As the main basic technology of manufacturing technology, cutting processing is the main processing technology of the automotive industry, aerospace industry, energy industry, military industry and emerging mold industry, electronics industry and other departments. It is also an important factor for the rapid development of these industrial sectors. Although near net forming technology and stack forming technology are very promising new processes, the status of cutting processing as the main basic process of manufacturing technology has not changed. On the contrary, cutting technology has entered a new era of rapid development - modern cutting technology. Therefore, understanding and mastering the development mechanism of modern cutting technology, understanding its technical characteristics and development trends, and how to apply modern cutting technology to improve processing efficiency is an important topic in the current mechanical processing industry.
1. The development mechanism of modern cutting technology
Machining has become a professional technology that began in the late 19th and early 20th centuries and has gone through a whole century. After the advent of self-cutting technology, it played an important role and made important contributions to the industrialization and economic development of industrialized countries. Although the cutting technology itself has made great progress in this process, it did not go beyond the traditional cutting technology in the 1970s. The most prominent marks are the development and production of tools and the use of tools. And the users are basically separated from each other, and there is no mechanism for mutual promotion and common development.
Due to the rapid development of emerging science and technology such as computers and microelectronics, and the rapid development of materials science closely related to cutting technology, cutting technology has developed rapidly with the development of manufacturing and manufacturing technology, and has entered a new stage of modern cutting technology. Compared with traditional cutting technology, modern cutting technology not only reflects faster cutting speed and higher processing efficiency, but also forms a new development mechanism and becomes an important technical factor driving the development of manufacturing and modern manufacturing technology.
In the long period after the advent of cutting technology, there was a problem that plagued the tool industry and tool users. That is, if you use a more expensive tool for cutting, it can increase the cutting efficiency, but it will increase the manufacturing cost. The user thinks that it is not worth the candle. Therefore, many users are reluctant to spend more money to buy good tools, or after buying a good knife, they are worried that the tool will be used quickly and the tool life will be long. These concepts and practices hinder the renewal of tools, affect the enthusiasm of tool manufacturers to develop new tools, and limit the improvement of cutting efficiency and the advancement of cutting technology.
It turns out that when using a good tool, if you don't pay attention to improving the cutting efficiency and just pursue to extend the tool life, you can only receive very limited results for reducing the manufacturing cost, and may even be counterproductive. The intrinsic link between improving cutting technology and creating considerable benefits for users and society has been recognized and accepted by more and more tool manufacturers and tool users, and has been transformed into a powerful driving force for cutting technology advancement in just 20 years. In the meantime, cutting technology has been pushed to a new stage in modern cutting technology.
The development mechanism of modern cutting technology can be summarized as follows: On the one hand, improving the cutting efficiency instead of concentrating on the benefits brought by the tool life gives the tool manufacturers great encouragement, and accordingly establishes “innovative processes, innovative tools, and improved cutting efficiency. The new business philosophy of "serving the user" has injected new vitality into the cutting of traditional manufacturing technology, making tool manufacturers the main force in the development of modern cutting technology; on the other hand, this concept has also been more and more Accepted by tool users, it has formed a new thinking of “actively adopting new cutting technology, applying advanced cutting tools to improve processing efficiency, reducing manufacturing costs and improving enterprise competitivenessâ€, making the manufacturing industry pay more attention to and demand for advanced tools. The degree has become a powerful force for the rapid development of cutting technology. This “pull†is not a simple acceleration of the development of cutting technology, but gives the cutting mechanism a new development mechanism and power to make it transition from traditional cutting technology using disjointed to modern cutting with user demand and use. A new phase of technology.
2. Technical characteristics and development trends of modern cutting technology
Cutting machining has entered a new stage of modern cutting technology, not only reflected in the development of cutting technology based on the mechanism of tool manufacturer and tool user linkage, but also shows the following obvious technical features and development trends.
(1) New cutting technology breaks through traditional cutting technology
New technologies such as high-speed, high-efficiency cutting, hard cutting, and dry cutting are used in the “big family†of cutting, such as automotive, aerospace, mold, and equipment manufacturing, which not only doubles the processing efficiency, but also promotes product development and process innovation. In recent years, the fast-developing mold industry can be said to grow together with high-efficiency mold cutting processes. Large-scale mold high-speed milling and hardened mold milling processes have changed the traditional mold processing technology and greatly shortened the mold development cycle.
At the same time, the boundaries of traditional cutting processes such as turning, milling and drilling have been continuously broken, and some new cutting methods have emerged. For example, the newly introduced milling cutter can be used as a hole machining tool for drilling and reaming, which reduces the tool change time and improves the machining efficiency. For example, it can efficiently remove the cavity metal inserting cutter and machine the crankshaft. In the compound turning center, the milling process of the milling machine, the carbide high-speed machining process using the carbide thread milling cutter instead of the hard alloy tap. In addition, with the development of various composite machine tools and the "one machine or one-time complete machining" technology, the traditional technology of cutting processing will be further changed.
(2) Significant progress in tool materials and coating technology
The new cutting technology has completely broken through the traditional cutting technology thanks to the improvement of tool materials and the development of coating technology.
The development of tool materials is reflected in the overall improvement of the performance of various tool materials, which has improved the processing efficiency in all fields of cutting. Among them, special emphasis is placed on the advancement of two tool materials, namely the advancement of superhard tool materials PCD, CBN and cemented carbide materials.
PCD and CBN materials have high hardness and particularly good wear resistance. They have been hoped to become the promoters of high-speed cutting, but due to their brittleness, their practical process has been slow for a long time after the advent. In recent years, through the control and adjustment of PCD, CBN material manufacturing process, formulation composition, tissue size and other factors, the material toughness has been significantly improved, the variety has increased, and the application field has expanded, making the hope of applying superhard tool materials for high-speed cutting become The reality.
As a tool material, cemented carbide has always been a contradiction between hardness and toughness. Although its application in cutting operations such as turning, milling, and hole machining has played an important role in improving machining efficiency over the years, its poor toughness has not been significantly improved. Nowadays, solid carbide drills and end mills made of ultra-fine grained carbide have been widely used, and the cutting speed can be increased several times than that of high-speed steel tools, making cemented carbide the most widely used and comprehensive performance. The best tool material. Another major advancement in cemented carbide materials is the development of gradient cemented carbide materials that make the surface of the coated carbide inserts rich in cobalt, which improves the toughness of the carbide insert edges, not only reduces chipping, but also The use of a base material resistant to plastic deformation improves the bearing capacity of the insert and significantly improves the cutting performance of the coated cemented carbide insert.
Significant progress has been made in coating technology for the past 10 years. In the field of CVD coatings, medium temperature CVD TiCN and thick film Al 2 O 3 coatings improve the wear resistance and crack propagation resistance of the insert. The development of PVD coatings is particularly striking, not only wear resistant coatings such as TiAlN, AlTiN, AlCrN, TiSiN, Al 2 O 3 , but also various lubricating coatings such as MoS 2 , DLC, WC/C, and gradients. New coating structures such as coatings and nano-coatings greatly improve the performance of the coating. At present, the development trend of coating technology is in the ascendant. With its many functions, good effects and rapid development, it has become the most effective means to improve cutting performance.
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