The highest cutting tool greatly improves producti

2022-07-23
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Shangao tools greatly improve production efficiency

the real productivity increase and processing cost reduction (considering all factors) need more powerful adjustment (see Figure 1). The first condition is to have correct cutting tools and be able to adapt to the environment (machine tools and materials). Next, you need to determine which tool is the most effective cutting condition. Only in this way can we really improve productivity and reduce costs

Figure 1. The real productivity increase and processing cost reduction

(considering all factors) require stronger adjustment

suitable tool

it is not easy to define a tool suitable for a machining task. In many cases, it depends on the batch size of the workpiece and the complexity of the actual processing (see Figure 2)

Figure 2 in many cases depends on the batch size of the workpiece and the complexity of the actual processing

one of the methods is to perfectly adjust the tool according to the processing technology to be completed. In this way, all variables need to be considered to ensure that the effective processing time (actual processing time) of each step is used as efficiently as possible. The disadvantage of this method is that it greatly reduces the starting friction force of different tools in a wide range. This will increase the downtime (machine/tool adjustment time) and reduce the available effective time. In short, this method provides a shorter effective time, but is very ideal

another method is to use general-purpose tools. This method will reduce downtime (less adjustment and maintenance of tools), thus increasing the available effective time. However, the use of effective time is not very efficient, because the tool does not achieve the best adjustment in the machining process

the best way is to mix the two alternatives. A practical application is feasible only through "simulation": compare alternatives, determine the time of use, and decide which method is the best overall solution

effective cutting conditions

effective cutting conditions can achieve the best combination of reducing processing costs and maximizing productivity (see Figure 3)

Figure 3 effective cutting conditions can be the best combination of reducing machining costs and maximizing productivity

obviously, the selection of cutting conditions determines the processing time and productivity level (the number of work steps per unit time)

with the improvement of cutting conditions, the processing time of the process is shortened. This means higher productivity because there are more steps per unit time. However, if the cutting conditions are set too high, the productivity will be reduced, and the downtime will be increased because too much time is wasted on maintaining the tools (replacing worn cutting edges and repairing spare parts)

if the cutting condition is improved, the processing cost of each step will be reduced because the processing time is shorter. At the same time, the tool cost of each step will also increase due to the shortening of tool life, which will actually require more cutting edges

the higher the cutting condition, the higher the tool cost of each step. However, this increase can be compensated by the lower processing cost of each step. Add these together (= total machining cost), and the cutting condition combination with the minimum total machining cost will appear

for lower cutting conditions, the processing cost increases because the processing cost is usually higher. If the cutting condition is too high, the machining cost will increase, because the increase of tool cost is faster than the decrease of machining cost

the area determined by the cutting conditions with minimum machining cost and the cutting conditions to maximize productivity is called hie (high efficiency) area

in practical application, determining hie cutting conditions is an exercise that requires considerable amount of calculation. This means that many operators have difficulty identifying them. In addition, is it really worth arguing about PVC pipes with a diameter of 1.5m? Can the time required to determine the high-efficiency cutting conditions weigh the potential savings of a general barrel length of 18:1 of its diameter? The Sango business solution is to provide more useful tools, making it easier to apply these considerations to practice

in order to select the correct tool and determine the correct basic cutting conditions, yamago provides wintool and secocut for its customers. Wintool is a tool to help you quickly select and manage tools. Secocut can help users determine the most effective cutting conditions for each tool. This includes the optimal combination of maximum productivity and minimum processing cost. Wintool and secocut help to easily generate a reasonable starting point. This starting point then serves as a platform for further improvement, so they are necessary

for any cutting process, Sango PCA is a system that can be used to determine the most profitable machining methods and cutting conditions. This simulation compares various options (method, tool and cutting conditions). These options can be weighed and compared according to their processing time (productivity) and processing cost. This allows the user to quickly determine which choice is his preference and what his choice means. In particular, the food packaging with a long shelf life can save up to 30%. The PCA study conducted by Sango tools in the customer's factory shows that up to 30% savings have been achieved, which shows that it is feasible to save costs and increase productivity by more than 30%. (end)

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