Auto parts are moving in the direction of lightweighting. Studies have shown that if the quality of a car can be reduced by 10%, its fuel economy can be increased by 3% to 4%, and car emissions will also be reduced. For this reason, in order to make the engine lighter, higher in speed, higher in power, and higher in durability, various automobile manufacturers in various countries have become more and more widely used in automotive parts for light weight and high strength materials. Aluminum alloy engine blocks have become the first choice for automotive lightweighting, and compacted graphite iron and superalloys also occupy a place in automotive manufacturing. These all pose new challenges to the tool. In response to the application of aluminum alloys, especially high-silicon aluminum alloys, the use of diamond tools is increasing. The diamond tool mentioned here includes both a diamond-welded tool and a diamond-coated tool. A nanostructured diamond coating from CCDia, supplied by the German company Saili, provides an excellent solution for the processing of high silicon aluminum alloys. Kennametal also introduced a pure diamond-coated KD1405 binder-free product to solve the similar wear resistance of high silicon aluminum alloys.
Compacted graphite iron (CGI) is a new type of cast iron material recently used in the manufacture of automotive parts. The graphite in the vermicular graphite cast iron is coral or worm-like, and its metallographic structure is not like gray cast iron, which will increase the stress and generate the fracture line during processing, and will not cause the loss of thermal conductivity like the ductile cast iron. This property makes compacted graphite iron a material for the manufacture of high-strength components for engines. The processing characteristics are between the ductile ductility and the gray cast iron brittleness, and the chips are partially broken. CGI's thermal conductivity is 78% of gray cast iron, which increases the thermal wear of the tool; CGI has good ductility, tensile strength and fatigue strength is about twice that of gray cast iron, which makes it more susceptible to burrs. The Walter company in Germany developed the so-called "Tiger Blade" Tiger "Tec technology for cast iron processing, and later extended this technology to steel, stainless steel, difficult-to-machine materials, etc. The iconic two-color coating of the tiger blade The use of different coatings for different processing characteristics of the front and back knives improves the processing of vermicular cast iron. Sandvik Coromant's GC1020 has a physical coating of titanium aluminum nitride that can be used on harder blade substrates. Achieve the necessary balance between the toughness required for different processing properties to improve the processing of vermicular cast iron. Kenner also promotes the use of silicon nitride in addition to cemented carbide inserts such as KC9315 in cast iron processing. Ceramic inserts such as pure silicon nitride KY3500 are available for higher processing speeds.
High speed machining
In order to reduce processing costs and improve processing efficiency, it has become a focus of many auto parts manufacturers. Among the measures to improve the processing efficiency, the easiest thing to think about is the increase in processing speed. When I participated in the "Tools Technology" and "Mechanical Workers" interview with Bernard North, vice president of Metalworking Solutions Group of Kennametal in 2006, Mr. North said that Kenner launched it five years ago. For coated carbide grade KC9110 for steel machining, the average cutting speed for this grade is approximately 250 m/min, and has now reached an average of 320 m/min. The high speed of machining brings more stringent requirements for tools. In order to meet this requirement, tool manufacturers have adopted various measures. Kenner said that they have broken through the 20mm limit of CVD coatings in the past and can now reach 30mm. This is the result of various techniques such as improving the adhesion of the coating to the substrate, improving the interlayer adhesion of the multilayer coating, and improving the contact of the surface coating with the workpiece.
Seco Tools published their results in research and improvement of coating nucleation. Seco Tools believes that optimized nucleation results in significantly improved wear performance, and that these types of a-Al2O3 layers are typically composed of relatively small, non-porous, defect-free particles. <1014> The structure of the a-Al2O3 layer exhibits the best wear resistance. The high level of a-based Al2O3 coating DurAtomic has reached the atomic level. The result is mechanical and thermal properties that exceed the capabilities of all currently produced Al2O3.
Compared to conventionally produced Al2O3, DurAtomic" coatings exhibit higher durability/toughness, outstanding heat/wear resistance, chemical inertness, and thus reduce the tendency for built-up edge formation. With cutting speed and processing Increased efficiency, reduced cutting forces and cutting heat have become another direction of tool improvement. For example, Iskar's hot wheels milling cutters have serrated cutting edges that overlap each other during processing. The tool structure makes machining more efficient. Such a cutter has high tool stability during machining, the chips are machined into finer chips, and the cutting force is small, so the required machine power is also low.
Near net size
As the manufacturing precision of the blanks becomes higher and higher, the shape and precision of the blanks of the automotive parts are getting closer to the final finished size, which is called the “near net size†(so-called NNS, NearNetShape). The "near net size" blanks are realized. Unlike the conventional blank forming technology, these blanks have precise shape, high dimensional accuracy, shape accuracy and good surface roughness, and the machining allowance is very small. The near-netning of this blank brings a series of effects to the machining process, which requires a small cutting force and a sharp cutting edge for the tool. In recent years, many tool manufacturers have introduced tools that are more suitable for small-volume machining than ever before. The main feature is that the tools are sharper and the wear resistance of the tool materials is better. It is a common choice to increase the sharpness of the tool as much as possible while taking into account the strength of the cutting edge. For example, the MF5 chipbreaker from Seco Tools is a tool for near-net size machining. It features a new open design with a semi-sharp cutting edge and a chamfer divided into two sections, +5° and +10°, respectively, which are incremental in the width direction and simultaneously positive It is smaller (for better depth when the depth is deeper), the front angle is 17°. This semi-sharp design cutting edge reduces cutting forces while machining, while being stronger than traditional "full sharp" inserts.
If other conditions remain the same, the sharpness of the tip will often lead to a drop in edge toughness. With the development of tool technology, we can make up for it by other means to better balance the wear resistance and toughness of the tool. At such a time, the fine graining of the tool material has become one of our choices, although the price of fine-grained tools may be higher than the cost of prior art tools. A material from Kennametal indicates that when milling 62HRC hardened material, the tool wear of the fine-grained carbide KC635M for 25min is equivalent to that of the ultra-fine grained carbide KC637M for 70min, indicating that in the processing of hard materials. The wear resistance of ultrafine grained cemented carbide KC637M is nearly three times higher than that of fine particle cemented carbide KC635M.
Flexible
In recent years, due to the continuous advancement of science and technology and the constant alienation of people's consumer demand, the life cycle of various products including automobile products has been shortened, and the speed of product upgrading has been accelerated. This situation is forcing many manufacturers to embark on multi-variety and small-batch production methods to adapt to the volatility of market demand and increase the market share of the company's products. This poses a challenge to standardization activities that lay the foundation and open the way for mass production of small varieties. For the flexible requirements of modern automobile manufacturing, the machine tool industry through reconfigurable machine tools, the fixture industry through the combination of fixtures, the oil industry through additives and other means to deal with, and the tool industry must also make its own for this production trend The response, I think one of the most important is the modular design and modular manufacturing of the tool. We can install a group of modules belonging to the same functional unit and installed on the same components (or modules) with the same combination of elements (including the same installation and connection form) to ensure different performance, use and internal structure. Modules are interchangeable when combined into a product. In this way, when there are some changes in the structure, size and materials of the automaker's workpieces, it is possible to solve the changing needs of the automakers by replacing the new modules and combining them into tools that meet the new functional requirements. Figure 8 is a modular milling cutter from Walter, Germany. It can be used to form a variety of rake angles and various lead angles by using different cutters and blades. Changes, the development and manufacture of new products offer a technical possibility. This modular tooling system can be used in a wide range of automation applications, from general milling machines to special milling machines to complex CNC machining centers and flexible production lines. The system is very versatile compared to other tools currently in use. In recent years, with the development of cutting tool technology, various new blade types, blade types and even cutting concepts have been developed. They have also introduced corresponding new modules, enabling users of the system to use new tools only by replacing modules. Technology has also reduced user investment and accelerated the pace of using new technologies.
The tool modular technology started to be used earlier in milling. In recent years, the tool modularization technology in various fields such as turning, drilling and reaming has also made great progress. For example, the Capto turning tools provided by Sandvik Coromant and Walter and the KM turning tools provided by Kennametal have been popularized in industrialized countries. Nowadays, foreign tool manufacturers have extended the concept of tool modularization to some special tools for modern automobile manufacturing, providing an economical choice for multi-variety and small-volume modern automobile manufacturing. Because the automotive industry is different from the general machinery processing industry, many processes must be made with special tools. For example, the crankshaft of the engine, whether it is crankshaft internal milling, car pulling or high-speed external milling of the crankshaft, the tools used are dedicated. The cutter bodies of these tools are complex to manufacture and expensive. However, if the variant of the car product involves the crankshaft crank or the size of the cheek plane, it may lead to the need to use a new tool body for crankshaft machining, which will affect the car manufacturer's product development cycle and manufacturing costs, and ultimately the impact The competitiveness of car manufacturers. Therefore, tool manufacturers should focus on the development of flexible crankshaft manufacturing special tools (Figure 9), together with the car manufacturer to do everything possible to shorten the development cycle and reduce manufacturing costs.
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