Constantly innovative new standards in tool technology

Figure 1 Advanced cutting tools can improve the efficiency of the shop. The hard material turning tools of Diamond Innovations are shown in the figure.

Tool technology is rapidly evolving to meet changing needs and address the toughest challenges from workpiece materials. Today's processing plants need to revisit the tool from different perspectives.

In the case of meeting various needs, the use of advanced tools can improve the processing capacity of the workshop. The tool shown in Figure 1 is a hard material turning tool from Diamond Innovations. Tool technology is evolving rapidly, so choosing the right tool can make a fundamental shift in the process. In the metalworking industry, there is no alternative to advanced technology. In the future, the demand for machining will be very large, and only advanced technology can meet this huge demand.

Mr. Chris Mills, Project Manager of Aerospace Development at Sandvik Coromant, cited the aerospace industry as an example: In the next 20 years, in order to meet the production needs of the aerospace industry, its production and processing capacity must be tripled from now on. So how to achieve this goal?

By doubling the processing capacity, is it simple to triple the number of machine tools, and the processing technology is still at the level of today? He said that it is virtually impossible. If you multiply the number of machines of the state of the art by 3, it means that the number of machine operators will increase by the same factor. This situation is simply unimaginable, because it is quite difficult for the factory to hire qualified workers who are qualified for the operation of the processing machinery.

Therefore, three times the production capacity needs to be obtained from the evolving advanced technology, and only in this way can the existing number of metal processing operators monitor a large number of machining operations.

So where do these advanced technologies come from? Of course, these technologies also involve the development of the machine itself. Nowadays, the machining speed and machining accuracy of machine tools are getting higher and higher. However, the workpieces themselves are not developed in the same incremental order, although they are also undergoing substantial changes. Nowadays, the processed workpieces not only put forward higher requirements on the processing precision, delivery time and quality, but many workshops are faced with more and more difficult materials that have never been encountered before. These materials include titanium alloys, nickel-based alloys, and compact graphite cast iron (CGI), not to mention, in some cases, composite materials instead of metal materials.

In other words, the development of workpiece materials is faster and more varied than the machine tools that machine them. There is a certain gap between the machine tool and the part material. In order to reduce or even exceed this gap, the fastest-growing technology comes from metal cutting tools, and its development speed exceeds that of any other processing technology.

It turns out that the development and changes of the tool are so great that, regardless of the size of the processing plant, it is necessary to re-evaluate the processing ideas of the tool. Not only does it need to re-examine the tool selection method, but it also needs to rethink some of the basic factors that affect the tool. But some of the core ideas are outdated and the standards for tools have changed.

Recently, three major companies related to knives have suggested how the processing shop should now think about the knives in different ways. These companies are: Diamond Innovations, Inc., the world's leading supplier of cubic boron nitride (CBN) materials and polycrystalline diamond (PCD) materials for tools; Precision Dormer, the alliance of two tool companies, dozens of companies Specialized technology for high efficiency drilling and threading has been available for the past year; Sandvik Coromant, the world's first supplier of metalworking tools. All the engineering and technical personnel of the three companies listed some of the main factors that have a fundamental impact on the nature and use of the tool:

Challenging materials, including alternative materials and difficult to machine alloy materials. Some of these materials are less than 25% more steel, and their processing costs per pound can reach several hundred dollars;

Parts with increasingly complex geometries, such as aircraft parts with very thin walls and complex shapes;

The demand for large parts, especially for turbines and heavy equipment, is increasing. The high cost of production of each part places more stringent requirements on the processing of these parts;

There is a growing demand for specialized quality and performance, such as the requirement for typical fatigue strength on the surface of machined parts.

All of these factors have prompted those leading processors to start thinking about the relevant tooling issues. Diamond Innovations, Precision Dormer and Sandvik Coromant have proposed five ways in which the shop must think differently about their tooling techniques and the companies that offer the technology. The five new criteria for selecting tools are: improving machine tool efficiency, meeting application expertise, increasing the percentage of diamond tool applications, focusing on the largest cost source, and considering tool issues from the start.

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