieves a breakthrough in efficiency in conventional slot milling and square shoulder milling, but also makes it possible to perform high-efficiency machining in cases where the spindle power is insufficient, clamping rigidity is poor, and the overhang depth is long.
2. EWB-UP high-speed ultra-precision boring head The first characteristic of fine boring head is to realize the adjustment accuracy and processing accuracy. Since the boring head genus is single-edge cutting, it is necessary to achieve high speed and efficient processing without dynamic balance. BIG integrates the dimensional accuracy adjustment and the dynamic balance adjustment with its offset equivalent into a steamed head part. The adjustment accuracy is easily achieved by two dials and the adjustment accuracy is 0.001 mm. The requirement for the dynamic balance coefficient G6.3 at the highest speed is required. . With diamond, CBN material processing of aluminum alloy parts (such as gearbox housing) and cast iron cylinder hole products, can achieve 200 ~ 2000m/min high-speed and high-efficiency processing, and get good processing results.
3. Non-standard composite cutting tools For a large number of products with complex structures, numerous processes and difficult to process, standard tools can no longer meet the requirements of high-efficiency machining. This requires a more targeted design of the tool structure based on the specific parts, effectively reducing tool change time. Sumitomo's special tools developed for the machining of crankshafts and camshafts in automotive engines, including broaches, valve seat milling cutters, and automatic guide boring burrs, are typical products for non-standard tools that promote efficient machining.
"Lee" its clamping, to achieve high cutting speed and large feed shank clamping system is the transmission of the machine tool spindle and the connection of the tool, it carries the accuracy of the spindle, rigidity and rigidity of the handle itself, and dynamic balance, clip Holding force and clamping accuracy are necessary conditions for high-speed and high-efficiency machining. Take BIG products as an example:
1. High-speed and high-precision clamping holders For cutting tools with a diameter of φ20mm or less, especially for φ0.25 to 12mm small-diameter cutting tools, high-efficiency, high-precision machining and excellent surface finish are required, which must be achieved through high-speed machining. The stricter grade requirements are imposed on the holder grip accuracy and dynamic balance performance indicators. BIG's clip holder series products have a clamping port runout accuracy of 0.001mm, a 4 fold diameter runout accuracy of 0.003mm, a jacket accuracy grade of AA, and toolholders that have been subjected to dynamic balance testing with a maximum speed of up to 40 000r. /min, and standard configuration center outlet, fully meet the requirements of high-speed high-precision drilling, reaming and milling processing. The φ8.5×5D drill hole of the aluminum alloy cylinder product is processed. After the U.S. clip holder is used, the OSG hard alloy coated drill bit FTO-GDS is used. The processing parameter is n=6000r/min, f=0.45mm/rev, 3 to 4 times more efficient. At the same time, the aperture accuracy is effectively guaranteed.
2. Heavy cutting type holder This type of holder is mainly used for larger diameter cutters of φ20~50mm. Because this diameter range belongs to the category of rough machining, it has higher requirements on the rigidity and clamping force of the holder. BIG's HMC series of powerful tool holders feature a unique slit mechanism, which allows the grip to be thickened, rigid and has a superb torque of 300Nm. BIG's other BBT clip high-speed force handle series can meet the needs of high-speed power cutting, clamping accuracy between 0.005 ~ 0.01mm. If the spindle is matched with the BBT spindle, the taper of the shank and the end face of the flange can be tightly matched, and the rigidity can be enhanced by 3 to 4 times to realize powerful and efficient recutting, and a good deep hole processing effect can be obtained.
In the automotive processing field, especially in the process of mass production, the accuracy, cutting speed and life of the tool directly affect the starting rate of the production line, the processing cycle, and even the final production efficiency. According to the survey, nearly 70% of users in China account for 2% to 3% of the total cost of tooling. Although the proportion is not very high, the selection of reliable, applicable, and efficient cutting tool products can significantly reduce the total production cost of the company. cost. #p#Page Title #e#
It is noteworthy that, in the course of continuous updating of tool products, although the tool suppliers constantly change the tool material, the original tool body has not been changed, and the changed tool price has not been adjusted. For complete vehicles and parts manufacturing companies, when the processing efficiency of a certain process is lacking or dissatisfied, trying to select a new tool product or change the original structure of the body product may not increase the cost at the same time It is an unexpected boost to efficient processing. At the same time, with the responsible and responsible tool management personnel, we believe that while effectively ensuring processing efficiency, we can significantly increase our production capacity.
Machine tools, tooling, processes, and even programming software, cutting fluids, etc. all affect the machining efficiency, but the main elements that make up the machining are: machine tools, tooling and tools. Among them, the tool plays a role in the final removal of the material and is an important factor in the ability to achieve efficient processing. In particular, the tools are selective, use the limits of existing production equipment, shorten the processing time through tools, and have a direct impetus to achieve efficient processing. According to the old saying, "All rights reserved must be the first to sharpen its tools." Nowadays, in the modern manufacturing industry, it has been given more extensive connotations. To improve processing efficiency and constantly optimize the "weapons" - the tool is critical, the following briefly introduces several ways to optimize the tool.
"Lee" its material, change the cutting speed For a long time, tool suppliers are constantly researching and developing tools with longer service life and faster cutting speed to realize higher feed speeds and improve machining efficiency. To change the cutting speed, the key is to change the cutting material base material and surface coating. At present, the tool supplier's choice of tool materials mainly focuses on hard alloys and some CBNs, and continues to increase research and development efforts to launch new products. Take the tool material introduced by Sumitomo Corporation as an example:
For general carbon steel and alloy steel cutting, early carbide coating material cutting speed V = 100 ~ 250m/min, and Sumitomo new material AC700G/AC820P through the parent metal and coating technology innovation in processing The SCM420 driveshaft has increased the cutting speed to V=390m/min. At the same time, with superior fracture resistance, when processing SCM425 gears, it can achieve 5mm depth of cut, the feed amount reaches 0.5mm/rev, which is 1.5~2.7 times of the service life of the original material.
For quenched steel (HRC58~62) material products, such as bearings, shaft keys, and gears, most of them adopt the method of turning before heat treatment and grinding, and the efficiency is low and the size is not easy to guarantee. Some users also use CBN (Cubic Boron Nitride) material processing, but the cutting speed is low (80 ~ 150m/min) moc.861ehcoaz.www, processing efficiency and surface quality is not high. Sumitomo launched a new material BNC100 cutting speed of 100 ~ 300m/min, and maintain a high linear velocity while the feed value to 0.1 ~ 0.35mm/rev. Similarly, in the car mold milling, BN700 round edge milling inserts developed by Sumitomo Corp. with BRC arbors, processing SKD quenched to HRC47~52 materials and NAK pre-hardened steel HRC40~45 materials can achieve 150~400m/min respectively. And ultra-high-speed finishing of 200~800m/min, the processing time is shortened 3~5 times, and the surface finish is excellent. "Lee" its structure, change the tool cutting allowance and feed "Lei" its structure mainly refers to constantly optimize the body structure and blade geometry design, from the cutting force to improve the cutting edge method and strength to achieve processing efficiency New breakthroughs, taking Japan BIG and Sumitomo products as examples:
1. The FCM fast peak milling cutter BIG performs a double rake angle design with a 20° axial rake angle and a large radial rake angle on the cutter, which not only cuts lightly, but also has extremely low resistance. Applied to the clamp type end mill, the back angle will not be too large, which will not affect the sharpness of the cutting edge, but also increase the strength of the cutting edge, not easy to collapse.
For example, on the BT40 spindle machine, cutting S50C material, φ32mm milling cutter, cutting depth 9mm, speed 1500r/min, feed up to 550mm/min. Due to the light cutting speed, ARCHEAN.net has a good right angle and beautiful wall surface after processing, the straight angle can be 0.01mm, and the roughness Ra is 0.51mm. This product not only achieves a breakthrough in efficiency in conventional slot milling and square shoulder milling, but also makes it possible to perform high-efficiency machining in cases where the spindle power is insufficient, clamping rigidity is poor, and the overhang depth is long.
2. EWB-UP high-speed ultra-precision boring head The first characteristic of fine boring head is to realize the adjustment accuracy and processing accuracy. Since the boring head genus is single-edge cutting, it is necessary to achieve high speed and efficient processing without dynamic balance. BIG integrates the dimensional accuracy adjustment and the dynamic balance adjustment with its offset equivalent into a steamed head part. The adjustment accuracy is easily achieved by two dials and the adjustment accuracy is 0.001 mm. The requirement for the dynamic balance coefficient G6.3 at the highest speed is required. . With diamond, CBN material processing of aluminum alloy parts (such as gearbox housing) and cast iron cylinder hole products, can achieve 200 ~ 2000m/min high-speed and high-efficiency processing, and get good processing results.
3. Non-standard composite cutting tools For a large number of products with complex structures, numerous processes and difficult to process, standard tools can no longer meet the requirements of high-efficiency machining. This requires a more targeted design of the tool structure based on the specific parts, effectively reducing tool change time. Sumitomo's special tools developed for the machining of crankshafts and camshafts in automotive engines, including broaches, valve seat milling cutters, and automatic guide boring burrs, are typical products for non-standard tools that promote efficient machining.
"Lee" its clamping, to achieve high cutting speed and large feed shank clamping system is the transmission of the machine tool spindle and the connection of the tool, it carries the accuracy of the spindle, rigidity and rigidity of the handle itself, and dynamic balance, clip Holding force and clamping accuracy are necessary conditions for high-speed and high-efficiency machining. Take BIG products as an example:
1. High-speed and high-precision clamping holders For cutting tools with a diameter of φ20mm or less, especially for φ0.25 to 12mm small-diameter cutting tools, high-efficiency, high-precision machining and excellent surface finish are required, which must be achieved through high-speed machining. The stricter grade requirements are imposed on the holder grip accuracy and dynamic balance performance indicators. BIG's clip holder series products have a clamping port runout accuracy of 0.001mm, a 4 fold diameter runout accuracy of 0.003mm, a jacket accuracy grade of AA, and toolholders that have been subjected to dynamic balance testing with a maximum speed of up to 40 000r. /min, and standard configuration center outlet, fully meet the requirements of high-speed high-precision drilling, reaming and milling processing. The φ8.5×5D drill hole of the aluminum alloy cylinder product is processed. After the U.S. clip holder is used, the OSG hard alloy coated drill bit FTO-GDS is used. The processing parameter is n=6000r/min, f=0.45mm/rev, 3 to 4 times more efficient. At the same time, the aperture accuracy is effectively guaranteed.
2. Heavy cutting type holder This type of holder is mainly used for larger diameter cutters of φ20~50mm. Because this diameter range belongs to the category of rough machining, it has higher requirements on the rigidity and clamping force of the holder. BIG's HMC series of powerful tool holders feature a unique slit mechanism, which allows the grip to be thickened, rigid and has a superb torque of 300Nm. BIG's other BBT clip high-speed force handle series can meet the needs of high-speed power cutting, clamping accuracy between 0.005 ~ 0.01mm. If the spindle is matched with the BBT spindle, the taper of the shank and the end face of the flange can be tightly matched, and the rigidity can be enhanced by 3 to 4 times to realize powerful and efficient recutting, and a good deep hole processing effect can be obtained.
In the automotive processing field, especially in the process of mass production, the accuracy, cutting speed and life of the tool directly affect the starting rate of the production line, the processing cycle, and even the final production efficiency. According to the survey, nearly 70% of users in China account for 2% to 3% of the total cost of tooling. Although the proportion is not very high, the selection of reliable, applicable, and efficient cutting tool products can significantly reduce the total production cost of the company. cost. #p#Page Title #e#
It is noteworthy that, in the course of continuous updating of tool products, although the tool suppliers constantly change the tool material, the original tool body has not been changed, and the changed tool price has not been adjusted. For complete vehicles and parts manufacturing companies, when the processing efficiency of a certain process is lacking or dissatisfied, trying to select a new tool product or change the original structure of the body product may not increase the cost at the same time It is an unexpected boost to efficient processing. At the same time, with the responsible and responsible tool management personnel, we believe that while effectively ensuring processing efficiency, we can significantly increase our production capacity.
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