China heavy truck Bridge Company: "those things" "play" cutters

Since we launched the "reform and innovation and upgrading year" campaign, bridge box company has been making great efforts to improve tool life and reduce the waste of tool production. China heavy duty truck production units interact with each other and learn from each other, actively carry out tool optimization activities, and reduce the emerging practices and experience of cutting tool costs into management system, optimize management processes and upgrade management standards.

(a)

In the man's center, the shell and fork's shaft hole 32 holes can be cast out small plane, but because of the casting defects of the blank, a large fillet is formed here, resulting in the difference between the shaft of the shaft and the fork shaft can't be correctly assembled, and the fork doesn't act. Although the blank manufacturer has repeatedly sent people to use wind sand turbine to grind out the round angle, the production is seriously affected by the large number of blank blank and low grinding efficiency.

In order to solve this problem, the staff is another way, using the same processing fork shaft hole with 40 violent drill, finished in 40 hole after processing, continue to move forward at a distance, the phi 32 orifice blank multi cast fillet drill out, the hole bottom plane approximately, ensure the fork assembly the head.

By skillful use of cutting tools, the problem of the assembly is seriously affected by the defects of the blank casting and the production efficiency of the shell reduction is greatly improved.

(two)

There is a shoulder shoulder structure with a thickness of 11 millimeters after the man's back shell and fork shaft plane. Because the plane edge is only 25 millimeters from the side plate of the tooling, the square shoulder milling cutter can't cut into it, so the milling cutter with 20 rods has been used to manufacture the plane and shoulder shoulders. The milling cutter of small diameter, due to poor anti vibration, resulting in axial engagement small, slow feed, and a knife to eat from the outside to the inside to walk two times to plane milling off one layer at a time, so take the knife three times to the size of the processing in place, so the efficiency is very low, step took 9 minutes and 20 seconds the whole process took 59 minutes.

After careful observation, the operators mentioned the 40 violent drilling drills to the milling step before drilling. After drilling 40 holes, the milling cutter was first inserted into the 40 hole by using 40 square shoulder milling cutter, and then the milling cutter was used to milling the plane and shoulder. This method takes only 2 minutes and 30 seconds, which saves 6 minutes and 50 seconds compared to the original, and the processing efficiency is greatly improved.

By optimizing the tool and improving the path of cutting tool ingeniously, the new cutting tool with higher cutting efficiency is used, which greatly improves the production efficiency of the shell reduction.

(three)

When the rear axle shafts were initially tried, one piece was processed for 70 minutes. One flight can only produce 6 pieces, after nearly one year of tool replacement and cutting parameters adjustment and optimization. The processing time was finally locked in 51 minutes, but there was also a reduction in the tool life. Especially the bearing hole D205, because the speed is too fast, it often causes the knife. The improvement of the processing efficiency of the mantle subtraction is always a chore in the subdivision of the shell.

The staff of the subdivision of the shell is measured by a knife and a knife. Through a week of detailed observation, several important factors that affect the processing efficiency of the shell are found. One is in the milling process, the cutter cutting by external to internal cutting, using high feed milling cutter, the 2 original into 1 knives, cutting away at the same time reduced by 30%; two is in the shift fork shaft end processing, by modifying the tooling, cancel the small diameter rod milling cutter the way of processing, the cutter bar end milling. Not only 1 cutting tools are saved, but the diameter of the fine milling cutter is 4 times that of the small diameter rod milling cutter, and the cutting speed is 3 times that of the rod milling cutter.

By optimizing the 15 program, after reducing the entire processing time, the shell shortened to 38 minutes, reducing production will increase to single shell number of each class of 10, production capacity reached 43%.

(four)

There is always a problem that there are some hard points in the blank of the billet after 205 men's bearing blank. Because of the small quantity, the blank inspection is difficult to detect, and the hard points are within the surface of the blank, before the processing can be seen by the naked eye. Once the rough hard points will result in rough boring bearing hole, hard rough boring blade will collapse, an accident will result in two and two knife blade is damaged, causing economic losses of 1900 yuan of tool.

Because only a few semifinished products have this problem, if we make articles on blank inspection, we will invest a lot of manpower and material resources, and the economic effect is not ideal. Thus, reducing production line shell Manchester skilled craftsmen who actively explore and concerted efforts. They found that through the comparative study, a series of fast milling around the rough milling cutter used in this process can be carried out on the inner wall of the bearing hole, and the rough milling insert strength and toughness than the rough boring blade are much larger, strong, resistant to collapse, can be down most of the hard milling, thus excluding hard little threat to the rough boring tool, avoid the tool damage.

After the bearing hole is wound and milling, the coarse boring allowance is reduced, and the service life of the coarse boring blade is prolonged. The cost of single piece machining is lower than that of rough boring blade, and the total cost of single piece cutting tool is reduced. All processing steps are completed by numerical control machine tools. Only one early programming is needed, all the work behind is finished automatically by numerical control program, simple and efficient, without adding any later manpower and material resources. Since the increase of milling around, and there haven't been damaged rough boring tool.