Optimization tool on the promotion of efficient and effective processing
In recent years, with the rapid development stage into the auto industry, diversity and individuality into the main features of its development, the same time, engines, transmissions and other auto parts and manufacturers have also made more efficient processing of urgent needs. Tool as the main factors affect the processing efficiency by more and more attention, while more tool in the tool material suppliers, to optimize the structure and so on.
In metal processing, for efficient processing of all manufacturing enterprises, including the eternal pursuit of tool manufacturers. In recent years, with the rapid development stage into the auto industry, diversity and individuality into the main features of its development, and improve the car manufacturers on changes in market demand rapid response capability is an important means to win the competition. At the same time, engines, transmissions and other auto parts and manufacturers have also made more efficient processing of urgent needs.
Machine tools, tooling, process or programming software, cutting fluid and so will affect the processing efficiency, but constitute the most important processing elements: machine tool, tooling and tool. Among them, the tools to play the role of the final removal of material is the ability for efficient processing of important factors. In particular, the tool is optional, limit the use of existing production equipment, through the tool to shorten the processing time for efficient processing on a direct role in promoting. As the old saying that "make bricks without straw his tools", now it is more in the modern manufacturing industry was given a broader meaning. To improve processing efficiency, and continuously optimizing "tool" – tool is essential, the following brief form of several optimization tools.
"Benefit" of their material, to change the cutting speed
All along, the tool vendors are constantly R & D to longer life, faster cutting speed tool to achieve a higher feed rate, improve processing efficiency. To change the cutting speed, the key is to change the cutting materials, base metal and surface coatings. Currently, tool vendors on the choice of tool material mainly in carbide and some CBN, also continue to increase research and development efforts, launch new products to the Japanese Sumitomo launched the tool material as an example:
For the average carbon steel and alloy steel cutting, cutting speed early carbide coating material for the V = 100 ~ 250m/min, while Sumitomo AC700G/AC820P new materials and coatings on the base metal through technical innovation in the processing SCM420 shaft when the cutting speed has been increased to V = 390m/min. At the same time, with superior resistance to damage of collapse, in the processing SCM425 gears, they can achieve 5mm depth of cut, the feed capacity of 0.5mm/rev, the original material life of 1.5 to 2.7 times.
For hardened steel (HRC58 ~ 62) material products, such as bearings, shaft key and gear they use a heat treatment carried out before turning and then grinding the way, low efficiency, size is not easy to ensure. There are some users with CBN (cubic boron nitride) materials processing, but the lower cutting speed (80 ~ 150m/min), processing efficiency and surface quality is not high. Sumitomo's new material BNC100 cutting speed to 100 ~ 300m/min, and in line speed while maintaining high feed value to reach 0.1 ~ 0.35mm/rev. Similarly, in the car mold milling, the Sumitomo BN700 materials developed with the BRC round Milling Arbor, processing SKD quenching to HRC47 ~ 52 materials and NAK pre-hard steel HRC40 ~ 45 materials, respectively, and to achieve 150 ~ 400m/min 200 ~ 800m/min ultra-high-speed finishing, processing time is reduced 3 to 5 times, and excellent surface finish.
"Benefit" of its structure, change the margin and the cutting tool can feed
"Benefit" its structure is constantly optimizing the main body structure and the blade cutter geometry, the cutting force from the improvement, cutting edge methods and intensity to achieve new breakthroughs in processing efficiency, Japan BIG (big Showa) and Sumitomo Product example:
1.FCM fast peak Mills
BIG in the cutter on the 20 ° axial front and dual front large radial design front, not only cutting light, and ultra-low resistance, while for the first time after the eccentric angle of technology to the machine clip stand cutter, so that the horn would not be significant, will not affect the edge sharpness, but also improve the edge strength, not easy to chipping. For example, BT40 spindle machine tools, cutting S50C material, ?32mm cutter, cutting depth 9mm, speed of 1500r/min, feed up to 550mm/min. As the cutting light, while the processed product has a good angle and nice wall, straight angle can be 0.01mm, the roughness Ra is 0.51mm. The product not only in conventional slot milling, square shoulder milling to achieve efficiency in the breakthrough, but also gives enough power in the spindle, poor clamping rigidity, suspension and efficient processing of deep-long occasion possible.
2.EWB-UP high-speed ultra precision boring head
Precision boring head is to achieve the primary characteristics of regulation accuracy and precision, as precision boring head is a single blade cutting, to achieve fast and efficient processing of the dynamic balance can not be separated. BIG company with size precision offset adjustment and balancing adjustment equal to a boring first part of the integration, circled through two twisted easily scale the regulation accuracy 0.001mm, the maximum speed when the coefficient of G6.3 balancing the requirements of . With diamond, CBN material of aluminum alloy components (eg gearbox housing) and cast iron cylinder bore products processing, enabling high-speed 200 ~ 2000m/min efficient processing, and get good processing results.
3. Non-standard tool composite structure
For a large number of complex, diverse and difficult processes processing products, the standard tool has been unable to meet the high processing requirements. This requires specific parts of the structure of a more targeted tool designed to effectively reduce tool change time. Sumitomo Corporation for the automobile crankshaft, camshaft hole processing dedicated research and development tools, including the car pull knives, valve seat cutter, automatic guided boring tool, etc., are non-standard tools to promote the development of efficient processing of typical products.
"Benefit" its grip, high cutting speed and large feed
Chuck clamping system is the transfer of the spindle and tool connection, it is the precision spindle bearing, rigid and rigid tool holder itself, while the dynamic balancing of the clamping force and clamping accuracy and efficiency to achieve high-speed processing of the necessary conditions . With BIG products as an example:
1. High-speed high-precision type clamping tool holders
Diameter ?20mm for the following cutting tools, particularly within the path in the ?0.25 ~ 12mm cutting tools, to achieve efficient, high-precision machining, and have excellent surface finish, achieved through high-speed machining, which precision and balance on the knife handle grip performance indicators more stringent level of requirements. BIG products beauty clip holder clamp port beating accuracy 0.001mm, 4 times the diameter of the former beat accuracy 0.003mm, jacket accuracy rating of AA, Holder both experimental treatment by balancing the highest speed up to 40000r / min, and standard configuration center of the water, fully meet the high-speed precision drilling, reaming and milling requirements. Aluminum alloy cylinder product ?8.5 × 5D drilling processing, using the United States after the clip shank carbide coating using OSG bit FTO-GDS, processing parameters for n = 6000r/min, f = 0.45mm/rev, improve the efficiency of 3 to 4 times. At the same time, so that the effective aperture to ensure accuracy.
2. Heavy cutting Powerful clamping shank
This type of knife handle targeted ?20 ~ 50mm larger diameter cutting tools, since the diameter is a rough area, so the holder of the rigid and has a higher clamping force requirements. BIG's HMC series has a unique slot powerful tool holder body, dominated by the Department of thick, rigid, and with 300Nm of torque super. BIG's another folder BBT speed times force the United States holder series, which can meet the needs of high-speed heavy cutting, clamping between the accuracy of 0.005 ~ 0.01mm. As with the BBT shank spindle with cone and flange allows both sides closely aligns with the face, stiffness can be increased 3 to 4 times the efficiency of re-cut to achieve great strength and get a good deep hole machining results.
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