Analysis of the role of tool technology in modern manufacturing

The world today is in a period of rapid development of advanced manufacturing technologies. With the advent of CNC machine tools, modern manufacturing has developed a series of CNC machining technologies, such as machining centers (MC), flexible manufacturing units (FMC), flexible manufacturing systems (FMS), computer integrated manufacturing systems (CIMS), parallel machine tools. Wait. These technologies are closely combined with high-speed machining technology, tool technology and cutting technology, which greatly reduces the labor intensity in machining, greatly shortens the auxiliary time, greatly improves product quality and production efficiency, and plays a huge role in the development of the manufacturing industry and the global economy. The driving force. At present, cutting processing accounts for about 90% of the total machining work. Modern cutting technology is one of the main forces of manufacturing technology. Cutting processing (including grinding) is still the leading processing method of machinery manufacturing throughout the 21st century. As an important basic process equipment in cutting, tool technology plays a vital role in the development of modern manufacturing.

1. The importance of the tool in cutting

In machining, metal cutting machines and tools are the basic process equipment for machining. At present, the cutting machine tools are constantly updated. After the high-speed spindle adopts ceramic bearings, hydrostatic bearings, aerostatic bearings and magnetic bearings, the spindle speed can reach 10,000-50000/min, and some even reach 150,000r/min. The feed mechanism using the ball screw has a speed of 40 to 60 m/min, the linear motor can reach 90 to 120 m/min, and the machining acceleration of the precision CNC machining center can reach 2 g (g is the gravitational acceleration). The rapid development of cutting machine tools provides the basic premise and technical guarantee for the development of modern manufacturing. However, no matter what kind of metal cutting machine, it must rely on the tool that directly contacts the workpiece and cuts the material from the workpiece. Tool performance and quality directly affect the production efficiency of cutting machine tools and the quality of processing, directly affecting the production technology level and economic benefits of the entire machinery manufacturing industry.

Because of this, foreign manufacturing industry has the saying that "the company's dividends are on the cutting edge". In the Chinese idioms, "the workers must be good at their work, and they must first sharpen their tools." The importance of cutting has been vividly and profoundly described. For example, a 200,000 kW generator rotor shaft has a net weight of 30 tons, and its forging blanks are 60 to 70 tons. The chips to be cut account for more than 50% of the gross weight of the parts. It is hard to imagine how to complete without efficient tools. Such a processing task. An internationally recognized expert in cutting and machine tools has evaluated the role of cutting tools as follows: “Improving tools has the potential to reduce cutting costs over any other single process change. Reasonable selection and application of modern cutting tools is a reduction in production. Cost, the key to achieving major economic benefits.” N. Zlatin of the United States once said: “The efficiency of a machine tool worth $250,000 depends largely on a $30 end mill. Performance."

2. Cost analysis of the tool in manufacturing

With the improvement of modern technology, the speed of equipment replacement is getting faster and faster, and the current speed of replacement can reach 10-15 years to replace one generation. To earn back equipment investment and create profits in such a short period of time, the potential of the tool must be fully exploited. According to relevant data analysis: tool costs account for 2.4 to 4% of manufacturing costs, but it directly affects 20% of the cost of machine tools and 38% of labor costs.

Another algorithm is that the machine-to-tool input ratio is 9:1 to 7:3. As long as the tool investment is in place, each 15 to 20% increase in cutting speed and feed rate can reduce manufacturing costs by 10 to 15%. According to the economic analysis of cutting processing, the cost of tooling is only 3% to 5% of the cost of manufacturing parts. If the purchase price of the tool is reduced by 30%, the company only saves 1% of the cost of parts. If you purchase a better tool and extend the tool life by 50%, the company will only save 1% of the part cost; but if you purchase a tool with excellent performance, you can improve the cutting ability and improve the processing efficiency (assuming a 20% increase) , then you can save 15% of the cost of parts. To date, this theory has been confirmed by many examples of machining.

Some data have been compared with different tools. In 1900, a tool made of carbon tool steel was used to machine a carbon steel shaft with a diameter of 100 mm and a length of 500 mm, which took 100 minutes to complete. Today, 100 years later, using the carbide coated tool or cubic boron nitride tool, the same shaft can be processed in just one minute, and the cutting efficiency is increased by 100 times. This shows that the potential of the tool in improving cutting efficiency is quite large.

3. Analysis of the status quo of China's cutting tool technology

Vigorously developing CNC machining technology and equipment has become a strategic decision of governments around the world. Arming modern industries and transforming traditional industries with CNC equipment has also become the direction of manufacturing development in countries around the world. After the reform and opening up, the development of China's manufacturing industry has attracted worldwide attention. The total output and technical level of machine tools have entered the world's first phalanx. The import consumption of machine tools has reached the top in the world in recent years. China has entered the ranks of the world's manufacturing powers, but It is not a manufacturing power. Among them, China's current manufacturing labor productivity is only equivalent to 1/23 of the United States, 1/25 of Japan, and 1/18 of Germany. Compared with advanced industrial countries, there is still a huge gap.

The CNC machine tools in industrialized countries have a driving rate of 60-70% under the two-shift working conditions, while many domestic enterprises in China often only reach 20-30%, which causes the low utilization rate of CNC machine tools in China. The equipment is unreasonable, the overall quality of technicians needs to be improved, the working environment of CNC machine tools is poor, and the preparation of production technology is lagging. The most important point is that the technical content of machine tools and tools are not matched, and quite a few manufacturers are still common. The use of welding tools for CNC machine tool processing, not paying attention to "doors to the right", "good horse with a good saddle", resulting in advanced machine tools equipped with backward tools, resulting in the potential of equipment not fully played out, resulting in huge waste. Therefore, updating the concept and widely applying advanced tools has become a top priority. At the same time of investing in the machine tool, it must be equipped with the corresponding tools to ensure the efficient operation of the equipment, effectively increase the productivity, and thus obtain greater profits.

Since the founding of the People's Republic of China, China's tool industry has done a lot of work for the development of machinery manufacturing industry, and has achieved great results. However, with the improvement of cutting speed, the use of difficult-to-cut materials, the popularization of numerical control equipment, and the cutting process The requirements for tools are getting higher and higher. Domestically produced tools have significant gaps with foreign developed countries in terms of service life and reliability. They are far from meeting the needs of China's manufacturing industry in terms of product variety, performance and quality. In recent years, the fact that the annual growth rate of imported tools in China is as high as 50% or more is worthy of our serious consideration and efforts to improve.

4. Prospects for the development of cutting tool technology in China

At present, the application of innovative cutting technology, the use of advanced tools, appropriate increase in tooling costs, improve processing efficiency and processing quality, reduce the overall cost of manufacturing, thereby improving labor productivity and the competitiveness of enterprises has become a mechanical processing enterprise in industrialized countries. The consensus has also attracted the attention of China's machinery processing enterprises. Reasonable tool input can double the productivity and product quality, which is a worthwhile investment to enhance the competitiveness of the company. Manufacturing companies only have to change traditional concepts, correctly understand the essence of reducing costs, and overcome the practice of one-sided control of tool costs. Therefore, it is of great practical significance in China to improve the application level of cutting tools from the tool application technology.

Domestic tool companies should change their concepts, raise market awareness and brand awareness, seize opportunities, accelerate their technological innovation and technological transformation, increase research and development efforts, improve product quality, and win customer trust with high-quality products and excellent services. With advanced cutting tools, new tool materials and coating technology, we continue to meet the needs of the machinery industry. Only in this way can domestic tool companies determine their own advantages and win more market share in the fierce market competition.

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Tag: tool material cutting speed shaft parts technical status analysis magnetic bearing

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