Looking at the development trend of cutting tools from the 13th International Mould Exhibition

The 13th China International Mould Exhibition was held at the Shanghai New International Expo Center from May 11th to 15th, 2010. It attracted more than 50 cutting tool manufacturers from home and abroad to participate in the exhibition. Manufacturing users have demonstrated the latest developments in tooling for tooling, and they also reflect new trends in cutting technology and tool development. The high-cut milling cutter with large depth and large feed is the main tool for mold processing, and its processing volume accounts for 80%-90% of the total amount of mold cutting, which has become the development focus of mold processing tools. At this exhibition, many tool companies exhibited a complete set of milling tools for mold processing, and the processed molds and tools were displayed together at the same time, attracting many visitors. For example, Sandvik Coromant exhibited many members of the CoroMill series of milling cutter “families”, many of which are milling cutters for mold processing. Since the milling cutter is the tool with the largest amount of metal removal in the cutting process, improving the milling efficiency has become one of the innovative directions of the milling cutter. The CoroMill 345 from Sandvik Coromant is a 45° lead angle face milling cutter with a wiper blade that increases the table feed speed by a factor of 3 compared to a standard face mill with parallel blade And get a better surface finish. Conventional milling cutters with wiper blades are usually fine milling cutters with a small depth of cut, while CoroMill 345 cutters have a maximum depth of cut of up to 6 mm. At this exhibition, Teguco also introduced a similar milling cutter. It can be predicted that the new products they exhibit set a new benchmark for deep cutting and large feed milling cutters, which will cause resonance and follow-up in the industry, which is of great significance for improving the quality and efficiency of large-scale face milling. The promotion of the new structure of the milling cutter At this exhibition, we can see that some new milling cutters developed in recent years have been applied to more milling cutters. Some cutter manufacturers have introduced a series of milling cutters with new structures. product. For example, the milling cutter that can be used for ramping is first developed for machining mold cavities or inner closed slots. It has many functions such as milling plane, milling cavity and milling hole, which is very suitable for the concentration of mold processing. Can reduce the tool change time. At this exhibition, the structural features of the milling cutter that can be used for ramping have been applied to different milling cutters such as face milling cutters, end mills, square shoulder cutters, and arc angle milling cutters, so that most milling cutters Variety has the versatility of not only for mold processing, but also for a wider range of conventional milling operations. Similar situations have also appeared on small depth-cutting and large-feed milling cutters. Zhuzhou Diamond Cutting Tools Co., Ltd. and Tungaloy have developed a series of such milling cutters to make full use of the advantages of large feed and improve milling efficiency. . Tungaloy even applied this concept to turning tools and introduced the Turning X super-feed tool to increase machining efficiency by a factor of eight. Zhuzhou Diamond Cutting Tool Co., Ltd. also exhibited the newly developed FMD03, FMD04, FMP03 series vertical insert gravity cutting face milling cutters. The LNKT series blades equipped with positive cutting angle and rake angle are easy to cut in machining. Low power consumption, cutting depth of up to 17mm, high processing efficiency.
Improving the economics of the tool In order to help the tool users overcome the difficulties caused by the financial crisis, starting from the structural design of the tool and improving the economics of the tool has become one of the characteristics of the new product development of the current milling cutter. A common practice is to design the indexable insert to be double sided, doubling the cutting edge. At the same time, you can increase the economics by increasing the number of sides of the polygon blade. At this exhibition, face milling cutters with hexagonal, heptagonal or octagonal double-sided inserts have become a selling point for exhibiting companies to promote product economics, such as Dijet's face milling cutter with a heptagonal blade. And Mitsubishi's face milling cutter with octagonal CBN inserts. In addition, VARGUS's threaded inserts increase the usual three tips to six and are double-sided inserts, reducing blade costs by more than double. The modular interchangeable end mills exhibited by the companies not only shorten the tool change time, but also reduce the number of tool bars and reduce tool costs. A vibration-damping tool post exhibited by Nikko Co., Ltd. is made of a special alloy to replace the commonly used hard alloy material, reducing the cost of the tool post. The fast-growing solid carbide milling cutter solid carbide end mill is also the mainstream tool for mold processing. From this exhibition, we can see that the main development trends are as follows: (1) Development of various vibration-eliminating milling cutters At this exhibition, the EPOCH MIRUS series of high-efficiency mold milling cutters introduced by Hitachi has optimized the design of new glutinous rice profiles. And the structure of the unequal offset of the adjacent blade cutters reduces the cutting force and vibration and improves the machining efficiency. (2) Development of milling cutters for hardened die steels These mills can process materials ranging in hardness from HRC45-HRC67 to HRC70. For example, the coated carbide end mills (with HARDMAX coating) exhibited by Unin are suitable for high-speed machining of hardness HRC45-HRC65 die steel. (3) Development of milling cutters for difficult-to-machine materials With the development of the aerospace industry and energy equipment manufacturing industry, the use of super-alloys (including superalloys, titanium alloys, etc.) has increased rapidly, and higher processing efficiency and tool life have been proposed. The requirements also promoted the development of new products for tool suppliers. For example, the CoolStar series of solid carbide end mills from Mitsubishi have a specially designed chip flute shape that improves the chip removal effect and provides multiple internal cooling holes in each chip flute to improve cooling. Together with the high toughness base material with good wear resistance, it can realize efficient processing of super alloy materials and prolong tool life. OSG exhibited an end mill for the processing of composite materials for the aerospace industry. The cutter has a special trough shape to avoid delamination and burrs when processing multi-layer composite sheets. (4) Development of milling cutters for processing graphite and aluminum alloys These tools use diamond or diamond-like coatings to provide powerful technical support for efficient processing of graphite electrodes and aluminum alloys. For example, OSK's aluminum roughing cutters have a flank for the front face of the aluminum roughing cutter, which makes the cutting lighter and prevents chip sticking and longer tool life. The tool application guide is worth mentioning. At this exhibition, Sandvik Coromant distributed two brochures on “Milling Application Guide” to visitors, including the selection of milling cutters and the setting of milling parameters. , the correct path and implementation plan. With the increasing popularity of CNC machine tools, the traditional milling methods can not meet the requirements of CNC milling, which greatly restricts the full performance of CNC machine tools. This comprehensive and systematic introduction to the new milling technology and practical application of the booklet is of great value in promoting the advancement and popularization of modern milling technology, improving the technical and social benefits of milling, and will have far-reaching effects. The technical guidebooks that were exhibited at the show included turning, milling, drilling, boring and tool holders, and introduced the new application techniques of modern tools. The value of these technical materials for the majority of tool users far exceeds that of a new tool exhibit, which has become a highlight of this exhibition and should be of concern to tool users. New grades of blade materials are emerging. Currently, the development of blade material grades is based on the processing object and application range of the blade, and the advantages of blade base, coating and geometry are integrated to develop special or general-purpose blade grades. . Both types of grades can be seen at this exhibition. At the show, Sandvik Coromant introduced two milling grades S30T and S40T for machining titanium. Titanium alloys are difficult-to-machine materials, and these two grades have been developed for the processing of titanium alloys, resulting in higher processing efficiency and longer tool life. The company also introduced a new grade of threaded insert GC 1135, which is a fine-grained carbide substrate with a PVD TiAlN coating and a sharp groove shape, especially for threading of stainless steel and heat-resistant alloys. The new grade of YBM253 (M20-M30) CVD coating for processing steel tubes introduced by Zhuzhou Diamond Cutting Tools Co., Ltd. uses a high-toughness gradient cemented carbide substrate and ultra-fine alumina coating. The surface is polished to make the blade have Good wear resistance and impact toughness. In addition, the company has developed YBM351 grades for rough milling of steel and stainless steel, YBG302 for rough milling of steel, stainless steel and cast iron, and YBG205 and YBG202 grades for the QC series of shallow grooving cutters. Tungaloy's PREMIUMTEC series of blade grades include T5100, T9100, AH725 and AH905 for the processing of cast iron, steel, stainless steel and high temperature heat resistant alloys. The first two are CVD coated and the last two are PVD coated. Teguco has developed TT9020, TT9030, TT1040 and TT6050 blade grades for solid carbide end mills for different processing materials and cutting conditions. The TT6050 grade is diamond coated for Processing graphite. CBN era is beckoning? In this exhibition, many companies have exhibited CBN tool series products, and CBN super-hard tools have shown a trend of further expansion of application range. OSG even claims that cutting tools have gradually entered the CBN era from the era of cemented carbide. The company exhibited the CBN end mill series, expanding its range and specifications, including four ball end mills and three flat end mills. Tungaloy has developed the CBN turning tool series, which has developed numerous grades for different conditions of use by adjusting the CBN content, particle size and coating treatment. Its applications cover hardened steel, ordinary cast iron and ductile iron, sintered metal, titanium. Processing applications such as alloys and spray materials. The expanded application of CBN will have a profound impact on cutting and manufacturing, not only to improve processing efficiency, but also to promote the popularization of new processes such as hard cutting, dry cutting, car grinding, and milling. HORN Company introduced the CBN milling cutter for the machining of constant velocity joints in the car, and replaced the grinding process with CBN hard milling technology. Each shift can process 600-800 ball cages, and the tool life can reach 2-3. Classes and significantly reduce processing costs. Another example is Mitsubishi's CBN octagonal blade face milling cutter, which is used for high-speed and efficient machining of cast iron, with long tool life and good economy. In order to process CBN, PCD and CVD thick film PCD inserts, DMG Machine Tool has developed LASERTEC 40, a 3D laser processing machine that can process such superhard inserts. The machine can perform three-dimensional groove machining on these inserts to improve the performance of super-hard tools and promote the popularization of super-hard tool materials. The highlights of the coating are also quite a few in the tool coating technology, which is similar to previous mold exhibitions. There are new tool coatings and coatings for the molds. Saili Coating Technology Co., Ltd. has launched Aluspeed titanium diboride coating. The coating has smooth surface, sharp edge, micro hardness of HV4000 and maximum temperature of 900 °C. It is very suitable for processing aluminum, copper and titanium. Alloy and silicon-aluminum alloy containing less than 10% silicon. The company also introduced the super-nitride coating HSN2, which can be used for hard and dry cutting tools and can process steels with a hardness of HRC50-70. Oerlikon Balzers has introduced a new BALINIT ALCRONA PRO coating, an upgraded version of the company's AlCrN coating, which has improved wear resistance, thermal stability and red hardness to increase cutting speed and feed. The company also introduced BALINIT ARCTIC, a low-temperature coating for molds. This coating technology can coat TiN, CrN, TiAlN and other coatings at a low temperature of 200 °C, thereby increasing the service life of the mold, reducing lubricant consumption and reducing Cost of production. The ta-C introduced by Star Arc Coating Technology Co., Ltd. is a hydrogen-free DLC (diamond-like carbon) coating. Because it does not use traditional hydrocarbon gas as a raw material, it uses graphite as a target, so the structure is more stable. The coating has a higher hardness (HV 6000) and a lower coefficient of friction (0.06). It can be used on tools for processing graphite or non-ferrous metals, as well as for mold coating. In addition to the new coatings developed by the above-mentioned specialist coating companies, some tool companies have also developed new coatings in combination with their own tooling products, such as the PN coating developed by Hitachi, which is formed by adding Si to the AlCr coating. The bonding strength with the substrate is higher, the crystal of the coating is finer and more wear-resistant, and the surface is smoother. For example, the CrN coating developed by Mitsubishi for the copper electrode processing series of milling cutters has high hardness, strong bonding force, good wear resistance and lubricity, and can significantly improve the cutting performance of the tool. Simultaneous development of tool matching technology This exhibition also showed various supporting technologies such as tool holder and tool clamping. For example, the 7:24 BIG PLUS taper shank with CAPTO interface from Sandvik Coromant expands the use of CAPTO tools (handles). The company also exhibited a hydraulic chuck for heavy-duty machining that is more reliable and improves the cutting capacity of cylindrical shank milling cutters. For example, the super-damping replaceable milling cutter holder exhibited by Nikko Co., Ltd. has a disc-shaped spring on the connecting end face of the cutter and the shank, which can increase the tool life by more than 50% and reduce the tool life. Wear of machine tool drive system parts. NT exhibited a length-adjustable tapping shank for rigid tapping for easy adjustment of the chuck length. ZOLLER has introduced the scale EDM, which can measure both the tool and the measuring electrode. The dual-purpose function is suitable for mold manufacturers. Coincidentally, HAIMER's new tool dynamic balancer TD2010 Automatic can also be used in one machine, which measures both the unbalance and the de-weighting function. The weight removed by the balancer can be automatically removed by a cutting unit. Gap and hope Zhuzhou Diamond Cutting Tools Co., Ltd. exhibited in this exhibition fully demonstrated their development strength in tool materials, coatings, troughs and structures, complete tool series and industry-oriented, user-oriented development concepts, display The characteristics of the world's advanced tools companies have left a deep impression. As the leader of China's tool industry, its level represents the highest level of China's tool technology, and its development momentum allows people to see the future of China's tool industry. The exhibiting Xiamen Golden Heron Special Alloy Co., Ltd. demonstrated the newly developed indexable inserts and took an important step in its development. It is emerging as China's new cemented carbide tool development and production base. The newly-launched Medium Hard Metal Cutting (Dalian) Co., Ltd. exhibited a newly developed series of carbide inserts that can provide grades and geometries for processing various materials, showing a certain potential for development. However, compared with the level of foreign tool companies participating in the exhibition, there is still a big gap in the comprehensive strength of domestic tool companies. Zhuzhou diamonds can only be ranked in the middle of the second square, and only this one. Faced with the ambitious goal of “building a strong manufacturing country”, China's manufacturing industry, especially the mold industry, automobile industry, aerospace industry, energy industry, etc., has a very urgent need for advanced tools. According to an interview with the reporter of the China Die & Mould Industry Association, Wu Bingshu said that the imported tools used in China's mold manufacturing industry accounted for more than 90%, and the high-precision tools used for five-sided processing and complex sports are still based on overseas products. . Comparing the tool exhibits at home and abroad, it also reflects that there is still a big gap between China's tool and cutting technology and foreign advanced level. In addition to weak innovation capabilities, there are too few comprehensive carbide tool companies like Zhuzhou Diamonds, and there is also a lack of specialized "little giant" companies with their own product features. The manufacturing industry is looking forward to the revitalization of China's tool industry, and hopes that more comprehensive and professional tool companies with world-class levels will develop more and more advanced tools and cutting technology. (Source: "Outlook tool" Author: Chengdu Tool Research Institute Zhao Bingzhen)  

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