Current Status and Development of CNC Tool and Measuring Instrument Technology in China

During the “Eleventh Five-Year Plan” period, China’s major projects in the manufacturing sector have included important areas of energy, automobile, aerospace and transportation related to national economy and people’s livelihood, and typical and key parts involved in the manufacture of major equipment in these industries. The characteristics are: large, heavy, complex and precise. The cutting process of new difficult-to-machine materials (such as silicon-aluminum alloy, titanium alloy, high-strength heat-resistant steel, carbon fiber and composite materials) occupies a considerable proportion. This puts new challenges on CNC machining technology and CNC cutting machine equipment. It also puts new requirements and challenges on CNC tool and digital measurement technology and measuring instrument, and provides new development opportunities and stage. At present, the development of CNC tools and instruments in China lags behind the development of CNC machine tools, which has become a bottleneck hindering the development of CNC cutting technology and CNC cutting machine tools in China. It is imperative to change the status quo.
In order to understand the needs and application status of CNC machine tools and measuring instruments in China's major machinery and equipment manufacturing industry, in order to further clarify the current situation of domestic CNC cutting tools and measuring instruments in key parts cutting and processing. Its gap with foreign advanced technology and products, in order to help objective and scientific confirmation: during the "Eleventh Five-Year Plan" period and for some time to come, China's tool industry in the field of CNC tools and digital measuring instruments in the field of research and direction, In June 2008, the author was fortunate to participate in the investigation of some manufacturers of nuclear power wind power equipment manufacturing and tool manufacturing organized by China Machine Tool Industry Association, and the status quo of China's CNC tool and measuring instrument in the national important machinery and equipment manufacturing industry. And development has a deeper feeling.
I. Application status of numerical control tools and digital measuring instruments in nuclear power wind power equipment manufacturing Energy equipment manufacturing industry, especially clean energy such as nuclear power and wind power equipment manufacturing industry has developed rapidly in recent years. Some typical key components in power generation equipment, such as steam turbine blades, rotor wheel slots, and turbine generator rotor weaving grooves, are processed because the materials to be processed are difficult-to-machine materials such as heat-resistant high-strength alloy steel and stainless steel. The cutting load is heavy, and the cutting performance of the numerical control tool, such as high temperature red hardness, bending shear strength, abrasion resistance, adhesion resistance, friction coefficient and the like are highly demanded. At the same time, the cutting of high-precision complex profiles puts higher demands on the accuracy of the CNC tool itself. Therefore, the processing and testing of these typical parts of power generation equipment, to a certain extent, represent and reflect the latest achievements and levels of advanced cutting technology and advanced numerical control tools, advanced digital measurement technology and measuring instruments, which has attracted the attention of the tool manufacturing industry. In addition, the high-precision, large-scale wind power transmission gearbox gear forming processing and measurement, as well as the new technology of the transmission rolling screw hard cutting forming process, were also deeply impressed.
1. CNC Machining of Steam Turbine Blade Profiles Today, five-axis CNC machining of steam turbine blades has been widely used. The number of steam turbine blades is large, the specifications are large, the contour shape is complex, the precision is high, and it is difficult to process. The high-performance alloy steel workpiece with heat resistance, high strength and corrosion resistance increases the difficulty of cutting. Therefore, the material and coating performance of the indexable insert base of the numerical control tool of the blade are very high. At present, most of the factory processing still uses foreign carbide coated tools/blades. In the investigation, it is understood that the processing of the impeller blades of the integral forging impact turbine has yet to be tackled. Regarding the detection of the shape accuracy of steam turbine blades, the coordinate measurement is usually performed by a coordinate measuring machine, such as PC-DMIS BLADE software for measurement and blade parameter analysis on a CMM; or in the field with a sample optical gap method, but after There is a lack of quantitative judgment. The company expects to provide digital instruments that can be easily applied to the production site and can quickly and accurately measure batch blades.
2. CNC Machining of Turbine Rotor Eucalyptus Wheel Grooves The forming cutters for processing turbine rotor eucalyptus wheel grooves are highly accurate and the line accuracy is up to micron. At present, the cutting performance and precision of the eucalyptus-type wheel groove milling cutter (M42 high-speed steel base + TiAlN coating) made by localization (including the self-developed by the steam turbine factory) can basically meet the needs of users, and it is gradually entering the production site to replace the import.
3. CNC Machining of Turbine Generator Rotary Shaft Groove Turbine Generator Rotary Shaft Groove is machined on a CNC rotor slot milling machine using a special indexable rotor slot milling cutter. Since the shaft material is high-strength alloy steel, the cutting groove is deep, the milling cutter has a large diameter, the cutting speed is high, and the cutting load is heavy, and the quality of the non-re-grinding CNC carbide coated blade is high. The production site is still dominated by foreign tool products.
4. CNC cutting of wind power transmission gearbox gears As a clean and environmentally friendly, renewable energy wind power generation equipment has developed rapidly in China in recent years. In order to meet the requirements of mass production of high-precision and large-modulus hard-toothed gears for wind power transmission gearboxes, gear CNC forming technology and equipment have been promoted and applied. China's important wind power gearbox development and manufacturing base Nanjing high-speed gear box factory, using advanced gear forming dry milling technology and forming grinding technology, as well as the corresponding large CNC CNC forming gear milling machine and CNC numerical control forming gear grinding machine The equipment is produced to achieve rapid growth of high-quality wind power gearbox products. During the processing and after the completion, the specified accuracy detection and monitoring of each gear is carried out, which is an important guarantee for the manufacture of high-performance, long-life wind power transmission gearboxes. The Grison-Pfalz large-scale forming gear grinding machine adopts the numerical control on-machine gear measuring device, which can perform on-machine scanning measurement on the tooth profile and tooth deviation of the gear; the new Klingberg P300 3-meter seat CNC The gear measuring instrument can measure the geometric accuracy of gear machining with high precision. The instrument adopts the work surface air floating technology to facilitate the safe assembly and adjustment of heavy workpieces. The high-precision grating sensor probe can quickly correct the workpiece installation eccentricity and implement software compensation. It is worth mentioning that the domestic CNC large-scale forming gear milling machine and CNC milling cutter head have been applied in the factory.
5. CNC Machining of Transmission Ball Screws Nanjing Process Equipment Factory has introduced German advanced ball screw hard cutting forming technology and CNC cutting equipment in recent years. CBN forming milling cutters are used for precision turning and hard cutting of hardened steel rods. Complete precision forming of the drive ball screw thread. Since it does not use coolant, it meets environmental requirements and achieves efficient, high-performance machining. It is worth mentioning that the domestic laser rolling screw inspection instrument has been well used in the factory.
Second, China's tool manufacturing CNC machine tools and measuring instrument technology status and development This survey of the tool industry's three major manufacturers: Shanghai Tool Factory Co., Ltd., Harbin Measuring Tool Group Co., Ltd. and Harbin No. 1 Tool Manufacturing Co., Ltd. . I deeply feel that China's economic strength has grown rapidly, especially the rapid development of machinery manufacturing industry for many years, creating unprecedented opportunities for China's tool manufacturing industry. The launch of the national “Eleventh Five-Year Plan” and major special projects has provided new development opportunities. According to their own characteristics, the relevant factories have formulated the short-term development policy and long-term development strategy goals, and have already carried out the implementation stage, achieved remarkable results, accelerated technological progress, continuously improved product quality, improved enterprise competitiveness, and sustainable development capability. Enhanced. In summary, there are several characteristics:
1. Based on traditional strong products, increase investment in technological transformation, introduce advanced technology, products and equipment, improve quality, expand scale, and establish and strengthen the dominant position in the industry.
According to the development goals set by the Shanghai Tool Factory, it has invested heavily in technical reforms in a planned manner, and introduced and developed its own CNC equipment and technology for advanced hard alloy hole machining tools and tap processing, and advanced super-hard tool CNC manufacturing equipment. Technology, advanced CNC tool/blade coating equipment and technology, and high-speed steel heat treatment technology. On the basis of digestion and absorption, we actively develop and innovate, attach importance to the development and development of core technology of CNC tool manufacturing, and upgrade product structure to ensure the leading position of processing tools and tap products in the industry. The implementation of the new round of technical transformation investment and development planning has made positive contributions to the rapid development of the company into a domestic tool manufacturing enterprise with the largest production scale, the most complete product variety and the strongest supporting capability.
In the past 10 years, the company has continuously strengthened its advantages in the development and manufacture of precision instruments such as gear measuring instruments, surface roughness measuring instruments and contour measuring instruments, and successfully developed the largest domestic 2 m CNC gear measuring instrument, which has become the most competitive in China. Manufacturer of precision measuring instruments. In 2005, through the acquisition of German Kaishi Company, the introduction of foreign advanced design and manufacturing technology and patents, the rapid establishment of advanced, double-sided constrained positioning and clamping HSK tool system production line, and the formation of mass production; quickly built CCD CNC tool pre-adjustment measuring instrument The production workshop of the series products has the capacity to produce 500-600 sets per year and has been exported to Europe in batches. Successful mergers, introductions, development and innovation, and localization have enabled Haliang to quickly establish its leading position in the country in terms of precision measuring instruments. In terms of related technologies and products, it has rapidly narrowed the gap with the international advanced level.
Ha Yigong passed the technical reform of the national debt (invested hundreds of millions of yuan in two years), built a new factory, invested in new equipment, and changed its face. Especially in the fist product broach, the introduction of foreign advanced CNC broach grinding machines and testing instruments, in order to continue to lead in the country, and the traditional advantages of CNC tools such as indexable tools and gear hobs have been further strengthened. The hard alloy arc bevel gear milling cutter and the newly developed CNC cylindrical gear forming milling cutter have been successfully applied and have been well received by users.
Zhuzhou Diamond Cutting Tool Co., Ltd. has invested 1 billion yuan in recent years. It has introduced complete sets of advanced manufacturing technologies and equipment to enable product development capabilities in the fields of solid carbide tools and CNC indexable inserts including carbide materials and CNC tools. And the quality of manufacturing has been greatly improved, becoming the hard-wearing CNC tool/indexable insert manufacturer with the strongest domestic competitiveness, the largest investment in research and development, and the largest production scale.
2. In accordance with the development of the tool industry, we will expand the upstream and downstream extension technologies and product areas. In order to better meet and adapt to market/national development needs, lay the foundation for the realization of corporate strategic development goals.
Based on the manufacture of hard alloy raw materials and semi-finished products, Zhuzhou Diamond has expanded into the deep processing field of CNC tools and indexable inserts, and has become the largest manufacturer of carbide tool/blade in China. The Shanggong plans to develop from tool manufacturing to tool material (hard alloy) manufacturing, high-grade CNC tool manufacturing equipment manufacturing, etc. The goal is to build a leading large-scale comprehensive metal cutting tool manufacturer in China, integrating tool research, manufacturing and One of the leading domestic companies in service.
3. Focus on basic, commonality, research and development of key technologies, actively undertake national and local scientific and technological research projects, establish a research and development system for “production, study and research”, and rapidly enhance the innovation capability and technology/product advantages of enterprises.
In recent years, the amount of research and development funds has accounted for more than 4% of sales revenue, and more than 30 new products have been developed and 165 patents have been issued. In 2005, he undertook the drafting of the “HSK Tool Cone Measuring Tool” standard for the National 863 Program. In 2006, he undertook the Harbin “Research and Application of HSK Tool System for High-speed CNC Machine Tools”. In 2007, it undertook the formulation of the national standard “tool pre-adjustment measuring instrument” and the scientific and technological research project of Harbin “CNC and CCD automatic aiming high-precision tool pre-adjustment measuring instrument”. In recent years, Shanggong has undertaken the Innovation Fund of the Ministry of Science and Technology of the People's Republic of China, “Development of Precision Composite Hole Machining Tools and High-efficiency Composite Coating Tools for Automobile Manufacturing Industry”, Shanghai Economic and Technological Research Project “Computer Platform Construction for Tool Research and Development” and “High-speed Cutting Coating Tools”. The research and development", "high-efficiency precision CNC tool manufacturing and application technology", etc., obtained a number of patents for tool coating.
4. Through the acquisition of mergers and acquisitions, professional talents and technology introduction, the integration of resources will be optimized and the overall strength of the company will be improved.
Haliang successfully merged with German Kaishi Company in 2005, and laid the manufacturing and development technology and capability for mass production of international level HSK tool system and CNC tool pre-measurement measuring instrument. Shanggong relied on the listing of Shanghai Jiyou Co., Ltd. in Hong Kong to raise funds. In 2007, it invested heavily in the development of “Technology Transformation Project for CNC Tool Production”. Through the company with the Italian company SU company, the company introduced advanced gear tool manufacturing technology and know-how, and enhanced the strength of gear cutter manufacturing.
Through research, we feel that the tool industry's technical level and production scale have been rapidly developing and progressing, and we also see that the gap with foreign advanced level is still very large. In the energy equipment manufacturing industry such as wind power and nuclear power, the numerical control tools and measuring instruments used in the cutting of key components are almost exclusively monopolized by foreign products. The main manufacturers are Sandvik, Kenner, Isca, Secco and so on. Domestic tools are mainly used for non-critical parts and rough and semi-finishing processes. Compared with foreign products, in addition to the large gap in cutting performance indicators, the bigger problem is that the quality is unstable, unreliable, and the product performance is highly dispersible. In addition, the gap in user services is small.
In China's research, development and manufacturing of CNC cutting technology and CNC cutting tools, the main gaps with foreign countries are reflected in the following three aspects:
(1) Basic theory and technical aspects of CNC cutting, especially microscopic quality control technology, metallographic structure analysis and quality control technology related to materials discipline, and in-depth research on cutting mechanism and technology of new difficult-to-machine materials.
(2) CNC tool manufacturing technology and equipment, especially in the key manufacturing process and process stability to quality control, such as ultra-fine grained carbide substrate, coating process quality control, superhard tool edge reinforcement technology Etc. Equipment: development and development of CNC tool grinding machines, edge strengthening equipment and coating equipment.
(3) CNC tool application technology and experimental research, for different industries, user needs, especially new difficult-to-machine materials such as high-temperature alloy, titanium alloy, silicon-aluminum alloy, composite materials and other workpiece processing, to provide users with scientific, reliable and practical Information platform for feasible CNC tool/indexable insert and cutting database for cutting parameters.
In terms of measuring instruments, the gap with foreign countries is even greater. In this survey, it is obvious that there are big gaps in the following three technical areas:
(1) CNC machine tool measurement technology and instrumentation, especially the high-precision dynamic and static CNC machine tool precision and performance testing technology represented by laser measurement system and precision compensation technology.
(2) CNC tool measurement technology and instrumentation, especially high-precision CNC numerical control tool measurement technology, CNC tool on-machine measurement technology, and CNC tool pre-adjustment measurement technology and instrument.
(3) On-machine/online digital measurement technology and instruments suitable for production sites, especially on-machine measurement and feedback correction compensation techniques and devices for complex precision contour machining, such as CNC forming gear grinding machine measurement and measurement technology and equipment, steam turbine On-line measurement technology and equipment for blade on-site.
In order to shorten and catch up with the advanced level of foreign countries as soon as possible, under the guidance and support of national policies, key technologies that involve the development of technology in the tool industry will be selected to carry out research projects, which will enhance the competitiveness of China's tool industry and its ability to sustain development. It is of great significance to adapt to the development needs of the national equipment manufacturing industry. With the support of the state and the efforts of the industry enterprises themselves, it is entirely possible for China's tool industry to greatly accelerate the process of narrowing the gap with the advanced level of foreign countries.
Third, the equipment manufacturing industry needs analysis of the tool industry 1. New tool system for high-speed CNC machine tools - HSK and other two-sided clamping positioning tool system for high-speed and high-precision cutting, two-sided clamping positioning tool system represented by HSK, is to adapt to today's high-speed and high-efficiency precision CNC machining Developed by technology and meeting the advanced processing performance requirements of high-end CNC cutting machine tools. The new tool system is characterized in that when the connection with the machine tool spindle is tightened, the taper surface and the end surface are simultaneously contacted and positioned to realize the two-sided constrained over-position, which enhances the dynamic rigidity/connection of the CNC machine tool spindle-tool system during high-speed machining. Strength and positioning accuracy. Typical examples are the HSK tool system that has become an international standard and the Sandtoc Capto tool system.
Many domestic enterprises have carried out a small amount of trial production and production of HSK tool system. Due to the lack of in-depth research and development of key technologies, no complete set of manufacturing technology and mass production capacity have been formed. After the merger of German Kaishi Company in 2005, Haji has gradually mastered the batch manufacturing technology and process of HSK tool system series from product design to dynamic balance and precision inspection. Now it has an annual output of more than 50,000. The ability of the set (all exported) has achieved remarkable results. Of course, there are still deficiencies in mass production technology, process routes, product quality testing and control, and it is still necessary to continue to absorb and innovate in order to further narrow the gap with foreign countries. Shanghai Tool Factory and Sichuan Yingge have also been able to produce HSK taper shank CNC tools in small quantities, providing users such as Shanghai General Motors. After the acquisition of Shanghai Annex 1 Plant, Shanggong has the ability to batch produce conventional tool systems. It has planned a “new tool holder system project for high-speed CNC machine tools”, introducing design and manufacturing technology, talents and key equipment to achieve an annual output of HSK knife. The production capacity of 20,000 pieces of handle chucks. In fact, China has not yet established a national and industry-level HSK tool system testing system, benchmark delivery system, physical benchmarks at all levels, and product quality certification system. This work is indispensable and should be planned and implemented as soon as possible.
2. Efficient indexable tool series and super-hard tool Efficient indexable tool series and super-hard tools are very important fields in CNC tools. The application of the products is extensive, and the key technologies and research topics involved in different application fields will be Different: the indexable insert base material, coating requirements, blade geometry parameters, blade clamping method, overall tool structure design, etc. will be very different, technical difficulty, and more research content. In addition, the design and manufacturing technology of 3D chipbreaker indexable inserts, including the suppression of precision blanks and edge strengthening, are all pending issues. Hard cutting, ultra-precision cutting and new material cutting, including composite materials, further drive the demand and development of superhard tools. In the development and production of high-quality super-hard tool materials, there is still a big gap in China. Even for domestic super-hard tools, most of the super-hard blade (PCD, CBN) materials are imported from GE and De Beers. The adoption of 3-dimensional shape super-hard blades is a new trend in the development of super-hard tools in recent years, and its manufacturing process is more difficult. In terms of high-efficiency indexable tool series, domestic enterprises such as Zhuzhou Diamond, Xiamen Golden Heron, Zigong Cemented Carbide, Shaanxi Hard, and Chengquan are all produced. Among them, Zhuzhou Diamond has the largest scale, the strongest strength and the highest overall level. A CNC indexable insert production line that is said to have reached the world-class level. The research center established in recent years, including design and development, use technology research, material performance test and cutting experimental equipment, has a good development platform. The Shanggong is in the development and production of super-hard tools, with more mature design and processing experience, advanced and sophisticated manufacturing equipment and successful service application results.
3. Ultra-fine grain solid carbide coated tool series Ultra-fine grain solid carbide coated tools are used in the automotive industry, aerospace and energy industries. Currently, solid carbide coated tools are used on key CNC machine tools. Most of them are monopolized by imported knives. Domestic knives are often purchased from ultra-fine grained carbide rods for processing, and their development is restricted. In recent years, some tool factories with solid carbide powder manufacturing capacity in China, such as Zhuzhou Diamond, Xiamen Golden Heron, and Shaanxi Hard, have developed ultra-fine grain carbide tool materials through technical transformation, introduction of technology and equipment. Acquired preliminary results (achieved sub-micron level. In recent years, advanced nano-coating technology has been adopted, and the quality of tool performance has been significantly improved. The work plan will implement the "ultra-fine grain solid carbide coated tool project" to achieve ultra-fine Development of complete technology for die-hard alloy materials and tool manufacturing. Domestic enterprises need to make the mass production of cemented carbides stable to ultra-fine 0.3-0.5μm, further improve the quality, narrow the gap with foreign advanced products, and then need to be in manufacturing technology. Basic techniques such as technology and technology are used to carry out technical research. In addition, how to have enough cobalt-rich layer on the front surface of the coating after finishing the tool is a key technology to improve the quality of the coating, which has yet to be tackled.
4. Efficient, high-performance, sophisticated CNC tools with high-performance, high-performance, sophisticated CNC tools represented by gear hobs, pinion cutters, shavers, and various types of broaches, in automotive, wind power, aerospace, marine, railway, construction machinery, etc. The use of gear transmissions in the industry is widely used and important.
The target parameters listed in the project are reasonable and necessary. There are two main problems in domestic precision gear cutters and broaches: material and coating. At present, the key occasions are all U-cobalt high-speed steel and powder metallurgy high-speed steel materials. Recently, many production plants have carried out technical transformation and equipment investment, using advanced coatings (such as TiAlN, TiAlCN, etc.) and high-speed steel heat treatment technology and not prepared, so that the quality performance of domestic gear cutters and broaches has been greatly improved, and has been reduced abroad. The gap partially replaces foreign products. In the past two years, 'Ha Yigong' has invested nearly 120 million yuan in the construction of new plants and advanced equipment at home and abroad. It is a complex CNC tool manufacturer that has become the first domestic broach production, gear cutter and indexable CNC tool. And work hard. Hanjiang Tool Factory has seized the opportunity of development in recent years and has become the most powerful gear hob manufacturer in China. Through cooperation with Balzers, the plant has ensured the quality of the gear cutter coating and improved the performance of the tool. The high-speed and high-efficiency machine-clamp type non-re-grinding CNC forming gear cutter is a new direction for the development of gear cutters and deserves industry consideration.
5. High-precision, fully automatic tool pre-adjustment measuring instrument series The development of China's digital tool pre-adjusting measuring instrument started late. In 2005, at the Beijing Machine Tool Exhibition, Haliang and Tianjin Tianmen debuted for the first time. Digital CCD pre-adjustment measuring instrument prototype. Since Harbin acquired the German company Kaiying in 2005, based on the digestion and absorption of its advanced design and manufacturing technology, it has developed a series of high-precision tool pre-adjustment measuring instruments. The factory has set up a knife adjustment instrument production section, which has an annual output of 500 to 600 sets of knife adjustment instruments. Currently, it is mainly used for manual export. For high-precision, CNC-automated, network-equipped tool presetting instruments, the plant is actively planning and developing to quickly catch up with today's advanced levels abroad. In addition, domestic Tianjin Tianmen, Chengquan, etc. are all under development, but there is still a certain gap in technology level and quality, and it is still necessary to continue to work hard.
6. High-performance laser measurement system High-performance laser measurement system is mainly used for precision detection and evaluation of high-end CNC equipment such as CNC machine tools and coordinate measuring machines. In recent years, the development direction of laser measurement systems is: high resolution, high precision, multi-function, miniaturization, the main manufacturers are Renishaw of the United Kingdom, API, Agilent and Photonics, and SIOS of Germany, etc. Xiao products have the largest sales volume in China. The new XL-80 light laser interferometry system, which was launched in 2007, is equipped with the XC-80 sensor to achieve miniaturization and improved performance. The measurement distance is 40m/80m, the resolution is 1nm, and the highest measurement speed is 1m/s. American API company's XD laser interferometry system has 5D/6D measurement function, which improves the efficiency and accuracy of CNC machine tool precision detection. China's domestic laser interferometry system, which is mainly developed and produced by Chengdu Tool Research Institute, has a certain gap compared with foreign advanced level. In recent years, through the support of the National Research Institute fund project, the measurement principle and measurement technology have made breakthroughs, and some achievements have been made in improving the performance of the domestic laser measurement system.
In short, through this survey, it is further confirmed that China's tool manufacturing industry has a large gap with foreign countries in terms of the technical level and performance quality of CNC tools and measuring instruments. However, after years of technological innovation investment, introduction and development, the gap has been narrowed, but the innovation capability is still insufficient. This is the result of insufficient basic attention and development of basic technology experimental research and overall lack of technical accumulation in the industry. Convinced that under the guidance of the policy of "production, learning, research and use", with the support of the state, the synergy of the industry, and the efforts of enterprises, China's tool manufacturing industry will be able to develop rapidly and rapidly narrow the gap with the advanced level of foreign countries. Adapt to the needs of the continuous and rapid development of China's machinery manufacturing industry.
Recently, the storm of global economic recession has rapidly expanded from virtual economy to real economy. The impact and impact on the overall tool industry in China suddenly appeared in mid-October 2008. This is a severe test. All tool factories have made great efforts to formulate strategies, adjust plans, and actively respond to the difficulties: at the same time actively strengthen internal strength, accelerate product upgrading, optimize transformation work, and prepare for the early recovery of the industry.

 

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