| 有了这几项技术，汽车关键零部件加工不再是难题！ |
| 添加时间：2017/9/7 14:28:06 浏览次数： |
| 随着汽车行业的复苏，汽车生产厂家对于产能增加的需求也更加迫切。但是投资新的生产线意味着需要更大的生产场地、更高的设备摊销和更多的人员成本，这些也同时带来了风险。于是，对于现有生产线效率的提升成为更多汽车生产厂家更实际的选择。那么如何使汽车发动机汽缸盖、变速箱轴、差速器以及活塞孔这些关键零部件的加工既高质又高效呢？小编今天介绍几个“加工神器”。 As the auto industry recovers, the demand for capacity increases is more urgent for auto manufacturers. But investing in new production lines means greater production sites, higher equipment amortization and more staff costs, which also pose risks. Therefore, the promotion of the efficiency of the existing production lines has become a more practical choice for more automobile manufacturers. So how do the key components of the car engine, cylinder head, transmission shaft, differential and piston hole be both high quality and efficient? Xiao Bian today describes several processing artifact". 对相关企业产品感兴趣的粉丝，可以点击左下角的“阅读原文”索取更多信息。 For fans interested in the related products, you can click on the "read the original" in the lower left corner for more information. 01 01 山特维克可乐满M5B90—气缸盖面铣 Sandvik M5B90 cylinder head surface milling 详细介绍 Detailed introduction 加工气缸盖时的最大挑战是在尽可能缩短生产节拍的情况下，生产出具有严格的公差和表面质量要求的零件。去毛刺、不规则的刀具磨损和不可预知的刀片寿命通常迫使面铣工序的生产节拍时间很长。 The greatest challenge in machining the cylinder head is to produce parts with strict tolerances and surface quality requirements as long as possible to shorten the production cycle. Deburring, irregular tool wear, and unpredictable blade life usually force the milling process to take a long time. 山特维克可乐满M5B90的设计采用独特的轴向和径向刀片定位，从而使每个刀片都能立即高效地切出切屑，而无需对刀片进行任何调整。每个刀具均针对零件量身定制，从而优化了切削刀片数量，而刀片始终采用Wiper (修光刃) 以确保出色的表面质量。因此与传统刀具相比可以实现高进给的切削并减少齿数。 The design of the unique M5B90 coromill axial and radial blade positioning, so that each blade can immediately and efficiently cut out of the chip, without any adjustment of blade. Each tool is tailored to the parts, thereby optimizing the number of cutting blades, while the blade always uses the Wiper (trimming blade) to ensure excellent surface quality. Therefore, compared with the traditional cutting tools, high feed cutting can be achieved and the number of teeth can be reduced. 加工案例 Machining case 一家西班牙的乘用车发动机气缸盖制造商向山特维克可乐满寻求帮助。加工过程不稳定并且存在毛刺问题。另一个问题是刀片寿命不确定，主要原因是小刀夹的调整位置在每次装夹时略有差异。 A Spanish passenger car engine manufacturers to Sandvik to seek help. The machining process is unstable and burr problems exist. Another problem is the uncertainty in the life of the blade, mainly due to a slight difference in the position of the clip in each clip. 对于这个问题，最大的挑战是提供稳定并且无毛刺的加工过程，并且刀片寿命可预知。质量要求：粗糙度：4 (Rmax：20)，表面波纹度 (W)：4，平面度：0.05 The biggest challenge for this problem is to provide a stable and glitch free machining process, and the blade life is predictable. Quality requirements: roughness: 4 (Rmax:20), surface waviness (W),:4, flatness: 0.05 解决方案 Solution 山特维克可乐满M5B90可提供流畅的精加工，磨损情况可预知并且无毛刺。由于该刀具的切屑较薄，可以轻松从零件上去除，从而不会在后续工序中对表面造成损害。 Finishing Sandvik M5B90 can provide smooth, predictable and no burr wear. Since the chip of the tool is thinner, it can be removed from the parts easily without damaging the surface in the subsequent process. 现有的刀具 Existing cutters M5B90 M5B90 齿数 The number of teeth 16 Sixteen 9 Nine 切削速度vc Cutting speed VC 3140 m/min 3140 m/min 3800 m/min 3800 m/min 主轴转速n Spindle speed n 5000 rpm 5000 rpm 6000 rpm 6000 rpm 进给率vf Feed rate VF 8280 mm/min 8280 mm/min 9000 mm/min 9000 mm/min 切深ap Cut depth AP 0.5 mm 0.5 mm 0.5 mm 0.5 mm 刀具平均寿命 Average life of tool 30000 Thirty thousand 45000 Forty-five thousand 由于刀片数量经过优化 (刀片始终在刀具上正确定位)，客户可以增大切削参数，并通过限制刀片数量和缩短周期时间来省钱。 Since the number of blades has been optimized (the blade is always correctly positioned on the cutter), the customer can increase the cutting parameters and save money by limiting the number of blades and shortening cycle time. 每年可节省：21 000欧元 Savings per year: 21000 euros 最后来看一段这个刀具的视频，更直接的了解它。 Finally, take a look at the video of this tool and learn more about it. wifi 下观看视频 View video under WiFi 02 02 山高新一代Duratomic®（金刚甲）技术—变速箱轴加工 New generation of high mountain Duratomic (Jin Gangjia) technology - transmission shaft processing 详细介绍 Detailed introduction 随着汽车行业的复苏，汽车生产厂家对于产能增加的需求也更加迫切。但是投资新的生产线意味着需要更大的生产场地、更高的设备摊销和更多的人员成本，这些也同时带来了风险。于是，对于现有生产线效率的提升成为更多汽车生产厂家更实际的选择。 As the auto industry recovers, the demand for capacity increases is more urgent for auto manufacturers. But investing in new production lines means greater production sites, higher equipment amortization and more staff costs, which also pose risks. Therefore, the promotion of the efficiency of the existing production lines has become a more practical choice for more automobile manufacturers. 山高刀具全新一代Duratomic®（金刚甲），在继承上一代产品优质特性和强度的同时，其在坚韧性和耐磨性方面都有了实质性的改进，将显著提升客户的生产率，为客户带来更大价值。Duratomic®（金刚甲）技术代表着业内首个量身定做的基于Al2O3的镀层，它重新定义了刀片的应用方式。通过控制原子和晶体并对其排序，它能够改善机械属性、热稳定性和化学稳定性。再加上韧性得到提升，所得到的性能会远远超过传统 Al2O3镀层的性能。此外，新镀层还改善了耐热性、化学稳定性并降低了工件材料粘附在切削刃上的趋向。 A new generation of seco Duratomic (Jin Gangjia), in succession to a generation of product quality characteristics and strength at the same time, the toughness and wear resistance are improved substantially, will significantly enhance customer productivity, bring greater value for customers. Duratomic (Jin Gangjia) technology represents the industry's first tailor-made Al2O3 based coating, which redefines the way blades are used. By controlling the ordering of atoms and crystals, it can improve mechanical properties, thermal stability, and chemical stability. In addition, the toughness is improved and the performance is much higher than that of the conventional Al2O3 coating. In addition, the new coating also improves heat resistance, chemical stability, and reduces the tendency of the workpiece material to adhere to the cutting edge. 在某严重断续加工的锻钢传动轴配件的实际生产中，原切削参数为：线速度Vc为120m/min，进给量fz为0.25mm，切深1.5mm，使用全新一代Duratomic®（金刚甲）的刀片后，不仅将寿命提升10%，效率也提升25%。 In the actual production of a forged steel transmission shaft parts of the severe intermittent process, the original cutting parameters: Vc line speed 120m/min, feed FZ 0.25mm, cutting depth of 1.5mm, the use of a new generation of Duratomic (Jin Gangjia) of the blade, will not only enhance the life of 10%, efficiency is also increased by 25%. 加工实例 Machining example 零件名称：变速箱轴 Part name: transmission shaft 零件材料：20CrMnTi Part material: 20CrMnTi 冷却方式：干切 Cooling method: dry cutting 加工类型：粗车 Machining type: rough car 刀片：DNMG150412-M3,TP0501 Blade: DNMG150412-M3, TP0501 切削参数：vc=240m/min，f=0.38mm/r，ap=2mm， Cutting parameters: vc=240m/min, f=0.38mm/r, ap=2mm, 零件名称：曲轴 Part name: crankshaft 零件材料：42CrMo Part material: 42CrMo 冷却方式：干切 Cooling method: dry cutting 加工类型：主轴颈粗车 Machining type: spindle neck, rough car 刀片：CNMG120416-MR7,TP2501 Blade: CNMG120416-MR7, TP2501 切削参数：vc=66m/min，f=0.25mm/r，ap=1.5mm， Cutting parameters: vc=66m/min, f=0.25mm/r, ap=1.5mm, 最后来看一段这个刀具的视频，更直接的了解它。 Finally, take a look at the video of this tool and learn more about it. wifi 下观看视频 View video under WiFi 03 03 台湾普慧—活塞孔内腔加工 Internal machining of Taiwan Hui piston hole 详细介绍 Detailed introduction 台湾普慧是同时具有设计电主轴、精密刀柄，非标刀具的制造商，其提供的汽车领域解决方案可协助客户打通设计到加工瓶颈并优化切削工艺，进而提升生产效率降低制造成本。 Taiwan Pu Hui is also designed with spindle precision handle, non-standard tool manufacturer, which provides car solutions can help customers to open up the design to processing bottlenecks and optimize the cutting process, and improve production efficiency and reduce manufacturing cost. |
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