Analysis on the Gap of Machining Tool between China and Japan

Date: 2017-11-01 15:00Pageviews:

The engine is the heart of the car, and parts of the manufacturing process level is generally higher than other parts of the car. Coated cutting tools, ceramic tools, superhard cutting tools and other advanced tools have been widely used in the manufacturing process of the engine. The car production line in China (especially car production line) parts are imported from foreign countries, the main production line imported tools in production, cutting dosage also uses the recommended values abroad. These tools set of new materials, new technology, cutting principle, surface treatment and other advanced technology, has the advantages of high performance, high life, high reliability, advanced level basically represents the modern tool technology.
 

  The fetters of engines and Cutters

 
  MITSUBISHI engine
 
 
  There are three obvious trends in the manufacturing technology of the new automobiles engine production line in china:
 

  high - speed

 
  The basic requirement of high speed machining is that:
(1) The spindle of machine tool can be operated at high speed;
(2) high precision and high rigidity HSK handle with powerful chuck;
(3) using coated carbide, cermet, ceramics, CBN, PCD and other advanced cutting tools
 

  Flexible

 
  Flexibility is one of the development trend of engine manufacturing. The local station in line with the traditional automatic CNC or processing center to achieve flexible production line called flexible automatic line (FTL), the general Japanese factories use more. Flexible manufacturing system composed of special machining center is mainly used for processing. From the analysis of the cylinder head and the cylinder block the yield point, with an annual output of 50 thousand can be reached from the traditional FMS system to start production of traditional automatic production line in 200 thousand.
 

  high efficiency

 
  
 
From the Japanese automobiles industry situation, on average every 5 years, the cutting efficiency is increased by 28%, the average cutting speed increased by 19%, the amount of feed was increased by an average of 8%, but in recent years the cutting efficiency in the range of more than 30%. The main parts of the engine manufacturing production cycle has been shortened to 30 ~ 40 seconds, reduced by 50% more than a dozen years ago. For example, using the block material of gray cast iron milling high speed machining center, the cutting speed can reach V=700 ~ 1500m/min, CBN milling tool with a blade. Aluminum Alloy cylinder, cylinder head, widely used PCD tool, considering the high speed rotation will produce large centrifugal force, so the knife body adopts high strength Aluminum Alloy materials.
 
In short, the engine manufacturing industry is an obvious trend is the use of high-speed processing technology to improve efficiency, shorten delivery time, reduce production costs, improve market competitiveness

  Tool market status

 
  The automobiles industry is the most widely used tool industry, is a measure of a country or a tool company logo. The technical level of automobiles production line in China (especially car production line) are mostly imported from abroad, and the cutter is mainly imported together with the equipment. At present, the domestic automobiles production line the United States, Europe and Japan and South Korea, as well as the independent type equipment based in Europe.
 
 
  In this way, the five tool faction was active in the mainstream China: one is Santak (including mountain), Sandvik company has a large and complex tool branch, the largest in the China market sales; two is the United States, mainly to Kenna, Ingersoll, valenite as the representative; three is Europe, mainly in Germany mainly including MAPAL, Guehring, Widia, TITEX, Walter; four is Japan and South Korea, including MITSUBISHI, Toshiba, OSG, Sumitomo, DIJET, Fujio, Hitachi, and South Korea's Taegutec, KORLOY company; five is the main line of Israel, if ISCAR (ISCA). These companies almost filled the car tool market space. In some large automobiles manufacturing plant, the cutters may only account for about 10% of the total project, therefore, the import tool still occupies a dominant position.
 

  Our short board

 
  The overall state of the domestic tool industry is the low starting point, start late, NC tool is only advanced in recent years with the development of CNC machine tools to CNC tool products R & D and production, so the foundation is relatively weak, the slow pace of development, competitiveness is not strong. Foreign tool industry can aggressively vied for main reason is: foreign China market tool products high, wide variety, good quality; and the tool is in contact with the machine, the machine often used abroad in foreign countries has been supporting the use of tools; plus domestic tool less variety in product, precision machining, high performance cutting and have special requirements when most of the use of foreign tools. Many factors the formation of the passive situation of domestic tool.
 
  The existence of heavy resistance tool localization process, a system disorder congenital. Taking the car production line as an example, in China in the initial stage of the introduction of the car and CNC automatic production line, often do not pay attention to domestic supporting tool, did not improve the technology level of the domestic car production line introduction tool. Special tool, with tools, different specifications, technical, professional and high level requirements, the existing domestic tool variety, quality, delivery and service capabilities are difficult to meet the requirements. At the same time, with a perfect, that is installed with dozens of foreign brands of the cutter tool look at fiercely as a tiger does domestic work difficult. Obviously, in a passive state.
 

  Comparison of cutting tool level at home and abroad

 
  From the beginning of 1980s, in the world manufacturing industry and manufacturing technology driven, cutting technology and tool gradually entered a new stage of development of high-speed, efficient, innovative technology, the machining efficiency is greatly improved and made an important contribution for the development of the manufacturing. The cutting process and tool, has become the basic technology and key technology the automobiles manufacturing industry. The high-speed cutting, dry cutting, hard cutting and other new cutting technology is changing the traditional processing techniques, showing strong vitality. The author believes that the domestic tool manufacturers to participate in international competition, the most fundamental way is to improve the overall level of tool technology enterprises.
 
  We must clearly see that the domestic tool enterprises in the technical level, production technology and equipment manufacturing compared with foreign counterparts, there is a big gap, cutting tool products in the processing quality, service life, reliability, technology services and other aspects still can not fully meet the growing needs of the user. Therefore, we have a long way to go. There are a lot of work to do, there is a long way to go, we will redouble our efforts.
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