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Since the second half of the 20th century, due to the rapid development of emerging science and technology such as computers and microelectronics and materials science closely related to cutting technology, cutting technology has developed rapidly with the development of manufacturing industry and the advancement of manufacturing technology. Entered a new stage in modern cutting technology. Compared with traditional cutting technology, modern cutting technology not only reflects faster cutting speed and higher processing efficiency, but also forms a new development mechanism and mode, showing new technical characteristics and promoting the development of manufacturing and modern manufacturing technology. Important technical factors.
Therefore, understanding and mastering the development mechanism and mode of modern cutting technology and its technical characteristics will help accelerate the development of cutting technology in China. The development mechanism of modern cutting technology
In the long period after the advent of cutting technology, there was a problem that plagued the tool industry and tool users. That is, if you use a more expensive tool for cutting, it can increase the cutting efficiency, but it will increase the manufacturing cost. The user thinks that it is not worth the candle. Therefore, many users are reluctant to spend more money to buy good tools, or after buying a good knife, they are worried that the tool will be used quickly and the tool life will be long. These concepts and practices hinder the renewal of tools, affecting the enthusiasm of tool manufacturers to develop new tools, and restricting the improvement of cutting efficiency and the advancement of cutting technology. 
Figure 1 Manufacturing cost model
A cost model for manufacturing economics (see Figure 1) reveals the intrinsic relationship between applied tools and reduced manufacturing costs. This model decomposes part manufacturing costs into tool costs, general management costs (processing-related overheads), and processing costs (machine tool usage fees, worker wages, etc.), where tool costs are only 3% to 4%, and general management costs. About 25%, and processing costs will be as high as 70%.
Based on this cost ratio, the following conclusion can be drawn: If the pursuit of reducing tool costs is negatively pursued, the result can only reduce the percentage of parts manufacturing costs, such as reducing tool costs by 50% and parts manufacturing costs by only about 2.5. %, and consider the cost of increasing downtime or reducing the amount of cutting due to the use of cheap tools. If a good tool is used, although the tool cost may increase, but the cutting speed or feed rate can be increased, for example, by 20%, the processing cost of 70% of the part manufacturing cost can be reduced by more than 10%, which is much higher than A 2.5% benefit from the savings in tooling costs. At present, the more common saying in the cutting industry is that increasing the cutting speed or feed rate by 15% to 20% can reduce the manufacturing cost by 10% to 15%. Many cost analysis cases also show that although the cost of good tools is more expensive, due to the increased processing efficiency, the cost of the tool allocated to each workpiece has not increased or even decreased.
The cost analysis model also tells us that when using good tools, if you do not pay attention to improving cutting efficiency and only pursue to extend tool life, you can only receive very limited results for reducing manufacturing costs, and may even be counterproductive.
Based on a similar manufacturing cost analysis model and the size of the US manufacturing industry, Sweden's Sandvik has made the following prediction: If the US manufacturing industry promotes the application of better-performing tools, the cutting speed is generally increased by 20%, then the annual processing cost can be reduced by 150. One hundred million U.S. dollars. The United States consumes about $3 billion in tool costs per year. If one-third of the tool input is added for this, it will cost only $1 billion, but it will generate $15 billion. It can be seen that the innovation of cutting tools can play the role of “four or two poundsâ€.
According to China's situation, China Machinery Industry Metal Cutting Tool Technology Association proposed in 2004 to carry out the "China Knife Association 20 Project" in the country, aiming at the promotion of talent training, modern cutting technology and advanced cutting tools, through the cutting industry "production, learning The joint efforts of research, research and use will increase the cutting efficiency of mechanical machining in China by 20%. If we need to double the cost of cutting tools in China, we need to increase the cost of cutting tools by 10 billion yuan. By increasing the cutting efficiency by 20%, the country can save processing costs of 800-100 billion yuan. There are already a few companies that have proven that it is entirely possible to improve cutting efficiency by 20% or more through hard work.
At present, the above model and a series of figures and cases reveal the intrinsic link between improving cutting technology and creating considerable benefits for users and society. It has been recognized and accepted by more and more tool manufacturers and tool users, and has been transformed into The powerful driving force of cutting technology advances cutting technology into a new stage of modern cutting technology in just 20 years.
The current situation is: on the one hand, the above cost model has greatly encouraged the tool manufacturers, and based on this, established a new business philosophy of “innovative processes, innovative tools, improved cutting efficiency, and customer serviceâ€, the traditional manufacturing for cutting. Process technology has injected new vitality, making tool manufacturers become the main force in the development of modern cutting technology; on the other hand, this cost model has been accepted by more and more tool users, forming a new result of actively adopting cutting technology. The application of advanced cutting tools to improve processing efficiency, reduce manufacturing costs, and enhance the competitiveness of enterprises has made the industry's attention and demand for advanced tools reach an unprecedented level, and has become a powerful force for the rapid development of cutting technology. This “pull†is not a simple acceleration of the development of cutting technology, but gives the cutting mechanism a new development mechanism and power to make it transition from traditional cutting technology using disjointed to modern cutting with user demand and use. A new phase of technology. Technical characteristics of modern cutting technology
Cutting machining enters a new stage of modern cutting technology, not only reflected in the development of cutting technology based on the mechanism of tool manufacturer and tool user linkage, but also shows the following obvious technical features.
These new processes are used in the “big family†of cutting, such as automotive, aerospace, mold, and equipment manufacturing, which not only doubles the processing efficiency, but also promotes product development and process innovation. For example, in the aerospace manufacturing industry, after the high-speed milling process of aluminum alloy components, the large structural parts of the aircraft do not have to be assembled with components, but can be replaced by integral thin-walled aluminum alloy components, which not only reduces the weight of the components, but also increases the strength and rigidity of the components. Moreover, the processing quality is improved and the manufacturing cost is reduced. The automotive industry, characterized by mass production, is a pioneer in the development and application of new cutting processes. It has developed a number of efficient new processes for processing major components such as engines and gearboxes, which has greatly shortened the production tact time. In recent years, the fast-developing mold industry can be said to grow together with high-efficiency mold cutting technology. Large-scale mold high-speed milling and hardened mold milling process have changed the traditional mold processing technology, greatly shortening the mold development cycle, and adapting to the rapid development of the mold industry. The need for a new series of "mold tools" for mold processing has become the fastest growing category of modern cutting tools. 
Figure 2 Cutting of hardened steel
At the same time, the boundaries of traditional cutting processes such as turning, milling and drilling have been continuously broken, and some new cutting methods have emerged. For example, the newly introduced milling cutter can be used as a hole machining tool for drilling and reaming, which reduces the tool change time and improves the machining efficiency. For example, it can efficiently remove the cavity metal inserting cutter and machine the crankshaft. In the compound turning center, the milling process of the milling machine, the carbide high-speed machining process using the carbide thread milling cutter instead of the hard alloy tap. The cutting process continues to evolve, showing a thriving life and opening up new areas of manufacturing technology.
In addition, with the development of various composite machine tools and the "one machine or one-time complete machining" technology, the traditional concept of machining will be further changed.
The practical application of high-speed cutting, high-efficiency cutting, hard cutting, and dry cutting should be attributed to the improvement of tool materials and the development of coating technology. The development of tool materials is reflected in the overall improvement of the performance of various tool materials, which has improved the processing efficiency in all fields of cutting. Among them, special emphasis is placed on the advancement of two tool materials, namely the advancement of superhard tool materials PCD, CBN and cemented carbide materials.
PCD and CBN materials have high hardness and particularly good wear resistance. They have been hoped to become the promoters of high-speed cutting, but due to their brittleness, their practical process has been slow for a long time after the advent. In recent years, through the control and adjustment of PCD, CBN material manufacturing process, formulation composition, tissue size and other factors, the material toughness has been significantly improved, the variety has increased, and the application field has expanded, making the hope of applying superhard tool materials for high-speed cutting become The reality. PCD plays a unique advantage in high-speed and high-efficiency machining of non-metallic materials such as aluminum alloys, non-ferrous metals such as graphite and synthetic materials; CBN is used for high-speed machining and hard cutting of cast iron. Excellent cutting performance has also been demonstrated in the development and application of new dry cutting processes. The new CBN tool is not only used for the finishing of quenching Hardware, but also for interrupted cutting and roughing, which brings greater expectations for the new development of cutting technology. 
Figure 3 Turning large rolls with CBN tools
As a tool material, cemented carbide has always been a contradiction between hardness and toughness. Although its application in cutting operations such as turning, milling, and hole machining has played an important role in improving machining efficiency over the years, its poor toughness has not been significantly improved. After the 1980s, the development of fine-grained, ultra-fine-grained cemented carbides has greatly improved the toughness of cemented carbides, which can be used to make general-purpose tools such as drills, end mills, and taps. The processing efficiency of general-purpose tools is greatly improved. Nowadays, solid carbide drills and end mills made of ultra-fine grained carbide have been widely used, and the cutting speed can be increased several times than that of high-speed steel tools, making cemented carbide the most widely used and comprehensive performance. The best tool material. Another major advancement in cemented carbide materials is the development of graded cemented carbide materials that make the surface of the coated carbide inserts rich in drills, improving the toughness of the carbide insert edges, not only reducing chipping, but also The use of a base material resistant to plastic deformation improves the bearing capacity of the insert and significantly improves the cutting performance of the coated cemented carbide insert.
The birth and application of tool coating technology is known as a milestone in the history of cutting technology, but significant progress in coating technology has been a matter of more than a decade. In the field of CVD coatings, medium temperature CVD TiCN and thick film Al 2 O 3 coatings improve the wear resistance and crack propagation resistance of the insert. The development of PVD coatings is particularly striking, not only wear-resistant coatings such as TiAiN, Al-TiN, AlCrN, TiSiN, Al 2 O 3 , but also various lubricating coatings such as MOS 2 , DLC and WC/C. As well as new coating structures such as gradient coatings and nano-coatings, the performance of the coatings is greatly improved. The wear resistance of the wear-resistant coating reaches 4500Hv, the initial oxidation temperature reaches 1100°C, the bond strength between the coating and the substrate is better, and the tool life is increased by 10 times. The lubricating coating reduces the friction of the tool and facilitates chip removal. Significantly reduces tool temperature and improves tool cutting performance. At present, the development trend of coating technology is in the ascendant. With its many functions, good effects and rapid development, it has become the most effective means to improve the cutting performance of cutting tools. The development prospect is very broad.
It should also be pointed out that significant advances in new tool materials (especially cemented carbide) and coating technology are important material foundations for modern cutting technology and are core technologies supporting the continued development of modern cutting technology, and are playing a role in the development of cutting technology. The main driving role. At present, the growth and development of the world's famous tool companies are based on these two core technologies. Understanding this point is of great significance for planning the development direction of China's tool industry. At present, only a few tool manufacturers in China have two core resources of cemented carbide materials and coating technology. This situation is not commensurate with the requirements of the development of modern cutting technology and must be changed. China is a big country with tungsten resources. It has unique conditions for developing and producing tool materials. It is the responsibility of China's tool industry to develop advanced tool materials and transform resource advantages into product advantages and competitive advantages. Creating a brand of innovative tool materials should become China's tool industry. Its characteristics and strengths play a decent role in the development of China and even the advancement of cutting technology in the world.
As a tool, tools are the most dynamic process factor in a manufacturing system and are in the process of continuous innovation. In the modern cutting technology stage, the development of the tool has two major characteristics: First, the speed of innovation is accelerating. The biennial Beijing International Machine Tool Show (CIMT) has become a “new product launch†for tool manufacturers around the world, new material grades, new coated products, new tool (sheet) structures, new tool barrels. And the clamping technology, new processing methods, etc. are endless, making visitors dizzying. These new products either have improved cutting speeds, reduced manufacturing costs, or improved processing quality. At the 9th CIMT Expo in 2005, experts from Kenner of the United States told us: "The new products developed by Kenner in 2001 in the past five years accounted for 17%, and by 2004 this proportion had risen to 45%. Now, every 1-2 weeks, new products are put on the market. According to the information of some famous tool companies, the new products developed in the past five years account for about 50% of the sales. Some companies say that they have developed new products within three years. Products account for 35%. Sandvik launched 600 new products at a new product launch in Beijing in 2005. In 2004, Kenner launched approximately 9,000 new products of different specifications.
The second is to establish innovative ideas for system optimization. As we all know, the cutting process varies greatly due to different machining parts, variable workpiece materials and specific processing conditions, showing diversity and complexity. To achieve good machining results, the tool that best fits the specific machining object should be used. Systematic optimization of tool materials, coatings and insert geometries, geometric parameters or structures, and the development of suitable tools to achieve the best cutting results. On the basis of system optimization, the newly developed coated hard alloy grades can often increase the cutting efficiency by more than 20% compared with the original grades, and some can even reach more than 50%. A new tool product can provide a new processing effect, or significantly improve the processing efficiency, such as the popular large feed milling cutter in recent years, the feed per tooth is 3.5 ~ 4.0mm, 10 times that of the general milling cutter In addition, the feed rate of the turning insert can be doubled. Some tools have multi-functional features, which can reduce tool change time and improve machine tool utilization. For example, multi-function milling cutter can complete 8 kinds of processes such as chamfering, milling plane, milling shoulder, milling slope and milling hole; The function thread milling cutter can continuously complete four steps of drilling, milling, chamfering and milling. The threaded hole can be machined on the solid material in one pass. Some tools have reduced cutting force and suppressed cutting vibration. Conducive to chip removal and other functions, can produce the effect of extending tool life and improving processing quality. These new products, which are based on the cutting principle and optimized for development, have a strong vitality and continue to play a new movement of modern cutting technology. 
Figure 4 Zhuzhou Diamond Cutting Tool Co., Ltd. processing black cast iron blade
China's tool industry must vigorously improve its independent innovation capability and play its due role in building an innovative country. To this end, we must first establish a business philosophy of "serving the user". The service for the user here is not the concept of "after-sales service" of general goods, but a comprehensive service for providing users with processing problem solutions, developing new processes and new tools. This service relationship between the supply and demand sides not only allows tool users to fully enjoy the excellent technical resources, but also enables tool manufacturers to obtain an inexhaustible source of innovation and accelerate the process of independent innovation. Chinese tool makers must change their mindsets, build a system that serves the users, and exercise the skills to serve the users, gradually becoming a qualified member of the modern tool industry.
After the cutting process entered the new stage of modern cutting technology, many new related technologies appeared, and became an indispensable part of modern cutting technology, which expanded the connotation of cutting technology. For example, high-speed cutting technology was first applied to rotating tools, mainly milling. In the early days, the spindle speed exceeded 10,000 rpm as the threshold for high-speed cutting. Around this goal, the technology related to the machining center was developed, including high-speed spindles. Rapid feed, high plus (minus) speed technology and CNC system for high-speed cutting; developed tool-related technologies including HSK (hollow short taper shank) shank, 7:24 two-sided contact shank, high-speed rotary tool Safety technology (including tool structure, safety certification, safe use, etc.) and tool balancing technology (including adjustable balance tool and tool holder, tool dynamic balance specification, dynamic balance test instrument, etc.). In order to use high-speed machining of solid carbide universal tools, it is necessary to improve the accuracy and rigidity of tool clamping. New hydraulic chucks and tooling adjustment technologies such as hydraulic chucks, hot chucks and force shrink chucks have been developed.
In addition, in order to improve tool utilization and reduce tool management costs, tools such as tool management software and cutting database have been developed to improve the overall level of cutting processing with modern information technology. At present, in addition to the development and production of these supporting technologies and products by specialized companies, some large-scale integrated tool manufacturers also include them in the conventional product series to form a supporting supply advantage and keep pace with the development of tool products. It can be said that without these supporting technologies, modern cutting technology cannot be mentioned.
Today, we are in a period of rapid development of cutting technology, which is also an era in which the cutting tool industry has a lot to offer. China is a country with relatively backward cutting technology. The existing technology and products can not meet the demand of advanced tools in the important industrial sectors of the manufacturing industry. China's high-end tools for CNC machine tools and imported production lines mainly rely on imports, and the annual import of tools. The amount already accounts for half of the total demand. Therefore, accelerating the development of cutting technology and making full use of the high-quality resources of advanced cutting tools will not only have great practical significance, but also become increasingly urgent for China's historical task of building and manufacturing a strong country and completing new industrialization, and realizing the goal of revitalizing the equipment manufacturing industry.
Development mechanism and technical characteristics of modern cutting technology
Since the beginning of the 20th century, cutting technology has developed rapidly in industrialized countries. By the end of the 20th century, a new stage of "modern cutting technology" with high-speed cutting and high-efficiency cutting was introduced. Looking back at history, machining has become a professional technology that began in the late 19th and early 20th centuries and has gone through a whole century. Since the advent of self-cutting technology, it has been playing an important role as the basic process of manufacturing technology, and has made important contributions to the industrialization and economic development of industrialized countries. Although the cutting technology itself has made great progress in this process, it did not go beyond the traditional cutting technology in the 1960s and 1970s. The most prominent mark is the development and production of tools and tools. The use and users are basically separated from each other, and there is no mechanism for mutual promotion and common development.