Development and application of modern cutting technology?

What is the development status of modern cutting technology? How is it applied in processing? Please read the article edited by Zhong Da Consulting Company.

As the main basic technology of manufacturing technology, cutting is the main processing technology of automobile industry, aerospace industry, energy industry, military industry, emerging mold industry, electronic industry and other departments, and it is also an important factor for the rapid development of these industrial departments.

Although near-net-shape forming technology and stacking forming technology are promising new technologies, the position of cutting as the main basic technology of manufacturing technology has not changed. On the contrary, cutting technology has entered a new period of rapid development-modern cutting technology stage. Therefore, understanding and mastering the development mechanism of modern cutting technology, understanding its technical characteristics and development trend, and how to apply modern cutting technology to improve machining efficiency are important topics in the current machining industry.

1, the development mechanism of modern cutting technology

Cutting has become a professional technology from the end of 19 to the beginning of the 20th century, which has gone through a whole century. Since the advent of cutting technology, it has played an important role and made important contributions to the industrialization and economic development of industrialized countries. Although the cutting technology itself has made great progress in this process, it did not exceed the scope of traditional cutting technology as a whole until the 1970s. Its most prominent sign is that the development and production of tools are basically separated from the use and users of tools, and there is no mechanism for mutual promotion and development.

Due to the rapid development of emerging science and technology, such as computer, microelectronics and material science, which are closely related to cutting technology, cutting technology has also developed rapidly with the development of manufacturing industry and manufacturing technology, and entered a new stage of modern cutting technology. Compared with traditional cutting technology, modern cutting technology not only embodies faster cutting speed and higher machining efficiency, but also forms a new development mechanism, which has become an important technical factor to promote the development of manufacturing industry and modern manufacturing technology.

For a long time after the advent of cutting technology, there is a problem that has been puzzling the tool industry and tool users, that is, if you use expensive and good tools to cut, although it can improve cutting efficiency, it will increase manufacturing costs, which users think is not worth the candle. Therefore, many users are unwilling to spend more money to buy a good tool, or worry that the tool will soon wear out after buying a good tool, and set the life of the tool to be very long. These concepts and practices hinder the renewal of tools, affect the enthusiasm of tool manufacturers to develop new tools, and restrict the improvement of cutting efficiency and the progress of cutting technology.

Facts have proved that if you don't pay attention to improving cutting efficiency when using good tools, you can only get very limited results in reducing manufacturing costs, and may even be counterproductive. The internal relationship between improving cutting technology and creating considerable benefits for users and society has been recognized and accepted by more and more tool manufacturers and tool users, and has been transformed into a powerful driving force to promote cutting technology progress. In just about 20 years, cutting technology has been pushed to a new stage of modern cutting technology.

The development mechanism of modern cutting technology can be summarized as follows: on the one hand, improving cutting efficiency instead of blindly emphasizing the benefits brought by tool life has greatly inspired tool manufacturers, and based on this, a brand-new business concept of "innovating technology, innovating tools, improving cutting efficiency and serving users" has been established, which has injected new vitality into cutting, a traditional manufacturing technology, and made tool manufacturers become the main force in developing modern cutting technology; On the other hand, this concept has been accepted by more and more tool users, forming a new thinking of "actively adopting new achievements in cutting technology, applying advanced tools to improve processing efficiency, reduce manufacturing costs and improve enterprise competitiveness", which has made the manufacturing industry pay unprecedented attention to and demand for advanced tools and become a powerful force to promote the rapid development of cutting technology. This kind of "pulling" is not a simple acceleration of the development of cutting technology, but a new development mechanism and power of cutting technology, which makes it transition from the traditional cutting technology that is separated from use to a new stage of modern cutting technology that faces the needs of users and is closely integrated with use.

2. Technical characteristics and development trend of modern cutting technology.

Cutting has entered a new stage of modern cutting technology, which is not only reflected in the fact that the development of cutting technology is based on the mechanism of mutual linkage between tool manufacturers and tool users, but also shows the following obvious technical characteristics and development trends.

(1) The new cutting technology completely breaks through the traditional cutting technology.

High-speed, high-efficiency cutting, hard cutting, dry cutting and other new technologies are applied to the "big households" of cutting processing such as automobiles, aviation, molds and equipment manufacturing, which not only greatly improves the processing efficiency, but also promotes product development and process innovation. In recent years, the rapid development of mold industry can be said to grow with efficient mold cutting technology. The high-speed milling of large dies and the milling of hardened dies have changed the traditional die processing technology and greatly shortened the die development cycle.

At the same time, the boundaries of traditional turning, milling, drilling and other cutting processes are constantly being broken, and some new cutting methods are constantly emerging. For example, the newly introduced milling cutter can be used as a hole machining tool for drilling and reaming, which reduces the tool changing time and improves the machining efficiency; Another example is the insert milling cutter that can efficiently remove the metal in the cavity, the turning-turning-drawing process for machining the crankshaft, the turning process in which milling replaces turning in the compound turning center, and the high-speed thread processing process in which cemented carbide thread milling cutter replaces cemented carbide tap. In addition, with the development of various compound machine tools and the technology of "one machine tool or one clamping to complete all processing", the traditional cutting technology will be further changed.

(2) Significant progress has been made in tool materials and coating technology.

The breakthrough of new cutting technology to traditional cutting technology should be attributed to the improvement of tool materials and the development of coating technology.

The development of cutting tool materials is reflected in the overall progress of various cutting tool materials, which improves the machining efficiency in various fields. Among them, special emphasis should be placed on the progress of two kinds of tool materials, namely, the progress of ultra-hard tool materials PCD, CBN and cemented carbide materials.

PCD and CBN materials have high hardness and particularly good wear resistance, and are expected to become promoters of high-speed cutting. However, due to their brittleness, their practical application process was slow for a long time after they came out. In recent years, by controlling and adjusting the manufacturing process, formula composition, microstructure and granularity, the toughness of PCD and CBN materials has been significantly improved, the varieties have increased, and the application fields have been expanded, making the hope of applying superhard tool materials to high-speed cutting a reality.

As a tool material, cemented carbide has always had a contradiction between hardness and toughness. Although its application in turning, milling and hole machining has played an important role in improving machining efficiency in an all-round way for many years, its defect of poor toughness has not been obviously improved. Nowadays, monolithic cemented carbide drill bits and end mills made of ultrafine cemented carbide have been widely used, and the cutting speed can be increased several times than that of high-speed steel tools, thus making cemented carbide truly the most widely used tool material with the best comprehensive performance. Another important progress of cemented carbide materials is the development of gradient cemented carbide materials, which makes the surface layer of coated cemented carbide blades rich in cobalt, improves the toughness of cemented carbide blades, not only reduces the edge collapse, but also can use matrix materials with good plastic deformation resistance, which improves the bearing capacity of blades and significantly improves the cutting performance of coated cemented carbide blades.

In recent 10 years, coating technology has made great progress. In the field of CVD coating, TICN and AL2O3 thick film coatings by medium temperature CVD improve the wear resistance and crack growth resistance of blades. The development of PVD coatings is particularly noticeable. Not only wear-resistant coatings such as TIALN, ALTIN, ALCRN, TISIN and AL2O3 have appeared, but also various lubricating coatings such as MOS2, DLC and WC/C, as well as new coating structures such as gradient coatings and nano-coatings, which greatly improved the performance of the coatings. At present, the development of coating technology is in the ascendant, and it has become the most effective means to improve the cutting performance of tools with its advantages of multi-function, good effect and rapid development.

(3) The innovation speed of new brands and new products of cutting tools has been greatly accelerated.

As a tool, tool is the most dynamic technical factor in manufacturing system, and it is in the process of continuous innovation.

In the stage of modern cutting technology, the development of cutting tools has two characteristics: First, the innovation speed is accelerated. The biennial Beijing International Machine Tool Exhibition (CIMT) has become a "new product conference" for global tool manufacturers, with new material grades, new coating products, new tool (blade) structures, new tool handles, clamping technologies and new processing methods emerging one after another. The second is to establish an innovative concept of system optimization. On the basis of system optimization, a newly developed coated cemented carbide brand can often improve the cutting efficiency by more than 20%, and some can even reach more than 50%. A new tool product can provide a new machining effect or significantly improve machining efficiency. For example, in recent years, the popular high-feed milling cutter has a feed per tooth of 3.5 ~ 4.0 mm/z, which is 10 times that of the general milling cutter. For example, the feed of the scraping blade can be doubled.

(4) Expanding the connotation of modern cutting technology.

After cutting entered a new stage of modern cutting technology, many new related technologies appeared correspondingly, which expanded the connotation of cutting technology. For example, high-speed cutting technology was first applied to rotary tools, mainly milling. In the early days, the spindle speed exceeded 10000 r/min as the threshold of high-speed cutting. Around this goal, the related technologies of machining center are developed, including high-speed spindle, fast feed, high acceleration (deceleration) technology and numerical control system suitable for high-speed cutting.

The developed tool-related technologies include HSK tool rest, 7∶24 double-sided contact tool rest, high-speed rotating tool safety technology, tool dynamic balance technology and so on. In order to carry out high-speed machining with the universal tool of solid cemented carbide, it is necessary to improve the accuracy and rigidity of tool clamping, and new tool chucks and tool adjustment technologies such as hydraulic chuck, hot chuck and shrinking force chuck have been developed one after another. In addition, in order to improve the utilization rate of tools and reduce the cost of tool management, supporting technologies such as tool management software and cutting database have been developed, and the overall level of cutting processing has been improved with modern information technology.

3. How to apply modern cutting technology to improve machining efficiency?

At present, the development situation of mechanical cutting industry is excellent. So, how to apply modern cutting technology to improve the processing efficiency of enterprises? You can start from the following aspects:

(1) Improve the performance of tool materials and develop coating technology.

An important sign of the rapid development of cutting technology in recent years is the continuous improvement of tool material properties and the rapid progress of coating technology, especially the large number and wide application of cemented carbide materials and indexable inserts for turning tools and milling cutters. The brand of cemented carbide blades newly developed by tool companies seems to have mushroomed, covering all fields of cutting processing. Usually introducing a new brand can improve the cutting efficiency by 20% ~ 30%, and some even reach 100%. Therefore, a comprehensive investigation of the old materials used by enterprises for a long time, the elimination of some old brands and the adoption of corresponding new materials and brands, especially the replacement of uncoated brands with coated brands, can have an immediate effect on improving processing efficiency.

(2) Develop a new tool structure

The rapid development of new tool structure plays an important role in improving machining efficiency. For example, CORODRILL880 cemented carbide indexable short-hole drill newly introduced by Sandvik Joeman, due to the remarkable improvement of the cutter (blade) structure, compared with the original short-hole drill, the feed speed or cutting speed can be nearly doubled, the machining efficiency can be improved by about 70%, and better machining accuracy and surface quality can be obtained. Another example is Harbin Steam Turbine Factory, which encountered the problem of machining large-diameter deep holes when producing the first 600,000 kW supercritical steam turbine unit in China. If traditional hole machining tools are used for machining, it will take 6.7H for each hole, and the machining task cannot be completed.

Later, the compound drill of Kenner Metal Company was adopted in the factory, and the processing time of each hole was only 0.5H, which reduced the processing time by about 93%. The processing task of about 200 deep holes that was not completed in 40 days was completed in 5 days. It can be seen that enterprises should actively use rich advanced tool resources to improve processing efficiency or solve processing problems encountered in production, and take this opportunity to continuously improve the application level of cutting technology and tools in enterprises.

(3) Develop and adopt new tools.

In recent years, the tool industry has developed new tools for some machinery industries. These tools have the characteristics of high efficiency or technological innovation and have played an important role in promoting the progress of processing technology in the industry. For example, the insert milling (drilling) cutter, multi-function milling cutter, large feed milling cutter and horn milling cutter developed for the mold industry have played a very important role in improving mold processing efficiency and innovating mold processing technology. Therefore, enterprises should timely understand and collect the latest progress of cutting tools in this industry for our use, so that enterprises can always maintain advanced cutting level and leading processing efficiency.

In addition, there are some achievements in cutting technology, such as indexable inserts such as rotary cutters, scraping turning tools and spiral edge milling cutters with rake angles, which can replace ordinary high-speed steel cutters, solid carbide drills and end mills. These tools play a universal role in improving the machining efficiency of turning, milling and drilling processes with a large volume and a wide range, which has long been proved by production practice. However, the unavoidable fact is that there are still quite a few enterprises that have not fully adopted this part of technology for various reasons, and are still using tools that have long fallen behind, thus restricting the development of enterprises for a long time. Enterprises should adopt general advanced cutting technology and tools in a planned and step-by-step manner, and quickly change the backward appearance of tools.

China is a relatively backward country in cutting technology, and the existing technology and products can no longer meet the demand of advanced tools in important industrial sectors of manufacturing industry. Therefore, accelerating the development of cutting technology and mastering the core technology of modern cutting is not only of great practical significance, but also increasingly urgent for China to build a manufacturing power, complete the historical task of new industrialization and realize the goal of revitalizing the equipment manufacturing industry.

The development and application of the above modern cutting technology is the content of Zhong Da's consultation and arrangement.

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