Ten suggestions for improving tool efficiency

Ten suggestions for improving tool efficiency

we specially train engineers and programmers to use good tools to improve production efficiency. Over the past 19 years, we have held hundreds of special lectures and training courses. According to the theory, students' questions and my deep understanding, I put forward the ten best suggestions for users to use good tools to improve production efficiency, some of which may be familiar to everyone. I hope to increase new insight and further improve the production efficiency of my enterprise by accepting the new suggestions

1. Focus on maximum limit Bayer materials technology is one of the largest polymer production companies in the world, which can reduce the whole processing cost of parts. Instead of focusing on reducing the cost of tool consumption. According to the latest relevant statistical data, the consumption cost of cutting tools accounts for only 3% of the processing cost of the whole part, which is insignificant compared with 97% of the processing time and consumption of machine tools. Therefore, our proposal also focuses on reducing the whole processing cost

2. Four goals. When designing a new machining scheme or modifying the existing machining program, it is suggested to take the following four tasks as the main objectives: cycle time, tool life, part quality and surface roughness. And it will be specific, clear, graded and quantified into indexes that can be inspected and accepted. At the same time, when designing the processing plan and formulating the expected goals, you should consult with the tool seller, and you will succeed and get faster and better returns

3. Understand and master the generation and action law of cutting force in cutting various materials. For example, if you master the action law of cutting force, you can select the cutting force direction that can improve the clamping stiffness of parts for machining. It can also be processed by changing the radial force into the direction of axial force by considering the method of reducing the cutting depth

4. Taking advantage of tool geometry, the production efficiency is extremely improved. For example, select the tool with the main deflection angle, increase the feed rate, increase the chip thickness, and improve the removal rate

5. Identify the problem. a: Please first check whether the four foot seats of the machine are in average contact with the pedestal. When there are problems and faults in the processing, it is necessary to carefully analyze and study them, and carefully judge whether it is the problem in the processing process or the problem caused by the improper use of tools. Don't be too anxious to blame the knife user. Instead, use the tips of the tool failure model to find out the root cause of the failure. For example, by analyzing the generated chips, we can preliminarily judge whether it is the problem of machine tool fixture or tool according to the phenomenon shown. Then check whether the tool is damaged, check the rigidity of the machine tool, cutting amount, tool geometry, chip removal and coolant, etc. If the problem is caused by the tool, replace and install the tool. Solve the problems in the processing one by one

6. Processing scheme management and offline to online support selection. The correct answer to improving production efficiency is sometimes to adopt special processing methods. For example, for single piece and short cycle production of large hole parts, milling holes with integral spiral milling cutter (compared with drilling large holes) will be the most efficient and economical processing scheme. There is another more unusual example of processing. Therefore, the oil pipe connection of the force adding part and the force measuring part will be affected by the deviation of the installation position and perpendicularity of the two parts. Choose to use the insert milling scheme. According to relevant information, it can improve the production efficiency by more than 4 times compared with ordinary end mills

7. The cutting temperature is studied deeply and carefully. That is, how does it produce, mainly produce local areas, and what are the advantages and disadvantages? Metal cutting usually produces high temperature by friction, which brings disadvantages to processing, but not all. Especially when cutting steel parts, you also want to soften parts through high temperature to form ideal chips. However, it is necessary to avoid too high cutting temperature that may cause part hardening, tool overheating or decarburization during machining

8. Tools with optimized geometric shapes are used according to the processing materials. Especially in product workshops that need to process a variety of workpiece materials, beware of using the so-called "general tools" for processing. When you change the material, the fixed time is changed to the tool with optimized design geometry. This will improve production efficiency and achieve good economic benefits. In addition, it should be noted that the figures on the tool price tag are the most meaningless economic figures in the processing economic equation

9. The ideal tool path is optimized. To ensure that the cutting system has the maximum rigidity and can carry out large feed cutting in the machining process

10. Return to school. Many companies have sent many engineers and programmers to our training courses. After learning, the learned knowledge is immediately applied to production practice, and good economic results are achieved in a very short time (a few weeks). It can make the new technology investment return quickly. Another advantage is that you can learn the latest cutting tools and processing technology when you return to school. Otherwise, you can only learn it in, which will greatly improve the competitiveness of the company in the international market. (end)