In recent years, with the development of mold manufacturing, mold parts and materials to improve their own requirements, super-hard tool materials such as CBN cubic boron nitride, PCD polycrystalline diamond tools and new carbide cutting tools are widely used, tool consumption and The purchase of mold manufacturers and tool manufacturers to become a common concern topic.
The application of integrated tool
According to research, in the domestic mold users choose the tool material, the most used is carbide cutting tools, accounting for 64.1%. The development of superhard tools, hard turning as a substitute for grinding a good way to popularize. The use of super-hard tool has been significantly improved, such as the cylinder cylinder hole processing in the semi-fine boring and fine boring process in a lot of cubic boron nitride blade, cutting speed reached a new height, tool life is also greatly extended.
Indexable tool in China has been promoting for many years, progressing smoothly, but the development is not balanced, the user coverage is still lower than the overall tool and welding tool. However, China's geostable tool technology in the promotion process has been a new progress, the rapid increase in the number of varieties of great potential.
Modern mold manufacturing machinery and the rapid development of the tool technology used by its high-tech is widely used in the processing technology, cutting methods, tool structure, tool materials, tool coating and other aspects have been used in the past, a large mechanical processing The difference. The new tool construction and blades with new cutting edges and geometries are continually researched and developed to accommodate tooling and tooling connections for CNC machine tools and high-speed machining, such as HSK shanks, hot cover shanks, hydraulic Knife handle, and other new tool holders are widely used.
In order to improve the production efficiency and reduce the tool change time, in the mold parts processing more and more use of a variety of composite tools, such as drilling and boring composite, drilling and honing composite, drilling and threading composite composite cutting tools, Complex expansion of the tool to meet a lot of special processing requirements, and some tools have even developed into machine, electricity, liquid integrated device, has gone far beyond the traditional concept of the tool.
Mold industry tool consumption characteristics
In order to achieve mold lean production, mold enterprises to organize the scientific procurement of materials and inventory management, need to study and explore how to ensure the normal operation of the production line in the case of lower inventory of the tool to occupy the tool to optimize the minimum inventory settings, tool procurement starting point , The reasonable purchase frequency of the tool and the purchase batch, the establishment of effective tool early warning mechanism, emergency mechanism and rapid response mechanism, a scientific and effective way to track, monitor the tool inventory status and procurement status.
It is understood that 68.5% of the user's enterprise tool costs accounted for less than 3% of the total cost, and the cost of manufacturing tools in developed countries accounted for about 4% of the cost of production, there is a big gap, which is caused by China's manufacturing cutting level is low A factor.
China's mold industry decentralized, low-scale, low-level phenomenon, the Chinese mold manufacturers are very large number of very few large, the rest are mostly small and medium-sized. These conditions determine the mold industry users use the characteristics of the tool: the amount of purchases, the number of frequent purchases, that is, up to two months or so once, this reflects the mold industry tool users in the development of the budget is more inclined to flexibility, Rather than keeping too much inventory. At the same time, due to the flexibility of user procurement, for those who have not yet entered the tool suppliers, the market provides access to the opportunity at any time. As a result of on-demand procurement, the use of the brand has been increasing competition is also increasing.
The problem of the tool used in the injection mold
In recent years, because of the increasingly fierce competition, many companies are committed to "reduce costs", "shorten the delivery time" and "improve the quality of" research, gradually aware of the high precision injection molding mold, the importance of efficient processing. Injection mold processing process indispensable cutting tool more and more attention.
However, the overall carbide end mill used for finishing, it mainly cuts the narrow and deep parts of the workpiece. The use of this tool for efficient deep cutting will occur when the following problems: cutting resistance is easy to increase, the top of the central blade part of the vulnerable and the central part of the cutting speed is difficult to improve, there is a theoretical part of the cutting residue.
The high efficiency rounded end mill used for roughing increases the machining efficiency by increasing the cutting depth, leaving a significant residual part of the workpiece after machining. This will increase the processing load of the subsequent finishing tool. Although the rough processing efficiency is high, but will reduce the follow-up process processing efficiency. Therefore, the tool should continue to improve, in order to meet the needs of injection mold processing.
Factors that affect the purchasing power of the tool
Users pay more attention to efficiency, input-output than optimization, rather than focus on simple price factors. "Service" has been the content of a simple pre-sale service development to the cutting program to solve.
The performance and quality of the tool directly affect the smooth processing of the required qualified products, whether the tool to meet the requirements of high-speed cutting, tool life and how the frequency of tool changes directly affect the production line rate, affecting the processing of the beat and production efficiency, And whether on time and to ensure the quality of the adjustment or grinding of a good tool to provide the production line will be directly related to the production can continue to continue.
Therefore, the mold industry tool users in the use of tools mainly consider the cutting efficiency of the tool, followed by the service life, the other need to pay attention to it is the service. Users pay more attention to efficiency, input and output than optimization, rather than focus on simple price factors. "Service" has been the content of a simple pre-sale service development to the cutting program to solve.
In recent years, China's cutting tool enterprise product level increased year by year, the competition between the tool enterprises are increasingly fierce, look at the country, large and small, internationally renowned tool manufacturing and agents abound, Sandvik, Walter, The following is the domestic brand of tool manufacturers products, the United States, the United States, the United States, the United States, the United States, the United States, the United States, the United States, Technology, services and other aspects of the comprehensive analysis of the hope that the procurement of mold industry to provide a reference.
Industry development highlights the role of tools
The rapid development of manufacturing industry not only led to the prosperity of the domestic mold industry, but also on the domestic mold manufacturers put forward higher and higher requirements: further shorten the delivery time, high-end mold products in short supply. Facing the huge market demand and fierce market competition, mold manufacturing enterprises are faced with the dual pressures of improving the grade of mold products and reducing the manufacturing cost, and this pressure will be transmitted to the upper and lower ends of the supply chain, so the corresponding tool The industry also made new demands.
Relative to the machine tool, the tool in the entire manufacturing cost of the proportion of only 3% to 5%, but its role can not be ignored. Machine tools can provide a good movement and control platform for mold production, but the real completion of the cutting process, and the workpiece is in direct contact with the tool, the workpiece shape, size, accuracy, surface morphology and so on through the role of the tool to achieve The Whether the machine is running adequately and whether the cutting of the workpiece is reasonable is closely related to the selection of the tool, the performance level, the quality difference, the process and so on.
The tool can finish the roughing of the mold, semi-roughing, finishing, margin milling and one (or secondary) clear root, the roughest mold is processed to meet the needs of various parts of the finished product. The use of advanced and efficient tooling can also help mold manufacturing enterprises to reduce processing costs and improve production efficiency.
The survival of the cutter business
The fierce competition in the market will inevitably bring more pressure to the tool manufacturers, but the development of the entire tool industry and tool users from the point of view, competition is good, there will be greater competition for 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, the tool industry is also true. For the tool manufacturers, on the one hand to continue to enhance the cost of the tool to meet the needs of mold enterprises, on the other hand to reduce their manufacturing costs to improve service quality to participate in fierce market competition. In the face of double challenges, how should the tool maker deal with it?
Cost-effective product line
Fierce competition in the market, reduce manufacturing costs and improve the efficiency of the multiple pressure so that mold manufacturing enterprises must choose cost-effective tool products, which is the tool enterprises to participate in market competition is facing the real situation. Roughing tools not only need to work quickly and efficiently, but also to withstand high temperatures, high pressure and wear resistance; finishing tools to improve the mold size, shape and surface roughness, reduce or even save the manual grinding, which greatly reduced Mold manufacturing enterprises to reduce production costs and shorten the mold manufacturing cycle, ahead of delivery.
The geometric characteristics of the tool provided by the tool manufacturer should be as much as possible and detailed, such as the type, diameter, blade length, overhang and the relevant parameters of the machine, etc., and according to the customer's request to meet the needs of the tool products and Related to the debugging work, so that mold enterprises as soon as possible to put into production, improve production efficiency.
Rapid response to technical solutions
One of the most important ways 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 and by increasing the amount of cutting; it can also be achieved by reducing the assist time, such as the replacement time of the tool, and by minimizing the chance of failure of certain processes.
This raises a higher demand for the technical solution capabilities of the tool supplier to analyze and discover the causes and influencing factors of the machining problems that occur in the tool-related manufacturing process and make timely decisions about the tool Response, quickly find the problem and propose solutions to the problem and recommendations, if necessary, soon to reach the scene of the problem, the tool itself, the various elements of strict control and make appropriate and timely improvement and optimization, to provide comprehensive and timely sales And after-sales service.
System engineering co - ordination
The actual production experience shows that the tool cutting problem is a complex system engineering. In the mold processing, the input of the system is the production requirement. The output of the system is the result of the machining process. In this system, there are many Factors and variables, machine tools, fixtures, tools, cutting fluid, workpiece material, rough status. 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 coating of the surface, and so on. All of these variables intersect and interact with each other. For example, the concentration of unreasonable or inappropriate types of cutting fluid will not only lead to shorter tool life, but also cause abnormal processing of the workpiece; parameter configuration unreasonable machine not only can not play the tool should function, but also may bring the tool Of the chipping, broken and so on.
The development of new technology comes from the actual production practice, therefore, for the tool manufacturers, on the one hand to continue to work in the tool technology has reached the level required by the mold manufacturing enterprises, on the other hand also need to strengthen with the machine tool manufacturers, fixture manufacturers , Cutting fluid manufacturers, materials, etc. to strengthen cooperation, when the processing of abnormal circumstances, the need to analyze and solve the problem from the perspective of systems engineering, and can not only see the system alone, the tool problem, from the system point of view to consider the problem , Analysis of the various important factors between the relevant, to enhance the processing of the system in the co-ordination of the ability to solve.
Innovative technical capabilities
In this society are to promote the atmosphere of innovation, of course, no matter the tool. Many companies have developed more advanced tools, such as the expansion of the knife, the blade is only a part of the entire tool, the entire tool also contains the drive and control agencies, the tool production efficiency is high; combination of tools (composite Tool), a composite knife can solve the original multi-station multi-channel processing, and reduce the number of tool change time, help to improve the processing accuracy and processing efficiency; therefore more by the customer's trust and support.
For example, the rigidity of the tool is inversely proportional to the amount of overhang of the tool. When using the ball end mill for profiling, the tool must have a large amount of overhang. Therefore, in the design of end mills, in order to improve the rigidity of the tool, usually in the blade and handle between the taper with the neck, but when the straight wall is high, this method is not enough, in order to solve the mold processing In the straight wall of the efficient, high-precision processing, the Japanese OSG developed FXS-MFE end mill, in the straight wall processing, to take ladder processing, to achieve high-speed processing.
For domestic enterprises, many enterprises are developing very rapidly, but from the development of the whole industry, the domestic enterprises in the overall technological innovation is still inferior to foreign enterprises.
