In the automotive industry, the importance and complexity of machining is very prominent. In recent years, the changes and development of cutting processing in the automobile manufacturing process are particularly eye-catching, and new processes and new methods are emerging one after another.
Figure 1 Feedback and control of the cutting system
Why is the importance and complexity of cutting in the automotive industry extremely prominent? This is because a large number of various types of parts need to be processed in a precise, high-speed, high-efficiency process; the automobile production itself is characterized by large-volume production of water flow strictly according to the beat; at the same time, the fierce competition in the market has further intensified the flexibility of automobile production. And cutting manufacturing manufacturing cost control requirements.
In recent years, it can be seen that the cutting process in the automobile manufacturing process has undergone great changes and new developments have been made, and many new processes and new methods have emerged.
For example, the crankshaft machining adopts the car-car pull, the outer milling or the inner milling; the connecting rod processing adopts the breaking process; the camshaft machining adopts the assembled camshaft and then the direct grinding forming process; the cylinder main bearing hole and the connecting rod big head The hole processing uses a twisting process or the like. In the production process, a large number of flexible processing lines set up by CNC machining centers are used. The cutting parameters such as cutting speed and feed rate are generally greatly improved, and the manufacturing process is accelerated toward high-speed and high-efficiency machining. Innovative tool structures and new tool materials are in progress. And new surface coatings are constantly being used, and so on. Moreover, the stability requirements for the production process and processing quality are also more stringent, and the control of manufacturing costs is also tightened.
All of this poses new challenges to cutting.
Machining is a system problem
In the high-precision, high-speed, high-efficiency large-scale automotive manufacturing cutting production, various abnormalities sometimes occur, including the workpiece processing size is too poor; the position degree does not meet the requirements; the processed surface topography is not ideal; the tool is chipped, Broken, abnormal wear, short tool life and high tool costs, and more. These problems need to be solved in the shortest possible time, otherwise it will have a great impact on the normal production of automobile manufacturing.
1. Just because the tool has a problem?
In practice, many people often have a habitual thinking. Once an abnormality occurs in the cutting process, it is considered that the tool has a problem. A lot of work and solutions are also around the tool. The result is a lot of energy. And the reason is still unclear, and the problem cannot be completely solved.
In fact, cutting, especially efficient machining, is a system problem, and the tool is just one part of the system. In the machining process, the workpiece blanks, equipment, tools, fixtures, cutting fluids, etc. are combined to form a system. The problem of machining is the product of multiple factors and variables in this system.
Moreover, for many companies, this "system" may not only be represented as a process or a piece of equipment, but the entire production line; and the tool itself is one of the subsystems, including the tool structure, geometry Shape, body material, cutting edge material, tool coating and many other aspects.
All the above factors are combined to influence and determine the size, shape, position, surface topography, machining accuracy, etc. of the product, and any factor in the whole system changes, the output of the system, ie the processing quality and processing efficiency. And processing costs have an impact.
As a well-understood example, in the past, although people have felt that cutting fluids have an effect on cutting, they are often only treated as general auxiliary materials in production processing. However, the current production practice tells people that the cutting fluid, which is one of the whole cutting system, has been so important that if the cutting fluid is not properly selected or managed improperly, the production will not work properly and the tool will not function properly. use.
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