Application of superhard tools in the field of roll processing
Roll processing industry
Many large-scale roller enterprises in China have used super-hard tools to carry out rough, rough and refined cars for various types of rolls such as chilled cast iron and hardened steel. All of them have achieved good benefits. 7 Average improvement of processing efficiency by 2 to 6 times, saving processing Working hours and electricity are 50% to 80%. For example, when the Wuhan Iron and Steel Company Rolling Mill has a chilled cast iron roll rough and semi-finished with a hardness of HS60-80, the cutting speed is increased by 3 times, and the car has 1 roll, saving electricity and working hours of more than 400 yuan, saving tool costs. Nearly one hundred yuan has achieved huge economic benefits. For example, when we use the FD22 cermet tool to turn the 86CrMoV7 hardened steel roll of HRC58~63 (Vc=60m/min, f=0.2mm/r, ap=0.8mm), the single-blade continuous cutting roll has a diameter of 15000m. The maximum width of the sharp flank wear band is VBmax=0.2mm), which satisfies the requirements of the car.
Industrial pump processing industry
At present, 70% to 80% of domestic pulp pump production plants have adopted superhard tools. The slurry pump is widely used in mining, electric power and other industries. It is an urgently needed product at home and abroad. Its sheath and shield are Cr15Mo3 high-hard iron castings of HRC63~67. In the past, it was difficult to turn this material because of various tools, so it was necessary to use a process of annealing, softening, and then quenching. After adopting the super-hard tool, the hardening process is successfully realized, and the two processes of annealing and quenching are eliminated, saving a lot of man-hours and electric power.
Automotive processing industry
In the machining of crankshafts, camshafts and drive shafts in the industries of automobiles and tractors, the processing of cutting tools, measuring tools and equipment maintenance often encounter the processing problems of hardened workpieces. For example, in a locomotive and vehicle factory in China, the inner ring of the bearing needs to be processed in the maintenance of the equipment. The hardness of the inner ring of the bearing (material GCr15 steel) is HRC60, the diameter of the inner ring is f285mm, and the grinding process is used, and the grinding allowance is uneven. It takes 2 hours to grind it; first, it uses an ultra-hard tool and it is processed into an inner ring in only 45 minutes.
After years of research and exploration, China has made great progress in superhard tools, but the application of superhard tools in production is still not extensive. The main reasons are as follows: Manufacturers and operators have insufficient understanding of the effect of hard turning with superhard tools. It is generally believed that hard materials can only be ground; the cost of tools is considered too high. The initial tool cost for hard turning is higher than that of ordinary carbide tools (such as PCBN is more than ten times more expensive than ordinary carbide), but the cost of distributing it on one part is lower than that of grinding, and the benefit is better than ordinary. Cemented carbide is much better; there is not enough research on the mechanism of superhard tool processing; the specification of superhard tool processing is not enough to guide production practice.
Therefore, in addition to in-depth study of the processing mechanism of superhard tools, it is necessary to strengthen superhard tools.
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