analyze the present situation and the development of the nc tool and quantity instrument technology
Date：2012-04-07
Information Summary：The current our country of nc tool and the development of instrument behind the development of numerical control machine, has become our country CNC cutting technology and hinder the development of numerical control cutting tools bottlenecks, to change the status quo is urgently needed.
The "eleventh five-year plan" period, China's manufacturing national priority development of major projects included energy, automotive, aerospace and transportation and other relevant important fields and the people's livelihood, and these major equipment manufacturing industry concerns are typical of the key parts, features are: big and heavy and complicated, precision, including new difficult-to-machine materials (such as silicon aluminium alloy, titanium alloy, high intensity of heat resistant steel, carbon fiber and composite material, etc) the cutting occupy a large proportion. This gives the numerical control machining technology and the CNC cutting machine tool equipment put forward the new subject, also on the nc tool and digital measuring technology and measuring instrument is put forward the new requirements and challenges, provide the new development opportunity and the stage. The current our country of nc tool and the development of instrument behind the development of numerical control machine, has become our country CNC cutting technology and hinder the development of numerical control cutting tools bottlenecks, to change the status quo is urgently needed.
In order to more clearly, real understanding of numerical control machine tool and quantity in use is in great demand in the machinery and equipment manufacturing and application situation, especially in order to further define the key parts in cutting process, home-made numerical control tool and quantity of the instrument with foreign present situation and its products and advanced technology gap, and to help an objective and scientific confirmation: the "eleventh five-year plan" period, and for a time, our country tool industry in the numerical control tools and digital measuring instruments in the field of research direction and goal, in June, 2008, the author attended by the China machine tool industry association to nuclear power, wind power equipment manufacturing industry and tools manufacturing partial manufacturer investigation and research, to our country of nc tool and quantity in the country is an important machinery and equipment manufacturing status and development of a deeper feeling.
A wind power equipment manufacturing, nuclear power in numerical control tools and the digital quantity meter application situation
Energy equipment manufacturing industry, especially the clean energy such as nuclear power, wind power equipment manufacturing industry in recent years the rapid development. Power gener
ation equipment of some typical key parts such as steam turbine blades, wheel rotor trough and the steam turbine generator rotor embedded trough of cutting processing, due to be processed materials belong to heat resistant high strength steel alloy, stainless steel etc difficult-to-machine materials, cutting capacity, cutting load heavy, nc tool for the cutting performance, such as high temperature red, rigid, bending shear resistance, wear resistance, resistance to adhesive sex, friction coefficient, etc have high requirements. At the same time, high precision of the factors of cutting the accuracy of nc tool itself also put forward higher request. Therefore, the power generation equipment typical parts processing and testing, and, to some extent, represent and reflects the advanced cutting technology and advanced numerical control tools, advanced digital measurement technology and the latest achievements of measuring instrument and level, the much tools manufacturing industry attention. In addition, the research see high precision, large size growth of wind power transmission box gear forming and measurement, and transmission rolling screw hard cutting machining and forming new technology such as also impressive.
1. The steam turbine blade type nc machining
Today, turbine blade five axis CNC machining process linkage has been widely used. The steam turbine blade quantity, specifications, outline more complex shape, high precision, and it's hard to processing. And having the heat, high strength and corrosion resistant alloy steel workpiece material high performance more increased the difficulty of cutting processing, and the blade of nc tool can turn a blade matrix materials and coating performance requirements is very high. At present, most of the processing factory is still foreign hard alloy coating tools/blade. In research in understanding arrives, for the whole of forgings impulse turbine impeller blade processing remains to be tackling. About the accuracy of the steam turbine blade shape detection, usually by three coordinate measuring machines to point measurement, if use PC-DMISBLADE software in three coordinate measuring machine measuring and blade parameter analysis; Or in the model with light gap method to detect, but the latter lack of quantitative determination. Enterprise looking forward to the market can provide convenient application in production site, to achieve rapid precision measurement batch leaves the digital instrument.
2. Steam turbine rotor type wheel slot fir CNC cutting processing
Processing steam turbine rotor type round the forming of fir slot cutter high accuracy, precision type line of micron grade. At present localization (including steam turbine factory self development) of the milling cutter groove type fir wheel (M42 HSS matrix + TiAlN coating) the cutting performance and accuracy basically has can satisfy user demand, is gradually into the production, import substitute.
3. The steam turbine generator rotor embedded trough of CNC cutting processing
The steam turbine generator rotor embedded trough is using special can turn a rotor slot cutter, rotor slot in the numerical control processing from the milling machine. Due to high strength steel shaft materials, cutting groove depth, milling large in diameter, and cutting speed
4. Wind growth of gear transmission box CNC cutting processing
As a clean environmental protection, renewable energy of wind power equipment in recent years the rapid development in our country. To adapt to the growth of wind power transmission box of high precision, large modulus hard surface gears batch production requirements, gear numerical control machining and forming technology and equipment is widely used. China's important manufacture base of wind power growth box development of nanjing high speed gearbox factory, using an advanced gears forming dry milling technology and forming grinding technology, and the corresponding large CNC milling gear machine and forming CNC grinding gears forming machine, CNC equipment production, realized the high quality wind power of the rapid growth of the growth of box products. In the machining process and, after the completion of the regulations of each gear of precision testing and monitoring, this is manufacturing high performance and long life of the growth of wind power transmission box important guarantee. Gleason yi gong made a large grinding gears forming method on the nc machine in the gear measurement device, may to the gear tooth profile, tooth to deviations in machine scans measured; The new type P300 berger's 3 m a type of gear measurement instrument of CNC can gear processing geometry precision for high precision measurement. The machines use working mesa floating technology, facilitate heavy work safety assembly and adjustment, the high accuracy grating sensors to head in the installation can quickly find with eccentric implementing software compensation. Be worth what carry is, made of numerical control large forming milling gear machine and CNC milling gear the knife dish has set up a file in the been applied.
5. Driving ball screw of CNC cutting processing
Nanjing process equipment factory in recent years, introduced the German advanced ball screw hard cutting machining and forming technology and CNC cutting equipment, the forming cutter wheel to CBN hardened steel rods car hard cutting precision milling, a complete transmission of precision ball screw thread forming. Because do not use cooling fluid and therefore is accord with environmental protection requirement, and can achieve high efficiency, high performance cutting processing. Be worth what carry is, domestic laser rolling screw checking in the factory got very good use.
Second, China CNC machine tool industry with cutting tools and the present situation and the development of instrument technology
The surve
y the tool industry three major manufacturers: Shanghai tool factory Co., LTD, Harbin gage rj group Co., LTD and Harbin first tools manufacture Co., LTD. Deeply felt, China's economic strength fast growth, especially machinery manufacturing high speed development for many years, for our country tool industry created unprecedented opportunities for development. National "" plan and major projects start and provides new opportunities for development. The factory to its own characteristics, formulated the recent development policy and long-term strategic development target, and has been going on for the implementation stage, scored a significant results, and technical progress, upgrading of product quality, improve the competitive power of enterprise, the ability of sustainable development improves. To sum up, has the following features:
1. Based on the strong traditional products, increase the technical improvement investment, the introduction of advanced technology, products and equipment, improve quality, enlarging the scale, establish and strengthen in the industry's advantage.
Shanghai tool factory according to the development goals set, continuous investment in a planned way huge sum of money carried on the technical improvement, introducing and developed by the advanced cemented carbide hole processing cutting tool and taps processing numerical control equipment and technology, advanced manufacturing equipment super hard CNC cutting tools and technology, advanced numerical control tools/blade coating equipment and technology, as well as high speed steel paper heat treatment technology and so on. In the digestion and absorption of basis, actively develop innovation, pay attention to tamp and development of nc tool manufacturing core technology to realize the upgrading of product structure, to ensure at work at the processing cutting tool and taps products in the industry's leading position. A new round of technical improvement and development in the implementation of the plan, for the company rapidly developed into production scale is biggest, the most complete varieties of products and a complete set of whole, the most powerful manufacturing enterprises and domestic tool to make positive contribution.
Ha amount nearly 10 years continuously strengthen in gear measurement instruments, surface roughness measuring instrument and outline of measuring devices such as precision instrument development manufacture advantages, successful development at present domestic biggest 2 m CNC gear measuring instrument, become the most domestic competition strength of precision measuring instrument manufacturer. In 2005, through the purchase of German kay lion company, the introduction of foreign advanced design and manufacturing technology and patent, quickly built advanced, double constraint positioning clamping HSK tool system production line, and form batch production; Quickly built nc tool presetters CCD measurement instrument se
ries product production workshop, form annual 500 ~ 600 sets of the ability, has batch export to Europe. Successful merger, introduce, development innovation, to realize the nationalization, the amount of volume, precision instrument products, quickly established in the domestic leading role in the relevant technology and products, quickly narrowed the gap with the international advanced level.
Ha a work through the national debt technical improvement (two years into the millions of yuan), built the new factory, investment the new equipment, face to look brand-new. Especially in the fist product broach, introduce the foreign complete advanced numerical control broach grinder and testing instrument, in order to continue to lead domestic, and in the numerical control can turn a cutting tool and gear hob complex on the tools such as the advantages of traditional get further strengthen. Hard alloy arc bevel gears and recent development of the milling cutter disk CNC cylindrical gears forming cutter disk successful application, obtained user high praise.
Zhuzhou diamond cutting tool company in recent years investment is 1 billion yuan, including hard alloy material, numerical control tools, the solid carbide cutting tools, numerical control can turn a blade, etc, the introduction of advanced manufacturing technology and complete sets of equipment, make the product development ability and manufacturing quality be improved a lot, and it has been the most powerful, the domestic competition development research, most the largest scale to produce hard alloy of nc tool/can turn a blade manufacture enterprise.
2. Different situations, tool industry development in accordance with the law, and expand the upstream and downstream extensions technology and products field. In order to better satisfy, adapt to the market/national development needs, for enterprise development strategy to achieve the goals of to lay the foundation.
Zhuzhou diamond in the original parent company to hard alloy raw materials, semi-finished products manufacturing give priority to, and on the basis of nc tool, can turn to a blade of deep processing technology and development into the largest cemented carbide numerical control tools/blade manufacturer. And at work at the planning tools manufacture from to cutting tool material (hard alloy) manufacturing, top grade of nc tool manufacturing equipment manufacturing field, the goal is built for the domestic leading large comprehensive metal cutting tool manufacture enterprise, the collection tool, research, manufacture and service of the one of the leading enterprises in China.
3. Paying attention to foundation, the common, key technology research and development, actively undertake state, local science research project, set up "with the combination of" scientific research and development system, rapidly promote enterprise innovation ability and technology/product advantage.
In recent years
, the average amount in scientific research fund accounts for more than 4% of sales revenue, develop new products in 30, patent 165. In 2005 the national 863 plan for project "HSK tools cone measuring tool" standard drafting, 2006 for the Harbin city "high numerical control machine tool with the HSK system research and the application" project. 2007 years for the national standard "tool presetters measuring instrument" make work, and bear Harbin city ", CNC and automatic aiming high precision tool presetters CCD measuring gauge developed "science research project, etc. At work at the ministry of science and technology innovation in recent years for state fund "automobile manufacturing precision compound hole processing cutting tool and the efficient compound coating tools development", Shanghai economic committee of Shanghai science research project "tool research and development platform construction", "high speed cutting coated tools in the research and development", "high precision nc tool manufacture and application technology", so as to obtain a patent tool coating.
4. Through the enterprise purchase annexation, professional talent and technology import, realize the integration of resources optimization to improve enterprise overall strength.
Ha amount in 2005 successful merger Germany kay lion company, and laid the batch production international level HSK tool system and the numerical control tool presetters of measuring apparatus manufacturing development technology and skills. At work at the Shanghai set depend on the optimal Co., LTD in the Hong Kong market, raising money, 2007 years invested a huge sum of money carried out the "development of nc tool production technical renovation project". Through the and Italy SU companies formed superiorly company, the introduction of advanced manufacturing process and technology gear cutting tools know-how, enhance the gear cutting tool manufacturing strength.
Through the investigation and research, and we feel in tool industry technical level and the scale of production get fast development progress at the same time, they see the gap with foreign advanced level is very big still. In the wind power, nuclear energy equipment manufacturing industry, cutting processing key parts of the nc tool and measuring instrument, almost entirely by foreign products monopoly, major manufacturers, vick, KenNa for mountain, ismail card, secco, etc. Domestic tool is mainly used for non-critical parts and thick, half finishing processes. Compared with the foreign products, in addition to cutting performance indicators are a large gap outside, the bigger problem is not stable quality, not reliable, the product performance dispersion. In addition, in the customer service gap also small coke to ignore.
Our country in the numerical control technology and cutting numerical control tools of research, development and manufacturing, and the overseas main gap reflected in the following thre
e aspects:
(1) CNC cutting theory and technology, especially the micro quality control technology, and materials related to the subject of metallographic organization structure analysis and quality control technology, a new difficult-to-machine materials cutting mechanism and technology research, etc.
(2) nc tool manufacturing technology and equipment, especially in key manufacturing technology and process quality control to the stability, such as super fine grain carbide substrate, coating process quality control, super hard tools such as the strengthening technology; Equipment terms: the numerical control tool grinding machine, strengthen the equipment and the development and the development of coating equipment, etc.
(3) CNC tooling application technology and experimental study, in different industries and user demand, especially new difficult-to-machine materials such as high temperature alloy, titanium alloy, silicon aluminium alloy and composite workpiece machining, to provide scientific and reliable, practical feasible numerical control tools/can turn a blade and cutting parameters such as cutting database information platform.
The volume of instrument, the gap with foreign more. In the survey, obviously feel mainly in the following three technology gap big:
(1) nc machine tool measuring technology and instruments, especially with the laser measurement system, as a representative of the high precision to the static and dynamic numerical control machine precision and performance testing technology and precision compensation technology, etc.
(2) nc tool measuring technology and instruments, especially high precision CNC tool measuring technique, numerical control tools in machine measurement technique, and the numerical control tool presetters measurement technology and equipment.
(3) applicable to the production of the scene in the machine/online digital measuring technology and equipment, especially complex precision processing machine measurement in contour with feedback fixed compensation technology and equipment, such as CNC grinding gears forming in machine measuring technology and equipment, the steam turbine blade online measurement technology and equipment, etc.
In order to shorten and catch up with as soon as possible to advanced level, in national policy guidance and support, with focuses choice involves tools industry technology development of the key technology for the research project, will our country to promote tool industry competition strength and have the capacity for sustainable development, in order to adapt to the need of the state of the equipment manufacturing industry has the extremely vital significance. In the support of the country and industry enterprise own efforts, our country tool industry could greatly quicken the narrowing gap with foreign advanced level in the process.
Three, the equipment manufacturing industry to tool industr
y demand analysis
1. The numerical control machine tool with a new system-such as high speed and high precision HSK applicable to cutting, two side clamping the positioning tool system
In the two aspects of HSK represented clamping positioning new tool system, is to get used to the high speed and high efficient precision CNC machining technology development, meet the CNC cutting machine tools of high-grade advanced processing performance requirements and development. New tools to the characteristics of the system is connected to the spindle bearing taut, the cone and the end face and contact positioning, realize the surface constraint positioning, enhance the high-speed machining, numerical control machine tool spindle-system dynamic rigid/connection strength and location accuracy. Among them is typically has become the international standard HSK tool system and the mountain, the company Capto tool system vick.
Some Chinese enterprise on HSK tool system for the trial and a small production, due to a lack of the key technology research development, not form a complete set manufacturing technology and batch production ability. Ha amount in 2005 the merger of the German kay lion company, after the digestion absorption, gradually from product design to master the dynamic balance and accuracy of a complete set of inspection and the HSK tool system mass manufacturing technology and craft series, now has more than 50000 sets of (all export) ability, made outstanding achievements. Of course, in batch production technology, process route and the product quality inspection and control, and the deficiency, is yet to be continue to digest absorb, research innovation, so as to further narrowing the gap with foreign countries. Shanghai tool factory, sichuan eng, etc have also been a small production enterprise can handle HSK cone nc tool, to offer, such as Shanghai general motors manufacturer, and user needs. At work at the Shanghai accessories factory after a merger, with the group of conventional tools in the ability of the system, has planned for "high-speed nc machine tools with the new system project", the introduction of design and manufacture technology, talent and key equipment, in order to achieve annual output of 20000 pieces of the HSK chuck production capacity. In fact, the domestic have not yet set up national and the HSK level industry system detection system, tool benchmark transfer system, all levels of real benchmark, and the product quality authentication system. The work is essential, should plan to arrange, implementation as soon as possible.
2. Efficient can turn a tool series and super-hard cutting tools
High efficiency can turn a tool series and super-hard cutting tools, is very important in the nc tool of the field, the product YingYongLiang bedding face is wide, the different application technologies involved in the key, research content will be different: the blade can turn a matrix materia
ls, coating requirements, the blade geometry parameters, the blade, cutting tool clamping way whole structure design, and so on will have very big difference, technology is difficult, research content more. In addition, bring 3 d broken flocks groove type can turn a blade design manufacture technology, including the precision of blank suppress sintering, strengthening the blade is to be research content. Hard cutting, ultra precision cutting and composite materials, including the new material cutting, further promoting the super-hard cutting tools of demand and development. In high quality super-hard cutting tool material on the development and production of our country still have large gap, even if is domestic super-hard cutting tools, the super hard blade (PCD, CBN) most materials from GE and Sweden imports. 3 d shape of the blade is super hard in recent years with the development of super hard tools is a new trend, its manufacturing process more difficult. High efficiency can turn a tool series, domestic enterprises such as zhuzhou diamond, xiamen JinLu, zigong hard alloy, shan hard, such as the quantity into has production, among them with zhuzhou largest diamond production, the most abundant strength, and the general level is the highest, with a world-class level of alleged achieve numerical control can turn a blade production line, a research center in recent years, including the design development, use technology research, material performance test and cutting experiment equipment, has the good development platform. And at work at the super hard tools in development, production and have a more mature design and processing experience, advanced manufacturing equipment and excellent service application effect of success.
3. Ultrafine grain solid carbide coating tool series
Super fine grain solid carbide coating tools in automotive, aerospace and energy industry use a lot and is currently in the key nc machine tools used in the solid carbide cutting tools for imported tools mostly coating the monopoly, domestic tool also often buy foreign super fine grain carbide rod materials processing, their own development be restricted. In China in recent years have hard alloy powder materials and manufacturing capacity of some of the tool factory, such as zhuzhou diamond, xiamen JinLu, shan hard, through the technical improvement investment, the introduction of technology and equipment, develop the ultrafine grain hard alloy tool materials, achieved initial results (to sub micron grade. In recent years, the advanced nano coating technology, the cutting tool performance quality are improved obviously. At work at the planning will be implemented "super fine grain solid carbide coating tools project" and realize the ultrafine grain hard alloy materials and tools manufacturing complete sets of technology development. Domestic enterprises should make batch production hard alloy particle size stability to super fine 0.3 ~ 0.5? M, further impr
ove the quality, reduce and foreign advanced product gap, need to be in manufacturing technology, process and other basic technology fluctuation kongfu for technology research. In addition, how to finish machining tools after coating surface has enough before rich cobalt layer, is to improve the quality of coating is a key technology, is yet to be tackling.
4. Efficient high performance sophisticated nc tool
The gear hob, pinion gear knife, gear shaver and various types of broach as a representative of high efficiency high performance sophisticated nc tool, in car, wind power nuclear power, aviation, the ships, the railway, engineering machinery and other industries gear transmission device used in manufacturing extensive and important.
Project target listed parameters reasonable and necessary. Domestic precision gear cutting tools and pull knife, the main existing two problems: material and coating. At present the key occasion for all is into U cobalt HSS and powder metallurgy HSS materials. Recently many factories for technical improvement and investment in equipment, the use of advanced coating (such as TiAlN, TiAlCN, etc) and high heat treatment technology and didn't prepare, make the homemade gear cutting tools and pull the sword quality performance greatly improved, narrowed the gap and abroad, some replace of foreign products. ', 'two years accumulative total investment work nearly 120 million, used for the new plant construction and the domestic and foreign advanced equipment purchase, for make become domestic broach production first, gear cutting tools and can turn a nc tool strong complex of nc tool manufacturing enterprises and effort. Hanjiang river catch this tool factory a few years the development opportunity, has become the most powerful domestic gear hob manufacture enterprise. The factory through baal, and by cooperation, make gear cutting tools coating quality guaranteed, improve the performance of the cutting tool. High efficient machine clip type not heavy nc forming grinding tool gear, gear cutting tools is the development of a new direction, it is worth considering industry development.
5. High precision, automatic tool presetters measuring instrument series
China digital tool presetters measuring instrument development start later, 2005 in Beijing machine exhibition have ha quantity and tianjin tianmen appeared for the first time on display with the ccd-array digital tool presetters measurement prototype. Ever since, in 2005, with the purchase of the German kay lion company later, in the digestion and absorption of its advanced design and manufacturing technology, and on the basis of developed series high precision tool presetters measuring instrument. The factory has established the knife is the production section, with an annual capacity of 500 ~ 600 units to the sword instrument, at present with the manual series is given priority to, for export. For high precision, CNC autom
atic, have the networking tool presetters measuring instrument, the factory is actively planning development, in order to catch up with the advanced level abroad. In addition, a domestic tianjin tianmen quantity etc are in the development, but the technical level, there is a certain difference in quality, is yet to be continue to work hard.
6. High performance measurement system
High performance measurement system is mainly used for numerical control machine tool and three coordinate measuring machine of high-grade numerical control equipment of precision testing and evaluation. In recent years the laser measurement system is the development direction of: high resolution, high precision, multi-function, miniaturization, the main production manufacturer for Britain, the United States, lenny shaw API, AnJieLun and light moving company, and the German SIOS etc, in order to rennie shaw products in China, the biggest sales. The new products listed in 2007 XL-80 light laser interference measuring system, with XC-80 sensors, realize the miniaturization, while improving the performance, the distance is measured 40 m / 80 m, the resolution to LNM, highest measurement speed 1 m/s. The United States API company XD laser interference measurement system, with 5 d / 6 d measuring function, improve the numerical control machine tool equipment precision testing accuracy and efficiency. Chengdu tools in China, the development and production of domestic mainly laser interference measuring system, compared with international advanced level, there is still a gap. In recent years, through the national research institutes fund project support, measuring principle and measuring technology breakthrough in improving domestic laser measurement system performance, has made some achievements.
All in all, through this investigation and research, and further proof, tool industry in China in the numerical control tool and measuring instrument technical level and the quality of performance, and foreign big gap. But after years of technical improvement investment, introduction and development, has narrowed the gap, but the innovation ability insufficient still, this is the foundation technology test research have not been paid enough attention and development, industry technology accumulation lack the result of the whole. Confident that in the production, study and research, using "the policy lead, on the support of the country, the synergy, enterprise of the industry efforts, our country tool industry can get fast development, quickly narrow the gap with foreign advanced level, in order to adapt to the mechanical manufacturing industry in our country the sustained and rapid development of the demand.
Recently, the global recession has been the storm from virtual economy to the entity economy expanding quickly, tool industry of our country and the influence of the overall impact, in the middle of October 2008 sudden revealed. This is a severe
test, each tool factory are quickly formulate strategies, adjusting plans, to actively respond to the dilemma with through: at the same time actively ramming the internal organs, speed up product upgrading, optimizing the transition work, to prepare for industry early recovery.
Sources of information：China Machine Tool Information
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