In recent years, China's machine tools and tool consumption have consistently ranked first in the world. Foreign well-known tool suppliers have entered China, occupying a large market share. At the same time, domestic tool companies are catching up, learning and innovating. It has achieved gratifying results; domestic aviation users have also continuously improved their tools through their own actual needs in production or cooperation with tool suppliers to develop and innovate independently; major scientific research institutions have become the main force for major key technology research and development. Key laboratories, key research projects have made important contributions to the development of tool technology and products.
In this survey, the distribution of survey objects is shown in Figure 1.
Efficient tool key technology
How modern and efficient tools adapt to the rapidly evolving world today, enabling users to maximize efficiency, maximize profitability, optimize quality, and continuously improve and innovate key technologies. The survey shows that tool materials, tool coatings, and tool structures are the main focus of the development of key tools for efficient tooling.
1 The decisive role of tool materials
The survey results show that the tool material is the basis of tool research and development and application. The development of tool material has a decisive influence on the cutting performance of the tool. Widely used tool materials include high speed steel, hard alloy, and superhard tool materials (including ceramics, cubic boron nitride, polydiamond, etc.). With the continuous development of the manufacturing industry, cemented carbide is replacing high-speed steel as the main tool material, and the proportion of super-hard tool materials is also increasing. Among the well-known tool suppliers, Seco Jabro's new solid carbide general-purpose milling cutter S oli d2 series can be used to increase the machining efficiency from 800 °C to 1100 °C. And tool life, the cost performance of the tool has been greatly improved. On the other hand, with the development of dry cutting and hard cutting, foreign companies have introduced new grades of ceramic and superhard tool materials.
2 tool coating can not be underestimated
Tool coating technology also plays an important role in improving tool performance and advances in cutting technology. In the investigation, the reporter learned that PVD is in the stage of rapid development in recent years. For different cutting processing application conditions, the composition and structure of the film can be selected, and the appropriate cutting method can be used to obtain satisfactory cutting effect. Great potential and unique advantages of tool performance. At the same time, in order to improve the efficiency of processing non-ferrous metals and non-metallic materials such as aluminum alloys, diamond coatings have been further applied, covering indexable tools and solid carbide tools.
3 Tool structure innovation speeds up
The innovation of the tool structure is reflected in the optimization of the tool structure, the reasonable distribution of the cutting load, the development of the three-dimensional chipbreaking groove, the development of the spiral blade with the rake angle and the development of the small-scale shallow hole drill. New indexable insert structures, such as high-efficiency squeegee blades for turning, complex angled insert blades, ball end mill blades, etc. Tool structure optimization and geometric parameters are more reasonable in order to improve and improve tool performance. Various new indexable tools not only have new breakthroughs in turning, milling and drilling applications, but also expand to broaching and gear processing. The field of processing of complex shapes. For example, Sandvik Coromant's Co r oMi ll 316 is the first interchangeable head milling product range that covers a diameter range of 10 to 25 m m due to its new chamfer and fillet radius carbide cutting head range The expansion is suitable for more applications. The tool holder and the interchangeable end mill are connected by a unique threaded interface, achieving a perfect combination of high strength and high precision.
Efficient tooling in the field of aviation
1 Application status
In the investigation, the reporter learned that with the development of materials science and processing technology, many high-strength lightweight alloy materials (such as titanium alloy, nickel-based alloy, new high-strength steel, etc.) and composite materials have been widely used in the aviation field, among which Titanium alloys account for a larger proportion of all materials in the engine. High-temperature alloys replace heat-resistant steels as the main material for high-temperature environmental components, and begin to use lighter carbon fiber composites instead of the original aluminum alloys or steels. Greatly reduce the weight of the whole machine. However, at the same time, the special physical and mechanical properties of these new materials make them a typical difficult-to-machine material, which puts higher demands on the processing tools.
In the selection of cutting tools, aviation companies still prefer well-known tool brands with good cost performance and high reliability, such as Sandvik, Seco, ISC AR, Kenner, Sentai Yingge, Walter, etc. Domestic brands include Zhuzhou Diamond. Harbin, Shanggong, Shaanxi Hard, Southwest Tools, etc. Among them, the proportion of cemented carbide tools, ceramic tools, CBN tools, high-speed steel tools is shown in Figure 2. Combined with the feedback in Figure 2 and the investigation process, it can be seen that the cemented carbide tool is the most widely used; the ceramic tool is mainly used for non-interrupted machining; the proportion of CBN tool is slightly inferior to that of ceramic tool, but it is on the rise in use. The application of high speed steel tools is significantly reduced compared to the previous.
2 Problems and solutions in the application
Through the investigation of aviation users, the following problems and solutions are summarized:
(1) The selection of tool materials is the key to efficient machining. When selecting, you must consider the matching between them and the workpiece materials to make reasonable selection. Otherwise, it will be half the effort. For example, stainless steel or titanium alloy containing T i is not suitable for the selection of P-type cemented carbide tools, because it is easy to cause the bonding wear of the tool.
(2) In the NC machining process, the main goal of rough machining is to remove more materials in the shortest time, but for difficult materials such as titanium alloy, traditional tools are difficult to meet high-efficiency machining requirements: such as high-speed steel cutter wear-resistant Poor sex, welded insert alloy tools are easy to change the blade material due to welding technology problems, the overall alloy tool cost is too high, the toughness is poor. In the survey, the aviation users summarized the rough machining using the indexable corn milling cutter for strong cutting with large depth and small feed; before the finishing, the rounding was used to machine the fillet to ensure uniform finishing allowance; finishing The process uses a coated carbide tool to achieve high depth milling with a small depth of cut and large feed (cutting speed over 120m/min).
(3) In recent years, composite materials have developed rapidly and are widely used in the aerospace industry. Among them, fiber-reinforced resin-based composite materials and hard-particle-reinforced metal matrix composites are difficult to cut. In the selection of tools, PCD is the best choice. Diamond tools and PCBN tools.
(4) For the processing characteristics of aluminum alloy, superhard tools such as ceramic, diamond and cubic boron nitride with high wear resistance can be selected, which are very suitable for high-speed machining of aluminum alloy.
In this survey, the distribution of survey objects is shown in Figure 1.
Efficient tool key technology
How modern and efficient tools adapt to the rapidly evolving world today, enabling users to maximize efficiency, maximize profitability, optimize quality, and continuously improve and innovate key technologies. The survey shows that tool materials, tool coatings, and tool structures are the main focus of the development of key tools for efficient tooling.
1 The decisive role of tool materials
The survey results show that the tool material is the basis of tool research and development and application. The development of tool material has a decisive influence on the cutting performance of the tool. Widely used tool materials include high speed steel, hard alloy, and superhard tool materials (including ceramics, cubic boron nitride, polydiamond, etc.). With the continuous development of the manufacturing industry, cemented carbide is replacing high-speed steel as the main tool material, and the proportion of super-hard tool materials is also increasing. Among the well-known tool suppliers, Seco Jabro's new solid carbide general-purpose milling cutter S oli d2 series can be used to increase the machining efficiency from 800 °C to 1100 °C. And tool life, the cost performance of the tool has been greatly improved. On the other hand, with the development of dry cutting and hard cutting, foreign companies have introduced new grades of ceramic and superhard tool materials.
2 tool coating can not be underestimated
Tool coating technology also plays an important role in improving tool performance and advances in cutting technology. In the investigation, the reporter learned that PVD is in the stage of rapid development in recent years. For different cutting processing application conditions, the composition and structure of the film can be selected, and the appropriate cutting method can be used to obtain satisfactory cutting effect. Great potential and unique advantages of tool performance. At the same time, in order to improve the efficiency of processing non-ferrous metals and non-metallic materials such as aluminum alloys, diamond coatings have been further applied, covering indexable tools and solid carbide tools.
3 Tool structure innovation speeds up
The innovation of the tool structure is reflected in the optimization of the tool structure, the reasonable distribution of the cutting load, the development of the three-dimensional chipbreaking groove, the development of the spiral blade with the rake angle and the development of the small-scale shallow hole drill. New indexable insert structures, such as high-efficiency squeegee blades for turning, complex angled insert blades, ball end mill blades, etc. Tool structure optimization and geometric parameters are more reasonable in order to improve and improve tool performance. Various new indexable tools not only have new breakthroughs in turning, milling and drilling applications, but also expand to broaching and gear processing. The field of processing of complex shapes. For example, Sandvik Coromant's Co r oMi ll 316 is the first interchangeable head milling product range that covers a diameter range of 10 to 25 m m due to its new chamfer and fillet radius carbide cutting head range The expansion is suitable for more applications. The tool holder and the interchangeable end mill are connected by a unique threaded interface, achieving a perfect combination of high strength and high precision.
Efficient tooling in the field of aviation
1 Application status
In the investigation, the reporter learned that with the development of materials science and processing technology, many high-strength lightweight alloy materials (such as titanium alloy, nickel-based alloy, new high-strength steel, etc.) and composite materials have been widely used in the aviation field, among which Titanium alloys account for a larger proportion of all materials in the engine. High-temperature alloys replace heat-resistant steels as the main material for high-temperature environmental components, and begin to use lighter carbon fiber composites instead of the original aluminum alloys or steels. Greatly reduce the weight of the whole machine. However, at the same time, the special physical and mechanical properties of these new materials make them a typical difficult-to-machine material, which puts higher demands on the processing tools.
In the selection of cutting tools, aviation companies still prefer well-known tool brands with good cost performance and high reliability, such as Sandvik, Seco, ISC AR, Kenner, Sentai Yingge, Walter, etc. Domestic brands include Zhuzhou Diamond. Harbin, Shanggong, Shaanxi Hard, Southwest Tools, etc. Among them, the proportion of cemented carbide tools, ceramic tools, CBN tools, high-speed steel tools is shown in Figure 2. Combined with the feedback in Figure 2 and the investigation process, it can be seen that the cemented carbide tool is the most widely used; the ceramic tool is mainly used for non-interrupted machining; the proportion of CBN tool is slightly inferior to that of ceramic tool, but it is on the rise in use. The application of high speed steel tools is significantly reduced compared to the previous.
2 Problems and solutions in the application
Through the investigation of aviation users, the following problems and solutions are summarized:
(1) The selection of tool materials is the key to efficient machining. When selecting, you must consider the matching between them and the workpiece materials to make reasonable selection. Otherwise, it will be half the effort. For example, stainless steel or titanium alloy containing T i is not suitable for the selection of P-type cemented carbide tools, because it is easy to cause the bonding wear of the tool.
(2) In the NC machining process, the main goal of rough machining is to remove more materials in the shortest time, but for difficult materials such as titanium alloy, traditional tools are difficult to meet high-efficiency machining requirements: such as high-speed steel cutter wear-resistant Poor sex, welded insert alloy tools are easy to change the blade material due to welding technology problems, the overall alloy tool cost is too high, the toughness is poor. In the survey, the aviation users summarized the rough machining using the indexable corn milling cutter for strong cutting with large depth and small feed; before the finishing, the rounding was used to machine the fillet to ensure uniform finishing allowance; finishing The process uses a coated carbide tool to achieve high depth milling with a small depth of cut and large feed (cutting speed over 120m/min).
(3) In recent years, composite materials have developed rapidly and are widely used in the aerospace industry. Among them, fiber-reinforced resin-based composite materials and hard-particle-reinforced metal matrix composites are difficult to cut. In the selection of tools, PCD is the best choice. Diamond tools and PCBN tools.
(4) For the processing characteristics of aluminum alloy, superhard tools such as ceramic, diamond and cubic boron nitride with high wear resistance can be selected, which are very suitable for high-speed machining of aluminum alloy.
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