3. Adopt QS system
The company's QS system is another system that reduces installation time and is used in Swiss-style lathes. With the QS system, the tool can be quickly loaded and unloaded and automatically locked in position on the center. According to the calculations of a shop floor user using a Swiss-type lathe, the system can save $100,000 per year in the commissioning and setup time of a machine (Figure 2).
Adopt unmanned management mode of operation. In addition to the tool life and speed, you should also think about the reliability of the tool. At present, no workshop can fully understand the potential value of the tool, and it is not known how high the tool can reach the constant performance level.
Why is constant performance so valuable? Because it can change the process with the highest potential profit, enough to free the operator from machine operation, enabling it to operate more machines, inspect parts, or run on machine tools. Simultaneous implementation of related 5S technology or other lean production management work. Sandvik Coromant calls it "green light production." If the machine shop can accurately predict when the tool needs to be replaced, the shop can run its machining process in this way, without having to ensure that an operator stays at the job site.
Sandvik Coromant's new GC1125 and GC1515 grades are specifically designed for "green light production." The reliability of the insert comes from the balance of the coating and the matrix material. In order to improve the toughness and density of the tool, the hardness of the matrix material is slightly lower, and the composition of the coating is beneficial to improve the wear resistance of the tool.
The cutting edges of these tools are also very sharp, which is another important feature of the “green production†tool. Because the sharp edge helps to eliminate burrs, the function of automatic burr removal is very important for long-term unmanned operation, because the workshop runs in this way, and it is not expected that large parts will be processed after completion. A lot of deburring work is also required.
Figure 3 shows another tool designed to process specialty materials – the CDX-Inox drill from Precision Dormer. In stainless steel machining, the drill uses a small machining allowance to minimize contact with the workpiece surface and to avoid work hardening of the stainless steel workpiece surface. Effective geometry and coolant input holes further help solve chip breakage and discharge problems in stainless steel machining
Meet the needs of application expertise
If the choice of tool technology is expanded, the key components of a tool need to have dedicated technical support behind it.
When developing high-performance tools, tool companies typically design tools and tooling systems to achieve the high performance required for specific machining applications. Tool suppliers often develop tools for a wide range of special applications, resulting in an ever-increasing range of tools and tools. In fact, today's processing plants can't rely on their limited knowledge to decide how to use the right tools, but to find a professional tool supplier.
The body of the stated technology is available in several different forms, including:
1. Professional research on materials
Mr. Andrew Hunte of Precision Dormer cites a variety of methods designed to meet the performance requirements of special materials. In the past, the requirements for tools were only “coated†or “coatedâ€, and now a variety of different coating materials have emerged to meet the needs of different materials. He said that people are now paying more attention to matrix materials, which is the most important area of ​​tool research and development today.
Second, the geometry of the tool itself is also important. These factors are mainly for the tool, not just for materials that are difficult to machine. Taking aluminum alloy materials as an example, the tungsten content is extremely high in tools specially designed for aluminum alloy processing. The surface of the workpiece machined with this tool is of good quality and prevents the blade from curling. In addition, its geometrical angle allows the chips to straighten and break, preventing the aluminum from becoming soft and sticky. Careful consideration of similar issues ensures that the drill bit achieves its highest performance in the processing of any metallic or non-metallic material.
2. Understanding the workpiece
In addition, the geometry of the workpiece also has great significance for the selection of the tool. Complex workpieces place a heavy burden on the shop's investment in non-standard tools, because challenging gap problems must be solved, and non-efficient tools may result in insufficient cutting force and insufficient support, making it difficult to handle materials with lower hardness. .
A professional tool supplier should not only have professional research in materials, but also have processing systems specially designed for "difficult" workpieces in the processing of such parts.
Figure 4 The SL70/40 system provides stable re-cutting of turbine blades and turbine casings. Only a few modules can be used to properly clamp and position the tool and provide proper machining clearance for various turbine operations.
For example, turbine blades and turbine casings are such "difficult" workpieces. These complex turning parts are often made of difficult-to-machine alloy materials, generally with molded crypts, and require tools to meet various difficult clearance requirements. To overcome these difficulties, Sandvik Coromant developed the modular SL70/40 tooling system – a freely configurable quick-change system that is suitable for the stable machining of heavy-duty parts such as turbine blades and turbine casings (Fig. 4). This tooling system requires only a few modules and different configurations to ensure proper machining of the various turbine workpieces with the right clearance. At the same time, HP technology integrated into this tool can be sprayed directly over the cutting edge. High-pressure coolant to help solve the processing problems of difficult-to-machine materials.
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