Abstract: The current development of manufacturing industry is characterized by intensified competition. How can we continuously improve production efficiency, reduce manufacturing costs, provide high-quality products to customers at competitive prices, and meet the growing needs of users in time to become an automobile manufacturing industry. The focus of common concern of all enterprises.
The current development of the manufacturing industry is characterized by increased competition, how to continuously improve production efficiency, reduce manufacturing costs, provide high-quality products to customers at competitive prices, and meet the growing needs of users in a timely manner, becoming a common enterprise in the automobile manufacturing industry. The focus of attention. The flexibility of automobile production is increasing. It is required to introduce new products or convert new models according to market demand. When the market has demand for a certain product, it must seize the opportunity to produce products that meet market needs. There are a large number of parts in the automobile manufacturing that need to be cut, which has the characteristics of high technology intensity, large production volume and fast manufacturing tempo. The tools used in the automobile manufacturing industry not only require good cutting performance and long working life, but also require them to have High stability and high performance-price ratio. Metal cutting and tool technology are one of the most active factors in the machining process, and become one of the key technologies to improve production efficiency, processing quality and reduce manufacturing costs. High-speed and large-cutting fast-feeding processing of automobiles and their parts manufacturing, especially in new factories and new projects, is increasingly moving toward high-speed machining. More and more CNC high-speed machining centers are used, many of which are processed. The spindle speed of the central machine has reached tens of thousands of revolutions. At the same time, rapid feed has also been greatly developed. With high-speed machining, the use of a dense-tooth milling cutter increases the feed speed. For example, in the machining of aluminum alloy gearbox parts, the milling feed speed of some faces is more than 15m/min. It can even reach more than 18m/min. In order to improve production efficiency, in the processing of automotive parts, the trend of reducing or merging the processing steps is also obvious, such as the elimination of semi-finishing, direct finishing after rough machining, direct fine grinding after roughing, and fine-finishing after drilling Once in place, a rough milling after surface roughing meets the requirements, cutting out the machining allowance as much as possible in the roughing, and the subsequent finishing directly guarantees the machining size and shape, positional accuracy and surface finishing quality, which is on the machine tool and The tools are all very demanding. New carbide tools and super-hard tools are widely used for efficient machining. Tool materials have changed a lot. New carbide tools and super-hard tools have been widely used in the modern automotive industry, especially in drilling. Cutting, reaming, milling, turning, etc. New cemented carbide tools have developed rapidly in recent years. They have high hardness and good comprehensive cutting performance, and at the same time have suitable performance and price ratio. They have been applied in the automotive industry and achieved good results. At present, cemented carbide tools are developing new formulations, adopting new forming and sintering technologies, and adopting nanotechnology and ultrafine powders to develop new carbide tools with high hardness and toughness. At the same time, superhard tools have gained wider and wider applications in the automotive industry, mainly CBN (cubic boron nitride), PCD (polycrystalline diamond) tools and ceramic tools. For example, CBN inserts are used in the machining of cylinder bores in semi-finished and fine-finished processes. The cutting speed can reach 800m/min and the tool life is greatly extended. Due to its extremely high hardness, PCD tools have a very high service life when processing aluminum workpieces and other non-ferrous metals and their alloys. In recent years, with the heavy use of lightweight materials (such as aluminum alloys, composite materials, etc.) in PC manufacturing, PCD tools The application has also increased significantly. Nowadays, many parts of the cylinder block, cylinder head, gearbox housing, valve body, groove body and side cover of the automobile engine are made of aluminum alloy. PCD tools are used in the processing of these parts, which has achieved good results. Generally, the life of each knife is about several thousand pieces of workpiece, and the length can reach 15,000 to 20,000 pieces. For example, in some processes of the gearbox housing, the original carbide boring tool is changed to With PCD tools, the tool life can be increased from 3,000 to tens of thousands, and the economic benefits are very obvious. In addition, ceramic knives are also a promising tool that is currently being used in the automotive industry. Due to its high hardness and competitive price, ceramic knives can be used in some processes. Instead of CBN tools, such as in the milling of the cylinder head surface of an inline four-cylinder engine cast iron cylinder, a new ceramic tool has been used to replace the original CBN tool, and the tool cost can be reduced by more than 35%. In the rough and semi-finished cylinder bore of cast iron cylinders, ceramic cutters are used in many cases. The main disadvantage of ceramic cutters is that they are brittle, so the advantages are obvious in the case of continuous cutting, and the tools need to be avoided. Cracks are caused by sudden and local temperature changes, so dry cutting is generally performed. The development of tool coatings and the application of coated tools due to the demanding conditions of efficient machining in the automotive industry, relying solely on the improvement of tool materials is far from satisfactory, surface engineering technology, tribological technology and coatings. Application and development have contributed greatly to improving the cutting performance and working life of the tool. At present, more coatings are used on the tools used in the automobile manufacturing industry, such as TiN, TiC, TiCN, TiAlN and new AlCrN coatings, etc., which are well applied to drills, reamers, gear hobs and taps. As a result, most of the carbide cutter blades used in the automotive industry have been coated, and the tool life has been significantly improved. The coated materials have a wide range of base materials, including high-speed steel, cemented carbide, ceramics, etc., for example. In the process of milling the engine cylinder block cylinder head joint surface with ceramic tools, the coated tool can be used for more than 20% longer than the uncoated tool. And as the regrind requirements for tools increase, more and more reground tools need to be re-coated, giving the coating application a broader perspective, and how to make the tool re-coated after grinding. To achieve the performance level of the original new tool, it is also necessary for the coating manufacturer and the coating tool user to make greater efforts together. At present, more and more aluminum alloy materials are used in the automobile manufacturing industry, and more and more aluminum parts are processed. However, some coatings with better application effects in the processing of cast iron and steel parts may not be good in the processing of aluminum parts. The effect is that some coating companies have developed some coatings that are more suitable for the processing of aluminum parts. For example, there is a composite coating of titanium aluminide and tungsten carbide recently, which is processed on aluminum parts. Good results. The diamond-coated tool also has a good effect on the processing of aluminum parts. The method of forming and covering the diamond-like coating on the cemented carbide tool can make the tool with complex shape or chipbreaker. Can have the processing properties of certain diamond tools. At present, the development of tool coatings and application research in the automotive industry are accelerating, and the development of nano-scale and multi-layer is progressing. Therefore, it is difficult to meet the requirements of improving the comprehensive performance of the tool due to the single coating material. The composition will tend to be diversified and composite; in the composite coating, the thickness of each single-component coating will become thinner and thinner, and the number of layers will be more and more, and some have reached more than 400 layers; In the development process, more emphasis will be placed on the application of cutting tribology. The theory and test of cutting tribology and coating evaluation methods will be beneficial to the development and application of new coatings. The new coating process will meet different cutting requirements. More targeted coatings. Development and standardization of compound tools In order to achieve efficient machining in the automotive industry, combined tools and composite tools have been used extensively to simplify processes, reduce tool count, reduce tool change time and reduce cycle time. Now, There is a combined tool for drilling and threading together. The front part of the composite tool is used for drilling, followed by the threaded part of the tool. After the threaded bottom hole is drilled, the tool is threaded. Milling, the complete machining of the hole is completed with only one tool, and has been applied in the processing of certain holes in the engine cylinder block to reduce the auxiliary time of the tool change and meet the requirements of the production cycle. Since the application of the combined tool greatly improves the production efficiency, it also increases the type and quantity of non-standard tools, and increases the requirements for tool management, especially when the abnormal consumption of the tool occurs, which increases the difficulty of quickly obtaining the replacement tool. And the risk of affecting the normal production of the production line. Therefore, how to ensure that the composite tool is used in large quantities for high productivity and the tool can be standardized as much as possible becomes a problem that needs to be paid attention to and solved by the tool manufacturing industry and the automobile manufacturing industry. The standard, the development of tools oriented to the platform, the establishment of some standard composite tool structure, according to the reasonable combination of production tasks or transformation of cutting and functional modules, and the use of standard blades in this composite tool as much as possible, quickly and inexpensively Manufacturing a variety of special tools, which will greatly reduce tool manufacturing, procurement and inventory costs, shorten tool delivery time, and significantly improve the emergency response and rapid response capability of abnormal tool consumption.
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