In recent years, the product level of China's tool companies has been increasing year by year, and the competition among tool companies has become increasingly fierce. Looking at the whole country, large and small, international and domestic famous tool manufacturing and agents abound, Sandvik, Walter, Isca, Lanzhi, KORIOY, Yujie, Hitachi, Mitsubishi, Kenner, Zhuneng, Xiamen Golden Heron... How to choose a mold factory in the face of a dazzling tool market? The following is Luo Baihui's comprehensive analysis and comparison of domestic brand tool manufacturers' products, technologies and services, and hopes to provide reference for the procurement of the mold industry.
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Industry development demonstrates the role of tools
The rapid development of the manufacturing industry not only drove the prosperity of the domestic mold industry, but also raised higher and higher requirements for domestic mold manufacturers: the delivery period was further shortened, and the supply of high-end mold products was in short supply. Faced with huge market demand and fierce market competition, mold manufacturers are faced with the dual pressure to improve the grade of mold products and reduce manufacturing costs, and this pressure will certainly be transmitted to the upper and lower ends of the supply chain, so the corresponding tools (tools) The industry has also put forward new requirements.
Compared with machine tools, tools account for only 3% to 5% of the total manufacturing cost, but their role can not be ignored. The machine tool can provide a good motion and control platform for mold production, but the tool that directly completes the cutting process and directly contacts the workpiece is the tool. The shape, size, precision and surface topography of the workpiece are all realized by the action of the tool. . Whether the operation of the machine tool is sufficient and whether the cutting of the workpiece is reasonable is closely related to the selection of the tool, the performance, the quality difference, and the process.
The tool can complete the roughing, semi-roughing, finishing, margin milling and primary (or secondary) rooting of the mold, and the roughest blank is processed into finished products that meet various needs. The use of advanced and efficient tools can also help mold manufacturers reduce processing costs and increase production efficiency.
Tool maker's survival secret
The fierce competition in the market will inevitably bring more pressure on tool manufacturers, but from the perspective of the development of the entire tool industry and the point of view of tool users, competition is beneficial, and competition will have greater progress. The most intuitive result of competition is the decline in product prices and the improvement of service quality to meet the needs of the market and customers, as well as the tool industry. For tool manufacturers, on the one hand, we must continuously improve the cost performance of the tool to meet the needs of mold companies, on the other hand, we must reduce our own manufacturing costs and improve service quality to participate in fierce market competition. How should tool makers deal with the double challenge?
Cost-effective product line
In order to further improve the product range of the tool, Seco successfully acquired the French tool holder and file manufacturing company EPB and the Dutch company Jabro which produces solid carbide milling cutters. The fierce market competition, the reduction of manufacturing costs and the multiple pressures to increase production efficiency have made it necessary for mold manufacturers to choose cost-effective tool products. This is also the real situation that tool companies face in the market competition. Roughing tools not only need to work quickly and efficiently, but also can withstand high temperatures, high pressures and wear resistance; finishing tools can improve the size, shape and surface roughness of the mold, reducing or even eliminating manual grinding, thus greatly reducing The manufacturing cost of the mold manufacturing company and the shortening of the manufacturing cycle of the mold, and delivery in advance. The geometrical parameters of the tool provided by the tool manufacturer to the customer should be as much as possible and detailed, such as the type, diameter, blade length, overhang and related parameters of the machine tool, and can provide the tool products and requirements according to the customer's requirements. The debugging work is to enable the mold company to put the tools into production as soon as possible and improve production efficiency.
Rapid response technology solution
One of the most important ways for mold makers to reduce costs is to increase cutting efficiency and reduce unit costs in manufacturing. This can be achieved not only by increasing the cutting speed but also by increasing the amount of cutting; it can also be achieved by reducing the auxiliary time, such as tool change time, and by minimizing the chance of failure in certain processes. This puts higher demands on the tool supplier's technical solution capability. It is necessary to be able to analyze and discover the causes and influencing factors of the cutting process problems occurring in the tool-related production process, and to make timely and relevant problems of the tool. Respond, quickly identify problems and propose solutions and suggestions for solving problems. If necessary, we should quickly reach the problem site, strictly control the various elements of the tool itself and make appropriate and timely improvements and optimizations to provide perfect and timely sales. And after sales service. Japan Daijie not only set up distribution points in major cities in China, but also set up offices in Shanghai and appointed senior technicians to provide pre-sales services and after-sales technical support and services.
System engineering coordinating ability
The actual production experience shows that the solution of the tool cutting problem is a complex system engineering. In the mold processing, the input of the system is the production requirement, and the output of the system is the processing result obtained through the machining process. There are multiple in this system. Factors and variables, machine tools, fixtures, tools, cutting fluids, workpiece materials, blank conditions, etc., in which the tool itself is a subsystem with many variables, the structure of the tool, the geometry of the cutting edge, the material of the tool, the coating of the surface Layers, etc., all of these variables intersect and interact with each other. For example, an unreasonable concentration or an inappropriate type of cutting fluid not only causes the tool life to become shorter, but also causes abnormalities in the workpiece being machined; Not only can the tool not function properly, but it can also cause chipping and breakage of the tool.
The development of new technology comes from the actual production practice. Walter has established a long-term technical exchange and cooperation relationship with the customer Makino Machine Tool to continuously adjust the harmonicity of the tool and the machine tool to maximize the processing efficiency of the machine tool. Therefore, for tool manufacturers, on the one hand, continuous efforts in tool technology have reached the level required by mold manufacturers, on the other hand, it is necessary to strengthen cooperation with machine tool manufacturers, fixture manufacturers, cutting fluid manufacturers, materials factories, etc. When an abnormal situation occurs in the process, it is necessary to analyze and solve the problem from the perspective of system engineering. Instead of simply seeing the tool problem in the system, it is necessary to consider the problem from a system perspective, analyze the relevant important factors, and improve The ability to coordinate the system engineering in the cutting process. Continuous technological innovation
In an atmosphere where innovation is advocated in this society, knives are no exception. From the exhibitions in recent years, we can find that innovation is indeed valued by many companies, especially some well-known foreign machine tool companies, many companies have developed more advanced tools, such as expansion tools, cutter blades are just a complete set of tools. In one component, the whole set of tools also includes transmission and control mechanisms, etc. The production efficiency of such tools is very high; combined tools (composite tools) and a composite knife can solve the processing of multiple processes in the original multiple stations. Moreover, the auxiliary time of multiple tool changes is reduced, which is beneficial to improve machining accuracy and processing efficiency; and so on, and therefore is more trusted and supported by customers.
For example, the rigidity of a tool is inversely proportional to the amount of overhang of the tool. When using a ball end mill for copy milling, the tool must have a large amount of overhang. Therefore, in order to improve the rigidity of the tool when designing the end mill Usually, a tapered neck is added between the blade and the shank, but when the straight wall is high, this method is not feasible. In order to solve the high-efficiency and high-precision machining of the straight wall in the mold processing, the Japanese OSG development The FXS-MFE end mill has been stepped up in straight wall machining for high speed machining.
As far as domestic tool companies are concerned, many companies are developing very rapidly, such as Zhuzhou Diamond and Xiamen Golden Heron. However, from the perspective of the development of the whole industry, domestic enterprises are still inferior to foreign companies in terms of technological innovation.
The survival of tool makers in the mold industry
Abstract In recent years, the product level of China's tool companies has been increasing year by year, and the competition among tool companies has become increasingly fierce. Looking at the whole country, large and small, international and domestic famous tool manufacturing and agents abound, Sandvik, Walter , Isca, Lanzi, KORIOY,...