European tool manufacturers have been instilling the idea of ​​introducing their products to Chinese customers: in the usual metalworking industry, tool costs only account for 3% to 4% of manufacturing costs, and cooling lubricants account for 10% to 12%. The rest are basically divided by management costs, equipment depreciation, energy consumption and labor costs. Therefore, it is not very meaningful to reduce the price of the tool at all times; the use of high-efficiency tools at the maximum limit can minimize the above costs, even if the cost of the tool allocated to each part is slightly increased. This view is basically correct, but the so-called high-efficiency tool is only relatively efficient, depending on the environment and occasion, and is suitable for high efficiency.
High efficiency, high precision, high stability and low cost have always been the direction that metal processing companies are striving for. To achieve this goal, the application of efficient tools is essential. When it comes to high-efficiency tools, many technicians think of large depth of cut, fast feed, and high line speed. Indeed, the continuous improvement of the three elements of cutting reflects the development of efficient tools and the industry's wide recognition. However, how to apply efficient tools is a topic worth exploring.
1. Efficient tools are not just high speed tools
A famous German equipment manufacturer and a tool manufacturer set up a production line for a domestic customer to process the engine cylinder head made of HT250. Due to the extremely high demand for the production cycle, the equipment manufacturer had to work hard to increase the cutting parameters of each tool. Taking the coated solid carbide internal cold straight groove drill as an example, the linear speed is as high as 280m/min. As a result, three or four drills will be broken and about 10 pieces will be broken. The field workers have to stop the tool change, which is time-consuming. Labor and cost, so fast and fast.
European and American people are generally high-powered. The design and application concepts of machine tools and cutting tools advocate the "muscle" type. They are free to use in the application of high speed and deep depth of cutting tools. Japan has a lack of resources, a large population, a strict attitude, and exquisite work. Machine tools and tools are more suitable for small depth of cut and fast feed. In general, the use of high-efficiency tools in Europe and the United States according to the parameters of Japanese tools sometimes does not highlight its performance advantages, only the price is high; and the use of Japanese high-efficiency tools according to European and American parameters sometimes does not reflect the price advantage, slightly delicate.
2. Efficient tools need to be matched to suitable processing objects
Efficient tools are not omnipotent, and they must be used in a targeted environment to be effective. CBN materials are used more and more widely in the efficient cutting of hardened steel, cast iron and sintered alloys. Sumitomo's BN700 processing HT250 line speed can reach 2000m / min, BNC160 in the processing of HRC62 hardened steel line speed is recommended to 220m / min, in the engine cylinder head (grey cast iron) plane finishing and gear quenching hard car Excellent performance in process applications. Some customers have tried to finish the quenched and tempered steel with hardness HRC30 at a line speed of 300m/min with CBN blade. The result is not satisfactory, because the current CBN material is not suitable for processing steel below HRC42; The lower coated cermet inserts are more efficient.
3. Efficient tools need to be equipped with suitable equipment
As the saying goes, "Lv Bu, Ma Zhong Red Rabbit", the right match can complement each other. As mentioned above, the BNC160 hard car HRC62 hardened steel example has high requirements on the rigidity of the process system and the power of the machine tool. If the rigidity of the process system is not enough, the blade will be easily broken due to chattering, and the tool tip will need to be changed frequently. If the power of the machine is not enough, the workpiece will not move, let alone efficient machining. As another example, solid carbide twist drills with a depth of more than 30 times the diameter of the drill are increasingly replacing the crankshaft oil bores. These drills are mostly double margins with cold water inside. The hole can be cooled by internal cooling or MQL, and the feed per minute can reach 2~3 times of the same diameter. This type of drill has special requirements for the equipment. The use of the drill is the same as that of the drill. When used on the MC machine, the repeatability of the machine is highly demanding. The machine or accessory can support the center water. Variable frequency motor control, Z-axis feed is controlled by servo motor. Ordinary machine tools or machines with low precision should not be used.
4. The application of efficient tools calls for skilled workers and strict process management
The same gun can be played in the hands of snipers, and in the hands of untrained people may be a hundred. Efficient machining can be achieved when the machine tool, fixture, tool, coolant, workpiece and gage are all satisfactory. Any deficiency can lead to undesirable situations. If even the parts that are machined are not required, there is no way to cut the tool efficiently. Therefore, strengthening the business training for employees and strictly implementing reasonable process documents is a powerful guarantee for fully utilizing efficient tool performance.
Efficient tool for metal machining
Embroidery Fabric,Embroidery Cloth,Fabric Embroidery,Embroidered Lace Fabric
Shaoxing Yiyang Textiles Co.,Ltd , https://www.yiyangfabrics.com