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Change ideas, fully understand the cutting tool to improve the efficiency of mechanical manufacturing

发布日期:2015-03-12    浏览次数:958

Since entering the new century, China's manufacturing industry sustained high-speed development, the current total amount after the United States and Japan, the world third, has become a veritable world manufacturing power, and in developing gradually accelerated the pace of in line with international standards, using a large number of advanced CNC machine tools and cutting tools, processing technology and production efficiency are increased obviously. Some advanced manufacturing industry, such as the car industry a large number of the introduction of modern advanced production technology, power station equipment manufacturing, air craft manufacture, large scale and high accuracy mould manufacturing through technology introduction and independent development, such as the use of advanced cutting technology and efficient tool, effectively improve the processing technology and labor productivity, improve the competitiveness of the enterprises.

But China's manufacturing industry "big but not strong", many enterprises manufacturing technology is not high, seriously restricted the further development of our country's manufacturing industry. So far, some modern cutting technology used in the machinery industry advanced and efficient tool to improve the production efficiency is to reduce costs is insufficient, so in our country, modern cutting technology and efficient use of advanced cutting tool development is not balanced, many enterprises still only pay attention to rely on cheap labor cost reduction, rather than by improving the processing technology to improve production efficiency. Machine tool production in our country has developed rapidly in recent years, manufacturing of machine tools is far ahead in the world, ranks first, but the cutting tool industry has lagged far behind. Advanced efficient machine with less than efficient advanced tool, still use the traditional standard cutting tool, cutting technology, make efficient machine tool processing efficiency is not play, the serious influence production efficiency, restrict the modernization of manufacturing industry.

Constrained the development of cutting technology and cutter industry in China, a big reason is that enterprise use of knives stay behind on the traditional concept of the cheap tool is used to control the cost, rather than with a efficient tool to improve processing efficiency to reduce costs. Many companies spent big money on CNC machine tools, but to spend less money to buy advanced efficient tool, the cutting technology, machine tool processing efficiency is very low, is actually saved money, but waste expensive machine hours, do more harm than good.

Modern cutting technology is advanced and efficient tool manufacturing efficiency of one of the most important and the most active factor. In developed countries, extensive use of advanced and efficient tool, the average tool costs accounted for about 4% of the manufacturing cost, and the traditional cutting tools by using cheap manufacturing in China, the average tool costs less than 3% of the manufacturing cost, causes our country mechanical industry production efficiency is much lower than abroad. According to statistics, adopting efficient advanced cutting tool, cutting tool costs may be increased by 50% or more, will make the parts cost increases about 1%, but efficient advanced cutting tool can obviously improve the efficiency of machining, has the potential to parts production costs fell by 10% ~ 15%, therefore using efficient advanced cutting tools are extremely significant economic benefits.

Using modern cutting technology to improve the effect of machining efficiency is very obvious. As currently used in the aviation industry of new type of aluminum alloy overall thin-walled components to replace welding, riveting, assembly of components of the whole processing these aluminum alloy thin-walled components need to be a lot of metal milling, adopt new technology of high speed cutting processing efficiency many times. Harbin steam turbine factory production of the domestic first 600000 mw supercritical steam turbine unit, the processing of large diameter deep hole in the high alloy steel, adopts a new type of bit of kerner metal company, make a hole machining hours from 6.7 hours to 0.5 hours, solve the production of key problem. In the high strength of oil pipeline thread machining, the original with three tooth comb knife cutting, then developed a new three three comb knife sets of gear process, improve the machining efficiency many times.

Again as in the high speed machining center, the new "circular spiral milling", realize the traditional composite cutting tool to complete a screw hole and chamfering of drilling and milling and cutting, enlarge the using range of the composite cutting tools, greatly improving the processing efficiency. This new screw hole drilling and milling process has been applied in automobile engine cylinder head and the screw hole on the gear case processing, depth of 14.1 mm on the processing engine cylinder head of M6 screw hole, the spindle speed 20000 r/min, feeding the 700 mm/min, processing a screw hole just 1.2 seconds. On aluminum alloy gear case with convex sets and the fluctuation of the chamfering m2-m24 x 1.5 screw hole, the original to the traditional cutting tools with 7, 7 processing procedures to complete, German Jel precision cutting tool company is recommended to use a brazing polycrystalline diamond blade screw drill milling composite cutting tools, when the spindle speed of 20000 r/min, automatically complete the processing in turn, the entire processing time with only four seconds.

The use of new materials cutting tools to make the cutting efficiency is greatly improved, high cobalt high vanadium high performance of high speed steel cutter durability than ordinary HSS increased by 1.5 ~ 3 times. Powder metallurgy high speed steel strength can be increased by 20% ~ 20%, the toughness increased by 1.5 ~ 2 times, and reliability than common high speed steel were increased significantly, on the machining center has been widely used abroad made in the powder metallurgy HSS drill, tap and milling cutter, etc., and has little use in our country. Abroad in recent years developed a variety of new ingredients, the new type of cemented carbide, develops the high strength and high toughness of 0.5 ~ 1 mu m ultrafine particles of tungsten carbide, developed a variety of new coated carbide, has obviously improved the cutting performance of cemented carbide, instead of a part of the past can only be made of high speed steel complex cutting tool. Ceramics, polycrystalline diamond and cubic boron nitride superhard material tool, day widely used abroad, several times higher cutting speed than cemented carbide, greatly improve the machining efficiency, in Germany, about 70% of the castings with ceramic cutting tool processing, the Japanese ceramic cutting tool in consumption has accounted for 8% ~ 10% of the total cutting tool, and super-hard material cutting tools in China with little enough.

Machine tool $5.82 billion in 2005, the U.S. consumption, consumption tool $3 billion; The same consumption of machine tool in China $10.78 billion, and consumption cutting tools just $1.7 billion. The contrast is obvious, China's machinery manufacturing industry, the advanced cutting technology and efficient tool to improve the production efficiency, not enough attention, and is greatly underestimated. Fully understanding and trying to promote the application of advanced cutting technology and efficient tool, improve the production efficiency, reduce costs, enhance the competitiveness of the enterprise, is the mechanical manufacturing industry development of our country facing the need to solve the major issues as soon as possible.