How will China's future tooling technology and market develop? This is a matter of benevolence and wisdom. In my opinion, our tool development will first work hard to improve efficiency. Because of the improvement of processing efficiency, it will become an important consideration for tool users. Tool users' requirements for improving processing efficiency are based in part on social development and international environmental development requirements. From 2000 to 2010, the average wages of employees in Wuxi, Shanghai, Beijing and Guangzhou increased by 500%, 300%, 320% and 290% respectively, and the increase in labor costs was seen. And this increase in labor costs is proportional to the cost of the product, which will lead to a decline in product competitiveness. Another aspect is the appreciation of our renminbi. From 2005 to the beginning of 2012, the exchange rate between the renminbi and the US dollar rose from about 1:8.1 to 1:6.3, an appreciation of nearly 30%; the euro rose from a high of 1:11 in 2008 to about 1:8.3 at the beginning of 2012, an appreciation of about 32.5. . The appreciation of the renminbi has caused the prices of Chinese exports to be settled in local currency values ​​abroad, while the renminbi settlement prices of imported products have fallen. This has brought additional competitive pressure to domestic export products and industries that import more foreign products. If these negative effects are to be diluted, increasing processing efficiency will be a solution for tool users. Because once the efficiency is increased, the number of products produced per unit time is increased, the equipment cost, labor cost, and management cost allocated to the single product will be reduced, and the total cost of the product will be greatly reduced. Processing efficiency requires working on both the manufacturing technology and the application technology of the tool. This article only describes its analysis from the perspective of tool manufacturing technology. Tool manufacturing technology In the manufacturing technology of tools, the material technology of the tool is first. The material technology of the tool is expected to develop in both the new type of material and the high performance of the original material. At the 2011 European Machine Tool Show, the German "LMT" "Speed ​​Core" is an example of a new type of material. The material of this hob should be said to be neither high-speed steel nor hard alloy, and its chemical composition is shown in Table 1. According to the blue flag, because there is no carbon in the new material, the “Rolling and Cutting King†no longer hardens by the metal alloy method, but improves the wear resistance of the material through age hardening. It is a new material technology. The cutting speed of the hob made by this material technology can be increased by more than 50% compared with the traditional high speed steel hob, and even 30% higher than that of powder metallurgy high speed steel (HSS-PM). The main trend of high performance materials today is particle refinement and the addition of trace elements to improve the properties of the material. Many of us have heard of the magic of nanomaterials. Although the nanotechnology of tool materials seems to be still in the laboratory stage and has not entered commercial applications, I believe that in the next 30 years, nanotechnology tool materials Will gradually enter the application phase. Nanomaterials generally refer to materials having a particle size of 100 nm, that is, 0.1 μm or less. According to the author's data, for solid carbide and indexable inserts, micro-drills and micro-milling cutters with a diameter of less than 0.1 mm currently use sub-nano materials with a particle size of about 0.7 μm, while other tool materials are used. Cemented carbides that can use particles of 1 to 1.3 μm can already be called microparticles. In general, harder carbides with finer particles are much stronger than coarse-grained cemented carbides, which is quite helpful in improving the performance of the tool. Table 2 shows the performance comparison of two solid carbide materials of Ruebig, Germany. It can be seen that the cemented carbide of 0.5 μm particles is 30% stronger than the cemented carbide of 2 μm particles. It is expected that in the next 30 years, the proportion of fine-grained, ultra-fine-grained cemented carbide will become higher and higher. Similarly, in the range of high-speed steel, fine-grained powder metallurgy high-speed steel will gradually replace ordinary high-speed steel with needle-shaped martensite. In tool making, the second important measure to improve the tool is to choose the right tool coating. The methods of tool coating mainly include chemical vapor deposition (CVD) and physical vapor deposition (PVD). Currently, carbide indexable inserts for machining steel and cast iron parts, especially turning inserts, mainly use CVD coatings, while other tools, including solid carbide tools, mainly use PVD coatings. CVD coatings From the current point of view, there are relatively few coatings that can be adapted: mainly for Al2O3 coatings and diamond (PCD) coatings. Although there are not many varieties suitable for coating, one of the two coatings (Al2O3) has a large market demand for processing steel and cast iron, and the other (PVD) is particularly suitable for lightweight aluminum alloys and The rapid growth of carbon fiber reinforced composite materials such as aerospace and wind power still has great development prospects. The author predicts that the development direction of Al2O3 coating should be in obtaining a thicker α-phase Al2O3 layer, controlled nucleation oriented growth technology of grains, grain refinement technology, reducing and eliminating microcracks and droplets of coatings, etc. aspect. The development of PVD technology should be diversified due to its own characteristics. The author predicts that PVD coating will improve the wear resistance of the coating, increase the heat resistance of the coating, reduce the friction of the coating-chip friction pair or the coating-worked surface friction pair, mainly by adding trace elements. The reduction of cutting heat transfer to the tool is achieved; on the other hand, the mechanical and chemical properties of the coating itself are also improved by refining the coated grains. In the manufacturing technology of the tool, the structure of the cutting edge has always been an extremely important factor in the working performance of the cutting edge together with the base material and the coating technology. As far as the geometry of the cutting edge itself is concerned, the endless streamline structure will continue to be launched continuously, but its goal will be to achieve higher levels in pursuit of sharpness, impact resistance, chip breaking and heat receiving. Balance. Figure 2 shows four new ISO geometries introduced by WALTER AG at the 2011 European Machine Tool Show: FP5, MP3, MP5 and RP5. According to Walter's tools, these grooves have large chip breaking areas and complement each other. Compared with the company's original trough type, the application range of these new troughs has been expanded by 20% to 40%, so only these four trough types can cover the entire application range of steel processing. At the same time, with the company's new cutting materials, users can achieve long and constant tool life, faster cutting speed, easy chip removal and high precision, more outstanding process reliability and machine tool utilization, which makes it possible Double the production efficiency of steel car processing. Another direction of tool manufacturing technology development is to challenge the processing objects that are still difficult to process. It includes materials such as titanium alloy, nickel-based alloy, hardened steel, and also includes small-size processing, deep-hole processing, and thin-wall processing. Processing objects such as large-size workpiece machining. Walter's tooling for titanium alloys uses a particularly strong cutting edge (blue) to resist crater wear, while it has a particularly narrow chipbreaker that makes it easy to produce chaotic titanium. The alloy chips are prone to breakage under such a groove shape. In contrast, the insert geometry for nickel-based, iron-based or cobalt-based superalloys has a sharp cutting edge and a positive rake groove for smooth cutting, and its chipbreaker reduces chipping. The risk of shock. For the processing of titanium alloys, another method being adopted by international manufacturers is high-pressure internal cooling, such as Sandvik Coromant, Kennametal, Seco Tools and so on. Not long ago, the world's first PCBN material was introduced. According to Seco Tools, the goal of this tool material is to meet the strict surface roughness, tolerance and cutting length requirements of nickel-based alloy parts, which brings unmatched tool life and reduces the number of tool changes. The machine is stopped. The result is a cost-effective, easy-to-use cutting tool that does not affect the surface quality of the part. For hardened steel materials, grinding is not the preferred finishing method because the cost per piece of hard turning is now greatly reduced. The hard turning metal removal rate is high and the processing cycle is short. Despite these advantages, hard turning often results in poor chip control, formation of nest-shaped chips, and surface scratches. Due to the structural characteristics of CBN itself, it has not been possible to apply chip breaking technology directly to low-content CBN inserts in the industry. Kennametal Corporation first developed the KB5610TM and KB5625TM with chip breakers by combining a dedicated chipbreaker with two high-performance PCBN materials, giving customers complete control over such problems with hard cars. A major problem in hard milling is that slippage is likely to occur between the milling cutter and the clamping mechanism due to the relatively large cutting forces. To this end, HAIMER has introduced a safety clamping technology that effectively prevents relative rotation between the milling cutter and the holder holding hole, ensuring the safety of milling. Heavy-duty cutting is also an important aspect of Chinese tooling in the future. Although the heavy machine tool heat has been cooled in previous years, the resulting increase in the number of heavy machine tools has become a reality. These machines will bring the use of heavy-duty, large-size machining tools to be continuously developed in the coming years. The Iskar Group's Ingersoll, Walter Tools, Kennametal, etc. are all increasing the development of heavy-duty machining tools. Kennametal's new MEGA 15°, 45°, 60° and 90° series milling cutters are the products for heavy-duty milling. According to Kennametal, each heavy-duty milling insert used in the series has four effective cutting edges, which allows for a lower cost of a single cutting edge while ensuring high productivity. The cutter features a brisk cutting edge design that reduces cutting forces by 30%. The integrated wiper helps to improve the roughness of the machined surface, while the sturdy blade helps to increase the metal removal rate (it is said that the metal removal rate can be increased by up to 30%). Small diameter micro drills and milling cutters will have wider applications in the electronics industry in the future. Nowadays, some high-end mobile phone products have begun to use metal to make the outer casing instead of engineering plastics. Fuel systems or medical device parts often require micro-drills. Walter-Texex can manufacture carbide drills with a minimum diameter of 0.1mm, while Kennametal offers the high-performance solid carbide drill GODrill with a minimum diameter of 1mm without internal cooling and a minimum diameter with internal cooling. Has reached 1.5mm. The GODrill drill has a bladeless design that reduces frictional heat generation and provides a longer life. Optimized cuts for micro-drilling ensure that there is no chip flow in the drill center. At the 2011 European Machine Tool Show, Walter increased the 30XD drilling depth to a considerable 70XD – perhaps a new world record in solid carbide twist drills. Walter has adopted a new process for the manufacture of solid carbide blanks, which makes it possible for the production of such long solid carbide drills for the first time. In addition, a special grinding process is required in production. Like all other Walter XD drills, the XD70 is also cooled by an internal cooling hole. Walter said that although the drilling depth is so large, there is no need for special cooling devices like external high-pressure systems, and it is sufficient to provide standard cooling devices in many machining centers. The future development direction of the tool market should include the informationization of the tool. The informationization of the tool undoubtedly requires the addition of information carriers on the tool. For the time being, the more suitable information carrier for the tool is the RF chip and the two-dimensional code pattern. The RF chip is usually attached to the shank, and the new high-speed shank HSK, CAPTO, and KM standards pre-position the RF chip. In the future, tool managers, designers, manufacturers, and users may be able to attach their own information to the chip, such as quality traceability information, geometry, usage specifications, preset parameters, and so on. The amount of information that the QR code can provide directly is quite limited, but the QR code can be set as a shortcut to access the network. You can also get a lot of information by scanning the QR code on the smartphone and connecting to the database of the network - although it needs Network support. Therefore, although the amount of information in the QR code itself is not large, with the popularity of wireless cities, wireless enterprises, wireless workshops, cloud storage, and cloud processing, this gap will soon become negligible. As far as the informationization of the tool is concerned, the two-dimensional code has an advantage compared with the radio frequency technology. Due to its own characteristics, it seems unlikely that many RF chips will be placed on many blades or integrated tools. Therefore, most of the current RF chips are placed near the tool changer of the tool holder. Even if the RF chip can be very miniaturized (such as a chip diameter of less than 3 mm), it can solve the problem of mounting on the tool body of the indexable tool, but it is difficult to damage the strength, rigidity and even the basic cutting function of the blade or the whole tool. avoid. It is very convenient to use laser technology to mark the QR code on the surface of the tool, and there is almost no increase in cost. With the popularization of smart phones, the use of iphone, Android, Saipan and other common systems to read the two-dimensional code and then find relevant information on the Internet has a material basis, it can be said that the popularity of two-dimensional code will come naturally. Therefore, at EMO2011, Sandvik Coromant, Seco Tools, Walter Tools, Lanzi Metalworking, etc. have begun to test the water, marking the QR code on the tool. In general, high-precision tools that meet the user's product upgrades and continuously improve machining accuracy and challenge processing limits, high-efficiency tools (including special tools) and high-reliability tools that meet the user's continuous improvement in production efficiency and lower production costs will be ours. The main direction of tool product development, and provide users with systematic, personalized tool management and tool technology services, will be the development direction of our tool service.
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