Yuji Branch Technical Department Engineer Wu Juan
The unit I work for is a state-owned large-scale textile machinery manufacturing company, which has been established for 60 years. From the beginning of the establishment of the factory, all kinds of machinery and equipment independently developed and produced by our company, especially the series of spinning machine products, have been sold in the domestic and foreign markets for a long time, and they are well-known at home and abroad. "When a worker wants to do something good, he must first sharpen his tools." How to apply advanced cutting tools, improve production efficiency and product precision, and provide a good foundation for increasingly diverse processing is an important issue facing our company.
Our company purchases more than 2 million yuan of tools per year. Considering the cost performance and applicability of the tools, we have selected Swedish Sandvik Coromant, American Kenner, Japan NIKKEN, Mitsubishi and domestic Zhuzhou diamonds, and other tools. In addition, in actual production applications, according to the accuracy of parts, processing technology and equipment, we also applied other brands of special tools, such as aluminum knives from Austria PLANSEE, Isca cutters, Japanese OSG drills, Swedish mountain high milling cutters and The taps in the domestic work have also achieved good application results in the production and processing of our parts.
The industry has reached a consensus and has been confirmed by the economic analysis and processing practice of cutting processing: the cost of tools is only 3% to 5% in the cost of manufacturing parts, so even if the tool purchase price drops by 30%, the company can save The manufacturing cost of parts is only 1%; but if the cutting ability can be improved by selecting a tool with excellent performance and the machining efficiency is increased by 20% (for example, using a new tool material grade), then the parts can be saved by the company. The cost can reach 15%. Because the cutting efficiency of the tool is improved, it means that the plant, electricity cost, time cost and labor cost of the individual products are effectively reduced, thereby reducing the average production cost of the individual products.
So how can we improve the level of advanced tool application? Let's talk about the application of advanced tools in our company.
Use advanced tool structure
Improve the application ratio of indexable and coated tools and apply solid carbide tools. Since the introduction of the first CNC machining center from Italy in the 1980s, we have been continuously exploring and advancing on the road of applying indexable tools and coated tools. Today, the application ratio of indexable tools and coated tools has accounted for 80% of our metal cutting operations. The indexable tool has high-speed, high-precision and high-precision machining characteristics. The coated tool has high surface hardness, good wear resistance, stable chemical properties, heat resistance and oxidation resistance. The effective application of these advanced tools creates fine textile machinery for our company. The foundation of success has been laid.
Our company has started to use carbide drills in production very early. In the past, it has been thought that drilling must be carried out at lower feed rates and cutting speeds, a view that was once correct under the processing conditions of a conventional drill bit. Later, with the advent of cemented carbide drill bits, the concept of drilling has also changed. In fact, by properly selecting the right carbide drill, the drilling productivity can be greatly improved and the processing cost per hole can be reduced.
According to different processing conditions, there are three basic types of carbide drills used in our company: solid carbide drills, carbide indexable inserts, and welded carbide drills. Each drill has its advantages for a particular processing condition.
The application of the solid carbide drill not only improves the production efficiency, reduces the occupation time of the CNC machine tool, saves the manufacturing cost of the parts in many aspects, and also makes the tool cost because the overall cemented carbide tool has good wear resistance, long service life and long service life. Effectively reduced. In the past two years, our company has also achieved good results in the application of solid carbide milling cutters.
Adopt new tool material grades
New tool material grades are used to better suit workpiece materials and cutting conditions. New tool material grades are used as precisely as possible to better suit the workpiece material and cutting conditions. In the modern manufacturing industry, the processed materials cover a wide range, including steel materials, non-ferrous metals and heat-resistant alloys, synthetic materials, etc. These workpiece materials not only have great differences in machinability between large categories, but also each major The inside of the material is also different in machinability due to mechanical properties or metallographic structure. For example, ferritic stainless steel and austenitic stainless steel, although belonging to stainless steel, have different machinability. Therefore, the selection of the tool material grade can be used to receive the effect of “the right medicineâ€. Not only that, users in the face of turning, milling, drilling and other different processing techniques and high-speed finishing, low-speed roughing and other different cutting conditions, must also choose the corresponding grades, in order to achieve the desired processing results.
Usually a new grade is developed to increase cutting efficiency by more than 20%. The timely discovery and application of new grades to replace existing grades should be a regular task for our company in improving the efficiency of cutting.
Strengthen cooperation with tool manufacturers
Improve the level of tool application and processing efficiency in the enterprise with the help of tool manufacturers. At this stage, the work of enterprises to improve tool application technology should rely more on the help of tool manufacturers. Modern tool manufacturers hold a large amount of cutting technology resources and information, and have established a business purpose of improving the efficiency of cutting processing for users. They are the professional team of cutting technology socialization. Their strong scientific research strength, huge development funds, modern technology and equipment, and advanced management concepts have promoted the progress of modern cutting technology. Strengthening the cooperation with tool manufacturers, with their help, to improve the application level and processing efficiency of the tools and shorten the delivery cycle, this is the secret of foreign tool users to gain competitive advantage, we should follow the example.
China's tool manufacturers should further accelerate the transformation of business philosophy, give full play to their advantages in tool materials, coatings, tool design, etc., and actively provide tool technical support and after-sales service to users, and become a reliable partner for users.
At present, the pace of development of the domestic machinery manufacturing industry is accelerating. It is a severe period of challenges and opportunities. Therefore, we must update our concepts and understand the advanced tools to optimize the processing, improve product accuracy, increase labor productivity, reduce costs, and shorten delivery time. To accelerate the development of new products, the company will increase investment in CNC production equipment and increase investment and application of advanced tools to achieve rapid development of enterprises.
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