자동차 제조업에서의 PCD 도구
In Europe, according to research published by the European aluminum Association (EAA), the amount of aluminum used in a new car in 1990 was 50kg. By 2005, that number had risen to 132 kilograms. A further 25kg of aluminum is expected to be used in each new car by 2010. According to the study, two million tons of aluminum parts were made in new cars made in Europe in 2005. Using aluminum parts to make cars lighter could save 1 billion liters of fuel a year and reduce carbon dioxide emissions by about 40 million tons over the life of those cars.
자동차 차체에서 알루미늄 부품의 대부분은 공조 시스템, 엔진 커버, 충격 흡수기 부품, 스티어링 기둥에 집중되어 있다.자동차 섀시와 서스펜션 총성 중 알루미늄 부품은 허브, 서스펜션 스탠드, 스티어링 시스템 총성 등의 부품에 초점이 맞춰져 있다.동력전달 시스템에서 알루미늄 부품의 대부분은 실린더 헤드, 실린더 블록, 실린더 헤드, 펌프 및 냉각기에 있습니다.또한 알루미늄 합금 씰, 차체 케이스, 섀시 적용도 꾸준히 증가하고 있다.
통용기계 제조와 항공 등 다른 산업에서는 강철을 더 높은 밀도의 재료로 대체하는 것이 전통적 구조 재료로도 중요하다.그러나 알루미늄 합금의 경도가 너무 높지 않고 인성이 높기 때문에 절단이 어렵습니다.가공 과정에서 알루미늄 합금은 공구 재료와 결합하기 쉽고 냉간 가공 경화 현상이 발생하기 때문에 저속 절삭 시 공구 전연에 절편종이 발생하기 쉽다.
드라이 컷
Due to sensitivity to environmental impacts, automotive parts are increasingly being cut dry or machined with minimal coolant. The cooling cost savings (including associated waste liquid recovery and treatment costs) are also driving a significant increase in cutting speed that is not possible with conventional cemented carbide tools.
기존의 공구 또는 공구 재료를 사용하여 드라이 컷을 수행할 경우 공구 칼날 포트 형상의 변화와 절삭 영역 마찰로 인한 열이 증가하여 가공소재의 서피스 마무리가 좋지 않습니다.
더 높은 기계 속도
Last but not least, the development of machine tool technology makes its spindle speed and feed constantly improve, so as to achieve faster machining. Only a few years ago, the spindle speed of the machine tool was only 6000r/min, but now it has reached 30,000-40000r /min, and the movement acceleration of the shaft can reach 2G. This machine, supported by powerful computer power, is capable of achieving the movement required for machining (e.g., screw interpolation in thread milling).In order to convert this speed advantage into a machining advantage at the point of action, the corresponding tool material is required. However, with carbide cutting tools, the cutting speed can only reach 400m/min. Tools with polycrystalline diamond (PCD) cutting edges can cut up to 3000m/min(depending on the cutting process).In addition to higher machining speed, the main benefits of PCD tools include longer tool life and (in many cases) better surface machining quality.
독일 코마이트 그룹의 일부인 JEL정밀 커터는 경질 합금 드릴에 사용되는 고효율 PCD 드릴의 DRILLCUT 및 Drillmax를 포함한 광범위한 PCD 커터를 시장에 공급하고 있다.이 두 드릴은 깊이가 5D에 달하는 구멍을 뚫을 수 있다.DRILLCUT는 두 개의 절삭날과 네 개의 가이드 칼날이 있고 내부 냉각을 위한 냉각 채널이 구비된 직선 슬롯 드릴이다. DRILLMAX도 동일한 내부 냉각 설계를 채택하지만, 두 개의 가이드 칼날이 있는 나선형 슬롯 드릴이다. DRILLMAX 드릴은 위치 정확도가 높고 it8-it9까지 파고들 수 있으며 긴 공구 수명과 우수한 표면 마무리를 얻을 수 있다.이 회사는 또한 제품 라인에 PCD 슬롯 커터를 포함합니다.머시닝하는 동안 커터의 PCD 커터 칼날이 가공소재의 상부에서 중심 구멍으로 파고들어 중심을 차단합니다.최대 컷 깊이는 커터 지름의 두 배입니다.또한 이러한 공구는 적절한 밀링에 사용할 수 있으며 원형 형상을 머시닝하여 서피스 마무리와 머시 없는 공구 칼날을 얻을 수 있습니다.표준 2날 PCD 커터의 최소 지름은 6mm이고 3날 커터의 지름은 16-20mm입니다.
고신뢰성 스레드 밀링
JEL is one of the few technical authorities in the field of complex internal threading, particularly when it comes to thread milling or developing specialized solutions for specific processing. The famous MGF and TO MILL thread mills are the most commonly used machining tools.MGF thread milling cutter with PCD tip has a sunk hole in the shank, and the cutter body is made of hard alloy material, especially suitable for processing aluminum alloy and other materials usually processed by PCD. The tool can mill m6-m12 standard thread sizes with a cutting edge length of 2 times a nominal diameter. Similarly, TO MILL(GWF) thread milling cutters with diameters of 16mm and 20mm can mill threads with diameters ≥20mm.In addition, JEL offers process-oriented solutions that include as many processing operations as possible.PCD tip drills and thread milling cutters (BGF) have also been developed that, in addition to producing screw holes, 90° chamfers and threads, can also produce protective countersunk holes in a single machining operation.
자동차 부품 가공의 예
One example of the vabos-k modular tool concept (variable drilling, counterboring and thread cutting system) with bit and thread milling cutters is machining spark plug threads on die-cast aluminum. With this tool, the machining of the screw hole, 90° chamfering, spot-facing, face facing with diameter 22mm and M14×1.25 thread can be completed through one processing. All cutting elements of the tool use PCD tips. The values-k modular tool system was developed for processing where the use of indexable blades in tool clips is not possible due to shape, size, or precision requirements. To process 90° chamfering, spot facing, and face facing, the PCD cutting edge is welded directly to the vabos-k head and the head is then fixed to the cutter body or clamp, and the cutter body or clamp can be easily removed to install the new PCD cutting edge. This knife clip is a one-time purchase of accessories. Center drills and thread mills can be easily installed in place without time-consuming adjustments.
Another example of a specialized tool developed by JEL is also a vabos-k tool system. The system consists of a solid carbide bit and thread milling cutter (BGF) for drilling through holes with internal threads, counter facing holes and M6 threads on aluminum shell workpiece. The salient feature of the tool is that it can process countersunk holes with a diameter of 50mm. Only the PCD tip can be used for machining at a steady maximum speed of 10000r/min (equivalent to a cutting speed of 1570m/min at a diameter of 50mm). Only in this way can a very short total processing time (3.9 seconds) be achieved.
연료 필터 하우징 프리캐스트 구멍을 마무리하기 위한 vabos-m 공구 시스템은 PCD Tomill 나사 연마를 가지고 있다.한 번의 머시닝으로 카운터보어 프로파일, 대각선 구멍, 아웃솔 디버러시, 밀링 S80×3 지그재그 스레드의 머시닝이 완료된다.각 구멍의 처리 시간은 믿을 수 없을 정도로 8.8초로 줄어들 수 있습니다.이 공구의 특징 중 하나는 스레드 밀링의 설계로 가공소재에서 머시닝된 첫 번째 스레드가 완전한 스레드가 된다는 것입니다.
원형 절단부 및 모서리 절단 가공
When contour machining is required on the inner and outer diameter of the workpiece (such as grooving in the hole and machining cavity), circular milling and turning can only be realized on the flexible machining center, and circular cutting and grooving is a feasible alternative processing method. This kind of processing will be in the lathe insert the principle of processing upside down and turning the workpiece rotation, tool static way is different, it is the workpiece static, tool movement. The tool is processed by the circular interpolation path generated by the CNC system of the machine tool into the stationary workpiece. In this process, the cutting edge of the tool is perpendicular to the tangent of the cylinder of the hole at each point in the circular interpolation path. The result is that for every turn the tool makes around the workpiece, it only turns around its axis once. The surface machined by circumferential cutting and grooving will not produce the special cutting mark surface of circumferential milling. Such tools with PCD cutting edges are also available for aluminum parts.
German Komet group is composed of the Komet precision tool company, Dihart precision tool company and JEL precision tool company. The group has approximately 1500 employees around the world, engaged in the production and sales of precision cutting tools, its main technical areas are a hole, thread general processing and precision processing, special thread cutting, standard, and special PCD tools and turning tools. Komet is a market leader in mechatronics (tools with built-in NC axis for cutting edge positioning and tools with NC contorting).
