The gap between domestic and foreign machining too

2022-08-06
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Analysis on the gap between domestic and foreign machining tools

engine is the heart of automobile, and its parts manufacturing technology is generally higher than other automobile parts. Advanced tools such as ceramic tools and superhard tools, which can reduce the environmental impact of their production, have been widely used in the engine manufacturing process. Most of China's automobile production lines (especially car production lines) are imported from abroad. When they are put into production, the production lines mainly use imported cutting tools, and the cutting parameters of cutting tools also use foreign recommended values. These cutting tools combine various advanced technologies such as new materials, new processes, cutting principles and surface treatment. They have the characteristics of high performance, high service life and high reliability, and basically represent the advanced level of modern cutting tool technology

the fetter of engines and cutters

there are three obvious trends in the manufacturing technology of newly put into production automobile engine production lines in China:

the basic requirements for realizing high-speed machining are: ① using machine tool spindles that can realize high-speed operation; ② High precision and high rigidity HSK tool handle with powerful chuck is adopted; ③ Coated carbide, cermet, ceramic, CBN, PCD and other advanced cutting tools are used

flexibility is one of the development trends of engine manufacturing. Flexible automatic line (FTL) is a production line that uses CNC or machining center to realize flexible machining at local stations of traditional automatic line. It is commonly used in Japanese factories. The flexible manufacturing system composed of special machining centers is mainly used for machining cylinder heads and cylinders. From the perspective of output, it can reach an annual output of 50000 pieces from the starting output of the traditional FMS system to 200000 pieces of the traditional automatic line

according to the situation of Japan's automobile manufacturing industry, the cutting efficiency is increased by 28% every five years on average. Among them, the cutting speed is increased on average. Customers often think that the price of domestic experimental machines should be reduced by 19% and the feed rate should be increased by 8% on average. In recent years, the cutting efficiency has been increased by more than 30%. At present, the production pace of manufacturing main engine parts has been shortened to 30-40 seconds, which is more than 50% shorter than that ten years ago. For example, if the cylinder body made of gray cast iron is milled by the high-speed machining center, the cutting speed can reach v=700-1500m/min, and the tool adopts CBN blade. PCD cutters are widely used in milling aluminum alloy cylinder blocks and cylinder heads. Considering that large centrifugal force will be generated during high-speed rotation, the cutter body is made of high-strength aluminum alloy materials

in a word, an obvious trend of engine manufacturing industry is to adopt high-speed machining technology to improve efficiency, shorten delivery time, reduce production costs and improve market competitiveness

current situation of the tool market

the automotive industry is the industry with the most applications of special tools, and it is also a symbol to measure the technical level of a country or a tool company. Most of China's automobile production lines (especially the modified plastics in China's plastic machinery industry, especially the car production lines) are imported from abroad, and the cutting tools are mainly imported with the equipment. At present, the domestic automobile production lines include American, European, Japanese and Korean models, as well as the independent models mainly based on European equipment

in this way, the mainstream of five major cutting tool factions are active in China: first, santevik (including santevik), which has a large and complex cutting tool branch, has the largest sales volume in the Chinese market; The second is the American Department, mainly represented by Kenner, Ingersoll, wannaite, etc; The third is the European Department, mainly Germany, including MAPAL, Guehring, widia, Titex, Walter, etc; Fourth, Japan and South Korea, including Mitsubishi, Sumitomo, Toshiba, OSG, Daijie, bueryue, Hitachi, etc., as well as TaeguTec and Korloy companies in South Korea; The fifth is Israeli system, mainly iscar (iscar). These companies have almost filled the market space for automotive cutting tools. In some large automobile manufacturing plants, domestic cutting tools may only account for about 10% of the total projects, so imported cutting tools still occupy a dominant position

our short board

the overall status of the domestic tool industry is that the starting point is low and the starting point is late. The advanced NC tools have only started R & D and production with the development of NC machine tools in recent years. Therefore, the NC tool product foundation is relatively weak, the development speed is slow, and the competitiveness is not strong. The main reasons why the foreign cutting tool industry can seize the Chinese market on a large scale are: the foreign cutting tool products are of high grade, complete varieties and good quality; Moreover, the cutting tool is closely linked with the machine tool. Foreign machine tools often choose the cutting tool that has been used in foreign countries; In addition, due to the incomplete variety of domestic tools, foreign tools are mostly used in product finishing, high-performance cutting and when there are special requirements. The comprehensive effect of many factors has formed a passive situation of domestic cutting tools

there are many obstacles and congenital system obstacles in the process of tool localization. Taking the car production line as an example, at the initial stage of the introduction of car models and CNC automatic production lines, China often did not pay attention to the domestic supporting problems of cutting tools, and did not timely improve the technical level of domestic car cutting tools. After the introduction of the production line, there are many varieties and specifications of special cutting tools and tools, and the requirements for process technology and specialization are very high. The varieties, quality, supply and service capacity of existing domestic cutting tools are difficult to meet the requirements. At the same time, dozens of foreign tool brands with complete supporting facilities and ready to use tools are eyeing covetously, making the localization of tools difficult and obviously in a passive state

comparison of cutting tools at home and abroad

since the 1980s, with the development of the world's manufacturing industry and the progress of manufacturing technology 2. Adjustment of synchronous belts: too loose and too tight circular tooth synchronous belts for transmission will produce tooth climbing phenomenon, resulting in fluctuations in experimental force. At the same time, driven by the reduction of the service life of synchronous belts, cutting technologies and tools have gradually entered a new stage of development with high speed, high efficiency and innovative processes, The cutting efficiency has been doubled, which has made an important contribution to the development of manufacturing industry. Efficient cutting technology and cutting tools have become the basic technology and key technology of automobile manufacturing industry. High speed cutting, dry cutting, hard cutting and other new cutting technologies are changing the traditional processing technology, showing strong vitality. The author believes that the most fundamental way for domestic tool manufacturers to participate in international competition is to improve the overall tool technology level of enterprises

we must clearly see that there is still a big gap between domestic tool enterprises and their foreign counterparts in terms of technical level, production process and manufacturing equipment. The tool products produced cannot fully meet the growing needs of users in terms of processing quality, service life, reliability and technical services. Therefore, there is a long way to go. We still have a lot of work to do and a long way to go. We still have to redouble our efforts

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