The global power generation equipment manufacturing industry has never emphasized speed. On the one hand, rotary tool orders continue to grow at a rate of 10%-15% per year, which has driven tool makers to catch up. On the other hand, as metal cutting tool suppliers continue to improve tools for the energy industry, metal removal rates have increased by an average of more than 50% per year for the past five years alone. Since 2003, Iskar's R&D investment in power generation equipment processing technology has increased by more than five times, and more than 1,000 new products have been developed, including all products from processing cabinets to eucalyptus roots, which have improved metal cutting. Efficiency and delivery speed.
In addition, from the feedback of early users, these new tools are constantly playing their potential. Turbine manufacturers use them to increase the capacity of existing CNC equipment and speed up the delivery of their products. Turbine blades that have been milled all day in the past are now only a few hours away. Large rotors that used to take five weeks or more to process are now in just four weeks. The underlying reason is that these tools have the ability to achieve higher cutting speeds, which in turn accelerates the speed at which the user delivers the product. The cutting speed is more important than the cutting edge life or tool cost.
Although the improved tool is more durable, it is not the key. The biggest potential benefit of any tool innovation is its strategic importance: improving corporate profitability, market competitiveness and sustainability. In today's power generation equipment manufacturing industry, it is imperative to remove unused metals more quickly.
A higher metal removal rate means an immediate increase in the capacity of existing equipment.
Higher metal removal rates mean faster delivery.
A higher metal removal rate means a higher return on investment from fixed assets.
As long as your metal removal rate is higher, you will both increase profit margins and reduce part costs. This is a win-win strategy.
From a purely economic point of view, the metal removal rate is higher, which can reduce the three largest variable costs in the process, and these costs have characteristics that change with time, respectively, labor costs, machine rental fees or Depreciation costs and indirect costs (Figure 1). Together they account for 75% of the total cost of part processing. Any one of these costs far exceeds the cost of the tool, which typically rarely exceeds 3% of the part's processing cost.
Let's take a $100 workpiece, such as a turbine blade. If the blade life is increased by 10%, save 3 cents per part. If the price of the blade is 10%, save 30 cents per part. If the cycle time is reduced by 10%, one more blade is produced during the original production of ten blades, saving up to $7.5 per part. In the same vein, if you complete a large cylinder that would have taken a month or more to process a week in advance, it is entirely possible to reduce the cost of tens of thousands of dollars.
What kind of savings do you prefer to get?
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