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Foreign data shows that the tool costs 2.5%~4%, but it directly affects the machine cost of 20% of the manufacturing cost and 38% of the labor cost. Therefore, the feed rate and cutting speed increase by 15%. ~20% can reduce manufacturing costs by 10% to 15%. It shows that even if a good tool is used, it will increase the cost of the tool. However, due to the increase in efficiency, the machine cost and labor cost are greatly reduced. This is one of the business strategies adopted by the manufacturing industry in developed countries.
At present, due to the majority of ordinary machine tools and machine tools that are out of service, and the low labor costs, the impact of cutting tools on manufacturing costs cannot be achieved to this extent. However, its low investment and quick effect are very suitable for the current situation of Chinese enterprises. Received very good results. In order to narrow the gap with industrialized countries, China's tool companies must work hard to accelerate the development and application of key technologies. Accelerating the development of new tool materials Reviewing the history of machining development, it can be seen that the development of tool materials plays a major role in promoting.
There will be two important trends in the development of tool materials in the early 21st century.
First, the application range of cemented carbide tools continues to expand, titanium carbonitride-based hard alloys (cermets), ultrafine-grained hard alloys, graded-structured hard alloys, and composite materials of cemented carbide and high-speed steel. It will replace a considerable number of high-speed steel tools, including simple general-purpose tools such as drills, end mills and taps, and sophisticated tools such as gear hobs and broaches. The proportion of high-speed steel tools is further reduced. In this way, cemented carbide will dominate the tool material, covering most of the conventional processing areas.
Second, the use of super-hard tool materials will increase significantly. Due to its high hardness, good chemical stability, small thermal expansion coefficient and high thermal conductivity, CBN will become the main processing tool for high-speed processing of ferrous metals, difficult-to-machine materials and dry cutting and hard cutting. Tool material. As its toughness is further improved, its proportion in cutting tools will be greatly improved. In addition, CBN is still the ultra-high-speed cutting of ferrous metals, breaking through the critical speed proposed by C. Salomon, which essentially improves the most promising tool materials in the cutting process. PCD and single crystal diamond are the best tools for the efficient and precise processing of non-metallic materials such as non-ferrous metals, ceramics, glass and graphite. With the increasing demand for these materials in the automotive, aerospace, electronics, military and other sectors, the application of PCD will be more extensive. Accelerate the development of coating technology Since the advent of the tool coating technology, it has played an important role in the improvement of tool performance and the advancement of machining technology. The coated tool has become the symbol of modern tools, and the proportion in the tool has exceeded 50%. . At the beginning of the 21st century, the proportion of coated tools will be further increased. It is expected to break through the CBN coating technology in technology and be practical, so that the excellent performance of CBN can be applied in more tools and cutting, even sophisticated tools and Forming tools, which will improve the overall level of machining of ferrous metals.
In addition, the development and application of nano-scale ultra-thin ultra-multilayer coatings and new coating materials will accelerate, and coating will become the main way to improve tool performance. Accelerate the development of multi-function and special-purpose tools In order to take advantage of the CNC machining technology represented by turning machining centers and boring and milling machining centers, and improve machining efficiency, the processing of complex parts requires centralized processing of multiple processes in one setup. And to dilute the boundaries of traditional cutting, milling, boring, thread processing and other different cutting processes, is an effective way to improve the efficiency of CNC machine tools and accelerate product development. To this end, it also puts forward a new multi-functional requirement for the tool, which requires a tool to complete the processing of different parts of the part, reduce the number of tool changes, save the time of tool change, reduce the number of tools and inventory, and facilitate management and Reduce manufacturing costs. More common types of turning tools, milling cutters, as well as boring and milling cutters, drilling and milling cutters, drilling-milling threads - chamfering and other multi-purpose tools.
At the same time, in the mass production line, special tools or intelligent tools developed for the process can improve processing efficiency and precision, and reduce investment. Some special tools can reduce the processing time of parts to less than one tenth of the original, and the effect is very remarkable. The application of special tools with complex structure, multi-tool combination and automatic feed or adjustment accuracy has become an important factor in measuring the technical level of the production line. In the new car gearbox synchronizer gear processing line in the 1990s, the barrel broach was used to replace the original gear. A double-position broaching machine can replace several gear shaping machines to process one gear. 13 seconds, several times higher than the original process, the product quality is stable, and the plant area is saved. The development of versatile multi-tools and specialized tools for the needs of users should be an important part of future tooling products. To provide users with a complete set of cutting technology tools, the manufacturing industry should speed up the concept update, and provide users with complete sets of cutting processing technology and innovative processing methods as the development direction and service content.
With the advancement of cutting technology, tool manufacturers have a more scientific understanding of the factors involved in and affect the cutting process, and are used in the development of new products and new technologies, with tens of thousands of specifications. For the average user, it is difficult to correctly select and apply the new achievements of the tool industry in the face of the ever-changing new products and technologies of tool materials, coating grades, structures, etc., as well as various processing problems that are constantly emerging. Achieve the best results. To this end, the tool companies should take the “selling tools†as the main business path for the user to “provide complete cutting technology and solve specific processing problemsâ€, and be proficient in the corresponding cutting process according to the specialization direction of their products. Innovative development of new products. On the other hand, the user industry of cutting tools should fully exploit the potential of cutting and cutting tools, improve product development capabilities, and utilize the professional strength of the tool industry and its achievements to serve the development of enterprises and enhance market competitiveness. In addition, the development of cutting technology should take the development path of close integration of machine tools, tools and production, education and research. This is the manufacturing industry in industrialized countries, and also the tool industry, which is taking the development path. According to the information of the Cologne Ford Motor Company in Germany, in the automotive industry, the joint work of automobile manufacturers, machine tool manufacturers, tool manufacturers and research institutes or universities is at the pre-research, development and production stages, and the tool manufacturers account for The share is around 20%. Taking high-speed cutting as an example, Germany's high-speed cutting technology is led by the association. It is based on the Institute of Manufacturing Technology of Darmstadt University of Technology and is attended by famous tool factories, machine tool factories and automobile factories. Similarly, the National Institute of Standards and Technology (NIST) and McDonnell Douglas, the University of Pennsylvania and other units jointly set up a high-speed milling test bench to study the dynamic performance of the cutting process during high-speed milling to improve the efficiency of high-speed milling and Precision. France's high-speed cutting technology innovation development projects include machine tool plants, automobile plants, the National Institute of Technology (Cetin) and universities. The practices of these countries reflect the development characteristics of manufacturing technology and cutting in the 21st century.
The tool industry should accelerate the development and application of key technologies
At present, the level of cutting and tooling technology in China is relatively backward compared with industrial developed countries for about 20 years. To narrow this gap, it is not enough to have the efforts of the tool industry. It is necessary to increase the investment in tools in the user industry and make full use of the tools. Efficiency, cost reduction, shortened lead times, and accelerated role in new product development.