It can be seen from the worldwide observation of the development of China's manufacturing industry that China's manufacturing industry has developed rapidly in recent years. For the CNC bending machine mold industry, this means a huge market. In this context, China's low level of manufacturing costs is a recognized fact. From the perspective of labor productivity, statistics show that China is about three to five times larger than developed countries such as Germany, the United States, and Japan. Such a large market, low level of labor productivity, coupled with the continuous advancement and development of manufacturing technology, is both an opportunity and a challenge for the CNC bending machine mold industry. The market demand for CNC bending machine molds is not only the increase in quantity, but more importantly, the improvement in quality. From the perspective of the user industry, there are seven major industries that have the most significant demand for CNC bending machine molds.
One is the power generation equipment manufacturing industry. In the context of global energy supply tensions day by day, yangyanlizd oil prices continue to rise, the demand for power generation equipment has become more and more obvious. In the manufacturing process of power generation equipment, the cost of only the mold part of the CNC bending machine is very considerable.
Mold manufacturing is also one of the largest industries for CNC bending machines. In the mold manufacturing process, CNC bending machine molds are required in almost all aspects of forming molds, hot working molds, cold working molds, and plastic molds. In addition, automobiles, high-speed trains, general machinery manufacturing, and the wood processing industry, which has gradually expanded in recent years, have become the main users of the CNC bending machine mold industry.
The aerospace industry is the most traditional and most important application of CNC bending machine molds. In this industry, CNC bending machine molds are generally used to cut aircraft structural parts. These structural members are generally bulky, and aluminum alloys have been used in large numbers in the past. With the expansion of the application fields of titanium alloys and composite materials, the requirements for mold processing of CNC bending machines are becoming higher and higher.
As one of the key national support industries, the government has invested a large amount of money in the research and development of large passenger aircraft in the aerospace industry in recent years. These R&D are all aspects. We extracted the aspects related to the CNC bending machine molds and analyzed the use of structural materials.
As can be seen from the latest Boeing 787 fuselage, the method of directly covering aluminum alloys in the past has been gradually abandoned, and the direct laying and winding of composite materials has been replaced. In addition, the amount of titanium alloy is also increasing. Compared with the past, the new method can greatly reduce the weight of the aircraft, save fuel and energy consumption, which is especially important for large passenger aircraft.
Titanium alloys are recognized as difficult to machine materials. Composite materials that only need to be laid and entangled do not seem to require a large amount of processing, but the requirements for processing quality are getting higher and higher. For the CNC bending machine mold industry, this is no small challenge. In addition to the fuselage structural components, the processing of aircraft engines is also a difficult point. The engine is generally made of difficult-to-machine materials, and has a complicated shape. It requires grooving, blade processing, etc., and the actual cutting effect of the CNC bending machine mold is very high. In addition, in order to meet the high quality requirements of aircraft structural parts, in general, the whole blank is used for processing, and more than 90% of the materials will be cut off. Due to the large processing volume, the processing efficiency is extremely high.
(II) Development trend of cutting processing technology From the development history of CNC bending machine mold, from the end of the 19th century to the middle of the 20th century, the CNC bending machine mold material was mainly represented by high-speed steel; in 1927, Germany first developed hard Alloy CNC bending machine mold materials have been widely used; in the 1950s, synthetic diamonds were synthesized in Sweden and the United States respectively, and the CNC bending machine molds were cut into the period represented by superhard materials. In the 1970s, people used high-pressure synthesis technology to synthesize polycrystalline diamond (PCD), which solved the problem of rare and expensive natural diamonds, and extended the application range of diamond CNC bending machine molds to aviation, aerospace, automobiles, Electronic, stone and other fields.
The selection of mold material for CNC bending machine is the basis for successful cutting. Compared with cemented carbide, PCD CNC bending machine mold speed can reach 4000m/min, while cemented carbide only has 1/4. From the perspective of life, PCD CNC bending machine molds can generally increase by 20 times. From the surface quality of the processed, the effect of PCD is 30% to 40% better than that of cemented carbide. In addition, the development of CBN (National Boron Nitride) super-hard material CNC bending machine mold and surface coating CNC bending machine mold has also contributed to the advancement of cutting technology.
For more than 100 years, the cutting speed of CNC bending machine molds has been continuously improved, which has brought about changes in processing efficiency and further expanded the processing range. The biggest mark of cutting development is the development of high speed cutting (HSC).
A high-speed machining system involves many aspects. From the processing point of view, the traditional cutting process, a workpiece (such as mold), through the blank annealing - roughing - finishing - quenching - EDM preparation - EDM - special finishing - manual polishing procedures . The high-speed machining only needs blank quenching-roughing-semi-finishing-finishing and super-finishing, which is reduced by three steps, and the processing time is shortened by 30%~50% compared with the traditional processing method; This advantage is especially noticeable when it comes to small parts. What's more, in the past, some companies used to make complex molds, which basically took 3 or 4 months to be delivered. After high-speed cutting, it only took half a month to complete.
A high-speed machining system consists of two parts: CNC bending machine mold and technology. The factors related to the mold of the CNC bending machine include the selection of the mold material of the CNC bending machine, the composition of the mold system of the CNC bending machine, and the edge shape of the CNC bending machine mold. Closely related to the technology is the choice of CAD/CAM system, the planning of the machining path of the CNC bending machine, the setting of cutting parameters and the cooling and lubrication.
Since the popularization of high-speed cutting, the processing efficiency has increased by 4 to 5 times in the half century from 1950 to 2000. Of course, it should be mentioned that high-speed cutting generally defines its "high speed" range from its processed objects.
The CNC bending machine mold does not account for a large proportion of the total processing cost. We take the manufacturing process of the automobile industry as an example: the investment in machine tools and other equipment accounts for 35% of the total cost, the energy consumption of the equipment accounts for 7%, the normal operating cost of the enterprise accounts for 27%, and the cooling and lubrication costs account for 17%. artificial 9%, CNC bending machine die 4%. Coincidentally, the production cost of machining workpieces of aluminum alloy, cooling and lubrication 16%, CNC bending machine die 4%, 80% other processing costs. As can be seen, the entire CNC bending machine tooling cost, only a very small part. However, it should not be overlooked that this 4% cost CNC bending machine mold may affect the overall processing efficiency of 10% to 15%.
CNC bending machine dies, the three most critical factors: cost, service life, efficiency. Experiments show that, when the CNC bending machine tooling costs by 30% to reduce the overall cost of about 1%; if 50% of CNC bending machine die life, the overall cost is reduced by approximately one percent; however, if cutting parameters optimized as , CNC bending machine die improve processing efficiency of 20%, then the overall cost for each piece can be reduced more than 15%.
Of course, to improve the production efficiency of the machine tool in an all-round way, not only should the cutting time of the workpiece be reduced by high-speed cutting, but also the machining auxiliary time must be greatly compressed (including machine adjustment, program operation check, idle travel, brake dry running, workpiece loading and unloading). And the time of clamping, tool change, etc.), standby time and downtime, because the effective cutting time of the machine tool generally only accounts for 25% to 35% of the total working time under the conditions of multi-variety and small batch production. It can be seen that in addition to high-speed cutting, how to process more effectively is one of the important issues facing the manufacturing industry.
At present, green processing technology has become a global hot spot. This green color includes economic, environmental protection and high efficiency. From the perspective of environmental protection, on the one hand, high-speed and high-efficiency processing brings about a reduction in energy consumption. On the other hand, the choice of coolant and lubricating fluid is very important. As mentioned above, the cost of the coolant accounts for a relatively high proportion of the overall cost, reaching around 16%. The effect of lubrication and cooling is also very relevant to the overall processing efficiency, especially for difficult-to-machine materials, such as titanium alloys, which must be properly cooled after cutting to a certain extent. With the development of high-speed cutting, when the coolant is poured, the mold of the CNC bending machine often has a thermal crack, which leads to a decrease in the life of the CNC bending machine, which needs to be improved.
In short, in processing technology, high precision, high efficiency, low cost, environmental protection, and predictability of results will be a clear trend. This predictability means that the processing results must be predictable, controllable, and not random. This requires the operator to have a deeper understanding of the processing technology.
(3) Discussion on modern manufacturing methods What is modern manufacturing? The first is the modern hardware, which includes the use of advanced machine tools, CNC machining systems, and advanced CNC bending machine molds; in terms of software, one is the improvement of cooling and lubrication technology and conditions, and the other is the optimization of cutting parameters (ie processing). Technical optimization). In China's aerospace industry, the government has invested in a large number of internationally advanced equipment, but found that it still cannot achieve very efficient and efficient processing. After repeated experiments, it was found that the software needs to be improved. It can be seen that modern manufacturing not only needs to invest a large amount of advanced instruments and equipment, but should also be better armed in terms of knowledge and advanced technology.
Adjustments in cutting parameters, different practices in different companies, are a matter of opinion, and will not be repeated here. From the CNC bending machine mold itself, the most important thing is to improve the service life of the CNC bending machine. As mentioned above, the service life of the CNC bending machine is closely related to the conditions and methods of cooling lubrication. High-speed cutting also promotes green cooling/lubrication technology. Here is a new technology for cooling and lubrication. If nitrogen is added to the cold oil mist lubrication (below 10 °C), the die life of the CNC bending machine can be increased by 10 times. At the same time, it can improve processing efficiency, reduce pollution and improve surface processing quality. Particularly suitable for processing difficult materials such as titanium alloys. The deviation generated during machining directly affects the cutting quality of the workpiece. There are many factors that cause machining deviation, such as the distribution of stress in the workpiece, the installation and clamping of the workpiece, the complexity of the workpiece structure, the degree of deformation of the CNC bending machine, the accuracy of the machine tool, the stiffness and thermal characteristics, the deformation of the workpiece, and the heat of the workpiece. Deformation, etc.
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