Dr. Ulrich Walter, turning specialist at Emeg Machine Tool, pointed out from a machine tool builder that the development of cutting-related technologies (such as tool clamping, tool change, workpiece handling) is not commensurate with the development of cutting technology itself. He believes that the use of standard machine tools for large-scale “Komplettbearbeitung†is wrong. Therefore, Emeg's approach is to determine the manufacturing solution for the machining task, including the use of composite machining (Kombibearbeitung). Despite the advancement of hard turning due to the continued development of CBN tool materials, grinding is still required, and the company's VCS series machines can perform dry turning and grinding in one setup of the workpiece. Since the CBN grinding wheel is used for grinding and is only used for finishing, it is possible to extend the interval between corrections twice, which is advantageous for improving the stability of the processing quality.
Saving time for tool change Approximately 1/3 of the total machining time is done for workpiece measurement or tool change, resulting in the idea of ​​“can change the tool without taking up timeâ€, Dr. Dieter Kress of Mapal If so. Can I use as many different steps as possible with the same tool? The circumferential milling cutter developed by Mapal can process both flat and machined holes. For example, it can be used for machining different parts when machining the gearbox housing. Another example is Kress's “Complete Machining†tool, which combines the pupil and the boring plane with the machining transition surface and the step by the corresponding design and the arrangement of the blade to complete the inner and outer surfaces in one pass. Processing.
Komet's tools have also shown similar features, and the company's adjustable precision boring tool can produce high precision holes. The tool is powered by the induction device and automatically measures the hole diameter. The machine's CNC system automatically compensates for tool wear based on the measurement results. In addition, as Komet's "U-Axis System", the tool can be radially adjusted on this mechatronic cutting device, which significantly expands the tool's processing range.
The shank has the potential to be digged. The shank is increasingly important for the machining process. Dr. Dieter Kress said: Although Germany can be proud of the HSK holder, it still needs to pay enough attention to the holder. Mapal has developed a practical tool holder, the HFS (Head Fitting System) system, which has a cutting fluid channel, simple operation, reliable use, high clamping accuracy, and can hold CBN, PCD, coated tools, etc. High precision tool.
The application of composite machine tools puts new demands on the tool. The price of composite machine tools is expensive, and it has a market share of 15% in Japan. With composite machine tools, it can complete various processes such as turning, milling and grinding in one setup. The tool holders required for the machining of composite machines should carry tool data for control and sharing by IT. “To do this, we have to develop a new universal language standard,†said Eric Tjernstroem of Sandvik Coromant. Tjernstroem also cites an example of Mazak. The company's machine tools can be machined with B, Z, and X axes. On such machines, "complete machining" is performed. The B axis is even rotated 45°, using general tools. It is impossible. The "Twin-Tool" toolholder developed by Sandvik, thanks to its versatile cutting angle, allows the same system to be used for turning and milling. The same blade can be used for roughing and finishing.
Micro-lubrication (MMS) is still a hot topic For many years, people have been trying to reduce the amount of cutting fluid, or even not at all. Since the cutting fluid treatment only filters out impurities larger than 0.03 mm, an average of 9 cents of sewage charges per 1000 L of emulsion is discharged, which is a big burden for mass production. For example, in the processing of the automobile transmission case, the cost of sewage disposal for each workpiece is about 40 minutes, which is equivalent to 30% to 40% of the total tool cost. Ford Motor Company's Alexander Stoll said the company has applied micro-lubrication technology to the processing of automotive powertrain components. For example, in the control valve production line, the die-casting of an aluminum alloy casing is quasi-dry cutting, the quality of the product and the processing efficiency are not affected, and the processing cost can be significantly reduced. However, Stoll pointed out that switching to micro-lubrication must be prudent because controlling the propagation and diffusion of heat in efficient machining and dry cutting is a big problem. At the company's Vorfeld plant, thermal analysis and non-contact sensors are used to accurately analyze the heat transfer and distribution, thereby improving the process. Ford Motor Company's practice in mass production is to monitor 80% of the area associated with the heated zone by the PT100 sensor, and the data sampled every 4 seconds is used as the control signal.
A similar situation was reported by Grob's Thomas Glueder, a device manufacturer that uses one or two channels of MMS in the machining of cylinders and gearboxes. Grob has been developing dry-cut machines since 1996. Since those machines are horizontal, the bed is swarfed. These experiences indicate that the lack of knowledge about temperature distribution and the treatment it deserves is difficult to use in MMS. Therefore, temperature control of tools, fixtures, etc. is required in advance in new projects.
According to Peter Haenle of Gühring, MMS is not only economically superior to conventional wet processing, but also contributes to chip processing. The company has achieved significant results with MMS on solid carbide drills. In this new type of drill bit, the positive rake angle not only makes the chip temperature lower, the length is shorter, but also easier to remove from the cutting area. At the same time, the drill bit also adopts the groove type and special chip flute suitable for MMS. The coating also allows the MMS air medium to reach a flow rate ten times that of the casting emulsion. Another advantage of MMS is the low amount of cutting fluid. A user of Gühring drills oil holes on the crankshaft (hole depth 20D), which does not require chipping during machining. The feed rate is 10-12 higher than that of carbide single-edged drill. Times, MMS consumption is 15ml per hour, which also extends the life of the tool.
Professor Klaus Weinert from the University of Dortmund's School of Cutting and Machining pointed out that in the case of high-alloy steels with more and more cutting operations, an updated cooling method can be expected, using "dry water".
A comprehensive mastery of tool manufacturing technology Walter's tooling experts report the company's approach to reducing machining forces with large positive rake angles to increase machining efficiency. The company's Dr. Michael Mueller demonstrated the effects of geometric angles, tool materials, and coatings. This is also a trend now. In addition to the coating process, the cemented carbide sintering process plays a decisive role.
A similar note by Dr. Tilo Krieg of Kennametal, tool manufacturers have proprietary technology, and users should pay attention to these proprietary technologies. He cited the company's SiAlON ceramics, which are particularly suitable for processing superalloys and cast irons. They are tool materials developed through proprietary process technologies that significantly improve tools when machining nickel-base superalloys compared to conventional Si3N4. Life expectancy can also save processing costs by a quarter.
The conference report also mentions a finite element software for designing tools, which is characterized by the definition of specific and repetitive load or stress conditions for a defined tool type. The software's calculation module includes the various components of the tool, such as the body, clamp Tightening and adjusting components, etc.
An Eternal Topic When selecting the report, the organizers of the seminar selected 22 reports, including the common topics in the past few years – machining strategy, cutting technology, measurement technology and mass production technology.
It is worth noting that most of the user companies that spoke at the meeting seemed to be less worried about cutting efficiency, and more concerned about shortening the total processing time – this eternal topic. As Weldemar Zielasko from Daimler Chrysler said, now we should do something to shorten the assist time.
Saving time for tool change Approximately 1/3 of the total machining time is done for workpiece measurement or tool change, resulting in the idea of ​​“can change the tool without taking up timeâ€, Dr. Dieter Kress of Mapal If so. Can I use as many different steps as possible with the same tool? The circumferential milling cutter developed by Mapal can process both flat and machined holes. For example, it can be used for machining different parts when machining the gearbox housing. Another example is Kress's “Complete Machining†tool, which combines the pupil and the boring plane with the machining transition surface and the step by the corresponding design and the arrangement of the blade to complete the inner and outer surfaces in one pass. Processing.
Komet's tools have also shown similar features, and the company's adjustable precision boring tool can produce high precision holes. The tool is powered by the induction device and automatically measures the hole diameter. The machine's CNC system automatically compensates for tool wear based on the measurement results. In addition, as Komet's "U-Axis System", the tool can be radially adjusted on this mechatronic cutting device, which significantly expands the tool's processing range.
The shank has the potential to be digged. The shank is increasingly important for the machining process. Dr. Dieter Kress said: Although Germany can be proud of the HSK holder, it still needs to pay enough attention to the holder. Mapal has developed a practical tool holder, the HFS (Head Fitting System) system, which has a cutting fluid channel, simple operation, reliable use, high clamping accuracy, and can hold CBN, PCD, coated tools, etc. High precision tool.
The application of composite machine tools puts new demands on the tool. The price of composite machine tools is expensive, and it has a market share of 15% in Japan. With composite machine tools, it can complete various processes such as turning, milling and grinding in one setup. The tool holders required for the machining of composite machines should carry tool data for control and sharing by IT. “To do this, we have to develop a new universal language standard,†said Eric Tjernstroem of Sandvik Coromant. Tjernstroem also cites an example of Mazak. The company's machine tools can be machined with B, Z, and X axes. On such machines, "complete machining" is performed. The B axis is even rotated 45°, using general tools. It is impossible. The "Twin-Tool" toolholder developed by Sandvik, thanks to its versatile cutting angle, allows the same system to be used for turning and milling. The same blade can be used for roughing and finishing.
Micro-lubrication (MMS) is still a hot topic For many years, people have been trying to reduce the amount of cutting fluid, or even not at all. Since the cutting fluid treatment only filters out impurities larger than 0.03 mm, an average of 9 cents of sewage charges per 1000 L of emulsion is discharged, which is a big burden for mass production. For example, in the processing of the automobile transmission case, the cost of sewage disposal for each workpiece is about 40 minutes, which is equivalent to 30% to 40% of the total tool cost. Ford Motor Company's Alexander Stoll said the company has applied micro-lubrication technology to the processing of automotive powertrain components. For example, in the control valve production line, the die-casting of an aluminum alloy casing is quasi-dry cutting, the quality of the product and the processing efficiency are not affected, and the processing cost can be significantly reduced. However, Stoll pointed out that switching to micro-lubrication must be prudent because controlling the propagation and diffusion of heat in efficient machining and dry cutting is a big problem. At the company's Vorfeld plant, thermal analysis and non-contact sensors are used to accurately analyze the heat transfer and distribution, thereby improving the process. Ford Motor Company's practice in mass production is to monitor 80% of the area associated with the heated zone by the PT100 sensor, and the data sampled every 4 seconds is used as the control signal.
A similar situation was reported by Grob's Thomas Glueder, a device manufacturer that uses one or two channels of MMS in the machining of cylinders and gearboxes. Grob has been developing dry-cut machines since 1996. Since those machines are horizontal, the bed is swarfed. These experiences indicate that the lack of knowledge about temperature distribution and the treatment it deserves is difficult to use in MMS. Therefore, temperature control of tools, fixtures, etc. is required in advance in new projects.
According to Peter Haenle of Gühring, MMS is not only economically superior to conventional wet processing, but also contributes to chip processing. The company has achieved significant results with MMS on solid carbide drills. In this new type of drill bit, the positive rake angle not only makes the chip temperature lower, the length is shorter, but also easier to remove from the cutting area. At the same time, the drill bit also adopts the groove type and special chip flute suitable for MMS. The coating also allows the MMS air medium to reach a flow rate ten times that of the casting emulsion. Another advantage of MMS is the low amount of cutting fluid. A user of Gühring drills oil holes on the crankshaft (hole depth 20D), which does not require chipping during machining. The feed rate is 10-12 higher than that of carbide single-edged drill. Times, MMS consumption is 15ml per hour, which also extends the life of the tool.
Professor Klaus Weinert from the University of Dortmund's School of Cutting and Machining pointed out that in the case of high-alloy steels with more and more cutting operations, an updated cooling method can be expected, using "dry water".
A comprehensive mastery of tool manufacturing technology Walter's tooling experts report the company's approach to reducing machining forces with large positive rake angles to increase machining efficiency. The company's Dr. Michael Mueller demonstrated the effects of geometric angles, tool materials, and coatings. This is also a trend now. In addition to the coating process, the cemented carbide sintering process plays a decisive role.
A similar note by Dr. Tilo Krieg of Kennametal, tool manufacturers have proprietary technology, and users should pay attention to these proprietary technologies. He cited the company's SiAlON ceramics, which are particularly suitable for processing superalloys and cast irons. They are tool materials developed through proprietary process technologies that significantly improve tools when machining nickel-base superalloys compared to conventional Si3N4. Life expectancy can also save processing costs by a quarter.
The conference report also mentions a finite element software for designing tools, which is characterized by the definition of specific and repetitive load or stress conditions for a defined tool type. The software's calculation module includes the various components of the tool, such as the body, clamp Tightening and adjusting components, etc.
An Eternal Topic When selecting the report, the organizers of the seminar selected 22 reports, including the common topics in the past few years – machining strategy, cutting technology, measurement technology and mass production technology.
It is worth noting that most of the user companies that spoke at the meeting seemed to be less worried about cutting efficiency, and more concerned about shortening the total processing time – this eternal topic. As Weldemar Zielasko from Daimler Chrysler said, now we should do something to shorten the assist time.
Rare Earth Magnets For Sale,Cylindrical Rare Earth Ndfeb Magnet,Rare Earth Magnetic Strip
Sunxal Magnetics Co., Ltd. , http://www.hlmagnets.com