The rapid development of the manufacturing industry not only drove the prosperity of the domestic mold industry, but also raised higher and higher requirements for domestic mold manufacturers: the delivery period was further shortened, and the supply of high-end mold products was in short supply. Faced with huge market demand and fierce market competition, mold manufacturers are faced with the dual pressure to improve the grade of mold products and reduce manufacturing costs, and this pressure will certainly be transmitted to the upper and lower ends of the supply chain, so the corresponding tools (tools) The industry has also put forward new requirements.
In recent years, the product level of China's tool companies has been increasing year by year, and the competition among tool companies has become increasingly fierce. Looking at the whole country, large and small, well-known domestic and foreign tool factories (tool agents) abound, Sandvik, Val Special, Isca, Lanzi, KORIOY, Daijie, Hitachi, Mitsubishi, Kenner, Zhuneng, Xiamen Golden Heron... In order to participate in the competition, the major tool manufacturers are also racking their brains, constantly solving the cost performance and technical services. Enhance core competitiveness in terms of programs and other aspects. How to choose a mold factory in the face of a dazzling tool market?
Compared with machine tools, tools account for only 3% to 5% of the total manufacturing cost, but their role can not be ignored. The machine tool can provide a good motion and control platform for mold production, but the tool that directly completes the cutting process and directly contacts the workpiece is the tool. The shape, size, precision and surface topography of the workpiece are all realized by the action of the tool. . Whether the operation of the machine tool is sufficient and whether the cutting of the workpiece is reasonable is closely related to the selection of the tool, the performance, the quality difference, and the process.
The tool can complete the roughing, semi-roughing, finishing, margin milling and primary (or secondary) rooting of the mold, and the roughest blank is processed into finished products that meet various needs. The use of advanced and efficient tools can also help mold manufacturers reduce processing costs and increase production efficiency.
Tool manufacturer's survival manual
The fierce competition in the market will inevitably bring more pressure on tool manufacturers, but from the perspective of the development of the entire tool industry and the point of view of tool users, competition is beneficial, and competition will have greater progress. The most intuitive result of competition is the decline in product prices and the improvement of service quality to meet the needs of the market and customers, as well as the tool industry.
For tool manufacturers, on the one hand, we must continuously improve the cost performance of the tool to meet the needs of mold companies, on the other hand, we must reduce our own manufacturing costs and improve service quality to participate in fierce market competition.
Rapid response technology solution
One of the most important ways for mold makers to reduce costs is to increase cutting efficiency and reduce unit costs in manufacturing. This can be achieved not only by increasing the cutting speed, but also by increasing the amount of cutting; it can also be achieved by reducing the auxiliary time (such as tool change time) and minimizing the chance of failure in certain processes. This puts higher demands on the tool supplier's technical solution capability. It is necessary to be able to analyze and discover the causes and influencing factors of the cutting process problems occurring in the tool-related production process, and to make timely and relevant problems of the tool. Respond, quickly identify problems and propose solutions and suggestions for solving problems. If necessary, we should quickly reach the problem site, strictly control the various elements of the tool itself and make appropriate and timely improvements and optimizations to provide perfect and timely sales. And after sales service. Japan Daijie not only set up distribution points in major cities in China, but also set up offices in Shanghai and appointed senior technicians to provide pre-sales services and after-sales technical support and services.
System engineering coordinating ability
The actual production experience shows that the solution of the tool cutting problem is a complicated system engineering. In the mold processing, the input of the system is the production requirement, and the output of the system is the processing result obtained through the machining process. There are many in this system. Factors and variables, machine tools, fixtures, tools, cutting fluids, workpiece materials, blank conditions, etc., where the tool itself is a subsystem with many variables, the structure of the tool, the geometry of the cutting edge, the material of the tool, the surface Coatings, etc., all of these variables intersect and interact with each other. For example, an unreasonable concentration or an inappropriate type of cutting fluid not only causes the tool life to become shorter, but also causes abnormalities in the workpiece being processed; the parameter configuration is unreasonable. Not only does the machine tool not allow the tool to function as it should, but it can also cause chipping and breakage of the tool.
The development of new technology comes from the actual production practice. Walter has established a long-term technical exchange and cooperation relationship with the customer Makino Machine Tool to continuously adjust the harmonicity of the tool and the machine tool to maximize the processing efficiency of the machine tool. Therefore, for tool manufacturers, on the one hand, continuous efforts in tool technology have reached the level required by mold manufacturers, on the other hand, it is necessary to strengthen cooperation with machine tool manufacturers, fixture manufacturers, cutting fluid manufacturers, materials factories, etc. When an abnormal situation occurs in the process, it is necessary to analyze and solve the problem from the perspective of system engineering. Instead of looking at the tool problem in the system alone, it is necessary to consider the problem from a system perspective, analyze the relevant important factors, and improve the cutting. Coordination of system engineering in processing.
Continuous technological innovation
In an atmosphere where innovation is advocated throughout the society, knives are no exception. From the exhibitions in recent years, it can be found that innovation is indeed valued by many companies, especially some well-known foreign machine tool companies. Many companies have developed more advanced tools, such as unfolding tools, and the cutter blades are only in the whole set of tools. As an integral part, the whole set of tools also includes the transmission and control mechanism, etc. The production efficiency of the tool is very high; the combined tool (composite tool) and a compound knife can solve the processing of multiple processes in the original multiple stations, and It reduces the auxiliary time of multiple tool changes, which is beneficial to improve machining accuracy and processing efficiency; and so on, so it is more trusted and supported by customers.
For example, the rigidity of a tool is inversely proportional to the amount of overhang of the tool. When using a ball end mill for copy milling, the tool must have a large amount of overhang. Therefore, in order to improve the rigidity of the tool when designing the end mill Usually, a tapered neck is added between the blade and the shank, but when the straight wall is high, this method is not feasible. In order to solve the high-efficiency and high-precision machining of the straight wall in the mold processing, the Japanese OSG development The FXS-MFE end mill has been stepped up in straight wall machining for high speed machining.
As far as domestic tool companies are concerned, many companies are developing very rapidly, such as Zhuzhou Diamond and Xiamen Golden Heron. However, from the perspective of the development of the whole industry, domestic enterprises are still inferior to foreign companies in terms of technological innovation.
Cost-effective product line
In order to further improve the product range of the tool, Seco successfully acquired the French tool holder and file manufacturing company EPB and the Dutch company Jabro which produces solid carbide milling cutters. The fierce market competition, the reduction of manufacturing costs and the multiple pressures to increase production efficiency have made it necessary for mold manufacturers to choose cost-effective tool products. This is also the real situation that tool companies face in the market competition. Roughing tools not only need to work quickly and efficiently, but also can withstand high temperatures, high pressures and wear resistance; finishing tools can improve the size, shape and surface roughness of the mold, reducing or even eliminating manual grinding, thus greatly reducing The manufacturing cost of the mold manufacturing company and the shortening of the manufacturing cycle of the mold, and delivery in advance.
The geometrical parameters of the tool provided by the tool manufacturer to the customer should be as much as possible and detailed, such as the type, diameter, blade length, overhang and related parameters of the machine tool, and can provide the tool products and requirements according to the customer's requirements. The debugging work is to enable the mold company to put the tools into production as soon as possible and improve production efficiency.
Faced with huge mold market demand and fierce market competition, major tool manufacturers at home and abroad are working hard to improve product performance, ensure product quality, reduce product cost and improve product cost performance. At the level of tool technology, domestic tools must not only strive for technical management, but also seek unique ways to find differentiated competition. For example, there are still few manufacturers in China that can provide high-performance, high-precision grinding and tooling equipment, mainly some internationally renowned companies such as Walter and Palek. Domestic companies show less power in this respect. Therefore, it is also a big market space for more domestic tool companies. Choosing a less competitive market space and conducting differentiated competition may create a different world.
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