Abstract: This paper introduces some applications of superhard material tools in mechanical cold processing in China. An example of using a superhard material tool in mechanical cold working to replace grinding with turning is described. In milling, boring, broaching, reaming, and drilling, some examples of high-hardness tool applications have been described to improve efficiency, reduce cost, and machine difficult workpieces. The market prospects for using superhard material tools in mechanical cold working are promising. Emphasize that due to the durability advantages of super-hard material tools, low overall cost and other advantages, the use of super-hard material tools in mechanical cold processing will be wider and larger.
Keywords: superhard material tool diamond turning milling boring reaping reaming drilling
First, the application of superhard material tools in machinery manufacturing
Superhard material tools are not only the ideal tool for machining high-hardness materials, but also suitable for high-speed precision and automatic machining, especially for super-hard material tools for car grinding and milling, which is more efficient and less expensive. It has the advantages of strong adaptability and shortened manufacturing cycle. It has been widely used in the processing of automotive zero {TodayHot} parts with high precision and large batch size. Although the price of such tools is more expensive than that of hard alloys, the cost of the tool allocated to each workpiece is lower than that of the carbide tool as long as the objects and conditions are properly selected. For example, FAW uses PCD tools to fine-tune the piston pin hole of silicon-aluminum alloy material (V=160m/min, f=0.08-0.10mm/r, a=0.05mm.), the tool durability is up to 42,500 pieces, which is the original hard 90 times of the alloy tool, the surface roughness value of the machine is reduced from the original *, the auxiliary time of the tool can be reduced by 30 minutes per shift, and the tool cost allocated to each workpiece is about 85% lower than that of the cemented carbide tool. The wear resistance of PCBN tools is 50 times higher than that of the last coated carbide tools, which is twice as high as that of coated carbide tools and 25 times higher than ceramic tools, but only close to half of the diamond tools.
Second, the application of superhard material abrasives in machinery manufacturing
Processing of metal materials. It can not only replace the grinding of ordinary abrasive tools, but also realize the high-speed and high-efficiency processing of cast and forged blanks, and finish coarse and fine grinding at one time. It is especially suitable for precision grinding of forming, profiling and sizing, which can improve the grinding quality and grinding efficiency by several times or even tens of times.
Processing of hard alloy products and hard-to-wear materials. Cemented carbide has high hardness and high wear resistance. {HotTag} replaces traditional silicon carbide and corundum abrasives with hard alloys to prevent burns and microcracks on the surface of the workpiece. Defects such as gaps or deterioration layers are too deep, which improves processing efficiency and saves grinding costs. The hardness of the super-hard material is much higher than that of the ordinary abrasive. The grinding ability is used to machine the workpiece hole by the composite involute toothed hole broach. The advantages are as follows: (1) The spline hole of the workpiece is processed by the technical knife. Since the coaxiality between the various shapes of the inner hole of the workpiece can be reliably ensured, the small-diameter circular surface can be uniformly used as a positioning reference in the subsequent processing steps of the workpiece, which greatly facilitates the positioning of the mandrel and the inspection mandrel in the subsequent processing steps of the workpiece. The production can reliably ensure the positional accuracy of all the machined surfaces of the workpiece. (2) The composite involute jumper inner hole broach is a kind of broach with better quality and economy. Since the cutter teeth of the utility knife adopt a reasonable tooth-displacement arrangement and a cutter-tooth structure with a spline edge-opening backlash, the manufacturing quality of the utility knife can be reliably ensured, and the manufacture of the broach is greatly facilitated. The manufacturing cost of the knife is almost the same as that of a conventional composite involute broach. It is 2000-10000 times as much as ordinary abrasives, so various forms of grinding of cemented carbide can be achieved with superhard materials.
Processing of ceramic materials. In recent years, ceramics has been used as a technological advancement product, and new ceramic materials can be used as an alternative material for metals and WCs for industrial applications. As engineering ceramic products, it is necessary to have good surface roughness and accurate dimensional tolerance. However, due to the high hardness, high strength and wear resistance of these ceramics, it is very difficult to process with ordinary tools, and the tool with superhard materials is The only economic and scientific method.
Ferrite material processing. Ferrite, also known as black ceramic, is an important electronic component. It has been processed with superhard materials since the 1960s and has been fully applied to date. Such as surface grinding core, double-face grinding speaker magnet, R forming mill-shaped magnetic steel. The advantages of using a superhard material grinding tool to grind ferrite are high work efficiency, energy saving, and reduction of waste. Improve the quality of the workpiece to reduce environmental pollution and reduce labor intensity.
Gem processing. Synthetic rubies, crystals, etc. are raw materials for industrial components. Their cutting, grinding, drilling, polishing, and grinding are all done with superhard materials.
Processing of semiconductor materials. Semiconductor silicon is hard and brittle, and its value is extremely valuable. With the introduction of computer technology into ultra-large-scale integration, the precision of silicon wafers. The requirements are becoming more and more stringent, and the processing with traditional ordinary abrasive tools can no longer meet the needs, and the super-hard material grinding tools must be used instead.
Electrical insulation material processing. Electrical insulating materials have the characteristics of poor thermal conductivity and heat resistance, heterogeneity and friction. Therefore, the conventional metal tools used for cutting, drilling, and surface processing have collapse. Defects such as delamination, burrs, burns, etc., resulting in a decrease in dielectric properties and physical and mechanical properties. The use of super-hard material tools not only eliminates the above drawbacks, but also has a low overall cost.
Taking the CBN grinding wheel as an example, because of its high hardness (2-3 times higher than ordinary abrasive corundum and silicon carbide), the cutting edge is wear-resistant and does not react with the iron group metal at a high grinding temperature. An ideal superhard abrasive for cutting iron and nickel based materials. CBN is considered when it is difficult to achieve high productivity and low production cost when grinding with ordinary abrasives, especially when it is necessary to process hard materials or other difficult materials, or when the quality of processed parts is high. Grinding tools are ground. In general, grinding with CBN grinding tools can increase efficiency by several tens of times and reduce total production costs by 25%-50%.
Third, the factors that restrict the application of superhard material tools and countermeasures
Strengthen the systematic research of superhard material tool manufacturing technology. The formulation of the tool should be based on a development-specific formula and systematized.
Strengthen the research on the application technology of superhard material tools. Includes principles for tool selection, optimization of process parameters, trimming, sharpening and cooling techniques.
Strengthen macro management and rational guidance. Encourage enterprises to unite and form large-scale groups to form large-scale production.
Strengthen the promotion and application of superhard material tools. Superhard material tool manufacturing enterprises should actively contact the users to increase the propaganda and correctly guide users to use them reasonably.
Keywords: superhard material tool diamond turning milling boring reaping reaming drilling
First, the application of superhard material tools in machinery manufacturing
Superhard material tools are not only the ideal tool for machining high-hardness materials, but also suitable for high-speed precision and automatic machining, especially for super-hard material tools for car grinding and milling, which is more efficient and less expensive. It has the advantages of strong adaptability and shortened manufacturing cycle. It has been widely used in the processing of automotive zero {TodayHot} parts with high precision and large batch size. Although the price of such tools is more expensive than that of hard alloys, the cost of the tool allocated to each workpiece is lower than that of the carbide tool as long as the objects and conditions are properly selected. For example, FAW uses PCD tools to fine-tune the piston pin hole of silicon-aluminum alloy material (V=160m/min, f=0.08-0.10mm/r, a=0.05mm.), the tool durability is up to 42,500 pieces, which is the original hard 90 times of the alloy tool, the surface roughness value of the machine is reduced from the original *, the auxiliary time of the tool can be reduced by 30 minutes per shift, and the tool cost allocated to each workpiece is about 85% lower than that of the cemented carbide tool. The wear resistance of PCBN tools is 50 times higher than that of the last coated carbide tools, which is twice as high as that of coated carbide tools and 25 times higher than ceramic tools, but only close to half of the diamond tools.
Second, the application of superhard material abrasives in machinery manufacturing
Processing of metal materials. It can not only replace the grinding of ordinary abrasive tools, but also realize the high-speed and high-efficiency processing of cast and forged blanks, and finish coarse and fine grinding at one time. It is especially suitable for precision grinding of forming, profiling and sizing, which can improve the grinding quality and grinding efficiency by several times or even tens of times.
Processing of hard alloy products and hard-to-wear materials. Cemented carbide has high hardness and high wear resistance. {HotTag} replaces traditional silicon carbide and corundum abrasives with hard alloys to prevent burns and microcracks on the surface of the workpiece. Defects such as gaps or deterioration layers are too deep, which improves processing efficiency and saves grinding costs. The hardness of the super-hard material is much higher than that of the ordinary abrasive. The grinding ability is used to machine the workpiece hole by the composite involute toothed hole broach. The advantages are as follows: (1) The spline hole of the workpiece is processed by the technical knife. Since the coaxiality between the various shapes of the inner hole of the workpiece can be reliably ensured, the small-diameter circular surface can be uniformly used as a positioning reference in the subsequent processing steps of the workpiece, which greatly facilitates the positioning of the mandrel and the inspection mandrel in the subsequent processing steps of the workpiece. The production can reliably ensure the positional accuracy of all the machined surfaces of the workpiece. (2) The composite involute jumper inner hole broach is a kind of broach with better quality and economy. Since the cutter teeth of the utility knife adopt a reasonable tooth-displacement arrangement and a cutter-tooth structure with a spline edge-opening backlash, the manufacturing quality of the utility knife can be reliably ensured, and the manufacture of the broach is greatly facilitated. The manufacturing cost of the knife is almost the same as that of a conventional composite involute broach. It is 2000-10000 times as much as ordinary abrasives, so various forms of grinding of cemented carbide can be achieved with superhard materials.
Processing of ceramic materials. In recent years, ceramics has been used as a technological advancement product, and new ceramic materials can be used as an alternative material for metals and WCs for industrial applications. As engineering ceramic products, it is necessary to have good surface roughness and accurate dimensional tolerance. However, due to the high hardness, high strength and wear resistance of these ceramics, it is very difficult to process with ordinary tools, and the tool with superhard materials is The only economic and scientific method.
Ferrite material processing. Ferrite, also known as black ceramic, is an important electronic component. It has been processed with superhard materials since the 1960s and has been fully applied to date. Such as surface grinding core, double-face grinding speaker magnet, R forming mill-shaped magnetic steel. The advantages of using a superhard material grinding tool to grind ferrite are high work efficiency, energy saving, and reduction of waste. Improve the quality of the workpiece to reduce environmental pollution and reduce labor intensity.
Gem processing. Synthetic rubies, crystals, etc. are raw materials for industrial components. Their cutting, grinding, drilling, polishing, and grinding are all done with superhard materials.
Processing of semiconductor materials. Semiconductor silicon is hard and brittle, and its value is extremely valuable. With the introduction of computer technology into ultra-large-scale integration, the precision of silicon wafers. The requirements are becoming more and more stringent, and the processing with traditional ordinary abrasive tools can no longer meet the needs, and the super-hard material grinding tools must be used instead.
Electrical insulation material processing. Electrical insulating materials have the characteristics of poor thermal conductivity and heat resistance, heterogeneity and friction. Therefore, the conventional metal tools used for cutting, drilling, and surface processing have collapse. Defects such as delamination, burrs, burns, etc., resulting in a decrease in dielectric properties and physical and mechanical properties. The use of super-hard material tools not only eliminates the above drawbacks, but also has a low overall cost.
Taking the CBN grinding wheel as an example, because of its high hardness (2-3 times higher than ordinary abrasive corundum and silicon carbide), the cutting edge is wear-resistant and does not react with the iron group metal at a high grinding temperature. An ideal superhard abrasive for cutting iron and nickel based materials. CBN is considered when it is difficult to achieve high productivity and low production cost when grinding with ordinary abrasives, especially when it is necessary to process hard materials or other difficult materials, or when the quality of processed parts is high. Grinding tools are ground. In general, grinding with CBN grinding tools can increase efficiency by several tens of times and reduce total production costs by 25%-50%.
Third, the factors that restrict the application of superhard material tools and countermeasures
Strengthen the systematic research of superhard material tool manufacturing technology. The formulation of the tool should be based on a development-specific formula and systematized.
Strengthen the research on the application technology of superhard material tools. Includes principles for tool selection, optimization of process parameters, trimming, sharpening and cooling techniques.
Strengthen macro management and rational guidance. Encourage enterprises to unite and form large-scale groups to form large-scale production.
Strengthen the promotion and application of superhard material tools. Superhard material tool manufacturing enterprises should actively contact the users to increase the propaganda and correctly guide users to use them reasonably.
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