3. Cognition of the terminal market
Different industries also have different processing requirements, and tool suppliers should be able to help the shop meet these requirements. Certain materials themselves are also increasingly changing with specific industry requirements. For example, composite materials are a good example. Precision Dormer is investing considerable capital in developing tools and application knowledge for drilling in aerospace industry composites.
The challenges faced by certain machined parts are also related to certain industries. Mr. Chris Mills, Project Manager, Aerospace Development at Sandvik Coromant, gave an example of surface integrity. This is an important issue to consider, and few processing shops outside the aerospace industry will face such problems in the same way. However, in the aerospace industry, processing forces and temperatures produce microhardness changes, plastic deformations, and residual stresses that cause parts to be less accurate.
The company has studied this phenomenon, specifically analyzing the effect of tool trailing edge wear on the machined surface. Tool and cutting technology was developed to control the wear of this edge in some way, and this method even allowed aircraft part producers to meet most of the required surface integrity requirements.
Figure 5. There is a certain relationship between more advanced workpieces and more advanced tools. The emergence of diamond tools also increases the need for efficient machining of aluminum alloys.
Increase the percentage of diamond tool applications
Diamond tools increase machine productivity and provide professional solutions to meet more demanding applications.
In any case, as long as the production capacity is tight, you should consider the application of polycrystalline diamond (PCD) or cubic boron nitride (CBN) tools.
There is a direct connection between advanced workpieces and advanced tools. As with automakers, more and more high-performance materials are being used for demanding parts. In order to process these materials in the most efficient manner, the use of diamond tools is becoming more common. This is also the case in the aircraft manufacturing industry, where they are increasingly using diamond tools to meet the growing demand for titanium machining.
Another important area of ​​application for diamond tools is the machining of composite materials, as long as the machine itself is suitable for diamond tooling. Precision Dormer has designed and developed a range of drill bits, such as drill bits with carbide hard materials, diamond coatings and PCD materials, to apply different grades of processing equipment to drill different apertures on composite materials.
Diamond tools and diamond-like tools, whether PCD, CBN or diamond-coated tools, will increasingly enter processing applications. Moreover, the proportion of tools used in this type of material will continue to grow.
Figure 6 shows the source of the cost of a typical workpiece from the pie chart. The table converts the percentage of each cost into dollars and cents. Because the proportion of machining and labor costs is so large, faster cutting can provide a great opportunity to save a lot of money, even when the cost of the tool is increased.
Jim Graham, Product Processing Manager at Diamond Innovations, said this is an inevitable trend. The development of PCD and CBN materials has led to an increasing use of these materials, making the variety of tools more colorful and cost-effective. At the same time, the machining speed and service life of these tools continue to increase, making the machining process reach the level of performance never reached by carbide carbide tools.
In fact, diamonds and their associated tools meet the aforementioned “improving the productivity of machine tools†and “meeting the needs of application expertiseâ€. Due to the extended service life of the tool and improved cutting parameters, the tool's machining capability is improved, the frequency of tool change is reduced, and the machine can process the production parts at a higher speed. At the same time, more professional technical solutions are integrated into the tool to further meet the needs of various application fields.
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