Analysis of the future development direction of innovative tool display manufacturing industry

Faced with increasing tool quality requirements and rising tool cost pressures, the balance between quality, efficiency and cost is increasingly becoming the focus of production companies. In view of the continuous development of high-speed machine tools, high-speed milling, composite machining, and micro-shape cutting have become the main directions for the development of cutting technology. This paper introduces a number of the latest cutting tool technologies in combination with practical applications. They not only have their advanced nature, but also have strong practicality, reflecting the development direction of new manufacturing industries in the future.

The new concept of gear processing "deformation hob"

In close cooperation with customers and machine tool builders, LMT-FETTE and Liebherr Group jointly developed a three-in-one combination gear machining tool. It replaces the previous three-step machining process of roughing-deburring-shaving on different machine tools, a roughing hob, a deburring chamfering cutter and a finishing hob "deformation hob" (Twist-Free-Hob) is mounted on the same shank so that the three steps of roughing hobbing, flank chamfering and gear finishing can be done on the same machine.

Gear cutting and deburring are done on the same machine. All the tools are mounted on one shank without any additional manual or machine grinding, and no need to add deburring machines and tools. This is the most economical gear finishing, especially for mass production of gears of the same or similar specifications. Moreover, roughing and finishing hobs can also be designed independently, with optimized number of teeth, number of slots, and special tooth profiles. In this way, the roughing hob can use the fastest machining speed without having to take into account the final tooth profile quality of the workpiece. The finishing hob "de-forming hob" (Fig. 1), because it does not require a large number of single-re-grinding, the production lot is significantly larger than those of the hobs that are both rough and finished. By correcting the tooth profile error with a finishing hob, a spur gear and a helical gear with no tooth error can be machined. The hob uses a diagonal hobbing method to eliminate the tooth profile error while hobbing the allowance, providing higher gear load carrying capacity and smooth running.

Blue Flags also developed gear chamfering tools to save the cost of removing gear burrs. The first chamfering cutter removes the burrs on the top of the gear and chamfers. The second chamfering knife removes the root burr and chamfers.

Schnell tools with special materials and special coatings

In innovative cutting technologies such as HardMilling, High Speed ​​Milling (HSM) and precision machining, Schnell's tools are known for their high speed, long life and high cost performance. Its tooling products feature advanced hardware and software technology, patents and know-how, and use special tool materials and special coatings. The coating technology is tailor-made by internationally renowned companies. The tool material is made of Swiss and German advanced powder metallurgical sintering technology. The material particles are nanometer-sized fine particles with a diameter of 0.2μm or less and are equipped with super-hard surface NOVA coating or High life LL coating. It can be used for high-speed machining of various hardened die steels and quenched alloy tool steels. The highest hardness of the machined parts is HRc70. This series of tools is the first to enter the traditional forbidden zone of cutting HRC70 hard quenching die steel, which poses a challenge to the EDM process.

The dazzling metallic blue LL coating in Figure 2 is an ultra-long-life coating developed in 2005 using nanotechnology. Schnell bought out the exclusive use of the product for 4 years. Experiments have shown that the LL-coated tool can make the operator more comfortable in the practical process of processing the hard-hardened steel material exceeding HRC70, just as it is to use ordinary tools to process ordinary hardness materials. In addition, tool life with LL coatings can be extended by a factor of two to three compared to conventional coatings, which significantly reduces production costs.

SS coating is an advanced ultra-smooth coating technology developed by Schneider Research. The use of this coating in the cutting of conventional hard steel or other metallic materials can significantly enhance the stability of the process and achieve a smoother surface. Under the same processing parameters, the ultra-smooth SS coating can overcome the sticking phenomenon and eliminate the blade blade. If the cavity surface of the injection mold is machined with a ball cutter, the effect of direct injection molding without polishing can be achieved.

SandivikGC4225 (Breakthrough No. 1) Improves the turning performance of steel parts

Parts, processes, materials, processing conditions, and blade sizes have changed significantly in the range of general steel turning applications (ISOP25 applications). No machining range is the same as the P25 grade, which has such a demanding requirement for the P25 cutting tools. How to get the best results with the same blade grade is a huge challenge for the metal cutting industry.

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