Turning engineers or turners often face some work problems, such as excessive chipping or chip entanglement caused by continuous scraping and causing hand cuts during cleaning; bar or workpiece due to vibration causes poor surface quality of parts The noise caused by vibration causes hearing damage; it is necessary to frequently replace damaged tools with unsatisfactory service life; the chuck clamping is often strengthened when necessary; the workpiece that is cut after the automatic core machine is finished is dropped into the chip flute and is difficult to remove; With the emergence of more and more advanced machine tools, turning engineers or turners must also learn new knowledge or technology (such as milling technology) and so on.
Technical experts from machine tool equipment and tool suppliers bring a wealth of excellent application technology and experience sharing. The following six tips on turning technology improvements may be the first time you hear about it, but they are all very good practical new technologies or know-how. I believe it will help you improve your processing capacity and reduce manufacturing costs!
Continuous and effective cooling
High-pressure jet cooling (HPC) is not a fantasy, and this technology has proven to be extremely effective in increasing machining efficiency and improving tool life because high-pressure jet cooling technology can effectively eliminate cutting areas in the first place. The cutting heat allows for higher or higher cutting parameters to be used without having to worry about the high cutting temperatures resulting in more cutting heat. From the surface and intuition you may feel that it is incredible to achieve such obvious efficiency improvement only by the rapid removal of cutting heat, but when you know that using HPC high pressure spray cooling instead of the traditional cooling method can make you achieve five times the cutting Will you hesitate if the speed increases?
The Sandvik Coromant CoroTurn 300 tool performs high-efficiency cutting in a two-way high-pressure spray (from the rake face and the flank face, respectively)
You don't have to worry about the HPC high-pressure spray cooling function, because you can completely transform the existing conventional cooling method and low-pressure coolant mode to achieve advanced high-pressure spray cold processing. Many tool companies have tool holders, tool holders, cooling system integrated modules and related process technologies for high-pressure spray cooling. These modified tool holders and toolholder systems can be processed in two-way high-pressure spray cooling, which is very effective. At the first time, the high-pressure coolant is sprayed toward the cutting area, thereby instantaneously removing the cutting heat.
Streamline suppliers or brands
The optimization of the cost of blade single-edged is important, but it is by no means an optimization. Choosing good tools for turning is a common cognition, but as a more savvy metal cutting expert, how to manage the tool warehouse scientifically and efficiently is also very important. Over the years, various tool brands and blade grades in the tool warehouse have come. The more and the mix of fish and dragons, maybe the parameter ability of inpidual blades can even run back to the level of CNC Machining just launched in the same year. The knives and salesmen who are passionate and good at selling will always find ways to get your tools in the past. Exhausted, you need to convince you to introduce a new set of tool brands before replenishment, which makes your inventory increasingly bloated and difficult to manage.
If the customer selected tool supplier has previously performed brand demonstration to ensure continuous improvement of efficiency and tool life, then select “IoT plus tool self-service vending machine” that can be used to monitor and manage the tool in real time. The new cooperation model means: zero-distance supply for the fastest delivery; zero-stock supply for cost optimization, it can help customers jointly enhance their core competitiveness and meet new challenges!
A new and efficient tool self-selection and management strategy is to configure the “IoT plus tool self-service vending machine” for real-time monitoring and management of tools on the customer's production site.
Taking the processing of nickel-based alloy shaft parts as an example, it is a troublesome thing to process conventional material parts. There may be one on the C-type inserts that use the conventional 80° blade angle. A lot of different options, if we do not focus on the selection, it means that we must face the understanding, screening, testing, reporting analysis, evaluation, etc. of many products, the results are not necessarily the most efficient of.
Optimization does not mean maximizing
When expecting and pursuing the excellence of turning tools, it is important to note that “optimization does not mean maximizing”. Even the longest actual service life of the tool or the maximum number of machineable parts does not mean the optimization of the actual machining cost. In many cases, the tool may continue to process 30 parts until there is enough wear or cutting edge that should be replaced, but from the impact of machining reliability on the overall economics of the process, perhaps when the tool is machined It is the best choice when it is replaced by the 25th part. In addition, even if the tool is working under a certain combination of cutting parameters and can maintain a very long tool life, this does not mean that it is the best combination of cutting parameters, in fact, if the actual continuous cumulative cutting life of the tool is 15min The left and right are optimal. The combination of cutting parameters corresponding to this service life is often the recommended combination of the cutting parameters for the specific workpiece material. The longer the tool can be used, the lower the cost.
If possible, all tools that just use the service life (ie the synchronous life design strategy of the product portfolio) should be replaced at the same time and at regular intervals.
The replacement life and replacement time of the tool should not be calibrated and separated from each other, but should be replaced according to a reasonable and regular synchronization interval. The most ideal state for processing should be: minimize the number of times of door opening and tool change. And time, to achieve predictable and regular and reasonable interval tool replacement, so that the machine tool and processing system maintain a good continuous independent processing work to free up enough regular time for other work. To achieve this effect, the previous process planning preparation, simultaneous optimization of tool life, optimization and integration of cutting parameters, management and operational regulation are prerequisites.
In some cases, inpidual tools are used for a period of time that is too low or extremely durable, and have a much longer service life than other tools. In this case, a time limit for mandatory tool change can be established by using regular rules. When the other tools are replaced uniformly, for example, in a group of turning tools, the service life of the roughing tool is 18min, the service life of the finishing tool is 67min, and the service life of the grooving tool is 39min. The following replacement time rules are achieved by optimizing the cutting parameters of each tool:
(1) Optimize the service life of the roughing tool to 15 minutes, and replace the roughing tool at the 15th minute;
(2) Optimize the service life of the grooving tool to 30 minutes, and replace the roughing tool and the grooving knife at the 30th minute;
(3) Replace the roughing tool at the 45th minute;
(4) Optimize the service life of the finishing tool to 60 minutes, and replace the coarse, fine and grooving tools at the 60th minute;
Cycle the above replacement rules.
Keep it clean and orderly and reliable
More than keeping your work area neat and orderly, it is more important to do routine maintenance of the machine tools and tools in the workshop and to ensure reliable working conditions, such as neglecting the daily maintenance and good working status of the tool holder. Or keep, such negligence is often caused by poor blade service life, poor processing quality of the workpiece, unstable processing quality, high defect rate, and even does not rule out more serious catastrophic accidents or losses.
Regularly and regularly checking and confirming the quality, effectiveness and reliability of the blade mounting groove on the tool holder is a very important task to ensure efficient operation of the turning system.
Regular inspection of the blade mounting seat is very important. The main aspects are to check the degree of wear and deformation of each positioning surface of the blade seat, whether the blade is intact, whether there is crack, and whether the blade clamping mechanism is still in good condition. Whether the blade can still be clamped very effectively, whether there is a gap between the blade and the positioning surface, whether the positioning pin is intact, and the like. The tool bar itself should be dismantled regularly from the machine tool holder or turret for inspection and safety confirmation. For example, after every 20-30 times of tool tip change, it depends on the customer's own grasp of the processing rules. The accumulated debris remaining in the blade holder groove should be cleaned in time to avoid affecting the correct installation of the blade, timely finding the damage in the blade seat groove of the tool bar or other such as the clamping mechanism, and timely using the fitter, oil stone, etc. Repair, but when the arbor does show obvious damage, it should not be replaced when it should be used.
Make timely records
Establishing and developing a system that requires all necessary data and information to be recorded in the first time in a work file induction system based on a PC desktop or tablet is essential, even if it is impossible to equip each device with one. , but must have at least one per production unit.
Institutionalization and normalization use the templated work log table to do daily work information document recording and management is to improve the basic protection of on-site scientific management, so as to ensure that all necessary information is recorded and saved in time for continuous inquiry, Tracking, reference, avoiding repetitive mistakes due to personnel changes and adjustments to experience cliffs.
The production workshop should be equipped with at least one working file recording device on a PC desktop or tablet basis for each production unit (floor) to standardize the necessary information data archiving. Of course, it is best to equip each device.
Even if the production workshop does not have such equipment and does not have such conditions for centralized data management of tools, it can also use various public resources or various APP software on the platform to obtain calculations such as processing efficiency and technical training materials. Sharing applications such as blade performance and performance identification make process engineers more comfortable, and can also use the rich resources and experience of the cloud tool library's big data system to find their own process, programming, etc. Rely on, support and strength.
Continuous learning and training
Today is an era in which new knowledge and new technologies are rapidly developing and full of fierce competition. Continuous learning is so necessary. Some companies have revoked the special process technology department, and instead let the first-line engineers in the workshop undertake and prepare technical work for the process plan, manufacturing plan, programming, tool selection, cutting parameter determination and so on.
In fact, the requirements for first-line turning operations engineers are getting higher and higher in terms of tool knowledge, design techniques, and usage skills. They must be able to handle almost all related work independently. Therefore, they should receive continuous training. Many industry suppliers of machine tools, fixtures, tools, software, etc., or their agents have a variety of regular training courses. Some of these courses are traditional face-to-face teaching modes. But more are online online training, corporate preset training, and so on.
For example, in a similar course offered by many tool companies, Sandvik Coromant has recommended the following training for turning engineers on its website:
Why is it possible to optimize the cutting force with a larger depth of cut than the tip radius?
Why is higher cutting line speed most effective for increasing blade life?
How to apply the blade wiper technology to achieve high efficiency, high surface roughness quality requirements for turning?
Why is the larger the cutting main deflection angle is more conducive to slowing the cutting vibration? And is it beneficial to improve cutting feed?
In addition: Please don't forget that the technical service specialists of machine tool companies and tool companies have accumulated a wealth of relevant technologies, knowledge and experience while providing services to a wide range of customers all the year round. How to get their services and support frequently? Brainstorming advice is well worth it.
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