In metal processing, efficient machining is the eternal pursuit of all manufacturing companies, including tool manufacturers. In recent years, as the automobile manufacturing industry enters a stage of rapid development, diversification and personalization have become the main features of its development, and improving the ability of automobile manufacturers to respond quickly to changes in market demand is an important means of winning competition. At the same time, auto parts manufacturers such as engines and gearboxes have also placed more pressing demands on efficient machining.
Machine tools, tooling, crafts and even programming software, cutting fluids, etc. all affect machining efficiency, but the most important components of machining are: machine tools, tooling and tools. Among them, the tool plays the role of the final material removal, and is an important factor that can achieve high-efficiency processing. In particular, the tool is selective, using the limits of existing production equipment, and shortening the machining time by the tool, which directly promotes efficient machining. The old saying goes, "When a worker wants to do something good, he must first sharpen his tools." Today, it is given a broader connotation in modern manufacturing. To improve machining efficiency and continually optimize the “tools†– the tools are crucial. Here are a few ways to optimize the tools.
"Lee" its material, changing the cutting speed
Tool suppliers have been continuously developing and introducing tools with longer service life and faster cutting speeds to achieve higher feed rates and improved machining efficiency. To change the cutting speed, the key is to change the base material and surface coating of the cutting material. At present, tool suppliers' choice of tool materials mainly focuses on hard alloys and some CBNs, and has continuously increased research and development efforts to introduce new products, taking the tool materials introduced by Sumitomo Corporation as an example:
For the cutting of general carbon steel and alloy steel, the cutting speed of early cemented carbide coating material is V=100～250m/min, and Sumitomo's new material AC700G/AC820P is processed through the technological innovation of base metal and coating. The cutting speed has been increased to V=390m/min for the SCM420 drive shaft. At the same time, it has excellent resistance to breakage. When machining SCM425 gears, it can achieve a cutting depth of 5mm, and the feed rate is 0.5mm/rev, which is 1.5~2.7 times of the service life of the original material.
For hardened steel (HRC58～62) material products, such as bearings, shaft keys and gears, most of them are processed by grinding before heat treatment, 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), the processing efficiency and surface quality is not high. The new material BNC100 from Sumitomo has a cutting speed of 100 to 300 m/min and a feed rate of 0.1 to 0.35 mm/rev while maintaining high line speed. Similarly, in automotive mold milling, the BN700 material round-blade milling cutter developed by Sumitomo Co., Ltd., together with the BRC arbor, can achieve 150-400 m/min when the SKD is quenched to HRC47-52 material and NAK pre-hardened steel HRC40-45 material. And ultra-high speed finishing of 200 to 800 m/min, the processing time is shortened by 3 to 5 times, and the surface finish is excellent. "Li" its structure, changing the cutting allowance and feed rate of the tool "profit". Its structure mainly refers to continuously optimizing the structure of the cutter body and the geometric design of the insert, and improving the machining efficiency from the aspects of improving cutting force, cutting edge mode and strength. A new breakthrough, taking Japan BIG (Dazhao) and Sumitomo products as examples:
1. FCM fast peak milling cutter BIG has a double front angle design of 20° axial rake angle and large radial rake angle on the milling cutter, which not only cuts lightly, but also has ultra-low resistance, and at the same time, the first eccentric relief technology It is applied to the machine clamp type end mill so that the back angle is not too large, which does not affect the sharpness of the blade, and can improve the blade strength and is not easy to chip.
For example, on the BT40 spindle machine, the S50C material is cut, the φ32mm milling cutter has a cutting depth of 9mm, the speed is 1500r/min, and the feed can reach 550mm/min. Due to the light cutting speed and the 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 enables efficient machining in situations where the spindle power is insufficient, the clamping rigidity is poor, and the suspension depth is long.
2. EWB-UP high-speed ultra-precision boring head The first characteristic of the fine boring head is the adjustment precision and machining accuracy. Since the fine boring head is single-edged, it is inseparable from high-speed and high-efficiency machining. BIG combines dimensional accuracy adjustment and offset equalization dynamic balance adjustment into one boring part. The adjustment accuracy of 0.001mm and the dynamic balance factor G6.3 at the highest speed are easily achieved by two dial rotations. . With diamond and CBN materials, aluminum alloy parts (such as gearbox housing) and cast iron cylinder bore products can be processed at high speed and high efficiency of 200-2000m/min, and good processing results are obtained.
3. Non-standard composite structure tools For a large number of products with complex structures, numerous processes and difficult to machine, standard tools can no longer meet the requirements of efficient machining. This requires a more targeted design of the tool structure based on specific parts, effectively reducing tool change time. Sumitomo's special tools for the machining of crankshafts and camshaft bores of automobile engines, including broaches, valve seat milling cutters, and automatic guide boring tools, are typical products for non-standard tools to promote efficient machining development.
"Li" clamping, high cutting speed and large feed shank clamping system is the connection between the machine tool spindle and the tool, it carries the precision and rigidity of the spindle and the rigidity of the shank itself, and the dynamic balance, clip Bearing force and clamping accuracy are necessary conditions for high-speed and efficient machining. Take BIG products as an example:
1. High-speed and high-precision clamping shank for cutting tools with a diameter of φ20mm or less, especially for small-diameter cutting tools with φ0.25~12mm. To achieve high-efficiency and high-precision machining, and to obtain excellent surface finish, it needs to be realized by high-speed machining. More stringent grade requirements are imposed on tool holder clamping accuracy and dynamic balance performance. BIG's beauty gripper series has a clamping port runout accuracy of 0.001mm, a 4x diameter front runout accuracy of 0.003mm, and a jacket accuracy grade of AA. The handles are processed by dynamic balance test, and the maximum speed can reach 40 000r. /min, and standard configuration center water, fully meet the requirements of high-speed high-precision drilling, reaming and milling. The φ8.5×5D drilling of the aluminum alloy cylinder product is processed, and the OSG hard alloy coated drill bit FTO-GDS is used after the US shank is used. The processing parameters are n=6000r/min, f=0.45mm/rev, The efficiency is increased by 3 to 4 times. At the same time, the aperture accuracy is effectively guaranteed.
2. Heavy-duty strong clamping shank This type of shank is mainly for φ20～50mm large diameter cutting tools. Since this diameter range is rough processing, it has higher requirements on the rigidity and clamping force of the shank. BIG's HMC powerful tool holder series features a unique slit mechanism, thickened grip, good rigidity and 300Nm of super torque. BIG's other BBT beauty clip high-speed double-handle series can meet the needs of high-speed and powerful cutting, and the clamping accuracy is between 0.005 and 0.01mm. If it is matched with the BBT main shaft, the taper surface of the shank and the end surface of the flange can be closely fitted, and the rigidity can be enhanced by 3 to 4 times, achieving strong and efficient re-cutting, and obtaining a good deep hole processing effect.
In the field of automotive processing, especially in the mass production process, 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 China's tool cost costs account for 2% to 3% of total production costs. Although the ratio is not very high, the selection of reliable, applicable and efficient tool products can significantly reduce the total production of enterprises. cost.
It is worth noting that while the tool product is constantly updating, the tool supplier has changed the tool material continuously, but the original tool body has not changed, and the changed tool price has not been adjusted. For the whole vehicle and parts manufacturing enterprises, when the processing efficiency of a certain process is lacking or dissatisfied, try to select a new tool product or change the original structure of the body product, which may increase the cost without increasing the cost. It has an unexpected boost to efficient processing. At the same time, with the responsible tool management personnel, I believe that while effectively ensuring the processing efficiency, it can greatly increase the production capacity.
Machine tools, tooling, crafts and even programming software, cutting fluids, etc. all affect machining efficiency, but the most important components of machining are: machine tools, tooling and tools. Among them, the tool plays the role of the final material removal, and is an important factor that can achieve high-efficiency processing. In particular, the tool is selective, using the limits of existing production equipment, and shortening the machining time by the tool, which directly promotes efficient machining. The old saying goes, "When a worker wants to do something good, he must first sharpen his tools." Today, it is given a broader connotation in modern manufacturing. To improve machining efficiency and continually optimize the “tools†– the tools are crucial. Here are a few ways to optimize the tools.
"Lee" its material, changing the cutting speed
Tool suppliers have been continuously developing and introducing tools with longer service life and faster cutting speeds to achieve higher feed rates and improved machining efficiency. To change the cutting speed, the key is to change the base material and surface coating of the cutting material. At present, tool suppliers' choice of tool materials mainly focuses on hard alloys and some CBNs, and has continuously increased research and development efforts to introduce new products, taking the tool materials introduced by Sumitomo Corporation as an example:
For the cutting of general carbon steel and alloy steel, the cutting speed of early cemented carbide coating material is V=100～250m/min, and Sumitomo's new material AC700G/AC820P is processed through the technological innovation of base metal and coating. The cutting speed has been increased to V=390m/min for the SCM420 drive shaft. At the same time, it has excellent resistance to breakage. When machining SCM425 gears, it can achieve a cutting depth of 5mm, and the feed rate is 0.5mm/rev, which is 1.5~2.7 times of the service life of the original material.
For hardened steel (HRC58～62) material products, such as bearings, shaft keys and gears, most of them are processed by grinding before heat treatment, 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), the processing efficiency and surface quality is not high. The new material BNC100 from Sumitomo has a cutting speed of 100 to 300 m/min and a feed rate of 0.1 to 0.35 mm/rev while maintaining high line speed. Similarly, in automotive mold milling, the BN700 material round-blade milling cutter developed by Sumitomo Co., Ltd., together with the BRC arbor, can achieve 150-400 m/min when the SKD is quenched to HRC47-52 material and NAK pre-hardened steel HRC40-45 material. And ultra-high speed finishing of 200 to 800 m/min, the processing time is shortened by 3 to 5 times, and the surface finish is excellent. "Li" its structure, changing the cutting allowance and feed rate of the tool "profit". Its structure mainly refers to continuously optimizing the structure of the cutter body and the geometric design of the insert, and improving the machining efficiency from the aspects of improving cutting force, cutting edge mode and strength. A new breakthrough, taking Japan BIG (Dazhao) and Sumitomo products as examples:
1. FCM fast peak milling cutter BIG has a double front angle design of 20° axial rake angle and large radial rake angle on the milling cutter, which not only cuts lightly, but also has ultra-low resistance, and at the same time, the first eccentric relief technology It is applied to the machine clamp type end mill so that the back angle is not too large, which does not affect the sharpness of the blade, and can improve the blade strength and is not easy to chip.
For example, on the BT40 spindle machine, the S50C material is cut, the φ32mm milling cutter has a cutting depth of 9mm, the speed is 1500r/min, and the feed can reach 550mm/min. Due to the light cutting speed and the 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 enables efficient machining in situations where the spindle power is insufficient, the clamping rigidity is poor, and the suspension depth is long.
2. EWB-UP high-speed ultra-precision boring head The first characteristic of the fine boring head is the adjustment precision and machining accuracy. Since the fine boring head is single-edged, it is inseparable from high-speed and high-efficiency machining. BIG combines dimensional accuracy adjustment and offset equalization dynamic balance adjustment into one boring part. The adjustment accuracy of 0.001mm and the dynamic balance factor G6.3 at the highest speed are easily achieved by two dial rotations. . With diamond and CBN materials, aluminum alloy parts (such as gearbox housing) and cast iron cylinder bore products can be processed at high speed and high efficiency of 200-2000m/min, and good processing results are obtained.
3. Non-standard composite structure tools For a large number of products with complex structures, numerous processes and difficult to machine, standard tools can no longer meet the requirements of efficient machining. This requires a more targeted design of the tool structure based on specific parts, effectively reducing tool change time. Sumitomo's special tools for the machining of crankshafts and camshaft bores of automobile engines, including broaches, valve seat milling cutters, and automatic guide boring tools, are typical products for non-standard tools to promote efficient machining development.
"Li" clamping, high cutting speed and large feed shank clamping system is the connection between the machine tool spindle and the tool, it carries the precision and rigidity of the spindle and the rigidity of the shank itself, and the dynamic balance, clip Bearing force and clamping accuracy are necessary conditions for high-speed and efficient machining. Take BIG products as an example:
1. High-speed and high-precision clamping shank for cutting tools with a diameter of φ20mm or less, especially for small-diameter cutting tools with φ0.25~12mm. To achieve high-efficiency and high-precision machining, and to obtain excellent surface finish, it needs to be realized by high-speed machining. More stringent grade requirements are imposed on tool holder clamping accuracy and dynamic balance performance. BIG's beauty gripper series has a clamping port runout accuracy of 0.001mm, a 4x diameter front runout accuracy of 0.003mm, and a jacket accuracy grade of AA. The handles are processed by dynamic balance test, and the maximum speed can reach 40 000r. /min, and standard configuration center water, fully meet the requirements of high-speed high-precision drilling, reaming and milling. The φ8.5×5D drilling of the aluminum alloy cylinder product is processed, and the OSG hard alloy coated drill bit FTO-GDS is used after the US shank is used. The processing parameters are n=6000r/min, f=0.45mm/rev, The efficiency is increased by 3 to 4 times. At the same time, the aperture accuracy is effectively guaranteed.
2. Heavy-duty strong clamping shank This type of shank is mainly for φ20～50mm large diameter cutting tools. Since this diameter range is rough processing, it has higher requirements on the rigidity and clamping force of the shank. BIG's HMC powerful tool holder series features a unique slit mechanism, thickened grip, good rigidity and 300Nm of super torque. BIG's other BBT beauty clip high-speed double-handle series can meet the needs of high-speed and powerful cutting, and the clamping accuracy is between 0.005 and 0.01mm. If it is matched with the BBT main shaft, the taper surface of the shank and the end surface of the flange can be closely fitted, and the rigidity can be enhanced by 3 to 4 times, achieving strong and efficient re-cutting, and obtaining a good deep hole processing effect.
In the field of automotive processing, especially in the mass production process, 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 China's tool cost costs account for 2% to 3% of total production costs. Although the ratio is not very high, the selection of reliable, applicable and efficient tool products can significantly reduce the total production of enterprises. cost.
It is worth noting that while the tool product is constantly updating, the tool supplier has changed the tool material continuously, but the original tool body has not changed, and the changed tool price has not been adjusted. For the whole vehicle and parts manufacturing enterprises, when the processing efficiency of a certain process is lacking or dissatisfied, try to select a new tool product or change the original structure of the body product, which may increase the cost without increasing the cost. It has an unexpected boost to efficient processing. At the same time, with the responsible tool management personnel, I believe that while effectively ensuring the processing efficiency, it can greatly increase the production capacity.
Hex Bolts,Allen Screw,Allen Bolt,Hex Head Bolt
Nantong Romax Hardware Co.,Ltd. , https://www.hardwarehouse.cn