2. Reduce tool change time
Reducing the tool change time and the adjustment and test time after the tool change will also help to reduce the non-machining time. For example, when a normal CNC lathe is produced in a small batch, it is necessary to re-align the tool after the workpiece is replaced and set the tool length and tool compensation in the CNC system. The use of Coromant Capto or Kenner's KM tool system can guarantee future reproduction. The tool change time can be reduced without re-setting the tool, setting the tool length and offset. These tool systems are all radially and axially positioned with high precision to ensure dimensional consistency after each setup. The average tooling time required for CNC lathes is 5 knives, 3 shifts for workers, 5 days per week, 46 weeks per year, and 60 hours per hour. The tool change time for common tool systems is required. 5 minutes, and the Kenneth KM tool system takes only half a minute to change the tool, saving $15,525 per year.
Another way to reduce tool change time is to use reasonable cutting techniques to extend tool life. In some cases, the tool life is extremely short. At this time, it may not be a problem with the quality of the tool itself, but the tool selection is incorrect or the method of use is problematic. At this time, you need to contact the cutting tool experts to listen to their opinions.
The bending deformation law in material mechanics can be used as a reference for studying the tool selection method. Most of the tools can be simplified to cantilever beams when used, and the deformation of the cantilever beam is related to the magnitude of the radial load, the effective overhang, the material's elastic modulus of the beam, and the diameter of the beam. Therefore, it is possible to reduce the radial load, shorten the effective overhang amount, select the tool material with high elastic modulus, and increase the effective tool diameter. For example, some users choose shallow hole drills with unbalanced cutting force, but only consider shallower drills with larger aspect ratios and choose larger aspect ratios, while ignoring the rigidity of shallow bore drills with large aspect ratios. Weak, the cutting speed and feed rate have to be reduced during machining to avoid problems with the tool. The reduction in processing efficiency often means a reduction in economic efficiency. Therefore, the smallest aspect ratio should be chosen as possible during processing (especially in mass production).
Sometimes we can choose other methods to enhance the rigidity of the tool. For example, when the other conditions are constant, the rigidity of the simply supported beam is much larger than that of the cantilever beam. If we convert the support of the tool into a simply supported beam, it is possible to further improve the machining efficiency.
3. Reduce the number of tool changes
Tool manufacturers have developed tools with multiple functions to meet different machining needs. Such as octagonal blade milling cutters provided by Isca, Seco, Kenner, Walter, etc., can complete various plane, chamfer, circumferential interpolation, cavity rough milling and other processing; Kenner's A4 turning tool and Iskar's Overlord knives can perform two-way turning and complex machining tasks such as squares and steps on the lathe.
4.Composite processing
Composite machining refers to the simultaneous processing of multiple processes, such as drilling / reaming / chamfering / boring planes are often compounded, drilling / chamfering / milling threads have recently been compounded.
A rough, forward chamfering, reverse chamfering, and precision boring tool holder can be moved radially so that the diameter of the non-working turret is smaller during the other processes to ensure that it will not Interference with the normal operation of the machining tool.
5. Reduce workpiece clamping time
The time required to stop the machining of the workpiece due to the clamping by the clamping technique is also a way to reduce the non-machining time. This can be done with the right machine attachment. For example, an exchange workbench on a horizontal machining center is a typical application that reduces downtime due to waiting for workpiece clamping. Recently, some of the machine tool milling machine tools provided by some machine tool manufacturers, as well as the quick clamping technology provided by Xiongke, can effectively reduce the number of times of clamping and clamping time of the workpiece, thereby improving the processing efficiency. Applying a pallet to a production line is also an effective way to reduce the clamping time of the workpiece.
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