First, it has created new technologies such as high-speed cutting, which has improved the processing efficiency.
High-speed cutting presents a unique advantage as a new cutting process. First of all, the cutting efficiency has been significantly improved. Taking the five-piece machining of a car engine as an example, in the past 10 years or so, the production efficiency has been improved by about 1 to 2 times, such as the PCD face milling cutter for processing aluminum alloy cylinder heads. The milling speed has reached 4021m/min, and the feed rate is 5670mm/min, which is doubled compared with the production line introduced in China in the early 1990s. For example, the CBN face milling cutter for finishing gray cast iron cylinders has a milling speed of 2000m/ Min, 10 times better than traditional carbide face milling cutters. Second, high-speed cutting is also beneficial to improve product quality, reduce manufacturing costs, and shorten lead times. In addition, on the basis of high-speed cutting technology, new technologies such as dry cutting (quasi-dry cutting, micro-lubricating cutting), hard cutting (by car grinding, milling and grinding) have been developed, which not only improve the processing efficiency but also change the tradition. The boundaries of different cutting operations, and the creation of a new era of cutting manufacturing "green manufacturing." The hard cutting technology has become a highly efficient new process for the machining of the inner hole of the automobile gear and the hardened mold processing. Figure 1 shows the mold for processing 65HRC.
At the same time, high-efficiency machining processes or high-productivity machining processes (HPM, HSM) with high feed rates have emerged according to different processing requirements, reflecting the tremendous development potential of high-speed cutting technology.
Second, the performance of various tool materials based on cemented carbide materials has been comprehensively improved.
The performance of cemented carbide is continuously improved, and the application surface is enlarged, which becomes the main tool material for cutting, which plays an important role in promoting the improvement of cutting efficiency. The first is the development of fine-grained, ultra-fine-grained hard alloy materials, which significantly improve the strength and toughness of cemented carbide materials. The overall hard alloy tools made from it, especially the general-purpose large and medium-sized drill bits. Tools such as end mills and taps are used to replace traditional high-speed steel tools, which increase the cutting speed and machining efficiency by several times. The universal tool with a large amount of face is brought into the range of high-speed cutting, and the cutting process is fully entered. Half of the high-speed cutting stage has been laid. At present, the whole solid carbide tool has become a routine product of domestic and foreign tool companies, and will be more and more widely used as the whole cutting processing level is improved. At present, domestic Hunan Diamond Carbide Tools Co., Ltd., Shanghai Tool Factory Co., Ltd., Siping Xinggong Cutting Tool Co., Ltd. and other enterprises can also produce solid carbide end mills, taps, drills and other products, as shown in Figure 2, Hunan. Solid carbide tool produced by Diamond Carbide. Not only that, but solid carbides are also used in some complex forming tools. Secondly, the development and use of new processes such as cemented carbide pressure sintering have improved the intrinsic quality of cemented carbide; and the development of special grades for different processing needs, and further improved the performance of cemented carbide. In the case of the base material of the chemically coated cemented carbide insert grade, a graded cemented carbide with good resistance to plastic deformation and a tough surface was developed, which improved the cutting performance and application range of the coated cemented carbide insert.
The variety of ceramic and cermet tool materials has increased, the strength and toughness have been improved, the application field and processing range have been expanded, and the hard alloy has been replaced in the finishing and semi-finishing of steel and cast iron, which has improved the processing efficiency and product quality. At present, such tool materials can be used not only in single-piece, small-batch production, but also in mass production of assembly lines, and because of the lower price, they can be used as the preferred tool for dry cutting and hard cutting.
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