Railway products use efficient tools to increase production efficiency

Zhao Wenhao, Process Engineer, Manufacturing Engineering Department, Dalian Locomotive Research Institute Co., Ltd., China CNR Group

As a mechanical processing enterprise for railway products, cutting processing is still our main process. Our company mainly produces pistons on diesel engines of diesel locomotives (see photo), superchargers and other components. The key components are low carbon alloy steel, wrought aluminum alloy and ductile iron, most of which are forged blanks and cast blanks. . Due to the high precision requirements of the products, the shape and shape of the parts are numerous, and most of the machining machines are CNC machine tools, including CNC lathes, CNC milling machines, turning centers, machining centers, etc., so the selection of CNC cutting tools for machining is especially important.

Imported tools are still mainstream:

Since the annual output of our products is about 10,000 sets, it can be regarded as a mass production mode. Therefore, the quality and service life of the tools are high. Most of the choices are imported tools, such as the main choice of turning tools. Ska, Kenner and other brands, milling cutters choose Sandvik Coromant, Seco, Kyocera and other brands, taps select YAMAWA, OSG and other brands, with standard turning tools, standard milling cutters, mainly used for half Finishing and finishing, using high-speed and low-feeding, grinding by car, surface roughness can reach Ra=1.6μm, the effect is still very good. The annual consumption of tools is very large. It has been counted that the total annual consumption of more than 20 kinds of tools is about three or four thousand pieces, and the total cost is also quite high. During the period, some domestically produced Zhuzhou diamonds, Taiwan Zhengheyuan and other tools were used, which were relatively inferior, mainly due to the insufficiency of service life. For example, a blade can be processed by foreign imports of 30 pieces, while domestically produced only 25 pieces can be processed. about.

piston

In the processing process, standard tools account for 60%, non-standard tools account for 40%, most non-standard tools are found by domestic tool processing manufacturers to use their proprietary equipment for production, in the early stage also looked for foreign brand tool manufacturers, because the price is too Expensive, although the current domestic non-standard tool processing manufacturers are cheaper, but the product quality and processing level is still visible, the tool life is low, and the tool material and coating technology. Taps are more commonly used in our company because the pistons and superchargers are assembled by bolts, and the bolt holes on the parts are machined by taps. At present, there is no tap with relatively high cost performance. Although there are famous brands of YAMAWA and OSG, we have been using it, but the price/performance ratio is not very high. This requires domestic tool manufacturers to make cost-effective taps, which are both easy to use and cheap.

Due to improper selection of cutting parameters, the cutting tool will have large cutting force, high cutting temperature and easy tool wear. Especially for machining different parts such as alloy steel, aluminum alloy and cast iron, how to choose the most suitable cutting besides the different tool materials. Parameters to reduce tool wear are especially important.

Several expectations for domestic tool manufacturers:

With the rapid development of the machining industry, the domestic cutting tool industry must keep up with the pace of modernization, from research and development capabilities to manufacturing levels, and accelerate the development of the domestic cutting tool industry. Here are some expectations for domestic tool manufacturers:

(1) It is necessary to master powder metallurgy high-speed steel to manufacture tools and improve the level of high-speed steel tools. Powder metallurgy high-speed steel has excellent performance, high strength, high hardness, high toughness, high wear resistance and good processability. It will inevitably replace cemented carbide into the mainstream in the future. Mastering its processing and preparation will give the domestic processing industry. Bring new changes.

(2) Accumulate the application of new materials and new coatings. The large-scale construction of high-speed railways and urban rail transit in China has brought huge market and business opportunities to the new materials market. It is believed that cutting tools will also be the same, satisfying the processing needs of various enterprises and actively adapting to the needs of customers.

(3) Guarantee the reliability and stability of the output of the tool products. The reliability and stability of tool quality has not only gained the trust of users, but also established the brand awareness of the tool.

(4) Ability to provide timely delivery. Most of the manufacturing industries are mass-produced. When the supply is insufficient, the company will lose a large number of orders and damage the company's honor.

(5) Technical personnel must have the ability to solve on-site cutting problems in a timely and accurate manner. Sometimes, due to a certain cutting parameter or an inappropriate selection of an angle, the result that the customer wants is not achieved. When the customer is in urgent need of help, whether it is on-site or telephone communication, the solution will be provided in time. The customer solves the problem.

The application of high-efficiency tools is an irreplaceable means to improve production efficiency. We must pay attention to the technology of tool application and jointly improve the level of metal cutting in China.

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