The hottest new standard of cutting tool technolog

2022-08-09
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The new standard of constantly innovative tool technology

tool technology is developing rapidly to meet the changing needs and meet the more severe challenges from workpiece materials. Today's processing workshops need to re-examine tools from a different perspective

under the condition of meeting various needs, the use of advanced tools can improve the processing capacity of the workshop. As shown in Figure 1, this tool is used for turning hard materials from diamond innovations. With the rapid development of cutting tool technology, the correct selection of cutting tool can fundamentally change the process. In the metal processing industry, there is no other choice but to adopt advanced technology. In the future, the demand for machining will be huge, and only advanced technology can meet this huge demand

Figure 1 advanced cutting tools can improve the working efficiency of the processing workshop

the figure shows the hard material turning tools of diamond innovations company

Mr. Chris mills, the project manager of the Aerospace Development Department of Sandvik Coromant company, takes the aerospace industry as an example, and points out that in the next 20 years, in order to meet the production needs of the aerospace industry, its production and processing capacity must be increased by three times from now on. So how to achieve this goal

increase the processing capacity by three times. Is it OK to simply increase the number of processing machines by three times, while the processing technology still remains at today's current level? He said that in fact, such a situation could not happen. If the number of machine tools at the current technical level is multiplied by 3, it means that the number of machine tool operators will increase by the same multiple. Such a situation is simply unimaginable, because it is quite difficult for factories to hire qualified workers who are competent for the operation of processing machinery

therefore, the tripling of production capacity needs to be obtained from the continuous development of advanced technology. Only through this way can the existing number of metal processing operators monitor a large number of processing operations

where do these advanced technologies come from? Of course, these technologies also involve the development of machine tools themselves. Now, the machining speed and accuracy of machine tools are getting higher and higher. However, the workpiece itself has not developed at the same incremental level, although they are also changing in essence. Nowadays, the processed workpiece not only puts forward higher requirements for its processing accuracy, delivery time and quality, but also faces more and more difficult material problems that have never been encountered before in many workshops. These materials include titanium alloy, nickel base alloy and dense graphite cast iron (CGI), not to mention that in some cases, composite materials are also used to replace metal materials

in other words, the development of workpiece materials is faster and changes more than the machine tools for machining them. There is a certain gap between machine tools and parts materials. In order to narrow or even exceed this gap, the fastest developing technology comes from metal cutting tools, and its development speed is faster than any other processing technology

facts have proved that the development and changes of cutting tools are so great that no matter how large the processing factory is, it needs to re evaluate its cutting tool processing ideas. It is not only necessary to recheck the tool selection method, but also to reconsider some basic factors that affect the tool. But some of the core ideas are out of date, and the standard of cutting tools has also changed

recently, three major companies related to cutting tools have proposed how processing workshops should now think about cutting tools in different ways. These companies are: Diamond innovations, the world's leading supplier of cubic boron nitride (CBN) and polycrystalline diamond (PCD) materials for cutting tools; Precision dormer, an alliance of two tool companies, has been providing special technology for efficient drilling and thread processing for decades; Sandvik Coromant, the world's first supplier of metal processing tools. All engineering and technical personnel of the three companies listed some main factors that have a fundamental impact on the nature and use of cutting tools at present:

challenging materials, including alternative materials and difficult to machine alloy materials. The processability of some materials is less than 25% of that of steel, and the processing cost per pound can reach hundreds of dollars

parts with increasingly complex geometry, such as aircraft parts with very thin wall thickness and complex shape

the demand for large parts, especially turbines and various heavy equipment, is increasing. The high cost production of each part puts forward stricter requirements for the processing of these parts

the requirements for professional quality and performance are higher and higher, such as the requirements for typical fatigue strength of machined aircraft parts

these factors have prompted those leading processing workshops to start considering related cutting tool problems. Diamond innovations, precision dormer and Sandvik Coromant have specifically proposed five ways. According to these five ways, the processing workshop must think about their tool technology and the companies that provide this technology in different ways. The five new criteria for selecting cutting tools are: improving the working efficiency of machine tools, meeting the needs of applying professional technology, increasing the percentage of diamond cutting tools, focusing on the largest cost source, and considering cutting tools from the beginning

improve the working efficiency of the machine tool

don't only choose tools with long service life or high speed. Innovative cutting tools can also change the process and expand the processing range of machine tools

coroturn HP tools focus on the flow direction of high-pressure coolant, and the spray point of its coolant is concentrated above the blade. Practice has proved that this way of spraying coolant can increase the service life of the tool by 50% and the speed by 20%

why does the machining workshop choose to replace tools under normal use? The most common reason for installing protection is that they want to extend the service life of the tool. If the new tool can work longer in the existing process, it is possible to save more money for the processing workshop, including the cost of replacing the tool and the labor cost required for multiple tool changes

in order to improve the processing speed of machine tools, many innovative machining workshops will try to use new tools. If the new tool plays a good role in the high-speed machining process and greatly improves the metal removal rate, the tool can save more money for the machining workshop. In other words, the tool can more effectively improve the productivity of the processing workshop, allowing it to process more parts per shift

these two major improvements in technology - the improvement of service life and processing speed show that its investment can be rewarded, which also makes it more reasonable for many processing workshops to adopt high-performance tools

however, the step of seeking to improve the process level through cutting tools should not stop here. It also has great potential to save more money. Therefore, the processing workshop should try its best to find various methods to improve their processing capacity, because advanced cutting tools can not only extend the processing technology, but also promote the further improvement of the technology

Andrew hunter, the product manager of precision dormer company, cited an example of tool conversion. This example seems very simple, but he specifically mentioned the current situation of precision drilling technology

Mr. Andrew Hunter said that reaming is no longer needed in many hole processing applications today. Drilling processing can reach higher quality standards than ever before, so that the workshop has greater potential. To achieve this goal, only through the process of drilling processing, the necessary hole processing accuracy and quality requirements can be achieved. In many processing workshops, although people may be very familiar with the hole processing technology using center drills, drills and reamers, it is difficult to ignore the cost of this process

precision dormer often provides consulting services for processing workshops and explains where reamers are not necessary. If the change of the cutting parameters of the drill is roughly equivalent to the parameters currently used in the workshop, then the holes that meet the quality can be machined. If this is not the case and some types of cork lignin can remain stable in the molten state, precision dormer can help the workshop quickly find and evaluate another drill with better processing performance. Even if the price of new tools is slightly higher, the increased cost is negligible compared with the saved cost, because unnecessary tools are no longer needed in the processing process, thus eliminating and solving the problem of tool replacement that is not needed in the processing cycle

bill Tisdall, business development manager of Sandvik Coromant, has been engaged in the testing and optimization of newly designed tools. He believes that there are many ways to improve productivity through the development of cutting tools. He urgently asked the processing workshop to think about how to use the cutting tools correctly in order to give full play to its potential advantages

1. Using the characteristics of the machine tool

can your tool give full play to its potential to improve the processing level of the machine tool every day? Generally, in the processing of machine tools, the most popular is to use high-pressure coolant. At present, few processing workshops make full use of 70bar (1bar=0.1mpa) pressure coolant for their cutting tools for machine tools

sandvik Coromant's coroturn HP tool can improve its efficiency through this pressure, and accurately spray high-pressure coolant onto the blade directly above the tool. The coroturn HP tool handle can turn the high-pressure cooling flow into a wedge, causing the chips to warp upward and be washed away by the cutting fluid. In the processing of Inconel 718, a difficult material, the service life of the tool can be increased by 50% or the speed can be increased by 20% by using this method

2. Reduce installation time

the Coromant capto system provided by Sandvik Coromant company is the industrial standard of rapid tool change system in turning. It allows rapid tool change or fast locking and positioning of the tool for new workpiece processing without adjusting the position of the tool or resetting the offset of the tool. The same Coromant capto concept has also been applied to rotary tools, so the use or replacement of new milling cutters or drill bits has become extremely convenient, and the locking and positioning is fast, without prolonging any replacement time

Figure 2 after using the QS system of Sandvik Coromant company on the Swiss lathe, it can lock and position quickly and automatically. There is a company using Swiss lathe. After adopting this system, a lot of tool debugging and installation time are saved every year, and 100000 US dollars are saved

3 Adopt QS system

the QS system of the company is another system that can reduce the installation time, which is applied to Swiss lathes. After adopting QS system, the cutting tools can be loaded and unloaded quickly and locked and positioned in the center automatically. According to the calculation of a workshop user using a Swiss lathe, using this system can save us $100000 per year in the commissioning and setting time of a machine tool (Figure 2)

adopt the operation mode of unmanned management. In addition to the service life and speed of tools, we should also think more about the reliability of tools. At present, no workshop can fully recognize the potential value of cutting tools and do not know the cutting tools

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