Main contents of the development of high-performance tools for key components of automobiles
The development of high-performance tools for key components of automobiles requires metal cutting around critical key technologies such as tool design, tool preparation, tool cutting performance evaluation, cutting force, cutting temperature coupling mechanism, and tool cutting database. Basic theoretical research and experimental technology research. In order to meet the requirements of high-performance machining of key components of automobiles, research on key technologies in the design and manufacture of high-performance tools is the design technology, forming technology, advanced coating technology and application technology of high-speed and high-efficiency cutting tools. The foundation provides theoretical guidance for the high-speed and high-efficiency cutting tool product series developed by related tool backbone enterprises.
Application of reverse engineering, parametric analysis and high-speed rotary tool system safety for tool optimization geometric design; application of multi-axis linkage CNC grinding and electro-erosion grinding technology to complete complex space curve edge forming; application of advanced coating technology for new multi-application Layer composite hard coating technology; application database integration for tool application technology promotion. The research of this subject is of great significance to the development of automobile manufacturing and tool manufacturing itself.
Research and development of complex blade-shaped polycrystalline diamond high-speed high-efficiency boring cutter series, precision composite solid carbide CNC cutting tool series, forming mass production capacity, reducing the dependence on imported tools.
Develop high-speed and high-efficiency gear cutters (high-speed dry-cut hob, high-speed and high-efficiency small-diameter hob, solid carbide hob, high-precision radial shaver, etc.), high-speed gear hob cutting speed of 200m/min or more, Form serialized products and small batch production capacity.
Developed the engine block cylinder head plane machining and hole machining tools as well as the crankshaft high-speed inner milling cutter, high-speed outer milling cutter, car broach and other precision composite tools to form mass production capacity.
Based on the high-performance and high-efficiency tool and workpiece material cutting performance adaptability model, a general-purpose cutting database is established; the database system has good expansion and model nesting functions to satisfy users' query, input, update, modification, deletion, optimization and transmission of the database. Such functional requirements apply to all types of cutting data management, including numbers, curves, charts, images, formulas, etc., reaching the domestic leading level.
Based on the high-speed cutting force-thermal coupling physical model of difficult-to-machine materials, the cutting parameter optimization prediction technology is researched, and a special cutting database for automobile manufacturing is established. The database system has an expert system of intelligent reasoning, judgment and decision-making to meet the requirements of high-end products. To reach the domestic leading level.
Based on the cutting process dynamic characteristic parameters and processing surface quality index detection technology, the tool cutting performance evaluation system is constructed to provide technical support for tool enterprises, material enterprises and tool application enterprises, and provide a test platform for tool standardization research, reaching the domestic leading level.
The automobile manufacturing industry is characterized by high technology intensity, large production volume and comprehensiveness. It plays a pivotal role in the national economy of any major industrialized country. At present, automobiles have become the leading products for the revitalization of manufacturing in many places in China, and the automobile manufacturing industry has long been a key pillar industry for driving rapid GDP growth. The equipment manufacturing industry is the foundation of all industries, and the development of the automobile manufacturing industry is also inseparable from advanced equipment manufacturing technology.
CNC machine tools are the most basic equipment technology for the development of automobile manufacturing and emerging high-tech industries. Today's manufacturing industries in the world widely use digital manufacturing technology to improve their adaptability and competitiveness to dynamic and volatile markets. Since 2002, China has been the world's largest machine tool consumer and the largest importer of machine tools. In the process of technological transformation of the automobile industry and traditional industry, China has introduced a large number of high-grade CNC machine tools, which makes the CNC machining technology develop in the direction of high speed, compound, intelligent and environmental protection.
In CNC machining, the CNC tool known as the "tooth" of CNC machine tools is also the most basic equipment technology, and has become the most active factor in the digital manufacturing process, which has a great impact on production efficiency and processing quality, especially for automotive zero. In terms of component production lines, the batch size is large, the efficiency is high, and the tempo is fast, so the cutting tool is developing in the direction of high efficiency, high precision, high reliability and specialization. At present, large automobile manufacturers, sole proprietorships and joint venture automobile manufacturing enterprises attach great importance to the comprehensive performance ratio of high-speed and high-efficiency cutting tools, and use a large number of high-speed and high-efficiency cutting tools and advanced cutting technology to improve the Chinese automobile manufacturing industry with cutting tools with superior performance and price. The level of metal cutting has a significant significance in improving the manufacturing level of China's automobile manufacturing industry.
There are a large number of stepped holes with different sizes, complex internal surfaces and small deep oil holes in the automotive parts, which require high processing precision. Therefore, the structure of the CNC composite hole machining tool and the composite coating tool, the main cutting edge shape, the tool material, the dynamic balance, the coating, and the chip breaking and chip discharging performance have higher specific requirements. From the aspect of tool structure analysis, the use of precision composite hole machining tools on the auto parts production line can simplify the process and reduce the number of tools, and can ensure the hole machining accuracy. Such as synchronous drilling, reaming or boring and chamfering compound step drill boring tool, precision machining stepped hole precision composite CBN/PCD boring tool, variable lead precision compound step reamer, complex blade shape Crystal diamond high-speed and high-efficiency boring and milling cutter, twist drill and single-blade drill with internal cooling function for oil hole deep hole drilling of engine block, cylinder head, crankshaft and connecting rod, etc. High-speed milling of large-diameter high-speed disk milling cutters with wiper blades is commonly used for the machining of engine cylinder heads. High-speed internal milling cutters, high-speed outer milling cutters, and broaching tools are commonly used for crankshaft machining. From the aspect of tool materials, high-efficiency composite coating tools, precision composite solid carbide CNC tools, polycrystalline diamond (PCD) tools and polycrystalline cubic boron nitride (PCBN) tools have occupied the main position to adapt to the car. The industry processes high efficiency, precision and environmental protection requirements.
At present, China's CNC tools have not formed scale, and the localization rate is low, mainly due to some low-end products. In the automobile manufacturing industry, advanced CNC machining tools mainly rely on imports. In the application technology of CNC tools, the lack of suitable high-speed cutting technology database system makes the use of CNC tools unreasonable. Most high-speed cutting machine tools still work. At the low spindle speed level, the advantages of high-efficiency precision machining inherent in high-speed CNC machine tools are not fully utilized, resulting in a large waste of fixed assets. It can be seen that the development and localization of high-performance tools and their application technologies have become bottlenecks in the development of China's tool industry, directly restricting the revitalization of China's equipment manufacturing industry and the healthy and rapid development of the automobile manufacturing industry.
Carrying out tool design, tool preparation, tool cutting performance evaluation, cutting force in cutting process - cutting temperature coupling mechanism, tool cutting database, etc., will force the research and development of high-performance tools in China's tool manufacturing enterprises, and improve China's CNC The overall level of tool design and manufacturing enhances the ability of China's precision tools and coated tools to participate in international competition and reduces the dependence on imported CNC tools. Form a virtuous circle between research and development and industrialization, and create a new situation with technology as the guide and product as the carrier.
Innovations and breakthroughs in the development of high-performance tools for key automotive components
Key technology to solve
Focusing on the processing characteristics of key automotive components and their special cutting process requirements, focusing on the development of advanced composite tools or special tool structures, through the application of reverse engineering techniques for digestion and absorption and innovation, parametric analysis and high-speed rotary tool systems Safety optimizes tool geometry design; structural design, geometry optimization, and heat treatment process innovation for complex tools and special tools for imported automotive parts.
To study the design principles of high-precision rolling, shaving, grooving gears and spiral bevel gears for engines, transmissions and transmissions for passenger cars and heavy trucks, to develop relevant machining techniques and equipment; to develop engine cylinder heads Precision boring and milling series tools and high-precision hole machining compound tools, crankshaft camshafts, high-efficiency machining broaches, turning tools, crankshaft high-speed inner/outer milling cutters, boring and milling cutters, etc., high precision, high efficiency, high reliability High-speed and high-efficiency composite cutting tool with specialized "three high and one special".
Several key technologies in the development of high-performance tools for automotive key components are focused on tool design techniques, tool forming techniques, tool coating techniques and tool application techniques.
Tool design technology: At present, domestic tool design mainly relies on experience and is oriented to tradition.
In the field of machining, there is no tool safety. This project is based on reverse engineering, tool parameter analysis and high-speed rotary tool system safety for precision composite solid carbide CNC tool design to meet high-speed and high-efficiency cutting performance requirements; reverse engineering technology is indispensable in modern design and manufacturing technology. The important method is to apply the laser fast scanning system to obtain the discrete point data about the physical characteristics of the sample, and then obtain the 3D simulation model of the sample through the space reconstruction technology, so as to achieve the purpose of rapid optimization design. The precision composite solid carbide CNC tool has complex structure and high design precision. The application of reverse engineering technology can greatly shorten the tool design cycle and meet the design requirements. The application of high-speed and high-efficiency cutting technology in the manufacture of auto parts is popular. Therefore, in the design of precision composite solid carbide CNC tools, the static model and dynamic model of the high-speed rotary tool system must be analyzed. The balance performance and the failure mechanism of the cutter body and the clamping mechanism are studied. The advanced reverse engineering software, hardware technology platform and dynamic balance test system are used to carry out the tool design research work.
Tool forming technology: The technical content is divided into two parts, namely multi-axis linkage CNC grinding technology and super-hard material electro-erosion grinding technology for complex space line edge forming.
Multi-axis linkage CNC full-grinding tool forming technology based on the principle of main cutting edge space forming; the main cutting edge space forming of full-grinding precision composite solid carbide CNC cutting tool is realized by multi-axis linkage of advanced CNC tool grinding machine. Accurate description of the trajectory of the grinding wheel space is the key technology to obtain the precise main cutting edge. Through the application of CAD/CAM 3D simulation cutting software, the 3D simulation of various complex surfaces such as step surface, curved surface and grinding wheel space cutting is carried out. . Through the CAM forward-looking function, the interference problem of the machining system is studied, and an optimized grinding process is obtained to ensure the reliability and quality stability of the actual grinding process system. On this basis, through secondary development, the formation of precision composite solid carbide CNC tool forming manufacturing technology with independent intellectual property rights.
At present, the domestic grinding of PCD and PCBN tools is mainly based on the application of mechanical methods to achieve straight line grinding.
The research is based on the principle of five-axis CNC wheel erosion and line erosion, PCD, PCBN tool precision sharpening forming technology, to achieve precise and efficient forming of complex curved edges.
CNC multi-axis electro-erosion grinding technology is an advanced composite grinding technology for the precision forming of superhard materials (HV 3500-7000) such as polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) tools. The key technology. It uses the principle of electric spark machining between the electric corrosion wheel (or molybdenum wire) and the workpiece, and realizes the forming electric corrosion grinding process of the main cutting edge of the tool by numerical control five-axis linkage. Compared with the traditional diamond grinding wheel grinding, the production efficiency is greatly improved. Through the development of CAM numerical control software, it can process all kinds of complex curved edge and stepped-shaped polycrystalline diamond boring and milling tools to form the precise shape of the main cutting edge with smooth connection and uniform corner angle. In particular, the use of wire erosion grinding has solved the problem of grinding the main cutting edge and the problem of internal blade grinding of complex shape tools that could not be processed in the past.
Tool coating technology
The single-layer coating material has a simple structure and cannot meet the comprehensive performance requirements of the tool for the coating. The research of the aluminum-rich multi-layer composite hard coating technology based on the gradient function makes the coating material have excellent comprehensive performance and reaches the advanced level in foreign countries, meeting the requirements of the tool under high-speed and high-efficiency cutting conditions. In the design of high-efficiency composite coated tools, the composition of the coating material, the coating thickness and the optimization of the coating structure are the guarantees for obtaining a gradient-functional composite coating. Tool substrate surface pretreatment technology and coating process control technology are key in the coating preparation process. This project adopts comprehensive treatment technology such as mechanical treatment, wet cleaning and particle etching to obtain the ideal surface suitable for coating and maximize the bonding strength of the coating. In the preparation process of the aluminum-rich coating, the multilayer structure and the layered design process of the composition are used to achieve the best mechanical properties by controlling the thickness and composition of each layer. On the one hand, by controlling the thickness of the layer, the growth of the crystal grains is suppressed, and a nano-coat layer is obtained. At the same time, the multilayer structure is advantageous for absorbing the microcrack phenomenon generated during the growth of the coating, thereby eliminating cracks and obtaining a continuous coating. On the other hand, by controlling the composition change, the process of gradual composition is adopted, which is beneficial to eliminate the stress in the coating process, and at the same time, the gradual layer structure design is beneficial to improve the coating adhesion. In the aspect of coating composition control, adjusting the atomic ratio of Al:Ti, increasing the content of Al, forming an aluminum-rich coating, inhibiting the formation of TiO2 due to temperature rise during the cutting process, and effectively improving the high temperature mechanical properties of the coating. By improving the surface hardness and oxidation temperature of the coating, the wear resistance of the tool is effectively improved, the service life of the tool is extended, and the coated tool is suitable for high-speed cutting and dry cutting, overcoming the conventional coating due to temperature rise during processing. Loss of the shortcomings of its mechanical properties.
Tool application technology
The so-called applicable cutting database has the connotation of selecting the applicable tool and recommending the optimized cutting parameters for specific workpiece materials, machining accuracy, surface quality and machining efficiency, and solving the problem of adaptability of the tool to the workpiece material. The characteristics and nature of high-speed and high-efficiency cutting are significantly different from those of ordinary cutting, so it is obviously not suitable to use the existing common cutting database. At present, the reasonable and applicable cutting data in China is still very scarce, which greatly limits the promotion and application of high-speed and high-efficiency cutting technology, and restricts the localization process of high-speed and high-efficiency cutting tools. When China's automobile manufacturing enterprises purchase a large number of advanced high-speed CNC machining centers from industrialized countries, they cannot introduce high-speed cutting database and other process technologies due to technical blockade, which seriously affects the normal application of advanced machining centers and causes potential waste of inherent assets. For the automobile manufacturing department, how to choose the tool, how to use the tool, make full use of the processing equipment capacity, fully reflect the good cost performance of the high-performance tool, and achieve high-efficiency and low-cost processing, which has always been the main theme of the auto parts production line. For tool manufacturers, newly developed tools require cutting performance evaluation before entering the market. The cutting performance test is most effective for further improvement of the tool and optimization of the cutting amount.
The core technology of the high-speed cutting database system is based on the cutting force model, the cutting temperature model, the tool wear model and the intelligent prediction technology of the workpiece surface quality model. There are three sources of high-speed cutting data: literature, production, and cutting tests.
Under the premise that China's high-speed cutting data is still scarce, especially for the situation that the high-speed cutting data of difficult-to-machine materials is more scarce, it is more urgent to carry out research on cutting parameter optimization prediction technology based on the physical model of high-speed cutting process of difficult-to-machine materials. important.
Technical innovation points, breakthrough points The key components of automobiles are generally steel, cast iron and aluminum alloy materials, but most of their processing is carried out on special CNC machine tools. The cutting process is special, and high-speed and efficient production cycle is required.
Focusing on the processing characteristics of key automotive components and their special cutting process requirements, focusing on the development of advanced composite tools or special tool structures, through the application of reverse engineering techniques for digestion and absorption and innovation, parametric analysis and high-speed rotary tool systems The tool is optimized for geometric design of the tool; the structural design, geometric shape optimization and heat treatment process innovation are carried out on the imported auto parts with complex tools and special tools to form independent development and innovation capabilities.
To study the design principles of high-precision rolling, shaving, grooving gears and spiral bevel gears for engines, transmissions and transmissions for passenger cars and heavy trucks, to develop relevant machining techniques and equipment; to develop engine cylinder heads Precision boring and milling series tools and high-precision hole machining compound tools, crankshaft camshafts, high-efficiency machining broaches, turning tools, crankshaft high-speed inner/outer milling cutters, boring and milling cutters, etc., high precision, high efficiency, high reliability High-speed and high-efficiency composite cutting tool with specialized "three high and one special".
The basic theory of metal cutting machining is carried out in the development project of high-performance tools for key parts of automobiles, related to tool design, tool preparation, tool cutting performance evaluation, cutting force-cutting temperature coupling mechanism, tool cutting database and other key common technologies. And experimental technology research. In order to meet the requirements of high-performance machining of key components of automobiles, research on key technologies in the design and manufacture of high-performance tools is the design technology, forming technology, advanced coating technology and application technology of high-speed and high-efficiency cutting tools. The foundation provides theoretical guidance for the high-speed and high-efficiency cutting tool product series developed by related tool backbone enterprises.
Innovation
Based on the high-speed and high-efficiency tool and workpiece material cutting performance adaptability model, a general-purpose cutting database is established. Based on the high-speed cutting force-thermal coupling physical model of difficult-to-machine materials, the cutting parameter optimization prediction technology is studied, and a special cutting database for automobile manufacturing is established. The database system has an expert system of intelligent reasoning, judgment and decision making to meet the cutting requirements of high-end products.
Based on the cutting process dynamic characteristic parameters and processing surface quality index detection technology, the tool cutting performance evaluation system is constructed to provide technical support for tool companies, material enterprises and tool application enterprises, and provide a test platform for tool standardization research; The optimization design technology of high-performance tools for key components; research and application of multi-axis linkage numerical control and electro-erosion grinding technology to complete the forming technology of space curve edge; research and development of aluminum-rich multi-layer composite hard coating tool technology.
Carry out structural design and optimization innovation of high-performance tools for various key components of automobiles, develop computer simulation (simulation cutting or simulation cutting) software; improve heat treatment computer temperature control system to achieve temperature control accuracy of ±3 °C; solve high-performance tool materials Forging technology, heat treatment technology and grinding technology to improve the processing efficiency and process quality stability of difficult-to-machine materials; study the application problems of various cutting tools and coating materials under different cutting environments, adapt to the requirements of high-speed and high-efficiency cutting development .
The main technical indicators (such as the formation of intellectual property rights, technical standards, new technologies, new products, new devices, monographs, etc., the number, indicators and their level, and the competition analysis of similar technologies or products at home and abroad, to meet the major The key parts of the automobile construction, or the development of major equipment, etc.) are mainly steel, cast iron and aluminum alloy materials, but most of the processing is carried out on special CNC machine tools. The cutting process is special, and the material needs high speed. Efficient production beats.
Focusing on the processing characteristics of key automotive components and their special cutting process requirements, focusing on the development of advanced composite tools or special tool structures, through the application of reverse engineering techniques for digestion and absorption and innovation, parametric analysis and high-speed rotary tool systems The tool is optimized for geometric design of the tool; the structural design, geometric shape optimization and heat treatment process innovation are carried out on the imported auto parts with complex tools and special tools to form independent development and innovation capabilities.
To study the design principle of large-scale, high-precision rolling-to-gear gear cutters and large-scale spiral bevel gear cutters for super-heavy trucks, and develop related processing technology and equipment; focus on the development of gearbox complex gears for complex precision gear processing and engine cylinder heads High-precision, high-efficiency, high-reliability, precision boring and milling tools and high-precision hole machining composite tools, crankshaft camshafts, high-efficiency machining broaches, turning tools, crankshaft high-speed inner/outer milling cutters, etc. Specialized "three high and one special" high speed and high efficiency composite cutting tool.
Research on multi-axis linkage CNC grinding and electro-erosion machining to realize the forming technology of complex space curve edge. Based on the high-speed and high-efficiency tool and workpiece material cutting performance adaptability model, a general-purpose cutting database is established. Based on the high-speed cutting force-thermal coupling physical model of difficult-to-machine materials, the cutting parameter optimization prediction technology is studied, and a special cutting database for automobile manufacturing is established. The database system has an expert system of intelligent reasoning, judgment and decision-making to meet the cutting requirements of high-end products. Based on the dynamic characteristic parameters of the cutting process and the detection technology of the surface quality indicators, the tool cutting performance evaluation system is constructed for tool enterprises, material enterprises and tool applications. The company provides technical support and provides a test platform for tool standardization research.
Application of reverse engineering to develop and optimize high-performance tools for key components of automobiles; application of multi-axis linkage CNC and electro-erosion grinding technology to complete the formation of space curve edges; development of aluminum-rich multi-layer composite hard coating tools.
China has become the world's new manufacturing and processing center, and the booming and rising industries of automobiles, aerospace, mold, machinery, electronics, metallurgy, etc., have provided a huge market space for the development of the tool industry. However, under the trend of economic globalization, the competition in the market economy is becoming increasingly fierce. The world's most famous tool companies have launched their products in the Chinese market. Especially in the automotive industry, precision composite hole machining tools and high-efficiency composite coating tools are almost all foreign. product.
However, China's CNC tools have not formed scale, and the localization rate is low, mainly due to some low-end products. In the automotive industry, advanced CNC machining tools rely mainly on imports.
The next step of high-performance tool development for key components of automobiles is to further break the technological monopoly of foreign famous brand tools, improve the design and manufacturing level of precision composite tools and high-efficiency composite tools in the automobile manufacturing industry, and domestic CNC tools must form large-scale production.
The development of high-performance tools for key components of automobiles requires metal cutting around critical key technologies such as tool design, tool preparation, tool cutting performance evaluation, cutting force, cutting temperature coupling mechanism, and tool cutting database. Basic theoretical research and experimental technology research. In order to meet the requirements of high-performance machining of key components of automobiles, research on key technologies in the design and manufacture of high-performance tools is the design technology, forming technology, advanced coating technology and application technology of high-speed and high-efficiency cutting tools. The foundation provides theoretical guidance for the high-speed and high-efficiency cutting tool product series developed by related tool backbone enterprises.
Application of reverse engineering, parametric analysis and high-speed rotary tool system safety for tool optimization geometric design; application of multi-axis linkage CNC grinding and electro-erosion grinding technology to complete complex space curve edge forming; application of advanced coating technology for new multi-application Layer composite hard coating technology; application database integration for tool application technology promotion. The research of this subject is of great significance to the development of automobile manufacturing and tool manufacturing itself.
Research and development of complex blade-shaped polycrystalline diamond high-speed high-efficiency boring cutter series, precision composite solid carbide CNC cutting tool series, forming mass production capacity, reducing the dependence on imported tools.
Develop high-speed and high-efficiency gear cutters (high-speed dry-cut hob, high-speed and high-efficiency small-diameter hob, solid carbide hob, high-precision radial shaver, etc.), high-speed gear hob cutting speed of 200m/min or more, Form serialized products and small batch production capacity.
Developed the engine block cylinder head plane machining and hole machining tools as well as the crankshaft high-speed inner milling cutter, high-speed outer milling cutter, car broach and other precision composite tools to form mass production capacity.
Based on the high-performance and high-efficiency tool and workpiece material cutting performance adaptability model, a general-purpose cutting database is established; the database system has good expansion and model nesting functions to satisfy users' query, input, update, modification, deletion, optimization and transmission of the database. Such functional requirements apply to all types of cutting data management, including numbers, curves, charts, images, formulas, etc., reaching the domestic leading level.
Based on the high-speed cutting force-thermal coupling physical model of difficult-to-machine materials, the cutting parameter optimization prediction technology is researched, and a special cutting database for automobile manufacturing is established. The database system has an expert system of intelligent reasoning, judgment and decision-making to meet the requirements of high-end products. To reach the domestic leading level.
Based on the cutting process dynamic characteristic parameters and processing surface quality index detection technology, the tool cutting performance evaluation system is constructed to provide technical support for tool enterprises, material enterprises and tool application enterprises, and provide a test platform for tool standardization research, reaching the domestic leading level.
The automobile manufacturing industry is characterized by high technology intensity, large production volume and comprehensiveness. It plays a pivotal role in the national economy of any major industrialized country. At present, automobiles have become the leading products for the revitalization of manufacturing in many places in China, and the automobile manufacturing industry has long been a key pillar industry for driving rapid GDP growth. The equipment manufacturing industry is the foundation of all industries, and the development of the automobile manufacturing industry is also inseparable from advanced equipment manufacturing technology.
CNC machine tools are the most basic equipment technology for the development of automobile manufacturing and emerging high-tech industries. Today's manufacturing industries in the world widely use digital manufacturing technology to improve their adaptability and competitiveness to dynamic and volatile markets. Since 2002, China has been the world's largest machine tool consumer and the largest importer of machine tools. In the process of technological transformation of the automobile industry and traditional industry, China has introduced a large number of high-grade CNC machine tools, which makes the CNC machining technology develop in the direction of high speed, compound, intelligent and environmental protection.
In CNC machining, the CNC tool known as the "tooth" of CNC machine tools is also the most basic equipment technology, and has become the most active factor in the digital manufacturing process, which has a great impact on production efficiency and processing quality, especially for automotive zero. In terms of component production lines, the batch size is large, the efficiency is high, and the tempo is fast, so the cutting tool is developing in the direction of high efficiency, high precision, high reliability and specialization. At present, large automobile manufacturers, sole proprietorships and joint venture automobile manufacturing enterprises attach great importance to the comprehensive performance ratio of high-speed and high-efficiency cutting tools, and use a large number of high-speed and high-efficiency cutting tools and advanced cutting technology to improve the Chinese automobile manufacturing industry with cutting tools with superior performance and price. The level of metal cutting has a significant significance in improving the manufacturing level of China's automobile manufacturing industry.
There are a large number of stepped holes with different sizes, complex internal surfaces and small deep oil holes in the automotive parts, which require high processing precision. Therefore, the structure of the CNC composite hole machining tool and the composite coating tool, the main cutting edge shape, the tool material, the dynamic balance, the coating, and the chip breaking and chip discharging performance have higher specific requirements. From the aspect of tool structure analysis, the use of precision composite hole machining tools on the auto parts production line can simplify the process and reduce the number of tools, and can ensure the hole machining accuracy. Such as synchronous drilling, reaming or boring and chamfering compound step drill boring tool, precision machining stepped hole precision composite CBN/PCD boring tool, variable lead precision compound step reamer, complex blade shape Crystal diamond high-speed and high-efficiency boring and milling cutter, twist drill and single-blade drill with internal cooling function for oil hole deep hole drilling of engine block, cylinder head, crankshaft and connecting rod, etc. High-speed milling of large-diameter high-speed disk milling cutters with wiper blades is commonly used for the machining of engine cylinder heads. High-speed internal milling cutters, high-speed outer milling cutters, and broaching tools are commonly used for crankshaft machining. From the aspect of tool materials, high-efficiency composite coating tools, precision composite solid carbide CNC tools, polycrystalline diamond (PCD) tools and polycrystalline cubic boron nitride (PCBN) tools have occupied the main position to adapt to the car. The industry processes high efficiency, precision and environmental protection requirements.
At present, China's CNC tools have not formed scale, and the localization rate is low, mainly due to some low-end products. In the automobile manufacturing industry, advanced CNC machining tools mainly rely on imports. In the application technology of CNC tools, the lack of suitable high-speed cutting technology database system makes the use of CNC tools unreasonable. Most high-speed cutting machine tools still work. At the low spindle speed level, the advantages of high-efficiency precision machining inherent in high-speed CNC machine tools are not fully utilized, resulting in a large waste of fixed assets. It can be seen that the development and localization of high-performance tools and their application technologies have become bottlenecks in the development of China's tool industry, directly restricting the revitalization of China's equipment manufacturing industry and the healthy and rapid development of the automobile manufacturing industry.
Carrying out tool design, tool preparation, tool cutting performance evaluation, cutting force in cutting process - cutting temperature coupling mechanism, tool cutting database, etc., will force the research and development of high-performance tools in China's tool manufacturing enterprises, and improve China's CNC The overall level of tool design and manufacturing enhances the ability of China's precision tools and coated tools to participate in international competition and reduces the dependence on imported CNC tools. Form a virtuous circle between research and development and industrialization, and create a new situation with technology as the guide and product as the carrier.
Innovations and breakthroughs in the development of high-performance tools for key automotive components
Key technology to solve
Focusing on the processing characteristics of key automotive components and their special cutting process requirements, focusing on the development of advanced composite tools or special tool structures, through the application of reverse engineering techniques for digestion and absorption and innovation, parametric analysis and high-speed rotary tool systems Safety optimizes tool geometry design; structural design, geometry optimization, and heat treatment process innovation for complex tools and special tools for imported automotive parts.
To study the design principles of high-precision rolling, shaving, grooving gears and spiral bevel gears for engines, transmissions and transmissions for passenger cars and heavy trucks, to develop relevant machining techniques and equipment; to develop engine cylinder heads Precision boring and milling series tools and high-precision hole machining compound tools, crankshaft camshafts, high-efficiency machining broaches, turning tools, crankshaft high-speed inner/outer milling cutters, boring and milling cutters, etc., high precision, high efficiency, high reliability High-speed and high-efficiency composite cutting tool with specialized "three high and one special".
Several key technologies in the development of high-performance tools for automotive key components are focused on tool design techniques, tool forming techniques, tool coating techniques and tool application techniques.
Tool design technology: At present, domestic tool design mainly relies on experience and is oriented to tradition.
In the field of machining, there is no tool safety. This project is based on reverse engineering, tool parameter analysis and high-speed rotary tool system safety for precision composite solid carbide CNC tool design to meet high-speed and high-efficiency cutting performance requirements; reverse engineering technology is indispensable in modern design and manufacturing technology. The important method is to apply the laser fast scanning system to obtain the discrete point data about the physical characteristics of the sample, and then obtain the 3D simulation model of the sample through the space reconstruction technology, so as to achieve the purpose of rapid optimization design. The precision composite solid carbide CNC tool has complex structure and high design precision. The application of reverse engineering technology can greatly shorten the tool design cycle and meet the design requirements. The application of high-speed and high-efficiency cutting technology in the manufacture of auto parts is popular. Therefore, in the design of precision composite solid carbide CNC tools, the static model and dynamic model of the high-speed rotary tool system must be analyzed. The balance performance and the failure mechanism of the cutter body and the clamping mechanism are studied. The advanced reverse engineering software, hardware technology platform and dynamic balance test system are used to carry out the tool design research work.
Tool forming technology: The technical content is divided into two parts, namely multi-axis linkage CNC grinding technology and super-hard material electro-erosion grinding technology for complex space line edge forming.
Multi-axis linkage CNC full-grinding tool forming technology based on the principle of main cutting edge space forming; the main cutting edge space forming of full-grinding precision composite solid carbide CNC cutting tool is realized by multi-axis linkage of advanced CNC tool grinding machine. Accurate description of the trajectory of the grinding wheel space is the key technology to obtain the precise main cutting edge. Through the application of CAD/CAM 3D simulation cutting software, the 3D simulation of various complex surfaces such as step surface, curved surface and grinding wheel space cutting is carried out. . Through the CAM forward-looking function, the interference problem of the machining system is studied, and an optimized grinding process is obtained to ensure the reliability and quality stability of the actual grinding process system. On this basis, through secondary development, the formation of precision composite solid carbide CNC tool forming manufacturing technology with independent intellectual property rights.
At present, the domestic grinding of PCD and PCBN tools is mainly based on the application of mechanical methods to achieve straight line grinding.
The research is based on the principle of five-axis CNC wheel erosion and line erosion, PCD, PCBN tool precision sharpening forming technology, to achieve precise and efficient forming of complex curved edges.
CNC multi-axis electro-erosion grinding technology is an advanced composite grinding technology for the precision forming of superhard materials (HV 3500-7000) such as polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) tools. The key technology. It uses the principle of electric spark machining between the electric corrosion wheel (or molybdenum wire) and the workpiece, and realizes the forming electric corrosion grinding process of the main cutting edge of the tool by numerical control five-axis linkage. Compared with the traditional diamond grinding wheel grinding, the production efficiency is greatly improved. Through the development of CAM numerical control software, it can process all kinds of complex curved edge and stepped-shaped polycrystalline diamond boring and milling tools to form the precise shape of the main cutting edge with smooth connection and uniform corner angle. In particular, the use of wire erosion grinding has solved the problem of grinding the main cutting edge and the problem of internal blade grinding of complex shape tools that could not be processed in the past.
Tool coating technology
The single-layer coating material has a simple structure and cannot meet the comprehensive performance requirements of the tool for the coating. The research of the aluminum-rich multi-layer composite hard coating technology based on the gradient function makes the coating material have excellent comprehensive performance and reaches the advanced level in foreign countries, meeting the requirements of the tool under high-speed and high-efficiency cutting conditions. In the design of high-efficiency composite coated tools, the composition of the coating material, the coating thickness and the optimization of the coating structure are the guarantees for obtaining a gradient-functional composite coating. Tool substrate surface pretreatment technology and coating process control technology are key in the coating preparation process. This project adopts comprehensive treatment technology such as mechanical treatment, wet cleaning and particle etching to obtain the ideal surface suitable for coating and maximize the bonding strength of the coating. In the preparation process of the aluminum-rich coating, the multilayer structure and the layered design process of the composition are used to achieve the best mechanical properties by controlling the thickness and composition of each layer. On the one hand, by controlling the thickness of the layer, the growth of the crystal grains is suppressed, and a nano-coat layer is obtained. At the same time, the multilayer structure is advantageous for absorbing the microcrack phenomenon generated during the growth of the coating, thereby eliminating cracks and obtaining a continuous coating. On the other hand, by controlling the composition change, the process of gradual composition is adopted, which is beneficial to eliminate the stress in the coating process, and at the same time, the gradual layer structure design is beneficial to improve the coating adhesion. In the aspect of coating composition control, adjusting the atomic ratio of Al:Ti, increasing the content of Al, forming an aluminum-rich coating, inhibiting the formation of TiO2 due to temperature rise during the cutting process, and effectively improving the high temperature mechanical properties of the coating. By improving the surface hardness and oxidation temperature of the coating, the wear resistance of the tool is effectively improved, the service life of the tool is extended, and the coated tool is suitable for high-speed cutting and dry cutting, overcoming the conventional coating due to temperature rise during processing. Loss of the shortcomings of its mechanical properties.
Tool application technology
The so-called applicable cutting database has the connotation of selecting the applicable tool and recommending the optimized cutting parameters for specific workpiece materials, machining accuracy, surface quality and machining efficiency, and solving the problem of adaptability of the tool to the workpiece material. The characteristics and nature of high-speed and high-efficiency cutting are significantly different from those of ordinary cutting, so it is obviously not suitable to use the existing common cutting database. At present, the reasonable and applicable cutting data in China is still very scarce, which greatly limits the promotion and application of high-speed and high-efficiency cutting technology, and restricts the localization process of high-speed and high-efficiency cutting tools. When China's automobile manufacturing enterprises purchase a large number of advanced high-speed CNC machining centers from industrialized countries, they cannot introduce high-speed cutting database and other process technologies due to technical blockade, which seriously affects the normal application of advanced machining centers and causes potential waste of inherent assets. For the automobile manufacturing department, how to choose the tool, how to use the tool, make full use of the processing equipment capacity, fully reflect the good cost performance of the high-performance tool, and achieve high-efficiency and low-cost processing, which has always been the main theme of the auto parts production line. For tool manufacturers, newly developed tools require cutting performance evaluation before entering the market. The cutting performance test is most effective for further improvement of the tool and optimization of the cutting amount.
The core technology of the high-speed cutting database system is based on the cutting force model, the cutting temperature model, the tool wear model and the intelligent prediction technology of the workpiece surface quality model. There are three sources of high-speed cutting data: literature, production, and cutting tests.
Under the premise that China's high-speed cutting data is still scarce, especially for the situation that the high-speed cutting data of difficult-to-machine materials is more scarce, it is more urgent to carry out research on cutting parameter optimization prediction technology based on the physical model of high-speed cutting process of difficult-to-machine materials. important.
Technical innovation points, breakthrough points The key components of automobiles are generally steel, cast iron and aluminum alloy materials, but most of their processing is carried out on special CNC machine tools. The cutting process is special, and high-speed and efficient production cycle is required.
Focusing on the processing characteristics of key automotive components and their special cutting process requirements, focusing on the development of advanced composite tools or special tool structures, through the application of reverse engineering techniques for digestion and absorption and innovation, parametric analysis and high-speed rotary tool systems The tool is optimized for geometric design of the tool; the structural design, geometric shape optimization and heat treatment process innovation are carried out on the imported auto parts with complex tools and special tools to form independent development and innovation capabilities.
To study the design principles of high-precision rolling, shaving, grooving gears and spiral bevel gears for engines, transmissions and transmissions for passenger cars and heavy trucks, to develop relevant machining techniques and equipment; to develop engine cylinder heads Precision boring and milling series tools and high-precision hole machining compound tools, crankshaft camshafts, high-efficiency machining broaches, turning tools, crankshaft high-speed inner/outer milling cutters, boring and milling cutters, etc., high precision, high efficiency, high reliability High-speed and high-efficiency composite cutting tool with specialized "three high and one special".
The basic theory of metal cutting machining is carried out in the development project of high-performance tools for key parts of automobiles, related to tool design, tool preparation, tool cutting performance evaluation, cutting force-cutting temperature coupling mechanism, tool cutting database and other key common technologies. And experimental technology research. In order to meet the requirements of high-performance machining of key components of automobiles, research on key technologies in the design and manufacture of high-performance tools is the design technology, forming technology, advanced coating technology and application technology of high-speed and high-efficiency cutting tools. The foundation provides theoretical guidance for the high-speed and high-efficiency cutting tool product series developed by related tool backbone enterprises.
Innovation
Based on the high-speed and high-efficiency tool and workpiece material cutting performance adaptability model, a general-purpose cutting database is established. Based on the high-speed cutting force-thermal coupling physical model of difficult-to-machine materials, the cutting parameter optimization prediction technology is studied, and a special cutting database for automobile manufacturing is established. The database system has an expert system of intelligent reasoning, judgment and decision making to meet the cutting requirements of high-end products.
Based on the cutting process dynamic characteristic parameters and processing surface quality index detection technology, the tool cutting performance evaluation system is constructed to provide technical support for tool companies, material enterprises and tool application enterprises, and provide a test platform for tool standardization research; The optimization design technology of high-performance tools for key components; research and application of multi-axis linkage numerical control and electro-erosion grinding technology to complete the forming technology of space curve edge; research and development of aluminum-rich multi-layer composite hard coating tool technology.
Carry out structural design and optimization innovation of high-performance tools for various key components of automobiles, develop computer simulation (simulation cutting or simulation cutting) software; improve heat treatment computer temperature control system to achieve temperature control accuracy of ±3 °C; solve high-performance tool materials Forging technology, heat treatment technology and grinding technology to improve the processing efficiency and process quality stability of difficult-to-machine materials; study the application problems of various cutting tools and coating materials under different cutting environments, adapt to the requirements of high-speed and high-efficiency cutting development .
The main technical indicators (such as the formation of intellectual property rights, technical standards, new technologies, new products, new devices, monographs, etc., the number, indicators and their level, and the competition analysis of similar technologies or products at home and abroad, to meet the major The key parts of the automobile construction, or the development of major equipment, etc.) are mainly steel, cast iron and aluminum alloy materials, but most of the processing is carried out on special CNC machine tools. The cutting process is special, and the material needs high speed. Efficient production beats.
Focusing on the processing characteristics of key automotive components and their special cutting process requirements, focusing on the development of advanced composite tools or special tool structures, through the application of reverse engineering techniques for digestion and absorption and innovation, parametric analysis and high-speed rotary tool systems The tool is optimized for geometric design of the tool; the structural design, geometric shape optimization and heat treatment process innovation are carried out on the imported auto parts with complex tools and special tools to form independent development and innovation capabilities.
To study the design principle of large-scale, high-precision rolling-to-gear gear cutters and large-scale spiral bevel gear cutters for super-heavy trucks, and develop related processing technology and equipment; focus on the development of gearbox complex gears for complex precision gear processing and engine cylinder heads High-precision, high-efficiency, high-reliability, precision boring and milling tools and high-precision hole machining composite tools, crankshaft camshafts, high-efficiency machining broaches, turning tools, crankshaft high-speed inner/outer milling cutters, etc. Specialized "three high and one special" high speed and high efficiency composite cutting tool.
Research on multi-axis linkage CNC grinding and electro-erosion machining to realize the forming technology of complex space curve edge. Based on the high-speed and high-efficiency tool and workpiece material cutting performance adaptability model, a general-purpose cutting database is established. Based on the high-speed cutting force-thermal coupling physical model of difficult-to-machine materials, the cutting parameter optimization prediction technology is studied, and a special cutting database for automobile manufacturing is established. The database system has an expert system of intelligent reasoning, judgment and decision-making to meet the cutting requirements of high-end products. Based on the dynamic characteristic parameters of the cutting process and the detection technology of the surface quality indicators, the tool cutting performance evaluation system is constructed for tool enterprises, material enterprises and tool applications. The company provides technical support and provides a test platform for tool standardization research.
Application of reverse engineering to develop and optimize high-performance tools for key components of automobiles; application of multi-axis linkage CNC and electro-erosion grinding technology to complete the formation of space curve edges; development of aluminum-rich multi-layer composite hard coating tools.
China has become the world's new manufacturing and processing center, and the booming and rising industries of automobiles, aerospace, mold, machinery, electronics, metallurgy, etc., have provided a huge market space for the development of the tool industry. However, under the trend of economic globalization, the competition in the market economy is becoming increasingly fierce. The world's most famous tool companies have launched their products in the Chinese market. Especially in the automotive industry, precision composite hole machining tools and high-efficiency composite coating tools are almost all foreign. product.
However, China's CNC tools have not formed scale, and the localization rate is low, mainly due to some low-end products. In the automotive industry, advanced CNC machining tools rely mainly on imports.
The next step of high-performance tool development for key components of automobiles is to further break the technological monopoly of foreign famous brand tools, improve the design and manufacturing level of precision composite tools and high-efficiency composite tools in the automobile manufacturing industry, and domestic CNC tools must form large-scale production.
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