Today's superabrasives affect the next generation of production
2018-09-19 23:01:41
The first use of diamonds in 1957 for the grinding of carbides and glass was the pioneer of today's large-scale global development of superabrasives. Cubic boron nitride (CBN), polycrystalline diamond (PCD), polycrystalline cubic boron nitride (PCBN), diamond wire mold, diamond saw and drill bit products are representative.
We can see that the future industry will continue to develop harder, higher strength, lighter and more tough workpiece materials to minimize part weight and increase part life. The automotive industry uses more wear and durable materials for pistons, drive chain components and engine parts, such as from cast iron to aluminum. Other industries, such as the aerospace sector, are using super-alloys, metal matrix composites and thermal spray materials, not to mention industrial ceramics and other materials still in the engineering stage. In many cases, processing these materials is expensive, but superabrasives are the only option.
Basic needs
In order to use superabrasives, the grinding machine and machining center have been significantly improved. CNC control systems, automatic loading and unloading, complex on-line measurements, high-speed spindles, and enclosed high-pressure/high-capacity coolant supply units are all designed to maximize the benefits of using superabrasives.
The use of traditional abrasives and equipment has a number of problems, such as quality, robustness, flaking and excess cost of production. They cannot win competition and profits. These companies are looking for new equipment for high efficiency, often designed for use with superabrasive tools. These companies used to feel good about their World War II machine tools, and now they are buying a new machine tool for $200,000 to $1 million, or renting equipment is cost-effective – reimbursed within six to 24 months. .
For the sake of explanation, the following is an example: an important hydraulic parts manufacturer, who replaced three conventional machine tools with three new machines equipped with superabrasives, significantly improved the production bottleneck, and now increases annual sales revenue, machine start Time has increased from 53% to 94%.
System engineering
Improvements in machine tools, materials and tools have led to systematic processing of part processing. The rough casting and forging can reduce many of the pre-processing steps in the production of parts. With new materials, some components such as camshafts, crankshafts, wheels, brakes and supports can now be pressed or forged and then finished with high-speed grinding or high-speed machining. This can significantly reduce the time from blank material to finished parts. Previously, it was necessary to remove a few hundredths of a millimeter (or 0.x) mm of material in many passes. Now it only takes one pass and the parts can be finished.
Environmental issues have also attracted global attention, and manufacturers must pay close attention to the cooling methods used and the final treatment of coolants. Can they be cleaned, separated, or completely eliminated? Companies with the best processing grinding and cutting systems will produce profitable products and keep their business. Water-based coolants, synthetic or oil-based coolants are generally cheaper, easier to filter, and cool the system faster. However, it is possible to draw mold, bacteria and allergic reactants back into the liquid stream. In general, the use of water-based liquids will result in a lower life of the grinding wheel than with pure oil. Pure oils have been used where there are special requirements, such as the forming of aerospace alloy materials and the processing of hardened gear steels for many years. However, many of the machines used in the past have not been designed for cooling with pure oil. Problems such as soot, fire, oil mist, etc., sometimes hinder production applications.
Many high-performance grinding machines are now designed with a fully enclosed enclosure that limits the diffusion of oil mist into the air, eliminating all of the aforementioned negative effects. Pure oil can now be completely re-reduced for use in grinding and cutting. These systems are allowed to be used for many years without replacement. Just have a good oil maintenance system to keep it well filtered and clean.
In order to improve the process, there is now a clear trend from water-based to oil-based or oil-based to water-based solutions, and there are many different applications, which is the development of cooling without the use of coolant. It means dry, low temperature (cold air) or another cooling medium that does not require treatment and does not pollute the working environment. The characteristics and performance advantages of diamond, cubic boron nitride, polycrystalline cubic boron nitride, and polycrystalline diamond—bearing capacity, colder processing environment, and long service life are the ideas of these cooling systems.
Education and information are important factors in the future. The producers, end users and operators of thousands of new machine tools will not be satisfied with the information on the grinding wheels and tools obtained from the commissioned suppliers. They need more information, such as what kind of wear-resistant material is in the grinding wheel and what kind of material is in the tool. They will ask about welding techniques, coating grades, dimensions and quality standards. You will find data on the Internet and read articles about improving your craft.
We can see that the future industry will continue to develop harder, higher strength, lighter and more tough workpiece materials to minimize part weight and increase part life. The automotive industry uses more wear and durable materials for pistons, drive chain components and engine parts, such as from cast iron to aluminum. Other industries, such as the aerospace sector, are using super-alloys, metal matrix composites and thermal spray materials, not to mention industrial ceramics and other materials still in the engineering stage. In many cases, processing these materials is expensive, but superabrasives are the only option.
Basic needs
In order to use superabrasives, the grinding machine and machining center have been significantly improved. CNC control systems, automatic loading and unloading, complex on-line measurements, high-speed spindles, and enclosed high-pressure/high-capacity coolant supply units are all designed to maximize the benefits of using superabrasives.
The use of traditional abrasives and equipment has a number of problems, such as quality, robustness, flaking and excess cost of production. They cannot win competition and profits. These companies are looking for new equipment for high efficiency, often designed for use with superabrasive tools. These companies used to feel good about their World War II machine tools, and now they are buying a new machine tool for $200,000 to $1 million, or renting equipment is cost-effective – reimbursed within six to 24 months. .
For the sake of explanation, the following is an example: an important hydraulic parts manufacturer, who replaced three conventional machine tools with three new machines equipped with superabrasives, significantly improved the production bottleneck, and now increases annual sales revenue, machine start Time has increased from 53% to 94%.
System engineering
Improvements in machine tools, materials and tools have led to systematic processing of part processing. The rough casting and forging can reduce many of the pre-processing steps in the production of parts. With new materials, some components such as camshafts, crankshafts, wheels, brakes and supports can now be pressed or forged and then finished with high-speed grinding or high-speed machining. This can significantly reduce the time from blank material to finished parts. Previously, it was necessary to remove a few hundredths of a millimeter (or 0.x) mm of material in many passes. Now it only takes one pass and the parts can be finished.
Environmental issues have also attracted global attention, and manufacturers must pay close attention to the cooling methods used and the final treatment of coolants. Can they be cleaned, separated, or completely eliminated? Companies with the best processing grinding and cutting systems will produce profitable products and keep their business. Water-based coolants, synthetic or oil-based coolants are generally cheaper, easier to filter, and cool the system faster. However, it is possible to draw mold, bacteria and allergic reactants back into the liquid stream. In general, the use of water-based liquids will result in a lower life of the grinding wheel than with pure oil. Pure oils have been used where there are special requirements, such as the forming of aerospace alloy materials and the processing of hardened gear steels for many years. However, many of the machines used in the past have not been designed for cooling with pure oil. Problems such as soot, fire, oil mist, etc., sometimes hinder production applications.
Many high-performance grinding machines are now designed with a fully enclosed enclosure that limits the diffusion of oil mist into the air, eliminating all of the aforementioned negative effects. Pure oil can now be completely re-reduced for use in grinding and cutting. These systems are allowed to be used for many years without replacement. Just have a good oil maintenance system to keep it well filtered and clean.
In order to improve the process, there is now a clear trend from water-based to oil-based or oil-based to water-based solutions, and there are many different applications, which is the development of cooling without the use of coolant. It means dry, low temperature (cold air) or another cooling medium that does not require treatment and does not pollute the working environment. The characteristics and performance advantages of diamond, cubic boron nitride, polycrystalline cubic boron nitride, and polycrystalline diamond—bearing capacity, colder processing environment, and long service life are the ideas of these cooling systems.
Education and information are important factors in the future. The producers, end users and operators of thousands of new machine tools will not be satisfied with the information on the grinding wheels and tools obtained from the commissioned suppliers. They need more information, such as what kind of wear-resistant material is in the grinding wheel and what kind of material is in the tool. They will ask about welding techniques, coating grades, dimensions and quality standards. You will find data on the Internet and read articles about improving your craft.
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