Advanced tools reduce the auxiliary time of non-cutting of machine tools by reasonable and extensive use of combined tools, so as to improve the production efficiency of powertrain production lines. Combined tools in advanced tools have the following characteristics: high efficiency, high quality and high stability. Combining tools generally combines several machining contents on one tool, so that all machining contents can be completed with only one feed. This not only reduces the processing time, but also reduces the auxiliary time such as tool change, improves the production cycle and production efficiency, and is more and more widely used in the manufacture of modern automobile powertrains. For the bottom hole machining of 20 threads M10X1.5, which is common in powertrains, chamfering or countersinking is often required (see Figure 2).
Figure 2 Thread planing
Comparing the results of the general D8.5 drill + chamfering drill secondary machining and combined machining step drilling, the conclusions of Table 2 clearly show that the combined step drill with one machining is more secondary than the drill + chamfer drill. The auxiliary time that can be saved is 17% of the total processing time. Of course, different processing conditions will have some differences, but the above conclusions show that advanced combined tools can play an important role in improving the efficiency of the powertrain. Therefore, in order to reduce the auxiliary time as much as possible and improve the processing efficiency, a large number of advanced combination tools can be used in the automotive powertrain processing to meet the high efficiency requirements.
Table 2 Comparison of traditional processing technology and combined processing
The optimized application of advanced tools can improve tool life, reduce the frequency of tool change in production, and increase the starting rate of machine tools, thus improving the production efficiency of the production line. For example, the roughing of the pump hole on an aluminum alloy cylinder (see Figure 3), the original plan uses a carbide blade, the tool life is 80 pieces, the tool needs to be changed twice per shift, each time the tool change time is 15min, the machine is started. The rate has a big impact. The new solution uses a PCD welding insert with a tool life of 1000 pieces, which greatly reduces the tool change time.
Figure 3: Pump hole roughing on an aluminum alloy cylinder block
The comparison of the two schemes is shown in Table 3. Compared with the original scheme, the advanced tool can save the production line for one month each year only when the tool change time is used. If the time can be fully utilized, the equipment and personnel are not added. Under the premise, it can produce about 20,000 parts per year, which will greatly improve the production efficiency of the production line.
Table 3 Comparison of machining between cemented carbide inserts and PCD welding inserts
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